March 2013 - Roger Barber Publishing Services

Transcription

ES FRONT COVER MARCH 2013:ES FRONT COVER FEB 2008
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One point of contact
1st MTA, your one stop shop for
high productivity machining accessories
Workholding equipment
Fixturing and clamping products
Machining accessories
Reduction bushes
High pressure coolant systems
Machine mounts
•
Deburring twister lathes
Fast delivery
Chucks
•
Customised solutions
•
Excellent warranty and service
•
Full technical support
•
Top quality products at competitive prices
Collets
Chuck jaws
Rotary tables
Vices
Tool sharpeners
Filtration units
arrange your free on site demonstration
St
Email: [email protected] Freephone: 0800 783 0510
Fax: 0800 783 0517
www.1mta.com
MTA
MACHINE TOOL ACCESSORIES
Call 0800 783 0510 today to find out more or
ES CONTENTS 2-3:ES CONTENTS 4-5
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To advertise in this section please call Anna Rodrigues on 01472 210712
or Email: [email protected]
New and innovative interlocking tool boxes
The new TRUMPF box provides stable, shock-proof storage for TruTool portable
fabrication tools. It also interlocks with other TRUMPF boxes, even those of
different sizes, to provide an efficient and space-saving method of stowing sets
of tools for maximum protection and easy access.
Moulded from 100% ABS plastic, the box protects the tools against water
splash, dust and accidental damage that can easily occur on a construction site.
A wide handle makes carriage safe and easy. When the cases are linked or
stacked, the TRUMPF box system saves time as several power tools can be
transported at once.
Special closures allow each power tool box to be opened individually without
requiring its removal from stack and with the name of the TruTool clearly marked
on the front and side of the box identification is quick and easy.
The TRUMPF boxes are now available for the small to medium range of
TruTool power tools that comprises shears, nibblers, deburrers, seam lockers,
power fasteners and bevellers for weld edge preparation.
TRUMPF Ltd Tel: 0844 4820188
Email: [email protected] www.trumpf-machines.com
New additions to the Mac Tools range of
hand tools
Mac Tools has introduced
two new additions to its
already extensive range
of hand tools.
The new 2 in 1 wire
stripper is made from
surgical steel and is a
must for quick, easy and
safe cable cutting and
stripping. It allows
technicians and mechanics to cut soft copper
wire with one end and
strip with the other. The cutting end comes with flush cut jaws making for a
perfect cut each time. The wire stripper self-adjusts to the wire size so that users
can catch, hold and strip the wire in one smooth movement. Mac Tools’ 2 in 1
stripper comes in two sizes: standard, for wires of 14 to 16AWG (IPA7870) and
large, for wires of 10 to 14AWG (IPA7896).
The Compo-Cast® dead-blow hammers are built from solid steel and are then
completely encased in a hot urethane Uni-Cast™ cover. This feature makes them
highly resistant to chemicals as well as perfect for use in non-spark
environments. The urethane cover also increases the life of the hammer
considerably, enabling the faces to retain their shape despite repeated striking
on hard surfaces and sharp edges. The threaded wraparound pattern on the
handle provides users with a comfortable and secure grip. Two models are
available: the 15-ounce CH15DS and 21-ounce CH21DS.
Mac Tools are available from all regional Mac Tools mobile distributors.
PRODUCT FOCUS
New guide to welding positions, electrodes and standards
Now available from ESAB is a free
guide to ASME IX/ BS EN ISO 6947
welding positions. As well as showing
all the different positions, the guide also
provides information on the
recommended ESAB electrodes when
welding mild steel across a range of
applications.
The simple guide is clearly illustrated
to show basic welding positions and
the correct ASME/BS EN ISO 6947
code, such as 2G/PC for horizontal/vertical welding. It is ideal for those involved in
welding as part of a production engineering department, in fabrication work,
design, welder training or welding inspection within a quality control regime.
The guide also explains the latest British/European MMA welding electrode
standards as a number have been re-designated into new BS EN ISO Standards.
To obtain a free copy of the handy QR coded guide, contact:
ESAB Tel: 0800 3893152
Email: [email protected] www.esab.co.uk
New counterboring inserts for perfect boring and turning
Perfect chipbreaking and therefore precise
cylindrical machining is generated by the new
E47 counterboring insert from tooling giant,
Walter GB. The straight cutting edge of the E47
geometry results in high accuracy even when
step drilling.
With variable design chipbreaker groove,
the inserts have universal use and, depending on
shape and size, depths of cut from 2.5 mm up to
6.3 mm are possible and chip removal is
excellent, even when interrupted cutting.
E47 is supplied in a variety of shapes (CC, WC
and SC) and sizes, and with different corner
radii, and in Tiger.tec WSM20 and WSM30 versions for ISO S, M and P
applications, as well as WPP20 for ISO P and K tasks.
The indexable inserts can be used for both boring and turning operations.
Walter GB Ltd Tel: 01527 839450
Email: [email protected] www.walter-tools.com
New product catalogue for position sensors
Sensors for distance, angle and inclination – with
application examples
With its new product catalogue ASM provides
engineers with a practical decision-making tool for
selecting the right position sensor.
Whether distance, angle or inclination, ASM offers
with six innovative product lines sensor solutions for a
wide variety of applications requiring feedback
position sensors. The company is known for three
decades for the production of high-quality sensors.
With this new catalogue, it provides not only an
overview of the unique product range with technical specifications. The
operating principle of each sensor line is described in detail, too. Along with
many application examples, design engineers receive a reference tool for the
selection of the right sensor technology and therefore the most suitable model.
Download catalog as PDF at:
http://www.asm-sensor.com/asm/pdf/pro/asm_short_cat_en.pdf
ASM Sales Office UK Tel: 0845-1222-123
Email: [email protected] www.asm-sensor.co.uk
Mac Tools www.mactools.co.uk
Engineering Subcontractor ■ MARCH 2013
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COVER STORY
www.rbpublishing.co.uk
VOLUME 10 | No. 3 ISSN 1742 -5778
CONTENTS
FEATURE - 5-AXIS MACHINING
6
MEDICAL REPORT
14
METAL CUTTING
16
FEATURE - WORKHOLDING
24
CUTTING TOOLS
32
FEATURE - MEASUREMENT & INSPECTION
40
CADCAM
52
FEATURE - LASER CUTTING
56
SAWING & CUTTING OFF
68
WELDING
72
PRODUCT FOCUS
75
NEXT ISSUE
APRIL 2013
• Oil & Gas Report
• Automation
• Fastening & Assembly
• Lubrication
• Welding
Published by Roger Barber Publishing
Enterprise House, Foundry Lane, Horsham, West Sussex, RH13 5PX
Tel: 01403 266022 Fax: 0208 916 0033
Publisher: Roger Barber
Email: [email protected]
Circulation: Chloe Barber - 01403 242803
Accounts: Jackie Barber - 01403 563791
Production Manager: Anna Rodrigues - 01472 210712
Design & Production: Roger Barber Publishing
Print: Holbrooks Printers Ltd, Portsmouth, Hampshire
Engineering Subcontractor is a controlled circulation magazine, available
free to selected personnel, at the discretion of the publisher. Please
complete and fax back the Reader Registration Sheet if you would like to
apply for a regular free copy. This material is copyright. No part of this publication
Compact vice provides
versatile clamping on
5-axis machines
Secure, accurate clamping with 40 kN of torque is offered by a new
vice from Kitagawa, Japan, designed to suit a variety of uses where
compactness is important, such as on 5-axis machining centres.
However, the VAX 125 unit is equally suited to multiple fixturing
applications on 3-axis machines. The vice is available in the UK
through sole agent, 1st Machine Tool Accessories (1st MTA Ltd).
The body has a footprint of only 256 mm x 154 mm and can be
equipped with an array of three jaws, two types of clamping insert and
other accessories to accommodate various workpieces. Nine clamping
arrangements can be configured from these basic elements. A toggle
mechanism allows many kinds of materials from hard to soft to be
secured without damage. The vice can even be supplied with a built-in
Kitagawa NC rotary table.
Rectangular workpieces up to 150 mm x 188 mm or round parts up
to 228 mm diameter may be secured by the VAX 125 clamping
system. Standard accessories include mounting bolts, a torque wrench
and three socket screw wrenches.
Offering a comprehensive selection of top quality products at
competitive prices, 1st Machine Tool Accessories is a leading supplier
of workholding and machining accessories, including: collets; chuck
jaws; Kitagawa chucks, rotary tables and vices; Chick, Tecnomors and
Best workholding equipment; Abbott and Leave fixturing and clamping
products; Darex tool sharpeners; OK-Vises; Brighetti reduction bushes;
CoolJet high pressure coolant systems; Micromag filtration units;
machine mounts; Overbeck deburring twister lathes; ScandMist
industrial air cleaners; and Iemca bar feeders and billet loaders.
1st MTA’s extensive stock holding is backed by excellent warranty
and service, provided by a dedicated team of technical engineers.
Demonstrations of selected products are available from external sales
specialists on request.
1st MTA Ltd Tel: 01725 512517
Email: [email protected] www.1mta.com
may be reproduced without express written permission. Please contact the publisher.
5
ES 5-AXIS FTR 6-13:ES CUTTING TOOLS FTR 38-51
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Feature - 5-AXIS MACHINING
5-axis innovation at Open House
DMG / MORI SEIKI has expanded its DMF
series of travelling column machining
centres to include a version specially
designed for the 5-axis machining of
integral components and blades
This is the second generation of successful
travelling column machines that DMG /
MORI SEIKI has developed for the
machining of long components. This latest
design not only reflects the innovative
character of the DMF series externally but
the complete machine concept has also been
optimised to ensure both optimum utilisation
of the work area as well as maximum
flexibility and productivity. The core
elements of the DMF series are the highly
stable machine bed with its vibration
damping mineral cast construction and the
thermo-symmetrical travelling column.
Integration of an NC rotary table and
swivel milling head as a controlled B-axis
enables efficient 5-axis machining with long
travel ranges of at least 700 mm in the Yand Z-directions. The large exponents of the
series achieve travel ranges of 1,100 mm in
the Y-axis and 900 mm in the Z-axis. The
DMF 180 has a travel range of 1,800 mm in
the X-axis and the DMF 260 and DMF 360
offer 2,600 mm or 3,600 mm here
respectively.
Thanks to a travelling magazine, with 30
tool pockets in the standard version and 60
6
or 120 as an option, chip-to-chip times have
been reduced to less than eight seconds and
chip removal volumes increased by up to 15
percent. It is here that the potential for the
manufacture of lightweight structural parts
becomes particularly evident.
Rapid traverses of 40m/min in the
standard versions have already proven just
how efficient DMF machines are. An
optional dynamic package is now available
in which the ball screw spindle drive in the Xaxis has been replaced by a linear drive so
that rapid traverse speeds of 80 m/min can
be achieved in all axes. Chip-to-chip times
are also reduced even further to less than six
seconds.
The modular spindle options start with a
standard 8,000-rpm milling spindle for high
removal volumes. More powerful options
available include 14,000 or 18,000-rpm
SK40/HSK A63 spindles and 10,000-rpm
SK50 / HSK-A100 spindles.
In the case of the two larger DMF 260 and
DMF 360 machines the extensive option
package includes not only the NC rotary
table but also the possibility of installing two
rotary tables. When combined with the
working area partition wall this enables
5-axis pendulum machining with very short
setup times. The mill-turn table is another
possible configuration. This expands the
range of machining applications to include
turning operations with speeds of up to
1,000 rpm.
At the recent Open House in Pfronten,
DMG / MORI SEIKI presented the DMF 2607 travelling column machining centre, an
example of yet another interesting working
area configuration intended specially for the
efficient machining of integral components
and blades. Instead of the rigid table this
model is equipped with two rotary tables
facing each other between which the
workpiece is clamped thus allowing
simultaneous 5-axis machining over the
entire length of the work area. Highlights of
this variant include the large workpiece
swing range with a diameter of 575 mm, the
large distance between centres of 2,600 mm
and excellent chip flow.
DECKEL MAHO has also extended the
optional equipment of the popular eVo
universal machining centres with some
innovative features. 5-axis and 5-sided
simultaneous milling combined with mill-turn
in a single setup is synonymous with
maximum productivity and sophisticated
production. With this range of functions, the
DMU 40 eVo linear has proved its value
since it was launched on the market, as a
multitude of satisfied customers can attest.
DECKEL MAHO is now offering a new
configuration with an integrated pallet
changer also for the smallest model in the
series. Setup parallel to machining and short
pallet changing times of 12 seconds will
ensure additional gains in productivity.
As the smallest model in the series, the
DMU 40 eVo linear with pallet changer
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5-AXIS MACHINING
stands up to any comparison. The work area
is optimally used in order to accommodate
pallets measuring 400 x 400 mm that can
handle loads of up to 250 kg. Its travel
ranges of 400 x 400 x 375 mm enable
maximum machining diversity. The design of
the integrated pallet changer also has an
invaluable advantage with regard to the
production area of the user: Standing at 6.7
m², its footprint is a mere 1.3 m² larger than
that of the DMU 40 eVo linear without a
pallet changer.
The successful DMU 60 eVo linear is now
offered in a configuration with a heavy-duty
machining spindle. With a torque of 200
Nm and a speed of 10,000 rpm it is ideally
suited for powerful and productive
machining with high chip removal volumes.
Its swivel-rotary table for 5-axis
simultaneous machining can handle
workpieces weighing up to 400 kg and with
dimensions up to 600 x 500 x 500 mm. The
impressive performance data of the dynamic
version have been retained: the DMU 60
eVo linear achieves rapid traverses up to 80
m/min and accelerations of 10 m/s². Like all
eVo universal machining centres, this
outstanding performance is based on a
revolutionary machine concept designed for
maximum rigidity and accuracy with a
footprint of just 6 m². A tool magazine with
30 pockets and direct measuring systems
are also part of the standard version.
Another highlight in Pfronten was the
DMU 100 eVo linear equipped with mill-turn
technology. This largest model in the series is
already successfully established on the
market and is now available with a powerful
200 Nm spindle for heavy-duty machining.
The potential chip removal volumes of the
DMU 100 eVo linear are enormous: the
spacious working area of the machine has
enough space to handle workpieces with
diameters of 1,000 mm and heights of 800
mm. The maximum loading capacity of its
table is 1,000 kg. Despite the large
workpiece dimensions, the footprint of even
the largest eVo machine is only 11.2 m².
DMG / MORI SEIKI is also expanding its
portfolio in the area of milling and turning in
a single setup to include the DMU 125 FD
monoBLOCK ® and the DMC 65 FD
monoBLOCK®.
The modular design of the monoBLOCK
series enables a variety of machine
configurations, from 5-axis simultaneous
machining to automated production using
pallet changers and on to include integrated
milling-turning operations. DMG / MORI
SEIKI presented both the DMU 125 FD
monoBLOCK and the DMC 65 FD
monoBLOCK, equipped with integrated
pallet changer with three pallets in the
system, at the Open House event in Pfronten.
The largest monoBLOCK universal milling
machine is now also available with a
mill/turn package The DMU 125 FD
monoBLOCK unites all the well-known
benefits of the normal version with the
outstanding characteristics of the millingturning package. The heart of all FD
machines is the FD table with its speed of up
to 500 rpm and maximum torque of 5,400
Nm. The table also features a clamping area
of 1,250 mm and a loading capacity of
2,000 kg in the standard version to enable
efficient milling and turning of large, heavy
workpieces. In the version with the tandem
drive the maximum table capacity is as high
as 2,600 kg. The FD package for the DMU
125 FD monoBLOCK also includes an HSK
A100 motor spindle whose 12,000 rpm, 44
kW and 299 Nm performance is sufficient
for heavy duty machining. The centre has a
full-protection safety cabin whose laminated
safety panes protect the operator reliably
during fast turning operations.
The FD version of the DMU 125
monoBLOCK boasts the whole range of
benefits of the monoBLOCK concept. High
static mass and generously dimensioned
roller guideways plus ball-threads that
ensure the stability and rigidity required for
high-precision production. Working ease
also remains paramount in this version: the
work area has perfect accessibility and can
be reached from above by crane. Tools can
be loaded parallel to primary machining
time and despite the large work area, its
footprint is just 22 m².
The FD capability of the DMC 65 FD
monoBLOCK means a plus increased
versatility, while at the same time retaining
all its outstanding characteristics. The
automatic pallet changer is the most
important feature of the DMC series. There
are a total of three integrated pallets that
each have a loading capacity of 500 kg and
can accommodate workpieces measuring
630 mm in diameter and 500 mm in height.
Good accessibility to the work area, setup
area and tool loading station ensures ideal
ergonomics for the operator. This is made
easier by the possibility of crane loading to
the work and setup areas offered in the
standard version. Another convincing
feature of this FD version is its extremely
small footprint of just 16.5 m² that includes
the machining centre and the pallet changer.
DMG/MORI SEIKI UK Ltd
Tel: 024 76 516120
www.dmgmoriseiki.com
7
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5-AXIS MACHINING
New software meets aerospace industry demands
Aimed at the production
of larger circular disc style
components such as
critical rotating blisk and
impeller components used
in the aerospace sector,
the latest Mitsui Seiki
HU63-T combined with
new software developments is able to manipulate high accuracy work
on its vertically orientated
table for 5-axis simultaneous machining up to
800 mm in diameter by
550 mm high and
weighing up to 300 kg.
Available through 2D
CNC, the 5-axis machines
are designed for high
precision cutting on tough
and hardened materials.
High power spindle
motors are able to deliver
torque levels up to 1081
Nm and in addition,
following specialised
software development by
Mitsui Seiki’s application
team. This offers a
customised solution not
available on any other 5-axis machine,
overcoming significant time losses attributed
to datuming fixtures and components.
Mitsui Seiki’s Advanced Dynamic 5-axis
Fixture Offset (ADFO) software is able to
automatically create the data for positioning
fixture/component offsets, thus enabling
important time savings to be made when
setting and datuming high value parts for
machining.
With an X-axis travel of 900 mm, Y-axis
and column travels in Z of 800 mm coupled to
the rotary table B-axis of -90 deg to -180 deg
and 360 deg C-axis, the ultra-high accuracy
table-on-table configured machine uses high
precision glass scales for position and
feedback working to an accuracy of 1 micron
in X, Y and Z and 0.001 degrees in B- and Caxes.
Working through the high specification
Fanuc 30iMA control, the ADFO software
adds an important functionality especially
when setting for simultaneous contouring type
applications. As the application is dynamic it
will continuously calculate any offset vectors
8
The combination of new machine design in 5-axis Mitsui Seiki HU63-T and ADFO
software is targeted at the aerospace sector
from current positions and will accordingly
offset X, Y and Z co-ordinates in real time.
By simply applying the work coordinate
offset adjustment, the Fanuc control will
continuously track and in real time and
dynamically update the vector points in the
part program. In certain applications, a
spindle probe can also be used to determine
the part datum and the control will
automatically apply any offsets for 5-axis
working.
When compared with other 5-axis
machine tool/control combinations, ADFO
overcomes the general problem where the
orbiting points of both B-and C-rotary axes
have to be taken into account to achieve or
maintain the accuracy of form while
maintaining high orders of surface finish.
In normal machining without ADFO, users
will have to probably utilise more elaborate
fixturing for workholding and the operator
has to be relied upon to always remember to
set new parts back to their respective centre
positions. As a result this has a direct
reflection on the cost and quality of fixturing,
the time involved in datum alignment and
most important the overall geometric
relationship of the part to its programmed
centre points.
The HU 63-T machine is part of a new
series of 5-axis machining centres with
capacities ranging from the HU40-T with 610
mm in X and 560 mm in Y and Z to the
HU100-T which has 1,300 mm in X and
1,000 mm in Y and Z.
2D CNC Machinery Ltd
Tel: 0844 8718584
www.2DCNC.co.uk
Confidence in
Aerospace Machining.
At Heller, we believe our people are bigger than our machines.
Heller, is a large machine tool manufacturer based in the UK, and our team of experienced
engineers provide technical service and support to keep your manufacturing world-class.
We work with you at saving costs, we introduce efficient ways of manufacturing and we provide
reliable solutions to maximise uptime.
We’re everything you need from a UK, world-class machine tool manufacturer.
HELLER Machine Tools Limited, Acanthus Road, Ravensbank Business Park, Redditch, Worcestershire B98 9EX.
Telephone: 0121 275 3300 www.heller.biz
AEROSPACE
AUTOMOTIVE
MEDICAL
PETRO CHEMICAL
MOTORSPORT
FULLY COMPREHENSIVE
AEROSPACE MACHINING
22/2/13
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5-AXIS MACHINING
Horizontal machining for superior productivity
In 2013 the focus for Handtmann is firmly on
horizontal machining centres. The market will
see more innovations in high performance
machining as the company further develops its
HBZ Trunnion 5-axis horizontal machining
centres.
The starting point for Handtmann’s
continuous development of its horizontal
machining concepts was the HBZ AeroCell,
which was designed for the high speed
machining of aluminium and offers table sizes
from 4m by 2m up to 7m by 2m. Its “little
brother”, the HBZ CompactCell, with table
sizes from 2m by 1m to 4m by 1m, has quickly
established itself on the international market,
machining structural parts for the aerospace
industry and both machines are now
generating orders on a regular basis from
customers throughout the international
aerospace industry.
The Handtmann HBZ product line is known
for its outstanding performance which allows
considerable reductions in downtime. The
addition of a pallet changing system further
increases machining productivity. With the
HBZ Trunnion Handtmann has developed a
machine concept that combines the most
significant productivity benefits of horizontal
machining and applies them to smaller
components.
The HBZ Trunnion is particularly fast
compared to conventional machining centres
when it comes to machining workpieces that
required deep pockets and drilled holes. On a
horizontal machine the chips fall out of the
cavity and so there is no chip build-up to cause
problems with quality or reduce cycle time.
According to customer reports, machining
on the HBZ Trunnion 80 can be up to 30%
more productive than machining on
competitive machines. The arrangement of the
axes, with X, Y and Z axis travel independent
from the workpiece and the rotary and swivel
C- and A-axes combined in an NC rotary
swivel table together with a single piece
machine bed and three point floor mounting,
give unbeatable rigidity and process reliability
to the ‘PowerCube’.
The main characteristics of the HBZ
Trunnion series are the horizontally arranged
spindle, the NC-rotaryswivel-table and an
unbeatable rigid machine design. These are
combined with a choice of spindles to provide
the optimum solution to every customer
requirement and to allow the most economic
machining of titanium, steel, aluminium and
10
composite. With its wide range of sizes,
including 800mm, 1200mm and 1600mm
table sizes and various spindle options, the
HBZ Trunnion is a suitable for a wide range of
applications in mould and die making,
general metal machining, machine
construction, energy and power generation,
automotive and aerospace.
To give increased productivity, Handtmann
has developed a pallet changing system for
the HBZ Trunnion for fast changeover of
workpieces. By installing an additional pallet
rack, the automation can be extended to
accommodate any number of pallets. To fully
exploit all the opportunities that its rigid and
flexible machine design offers, the HBZ
Trunnion will be equipped with an additional
turning option. The turning option expands the
machining centre into a 5-axis milling and
turning centre. Components that need both
milling and turning can be machined
economically at 800 revs/min. With the
expansion of the HBZ Trunnion series towards
larger cube sizes Handtmann has established
a unique selling point. With table sizes of
1,200 mm and 1,600 mm, the HBZ Trunnion
120 and the HBZ Trunnion 160 offer the same
machining advantages as the Trunnion 80 for
larger workpieces. Thus these larger machines
are also characterised by unbeatable rigidity
and can machine both titanium and steel.
The HBZ Trunnion 120 offers axis travels of
1,270 mm in X, 1,100 mm in Y and 900 mm
in Z, with travel speeds up to 60 m/min. The
spindles offer range from 31 Nm to 1,010
Nm, with speeds from 6,000 to 30,000
revs/min and powers from 31 kW to 125 kW.
With similar axis travel speeds of 60 m/min,
the HBZ Trunnion 160 offers axis travels of
1,670 mm (X), 1,350 mm (Y) and 1,100 mm
(Z).
UK Distributor:
Engineering Technology Group
Tel: 01926 818418
www.engtechgroup.com
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5-AXIS MACHINING
Entry-level machining centre
A new, vertical-spindle machining centre,
which can be supplied in 3-axis or 5-axis
configuration, has been added to the range
manufactured by Hermle, Germany. The
C 400 Basic is available in the UK through sole
agent, Gosport-based Geo Kingsbury
Machine Tools.
The machine has fundamental attributes
similar to those of Hermle's high-end models,
such as a modified gantry design, mineral cast
bed and trunnion-mounted rotary table for the
fourth and fifth CNC axes, all offering rigidity,
low vibration and high machining accuracy.
Stainless steel cladding throughout the
working area is also to be found in the new
machine. However, it comes with fewer
options and is not intended to be automated.
Linear axis travels of 850 x 700 x 500 mm
give the machine approximately equivalent
capacity to the established C 42 U model.
The new Hermle C 400 Basic vertical
machining centre in 5-axis configuration
from Geo Kingsbury Machine Tools
Workpieces weighing up to two tonnes can
be processed on the fixed, 1070 mm x 700
mm table of the 3-axis version, while the 5axis machine table can support 600 kg. The
large swivel diameter of one metre between
the side plates of the trunnion and the 650 mm
diameter rotary table flattened on two sides to
540 mm provide versatility of production.
Spindle speed options are 15000 or 18000
rpm (20 kW / 180 Nm) and both are
equipped with Hermle's patented collision
protection system. In the event of a collision in
the Z-axis direction, the energy is absorbed by
six displacement sleeves, in many cases
preventing spindle damage. In standard
design, the C 400 Basic has a 38-tool
magazine integrated into the machine bed.
An optional, additional magazine with 87
tools is available. Tool breakage monitoring
and measuring is included.
Minimal idle times result from 6m/s 2
acceleration to 35 m/min rapids in all linear
axes. Trunnion swivel is at 25 rpm through
+91/-139 degrees, while C-axis positioning is
at 35 rpm. Control is by the Heidenhain iTNC
530 CNC containing numerous Hermle user
cycles that considerably improve or simplify
machining processes.
To view a short video, visit:
http://www.youtube.com/watch?v=pM0Kt9
Tub1g
Geo Kingsbury Machine Tools Ltd
Tel: 023 9258 0371
www.gkholdings.com
Machining area of the Hermle C 400 Basic 5-axis model
12
22/2/13
12:50
Page 13
5-AXIS MACHINING
More than you think for less than you thought
GF AgieCharmilles has launched a new, highfunctionality, cost-competitive 5-axis (3- + 2axis) machine tool range into the market.
The new HEM 500U machines available
now in the UK and Ireland provide
manufacturers have all the advantages and
benefits of GF AgieCharmilles’ 5-axis
machine tools. High productivity, impressive
cutting performance, manufacturing flexibility,
process reliability and first-class after-sales
support, all at a competitive price, will,
according to Martin Spencer, Agie
Charmilles’ managing director “have
customers and prospects licking their lips, and
competitors scratching their heads”.
“The HEM 500U is the ideal 5-axis machine
for manufacturers who perhaps have looked
at 5-axis machining in the past but were put
off making an investment owing to the
relatively ‘high’ cost of many machines
currently available on the market. The arrival
of the HEM 500U is bound to appeal to these
manufacturers.”
Although the HEM 500U is a universal
machining centre, it is specifically aimed at
subcontractors that are machining one–offs
and small batch precision parts and need a
versatile machine that complements their
production requirements.
The HEM 500U has a compact footprint
with X-, Y- and Z-axis travels of 500mm x
450mm x 400mm respectively and the
machine’s 5-side/face machining capabilities
are provided by a rotary tilting table (65/+110mm degrees/B-axis and n x 360
degrees/C-axis). The machines are fast with
30m/min rapid rates in X-, Y- and Z-axes and
are equipped with a powerful 12,000rpm/BT
40 inline spindle with a 20bar throughspindle-coolant capability with versatility
being assured via a flexible 30-position ATC.
A 60-position ATC option is also available.
For increased productivity the HEM 500U
can be supplied with integrated automation
via a 7 x station (Dynafix or UPC systems) or a
5 x station (MTS system) Workpiece Pallet
Changer (WPC), boasting a 30 second palletto-pallet change time.
The HEM 500U is also supplied with a
number of process reliability technologies that
include a touch tool probe, laser measurement
system as well as a range of SMART
technology modules that increase the
machine’s thermal stability and operator
effectiveness prior to and during operation.
Agie Charmilles Ltd
Tel: 02476 538666
www.uk.gfac.com
Looking to improve
5-Axis productivity?
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ES MEDICAL RPT 14-15:ES CUTTING TOOLS FTR 38-51
22/2/13
12:50
Page 14
MEDICAL REPORT
Haas technology implanted at PPM
Before he founded his company 40-years
ago, Fran Phillips was a lone machinist, a
hands-on guy with a mill and a lathe during
the space-race era, when NASA was
spending liberally to make JFK’s promise a
reality and every willing and able machine
shop in the country could benefit.
One of the parts he made at that time is still
on the moon, precisely where the Apollo
astronauts left it. One of the parts he made
more recently, just as out-of-reach but much
closer to home, is lodged precisely and for all
time in his own spine. Like many thousands of
patients around the world, Fran Phillips lives
with an implant. His was made on Haas CNC
machine tools by Elmwood, New Jerseybased Phillips Precision Medicraft (PPM).
Located less than 20 miles from New York
City, PPM has grown to become a recognised
leader in manufacturing advanced
orthopaedic implants, instrumentation and
sterilised delivery systems. The company uses
40 Haas CNC milling machines and 6 Haas
CNC turning centres, and specialises in
implants for the knee, hip, elbow, shoulder
and spine, as well as the instrumentation and
tooling necessary to install such devices in the
body.
“We purchased our first Haas mill in 1992
and have continued investing in Haas
technology ever since,” states John Phillips,
Fran’s eldest son and PPM’s president of
operations. “Standardising on the Haas
platform makes it easier to schedule work and
to move employees from machine to
machine.”
PPM provides a made-to-order service for
orthopaedic industry customers that include
Stryker, Zimmer and Biomet, to name but a
few. The company’s machining capability
helps facilitate a complete ‘art-to-part’ offer,
using Haas Super VF series mills and SL series
turning centres.
“We’ve had Haas machines for the past 20
years, but we’ve retired only a few,” says
John Phillips. “Most of them run 20 hours a
day, but still produce the same quality as
when they were new. We certainly get our
14
John Phillips, PPM’s president of operations
money’s worth. In our opinion, the ratio of
performance to price offered by Haas cannot
be matched.”
PPM isn’t making commodity parts; the
components produced on the long lines of
neatly laid out machines contain high
precision, high complexity features.
“Take this hip broach, for example,” says
John Phillips, holding a part approximately
10” long with tapered cutting tooth geometry
at one end, transposing to hexagon geometry
at the other. “It would normally be produced
on a CNC grinding machine, but we use
Haas fourth axis and right-angle head
technology to introduce a tool at such an
angle and high RPM that we’re able to
simulate a 5-axis application, producing the
broach with a tool geometry that cannot be
duplicated using grinding technology. The
resulting broach offers a very aggressive
cutting tooth design, which the doctors love
because they can get in and out very quickly,
reducing surgery times.”
He explains that the company rarely gets
much advance notice of what parts will be
required, or when. As a result, the flexibility of
the Haas machines is another vital element in
the day-to-day success of the business. PPM
can offer up to 60 different sizes of conical
stems, for example, at the touch of a ‘start’
button, often in batches up to 1200 or 1500 a
month. At the same time, the company will
often produce custom runs of just 5, 20 or
100 off.
PPM’s conical stems are complex titanium
parts that utilise several Haas machines for
operations that include close angular tapers,
milling, drilling, tapping, turning and
broaching hexagons. This is a far cry from the
business that Fran Phillips started in his
basement back in 1967. However, from
modest beginnings the business soon grew
and moved to a 40-man machine shop in the
70s, before a strategic shift in the early 80s
was to shape the future of PPM thereafter.
“Basically we upgraded to the manufacture
of medical devices and never looked back,”
says John Phillips. “No one was in
orthopaedics back then so it was a major
opportunity for the business. Obviously
nowadays it’s a whole different game; we
made a concerted effort to invest a few million
ES MEDICAL RPT 14-15:ES CUTTING TOOLS FTR 38-51
22/2/13
12:50
Page 15
MEDICAL REPORT
dollars to build our quality
systems, procedures and control
plans to ISO 13485 standards,
which is what we’ve done. After
all, the key to our success, the
most important thing we build, is
not for sale: our reputation.”
Today, the pressures faced by
PPM centre largely on customers
seeking offshore solutions,
typically from China, Malaysia
and other low-cost areas of the
world. As a result, the company
has created a niche for
machining high-end medical
components, which “no one else
wants to cut because it’s just not
profitable for them”.
John Phillips describes PPM’s
manufacturing style as “probably
a little different”, positively
“attacking CAD models in ProEngineer and then generating our
machine code in the same CAD package,
returning seamlessly what the client ordered
from solid geometry to the reality of actual
products manufactured exactly to
specification.
“Using Haas technology we get greedy.
We utilise a fourth axis rotary head to enable
us to machine four sides of the workpiece and
then with one fixture, flip it and we’re done in
two operations before it goes into our
finishing department for deburring,” he adds.
Typical materials processed on the Haas
machines include 17/4 stainless steel, 400
and 300 series stainless steel, titanium, cobalt
chrome and PEEK (PolyEtherEtherKetone). In
terms of the latter, PPM has just secured its first
order for PEEK, and these parts will also be
produced using Haas technology.
“We’re a no-debt operation; we buy our
equipment, pay it off and move on,” explains
John Phillips. “The Haas machines are
particularly good for us, as is the price
structure. The machines we acquired weren’t
$500,000 like some makes; they were a lot
less, so we had the means to bring them in as
needed and we could own them outright. In
addition, for the size of product that we
manufacture, the machining envelopes and
tables are just the right size and the machines
have no problem holding the close tolerances
our parts require.”
John Phillips and his family understand fully
the importance of the parts they are making,
the difference they can make to a recipient’s
life and the need to pay close attention to
specifications and quality.
“My father has just turned 73, but when he
was 62 he had only recently begun to enjoy a
reduced work schedule and was spending
more time playing his favourite game, golf.
However, he fractured his L4 lumber spine
and couldn’t walk. He was on pain pills and
clutching chairs to move around. Here was a
guy coming into his golden years and
wanting to enjoy himself and suddenly he’s
debilitated. Well that same guy now has new
PPM spine parts and you would never know
he had a problem. In fact, he just won his golf
club championship!”
A video can be viewed or downloaded from
YouTube at:
http://www.youtube.com/watch?v=ERwZtJo19Q&list=PLIpdfqwvUhG_ikWkqIhlJc
87TePunG4X&index=1&feature=plpp_video
Haas Automation Ltd
Tel: 01603 760539
www.haas.co.uk
15
ES METAL CUTTING 16-23:ES CUTTING TOOLS FTR 38-51
25/2/13
15:31
Page 16
METAL CUTTING
The drive to succeed
Investment in new Doosan machine tools helps automotive wheel
manufacturer improve productivity, part quality and response times
A little over two years ago Rimstock Plc, a
world-leading, vertically-integrated manufacturer of high-performance alloy wheels,
had never used Doosan machine tools from
Mills CNC. However, over the last 24 months
the situation has changed dramatically with
the company having now installed three
Doosan vertical turning lathes and three
Doosan vertical machining centres at its West
Bromwich manufacturing facility in the West
Midlands.
The investment in Doosan machines is
described as “brilliant news”, by Nick
Frampton, Mills CNC’s managing director.
The reasons why the six new machine tools
were purchased and are now in operation,
virtually around the clock, are explained by
Matt Neal, Rimstock’s marketing director:
“The automotive supply chain is
characterised by innovation, quality, speed
and reliability of delivery and costcompetitiveness. As a progressive manufacturer in the sector with a growing number of
high-profile OEM customers that includes
Jaguar Land Rover, Lotus, Honda, Toyota and
Nissan, we constantly monitor our
performance in all these regards and, to
ensure continuous improvement, make regular
and prudent investment in upgrading our
plant and equipment, and our manufacturing
processes and systems.”
In 2010, the company made a strategic
decision to expand and to diversify its
operations enabling it to both enter and
strengthen its position in a number of growing
and innovative niche markets.
These included the defence and security
markets where, over the last 2 years, Rimstock
has been particularly successful with its Bead
Lock and High Load Alloy Wheels and the
motorsport sector where the company has built
on its ‘Team Dynamics’ brand heritage to
supply high-performance cast and forged
race wheels to many national and
international race teams and race car
constructors. In 2010 the company secured a
three year contract to supply forged race
16
wheels for the Australian V8 Supercar
Championship.
As an integral part of its repositioning
strategy Rimstock also strengthened its forged
aluminium alloy wheel manufacturing
capacity and capabilities.
Matt Neal continues: “Modern car
designers and manufacturers are constantly
looking to minimise wheel weight and
therefore the unsprung weight of vehicles of
performance cars, whilst maintaining strength
and durability. Reducing weight has a
dramatic impact on car dynamics and
performance. With forged aluminium weight
savings approaching 30% can be achieved
over traditional cast alloy wheels and the
wheel produced is stronger and stiffer, and
improves acceleration, handling and braking
performance.”
In order to expand its forged alloy wheel
production Rimstock undertook a thorough
examination and appraisal of its existing
manufacturing capabilities, the results of
which helped spearhead the decision to invest
in new Doosan machine tools. The deciding
factors included the performance and
pedigree of the VT 750 machine and of
Doosan’s vertical turning technologies in
general, the price and availability of the
machine and the support and after-sales
service provided by Mills CNC.
The first Doosan VT 750, equipped with a
powerful, high torque 30kW 2,000rpm
spindle and 15” chuck capacity was installed
at Rimstock’s manufacturing facility in early
2011. Since its installation the company has
fine-tuned the machine’s operation and
improved its performance through the inhouse design and manufacture of ingenious
‘modular’ jig and fixture systems to cope with
the different wheel diameters and wheel
designs manufactured.
The bespoke workholding has enabled
Rimstock to increase its productivity and
reduce part cycle times, so that parts are able
to be finished on the VT 750 in just one setup
and two machining operations using external
profiling tools and boring bars. The
performance of the first VT 750 has led to
further investment in two more vertical turning
lathes, and three Doosan DNM 650 vertical
machining centres.
The large capacity Doosan DNM 650
machines, equipped with 15kW 12,000rpm
spindles, have been retrofitted with rotary axis
tables and provide Rimstock with full 5-axis
machining capability. The machines are used
for roughing and finishing forged and castalloy wheels, and cycle times, especially
where the engraving of fine details is required,
can be as long as 10 hours.
Mills CNC Ltd
Tel: 01926 736736
www.millscnc.co.uk
22/2/13
12:52
Page 17
Time to turn
over a new leaf
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22/2/13
12:53
Page 18
METAL CUTTING
Deep-hole EDM drilling of turbine
components is seven times faster
Japanese machine tool builder, Makino has
developed new technology for drilling cooling
holes in nickel alloy engine blades and vanes
more quickly and efficiently. It has resulted in
the launch of the EDBV3 electric discharge
machining (EDM) drilling machine, which is
available in the UK through sole agent,
NCMT.
The CNC machine provides aerospace
manufacturers with the speed, flexibility and
reliability to produce in a single set-up a wide
range of hole sizes and shapes, significantly
reducing the variety of tools needed and
overall cycle times. The ability to machine
holes of different shapes increases cooling
efficiency, allowing jet engine combustion
temperature to be raised to 1,500°C or more,
boosting fuel efficiency.
By combining each pipe electrode,
electrode holder and positioning guide in one
assembly, Makino has eliminated the need to
insert the electrode during automatic tool
change, which takes 30 seconds. Automatic
exchange allows holes of different diameter to
be produced at freely programmable angles
and positions during unattended operation.
The usual restrictions of multiple-electrode
comb-machining are thus avoided. The
standard machine configuration includes a
24-station tool carousel system which itself can
be exchanged robotically for extended
automated operation.
A rigid arm assembly holds, locates and
supports the die guide. An integrated middle
guide can be deployed for smaller diameter
electrodes, preventing whipping, bending and
vibration. The middle guide fingers
automatically retract as the rotating, tubular
electrode reduces in size, maximising
electrode length usage. A length management
system provides electrode wear tracking and
automatically instigates tool change when it
becomes too short.
The rotary C-axis head accepts electrode
diameters down to 0.2 mm. The EDM drill
rotates at 1,000 rpm and is designed to
withstand internal pressures of up to 10 Mpa,
ensuring effective flushing and high material
removal rates. Drilling is performed fully
submerged in a water-based dielectric for
high part quality, improved stability and faster
processing speeds than are possible using
conventional technologies.
As a result of the submerged machining and
newly developed generator technology, the
EDBV3 can drill cooling holes seven times
faster than pre-existing EDM drilling
technology, according to Makino. Despite
such a high machining speed, the heataffected zone in the workpieces is within
permitted tolerance limits for aircraft engine
construction.
Makino’s proven EDM drilling software is
integrated into the control, providing userfriendly input screens with direct G- and Mcode programming formats. To prevent back-
wall impingement when penetrating cavitywall blades and vanes, the EDBV3 includes
sensitive breakthrough detection using a
combination of adaptive process monitoring
techniques that is effective even when
machining parameters are set to maximum.
The EDBV3 has X-, Y- and Z-axis travels of
370 mm, 270 mm and 500mm respectively
and the 2-axis, 250 mm x 270mm table
supports a maximum workpiece load of 5kg
(optionally 15kg). The high-precision EDM
sinking technology can also be employed in
other industrial applications, such as the
manufacture of medical parts, fuel injector
nozzles, filters and die plates.
NCMT Ltd
Tel: 020 8398 4277
www.ncmt.co.uk
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25/2/13
15:31
Page 19
METAL CUTTING
Write for much further than 70km
Andreas Maier GmbH has introduced the
AMF Writer marking tool, a fast and costeffective way of marking workpieces
automatically. The permanent markings are
made by the machine itself in the machining
centre. To do this, the machine loads the tool
automatically. A separate operation on a
special marking machine is no longer
required.
The AMF Writer marking tool produces a
permanent mark on rough and smooth
surfaces of various materials. As the material
is displaced and compacted, high-quality
markings are applied to plastic, graphite,
aluminium, steel or titanium surfaces, for
instance. During the process, no burr occurs
on the marking line so that neither the surface
nor microstructure are damaged. The
engraving is rolled in, as it were, with a hard
ball thus creating a high-quality typeface.
Images and logos are also possible. Surfaces
with a hardness of up to 57 HRC can be
marked using this process, even if they have
been tempered.
Flexible, continuous markings made up of
letters and logos can be applied using a
special needle developed by the
manufacturer, available in three different
designs, a total of seven variants and adapted
to various materials. The needles offer the
special feature of a service life spanning
several years without their tips having to be
remachined. The needle is simply replaced
every two to five years, depending on use. The
tool holder hardly wears at all.
The tool works without revolving and
without lubricant. During the marking process,
the resilient needle equals out surface
unevenness of between three and seven
millimetres. This allows even inclined or round
surfaces (up to 15°) to be marked. Users gain
a considerable time advantage, because the
entire marking process is performed in the
CNC machine. The tool, primarily clamped in
Weldon fixtures, has an interface to the
machine spindle, is loaded fully-automatically
and functions independently. Thanks to
selectable tool fixtures such as SK, KM, HSK,
Capto and so on, the AMF Writer can be used
at all standard interfaces. It can also be used
in robot cells.
Andreas Maier GmbH & Co KG
UK Sales Office:
Tel: 01924 242972
www.amf.de
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25/2/13
16:15
Page 20
METAL CUTTING
FT Gearing selects Citizen as
‘key machine partner’
FT Gearing Systems totally projects the image
of precision for its gear manufacturing services
from its temperature controlled machine shop,
the selection of its production plant and
measuring equipment to the attitude of the
high skill base of its 70 employees. Indeed,
such is the level of attention to detail that in a
critical assembly area for aerospace parts
people are wearing white gloves. With its level
of expertise the company is often called upon
to apply its knowledge of transmissions and
gearing to provide design for production input
to its customers.
Set in three separate units totalling some
14,000 ft2 in Aldershot, the company is still
expanding with a recent move to occupy a
fourth unit to meet ever growing demand from
aerospace and defence customers. This family
owned business, that started in a potting shed
with five people in 1978 under Des Fitzgerald,
the current chairman and sons Graham,
managing director and Nigel, technical
director, is certainly process and quality driven
which has been the life-blood leading to it
becoming the specialist £6 million turnover
company it is today.
The Fitzgeralds have a very strict plant
purchase policy, to buy the highest level of
technical capability and quality they can
afford. Indeed, the nameplates on the
shopfloor are a testimony to those installation
decisions which have absorbed over £2
million in investment over the last two years
alone. Des Fitzgerald says: “Due to the type of
work we produce we have a very close
rapport with our chosen suppliers.”
He then explained how they have even been
involved with the development of specific
20
software with a machine tool
builder in Europe for producing
gearing to meet a customer’s
specific demands for ultraprecision, high performance.”
Graham Fitzgerald adds: “In
our view, the customer and
supplier relationship works both
ways so to machine components
up to 32 mm bar diameter,
Citizen Machinery UK is our
selected ‘Key Machine
Partner’.”
Citizen has supplied six CNC
sliding head turn-mill centres which are
installed on the various areas of the shopfloor.
Two are top-of-the-range 14-axis Citizen
M32s, one each L20 and A20 and two B12s
from its headquarters in Bushey, Watford.
He continues: “With these series of
machines, we have a spread of capability to
meet our batch requirements that are normally
between 10 and 200 parts. We are not totally
cycle time driven although this has an
important bearing on lead and delivery times,
but our business success is about quality and
precision. We have created the in-house skill
to achieve that.”
The company is dedicated to supplying the
aerospace and defence sectors with
assemblies and critical ‘Class 1’ components
used in wing surface actuation and engine
controls, instrument gearing, miniature gear
heads, epicyclic fuel pump gears, drive shafts,
and thrust reversing gears. Materials
machined include a wide range of stainless
steels, titanium, nimonics and Maraging steel.
As an example of the level of precision
achieved within its temperature
controlled clean room, where
diamond lapping is carried out,
light band tolerances generating a
flatness of 0.0003 mm with surface
finishes of 0.025 µm are
maintained.
The choice of Citizen sliding
head for turned parts over fixed
head machine configurations is
largely made on the ability to
provide a consistent level of size
and surface finish. For instance,
speeds and feeds tend to be throttled back to
prevent tool degradation and to help provide
a more stable cutting operation. Des
Fitzgerald says: “We have frequently proven
that we can maintain tolerances of a few
microns over a batch on the Citizen machines
and that’s even without subjecting the
machines to pre-warm up cycles.”
Whilst the company does not use its CNC
sliding head or larger fixed head turn-milling
capability to cut gears in-cycle, preferring to
use dedicated gear cutting equipment,
combined operations now performed on the
Citizen M32 include an aerospace shaft
machined from S145 corrosion resisting alloy
steel.
This process now combines a previous
drawn-out sequence of eight operations into a
single cycle giving obvious lead time
advantages.
Citizen Machinery UK Ltd
Tel: 01923 691500
www.citizenmachinery.co.uk
25/2/13
15:33
Page 21
METAL CUTTING
Erodex announces new partnership with Berkenhoff
Erodex (UK) Ltd has signed an agreement to
promote the topas ® plus range of wires
developed by Berkenhoff for use on all
machine types. In a new development this
agreement has now been expanded into a fullblown partnership in the UK and Ireland.
Erodex has enhanced its technical field sales
team to promote the topas plus wires and to
enable their customers to reap the full benefit
of the exceptional speed increases that they
can offer.
The topas plus range delivers tailor-made
solutions for all modern WEDM machines.
Both the machine type and customer
application are decisive in the choice of
exactly which topas plus wire will deliver the
optimum cutting results. Erodex technicians
can assist the customer in making the correct
wire-choice for the best cost / value decisionmaking and in capturing potential speed
increases, that Erodex have proven in the field,
of up to 60%.
topas plus wires can be of particular benefit
to the aerospace sector, where their quality
and stability allow peace-of-mind in
aerospace’s demanding zero-defect
environment. The remarkable speed and
accuracy increases that can be achieved in the
machining of hard aerospace alloys can also
provide an essential route to capacity
increases, without capital spend on new
equipment, as the sector continues to grow
strongly.
Director Steve Rolinson is keen to raise
awareness of the opportunity to increase
process speeds and capacity while enhancing
quality simply by switching to topas plus from
brass wire or some inferior coated wires:
“Wherever speed is important, or capacity is
constrained, our customers can dramatically
increase throughput and lower production
costs by introducing topas plus. We can work
with customers on individual projects to get the
most out of these wires, but in truth a great
many of the advantages can be captured
simply by replacing the existing wires and
running the same machine settings.”
WEDM technology is not new and
manufacturers are well aware of the
advantages that it has when producing
complicated, accurate 2D shapes in
configurations or materials that would be
difficult to machine conventionally. However,
the topas plus Gamma-Phase products have
taken that to a new level.
“The topas plus-family uses a layer of Zincenriched Gamma-Phase material over a brass
core. This process has been perfected and
patented by Berkenhoff and we are proud to
offer the fullest range of their products in the
UK,” adds Steve Rolinson.
Erodex (UK) Ltd
Tel: 01384 892011
www.erodex.com
25/2/13
16:18
Page 22
METAL CUTTING
Hardinge VMCs add capability and
capacity at EDS
The purchase of three Hardinge/Bridgeport
XR 760 vertical machining centres is the latest
phase in an on-going programme of machine
tool investment by Chelmsford based EDS
Engineering Ltd.
Two of the three machines, all high
specification models with the addition of tool
and component probing and a 4th axis, are
operating in ‘one man, two machine’ cells
whilst the third is a standalone unit offering
maximum flexibility in low run manufacture.
EDS is a long established, highly regarded
supplier of components to Tier One
manufacturers, increasingly in the USA
defence and aerospace industries.
Typically it supplies small batch quantities of
precision components, predominantly in
aerospace grade aluminiums and stainless
steels, that end up in demanding componentry
such as head up display systems and similar.
However its roots are in jigs and fixtures and
mould and die manufacture, the latter being
an area in which it is still very active but which
market forces have seen reduce in recent years
in favour of its aerospace and defence
capability.
“As a business we’ve always adapted well
to changes in the manufacturing climate and
have continued to invest in our capacity and
capability to ensure we stay in the forefront,”
explains EDS managing director Stuart
Clarke.
“The three newest machines continue a long
standing relationship we have with
Hardinge/Bridgeport and, after considerable
research, we opted for them again because of
the high standard specification of the
machines and the value they offered. They
have quickly become an integral part of our
operations,” he adds.
Hardinge XR 760 VMC’s are high
performance machines featuring Weiss 40
taper spindle technology which produces
exceptional radial and axial rigidity and offers
a unique grease replenishment system.
The construction of the machines is based on
an engineered double ribbed machine base
and this heavy duty approach is also evident
in the low friction linear guide ways, oversize
45mm double-nut ball screws and rugged axis
drives. The tool changer has a 30 tool capacity
and the machining envelope has a ‘best in
class’ working cube with a 610mm (24”) Yaxis travel. The spindle offers a maximum
speed of 12,000 rpm giving it a high precision
contouring capability.
However, mindful of its reputation for
meeting the very highest tolerances, EDS has
added further to its machines’ capabilities. Its
three machines are equipped with Heidenhain
iTNC530 3-axis controls which have integral
probe cycle software as standard. Therefore
fitting inspection/calibration probes to the
machines was a relatively straight forward
option, taking approximately two days per
machine to install, set up and fully calibrate.
On Hardinge’s recommendation, Renishaw
wireless OMP40-2 spindle inspection probes
were fitted along with an OTS table mounted
tool measurement/calibration touch probe,
both linked to the control via an infra-red
receiver that is hard wired into the control.
The 4th axis interface added to all three
machines was configured to suit a Kitagawa
MR200 rotary table, the interface comprising
an additional axis drive added to the
Heidenhain to change it into a 4-axis control.
This enables the rotary tables, motor and
pneumatics to be connected to the machine
and, with additional software options, adapts
the control to function in 4-axes
simultaneously. The control parameters were
also amended and tuned to ensure that when
the rotary table was connected it functioned in
harmony with the rest of the machine
operations. After installation of the 4th axis
interface, it is possible to operate the machines
either as 4-axis machines with the rotary table
connected or as a standard 3-axis machines if
the rotary table is removed or isolated.
Hardinge Machine Tools Ltd
Tel: 01162 869900
www.hardinge.co.uk
Saw 300% faster
than industry norms…
…whatever the metal!
BILLET • STRUCTURAL • TUBE • PLATE • STRAIGHT & MITRE • SEMI & FULLY AUTO
Kaltenbach Ltd, 6-8 Brunel Road, Bedford MK41 9TG t: 01234 213201 e: [email protected] www.kaltenbach.co.uk/news
22
22/2/13
12:55
Page 23
METAL CUTTING
Expert toolmaker upgrades to latest EDM technology
Banbury-based Hanley Precision Tools, a specialist toolmaking
company, has upgraded to the latest CNC wire and die sink technology
from Sodi-Tech EDM. Among the many improvements in these state-ofthe-art machines, the company reports “a quantum leap” in its
programming and setup features, as well as in overall performance.
Located side-by-side on the same industrial park, Hanley Precision
Tools is closely associated with the Glazpart Group of Companies, with
both entities having been founded by owner Ken Hanley. Supplying
accessories to the glazing and fenestration industries and the furniture
sector, as well as specialised bespoke products to meet specific
customer requirements in the medical, automotive, electrical and
packaging sectors, the businesses can offer their customers a “cradle to
grave” design and manufacturing service.
Glazpart Ltd employs 80 staff at its ISO 9001:2008 certified site,
producing millions of mouldings each month. Hanley Precision
therefore offers quick and responsive tool making and tool
maintenance services.
“We are seeing many customers bringing work back from China, fed
up with the logistical challenge of having cash tied up in transit and the
poor lead times,” states Glazpart’s operations director, Mark
O’Mahoney. “Most mould shops cannot afford to operate their own inhouse toolroom, which is one of Glazpart’s differentiating benefits.
Customers love the fact we have Hanley Precision next door, offering a
“one stop shop”.
As part of a new investment programme, the latest arrivals from
Sodi-Tech EDM are an AG600L wire EDW and an AG60L die sink
EDM. Both are similar in size to the machines that they replaced, but
considerably faster and more efficient than their predecessors.
“Although they were installed as recently as July 2012, the
toolmakers can already see that these new machines represent a real
step change,” says Mark O’Mahoney. “The linear drive technology is
excellent, while the improvements in speed and reliability are equally
impressive.”
“Programming times are at least 50-60% faster due to in-built default
features on the Sodick machines that help accelerate program
generation. This is particularly useful when using the wire machine as it
means we can produce wire programs for the path of a complex shape
in a greatly reduced time. On the die sink we have found that we no
longer need to pre-rough cut cavity forms, making the process much
faster, whilst finishing is now more refined. We have System 3R
technology on both machines for rapid setup.”
Hanley Precision manufactures tools from materials that include steel,
stainless steel and aluminium, including multi-cavity and hot runner
system moulds. Moulded parts are produced in every engineering
grade plastic, including rigid PVCs. The company is keen to point out
that quantity requirements are one of its differentiating features, and is
pleased to handle low volume requirements, even one-off if required.
Add to toolmaking and production a full design and prototyping
service, and the provision of secondary operations such as assembly,
printing, foiling, labelling, special Aqua decoration and packaging,
and it’s clear that few others can match the comprehensive range of
products and services.
Hanley Precision runs its Sodick machines to the limit, filling in any
gaps in mouldmaking and mould servicing with precision batch
production work on a subcontract basis, often for customers in
aerospace and motorsport – the company is located near to several
Formula One teams.
“The machines have made us more efficient; more competitive, while
we can now run thinner wire, making us more cost-effective without any
loss of performance. The automatic wire threading capability is also
faster and more reliable, which along with a six-station toolchanger on
the die sink, means the machines better support our 24-hour
operation.”
Sodi-Tech EDM Ltd
Tel: 024 76 511677
Email:[email protected]
www.sodi-techedm.co.uk
Plant and
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Tool
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[email protected] www.acs-ltd.com
ES WORKHOLDING FTR 24-31:ES CUTTING TOOLS FTR 38-51
25/2/13
16:05
Page 24
Feature - WORKHOLDING
Award winning workholding
”To offer more than the customer expects”, this
was the motto of Friedrich Schunk, when he
opened his machine shop in a garage in
Lauffen, Germany, right after World War II.
Today, SCHUNK is a German innovative
family-owned company as well as a global
player.
According to the mission statement “With a
pioneering spirit and perfection, we are
setting worldwide standards” Heinz-Dieter
Schunk, his son Henrik A. Schunk and his
daughter Kristina I. Schunk manage the
company. With 2000 employees and a
worldwide network of directly owned
subsidiaries and distribution partners in more
than 50 countries all over the world, SCHUNK
is known as the leading supplier for clamping
technology and gripping systems. Over the
past 25 years, SCHUNK has grown by more
than 12% on average.
The clamping technology business unit
comprises toolholding systems, stationary
workholding, lathe chucks, chuck jaws, special
hydraulic expansion technology solutions and
magnetic technology. The gripping systems
business unit produces and distributes
gripping modules, rotary modules, linear
modules, robot accessories, modular
assembly automation, gripping system
solutions and mobile gripping systems. The
third and youngest business unit is the
SCHUNK laser technology.
A double strategy is pursued by the owner
family in terms of the product program: on the
one hand, they promote
the technical development
and continuously explore
new niches. On the other
hand, the company is
constantly improving the
quality of its existing
products. Thus, the world’s
largest product portfolio of
standard chuck jaws
(1,200 standard chuck
jaws) was developed, the
most extensive range of
clamping technology
(more than 10,000 standard products), as
well as the world’s largest product program
for standard grippers (more than 10000
components).
For his life’s work, Heinz-Dieter Schunk was
awarded the German Machine Tool Industry
Award in 2008. In 2010, he received the Engelberger Robotics Award, the worldwide
most prestigious award in the robotics field.
Since 2012 the world-class goalkeeper Jens
Lehmann is a brand ambassador for precise
gripping and concentrated, safe holding in the
SCHUNK team.
Clamping force block with flexible
chuck jaw monitoring
The TANDEM KSP plus clamping force block
from SCHUNK, the competence leader for
clamping technology and gripping systems, is
setting new standards in automated
manufacturing. For the first time ever, a
standardised clamping force block provides
for flexible monitoring along the whole jaw
stroke. Whether using I.D. or O.D. clamping,
with a few grips the positions “opened“ or
”clamped“ for any base jaw position can be
adjusted. Monitoring is done via two inductive
proximity switches, which are integrated in
two special recesses of the base jaws. The
system is sealed, and is therefore resistant
against dirt. Since the signal can be directly
processed in the machine control unit, the
flexible queried clamping force blocks can be
quickly and easily integrated into existing
One team, one family: Hans-Dieter Schunk machines.
The compact clamping block disposes of
(r) with daughter Kristina I. Schunk and son
clamping force and precision. The one-piece,
Henrik A. Schunk
24
TANDEM KSP plus clamping force blocks
with jaw monitoring increase flexibility and
ensure process stability for automated
machine loading
rigid base body, wedge hook kinematics and
long ground jaw guidances provide for
concentrated clamping forces of up to 55 kN.
The excellent repeat accuracy of up to 0.01
mm also ensures exact results. They are
therefore absolutely suitable for demanding
milling operations at a high metal removal
rate, high cycle times, and minimum
tolerances. Due to the two integrated jaw interfaces, top jaws with tongue and groove, and
jaws with a fine serration can be used. On
option, the clamping force blocks are also
available with a jaw quick-change system. The
optimised outside contour and the minimum
gaps prevent the build-up of dust pockets, or
that chips and dust will penetrate into the
clamping block. A special fitting screw ensures
that the clamping block can be exchanged at
the highest repeat accuracy. As of size 100,
the TANDEM KSP plus clamping force blocks
are equipped with the jaw monitoring system.
SCHUNK Intec Ltd
Tel: 01908 611127
www.gb.schunk.com
22/2/13
12:59
Page 25
WORKHOLDING
Sorting out irregularities
If you’ve got unusual or double the
workholding requirements, ALLMATIC JAKOB
of Germany, together with Stocdon UK, have
the experience and technology to help.
The DUO PLUS system from Allmatic uses
Gripp technology to hold two components,
identical or different, at the same time. GRIPP
technology applies the same ideas as their
TITAN/CENTRIC Vices with the ability to hold
non-prismatic parts, especially castings/
forgings/flame cuts and rough sided material,
securely.
With the addition of PIVOT jaws, Allmatic
Duo Plus 125 can hold parts previously
considered for fixtures, therefore reducing
lead times and setting times for workholding.
The ALLMATIC DUO PLUS 125, as the
name suggests, is a double vice, offering
125mm wide body and jaws arrangements,
including step jaws, master adapting jaws and
GRIPP jaw selections.
Now it is possible to adjust the jaw width
opening, so that two different size jobs can be
held as well as two types of work, leading to
pallet change increasing output dramatically.
ALLMATIC is well-known for its preselectable clamping pressure up to 4 tons on
the vice, so all jobs can be covered, from light
aluminium to heavy rough castings. With
absolute accuracy in clamping, heavy
material removal is possible.
You can find out all the clamping options
available for your application with Stocdon’s
online calculator, which eliminates the need
for fixtures so that standard elements can be
used.
The Allmatic DUO PLUS can be used on
vertical machines with several on the table, or
for horizontal machines, pallet setups or
monoblocs are available - a real benefit for
irregular workpieces.
STOCDON LTD
Tel: 01242-241123
www.stocdon.co.uk
1st operation and 2nd operation work, or
semi finishing/finish machining, with each
Vacuum
Clamping
Systems
Hydraulic Clamping Systems
ANDREAS MAIER GmbH & Co KG
Waiblinger Strasse 116
D-70734 Fellbach
Germany
Tel. +49 711 576 6212
Fax.+49 711 57 57 25
[email protected]
www.amf.de wap.amf.de
UK Sales Office
Wakefield, West Yorkshire
Contact: Tony Fornsworth
Tel:
01924 242972
Fax: 01924 242981
Mob: 07976 942421
www.amf.de
Zero Point
Clamping Systems
The AMF Service Guarantee
• Full technical & design support
• Short delivery times
• High quality components
• Outstanding warranty
• Tailored solutions
22/2/13
12:59
Page 26
WORKHOLDING
Workholding ensures Exactaform remains at
the cutting edge
Since 1979, Coventry-based Exactaform
Cutting Tools has become the UK’s largest
manufacturer of PCD tooling for aerospace
and automotive applications. Over the past 15
years, System 3R has played its part in this
dominance through the use of Macro
workholding technology across all of
Exactaform’s EDM processes.
Depending on the nature of the tool, up to
25 diamond cutting tips could be inserted into
the tool body and each of those tips has to be
produced to micron accuracy. The diamond
tips are cut from carbide substrate discs which,
because of their exceptionally high cost
typically US$ 700 each, require the optimum
utilisation of material i.e. minimum wastage.
The cutting tips are laid out on each 70mm
diameter disc using AutoCad, similar to a
master tailor producing a fashion garment,
with a range of different tips fitted into the
surface to maximise the usage of the material.
A CADCAM cutting programme is then
produced that traces the EDM wire path on the
disk, and this is where Macro workholders
come into their own.
Two discs at a time can be loaded into the
company’s two Sodick Precision Wire Erosion
Machines (an AQ300L and an A325), with
each disc being held in its own Macro holder.
“All we need do is fit the disc into its holder,
find the zero point, save it, and the job is then
set up,” explains Jamie White, grandson of
founder, John Inglis. “Setup is so easy and
quick as clocking the disc in is not required,
and we have gone from 20 minutes to less
than 5. The assured repeatable accuracy
delivered by Macro also allows us to enjoy the
Macro workholding technology cuts setup
of two discs or part discs at a time in the
Sodick wire erosion machines from 20
minutes to 5 minutes
26
A selection of Exactaform PCD tooling in which up to 25 highly accurate diamond tips
are inserted
benefits of lights-out production, with 4 discs
being cut overnight, every night. Machine
utilisation is maximised and it has thus saved
us having to buy another machine.”
Knowing where the disc is in each Macro
the envy of their competitors. It runs 24/7 to
satisfy the quick delivery demanded in today’s
challenging global marketplace.
“There is no doubt that System 3R have
helped us double our capacity in tip cutting
Macro workholding is also used in
the Charmilles Roboform sink eroder
to provide the highly accurate
pockets in the tooling bodies into
which the diamond cutting tips are
inserted
holder also provides a very high degree of
flexibility in production. If a job needs to be put
on very quickly, then taking off a partially cut
disc and putting it back at a later stage
presents no problems. This also helps when
only part of a disc remains to be used at
another time. As long as the work remains on
its holder, reinstating a job or starting a new
one is plain sailing.
The tools’ carbide bodies have the pockets
for the tips eroded into them on a Charmilles
Roboform 35P Sink Eroder, which also utilises
Macro for speed of setup and repeatable
accuracy.
Exactaform has invested over £4 million
into making its diamond finishing shop, in
which the tools are assembled and finished,
with the substantial time saved in setup. It not
only allows us to maximise machine utilisation
and productivity but also enables us to
optimise our skilled workforce by enabling
them to do other tasks,” concludes Jamie
White.
Macro workholding is also used in the
Charmilles Roboform sink eroder to provide
the highly accurate pockets in the tooling
bodies into which the diamond cutting tips are
inserted
System 3R UK
Tel: 024 7653 8653
www.system3r.com
22/2/13
13:00
Page 27
WORKHOLDING
3 jaw to collet or mandrel in two minutes
With the B-Top3 modular clamping system
everything fits together perfectly.
No more taking off 3 jaw chucks. You can
achieve an extremely fast changeover from
outside to inside clamping with collet or
mandrel in a couple of minutes.
But the merits of the B-Top3 system don’t
stop there. The chuck has guidance jaws
with high repeatability which are especially
ideal for small bore sizes and give maximum
repeatability. Repeated jaw skimming is
therefore not necessary in most cases,
saving both time and effort and increasing
efficiency. Also, the new innovative
lubrication system ensures improved
clamping force, longer lubrication intervals
and vastly improved overall operation of the
wedge bar principle.
Due to the patented Centrotex positioning
system, there is no need to adjust for radical
accuracy, the collet chuck and mandrel can
be loaded within 0.005mm.
Everything is safety protected and
changeovers can only be completed with all
parts in the correct position.
The B-Top3 is small yet efficient
The B-Top3 with changing fixture
The B-Top3 with attachments
The advantages of the B-Top3 can be
summarised as: superfast changeovers, high
efficiency, high repeatability, flexibility and
operational safety.
Hainbuch UK
Tel: 01543 478710
www.hainbuch.com
MicroLoc

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&I[FSHJI7JKJWJSHNSL<TWPMTQINSL8^XYJRX
5WTIZHYNTS&ZYTRTYN[J&JWTXUFHJ8ZG(TS
)JXNLSJIFSI2FSZKFHYZWJINSYMJ:0G^2NHWTS<TWPMTQINSL
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22/2/13
13:00
Page 28
WORKHOLDING
New zero point system offers significant advantages
Leader Chuck recently launched its new
ZeroClamp ® zero point clamping system.
Designed to significantly reduce setup times
and increase machining efficiency, the
Patent-registered new system provides an
effective route to producing more
components, quicker and at a lower cost.
A number of features set this reliable and
robust workholding solution apart from
other competitor systems. Using the face and
taper HSK spindle tooling principle the
Leader ZeroClamp ® can achieve a
repeatability of +/- 2.5 micron, around 10
times more accurate than existing systems.
As the hollow, tapered-shank bolt is drawn
into the clamping pot the elastic properties
of the seating ring expand slightly, allowing
the taper to locate positively and the faces of
the pot and the pallet or raw material to
engage and locate solidly. Subsequently
each fixing point has a break-out force of
between 12.5 kN and 60 kN, depending on
the clamping pot diameter.
This principle also removes any
machining induced vibration, minimises all
thermal effects and compensates for hole
misalignments of up to +/- 0.1 mm as the
tapers always compensate towards the
centre of the clamping position. The tapered
bolts are produced from case hardened
42CrMO2 steel and are very strong,
allowing the workpiece or raw material to
stand on them for storage. Only one design
is used, avoiding the confusion caused by
‘fixed’ systems, which usually require three
different bolt designs that also known to
magnify any thermal errors.
28
“Thanks to the highly accurate
repeatability of the ZeroClamp system parts
can be unloaded and reloaded with the
minimum of fuss,” says Mark Jones,
managing director, Leader Chuck Systems.
“So, moving components from one machine
to another can be carried out without any
accumulated errors and important features
can be measured part way through the
machining sequence with the safe
knowledge that the part can be reloaded
accurately.”
Another advantage of the taper bolt
design featured on the Leader ZeroClamp
design is the ability to tilt the pallet or
workpiece during loading and unloading
without fear of damage, making heavy and
unbalanced workpieces easier to handle. It
also means the units can be fitted at any
angle, so they can be used in conjunction
with tombstones or similar fixtures on
horizontal machining centres. By contrast
fixed systems are often only used on vertical
machining centres as they need to be lifted
parallel or they can deform or lock together.
Fail-safe clamping is achieved on the
Leader ZeroClamp system by a stack of
precision manufactured segmented spring
steel collars that, by design, lock the taper
bolt in. These collars are opened by an
expanding bellows inflated with compressed
air at standard shopfloor pressure. The
bellows are guaranteed for 1 million
operational cycles. The simple design uses
just a few high quality stainless or corrosion
resistant steel components so it is very robust
and is unaffected by swarf or coolant
ingress, the pots can be quickly cleaned out
with a blast from a standard airline gun.
Avoiding all the disadvantages of a
hydraulic system, the smart design of the
Leader ZeroClamp system means that the
units are around half the height of any
alternative zero point fixtures, which allows
the machine tool to keep more of its working
envelope capacity.
“This is an important point as the fixturing
is often fitted to the worktable and it
therefore reduces the distance between the
spindle nose and the workpiece,” explains
Mark Jones. “We have kept this to a
minimum so that larger parts can still be
loaded and machined. The typical use of
zero point fixturing involves manual pallets,
which improve efficiency by allowing parts
to be loaded and set up outside of the
machine tool. However, the full application
and benefits of the Leader ZeroClamp
system is only really limited to the
imagination of the engineer considering its
use.”
Leader Chuck Systems Ltd
Tel: 01827 700000
www.leaderchuck.com
25/2/13
13:57
Page 29
WORKHOLDING
Cleaning machines quickly, automatically and unmanned
The practical AMF Cleaner from Andreas
Maier GmbH & Co. KG (AMF) allows
users to clean workpieces and clamping
fixtures as well as tools and machines
during and after machining in a fullyautomated process.
Differently designed Stick and Ball
cleaning tools are automatically loaded
as required into the machine spindles of
CNC machines, and clean using cooling
lubricant or compressed air. The Ball
version of the AMF Cleaner, with a
circumferential nozzle arrangement,
allows all nozzles to be individually
opened or closed. This enables fullyautomated, systematic and pinpoint
cleaning processes. Expensive bed
flushing
The automatic AMF Cleaner tool
employs the functions of CNC machine
and machining centres for rapid and inexpensive cleaning and drying.
The cleaning tools, which the company offers in a practical set, have an
interface to the machine spindle. The tool changing system in the
machining centre loads and unloads these tools, just like a cutting tool,
in a fully-automated process. Rotating the tools in the spindle at a
maximum of 100 rpm improves cleaning performance. It suffices for
cleaning workpieces, clamping fixtures, the machine table or the entire
machine interior fully automatically and unmanned, faster than any
operator can achieve. The AMF Cleaner cleans in rapid traverse and
can be integrated into the automation process quickly and simply. Both
cooling lubricant and compressed air can be used as the cleaning
medium.
360° cleaning range
The medium is fed through the spindle to remove swarf. The tool cleans
extremely thoroughly thanks to pulsating injection during a rotational
movement. In addition, the cleaning tool is able to systematically
approach selected positions or traverse critical contours. With a
cleaning range of over 360°, the laterally attached Ball version of the
AMF Cleaner enables even the spindle nose to be cleaned of swarf. The
cooling lubricant pressure range is 5–120 bar. For a targeted control of
partial surfaces or areas within the machine room, up to 15 nozzles can
be opened or closed individually. This is achieved quick and easily
using the tool supplied.
The Stick version is available in working lengths of 30, 100 and 180
mm and is the ideal solution for mechanically removing swarf from
workpieces and for cleaning clamping fixtures, before the next
workpiece is loaded. The automatic AMF Cleaner tools have a 5/8" or
16 mm straight shank with clamping surfaces for Weldon fixtures. A
sealing ring is used to create the seal between tool and tool fixture.
Thanks to selectable tool fixtures such as SK, KM, HSK, Capto and so
on, AMF offers all standard interfaces. The practical aids are supplied
in compact box sets, enabling two or more machines to be equipped.
Andreas Maier GmbH & Co KG
UK Sales Office:
Tel: 01924 242972
www.amf.de
The automatic AMF Cleaner tool employs the functions of CNC
machine and machining centres for rapid and inexpensive
cleaning and drying
22/2/13
13:01
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WORKHOLDING
New workholding range offers accuracy and affordability
YMT Technologies Tooling
Division offers an extensive
range of cost-effective high
precision tool and workholding
solutions, as well as efficiencyimproving machine tool and
workshop ancillaries. The latest
addition to the Yeovil-based
company’s comprehensive list of
high quality products is the 5th
Axis range of workholding
solutions for improved efficiency
when machining in 3-, 4- and 5
axes. Like all the products offered
by YMT, this new range comes
with full pre- and post-sales
technical support.
To withstand the pressures and forces of
CNC machining all 5th Axis fixtures are
manufactured from hardened alloy steel to
extremely tight tolerances and exacting
standards. Designed to allow cutting tool
access to five surfaces of the workpiece the
innovative fixtures are lighter, stronger and
more efficient than many traditional vices on
the market. Manufacturers using this stateof-the-art fixturing system can lower
component prices and reduce running costs
as workpieces are completed in as few
operations as possible.
Simple and robust the dovetail fixture is
designed for all 3-, 4- and 5-axis CNC
machines. Featuring a low profile design
and precision ground surfaces the unit
optimises tool clearance and minimises
second operation clean up thereby saving
time, money and material.
components. The vice design also lends itself
to mounting on tombstones and other
productivity enhancing workholding
solutions for maximum equipment efficiency.
A precision ground locating pin repeats
within 25 micron, meaning that parts can be
easily located and removed from the fixture
without loss of accuracy or the
inconvenience of the parts being relocated
in the wrong position.
Jason Short continues: “Any manufacturing company looking to increase
productivity requires high quality precision
tooling, workholding and a full range of
manufacturing support equipment. To
address these needs we have carefully
Jason Short, YMT Technologies’
tooling and equipment manager,
explains: “The 45˚ dovetail ensures a
high clamping force, guaranteeing
positive holding during both high
material removal cutting cycles and
precision finishing operations. The
dovetail fixture clamps onto as little as
1.5 mm of material. This reduces
material costs by allowing the use of
smaller raw material stock sizes, and
shortens the machining cycle time by
having less redundant material that has
to be machined away. Although a
dovetail preparation is required a
recent study showed that the savings gained
from using the dovetail fixtures outweighed
this by a factor of 2:1.”
Compatible with many popular multi-axis
fixturing systems the 5th Axis vices can also
be installed in arrays to hold large
selected our products to ensure high quality
tooling at competitive prices. As well as the
multi-axis 5th Axis fixturing our
comprehensive range includes machine
vices and spindle tooling that can help
increase machining capabilities. Our
innovative product range is constantly
improving so customers can rely on YMT for
all their tooling requirements.”
YMT stocks the 5th Axis range at its
extensive facility, as Jason Short concludes:
“For the UK’s advanced manufacturing
sectors, such as motorsport, power
generation, automotive and aerospace, we
supply high quality tool and workholding
solutions at competitive prices. We are
constantly updating and developing our
ranges to stay ahead of the latest machining
applications and the new 5th Axis range is a
perfect example of our commitment to this.”
YMT Technologies
Tel: 01935 428375
www.ymtltd.co.uk
30
22/2/13
13:02
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WORKHOLDING
MNG Zero Point baseplate system simplifies
workholding setup
The new MNG Zero Point system of baseplates
from WNT (UK) provides a simple and highly
versatile method of locating vices and fixtures
to the machine table. The mechanical system
used by WNT also makes the MNG Zero Point
system highly cost-effective.
Fully compatible with WNT’s range of
workholding vices, as well as systems from
other manufacturers, the new MNG Zero Point
base plates provide users with the ability to
quickly, and accurately position vices on the
machine table. Making use of a simple
mechanical clamping system WNT has
eliminated the need for hydraulics or air
connections, which in turn reduces the initial
cost to purchase the MNG Zero Point system
by up to 40 per cent compared to a hydraulic
system This simple clamping system, which
features just a single clamp screw to locate the
vice/tombstone, also reduces the overall
height of the base plate to 30mm, creating
minimum impact on the machining envelope.
In addition to the flat base plates for 3-axis
machines, variants are also available, exstock, for 4- and 5-axis setups
The use of MNG Zero Point, with its
accurate repositioning of workholding devices
(repeatability < 0.01 mm) dramatically
shortens setup times. When compared to
clamping vices/tombstones directly to the
machine table the setup time when using
MNG Zero Point is reduced by as much as 86
percent. Taking 30 minutes as the typical
conventional setup time to change a machine
vice with one setup per day using MNG Zero
Point would free up 30 hours of machine time
over a month.
Users of MNG Zero Point also benefit from
additional process security, due to the fact that
the clamping mechanism generates a
A MNG Zero Point Base Plate shown with a
WNT ESG Mini vice
clamping force of 20kN, which is between 6070% higher than other clamping methods. This
significantly increases the rigidity of the setup
allowing cutting data to be maximised. Plus,
due to the fact that the system uses a positively
driven clamp and unclamp mechanism, there
is no risk of the vice or tombstone that is being
clamped getting ‘stuck’ to the baseplate. A
further advantage of the MNG Zero Point
system from WNT is that by using standard
base plate elements it is possible to quickly
and easily create bespoke workholding
solutions, which would otherwise require
specialist fixturing and extended leadtimes.
“The MNG Zero Point System is a terrific
addition to WNT’s already extensive range of
workholding solutions,” says Adrian Fitts,
WNT (UK) business development manager.
“The reduction in setup time generated by use
of MNG Zero Point makes it highly costeffective, with payback time measured in just a
few weeks depending on usage. By combining
the MNG Zero Point system with for instance,
our ESG Mini Series of vices a single machine
can be set to perform first and second
operation work or multiple setups. We have
built our reputation on providing high quality
cutting tools with detailed technical support for
MNG Zero Point Base Plates can be
configured to suit individual applications
our customers. That same philosophy applies
to the workholding systems available from
WNT, with customers able to call on technical
support to ensure they are choosing the best
system for their applications.”
The MNG Zero Point system is available for
demonstration at WNT’s technical centre in
Sheffield where it is being shown alongside
the ESG Mini and H5G vice systems.
Alternatively, WNT’s Technical Sales Team
has demonstration kits that can be brought to
customers premises for evaluation. As with
WNT’s cutting tool range, the workholding is
available as ex-stock items, with next working
day delivery guaranteed.
WNT (UK) Ltd
Tel: 0800 073 2 073
www.wnt.com
31
ES CUTTING TOOLS 32-39:ES CUTTING TOOLS FTR 38-51
25/2/13
11:48
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CUTTING TOOLS
SGS Carbide Tool invests in
UK manufacturing
On the 22nd January 2013, more than 130
visitors attended the official inauguration of
SGS Carbide Tools’ new UK manufacturing
facility and European headquarters in
Wokingham, Berkshire. In front of the guests
that included the Mayor of Wokingham,
councillor Bob Wyatt, a ceremonial plaque
marking the occasion was officially unveiled
by former land speed record holder, Richard
Noble, OBE.
Representing an investment of over £6
million in facilities and new CNC tool and
cutter grinding machines, the 25,000 ft2
manufacturing and logistics supply centre
will form the hub of the company’s European
operations. This will provide a springboard
for further growth with customers in the
aerospace, defence, motorsport, medical,
power generation, oil & gas, as well as
precision general engineering sectors.
These are, of course, the most technically
demanding industry sectors and customers
often require bespoke solutions for their
machining tasks. As one of the most
advanced high performance cutting tooling
manufacturers, SGS is well aware that it has
to provide specific solutions to address the
machining challenges faced by industry.
New ferrous and non-ferrous alloys and
advanced composite materials are creating
many opportunities, and the investment in
the new facility will allow customers to
directly access the cutting tool technology
available from SGS.
After a warm welcome, company
president and CEO, Tom Haag presented
the company’s ‘Past, Present and Future’.
“The company was established in Akron,
Ohio in 1951, by Seybold, Graves and
Stahl – that’s the SGS,” he explained.
“Originally, we reconditioned cutting tools
for the local mould and die market that had
set up to support the tyre manufacturers in
the area.”
Today, SGS has evolved primarily into a
major manufacturer of high performance
solid carbide rotary cutting tools for the
machining and metalworking industry.
Significant business growth began in 2000,
32
(From left to right) company president, Tom Haag and Bloodhound SSC Project
Director, Richard Noble, OBE, officially opened the new SGS Carbide Tool European
headquarters
when the company acquired the patent for a
new variable helix end mill. Called Z-Carb
this milling cutter designed with unequal
helix geometry offered significant machining
performance benefits, and the much
extended range is still very popular. The
company also produces solid carbide drills
and milling tools under the brands S-Carb,
V-Carb, HiPer-Carb and Multi-Carb brands
for customers across the globe.
Employing 210 people in North America,
last year the company produced over 7
million cutting tools. Growth and investment
has allowed the company to support
complementary technologies, including
Action Super Abrasives, producing vitrified
and diamond grinding wheels, Hardcoating
Technologies providing advanced multilayer cutting tool coating services and
Oakview Tooling producing solid carbide
tools for orthopaedic manufacturing and
stainless steel tools for medical operations.
SGS opened its first UK office in 1986 and
began manufacturing tools here in 2005.
Today the UK operation employs over 40
staff supporting and supplying customers in
the automotive, aerospace, medical and
high precision engineering sectors. Demand
for its range across Europe has risen to the
point where it had to increase production
and stock levels as well as enhance its focus
on Research & Development. This new
facility provides SGS staff with the
opportunity to bring more technology to its
customers under one roof. Currently
equipped with eight 5-axis Walter CNC tool
and cutter grinding machines with
automated robotic loading producing tools,
plans exist for additional machines to match
growth from the market. Three state-of-theart non-contact CNC Walter Helicheck
inspection machines ensure product quality.
A separate section has also been set up
where advanced hard coatings, including
25/2/13
15:34
Page 33
CUTTING TOOLS
Super Nitride, can be applied. In-house
design capabilities allow new tool
geometries to be developed for specials
ordered by customers. As the European
headquarters the new site also holds more
than 150,000 tools, valued at £3 million,
ready for next day delivery to customers
across Europe.
With the unveiling of a ceremonial
plaque, the new building was officially
opened by company president, Tom Haag
and Richard Noble, former land speed
record holder and project director of the
Bloodhound SSC project that aims to build
the first car to achieve 1,000mph in South
Africa next year.
As a product sponsor of Bloodhound SSC
project, SGS is providing the cutting tools
required to produce many of the
components for the car. Richard Noble took
the opportunity to inform guests of the latest
project developments, including the success
of the firing of the rocket engine, and the
inspirational work he and his team is
promoting in schools to stimulate the next
generation of engineers.
After presentations by SGS partners
DMG/MORI SEIKI and Delcam, visitors
were invited on the ‘Build a Tool’ tour which
guided them, step-by-step, through the
comprehensive process adopted by SGS to
produce its high performance cutting tools.
From initial enquiry to design,
manufacturing and inspection, and on to
product testing, the tour provided everyone
with an insight into the commitment to
quality and customer satisfaction adhered to
by the staff at the company.
Over 130 visitors attended the inauguration of the new facilities
At the end of the tour, visitors were able to
discover the new Technical Centre, designed
to offer tool demonstrations and machining
solutions for customers. Equipped with a
DMG/Mori Seiki DMU 50 full 5-axis
machining centre linked to the latest Delcam
software, which will also provide a centre for
staff training, the Technical Centre supports
the company ethos that is solutions based.
Discussions with customers will provide clear
objectives regarding what they want to
achieve. They may wish to reduce cycle
times or lower their tooling costs. Whatever
their needs the team at SGS aims to deliver a
solution that best suits the goals. One of the
greatest strengths will be the ability to test
tools and machining strategies for
customers. The Technical Centre has the
right machine tool with state-of-the-art tool
holding and work holding, as well as
advanced coolants, to provide customers
with an overview of what can be achieved
on their shop floor. The customer can come
and see how they can address their
challenges.
The total investment demonstrates SGS’s
commitment to providing bespoke tooling
for customers tackling the latest materials,
increased competition and demanding
contracts. The new factory will also export
tools back to the USA. As leading
companies in the aerospace and automotive
industries produce new materials to test,
SGS can deliver new cutting tools and
develop more efficient geometries. It is a
proactive approach that will improve and
increase the company’s portfolio of products
by organically evolving tools.
SGS Carbide Tool is a premier
manufacturer of high performance,
precision solid carbide rotary cutting tools,
with a metric and an imperial inventory of
over 16,000 items, plus an industry leading
bespoke special tooling service to meet
customer specific requirements. Headquartered in Ohio, USA, SGS has a 25,000
ft 2 European headquarters and
manufacturing facility in Wokingham, UK.
SGS Carbide Tool (UK) Ltd
Tel: 01189 795200
Email : [email protected]
www.sgstool.co.uk
New tool and cutter grinding machines are equipped with automated robot loading
and unloading
33
25/2/13
11:50
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CUTTING TOOLS
Iscar’s IQ range an instant success
Now in its third decade in the UK, Iscar has
successfully developed a major presence in
the metalworking industry by helping
customers to improve their productivity
through the application of its leading edge
technologies and unique cutting tools.
The cutting edge work of Iscar’s prolific
Research and Development Department has
enabled the company to remain at the very
forefront of cutting tool development. To help
ensure continued progress within the field,
Iscar invests approximately 8% of its total
resources into its R&D activities. Iscar’s
progressive R&D activities have enabled the
company to claim many ‘firsts’ within the
field of cutting tools, whilst it has set new
standards in areas such as toolholders, new
coatings, tooling geometry and in
metalworking applications for turning,
milling and drilling.
However, Iscar innovations are not limited
to new metalworking products. New, more
efficient and more cost-effective
manufacturing procedures and processes
are constantly being implemented by the
company. Improvements in computerisation,
data flow, quality assurance, employee
safety and environmental protection are all a
part of the Iscar mentality.
Each new product begins as an idea in an
engineer’s mind. The image is entered into a
computer aided design/machining
(CAD/CAM) program, prototype produced
and it then goes through exhaustive
analyses. Repeated refinements, analyses,
and testing continue until the exact results
are achieved. Only after such an extensive
development and testing sequence can the
new idea move from the prototype phase to
development for manufacturing.
In addition to the unremitting evolution of
34
the Iscar range, occasionally the company
makes a quantum leap forward. Several
years ago Iscar’s ‘Sumo’ range was
launched in a fanfare of publicity and the
advantages that users gain from the Sumo
ranges advanced coatings ensured that to
this day Iscar’s Sumo tools are extremely
popular throughout the UK production
environment.
Having conducted a similar’ high-profile
global launch in November 2012 when
introducing the company's HIghQLine (IQ)
'Intelligent Machining' range, it became
clear that Iscar’s comprehensive new range
of advanced cutting tools represented
another revolutionary jump forward.
Covering all of the main tooling categories,
Iscar’s comprehensive new IQ range consists
of 20 separate product families and over
1300 new product lines.
The time and money savings attributes of
the IQ range means that Iscar UK’s sales
engineers and the staff of the company’s
independent distributors are now extremely
busy undertaking demonstrations and
machining trials with many potential users.
Indeed, sales of tools throughout the IQ
range, since its launch just 3 months ago,
have exceeded all of the company’s
expectations. Both existing Iscar users who
have converted seemlessly to IQ tools and IQ
customers new to the Iscar brand have
gained a range of real advantages. New
users have benefited from the ability to
increase feeds and speeds, have welcomed
the longer lasting characteristics of IQ tools
and also the fact that often a single IQ tool
will perform a range of processes that
previously needed 2–3 tools.
New users have found that the conversion
to Iscar’s IQ range has been made simple
through Iscar’s readily available technical
back-up. In addition to the company’s expert
external sales engineers and the
knowledgeable staff of its independent
distributors, Iscar UK ensures that machining
specialists are just a phone call away at the
company’s impressive purpose built
headquarters. Conveniently located in the
South West outskirts of Birmingham, close to
the motorway network, the facility houses all
UK sales and administration functions.
Whilst in the field, a team of 45 engineers
and 31 independent distributors provide on
the spot support to customers.
Registered to BS EN ISO 9002 since 1994
and Investors in People standards since
1996, Iscar’s headquarters incorporates a
dedicated, state-of-the-art Training and
Seminar Centre. Facilities include a 90 seat
auditorium, 450m 2 showroom and
demonstration unit housing four CNC
machines. These first class amenities are
used to provide top quality courses in the
application of new cutting tool technologies.
Increasing demands for tailor-made
tooling are also satisfied in-house by a new
Integrated
Design
and
800m 2
Manufacturing Centre.
Iscar Tools Ltd
Tel: 0121 422 8585
www.iscar.co.uk
22/2/13
13:03
Page 35
22/2/13
13:03
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CUTTING TOOLS
Rainford carves into HAM’s success
Rainford Precision has announced that it has
now signed an agreement with
Hartmetallwerkzeugfabrik Andreas Maier
GmbH (HAM Tools, www.ham-tools.com) to
distribute the cutting tools manufactured by
this leading German manufacturer, that has
established a reputation for quality throughout
Europe. The new range of HAM cutting tools
will be the perfect complement to the existing
range of products available from Rainford
Precision.
The agreement between the two companies
will see Rainford Precision increase its range of
solid carbide drills and endmills. From a
drilling perspective, the extensive HAM range
will give Rainford customers access to the
renowned HAM SuperDrill and MultiDrill
series of solid carbide twist drills, spiral fluted
drills and step-drills for machining universal
workpiece materials, steels and hard materials
up to 22 mm diameters. HAM has a series of
deep hole drills available from 3xD to 40xD,
most with through coolant capability to
improve swarf evacuation which are popular
with sliding head machine users.
For the drilling of stainless steel, titanium
and heat resistant alloys, the HAM Nirodrill is
available as well as a range of straight fluted
multi-drills for machining aluminium and nonferrous materials. For specialised applications,
the Rainford based cutting tool specialist will
be offering a selection of PCD drills and step-
Unbenannt-8 1
36
With such an extensive selection of drilling
and milling products available from the
standard HAM catalogues, Rainford Precision
is naturally delighted with the new agency
agreement. Rainford Precision's managing
director, Arthur Turner comments: "The HAM
range of products fits perfectly with our
philosophy of providing the marketplace with
cutting tool and machine tool solutions of the
highest quality with exceptional technical
support. Already working with leading cutting
tool manufacturers such as Union Tool and
Kyocera Micro Tools, the HAM products fit
perfectly into our portfolio and give our
customers access to an extremely diverse
drills as well as solid carbide and Cermet
reamers for specific demands. The technical
expertise afforded to Rainford by the
manufacturer will enable Rainford to supply
drills with points that are ground to unique
geometries for high performance hole making
in diverse materials and applications.
To complement the high performance
drilling range, HAM will also be offering its
renowned series of endmill products. With
such an extensive product offering, Rainford
will be focusing its attention on the 1 to 32 mm
diameter range of standard endmills for
machining anything from plastics through to
hardened steels and aluminium alloys. Despite
Rainford initially focusing its attention on the
standard HAM series of milling products, this
range also incorporates roughing endmills for
high material removal rates, ball nose and
radius cutters for 3D profile machining and
solid carbide endmills with multiple flute and
cutting edge geometries and options. For more
application and material specific
requirements, Rainford Precision will be
offering solid carbide cutters for
countersinking, engraving and corner
rounding as well as PCD endmills for high
performance machining on aluminium alloys,
graphite, composite and additional abrasive
materials such as glass fibre composites.
range of cutting tools. This synergy between
the product ranges will be a seamless fit for our
technical team and will further enhance our
position in delivering productive, cost effective
cutting tool solutions to the end users."
Rainford Precision Ltd
Tel: 01744 889726
www.rainfordprecision.com
20.11.2008 14:25:44
IENT ANISM
C
I
F
EF MECH
KING
LOC
Brilliant
Grooving
New Tiger Line for
Heavy Deep Grooving
Dovetail
Front
Back - Blind Hole
• New Tiger Insert Provides Improved
Secure Clamping
• Enables Interruption- Free Chip Flow
• Bottom Clamping Mechanism
for Rigid and Easy Clamping
• Coolant Directed to the Cutting Edge
by 3 Nozzles to Ensure Long Edge Life
• Wide Variety of Standard Sizes in a
Range of 10 to 20 mm
www.iscar.co.uk
IQ ads_UK.indd 4
9/4/12 12:18 PM
22/2/13
13:04
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CUTTING TOOLS
Crazy drilling performance from Floyd
Floyd Automatic Tooling has now
launched the new CrazyDrill Flex
series of drilling products from leading
Swiss precision manufacturer Mikron
Tool for the drilling of ultra precise
holes. The new range of solid carbide
drills are extremely flexible and
therefore suitable for deep hole drilling
up to 50XD.
The new CrazyDrill Flex is
manufactured from high grade
carbide with an innovative geometry
that makes the new drills extremely
flexible and accurate. These attributes
are advantageous when alignment
errors occur, especially in applications
with highly productive sliding head
lathes, multi-spindle machines and
transfer machines. The CrazyDrill Flex
can effortlessly compensate 40% of its
diameter thanks to its flexible centerpart that
prevents breakages and provides flexibility
only previously available with HSS drills.
The special tool geometry makes it possible
to drill even in the instance of drill alignment
errors. The CrazyDrill Flex eliminates errors
quickly without cutting edge breakouts to
guarantee reliability and extended tool life.
The CrazyDrill Flex has been developed with a
host of innovations such as a special tool tip
geometry that reduces feed force by 50% to
permit maximum drilling speeds and minimal
heat. The flanks of the drill incorporate an
edge protection system that prevents the
cutting edges from breaking when drilling
holes at high speeds and feeds.
The newly developed drill point is
complemented by a unique chip flute
geometry that creates short chips that can be
evacuated with ease. Beyond the drill flutes is
the flexible centrepiece. This flexible shank
prevents breakages caused by alignment
errors enabling customers to achieve the
38
staggering 50XD drilling depth. With a
precision ground 3mm shank, the customer
can be confident that run-out is eliminated. The
combination of these attributes gives
productivity 8-10 times faster than single flute
gun drills whilst minimising lateral forces and
run-out for exceptional positional accuracy.
The new CrazyDrill Flex is available in
20XD, 30XD and 50XD with a range of
FlexPilot drills also available for drilling at 3XD
with diameters from 0.1 to 1.2mm in 0.01mm
increments. The CrazyDrill Flex is available
with two coating types that are differentiated
by name, the CrazyDrill Flex Steel and the Flex
Titanium. The Flex Titanium has been
developed for the drilling of tough and long
chipping materials such as copper and
titanium alloys whereas the Flex Steel is a more
diverse drill that is capable of drilling alloy and
non-alloy steels, cast iron, aluminium alloys
and brass.
The CrazyDrill Flex 20XD drills are
available in diameters from 0.1mm to 1.2mm
with cutting lengths from 2 to 24mm whilst the
30XD drills are available with the same
diameters but with a cutting depth from 3 to
36mm with overall lengths from 40 to 70mm
depending upon drill diameter. With regard to
the exciting new 50XD drills, the diameters
vary from 0.3 to 1.2mm in 0.1mm increments
with drilling depths from 15 to 60mm with
overall lengths from 53 to 95mm.
The CrazyDrill Flex incorporates three
coolant channels in the drill shank to optimise
tool life, machining performance and
evacuate swarf. The Swiss precision specialists
recommend using a cutting fluid at a minimum
pressure of 10Bar to optimise performance.
Floyd Automatic Tooling Ltd
Tel: 01462 491919
www.floydautomatic.co.uk
22/2/13
13:05
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CUTTING TOOLS
New Dormer taps tackle tough materials
Dormer Tools’ latest product launch
encompasses a range of taps designed to
support a high level of performance in a range
of hard to machine materials. The material,
coating and geometry of the new taps has
been engineered specifically to facilitate a
continuous production process in tough
materials including, in particular, stainless
steels.
The range, unveiled at February’s Southern
Manufacturing event in Farnborough,
coincides with both Dormer’s centenary and
the centenary of Harry Brearley’s invention of
stainless steel.
Simon Winstanley, marketing coordinator
at Dormer Tools, says: “Stainless steel has
been very much a part of Dormer’s history
right from the very early days. It therefore
seems fitting that the launch of these new taps
comes in a year that marks not only the 100th
anniversary of stainless steel but also Dormer’s
own 100 years landmark.”
Manufactured from premium grade high
speed cobalt steel with a choice of surface
finishes, the taps offer improved wear
resistance and low material adhesion. The
flute geometry allows adequate space for
rapid and smooth chip evacuation, meaning
negligible swarf congestion and, therefore,
increased productivity. The spiral flute taps
feature a short thread length that generates
less torque and further improves chip
evacuation capabilities, meaning they can
support higher cutting conditions than
comparable equivalents.
The range includes spiral point and spiral
flute geometries in a variety of thread forms
with steam tempered or Super-B (TiAlN plus
an additional edge treatment) coating.
Dormer Tools Ltd, originally formed as The
Sheffield Twist Drill Co. Ltd, celebrates its
centenary in 2013. Today, the company is a
key member of the Sandvik group with sales
units in 25 countries serving over 100 markets
worldwide. Its expertise lies in the manufacture
of superior quality round tools, primarily drills,
taps and milling cutters, in solid carbide and
high speed steel.
Dormer Tools UK moved to a purpose built
facility at the Advanced Manufacturing Park in
South Yorkshire in January 2009. The site
incorporates state-of-the-art training facilities
and an international export service to support
emerging and developing markets.
Dormer Tools Ltd
Tel: 0870 8504466
www.dormertools.com
New high precision chuck
March 1st sees the launch of CoroChuck 930.
This high precision hydraulic chuck from
Sandvik Coromant brings a secure tooling
performance to milling and drilling
operations. Perfect for meeting the demands
for high run out precision, extensive tests have
shown this new hydraulic chuck provides the
best pull-out security available.
Fulcrum technology
The secret behind the high precision and pullout security is in the optimised design of the
brazed membrane which allows for maximum
secure clamping with two supports on each
side (fulcrums). This design ensures excellent
torque transmission to improve the
performance of solid carbide end mills, drills
and reaming tools. This performance is
repeated over multiple clamping cycles to
retain high quality component surfaces and
extend tool life. Additionally, the CoroChuck
930 is designed with dampening features that
minimise vibrations during the machining
process.
Based on a hydraulic tool clamping system,
the CoroChuck 930 can be quickly tightened
or released with a dedicated torque wrench,
improving efficiency through quick and easy
set-ups and changes. No external equipment
is required to clamp or unclamp the system.
The chuck holds tolerances within microns to
improve tool precision, surface finish and
productivity.The precision run-out can be
measured at <4 µm (157 µinch) at 2.5 × DC.
CoroChuck 930 is suitable for all types of
machine tools that either have a rotating
spindle or workpiece; lathes, multi-task
machines, machining centres and driven tools
in turning centres, and vertical turning lathes.
Available in pencil, slender and heavy duty
design, CoroChuck 930 is balanced
according to DIN 69888. For a more
information and a closer look at the new
CoroChuck 930 visit:
www.sandvik.coromant.com/productnews
Sandvik Coromant is a global leading
supplier of cutting tools, tooling solutions and
know-how to the metalworking industry. With
extensive investments in research and
development the company creates unique
innovations and set new productivity
standards together with customers. These
include the world's major automotive,
aerospace and energy industries. Sandvik
Coromant has 8000 employees, is
represented in 130 countries and is part of the
business area Sandvik Machining Solutions
within the global industrial group Sandvik.
Sandvik Coromant
Tel: 0121 504 5400
www.sandvik.coromant.com.
39
ES M&I FTR 40-51:ES MACHINING CTRS FTR 32-37
22/2/13
13:05
Page 40
Feature - MEASUREMENT & INSPECTION
Vollmer UK signs service and
distribution agreement with Zoller
Vollmer UK has signed an agreement with
German presetting and tool measuring
machine manufacturer Zoller, to service,
support and sell its product range in the UK.
Vollmer is renowned as the market leading
machine tool supplier for the production of
high specification cutting tools, so the new
agreement will deliver a complete synergy
between the two product portfolios. The new
agreement will give manufacturers the
equipment to pre-set, manufacture and inspect
tools, all from one supplier.
Vollmer UK's managing director, Peter
Allen comments: "The synergy between our
machine range and the Zoller presetting and
measuring products is apparent. Both
companies have unsurpassed reputations for
high quality, high precision solutions for the
setting, production and inspection of cutting
tools. By working together, the Zoller range
can be utilised for the presetting and
calibration of tools, the Vollmer machine
range can manufacture and polish whilst the
Zoller inspection, measuring and tool
management systems can qualify that the
products are manufactured to specification
with full conformity reports to meet the
demands of ISO certification."
With Vollmer's reputation for providing
exceptional customer support, Zoller was keen
to build a relationship with Vollmer UK. The
Vollmer UK team is currently undergoing a full
Zoller training program to support the
company's expanding UK customer base and
to ensure that customers' annual calibration
checks for ISO certification are fully met. The
40
training will also incorporate full service and
support of the Zoller range, as Vollmer UK will
be responsible for selling the Smile,
Smartcheck and Genius product ranges to the
UK marketplace.
The Zoller Smile is a simple to operate
universal tool presetter and measuring
machine that has been designed specifically
for measuring tools prior to the production
process. This will be complemented by the
SmartCheck machine that can be used
manually or as a 3-axis CNC version. The
Smartcheck provides an economical means of
checking before and after sharpening and
documenting to comply with ISO:9000
directives. Also, the swivelling incident light
camera allows customers to check, measure
and document the axial or radial geometries
of tools with simplicity.
These two machines will be available from
Vollmer UK, alongside the Genius universal
measuring machine for the rapid testing of
individual criteria through to complete, fully
automatic operator independant checks on
cutting tools. The measurement results are
documented in detail and can be transferred
to the grinding machines at the push of a
button.
"For cutting tool manufacturers that are
committed to delivering product ranges that
exceed customer expectations with regard to
quality and productivity; the addition of the
Zoller portfolio gives Vollmer customers access
to machine tools and expertise for the whole
cutting tool life cycle. This cradle to grave
expertise that is available from Vollmer is
beyond anything available from alternate
suppliers. The new working relationship will
open doors for both parties, but will most
importantly improve the service and support
that our end users will receive," concludes
Peter Allen.
Vollmer UK Ltd
Tel: 0115 949 1040
www.voller-group.com
© 2013 Hexagon Metrology – Part of Hexagon
10’000 SINGLE PARTS.
1 METROLOGY PARTNER.
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Hexagon Metrology offers a comprehensive range of products and services for all industrial metrology applications
in sectors such as automotive, aerospace, energy and medical. We support our customers with actionable measurement
information along the complete life cycle of a product – from development and design to production, assembly
and final inspection.
With more than 20 production facilities and 70 Precision Centers for service and demonstrations, and a network of
over 100 distribution partners on five continents, we empower our customers to fully control their manufacturing
processes, enhancing the quality of products and increasing efficiency in manufacturing plants around the world.
Learn more
 www.hexagonmetrology.com
25/2/13
15:35
Page 42
MEASUREMENT & INSPECTION
Continued investment in UK support and training
Hexagon Metrology recently opened its new
Chester Technology Centre. The purpose of the
new facility is to support core customers and to
respond to the significant growth in its installed
customer base. Steve Shickell, UK sales
manager, Portable Metrology, explained that
the company has a particularly strong
presence in the aerospace sector, with 50% of
customers accessible from the new Centre. The
facility features AT 401 calibration up to 80
metres in a temperature-controlled
environment. Laser tracker repairs will be
carried out here and a customer support van is
available for collection and delivery. A
training area facilitates hands on tracker
training as well as customer telephone
support. A contract inspection facility is also
available.
David Brown, general manager – director
of Hexagon Metrology Ltd outlined the global
performance in 2012 of £2.2 billion net sales,
with 13,000 enquiries across more than 40
countries. The company invested 12% in R&D,
demonstrating its commitment to develop the
most innovative solutions in the market. It has
also acquired 70 companies since 2000, the
most recent being New River Kinematics, the
US-based company that specializes in 3D
analysis software for portable metrology
applications. However, he went on to explain
that as well as a truly international player,
Hexagon was also focused on local markets.
The three pillars to the Hexagon Metrology
business are: Metrology (improving the
manufacturing process), Geosystems (mainly
in the construction industry and in the field);
Technology group (software).
There are now five locations in the UK, in
Telford, Swindon, Milton Keynes, Chester and
Belfast, with 90 staff dedicated to the UK
business, including 4 apprentices.
A new UK training facility has also been
opened in the company’s Telford
headquarters. At the brand new training
facility, up to 12 new and existing software
users can be trained per day in a high
technology environment. Packed with the latest
state-of-the-art technical equipment the new
facility provides the best possible environment
for customers needing to learn about
Coordinate Measuring Machine (CMM)
operations and software programming.
David Brown says: “We believe UK
manufacturing and its engineers have
something unique to offer the world. Our
behaviours and inherent British character
42
(Left to right): Richard Noble OBE with Hexagon’s Steve Shickell
drives invention and innovation creating
cutting edge products and services. We
believe that to stay at the front of the world
pack we have to invest in our engineers
ensuring they are highly skilled and above all
maintain their optimum skill level.”
In the UK Hexagon Metrology have several
thousand seats of metrology software
installed, with each seat having multiple users.
The software like most is evolving at a rapid
rate providing added functionality that users
can use to speed up what they do and how
they do it, in turn improving productivity and
maximising the return on investment from
metrology equipment.
“We talk and listen a lot to our customers to
understand their need for further metrology
and software training”, says Sam O’Prey,
Aftermarket commercial manager for the UK.
“In the current environment, as UK
manufacturing bucks the trend and continues
to grow in some segments, customers are
taking on exciting new contracts and projects.
This often means running their production lines
and quality inspection departments 24/7. In
turn this produces a real need for additional
skilled resources that have the best capability
and understanding of CMMs and their
software."
To support the new training facility the
company has also increased course
availability and frequency within its training
calendar. The new facility is open and in full
use now. The 2013 training courses and dates
can be viewed at:
www.hexagonmetrology.co.uk/training
Hexagon Metrology offers a comprehensive
range of products and services for all
industrial metrology applications in sectors
such as automotive, aerospace, energy and
medical. It supports customers with actionable
measurement information along the complete
life cycle of a product, from development and
design to production, assembly and final
inspection.
With more than 20 production facilities and
70 Precision Centre’s for service and
demonstrations, and a network of over 100
distribution partners on five continents, we
empower our customers to fully control their
manufacturing processes, enhancing the
quality of products and increasing efficiency in
manufacturing plants around the world.
Hexagon Metrology plc
Tel: 0870 4462667
www.hexagonmetrology.com
Trusted the world over
Customers across the globe rely on Mitutoyo to supply industry leading
products with comprehensive service and support as standard.
Modern manufacture demands top-class measuring equipment for
quality assurance and so, knowing the reputation of your company
depends on meeting production targets with reliable products,
Mitutoyo offers you the highest quality metrology solutions backed
by the most comprehensive service and support available.
Coordinate Measuring Machines ■
Vision Measuring Machines ■
Form Measurement ■
Optical Measuring ■
Sensor Systems ■
Test Equipment and Seismometers ■
Call us on 01264 353123
or visit us at www.mitutoyo.co.uk
Claim your FREE Quick Guide to Measurement!
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new 50-page full-colour quick guide completely free.
Digital Scale and DRO Systems ■
Small Tool Instruments and Data Management ■
22/2/13
13:07
Page 44
Viewing sales from a great ‘Vantage’ point
New FARO Vantage, portable Laser Tracker proves to be an instant success
Following the high-profile July launch of the
eagerly anticipated Vantage Laser Tracker,
sales volumes in the second half of 2012 far
exceeded FARO Technologies UK’s ambitious
projections.
The advanced new model’s long list of
attributes and cost-effective price makes the
Vantage ideal for use on a multitude
applications across a wide range of industries.
This universal appeal in reflected in the diverse
nature of the businesses that have already
invested in FARO‘s new model. Amongst
many others, early sales have been made to
OEMs involved in the wind power energy,
energy provision, bus and coach, tooling,
automation and subcontract measurement
service industries.
The Vantage provides customers with a truly
portable, scanning capable, IP rated Laser
Tracker that has been specified and designed
to meet the demands of real Laser Tracker
applications. The Vantage is portable enough
to travel as hand luggage whilst the new agile
TruADM (Absolute Distant Meter), FARO's
Patented 5th generation ADM, offers dynamic
scanning capability previously only seen in
much larger, less portable Laser Trackers.
Commenting on the early success of the
Vantage Laser Tracker, Andrew Tagg, FARO
Technologies UK sales manager says: “As
early 2013 sales are following the outstanding
trend established last year, our assertion that
‘the Vantage was the answer to the UK
industry’s quest for a value for money, fully
capable dynamic tracker’ has been
vindicated. All potential UK laser tracker users
are now able to purchase a cost-effective
solution that offers extreme portability,
supreme accuracy, and shop floor durability.”
Faro measures the success of
Southern Manufacturing
The interest shown in FARO‘s new Laser
Tracker and the many sales leads generated
for both new and established products
ensured a very successful Southern
Manufacturing & Electronics exhibition for
FARO Technologies UK.
The recent exhibition proved to be great
success. As well as portable CMMs and 3D
imaging devices, the new FARO Laser Tracker
made its debut at the Farnborough-based
exhibition. Sales staff were kept busy
throughout, demonstrating both the extremely
accurate device and the company’s
established range of high quality measuring
technology.
Andrew Tagg reports: “Southern
Manufacturing & Electronics 2013 was a
tremendous success for FARO. Not only were
sales enquiries up by an impressive 75% on
the 2012 exhibition, the overall quality of the
leads generated was also better. Our
advanced new Laser Tracker Vantage is an
extremely accurate, portable coordinate
measuring machine that enables users to build
products, optimise processes and deliver
solutions, and it created excellent levels of
interest on our stand.
“In addition to generating high levels of
sales enquiries across our entire range of
portable CMMs and 3D imaging devices with
potential new customers, the show gave us an
ideal opportunity to introduce our new
products to many of our existing customers.
Our sales engineers will now be kept busy
performing in-house demonstrations related to
the many sales leads generated at the show.”
FARO Technologies UK Ltd
Tel: 024 76 217690
www.faro.com
44
22/2/13
13:07
Page 45
Maximise cutting tool life
Don’t leave tool life to chance - use the Alicona IF-EdgeMaster
Tool wear rates are critical in machining and if this can be optimised
then tool costs and machining downtimes caused by tool change can
be reduced and component scrap rates minimised by optimising the
tools cutting parameters. The Alicona IF-Edgemaster tool measuring
system can provide the information necessary to optimise tool life by
providing the information to achieve these benefits.
The IF-Edgemaster is an optical 3D measurement device to
automatically measure cutting tools. Using the FocusVariation
technology developed by Alicona, the Edgemaster scans vertically
over an insert edge or cutting flute and captures a full 3D model of
the feature to be measured. When used on worn tools the data can
be compared against the new data to provide accurate information
on wear rates and patterns. This data is stored in user defined
databases for record and comparison purposes
Typically, the system is used to measure cutting edges regardless
of type, size, material or surface finish of the tool. Users can measure
edge radii > 2µm in addition to rake, wedge and clearance angle of
cutting edges. The robust technology of Focus-Variation delivers
stable and traceable results in a near production environ-ment and
results are obtained within 20 seconds, no pre-treatment of the
surface is required.
The system is very simple to use with user defined procedures
being stored for rapid selection by the operator, the system also
allows comparison against a master or “golden” tool allowing very
effective quality assurance and comparison.The use of this system,
already in use with tool makers and regrinders, allows large tool
users to optimise performance and reduce cost.
Alicona UK Ltd
Tel. 01732 746670
www.alicona.com
BOWERS METROLOGY: LEADING THE WAY
IN QUALITY AND INSPECTION SOLUTIONS
Swiss Precision with
the new Sylvac D300S
Digital Display
Small Bore
Measurement with the
NEW Bowers MicroGauge
Accuracy and
Repeatability
from the
Trimos VL Digital
Height Gauge
Partners in Precision
The Bowers Metrology Group of Companies
Unit 15, Bordon Trading Estate,
Bordon, Hampshire GU35 9HH
Telephone: 08708 50 90 50 Fax: 08708 50 90 60
www.bowers.co.uk [email protected]
45
22/2/13
13:08
Page 46
Aberlink helps keep the ‘Q’ in Q-Mass
When Q-Mass commenced trading as a
subcontract machining business in early
2006, it was clear that, mindful of the
established competition serving the
demanding Oil and Gas industry, the
fledgling business needed to provide
something different to become successful.
With the new company’s main focus
concentrated on the quality of its work, the
owners of Q-Mass (Quality Manufacturing
and Supply Solutions) knew that they had to
deliver consistently high-quality, added value
components, on time and at a competitive
price. To enable the company’s ambitious
objectives to be realised, Q-Mass recruited a
strong team of people whose array of abilities
encompassed all of the required technical
skills. The company also invested in a variety
of state-of the-art machine tools. The early
success of Q-Mass proved the founding
principles of the company to be correct.
Further continuous investment has resulted in
Q-Mass becoming regarded as one of the
most capable UK machine shops serving the
Oil and Gas industry.
Now operating from a modern 30,000
square feet manufacturing plant in Central
Scotland, much of Q-Mass's work is related to
new product development, where the
technology required by the oil industry means
increasingly complex designs need to be
manufactured. These intricate parts often
include complex geometries, gun drilling,
hydraulic ports, tight tolerances, and are often
characterised by challenging lead times.
To ensure the highest standards of
components being delivered to its customers,
in addition to thorough 'in process' inspection
procedures being carried out, painstaking
final inspection routines are undertaken on all
of Q-Mass’s output. Prompted by the growing
complexity of Q-Mass’s output and the
increasing size of components manufactured
by the company, a recent search for a large
volume coordinate measuring machine
(CMM) was undertaken.
Company owner, Ronnie Robertson
explains: “It is no coincidence that the ‘Q’ of
Q-Mass (Quality Manufacturing and Supply
Solutions) stands for ‘Quality’. Having set out
to found our company ethos on the quality of
the work we undertake, we have now firmly
established our reputation through the high
standards of our output.
“To enable the precise measurement of our
ever more complex parts and to allow the
inspection of our increasingly larger
components, we recently carried out a search
for a large capacity CMM. After considering
the alternative machines, we purchased a
Zenith Too CNC CMM from Northern
Metrology. Following training on the new
Aberlink CMM, our inspectors have been able
to master the machine’s relatively simple
controls and Aberlink’s intuitive measuring
software.
“In addition to our new CMM’s generous
XYZ measuring envelope of 40" x 60" x 32",
that is able to accommodate our larger parts,
the Zenith Too’s ease of use and
comprehensive capability ensures that even
our most demanding of parts can be inspected
with high levels of accuracy.
“As much or our output is under challenging
time constraints we have been delighted that
the rapid CNC action of the new Aberlink
CMM has also resulted in significantly
reduced inspection times.”
Manufactured by Aberlink Innovative
Metrology, the largest UK-owned coordinate
measuring machine manufacturer, the large
capacity Zenith Too Coordinate Measuring
Machine range consists of 10 machines with
XYZ capacities from 1000x1000x
600–1000x3000x800.
The range’s cutting edge, all aluminium
construction, advanced drive design and
raised guide-ways ensures that despite their
generous measuring envelopes, the machines’
extremely low inertia characteristics
guarantees supreme speed of operation.
Impressive accuracy and repeatability figures
are further aided by the range’s measuring
structure being completely independent of the
machine’s granite surface table.
To further improve Aberlink’s popular
Zenith Too series, a range of improvements
were recently announced. Each machine is
now supplied with an ingenious,
ergonomically adjustable arm, supporting the
machine’s keyboard, mouse and new, highquality 22" flat screen monitor. Whilst a new,
easy to access storage compartment, situated
beneath the CMM table, houses the machine’s
printer and probe controller. These latest
improvements have negated the need for the
Zenith Too’s previous desk unit and further
reducing the machines’ overall footprint.
Offering what Aberlink claim is the industry’s
best performance to cost ratio for this class of
CMM, the imaginative new improvements
have not changed the cost effective, end-user
price of the popular Zenith Too series.
ABERLINK INNOVATIVE METROLOGY
Tel: 01453 884461
www.aberlink.com
46
22/2/13
13:08
Page 47
Bowled over by Phase
Vision’s measurement
technology
Phase Vision recently
teamed up with Scotland’s
Taylor Bowls Ltd to address
a series of measurement
challenges for the sporting
goods manufacturer. The
Phase Vision Quartz
Scanner has helped Taylor
Bowls to gain insight in 3D
to their manufacturing
processes.
Founded in 1796,
Taylor Bowls Ltd is the
Glasgow-based world leader in the manufacture of lawn bowls.
Traditionally made of wood, lawn bowls are now manufactured
from high-performance polymer material for reasons of cost and
durability. CNC lathes are used to perform successive turning
operations to form the asymmetric profile of the bowl, giving the
desired bias properties, ie the curved path which the bowl will
naturally follow when rolled along a flat surface. After testing, the
bowls are polished, branded and packed. Taylor Bowls currently
export bowls and accessories to 97 countries.
Bias is tested as part of Taylors’ production process by comparing
the path of the bowl against a calibrated bowl. If a bowl is out of
specification, it is sent back to have its profile rematched. This
judgment-based approach takes time, and is lacking in absolute
precision. Taylor Bowls sought a 3D measurement solution which
would allow them to characterise their manufacturing process and to
model the effects of different corrective actions.
Phase Vision’s Applications Engineers measured batches of bowls
after machining, and compared measured profiles to that of the
master bowl. A repeatability exercise was also carried out on a total
of 60 bowls and the measurement speed of the Phase Vision Quartz
Scanner was a particular benefit for this task. By converting the 3D
measurement data into STL format, it was also possible to generate
software for use with other manufacturing technologies including
laser positioning and robotic handling.
Taylor Bowls general manager, Andy Jolly states: “Phase Vision
provided a ‘one stop shop’ solution to deliver all of the measurement
services we required, and gave us the ability to move our key
manufacturing process forward. This gave us peace of mind that all
our products are being manufactured to a high and consistent
standard in order to compete effectively in all of our global markets.”
Phase Vision Ltd
Tel: 01509 839000
www.phasevision.com
47
22/2/13
13:09
Page 48
New CMM with unique wireless
thermal compensation system
COORD3 has announced the world launch of its all new ‘Universal’ line of CMMs
The Universal CMMs utilise a high-technology
alloy moving frame design that provides the
benchmark for dynamics and measuring
accuracy performance. This design overcomes
the issues associated with operating traditional
granite CMM structures, in the typical, less
than perfect, CMM operating environments. In
addition, the Universal CMM introduces an
‘industry-first’ by incorporating a wireless
CMM thermal compensation system of both
machine and part, allowing the measuring
system to automatically and dynamically
compensate for changes in the CMM
operating environment. This system allows the
CMM to perform with stated measuring
accuracy between 16 and 26-degrees C.
Gold-plated 0.1µm measuring scales are freefloating in support tracks, eliminating any
CMM structural changes from influencing its
measuring accuracy.
The COORD3 Universal CMMs provide a
highly rigid structural coordinate measuring
platform, allowing the use of point-to-point,
analog contact scanning and laser scanning
sensors, making it ideal for full 5-axis and
gear measuring applications.
Universal CMMs have a very efficient
design in terms of machine complexity which
improves long-term reliability and ultimately
cost of CMM ownership. The COORD3
Universal CMMs have an isostatic design for
each axis that provides optimum machine
geometrical alignment in the construction of
the machine, which ultimately benefits the
ability to make accurate field calibrations.
There is a monolithic base-plate, with integral
inverted dovetail guideways, and a generous
90 mm x 90 mm Z Ram section, that provides
outstanding metrological performances. Direct
axis drives, using toothed drive belts, provide
the vibration-free motion with zero hysteresis.
COORD3 CEO Angelo Muscarella states:
“Since taking the company back into private
ownership 3 years ago, we have focused on
rebuilding our international distribution and
engineering growth in the large CMM market
segment. With the introduction of the
COORD3 Universal Bridge CMM, we focus
the company into the highly competitive global
48
bridge CMM market at a time when all of our
major competitors are supplying an
increasing array of Chinese manufactured
CMM units.
The Universal CMM applies our ‘design-formanufacture’ focus that dramatically reduces
CMM assembly and calibration times and
allows COORD3 to not only compete in global
markets against low-cost manufacturing
operations, but also allows COORD3 to
double our CMM manufacturing capacity,
with a negligible increase in factory space or
workforce.”
Universal CMMs can also be equipped with
an optional SZP (Safety Zone Protection
System) which uses laser scanners to monitor
the defined protection zone when the CMM is
in high speed automatic measuring mode. SZP
reduces the CMM speed upon infringement of
the safety zone by an operator and
automatically returns the CMM to its full
measuring speed, only after the zone
infringement has been cleared. The SZP
system allows safe use of the CMM in a
production, shop floor and fully-automated
applications.
A Nano Technology (NT) version of the
Universal CMM is also available, that uses a
silicon carbide Z ram and enhanced
measuring scale system to provide higher
speed scanning with further enhanced
accuracy and a 0.3 µm reduction in
measuring uncertainty.
The COORD3Universal CMM family of
machines is currently available with
measuring strokes for the X-axis of 1500 mm,
2000 mm, 2500 mm and 3000 mm, with a Yaxis of 1000 and 1500 mm and Z-axis of 900
and 1000 mm.
COORD3 Metrology, based in Torino Italy,
is an ISO 9001:2000 certified CMM
manufacturer.
Measurement Solutions Ltd
Tel: 01733 325252
www.measurement-solutions.co.uk
www.coord3-cmm.com
22/2/13
13:09
Page 49
Advanced hardness tester is the ‘automatic’ choice
Bowers Metrology has announced the launch of the advanced Nexus
3001XLM-IMP, fully automated hardness tester. Designed for use
within the harshest of industrial environments or within the most
demanding of academic or research areas, Bowers’ new bench
hardness tester is able to deliver precise Brinell results and simultaneous
conversions to Rockwell, Vickers, Brinell and Leeb rebound hardness
scales, whilst test loads, from 30kgf - 3000kgf can be applied.
The Nexus 3001 XLM-IMP is able to accept large components and
features a load cell, closed loop system and a motorised spindle. To
ensure the highest standards of accuracy, Bowers’ new hardness tester
also boasts a high quality optical system with automatic motorised
rotating turret (indenter/objective positions).
Ease of use is further enhanced by a Brinell IMPRESSIONS automatic
video indent measuring system, whilst the unit’s side mounted, 15”
touch screen displays all current tester settings, hardness values and, if
required, in-depth statistical analysis of the tests undertaken. In
addition, all captured data and images can be stored on the tester’s
powerful PC and if required, can be exported via a bi-directional RS232 output.
As well as full installation and certification, the Nexus 3001XLM-IMP
is supplied with a range of standard anvils, indenters and test blocks. A
wide choice of additional options enables Bowers’ advanced new
hardness tester to be adapted to a variety of specialised applications.
Bowers Metrology Ltd Tel: 08708 509050
Email: [email protected] www.bowers.co.uk
Maximise cutting
c
tool
tool life..
life
Don’t leave it to chance; use the
Alicona IF-EdgeMaster
Negative
Bevel
Positive
Bevel
+44 (0) 173
1732
32 746670
Chipping
Curved
Edge
Basket
Arch
Type 1
Type 2
Type 3
www.alicona.com
www.alicona
a.com
49
25/2/13
15:41
Page 50
A new level of accuracy in diameter measurement
Scantron Industrial Products has announced
the latest in its line of laser gauges for
measuring thermal expansion more
accurately than ever.
Laser measurement of product diameter has
always been highly accurate. However, in
non-thermally controlled environments, such
as a workshop or on-line, there was always
the chance of incorrect readings due to
thermal expansion. Small fluctuations in the
ambient temperature could affect both the
laser gauge and the part, and therefore the
measurement.
Now, thanks to the NO-VAR (NoVARiation) technology, this is a thing of the
past, even in non-thermally controlled
environments. The thermal coefficient of the
gauge and the part are determined and then
stored in the instrument's memory. Sensors
installed in the gauge then measure the
ambient temperature and smart software
compensates for temperature changes and
adjusts the reading accordingly.
With high precision manufacturing
requiring very tight
tolerances, gauge repeatability and reproducibility (R&R) to a tenth
of the tolerances or better
is a requirement when
demonstrating process
capability (Cpk). A 10mm
diameter steel part will
change by in excess of a
tenth of a micron per
degree change in
temperature of the part
(Thermal Expansion
Coefficient of Steel is ~12
microns per meter per
degree C). The 40mm
high speed Xactum
gauge offers R&R of ±0.1
microns (±3σ over 1
second) and, with a
resolution of 10 nanometers, can accurately
measure changes in diameter of this order.
Operations such as machining can alter the
temperature of parts. In this situation, the
diameter of the part is simply measured
immediately after machining and after it has
returned to room temperature. An offset value
is then programmed into the gauge, so it can
compensate for this size variation with
temperature.
To find out more about this next generation
of high-accuracy laser micrometers contact
Scantron Industrial Products Ltd to discuss your
application.
Taunton-based Scantron is a world leader
in non-contact laser measurement and
profilometry. Offering specialist solutions to
applications across many industries, it is an
expert in solving clients' measurement issues,
both on and off line.
Scantron Industrial Products Ltd
Tel: 01823 333343
www.scantronltd.co.uk
50
22/2/13
13:10
Page 51
New digital magnifier for
portable inspection
CamZ from Vision Engineering is for portable magnification inspection
and documentation. Suitable for production environments and ideal
for inspection of immobile objects, it provides up to 14x magnification,
stores up to 100 images, and has grids and cursors for X and Y
dimensioning, where you want and when you want.
With a high resolution colour display, simple button operation and
image capture/download capability, CamZ is ideal for roving
inspection tasks, documenting faults, or for inspecting immobile
subjects.
Optimised for macro imaging, CamZ benefits from dual LED
illumination, and the sensor video captures 30 frames a second for a
crisp, high contrast image. Designed for ergonomic one-handed
operation, the CamZ is lightweight and comes in a durable carrying
case, with a USB transfer cable, and charger included. Suitable for use
in electronics, engineering, plastics engineering, medical, pharmacy,
biology, laboratory, incoming and outgoing inspection, research and
development, design, and wherever fast digital documentation is
needed; in one step using one tool.
-
+
u r m e t e r | p a r i s | 1791
THE STANDARD METRE GAVE US
ORDER, MAHR GIVES YOU PRECISION.
In the beginning there was the standard metre – which in turn
laid the basis for ever greater precision. Mahr has been a leading
light in this evolution for the last 150 years. Today, our measuring
instruments are employed wherever high precision and reliability are paramount, from the automotive industry and semiconductor production to medical technology and the aerospace
industry. Precision is universal. Mahr crosses all borders.
PRECISION LENGTH
METROLOGY
SURFACE
METROLOGY
Vision Engineering designs and manufactures eyepieceless and
expanded pupil microscopes for laboratory and industrial applications.
Established in 1958, more than 300,000 systems have been installed
worldwide for inspection and measurement tasks. Company
headquarters are based in Woking, UK with manufacturing facilities in
the US and UK. Regional offices are located throughout North
America, Japan, Europe and Southeast Asia.
Vision Engineering Ltd Tel: 01483 248300
Email: [email protected] www.visioneng.com
Mahr U.K. Plc - 19 Drakes Mews, Crownhill,
Milton Keynes, MK8 0ER, GB
www.mahr.com
51
ES CADCAM 52-55:ES CUTTING TOOLS FTR 38-51
22/2/13
13:12
Page 52
CADCAM
MKW & OPEN MIND help Bluebird to sail again
Many people will remember the 4th January
1967 as the landmark date that Donald
Campbell took his Bluebird K7 to the water
for the last time on Lake Coniston. Laying in
a watery grave for over 30 years, it was a
song about Donald Campbell, 'Out of this
world' by rock group Marillion that inspired
the family's search for his body.
Closure for the family finally came in May
2001 when Donald's body and the Bluebird
were both raised from the lake bed. Five
years later, a team of engineers and
enthusiasts decided to rebuild the famous
craft, a project that has enlisted the
charitable support from companies in the
North East, such as MKW Engineering. The
rebuild project that started in 2006 is
approaching completion thanks to
manufacturers like MKW Engineering that
are utilising high end CAM software from
OPEN MIND Technologies.
As part of the MKW Group, the Tyneside
based company has provided its expertise to
manufacture critical components that sit on
the underside of the Bluebird's sponsons.
The 14foot long sponsons are the floating
wings on each side of the craft; that during
the final journey at 305mph were identified
to be continually bouncing off the water.
Unfortunately when the sponsons bounced
past the maximum 5.5 degree pitch angle,
the boat left the water for the last time.
MKW's involvement in the project
occurred as a recommendation, due to its
manufacturing expertise in the defence,
aerospace and oil & gas industry that sees
the prestigious manufacturer producing
complex 5-axis components such as satellite,
communications and aircraft components
plus large jigs and fixtures for the assembly
of satellite systems for OEMs such as Rolls
Royce, EADS, BAE, Lockheed Martin,
Raytheon, BP, Total, Procter & Gamble,
Nissan and the MoD, to name but a few.
MKW acquired its first 5-axis machine
tool over 10 years ago to accommodate its
increasingly complex workload and to
reduce cycle times on its large parts with
small batch sizes. Since 2002, the company
has invested heavily in 5-axis machine tools.
52
Out of its 26 machine tools, seven are now
5-axis. With the capacity to machine jobs up
to 6m long by 2.5m wide, the majority of
work at MKW is aluminium, stainless steels,
duplex and titanium, with material costing
anything upwards of £15,000 per part.
With high material costs on large parts and
the overall value of components after
machining exceeding £25,000, getting the
job 'right fist time' takes on a new level of
importance.
MKW's sales & commercial director,
Rahmon Nassor comments: "We have
invested over £6m in 10 years on machine
tools and this investment has continued with
the addition of a full 5-Axis VTC800/30SR
from Mazak in May this year. It has taken
our count of Mazak's to 11. With continued
investment in machine tools, our CAM
package was creating problems as the postprocessors were incapable of supporting the
complex tool-paths on our 5-axis
investments. This created scrapped parts,
tool breakages, machine crashes and a
culture of nervousness. Additionally, the
package couldn't keep up with our high
workload of one-off or small batch
production of complex parts.
"We knew we needed a new CAM
package and with recommendations from
numerous machine tool installation
engineers and our own investigation of three
leading vendors, we opted for OPEN
MIND's hyperMILL. The results have been
exceptional."
Despite putting up with a limited CAM
package for some time, the final straw came
when the 140 employee company won a
new order for batch a of complex propulsion
components for an airship for the USA. The
parts were virtually impossible to program
on the previous CAM system, so the decision
was made. hyperMILL was installed in 2011
and it immediately took the programming
time from 40 hours to 24 on the propulsion
part. Not only did hyperMILL reduce
programming times by 45%, it also reduced
the machining time by 30% for the ISO 9001
company.
As soon as hyperMILL was installed, the
benefits arrived in abundance. Firstly, the
ability to simulate part production prior to
any physical cutting gave the programmer
confidence that parts were not going to be
scrapped. This confidence was backed by
OPEN MIND's ability to supply postprocessors for each individual machine to
ensure the part programmed on screen was
exactly what would be cut by the machine.
Secondly, the ability to simulate the part
prior to machining enabled MKW to
accurately quote jobs. Rahmon Nassor
continues: "Rapidly simulating parts from
drawings and electronic files enables us to
price work accurately for customers based
on the knowledge of the machining
strategies required, the cutting tools and the
hours required for each job. Depending
upon the features of each component,
hyperMILL has reduced our programming
times on average from 30 to 50%. This
improved programming time is credit to a
user friendly platform that is intuitive and
guides the programmer through each step."
Other benefits include the significant time
saving for the programmer by using the easy
to use tool database and the feature
recognition option. This enables the
programmer to select a feature on a part
such as a hole, and hyperMILL will
automatically identify all other holes with the
parameters and calculate the tool paths
accordingly to eliminate unnecessary tool
changes.
Feature recognition has proved of major
benefit on the sponsons manufactured for
the Bluebird K7 project. Each of the two
1.8m long aluminium sponson parts has
22/2/13
13:13
Page 53
CADCAM
over 480 holes of differing diameters and
hyperMILL reduces the tool changeovers and
optimises tool paths with its feature
recognition cycle. Another key feature is the
mirroring function. This enables the
programmer to mirror a program in all axes
for left or right hand parts. Particularly
beneficial to the F1 and aerospace
industries with symmetrical structures, the
sponson component initially took 8 hours to
program. Instead of programming the
opposite hand part with an estimated
programming time of an additional 8 hours,
the MKW team utilised the mirror function to
create the opposite hand sponson part in
minutes.
When MKW acquired its hyperMILL seat
18 months ago, the company also opted for
the hyperMAXX roughing module. The
Bluebird K7 project was the first part the
company has applied the hyperMAXX
module to. Despite the sponson parts
primarily consisting of holes and slots, the
application of hyperMAXX shaved 20% off
the four hour machining cycle time for each
part.
The Bluebird K7 is being re-built around
the original construction and, with many
components obsolete, this is a painstaking
process for the engineering team. Upon its
eventual completion, which is estimated to
be in another 2 years, the Bluebird K7 will
sail on Lake Coneston and then be the
centrepiece of a purpose built £1m museum
on the lakeside.
For further information, visit
www.bluebirdproject.com or
www.bluebirdk7.com
OPEN MIND Technologies
Tel: 01869 290003
www.openmind-tech.com
MKW Engineering
Tel: 0191 413 0000
www.mkw.co.uk
53
25/2/13
15:37
Page 54
CADCAM
Delcam partners on new machining method for
“fir-tree” profiles
Delcam is working with Iruba, a German
provider of engineered solutions, and
machine-tool manufacturer Hermle to
develop a novel 5-axis machining method,
programmed with the PowerMILL CAM
system, for the creation of “fir-tree” profiles
in components for turbo machinery. The new
process, which provides an alternative to
broaching, was demonstrated to an
enthusiastic response during last
year’s IMTS exhibition in Chicago.
The milling approach, which is
based on the trochoidal machining
strategies in PowerMILL, has been
patented by Iruba. It allows
complex “fir-tree” profiles to be
produced on milling machines,
such as the Hermle C60 5-axis
machining centre, rather than
having to use specialist broaching
equipment.
The use of PowerMILL’s
trochoidal strategies gives a
number of benefits, in particular
giving high material removal rates
with lower, and more consistent,
cutting forces. The more consistent
cutting forces also ensure higher
accuracy in the position and in the
shape of the slots, with minimal
thermal effects on the surface of the
profiles. The process also reduces
the number of specialist cutting
tools that are required, and cuts the
machining time in steel alloys by
between 30 and 40 percent,
compared to alternative standard
milling solutions, giving a time
almost equal to broaching.
Commenting on the process,
Brett Hopkins, manager of Delcam
Professional Services North America, says:
“We are pleased to be working with other
leaders in manufacturing technology like
Hermle and Iruba to develop this innovative
technology. The collective collaboration
began several months ago and was received
with great enthusiasm when we presented
the process at IMTS.”
Mattias Rutschinski, managing director of
Iruba, adds: “At IMTS, we presented, with
Hermle and Delcam, a world premiere of
milling small fir-tree geometries in IN718, a
54
The new turbo machining process using Delcam’s PowerMILL offers an alternative to
broaching
typical material for aero-engine parts. The
presentation impressed our visitors and
made it very clear that milling is the more
effective technology, since we could mill
even curved slots, deburr them and measure
them in one process on Hermle’s smallest
5axis machine, the C22.”
“Broaching is a technology developed at
the end of the 19th century,” concludes
Mattias Rutschinski. “Many applications
can be completed today with much lower
power consumption and oil waste, by much
more integrated and flexible solutions, fitting
the production demands of the 21st
century.”
Delcam plc
Tel: 0121 683 1081
www.delcam.com
22/2/13
13:13
Page 55
CADCAM
Vero Software acquires Sescoi International
Vero Software, a leading provider of
CAD/CAM/CAE solutions, has announced
the acquisition of Sescoi International, an
industry specialist for 2D to 5-axis NC
machining with its WorkNC product suite.
The acquisition of Sescoi International firmly
establishes Vero as the world’s largest and
number one CAM specialist. The acquisition
will provide the platform to build even stronger
products across the range through a
significantly enlarged development team and
distribution channel, with experienced, time
served, industrial knowledge.
Commenting on the acquisition, Richard
Smith, CEO of Vero Software says: "Across
the enlarged Group, the complementary
products address the worldwide need for
efficient and innovative CAD/CAM/CAE
technology. With an unrivalled breadth of
market leading solutions for specific
manufacturing techniques and an expanded
distribution capability, we will continue to
provide excellent service and support to both
existing and new customers and further extend
a growing influence on the global market. We
fully recognise the importance of product
branding and customer loyalty. It is important
to emphasise that we will continue to invest in
the WorkNC product suite and welcome the
existing Sescoi partners and resellers into the
Vero network. We will move forward together
with the expertise, knowledge and resources
necessary to deliver even higher levels of
productivity to our customers."
Bruno Marko, founder of the Sescoi Group
comments, "We are extremely pleased to be
joining the Vero Group. Since originally
founding the company in 1987, Sescoi has
become one of the world’s key CAD/CAM
providers with WorkNC. However, with
Vero’s global distribution, additional
development resources and proven
technology sharing concept, I am certain the
products will advance at an even faster pace
and continue to provide innovative solutions
that
boost
productivity,
bolster
competitiveness, reduce costs and improve
quality."
Vero Software
Tel: 01242 542040
www.verosoftware.com
55
ES LASER CUTTING FTR 56-67:ES CUTTING TOOLS FTR 38-51
22/2/13
13:14
Page 56
Feature - LASER CUTTING
Reliable laser cutting crucial to
subcontractor’s success
Plant reliability is vital for any manufacturing
enterprise, but particularly for a
subcontractor starting out with a single
machine tool. This was the position Danny
Fantom found himself in at the start of last
year when he formed FC Laser Ltd to provide
subcontract laser cutting and forming
services.
Previous good experience with equipment
from Bystronic UK led him to order a 4.4 kW
Bysprint Pro flatbed laser cutting machine.
Ever since the machine was commissioned in
June 2012, it has operated faultlessly in FC
Laser's 9,000 sq ft sheet metalworking
facility in Ilkeston, Derbyshire.
He comments: "The machine has not
missed a beat during more than 3,000 hours
of operation and we have not had to call out
a service engineer once. The Bysprint Pro
has been instrumental in expanding our
customer base, from a single firm in the
power generation field when we started to
over 100 clients now. New enquiries are
coming in each week across many different
industries, which in turn have given us an
increasing order book, month on month."
Rapid influx of business from the nuclear,
shopfitting, architectural and prestige
automotive sectors has allowed FC Laser to
grow quickly from six staff at the outset to 12
currently, including two apprentices on day
release to Chesterfield College.
Danny Fantom underwent a five-year
sheet metalworking apprenticeship at an
aerospace company producing precision
components and assemblies for the aircraft
industry. He therefore knows the importance
to manufacturing industry of training new
engineers and, more specifically, the benefit
56
of employing skilled staff familiar with the
working practices at FC Laser.
Highlights of the company's service are
quotation within an hour of receiving an
enquiry, rapid turnaround of orders
supported by 24/7 working when required,
and next-day delivery anywhere in the UK,
whether to a small business or a
multinational company. Competitive prices
are offered, partly as a result of having the
confidence to over-run the Bysprint Pro
lights-out after the 6.00 am to 10.00 pm
manned shifts. Thicker materials are
normally processed during the night to take
maximum advantage of the extra capacity.
A sheet on each of the two beds can provide
five hours' unattended production.
To ensure quick deliveries, one tonne of
each standard gauge of mild steel from 0.9
mm to 20 mm is held in stock, as well as
stainless steel from 0.9 mm to 15 mm and up
to 12 mm aluminium. Sheet size is usually 3
m x 1.5 m, which is the nominal bed
capacity of the laser cutting machine. Other
material sizes are bought in if it is possible to
nest jobs more efficiently and so minimise
waste, which is particularly important if
larger batch quantities are involved.
Danny Fantom continues: "Our machine is
very productive, with extremely fast
acceleration and 169 m/min simultaneous
positioning speed. It is capable of
instantaneous hole piercing up to 10 mm
thickness and can produce 600 holes per
minute in 1 mm mild steel. We produce
various batch quantities of components from
different materials, so quick machine
changeover is important to minimise
downtime. Operators can carry out a nozzle
change to swap between processing 0.9 mm
and 20 mm materials in under a minute.
“We have been so pleased with the first
machine that we have ordered a second 4.4
kW Bysprint Pro, this time opting for a larger
cutting surface of 4 metres x 2 metres. It has
the added advantage of automatic nozzle
centring, which will further reduce machine
downtime. It is scheduled for delivery in May
2013 and will open up additional markets to
us.”
FC Laser has also installed a 3-axis CNC
press brake from Bystronic UK. The 3-metre
bed, 150-tonne machine with CNC
crowning produces bends that are accurate
to less than 0.1 mm and 0.25 degree over
the entire bed length up to 6 mm capacity.
This in-house bending facility, together with
the use of outside services such as water jet
cutting, fabrication and powder coating,
allows FC Laser to offer a comprehensive
service to customers that prefer one-stop
manufacturing.
Bystronic UK Ltd
Tel: 0844 848 5850
www.bystronic.com
FC Laser Ltd
Tel: 01159 443428
www.fclaser.co.uk
22/2/13
13:19
Page 67
LASER CUTTING
Salvagnini Fiber revolution hits 250 units and the range extends
Worldwide sales of Salvagnini’s Fiber
lasers have now gone past 250
machines. Along with the L3 model, the
based company is now having great
success with the L5 model, a highly
dynamic laser cutting machine with a
patented compass structure.
This structure, made possible by the
absence of a defined optical path and
driven by a pair of rotary motors, allows
the cutting head to be moved over a
distance of 170 mm on the XY plane,
with dynamics of up to 5g and extremely low
consumption thanks to its light weight.
The compass is the very heart of the
mechanical solution patented by Salvagnini,
offering similar dynamics to linear motors yet
keeping energy consumption and running
costs low.
The L5 KinEtic also broadens the choice of
fibre sources available, complementing the
2 kW and 3 kW range with a new 4 kW
model. This considerably enhances machine
performance as sheets from 5 to 15 mm thick
can be cut even more rapidly and with
improved quality, while the 2 and 3 kW laser
sources offer a more economical solution
when production is principally composed of
thinner material.
The L5 features exceptionally high dynamics
and accelerations yet has extremely low
consumption, thanks to the patented
mechanical structure which eliminates the
need for costly and energy-consuming linear
motors. The movements of the arms of the
compass allow the machine to cut and pierce
at very high speed without moving the gantry.
Moreover, thanks to the characteristics of fibre
and the absence of a defined optical path,
these arms are made of carbon and are
extremely light, further reducing the
weight and thus the masses in
movement. The result is a patented
mechanical structure which consumes
less than 1 kW, despite achieving 5g
acceleration.
While linear motor technology would
indeed allow higher speeds to be
reached on straight lines, such motors
are often quite unnecessary when cutting
sheet metal, as contours and small holes
are generally far more frequent than
long cuts. Another disadvantage of linear
motor technology when cutting flat material is
the fact that linear motors require considerable
cooling and extensive maintenance,
cancelling out their dynamic advantage over
Salvagnini’s patented mechanical solution,
where the source requires a third of the
installed power on machines equipped with
linear motors.
Salvagnini United Kingdom & Ireland
Tel: 01989 767032
www.salvagninigroup.com
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CONTACT:
Laser Lines Ltd
01295 672500
www.laserlines.co.uk
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25/2/13
15:41
Page 58
LASER CUTTING
Amada makes light work of shipbuilding
parts at BAE Systems
Amada UK has installed a FO3015 MkII 4kW
laser with rotary index tube cutter at Her
Majesty's Naval Base (HMNB) in Portsmouth,
a facility controlled and operated by the Royal
Navy in co-operation with BAE Systems. The
machine is processing ship components so
efficiently that other parts of the business are
now eyeing the investment with growing
interest.
HMNB is the home port to 60% of the Royal
Navy's surface ships. In fact, Naval
shipbuilding and repair operations have been
core business at the site since the first dock was
built in 1194. There are now over 3,000 BAE
Systems employees working on HMNBP and
just like the scale of this operation, the parts
produced here are sizeable to say the least.
“We have existing large-bed laser cutters.
However, for what we call our light plate work
between 1 and 20mm thick, the big machines
don’t handle this in an optimum way. As a
result we decided to seek an alternative
solution,” states Trevor Parsons, production
engineer, at BAE Systems.
BAE Systems wanted a machine that not
only processed flat sheet and plate but offered
integrated tube/section cutting. This would
avoid relying on sawing machines for cutting
material of this nature. With this in mind, the
major reason for selecting the Amada
FO3015 was the option to add a rotary index
tube cutter, which in combination with Amada
software Dr ABE Blank and Dr ABE Tube
makes this a unique offer in the marketplace.
There are 45,000 components that are
suitable for cutting with the Amada machine’s
rotary index.
“Amada was the only supplier that could
offer an integrated solution for bar cutting that
was well matched to our light plate shop
requirements,” continues Trevor Parsons. “It
gives us the flexibility we need to go from flat
sheet cutting to box/angle/section and pipe
cutting at fast speeds. We can also cut angle
section and channel with non-uniform wall
thickness, a common challenge on our parts.”
Installed in February 2012, the Amada
FO3015 runs all day between 06:30 and
16:00 when the light fabrication hall is
manned, following which the machine will
typically run two programs “lights-out” with
each job running for 2-3 hours. This is
facilitated by automated Amada pallet change
technology, providing another new capability
at the Portsmouth facility. The machine
processes multiple material types, ranging
from traditional metals such aluminium, steel
and stainless steel, through to more unusual
materials, such as armour plate, plywood and
even certain types of rubber.
“The Amada FO3015 is perfectly suited to
the smaller size of our light plate parts, making
it a very efficient solution,”explains Trevor
Parsons. “For instance, using our larger laser
cutters, the off-cuts produced were previously
consigned to waste streams, whereas now
they are ideal for making parts on the new
Amada. We’re not purchasing any speciallysized material anymore, which is saving
money. As everyone knows, engineering
materials are phenomenally expensive these
days. This change also facilitates greater
control over our inventory. The parts also come
off the machine with a really clean finish and
so require no further operations.”
AMADA United Kingdom Ltd
Tel: 01562 749500
www.amada.co.uk
58
22/2/13
13:15
Page 59
Best choice.
24/7
Lightly-manned production of parts around the clock. The
ByAutonom laser cutting system makes it possible, even if the
raw material has to be changed. It changes the focal length,
changes and centers the nozzle, detects collisions and rectifies
their consequences. And everything automatically.
Laser | Bending | Waterjet
bystronic.com
Bystronic iPhone + Android App
25/2/13
15:42
Page 60
LASER CUTTING
Entry level fibre-guided laser
The TruLaser 1030 fiber provides all design
and performance benefits of its CO 2
forerunner: low purchase price, easy
installation, simple operation and minimal
maintenance. However, as this machine has
a solid state laser it offers enhanced
productivity in thin sheets and also allows for
a greater diversity in material processing.
This includes the process-reliable and costefficient cutting of non-ferrous metals with
TRUMPF standard cutting data for copper
and brass. High absorption of the solid-state
laser wavelength is assured, an important
factor when processing highly reflective
materials.
Low cost and space saving
The TruDisk fibre-guided laser also provides
several other benefits such as a favourably
priced entry into laser welding by using the
machine’s TruDisk laser as a beam source.
The welding solution is simply connected to
the TruDisk laser by a fibre-optic laser cable.
It is then possible to choose between the
applications on an hourly or shift basis.
Also, energy consumption at comparable
laser power is around 40% less than the
TruCoax 2500, its CO2 counterpart. And as
the TruLaser 1030 fiber requires neither
beam delivery gas nor laser gas, even
greater cost efficiencies are provided. The
TruDisk laser also makes it simpler and
quicker to replace all components in the
field.
The TruLaser 1030 fiber is a full 3000 x
1500mm machine but occupies a footprint
less than 25m2. Thanks to its low weight it
does not require a reinforced foundation or
floor anchors so installation is quick and
easy. The highly compact TruDisk laser is
connected to the machine via a fibre optic
60
cable. This allows the laser source to be
located where it is most convenient, next to
the machine or at several metres away.
This new machine is also easy to operate
even for complete novices. The operating
concept allows the user to choose between a
beginner and professional level. Only the
keys needed for fast part cutting are visible
for beginners whilst for the more advanced
users all technology values are accessible for
adjustment.
The reduced training requirements
associated with this machine also cut costs.
The intuitive operating concept can be
learned quickly and easily.
The TruLaser 1030 fiber comes with the
new TRUMPF universal cutting head for
processing all material types and
thicknesses. Minimal setup time is its big
advantage and it also reduces idle time.
There is also no need to centre the nozzle
after cleaning the glass guard. These factors
and also the need for fewer personnel
ensure fast return on investment.
Not just an entry level machine
Although clearly ideal for companies that
are new to laser, the TruLaser 1030 fiber is
also a valuable addition to any laser shop
that handles thin sheet and a greater range
of materials. Indeed it is the most economical
TRUMPF machine for low utilisation on
single shift operation, so it is good for
prototype and small scale production and
also a practical training machine for
employees or apprentices.
A choice of three different material
handling options is provided so that the
machine can be inexpensively upgraded in
line with customers’ changing production
needs. It is supplied as a standalone
machine with easy access from the front or
rear. Stage one upgrade is with a moveable
pallet that provides manual loading and
ergonomic unloading. The next stage up is a
semi-automatic pallet changer for loading
and unloading parallel to production, A fully
automatic pallet changer may also be
specified.
Power of choice
Determining whether CO2 or solid state is the
best choice is a subject of much debate in the
sheet metal fabricating industry. In truth it
depends on the application. However, most
manufacturers of laser cutting machines
typically only offer one technology and are
therefore biased. This can lead to
manufacturers choosing a laser source that
is not optimally suited to the task.
By introducing the TruLaser 1030 fiber,
TRUMPF has given the market both options;
a development in compliance with the
company’s ‘Power of Choice’ programme.
TRUMPF Ltd
Tel: 0844 4820188
www.trumpf-machines.com
10962_Mazak_OptiplexFIBER_Ad_EngineeringSub_210x297mm_AW.indd 1
15/02/2013 14:19
25/2/13
12:57
Page 62
LASER CUTTING
Laser proves unexpectedly versatile
for vehicle parts manufacturer
A new eX3015 4.5kW laser cutting machine
from Mitsubishi Electric, supplied by laser
cutting specialist World Machinery, has
significantly improved manufacturing
flexibility and capacity at PSS Ltd, a Norfolk
based manufacturer of power steering
components and other equipment for the
commercial vehicle, construction and
agricultural equipment markets.
The catalyst for the purchase of the new
machine was the acquisition by PSS of
George Moate Ltd, a manufacturer of
specialist agricultural equipment, including
the Tillerstar, an innovative tilling, de-stoning
and bed preparation machine for the potato
and root vegetable industry. “We were
already considering adding a laser cutting
capability to our range of state of the art
CNC manufacturing equipment,” explains
PSS managing director Richard Pratt, “But it
was the Tillerstar, which makes extensive use
of sheet materials in its construction, that
finally tipped the balance.”
Since its installation, The Mitsubishi laser
machine has quickly become an integral
part of PSS’ manufacturing operations and
the company is currently using the machine
to process up to three tonnes of material a
day, including steel, stainless and plastic in
thicknesses ranging from 1.5mm to 25mm.
“We chose the eX machine based on its
speed of cutting and simplicity of
programming,” explains Richard Pratt. “For
production work, we can download CAD
files directly from our design office, but our
operators also make use of the on-board
CNC controller for prototypes and short
runs.”
The speed and flexibility of the new
62
machine has allowed PSS to extend its use to
a wide variety of other jobs, as well as the
production of sheet parts for the Tillerstar.
“Now we are getting used to the machine we
are finding new jobs for it all the time,” says
Richard Pratt, “We are increasingly using it
to rough out parts like washers that might
previously have been cut from bar on one of
our CNC lathes. We are also finding that we
can now produce various sheet components
that we would previously have outsourced,
which helps us to cut the number of parts we
need to keep in stock, and reduces our input
costs.”
The addition of laser cutting to the range
of CNC machining capabilities already
installed at PSS also allows it to extend its
offering to customers. “One of the key
reasons companies come to us is our ability
to be extremely flexible in the
volumes of the products we
produce,” notes Richard Pratt.
“We are able to manufacture
anything from ten parts or less to
many hundreds, which is very
valuable for customers in
supporting older products or
niche models. The flexibility of
the Mitsubishi machine allows us
to extend that service into new
categories of component, while
maintaining the same rigorous
quality and delivery performance our
customers rely on.” Such is the capacity of
the new machine that PSS is also considering
taking on subcontract laser cutting work for
other manufacturers, the first time it has
made use of one of its machines for such
work.
Part of the reason the new machine has
proved so productive, so quickly is thanks to
the “seamless” delivery and commissioning
service from its supplier, World Machinery,
according to Richard Pratt. “The guys at
World Machinery worked with us right from
the start of the purchase process,” he says.
“They came in and measured the site,
installed the machine and provided training
for our operators. They are still helping us
now with the manufacture of some
particularly complex components.”
PSS has plans to further develop the
capabilities of its Mitsubishi eX laser cutter,
with the future addition of a 4th axis for the
machine. “We are 90 percent certain we’ll
go ahead with that modification,” says
Richard Pratt, “but we wanted to make sure
we were comfortable operating the basic
machine before adding the extra axis.”
World Machinery Ltd
Tel: 01746 780154
www.worldmc.co.uk
25/2/13
16:38
Page 63
22/2/13
13:17
Page 64
LASER CUTTING
New 5-axis fibre laser cutting system
Maximised part accessibility for high speed, precision fibre laser cutting of thin metals
Miyachi Unitek Corporation, a leading
manufacturer of welding equipment and laser
systems, has announced the availability of its
Sigma 5-Axis Fiber Laser Cutting System, a
unique technology that enables three
dimensional cut paths.
The Sigma 5-Axis Laser Cutting System
features high speed, high precision, positionbased firing laser power control, and unique
cutting features that make it ideal for use in
cutting thin metals, especially those used in
precision medical cutting tools.
The flexible system configuration of a 2-axis
rotary assembly, mounted to an XY stage,
maximises laser on-part accessibility, system
simplicity, and tooling path efficiency for high
speed, high precision laser cutting of thin
metals. It is ideal for thin metals with unique cut
paths, non-symmetrical features, beveled
edges, off axes cutting, compound angles,
and internal cut radii of less than 50 microns.
Linear motors and high torque direct drive
rotary axes on the Sigma 5-Axis Laser Cutting
System have been optimally configured to
provide the best performance for speed and
quality, while maintaining part dimensional
accuracy. The LF series fibre lasers handle
focus spot sizes down to 20 microns, and offer
high pulse frequency, excellent power and
pulse stability, fine control of pulse width and
laser power levels up to 500W, which enables
a wide variety of metal and thickness to be cut
to high dimensional accuracy. The unique
position-based firing control method
accommodates multi-linear and rotary axis
motion to control the laser pulse frequency for
consistent pulse overlap according to the
position of the laser spot on the part.
Miyachi Unitek is a leading manufacturer of
equipment and systems for resistance welding,
laser welding, laser marking, laser cutting,
and hot bar reflow soldering and bonding.
The company provides products to a wide
range of markets, including the medical
device, battery, electric vehicle, and solar
industries, as well as the global electronics,
automotive, and general industrial markets.
Miyachi Unitek is an ISO9001 certified
company.
Miyachi Unitek
Tel: 001 626 303 5676
www.miyachiunitek.com.
OEM version makes integration easy
Self contained “sealed-off” lasers are ideal
tools for light industrial applications such as
cutting, drilling and marking.
The OEM 40 iX is the latest model from the
successful ROFIN SC Series. With an output
power of 400 W and a beam quality of K >
0.8, this sealed-off CO2 laser, based on the
industry proven Slab principle, is ideal for
processing organic materials, plastics,
ceramics, glass and metals. With its integrated HF power supply and a
total weight of 75 kg, the ROFIN OEM 40 iX
is extraordinarily compact and lightweight.
These attributes allow the unit to be easily
integrated into a variety of system concepts
in combination with scanners or other beam
guidance components.
The OEM 40iX is also the perfect choice
for those who wish to replace older laser
sources with the latest technology.
Furthermore, the laser distinguishes itself by
its high reliability and a long lifetime of the
laser unit in industrial production. Compact laser workstation for
precision welding, cutting and
drilling
The Rofin OEM 40iX makes integration
easy for machine and system builders
64
The LASAG PWS Mini desktop workstation
incorporates a compact high accuracy
design whilst maintaining great flexibility.
Designed for laser processing precision
miniature components, laser energy can be
transmitted to the workpiece via single or
multiple fibre optic delivery.
Primary applications for this system can
be found in the medical, dental, electronics,
computer, communications, and micro
The LASAG PWS Mini is targeted at
applications on precision miniature
components
machining industries. The LASAG PWS Mini
is ideally suited for components that may
require spot and seam welding or cutting
and drilling.
This extremely workstation can be
equipped with any standard LASAG laser
source and is therefore extremely flexible in
use.
Rofin-Baasel UK Ltd
Tel: 01327 701 100
www.rofin.co.uk
25/2/13
15:42
Page 65
LASER CUTTING
Sixth consecutive show
Laser Process Ltd, the Staffordshire-based laser cutting company,
recently exhibited for the sixth consecutive year at the Southern
Manufacturing Show.
The Midlands-based firm was keen to show off its subcontract laser
cutting expertise and streamlined methods of increasing productivity.
The firm was also looking to showcase its recent investment in a
£50,000 innovative Dugard ECO1000 vertical machining centre. The
investment allows the company to perform a range of secondary
machining operations on parts they have laser cut. The operations
made possible by this machine include drilling and tapping, chamfers,
rebates, countersinking and counterbores.
Managing director, David Lindsey says: “Southern Manufacturing is
the largest regional engineering exhibition in the UK and, as such, we
feel it is important that Laser Process is represented. We aim to confirm
our status as a leading subcontractor and to further support our position
as champions of quality and service.”
Year on year, the Southern Manufacturing show welcomes
companies such as Laser Process to showcase their positive
achievements within the industry, to a diverse range of exhibitors and
potential customers.
Laser Process sees the Southern Manufacturing Show as an important
networking opportunity with UK industry. The company recently gained
an order from a customer they networked with two years ago at the
show. On the back of this, Laser Process states that the annual show has
a lasting positive influence towards increasing their industry presence.
David Lindsey with the new Dugard ECO 1000 vertical machining
centre
Building upon a successful 2012, the firm has also taken on an extra
3000 sq ft unit in Cannock alongside new staff to operate the new
machine and for assembly operations. Laser Process is now keen to
build upon their accomplishments throughout 2013.
Laser Process Ltd
Tel: 01543 495000
www.laserprocess.co.uk
FLW 4000 M3
ser Welder
Fibre La
New Fibre Laser Technology
FOL 3015 AJibre Laser
F
Available in 2, 4 & 6kW
Unique beam weaving function
Weld dissimilar materials
Increased up-time – ofﬂine
programming
Available in 2 & 4 kW
70% energy saving
Cut exotic materials
Cut faster & more proﬁtably
For more information please visit www.amada.co.uk, call Cathryn on 01562 749736 or email [email protected]
65
22/2/13
13:19
Page 66
LASER CUTTING
Bevel cutting with the fibre laser
Messer Cutting Systems presented a new,
record breaking laser cutting machine at
EuroBlech 2012. With the modern fibre laser
technology, extremely powerful drives, large
working areas and a multifaceted bevel head,
the new PowerBlade is equipped for a wide
range of applications that up until now were
either not possible or at best ran much more
slowly.
With working widths of over 4 m and track
lengths of 40 m and more, this machine is
predestined for jobs that require a large plate
size. In addition to vertical cuts, the widest
range of bevel cuts can be combined in one
part, for example to produce optimum weld
seam preparations all in one operation. The
laser is characterised by high efficiency as well
as a robust and long lasting construction. The
laser beam is carried in the energy chain
through a glass fibre. So the high beam quality
and with it the cut results are consistent over
the entire working area. No adjustment and
no beam path purging is needed right the way
up to the cross carriage. At the same time, the
laser resonator does not have any negative
effect on the machine dynamics, as it is
installed statically beside the machine.
Guided by the Global Control, the
PowerBlade is thus extremely user friendly and
economical. The machine equipment includes
a unit which opens up new fields of
application for cutting with the fibre laser. The
Messer Global Controlplus, the newest touchscreen based CNC control in the market,
ensures easy operation. The machine meets all
expectations for simple operation, low costs
and high reliability.
It is also a genuine Messer cutting machine
with the proverbial reliability that for decades
has been the company’s hallmark. Another
machine from this global player shows how
efficiency can be increased by raising the level
of automation. As a one-stop-shop for all
aspects of thermal cutting, the company also
demonstrated its made to measure software
solutions, environmental equipment,
professional spare parts and consumables
service as well as its TÜV Hessen certified
training modules. In addition the Oxyfuel
equipment department will be showing a
range of combined torches for welding,
cutting, brazing and heating.
At EuroBLECH 2012, the five companies of
Messer World shared an exhibition area with
Jenoptik’s laser and laser systems business
units. The companies’ joint participation in the
trade fair is a tradition dating back to
EuroBLECH 2010, when the concept proved a
big success. Using live demonstrations, each
company once again presented its latest
products and services to the industry specialists
attending this important trade fair. In addition
to welding demonstrations with shielding
gases, the main focus was on state-of-the-art
laser technology, ranging from the optimal
choice of gases for cutting and welding to
laser resonators, production-related and
business software and appropriate laser
sources, through to the latest generation of
laser machines for 3D and 2D metal cutting,
using a fibre laser.
Messer Cutting Systems
Tel: 0191 250 4621
www.messer-cs.co.uk
66
25/2/13
15:43
Page 67
LASER CUTTING
Salvagnini Fiber revolution hits 250 units and the range extends
Worldwide sales of Salvagnini Fiber
lasers have now gone past 250
machines. Along with the L3 model, the
Herefordshire-based company is now
having great success with the L5 model,
a highly dynamic laser cutting machine
with a patented compass structure.
This structure, made possible by the
absence of a defined optical path and
driven by a pair of rotary motors, allows
the cutting head to be moved over a
distance of 170 mm on the XY plane,
with dynamics of up to 5g and extremely low
consumption thanks to its light weight.
The compass is the very heart of the
mechanical solution patented by Salvagnini,
offering similar dynamics to linear motors yet
keeping energy consumption and running
costs low.
The L5 KinEtic also broadens the choice of
fibre sources available, complementing the
2 kW and 3 kW range with a new 4 kW
model. This considerably enhances machine
performance as sheets from 5 to 15 mm thick
can be cut even more rapidly and with
improved quality, while the 2 and 3 kW laser
sources offer a more economical solution
when production is principally composed of
thinner material.
The L5 features exceptionally high dynamics
and accelerations yet has extremely low
consumption, thanks to the patented
mechanical structure which eliminates the
need for costly and energy-consuming linear
motors. The movements of the arms of the
compass allow the machine to cut and pierce
at very high speed without moving the gantry.
Moreover, thanks to the characteristics of fibre
and the absence of a defined optical path,
these arms are made of carbon and are
extremely light, further reducing the
weight and thus the masses in
movement. The result is a patented
mechanical structure which consumes
less than 1 kW, despite achieving 5g
acceleration.
While linear motor technology would
indeed allow higher speeds to be
reached on straight lines, such motors
are often quite unnecessary when cutting
sheet metal, as contours and small holes
are generally far more frequent than
long cuts. Another disadvantage of linear
motor technology when cutting flat material is
the fact that linear motors require considerable
cooling and extensive maintenance,
cancelling out their dynamic advantage over
Salvagnini’s patented mechanical solution,
where the source requires a third of the
installed power on machines equipped with
linear motors.
Salvagnini United Kingdom & Ireland
Tel: 01989 767032
www.salvagninigroup.com
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01295 672500
www.laserlines.co.uk
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ES SAWING & CUTTING OFF 68-71:ES CUTTING TOOLS FTR 38-51
25/2/13
16:41
Page 68
Kaltenbach UK reports best start to the year for
five years
Good news is always worth reporting.
Kaltenbach Ltd, the Bedford-based, UK
division of the German Global leader in
sawing, drilling, profiling, finishing and
associated technologies, has announced its
best trading start to the year for five years.
“We have the technology to make a
marked difference to any company’s
production efficiency,” says Barry Rooney,
sales and marketing director. “Our continual
technology advances and particularly some
of the recent gains in more sawing efficiency
are satisfying our customers’ constant
demand for ever greater cost-efficient
productivity.
“We showed several new advanced
sawing systems at MACH2012 that offered
further, very marked productivity gains for
the stockholding, general engineering and
structural steel sectors, which, we are
pleased to say, have generated firm orders.”
The latest saws include the revolutionary
Kaltenbach KBS1051 DG, the world’s fastest
structural steel mitring band saw (it autosenses & adjusts band-cutting angle ‘during’
the cutting cycle) and the Behringer HBMSC, which claims to be the industry’s fastest
straight-cutting band saw by some margin.
Stockholders lead the way
Stockholders are leading industry in
their pursuit of the latest high-speed,
high-efficiency sawing technologies,
where sawing performance gains are
making a key difference to service and
competitiveness. The new generation
of Behringer HBM-SC (Speed Cutting)
high-performance, straight-cutting,
automatic band saws are providing a
further 30% improvement in cutting
cycle times for straight-cutting
Behringer band saws that had
previously claimed to be the industries
fastest by some margin. “Stockholders
are reporting that their new HBM-SC
band saws are achieving at least a
30% production gain, over their
previous saws, which they had
considered the fastest available just 23 years ago”, adds Barry Rooney, “A
performance gain the competitive
stockholding sector really values”.
TCT (Tungsten Carbide Tipped)
blade life; an important factor
TCT bands have made advances in band
sawing machine performances possible, but
Kaltenbach KBS1051 DG – the world’s fastest structural steel mitring band saw
68
Behringer HBM-SC (Speed-cutting) ultra
high-performance band saw
only by having machines that can withstand
the incredible blade loads that TCT
demands, to cut at their optimum efficiency,
high-performance capability. TCT blades
are more expensive. However, a current
significant technical differential between
band saw machine manufacturers is not just
the speed of a cut cycle but for how long the
TCT blade will last. Kaltenbach considers it a
vital purchasing decision to accurately
assess TCT blade life for a machine, under a
customer’s expected worse case material
cutting conditions. The expense of replacing
blades and the downtime while making the
change becomes far more apparent under
harsh, realistic production conditions and so
has become a significant purchasing
decision when selecting a new sawing
machine.
The HBM-SC range material capacity
choices are Ø800, 540, 440 and 370mm,
with ferrous and non-ferrous options. More
details of these products can be found at:
www.kaltenbach.co.uk/news.
Kaltenbach Ltd
Tel: 01234 213201
www.kaltenbach.co.uk
25/2/13
16:54
Page 69
25/2/13
15:45
Page 70
FICEP works its magic
Lainco has tripled productivity
and minimised production costs
with the 'Lights Out' production
capability of the fully automated
FICEP 1001 DFB drilling &
sawing line
Founder Martin Lachapelle
decided to take his fabrication
company Lainco to the next level
by seeking a fully automated
production capability to
minimise production costs and
increase productivity.
The objective was to run a
'lights out’ operation at night or
weekends when the factory is
closed with a requirement to
also automatically download all
the layout information from 3D
CAD models into a CNC
program to scribe the layout
location and the relative
references for specific details at
a scribed location.
Having undertaken extensive research in the
drill/saw machinery market, Martin found that
there were those suppliers who claimed to
offer an automated solution to one degree or
another but ultimately they lacked the
integrated 'lights out' technology he was
looking for FICEP was the only company that
possessed the required technology and had
existing installations that were able to
demonstrate the required 'lights out'
production process. Using conventional
manual methods with 27 shop employees
Lainco was able to process an average of 80
tons per week. After the installation of the
FICEP 1001 DFB single rotating spindle
drill/saw line, the company was able to
routinely fabricate between 200-250 tons per
week, with the same number of employees, by
using the line for drilling, sawing and scribing
layout locations on all four sides.
The FICEP 1001 DFB transfers stock length
material on to the in-feed conveyor, measures
and confirms the material stock length, loads
the proper CNC program, performs all the
drilling, scribing and sawing functions then
removes trim cuts, remnants and finished
lengths without any operator involvement.
FICEP’s automated scribing has significantly
reduced the fit-up time, eliminated mistakes
and drastically reduced the amount of time the
material is located in the fit up bay.
A delighted Martin Lachapelle, founder of
Lainco, says: “Before we leave at the end of a
work day, we make sure our stock length
magazine is fully loaded, turn out the lights
and let the FICEP perform its magic. In the
morning when we return, the stock lengths that
were on the loading table when we left have
been turned into cut to length sections
complete with holes and full four side scribing
ready for my fitters.
Our productivity and volume capacity has
now tripled and we are able to take on bigger,
heavier and more complex projects, resulting
in significant growth for our company.
Basically, we have captured the previously
unused potential of our workforce and finally
reached maximum efficiency. The FICEP line
has exceeded our objectives and we could not
be happier.”
Lainco is a leading steel fabricator
specialising in fast-track design and build
projects for the industrial, institutional/
governmental and commercial sectors in
Quebec, Ontario, and the Northern
Territories.
FICEP UK Ltd
Tel: 01924 223530
www.ficep.co.uk
Saw 300% faster
than industry norms…
…whatever the metal!
BILLET • STRUCTURAL • TUBE • PLATE • STRAIGHT & MITRE • SEMI & FULLY AUTO
Kaltenbach Ltd, 6-8 Brunel Road, Bedford MK41 9TG t: 01234 213201 e: [email protected] www.kaltenbach.co.uk/news
70
22/2/13
14:53
Page 71
Meba introduces the first electronic
production cutting bandsaw
Constant increases in energy costs have resulted in Meba producing the
first high spec electricly powered high production bandsaw without
compromising on performance. The Meba e-cut range operates
without the need for a hydraulic motor, operating purly on electrical
drives increasing efficency and reducing running costs to the end user.
All drives on Meba e-cut models are powered by soft start motors,
eliminating voltage spikes. Electrical axles are moved with high
precision and accuracy resulting in efficient power consumption,
improving cutting accuracy and increasing the life of the saw blade.
Electrical driven systems have a significantly lower power demand
when compared to a hydraulic based system. For example, hydraulic
clamping requires a permanent pressure, consuming energy during a
cutting cycle. Electric clamps only require energy for the vice movement
(clamping and releasing).
Meba e-cut machines also score compared to hydraulic based
systems in the following areas: lower maintenance/running costs, with
no need to replace hydraulic oils /filters etc; machine /blade
performance due to temperature change affecting hydraulic systems;
hydraulic leaks, which can be a major concern in the maintenance of
cutting fluids and operator safety and reducing risks of dermatitis; noise
reduction, the only noise generated is the sound of the blade cutting the
material (hydraulic based machines have additional pumps running.
This results in a much quieter cut which can be a major consideration
when purchasing new equipment due to Health & Safety restrictions on
noise levels within the working environment.
Almost 10 years ago, Meba was the first industrial manufacture to
integrate electrical systems into its machines with the linear ball screw
feeds.
Further features which ensure the highest quality and performance
are: a ridged saw frame construction; band wheels supported on the
front and back of bearings creating a spindle axle; a powerful 5.5 KW
/ 7.5KW Motor depending upon the chosen model; a new CNC
control available based upon windows CE with touch sensitive panel;
the chip conveyor can be mounted on either side of the machine.
Meba Saw Company
Tel: 01423 881600
www.meba-saw.co.uk
71
ES WELDING 72-74:ES CUTTING TOOLS FTR 38-51
22/2/13
16:04
Page 72
WELDING
Pressurefab invests in ESAB welding for today
and tomorrow
PressureFab Group of Dundee is a leading supplier of transport
and development equipment for the offshore oil and gas
industry, as well as fabrications for the fast growing renewable
energy market. Exports account for some 50% of sales and the
company’s success to date is built on the quality of its finished
products. Quality welding is a critical element of the company’s
production programme and to achieve the high standards
required, PressureFab Group is both replacing existing welding
plant and extending its welding facilities by making significant
investment in ESAB welding equipment.
PressureFab Group’s offshore containers and filtration
systems are manufactured to rigorous industry standards
including DNV 2.7-1, DNV2.7-3, BS EN 12079 and PD
5500. Operating from its 11,000m2 facility, the company
has in-house design, fabrication and industrial coating
facilities. PressureFab Group’s audited quality system
supports 100% material traceability, essential to meet the strict
requirements of the certifying bodies operating in the offshore
oil and gas industry, such as Lloyd’s Register and Det Norske
Veritas (DNV).
Initial investment in ESAB welding technology came some
18 months ago with the specification of ESAB OK Aristorod
12.50 solid welding wire in 250kg Marathon Pacs for MAG
welding of non-alloyed steels and well suited to the type of
welding undertaken by PressureFab Group. Eight Origo MIG
340 Pros, step controlled power sources for MIG/MAG
welding, were purchased over the coming months as the
company became increasingly confident in the quality of weld
that could be produced and also recognised the high levels of
the technical support provided by ESAB.
2012 saw the acquisition of 15 ESAB Origo MIG 4004i air
cooled electronic controlled MIG/MAG/MMA lightweight
multi-process inverter based welding packages. They are
designed for high productivity welding and with their high
duty cycle are ideal for PressureFab Group’s long runs. Origo
Feed 3004 MA23 electronically controlled wire feed units and
five metres of interconnections have also been purchased.
Managing director, Hermann Twickler has recognised the benefits of
dealing with ESAB: ”ESAB is a leading global brand, offers excellent
warranties and technical back-up throughout the world,” he says.
“The product features of the Origo MIG 4004i’s were also important
in terms of their compact design, simple operation, functionality and
easy to read displays. Their welding performance in the type of
fabrication work we undertake, typically on carbon steel to subsea
specification, is critical. With continuous welding, it is easy to switch
between settings and the inverter technology ensures high
performance. The lightweight wire feeders also help us to weld freely
in and around the containers we are manufacturing.”
PressureFab Group is also extending its business beyond the
traditional oil and gas industry and has moved into the renewable
energy market with the fabrication of products such as towers and
72
foundations for wind turbines. The company recently exhibited at the
American Wind Energy Association (AWEA) Offshore Windpower
Conference & Exhibition in Virginia Beach during October 2012.
“As far as welding technology is concerned we see ESAB as being
able to meet our future requirements in this industry too,” concludes
Hermann Twickler.
ESAB
Tel: 0800 389 3152
www.esab.co.uk
25/2/13
16:55
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WELDING
£10M in machine sales confirms PTG as a ‘supplier of choice’
PTG Heavy Industries, part of the UK-based
Precision Technologies Group, has long
been recognised as a byword for unrivalled
expertise in the design and manufacture of
heavy duty lathes, deep hole boring
machines and friction stir welding
technologies.
With the division’s machine sales topping
£10 million during 2012, an increase of
30% over the previous 12-month period,
customer appreciation of the inspiring
engineering solutions that PTG Heavy
Industries provides is clearly reflected in sales.
“As you can imagine, we are delighted to
report exceptional sales growth during 2012,”
enthuses sales manager, Chris Cheetham.
“Perhaps most importantly, the year also saw
us make considerable headway into several
new markets. For example, we achieved a
particularly significant order from the United
States.
“Worth $2.3 million, this order was for a
25,000kg-capability deep hole boring
machine that will be used for the deep hole
drilling of nickel alloys, with up to 15”
diameter holes. Another order from the USA
then followed, this time for a roll turning lathe
worth $900,000. It will be used by a customer
in the steel industry.
“Without a shadow of a doubt, however, the
real highlight of the year for us was the design
and build of a Powerstir Friction Stir Welding
Machine with a 6m x 4m gantry, for a
customer in China’s avionics industry.”
Specially designed for research and
development purposes, and believed to be the
most powerful friction stir welder in the world,
the machine is capable of producing superior
friction stir welds in aluminium alloys, titanium
and stainless steel.
Two orders from the Russian space sector
also demonstrate the considerable
capabilities of PTG’s Powerstir technology.
Scheduled for delivery in early 2013 and
with a combined value of more than £2
million the machines will provide an
exciting new market opportunity for PTG
Heavy Industries.
During 2012, PTG Heavy Industries also
supplied six high capacity lathes to
customers in India, while a UK steel
manufacturer expanded its portfolio of PTG
lathes to 13 machines. Two older machines, a
roll grinder and a lathe, were then reengineered for UK customers. PTG Heavy
Industries offers a comprehensive
refurbishment and upgrade service for older
machines and the two models in question were
brought up-to-date with current day
specifications and technologies.
PTG Heavy Industries
Tel: 01706 526590
www.ptgltd.com
Victor®Thermal Dynamics introduces HeavyCut™Technology
Historically plasma cutting was the most
common process used for cutting mild steel up
to 20mm and above this thickness oxyfuel was
still the most popular cutting process. Recent
introductions of plasma systems with outputs
up to 400A have tried to push this limit up to
50mm, however at these thicknesses
consumables lifetime is reduced and cut
quality is not as good as on thinner plate.
HeavyCut Technology improves cutting
efficiency on thicker mild steel and extends the
useful life of the consumable parts. Utilising
advanced consumable parts and intelligent
process parameters to cut thicker plates results
in better cut quality, longer lasting
consumables and a lower cost per cut,
meaning that true precision performance is no
longer limited to thinner plates.
With HeavyCut Technology you can cut up
to 50mm with the same high quality
achievable on thinner plate. This is achieved
through specially designed torch consumables
and highly optimised cutting parameters.
HeavyCut Technology introduces an
advanced consumables set that includes: new
electrode with multiple hafnium inserts to
74
increase parts life during high current
applications; new two-piece tip that provides
cooling all the way to the tip orifice for the best
cut quality over its complete lifespan; new
heavy duty shield cup designed to withstand
piercing 50mm at 400 Amps and capable of
over 400 piercings without compromising cut
quality; new cutting parameters - Victor
Thermal Dynamics has rigorously tested these
consumable parts to create the optimum
cutting parameters, allowing you to get the
best possible quality, speeds and consumables
lifetime.
HeavyCut Technology is available for all
Ultra-Cut 300 and 400 systems, for systems
with either manual or automatic gas control.
Please note that older systems may require a
firmware upgrade to take advantage of
HeavyCut technology.
Headquartered in St. Louis, Missouri, Victor
Technologies provides superior solutions for
cutting, welding and gas control equipment
under brand names that include Victor ®,
Victor®Thermal Dynamics®, Victor®Arcair®,
Victor®TurboTorch®, Tweco®, Thermal Arc®,
Stoody®, Firepower® and Cigweld®. For more
information about Victor Technologies, its
products and services, contact:
Victor Technologies Europe
Tel: 01257 224838
www.victortechnologies.com.