Sept 2015 - Roger Barber Publishing Services

Transcription

GSF FRONT COVER SEPT 2015_GSF FRONT COVER APRIL 08 19/08/2015 14:04 Page 1
SEPTEMBER 2015
High-Tech for
High-Flyers
Tim Kern and Wolfram Hermle from
Haas talk about Custom Grinding
Processes for the Aerospace Industry.
Grinding with
attitude!
Your
challenge
Our
solution
Technological advance through innovations
Rollomatic will exhibit 6 models for the efficient and reliable production of high-end cutting tools, including
a laser machine for economical manufacturing of PCD/CVD-D cutting tools with highest quality demands
for the IT, aerospace, automotive and medical industries. In addition, the latest development of the Kawada
Nextage Humanoid Robot to economize your tool production will be on display during the EMO 2015.
Please visit our booth at Hall 14, Booth M16
[email protected] www.rollomaticsa.com
GSF CONTENTS 2-3_GSF CONTENTS p2-3 20/08/2015 12:26 Page 3
SEPTEMBER 2015
COVER STORY 3
VOLUME 13 | No.4 ISSN 1740 - 1100
Safe grinding process for
sensitive components
www.rbpublishing.co.uk
SPECIAL REPORT
4
News
6
EMO PREVIEW
8
AEROSPACE REPORT
18
Production Grinding
22
Machine Safety
32
Grinding Wheels & Discs
34
Deburring
44
FEATURE - POLISHING & LAPPING
50
Honing
54
Filtration & Lubrication
56
Surface Measurement
58
Solving complex grinding challenges is a part of everyday business
for Haas Schleifmaschinen GmbH. Aero engine makers, amongst
others, appreciate Multigrind® grinding machines for their
exceptional performance and precision. There’s also the extensive
experience of the Haas grinding experts and the extraordinary
spirit of invention that go into developing the ideal machining
strategy for a component such as a shroud segment.
FEATURE - TOOL & PROFILE GRINDING 60
Component Cleaning
70
Metal Finishing
76
AT YOUR SERVICE
82
Published by Roger Barber Publishing
Enterprise House, Foundry Lane, Horsham, West Sussex, RH13 5PX
Publisher: Roger Barber
Sales: 01403 266022 Fax: 020 8916 0033
Email: [email protected]
Assistant editor: John Barber - 01403 242803
Circulation: Chloe Barber - 01403 242803
Accounts: Jackie Barber - 01403 563791
Design & Production: Roger Barber Publishing
Production manager: Anna Rodrigues - 01472 210712
Print: Holbrooks Printers Ltd, Portsmouth, Hampshire
Grinding & Surface Finishing is a controlled circulation magazine, available
free to selected personnel, at the discretion of the publisher.
This material is copyright. No part of this publication may be reproduced without
express written permission. Please contact the publisher.
NEXT ISSUE - NOVEMBER 2015
• Automotive Report
• Component Cleaning
• Deburring
• Dust & Fume Extraction
• Honing & Bore Finishing
GSF SEPTEMBER 2015
Precision to one one-thousandth of a millimetre - grinding a shroud
component for aircraft turbines
Shroud segments are sealing elements which maintain a seal
between the head of the rotor blade and the turbine housing.
Because the conditions inside the high-pressure area of a turbine
are extreme, shrouds are made from high-temperature nickel
alloys. To reduce weight, components feature the thinnest walls
possible, representing a challenge for the grinding process.
Clamping, machining strategy and cooling are all factors that play a
key role. Haas customers grind shroud segments in just two
clamping operations. The overall processing time is just about 15
minutes with profile and shape tolerances of no more than 0.05
mm. Time and quality play an important role, as 40 to 60 shroud
segments, depending on the type, are installed in the highpressure area of an aircraft turbine. Grinding has proven to be an
economical manufacturing process.
To ensure quality, Haas uses a high-precision coordinate
measuring machine and a variety of control gauges when
machining shrouds. Other measurement technologies are used for
other aerospace components such as optical measurement
systems and gear inspection machines. Haas engineers are
currently working on integrated equipment for measuring
mechanical vibration. The mechanical engineers in southern
Germany are always looking for a little more precision.
UK Agent:
Advanced Grinding Solutions Ltd
Tel: 024 76 226611
Email:[email protected]
www.advancedgrindingsolutions.co.uk
GSF SPECIAL REPORT 4-5_ES CONTENTS 4-5 21/08/2015 11:31 Page 4
SPECIAL REPORT
Internal affairs
Biel is home to the Fritz Studer AG Internal
Cylindrical Grinding Competence Center.
The result of the integration of COMBITEC
AG, manufacturer of high-precision internal
grinding machines, into the Thun company
in 2008, today all internal cylindrical
grinding expertise is concentrated in Biel.
STUDER's prime aim with this pooling of
know-how is to boost the importance of
internal cylindrical grinding. Specifically
developed system components are applied
to the basic machines built in Thun and
equipped with extensive grinding
know-how, in line with customer
requirements. Specially developed loaders
or complete automation systems round off
the machines. Around 45 internal cylindrical
grinding machines are built in the Internal
Grinding Competence Center every year,
and the plan is to increase sales to 90
machines per year over the next few years.
Broad-based internal cylindrical grinding
platform
The STUDER internal cylindrical grinding
platform consists of four areas: basic,
universal, radius and production machines.
While the S110 and S120 basic grinding
machines and the CT750 and CT960 radius
grinding machines belong to the established
portfolio, the S121 (new at EMO 2015),
S131, S141 and S151 universal internal
cylindrical grinding machines and the S122
production internal cylindrical grinding
machine are part of a completely new
modular system. With four machine areas
and up to four machines per area, STUDER
offers a broad-based machine portfolio
which allows the user to specifically access
the machine size and technology as
required.
The S110 and S120 are basic machines
which STUDER has equipped with simple
technologies such as anti-friction guideways
and recirculating ball screws. With the same
machine concept and the integration of
identical technologies, the machines are
differentiated by the machinable workpiece
diameters and lengths. The machines have a
movable workhead, which always
guarantees good accessibility and can be
used as a loading axis. Because an
integrated loader requires one axis less, the
S110 and S120 can easily be automated. The
machines can be used with up to four
spindles, which are arranged in parallel.
4
The Fritz Studer management (from l to r): Fred Gaegauf, Dr. Gereon Heinemann, Gerd König, Jens Bleher
Alternatively, the installation of
high-frequency spindles or belt-driven
spindles is possible. The S110 and S120 are
targeted at users who must achieve low
workpiece prices with the smallest possible
investment.
The S121, S131, S141 and S151 belong to
a brand new series of universal internal
cylindrical grinding machines from STUDER
and can be used to machine workpieces of
different dimensions, depending on the
machine size. Equipped with up to two
external grinding spindles, these internal
cylindrical grinding machines can also be
used for external grinding applications. The
four machine models S121 to S151 are
based on STUDER's latest machine
technology. They feature machine beds
comprising of Granitan® S103 mineral
casting, as well as the StuderGuide®
guideway system with linear motors or the
newest generation of glass scales,
technologies previously only available in
STUDER's universal and external grinding
areas. The Thun company is thus entering a
completely new dimension in internal
cylindrical grinding technology. The series is
aimed at precision grinders and with them
the entire spectrum of workpieces that
require high-precision internal grinding.
With the S141 and S151 STUDER is also
particularly aiming at manufacturers of main
spindles.
The CT750 and CT960 radius grinding
machines represent a niche in internal
Grinding & Surface Finishing n SEPTEMBER 2015
cylindrical grinding and are used to machine
extra hard materials such as tungsten
carbide, ceramic or sapphire. Simply shaped
diamond tools are generally used for
grinding such materials. So that complex
component geometries can also be created
with these shapes, the workpiece moves
around the grinding wheels. The CT750 and
CT960 are therefore equipped with a swivel
axis or a full-blown interpolating B-axis,
which enable turning of the workpiece and
the production of ground and polished radii
in the oscillation grinding process. These
machines, which are available in two sizes,
also feature the latest STUDER technology,
such as a turret with direct drive or directly
driven B-axis. The area of application of the
machines is the manufacturing of draw dies,
piston or hydraulic components.
The STUDER internal cylindrical grinding
platform is completed by the S122, a pure
system machine for production. This
GSF SPECIAL REPORT 4-5_ES CONTENTS 4-5 21/08/2015 11:34 Page 5
SPECIAL REPORT
machine was designed for the production of
hydraulic and automotive components.
Equipped with up to three spindles in a
linear arrangement and an integrated quick
loading concept, STUDER has placed the
priority on minimising auxiliary times with
the S122. The system machine is always
application-specifically equipped,
depending on the workpiece and the
specified process. As the extensive
know-how of the Internal Grinding
Competence Center in terms of technology
and process design is incorporated into the
machine design, the customer gets a quick
machine and an optimised grinding process.
Minimised to the max
The S121 from STUDER is a universal
internal cylindrical grinding machine for
medium-sized workpieces in individual and
small batch production and will make its
worldwide debut at EMO 2015.
and direct measuring systems
guarantee exceptional
interpolation accuracies.
Although the smallest machine
in the universal series in terms
of space requirement, larger
diameters can be machined on
the S121 than on an S131. This
makes it a high-performance
machine with an impressively
compact design and excellent
ergonomics. STUDER's
offering of high performance in
a small footprint with the
customized S121 is evident in
the swing diameter over the
table of 400 mm and the
maximum workpiece length of
300 mm, with a maximum
grinding length of 175 mm for
internal and 100 mm for
external diameters. This large
range of workpiece dimensions
is made possible by optimal
arrangement of the machine
components.
Tailored to the perfect size
The configuration of the S121 as a
tailor-made machine is above all made
possible by the fact that the machine can be
equipped with a fixed spindle or a spindle
turret with two spindles. When using a
spindle turret, the turret swivels
hydraulically through 180° to a stop, and
one spindle can be fitted with an external
grinding wheel. However, STUDER also
Equipped with the advanced technology
implements the "tailor-made" principle
of its sister machines S131, S141 and S151,
through a workhead with manual cylindricity
this series model has been limited to the
correction, which is adjustably mounted on
essential equipment. A striking example is
the workpiece table, and a high-resolution
the spindle turret, which swivels through
C-axis with direct measuring system, which
180° to a stop and is equipped with two
is ideally suited for form and thread
grinding spindles. Alternatively a fixed
grinding. The machine concept always
spindle is possible. With the S121 STUDER
allows optimum accessibility for the
has thus created a tailor-made machine for
operator, whether for workpiece
internal, surface and external grinding of
changeover, dressing or changing the
chuck components, which offers exceptional grinding wheel.
value for money. While a T-slide
The S121 is a universal internal cylindrical
arrangement or the use of maximum two
grinding machine, which is designed for the
tools guarantees the attractive price, the
production of high-precision parts. The
manufacturer has made no compromises in
basis for this precision is the machine bed
terms of the advanced technologies used.
comprising of Granitan S103 which, with its
This is evident in the StuderGuide guideway excellent cushioning and thermal behavior,
system for the X- and Z-axis, which
ensures outstanding surface quality of the
guarantees high geometrical traversing and ground components. The excellent
guidance accuracy through the entire speed cushioning behavior also extends the
range, together with high load capacity and service life of the grinding wheel, which in
cushioning levels. At the same time the
turn reduces auxiliary times. As the machine
combination of StuderGuide, linear motors
bed largely equalizes temporary
temperature fluctuations, a high
dimensional stability is ensured throughout
the machining time. The modules of the
S121 are ideally suited to each other and
produced with the customary STUDER
precision. The large distance between the
guideways and the very rigidly constructed
slides are further cornerstones for the
precision and productivity of this machine.
Simple, reliable programming and efficient
operation of the S121 is guaranteed by the
StuderWIN software. The possibility of fully
integrating the in-process gauging and
sensor technology for process monitoring as
well as contact detection and automatic
balancing systems in the control enable
standardised programming of the different
systems. The drive elements are optimally
adapted to the control.
The S121 is tailor-made for a large range
of internal grinding applications. Numerous
applications are in the production of
machine tools, drive elements as well as in
the aircraft and die industries.
Fritz Studer AG
Tel: 0141 33439 1279
www.studer.com
5
GSF NEWS 6-7_ES CONTENTS 4-5 21/08/2015 10:09 Page 6
News
UK manufacturing comes together at
Advanced Engineering 2015
From 4th to 5th November, the UK’s
advanced engineering communities will
come together for their own bonfire night
display: in this case the 2015 edition of
Advanced Engineering UK, including co
locating shows: Composites Engineering
Show; Aero Engineering Show; Automotive
Engineering Show; Performance Metals
Engineering, together with one of the most
comprehensive free conference
programmes in the industry.
Rapidly shaping up to be the largest
Advanced Engineering to date, more than
750 exhibiting supply chain partners will be
meeting and doing business with engineering and procurement management
from OEMs and top tier supply chain
organisations across aerospace, automotive,
motorsport, marine, defence and more.
Innovation, innovation, innovation
Providing more feature exhibit areas than
any other trade event in its sector,
Advanced Engineering UK is particularly
well positioned to showcase the kind of
innovative technology the UK is particularly
known for, with an emphasis on its
commercialisation possibilities. Typical
areas of coverage will include graphene,
wearable/printable electronics, smart
materials, additive manufacturing, new
approaches to design and manufacturing
and much more.
Free to attend presentations from the
highest quality speakers
Across the show floor, six Open Conference
auditoria will host presentations ranging
from companies like Boeing, to industry
bodies such as Composites UK. Short, sharp
deliveries will provide attendees with
6
quickly accessible industry intelligence,
applications case studies, and technology
updates.
from commercial vehicles to motorcycles,
specialist low carbon vehicles and the
engine sector.
The co-locating show zones are:
The Aero Engineering Show:
The Aero Engineering Show 2015 is the UK’s
only dedicated show and open conference
for the aero structures, power plant and
aero systems engineering communities: it is
a unique annual showcase of technology
and engineering suppliers supporting the
UK’s critically important Aero Engineering
supply chain, the second largest in the
world.
The Composites Engineering Show:
Reflecting UK industry’s increasing demand
across diverse sectors for harnessing the
benefits of composites materials, the
Composites Engineering Show 2015 is a
single UK showcase of the very latest in
composites materials, composites
processing equipment, tooling and
technologies, related design and simulation
technology, specialist composites
processing services, composites test and
inspection technologies, and much more.
The Automotive Engineering Show:
Representing the UK’s only dedicated show
and open conference for
automotive body, chassis,
powertrain and supply chain
engineering, the Automotive
Engineering Show 2015,
provides a showcase of
specialist UK and international
engineering services,
technology and supply chain
partners supporting the UK’s
multiple vehicle engineering
programmes, from passenger
cars to performance vehicles;
Performance Metals Engineering:
The addition of this show is a response to
increasing demands for higher performance
from metallic materials in a range of
capabilities vital to tomorrow’s engineering
programmes, calling for greater strength,
lighter weight and extended functionality
with processing efficiency.
Register now for your free entry badge at
www.advancedengineeringuk.com
UK Tech Events Ltd
Tel: 020 8783 3573
www.uktechevents.com
GSF NEWS 6-7_ES CONTENTS 4-5 24/08/2015 11:45 Page 7
News
GSF is sad to report the loss of a major
figure in the abrasive and metal finishing
sector. Klaus Lehnen, the MD of Surface
Technology Products Ltd died peacefully
at his home in Solihull in July.
Born in 1941 in Hannover, Germany, he
joined VSM Abrasives at their headquarters
there to do his technical apprenticeship. In
the early 1960’s, VSM was trying to build up
its presence in the UK and he was sent to the
company’s London office/small business
unit to develop the business, moving on to
Manchester and Liverpool. He left VSM to
develop sales at TESA Tapes industrial
division, part of the large Beiersdorf group.
He then relocated to the Midlands, and
came up with the idea of starting his own
company, initially called Hilzinger Balmond
Abrasives. The ethos was always to
introduce new ideas and technology into the
UK abrasive and polishing/abrasive
machinery market.
In 1973 the company name was changed
to Surface Technology Products or Surtech
for short, and the focus was on selling
abrasive and polishing machinery, not just
consumables. Klaus was a pioneer in making
the link between solving customers’
problems and issues with a combination of
the correct machines and consumables, a
fairly ground breaking concept at the time.
From the 1980s onwards, the focus was on
portable tools, especially with the now very
famous US brand Dynabrade which Surtech
helped build up in the UK. The sales network
was expanded to promote these machines
and other brands of pedestal machines via
industrial abrasive distributors. The
company worked very closely with 3M to
reinforce the link between the correct tool
and abrasive for the application.
Under Klaus’s leadership, the company
was able to build up an unrivalled range of
machines from across Europe and even the
world, had the best technical reference
library for anything to do with the industry,
and forged numerous contacts with all the
European abrasive machine tool suppliers
and manufacturers. He had a vast
knowledge of the industry, problem solving
and applications, wrote editorials, created
his own leaflets and brochures, as well as
press releases. The subject was his passion
and hobby at the same time, but he still
made time to do what he liked, travelling,
the great outdoors, good wine and food
Klaus was a pioneer in many ways. He was
an immense help when we launched
Grinding & Surface Finishing and we shall
miss his knowledge and understanding of
our business, as well as his friendship. His
death marks the end of an era, as he was old
school, honest, hardworking, forthright
sometimes, but above all had conviction of
doing what he thought was right
3M’s latest innovation recognised at BSIF Safety Awards ceremony
3M is celebrating after winning a prestigious
award for its latest revolutionary product,
designed to improve occupational health for
respirator users in the workplace.
At the Safety and Health Expo, held in
London, the diversified technology
company won a British Safety Industry
Federation (BSIF) Award for its Organic Gas
and Vapour End of Service Life Indicator
Filters.
The Safety Awards are highly regarded in
the health and safety industry and judges
awarded accolades in three categories:
product innovation, service award and
safety excellence.
3M’s filter, which is the first of its kind,
won the product innovation category. The
product utilises the company’s End of
Service Life Indicator (ESLI) Technology to
help respirator users in appropriate
environments determine when a filter needs
replacing, so they are not exposed to certain
harmful organic gases and vapours.
Currently, some users change their filters
only when they can detect contaminant
odour, taste, or irritation inside the
respirator, with the result that the harmful
substance has already broken through.
To combat this problem, the ESLI
Technology is located inside the filter next
to the activated carbon. As organic vapours
travel through the filter, they are also
absorbed into the ESLI Technology.
As this happens, the indicator changes
colour, visually marking the course of the
organic vapours through the filter.
Dependent on the viewing angle, the user
will either see a red bar on a green
background, or vice-versa. Once the bar
reaches the end-of-service line, the filter will
need replacing.
Jenn Raymond, senior marketing
executive at 3M, said: “We are delighted
that the Organic Gas and Vapour End of
Service Life Indicator Filter has been
recognised at the BSIF Safety Awards. This is
such an innovative product, which will really
make a difference to occupational health, so
it is fantastic that this has been reinforced by
the BSIF accolade.”
3M and 3M Science Applied to Life are
trademarks of 3M Company
To learn more about 3M's creative solutions
to the world's problems, visit
www.3M.co.uk or follow @3M_UK on
Twitter
7
GSF EMO PREVIEW 8-17_ES CONTENTS 4-5 19/08/2015 14:14 Page 8
EMO PREVIEW
Avanti a Milano
After six years, EMO, the worldwide
exhibition of machine tools returns to Italy.
Promoted by CECIMO, the European
Association for Machine Tool Industries, the
tradeshow will take place from the 5th to the
10th of October 2015 in the prestigious
fieramilano exhibition centre.
The biennial leading machine tool event,
whose trademark is owned by CECIMO, has
chosen Milan as one of its locations
alternating with Hanover. This reflects both
the foresight of the organisation, relying on
a long-standing experience in the
organisation of events and the status of the
city in showcasing the expertise of the Italian
industry, which ranks fourth worldwide for
production and third for export.
More than 110,000 square metres of net
exhibition space was already booked six
months before the opening of EMO
MILANO 2015 and the previous 95,000 sq m
of exhibition occupied by the 2009 show has
been exceeded. Should the current trend be
confirmed it is predicted that the exhibition
will occupy 120,000 sq m.
More than 1,300 companies are already
registered to exhibit at EMO MILANO 2015,
with, of course, Italian companies to the
fore, closely followed by the Germans, the
Taiwanese, Chinese and Swiss.
8
committed to transforming the concurrence
of the two tradeshows into real
opportunities for our operators, by planning
The halls of the exhibition centre of
‘connection activities’ and by activating
fieramilano Rho-Pero will host the biggest
numerous special services. An example is
factory showroom in the world, where
the Hospitality programme which accurately
machine tools, robots, automation, additive lists a large range of accommodation
manufacturing, mechatronic solutions and
options reserved for trade visitors attending
auxiliary technologies will be exhibited,
EMO MILANO 2015”.
expressing the importance of the sector’s
“In the first quarter of 2015,” declares
international production that accounts for
Alfredo Mariotti, director of EMO MILANO,
64 billion euros.
the index, produced by the Studies
“EMO has always been considered the
Department of UCIMU-SISTEMI PER
most important event at the disposal of
PRODURRE regarding the quantity of
trade operators from the world's
machine tool orders received by Italian
manufacturing industry to keep up-to-date
manufacturers, registered an increase of 2.2
on the new production technologies,” states percent compared to the same period in
Pier Luigi Streparava, appointed by
2014, making it 6 positive quarters in a row.
CECIMO as Commissioner General EMO
The increase in the internal market (+15.4
MILANO 2015. "It's exactly for this reason
percent), has been instrumental to this
that we decided to include additive
positive trend. This information confirms a
manufacturing into the technological index
new period of development and increase for
of products of the sector’s leading
the use of machine tools in Italy. This will be
international exhibition. This is one of the
enhanced with stronger and stronger
technologies that will be increasingly
increases: +5.3 percent in 2015, +5 percent
developed in future and to which the
in 2016, +7.4 percent in 2017 (Oxford of
tradeshow will dedicate a special in-depth
Economics figures), to the benefit of EMO
focus”.
MILANO 2015”.
150,000 visitors from approximately 100
“This data, together with the positive
countries: these are the figures expected for forecast on the global use of machine tools,
EMO MILANO 2015 and which will also take that will reach 60 billion in 2015, 63 billion in
advantage of the show running concurrently 2016 (+5.2 percent), 66 billion in 2017 (+4.8
with EXPO 2015. On this occasion, Milan will percent), are a good indication for a
show a completely renovated look and an
successful exhibition,” he concludes.
improved traffic flow, thanks to a revised
Updated information, special services for
and strengthened public transport service.
exhibitors and visitors, the video
Directly connected with the exhibition
advertisement and one of the music tracks
centre of fieramilano Rho-Pero, Expo 2015
from the EMOTION 2015 collection, the CD
will offer visitors to EMO MILANO 2015 a
made to promote the event, are available on
unique programme of complementary
the website below.
events, creating really interesting synergies
for the hundreds of thousands of visitors
EMO Milano 2015
who will be coming to Milan from every
Tel: 0039 0226 255 860/861
corner of the globe.
Pier Luigi Streparava continues: “As
www.emo-milano.com
organisers of this exhibition, we are
EMO
05.10. - 10.10.2015,
Milan, Hall 14,
Stand L05
G&SF_Nr9_UGG_EN_EMO_2015_Print.indd 1
09.06.15 09:49
EMO PREVIEW
Italian machine tool manufacturers on home turf
Italian grinding machine specialist AZ spa
specialises in machines for crankshafts and
aircraft landing gear and will exhibit the
following machines in Hall 14 Stand N08:
The RU2B2500 CNC Cylindrical Grinding
Machine is designed to grind aerospace
turbo spindles. The 2B2500 is part of a new
series of RU universal grinding machines for
special aerospace components. These new
machines with the most advanced
technology are specifically designed to
grind such as turbine spindles and aircraft
landing gear. The RU series have a moving
table configuration and RU2B series have a
moving wheel-head configuration. Features
include: distance between centres 1000 mm
to 6000 mm, maximum swing 1600 mm,
conventional, CBN or diamond grinding
wheels for ID and OD grinding, grinding
plunge right and oblique, B-axis wheelhead
and double wheel configuration for
simultaneous grinding and cycle time
reduction.
Grinding wheel diameters are 600 mm
and 450 mm, spindle power 15 kW, distance
between centres 2500 mm and CNC control
and in-process measurement system range
300 mm.
The IMT Grinding Group will exhibit the
following machines in Hall 14 Stand N12:
IMT Tacchella ELEKTRA 1018 UA Plus
Universal Grinding Machine with four
external grinding wheels.
IMT Tacchella ELEKTRA 1200 UA-Plus line
of universal grinding machines is enriched
with new machine configurations that
represent a further increase in usage
flexibility, adding new application fields.
One of the new configuration foresees
one external wheel on the left side, and two
units with electro-spindles for internal
grinding (execution L/I/I-B), for typical
operations of straight grinding and internal
grinding operations in sequence. Spindles
can be mounted on the machine can be
mounted for internal grinding of holes to a
depth of 320 mm. Another new
configuration allows the mounting of up to
four external wheels (execution LR/LR-B) on
two motor-spindles and this will be
exhibited at EMO.
Each configuration uses external wheels
with diameter up to 508 mm. The automatic
swivelling of the CNC-controlled B-axis
allows the combination of different grinding
cycles in a single setup, reducing retooling
time to almost zero. External and internal
grinding can be carried out, together with
the grinding of diameters, shoulders,
threads, polygons, eccentrics and cams.
The Tacchella ELEKTRA universal grinding
machines are available in three centre
distances: 700, 1200 and1700 mm.
Also new is the operative surface of the
Tool Operator Package software (TOP).
IMT Tacchella will also present important
innovations in new software modules
specifically aimed at grinding operations
based on the interpolation within the C-axis
and the main X and Z working axes, Easy
Thread for threads grinding, Easy Polygon
for polygons, Easy Eccentric for eccentrics,
Easy Cam for cams and Easy Custom Profile
for grinding of specific profiles on
customer’s demand.
Monzesi SRL will exhibit centreless
grinding machines, single and double disc
grinding machines in Hall 14 Stand N04.
The Monza Centreless Grinding Machine
is a completely new design of machine and
will be exhibited for the first time as well as
the Viotto Double Sided Disc Grinding
Machine in a completely new design.
Rosa Ermando will be exhibiting in Hall
14 Booth G02 and showcasing its
reciprocating / creep feed and rotary table
surface grinding machines. The four
machines on show will be:
The IRON 08.6 N “Digital Axis” surface
grinding machine, with a capacity of 850 x
10 Grinding & Surface Finishing n SEPTEMBER 2015
630 x 480(h) mm, 11.0 kW, grinding wheel
dimensions ø 400 x 80 x ø 127 mm and a
ROSA System N “Sinumerik 840 DE
“Touch” control system.
The STEEL Linear 11.7 CNC linear motor
X-axis, creep feed surface grinding machine,
capacity 1.200 x 750 x 600(h) mm, 15.0 kW
grinding wheel dimensions ø 400 x 100 x ø
127 mm.
The ROTOR 800 CN “Torque Drive”
rotary table grinding machine, with a
capacity of ø 1.000 x 480(h) mm, 1.0 kW
grinding wheel dimensions ø400 x 80 x
ø127 mm .
The GOLD 20.10 CN “Digital Axis”
surface grinding machine, capacity 2.150 x
1.100 x 800(h) mm, 30.0 kW grinding wheel
dimensions ø 610 x 150 x ø305 mm.
All four machines will feature variations of
the ROSA Sinumerik control systems.
UK Agent
NL Machine Tool Consulting Ltd
Tel: 01908 675434
www.nlmtc.co.uk
The Art of Grinding.
THREADING THE NEEDLE IS
NOT OUR CORE COMPETENCY.
Grinding 100 000 times more accurate is.
«The Art of Grinding.» is our passion, the highest
precision our claim and Swiss Quality our benchmark. Grinding is an Art that STUDER can handle in
a special way with manufacturing tolerances in the
Nano range. Visit us at the EMO in Milan from the
5th to the 10th Oct 2015 in Hall 14, Booth L05. For the
first time we present to you, our new internal cylindrical grinding machine the S121. Other exhibits:
S33, S41 and S141.
www.studer.com – «The Art of Grinding.»
A member of the UNITED GRINDING Group
EMO PREVIEW
Filtermist chooses EMO to showcase brand new product
Leading UK-based oil mist collector
manufacturer, Filtermist will be showcasing
the latest addition to its accessories range,
the SD Afterfilter, as well as a brand new
CGI company film, on stand D18 at the EMO
2015.
Stuart Plimmer, Filtermist’s global sales
director, comments: “As one of the world’s
leading trade shows, EMO is an ideal
platform to publically launch some of the
latest developments designed to support
our global growth.
“The 2013 show was extremely
worthwhile for Filtermist. As well as
providing a platform for showcasing new
products, it also offers an excellent
opportunity for us to meet with a large
number of our global distributors who play a
vital role in our export success.”
The brand new, independently tested,
Self-Draining Afterfilter is specifically
designed for use in neat oil applications,
including those involving high pressure.
Filtermist will be launching a brand new
Afterfilter specifically designed for use in
neat oil applications, including those
involving high pressure, at EMO.
The independently tested Self-Draining
Afterfilter (SDA) has been added to the
company’s accessories range to provide a
viable solution for Filtermist customers that
generate a significant amount of oil mist in
their manufacturing operations.
The self-draining afterfilter is created from
hi-tech synthetic materials connected to a
patented venturi suction system, created by
a specially developed connection to the
Filtermist unit’s drain tube. The system
ensures that a large percentage of the oil
The independently-tested Self-Draining Afterfilter
has been added to Filtermist’s accessory range
James Stansfield, managing director of Filtermist International Ltd
filtered out by the paper media is drained
back to the machine, thus increasing the
lifetime of the filter.
The SDA is currently available to fit the
S400 and S800 units in Filtermist’s compact
S Series range, designed specifically for
smaller ‘swiss style’ sliding head lathes. It
can also be purchased as part of a
cost-effective new ‘neat oil solutions’ kit that
includes the oil mist collector and a SD
Afterfilter.
The new Afterfilter will be available to
order from 1st October and more details will
be available on Filtermist’s stand at EMO.
Managing director, James Stansfield says,
“Filtermist has almost 50 years’ experience
in the field of oil mist collection and issues
around coping with large volumes of mist
caused in neat oil applications have been
high on our agenda for a while now. Modern
high-pressure coolant systems atomise the
neat oil into thousands of sub-micron
particles, which quickly block up traditional
filter cartridges.
“Combining the proven efficiency of the
Filtermist centrifugal system with modern
synthetic fibre technologies, we are
confident that this latest product will be
well-received by a wide range of end-users.”
The brand new CGI film, meanwhile, is
designed to showcase how Filtermist oil mist
collectors remove hazardous airborne
particles generated in a wide range of
manufacturing applications.
The film has been produced to ensure
customers around the world can easily find
out more about Filtermist whenever they
need information and will be hosted on the
company’s YouTube channel and global
website, www.filtermist.com, to allow 24/7
access.
James Stansfield continues: “The global
nature of our business means we are very
focused on ensuring all of our customers can
access as much information as possible
whenever needed. The internet has made
this job significantly easier and is ideal for
sharing useful content with customers all
around the world.
“We are continually evaluating our
product range to identify any areas where
we may be able to help resolve problems
that our customers are regularly faced with.”
Filtermist’s compact oil mist collectors are
used by some of the world’s leading
manufacturers in a range of industrial
sectors including aerospace, automotive,
medical devices and precision engineering.
Formed in Bridgnorth, Shropshire in 1969,
Filtermist International manufactures and
markets Oil Mist, Fume and Dust extraction
equipment for all types of manufacturing
and engineering processes. With over
200,000 units in daily operation in over 60
countries, the company won a Queens
Award for Export Achievement in 1990 and
continues to expand its export operations as
well as its UK client base.
Filtermist International Ltd
Tel: 01952 290500
Email: sales@filtermist.com
www.filtermist.com
EMO PREVIEW
UK grinding specialist has a strong
presence at EMO
Coventry-based Advanced Grinding
Solutions will be supporting three of its
principals at the forthcoming EMO
exhibition with Nova, Magnetfinish and
Haas all exhibiting their latest machines.
Haas will be showing its latest grinding
machines used for the production of parts
such as cutting tools, turbine blades and
medical components such as artificial knee
joints on stand G12/H11 in Hall 14.
Magnetfinish will be exhibiting its latest
deburring machines that are commonly
used for rotary cutting tools and inserts on
stand A17 in Hall 10. On home soil, the
Italian specialist grinding machine
manufacturer Nova completes the trio of
companies, showing machinery on stand
H14 in hall 14.
The Nova stand will be of particular
interest as the Italian grinding machine
specialist is exhibiting one of its latest
internal grinding machines.
Nova’s core business is manufacturing
grinding machines for external, internal and
the multi-surface grinding of components
ranging from 3 mm to 480 mm OD as
utilised in the bearing, automotive and
aerospace industries, with the bearing
industry being the major market sector
served by Nova. The production of CV Joint
components is another application for which
Nova supplies special machines. Nova’s
special machine division produces machines
for grinding parts of up to 800 mm in
diameter. Key customers include bearing
manufacturers such as INA, FAG and Barden
(The Schaeffler Group) as well as SKF,
Timken and NBC. Other users of Nova
grinding machines include Eaton, Delphi,
Bosch, Ford and GKN. At EMO Nova is
exhibiting the Novamatic 2G machine which
provides very high productivity and allows
for extremely tight tolerances to be held
with statistical control. The machine’s
unique wheel head design enables a
contamination-free environment for the
slides and it has a fixed work head unit for
maximum rigidity and easy automation. The
CBN grinding wheels employed on this
machine are dressed by means of a
high-frequency spindle with cup wheel and
the machine benefits from automatic taper
correction and is fitted with a compact
integrated automatic robot based loading
system.
Nova currently employs around 150
people at its 14,000 sq m HQ in Zola
Predosa, Italy with an impressive 22 percent
of employees in research and development.
Turnover this year is looking to exceed Euro
50 million. Nova continues to expand
worldwide with currently 45 percent of its
grinding machine sales within Europe, 25
percent sold within the NAFTA area and 30
percent to the BRIC countries.
Magnetfinish supplies machines to
specialist tool manufacturers who are using
this unique technology to offer end users
within the aerospace and mould and die
industries premium solutions whereby the
finest and most highly precise milling
cutters, drills and taps are required for
arduous machining tasks.
After being produced by a grinding
process, cutting tools of all types can suffer
from having jagged and sometimes very
sharp cutting edges as well as micro sized
burrs. These impact heavily upon the
lifetime of cutting tools and can also affect
their performance during heavy cutting and
this often means that tools cannot be used
at optimum speeds and feeds. When
milling, drilling or tapping at extreme
speeds the resulting high temperatures that
develop at the cutting edges are the main
source for such problems because the tool
becomes highly susceptible to wear and
even fracture. Deformed hot chips, which
may even weld to the tool surface and form
built-up edges, also greatly impair
high-speed machining. The subsequent
jamming of chips or even more minor
impairment to chip flow that results from
this quickly brings about a premature end to
tool life. The patented Magnetfinish
technology that has been developed by Dr
Wolfgang Thiel of Magnetfinish addresses
this problem.
Haas will be highlighting the production
of cutting tools on its latest CU machine.
This compact tool grinder is only 1.6 metres
wide, with an integrated 14 station wheel
changer. It’s 12 Kw grinding spindle has
ample power for the production of tools of
all kinds and since its launch late last year
Haas have gone onto supplying many of
these machines to major cutting tool
manufacturers.
Despite being very compact, the Haas CU
has a general working envelope of 300 mm
long x 180 mm in diameter making in easily
capable of manufacturing the vast majority
of cutting tools. The automatic change of
wheels and coolant nozzles is catered for as
is the auto loading of parts and wheel
dressing.
Tel: 024 76 226611
EMO PREVIEW
GER focuses on precision demos at EMO
Spanish machine tool manufacturer GER will
be demonstrating both cylindrical and
surface CNC grinding machines at EMO
2016. Two test pieces have been created
that highlight the high productivity features
of the machines as well as the exceptional
levels of precision that can be maintained
over extended periods of operation.
On the cylindrical grinder, which has a
capacity of 1,000 mm between centres and a
maximum workpiece diameter of 280 mm, a
non-cylindrical part will be machined. Flats
will be ground on a 15 mm square to an
accuracy of eight micron, with each face flat
to within two micron. This demands precise
control of the angular position spindle
relative to the X axis wheel head slide.
Hydrostatic bearings enable small axial
incremental movements to be synchronised
with the main spindle drive without
encountering slip/stick problems Similar
accuracies can be achieved when grinding
other cross-sections such as triangular,
hexagon, ’D’, ovals or ob-rounds.
On the CNC surface grinder with its 800 x
400 mm table, visitors will see a profiled
section being ground using the CNC system
to generate the profile across the table.
Digital scales give absolute measurements
for the traverse (Z-axis) and vertical (Y-axis)
to maintain profile accuracy. The CNC
control allows the profile to be monitored
and modified in real time via the interactive
screen.
Other key machine features include a ball
screw driven X axis on the table, frequency
converter for constant cutting speed, and
finally a range of optional dressing cycles.
Both machines are fitted with Fanuc CNC
controls and axis drives with one important
addition: the software for the interactive
screen and operator interface was
specifically written by GER to incorporate
many features specific to the grinding
process. For example, geometric profile
corrections for taper, barrelling, and camber
are standard.
Other facilities take in air gap elimination
and collision management as well as wheel
data storage together with automatic wheel
dressing. The CNC system also introduces
closer integration between various axis
movements. On the cylindrical grinder, for
example, the spindle movement (C-axis) and
cross slide (X-axis). This directly contributes
to the levels of accuracy essential for
grinding precision non circular cross
sections.
For maximum customer support, all
machines in the field can be supported by
internet diagnostics.
For further information, contact:
UK Agent:
International Manufacturing Solutions
Tel: 01269 843 994
www.imsl.eu
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15
EMO PREVIEW
Schaublin to demonstrate 8-axis
turn/mill & grinding machine
Schaublin Machines has now successfully launched its 202TG 8-axis machine
Configured in several versions, enabling
hard turning, milling and grinding, it offers
impeccable precision levels for applications
in the automotive, micro manufacturing,
cutting tool, optical, aerospace, medical and
defence industry sectors, such is its diverse
capabilities.
The exciting new 202 TG will be
demonstrated at EMO in HALL 7 Stand
A02. The 202 TG has been developed to
improve productivity, precision and
component quality, whilst reducing setup
and cycle times with three operations in one
machine tool that can operate
simultaneously. Created as a flexible
solution, the new 202TG is as comfortable in
a production environment as it would be
producing small batch runs and prototypes.
The new 202TG has a machining diameter
capacity of 80 mm with a maximum
machining length of 160 mm, whilst the
headstock offers a maximum through-bore
of 19 mm. Schaublin Machines is a
manufacturer synonymous with power and
precision and the latest offering has a
continuous headstock torque of 35.1Nm
with a spindle speed capable of reaching
7000 rpm. The stroke of the X1-X2 and the
Z1-Z2 axis is 160 and 300 mm respectively
with the ability to reach working feed rates
of 8 m/min. As one of a select few products
on the market to seamlessly offer hard
turning, milling and grinding in one
machine, the 202TG provides
thermally-cooled grinding spindles with
exceptional power and speed outputs.
When developing the new
202TG, Schaublin Machines had a
set of target criteria that it wanted
to achieve. The recent launch of
the new machine bears the fruit of
the company's achievements with
a hard turning and grinding centre
capable of milling through its
driven tooling stations. In
developing the 2020TG, the Swiss
manufacturer focused upon
creating a machine tool that is
extremely precise and suitable for
machining small diameters whilst
offering modularity and an
ergonomically friendly design for
ease of use and flexibility. Part of
this flexibility is the ability to
accept collets and chucks for
workholding and the ability to
integrate the machine into an automated
environment with a bar-loading facility and
the easy integration of an unloading arm or
conveyor if desired.
At the base of the machine the quality is
apparent. The 202TG has spindle and servo
motor cooling to prevent thermal instability
and to guarantee that accuracy is
maintained on long production runs. The
spindles are driven by synchronous motors
that can start, hit top speeds and stop
significantly faster than competitor machine
tools. This quality is also built into the cross
slide with glass scales delivering a resolution
of 0.0005 mm to ensure unparalleled
accuracy and repeatability.
With previous machines
that offer turning and milling
with a grinding facility, a key
concern to end users was the
ability of abrasive powders
and materials to create
friction and wear of the
moving parts of the machine.
However, Schaublin has
covered this base with all
moving parts being fully
protected to ensure a long
service life of the new 202TG.
The optional revolving tool
turret on the new 202TG
utilises a VDI16 system that accommodates
up to 12 tool positions with up to six tools
having driven capability. With a maximum
rotational speed of 6000 rpm and a 7 Nm
torque, the turret offers flexibility, power,
speed and rigidity to meet all the machining
needs of the end user.
Further options include the internal and
external grinding spindles for precision
production beyond the realms of alternate
machine tools. The internal spindle offers a
maximum speed of 60,000 rpm and a power
output of 6 kW, while the external grinding
spindle has a maximum speed of 25,000 rpm
with a power output of 7 kW.
As both spindles are controlled by a
synchronous motor, the power, efficiency
and ability to reach operational speed
rapidly are unrivalled. As waste removal is an
issue with such a diverse machine, the
202TG incorporates a chip conveyor system
for removal of chips whilst grinding waste is
controlled in the 300 litre coolant sump that
has paper filtration for waste as small as 10
to 20 microns.
Schaublin Machines
Tel: 01264 811602
www.schaublinmachines.co.uk
EMO PREVIEW
Enhanced tool management system on Moore jig grinder
Moore Tool has recently enhanced the tool
management software for its 500 Series
(19.6 in. in X-axis by 11.8 in. in Y-axis travel)
and 1280 Series (52 in. in X-axis by 32.3 in. in
Y-axis-travel) CNC-controlled jig grinders.
The tool management system better
enables the management of dressable and
non-dressable wheels. For dressable wheels,
the user can now select the maximum
amount of allowable wheel wear, in
millimetres or inches, before the wheel
should be changed. This is used in
conjunction with the AutoSize program, a
cycle for automatic sizing wheel diameter.
Through the AutoSize program, the control
monitors and automatically detects when
the maximum amount of wheel has been
dressed off or, otherwise, removed through
the grinding process. This removes the
manual process today of checking for wheel
wear.
For non-dressable wheels, the system
enables the user to set the maximum
amount of time the wheel can be used
before a replacement tool is required.
Easy-to-access screens will show the user, in
real time, how much time a wheel has left
before it needs to be changed. These
enhancements help improve the grinding
process by automatically keeping track of
the tool’s life.
In addition to these enhancements, the
tool management system allows a user to
easily update tool information (tool length,
wheel diameter, wheel thickness). Once tool
information is loaded, it is stored for use by
the AutoSize and the Wheel Dressing
programs. These programs have been
enhanced for faster setup whether utilising a
Renishaw OMP400 Probe or a conventional
indicating process.
The Moore Tool Company manufactures a
complete line of jig grinders and has a
precision manufacturing business certified
to ISO 9001:2008 and AS9100C. The
company is ITAR registered.
Moore’s machine tool business builds fully
automated and highly productive CNC
continuous path jig grinders. It offers a
complete line of machine accessories,
including the ProGrind system which
includes electric grinding spindles, flood
coolant enclosures, as well as advanced
sensor-based systems such as Moore
AutoGrind and the patented Moore
AutoSize.
Moore Tool Company is part of The PMT
Group, parent company of three operating
companies: Moore Tool Company Inc,
Moore Nanotechnology Systems, LLC and
the Producto Corpo.
UK Sales Agent:
Tel: 01908 675434
www.nlmtc.co.uk
www.mooretool.com
INNOVATIONS MADE BY KLINGELNBERG
NEXT FAIRS:
The KLINGELNBERG Group is one of the world leaders in the development, manufacture and
sale of machines for bevel gear and cylindrical gear production, measuring centers for gearing
and axially symmetrical components as well as customized high-precision gear components. The
company‘s products are used by customers in automotive, truck, aircraft, agriculture, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets.
EMO MILANO
Oct 5-10, 2015
Hall 4 Booth D23
Milano, Italy
GEAR EXPO
Oct 20-22, 2015
Booth 1410
Detroit, USA
The activities of the KLINGELNBERG Group, whose origins date from 1863, is managed today, in
the seventh generation,
generattion, by Jan Klingelnberg.
Klingelnberg.
WWW.KLINGELNBERG.COM WWW
.HOFLER.COM INFO
@KLINGELNBERG.COM
WWW.KLINGELNBERG.COM
WWW.HOFLER.COM
[email protected]
17
GSF AEROSPACE REPORT 18-21_ES CONTENTS 4-5 19/08/2015 14:28 Page 18
AEROSPACE REPORT
‘Only grinding is considered for that’
Haas Schleifmaschinen GmbH is a great
partner for manufacturers in the aerospace
industry because the Multigrind® grinding
machines made by Haas master the most
demanding grinding tasks with flying
colours.
Tim Kern is responsible for demonstrating
the machines and for setting up the grinding
processes on customer premises. His
specialities include the grinding of medical
implants and instruments as well as
machining parts for the aerospace industry.
Wolfram Hermle manages the software
development at Haas. With the Multigrind
Horizon software, he and his team have
developed a completely new type of
grinding software whose advantages are
particularly appreciated by users in the
aerospace segment.
They were asked about the role of Haas in
the aerospace industry.
Where are the Multigrind grinding
machines used in the aerospace industry?
Wolfram Hermle: Haas users machine a
variety of workpieces ranging from IP
(intermediate pressure) compressor blades
through to HP (high pressure) turbine
blades, HP vanes or HP shroud segments for
aircraft engines. These are all components in
the high-pressure area of an aircraft turbine
which are exposed to extremely high
thermal and physical stresses. Here, we are
dealing with very demanding materials
which are hard to machine. You can only use
grinding for that.
The complete machining of turbine blades with the Haas sandwich clamping process
How do you see Haas’ position in the
aerospace industry?
Tim Kern: We encounter a lot of technical
expertise, from engineers and technicians
who know what they want. In comparison to
medical equipment, the technical
specifications are much tighter in this sector.
We have the technical ability to meet the
high requirements which prevail in this
sector, with our grinding software, our
grinding machines and our experience. That
spreads by word of mouth.
What are the technical challenges when
grinding aero engine components?
Wolfram Hermle: Our customers want
absolutely reliable, absolutely robust
processes with which they can achieve
reproducible quality. One component
should be just the same as the next. Tim
Kern: These challenges from aero engine
makers are just what we like to hear. Where
possible, we only clamp a component once,
then measure it and machine it in a single
operation to produce the finished item.
Having to re-clamp several times must cost
time?
Wolfram Hermle: And money, plus above
all, precision. Fewer clamping operations
also mean that the workpiece spends less
time waiting around, thus shortening the
cycle times. You have fewer half-finished,
expensive components lying about, require
less effort for quality assurance and
measurements and need less staff, as they
don’t have to operate five machines, just a
single grinding machine.
Tim Kern, demonstrations manager, and Wolfram Hermle, software development manager at Haas
What does quality assurance look like at
Haas?
Wolfram Hermle: At Haas, we work with a
variety of measurement technologies,
including three-two-one measurements to
exactly locate the workpiece in space. In this
AEROSPACE REPORT
type of measurement, we have three points
to define the plane, two other points then
define the axis and the third point is then on
the workpiece itself. In itself, this is nothing
completely new, but so far it has not been
common practice to use the integrated
three-two-one measurement when grinding.
Especially not in the way that we further
process the result of the three-two-one
measurement with our Multigrind Horizon
grinding software. This automatically adapts
the grinding program to the workpiece’s
exact position in the working space.
In this type of measurement, we have
three points to define the plane, two other
points then define the axis and the third
point is then on the workpiece itself. In itself,
this is nothing completely new, but so far it
has not been common practice to use the
integrated three-two-one measurement
when grinding. Especially not in the way that
we further process the result of the
three-two-one measurement with our
Multigrind Horizon grinding software. This
automatically adapts the grinding program
to the workpiece’s exact position in the
working space.
workpieces. All of the measurement
functions and the dressing technology
to dress the tools in the process are
included in the basic package.
To what extent does the casting of
high-pressure compressor blades in
affect the dimensional accuracy of the
part?
Tim Kern: It is expensive and time
consuming. The position of the part
plays a responsible role in this. It means
that the process decides whether I get a
good part or an expensive reject.
Wolfram Hermle: With the three-two-one
measurement and the Haas sandwich
clamping, we have the technical ability to
compensate for casting tolerances. When
measuring a compressor blade, if deviations
such as a visually imperceptible warp are
revealed, then the measurements will be
introduced into our grinding program. We
correct casting faults in the grinding
process. This permits optimum efficiency to
be achieved for the engine.
What sort of materials are we dealing with
for turbine components?
Which software module does a user from
Tim Kern: Alloys, titanium, titanium
the aerospace industry need?
aluminium alloys, aluminium alloys and
Wolfram Hermle: With the Multigrind
ceramic coatings. These are all materials
Horizon® 3D-CAD package and the 3D-CAM which can withstand the enormous physical
package, users can cover about 90 per cent stress within a turbine. Important
of all grinding tasks in turbines. If users also
characteristics here include low weight, high
want to machine, then they will also need
operating temperature and tensile strength.
the package for rotationally symmetrical
How do you see the role of the grinding
software in the overall grinding process?
Tim Kern: Our grinding software is
becoming ever more important and
powerful, especially in the high-precision
area where one one-thousandth of a
millimetre is important. Our Multigrind
Horizon can generate a lot more than
grinding paths. It is a genuine CAM system,
a grinding programming system, a tool
management system, a robot-handling
program, an interface to a measurement
system and, last but not least, operating
software which is really easy to use. Our
grinding software is so flexible and has so
many facets that both the designer in the
development department as well as the
operator of the machine can work with it –
each at their own user level.
Wolfram Hermle: Working with varying
rights or user levels has the advantage that a
validated grinding process as required by
the FAA (Federal Aviation Administration in
the United States) cannot be changed by an
unauthorised person. This means that the
Multigrind Horizon ensures traceability at all
times of who changed what and when in the
grinding process. This documentation of
absolutely everything is mandatory in the
aerospace industry.
What do aerospace industry customers
attach the most importance to?
Tim Kern: Our users want a grinding process
which has been properly run in and which
will produce faultlessly from the very first
day. This means developing robust
processes and then automating them. And
the processes should work just as well in the
United Kingdom as in France, China or the
United States.
Precision to one one-thousandth of a millimetre - grinding a shroud component for aircraft turbines
UK Agent:
Tel: 024 76 226611
19
AEROSPACE REPORT
Modified VIPER configuration on show
NCMT has sold Makino machines in the UK
and Ireland since 1964, when the company
was established in Thames Ditton, Surrey.
One of Makino’s significant technology
advances that dates back 17 years was the
development of VIPER creep-feed grinding
in collaboration with Rolls-Royce. It was
introduced for highly productive
manufacture of nickel alloy aero engine and
land turbine parts, notably blades, vanes,
blisks and casings.
It revolutionised machining of these
components, as it was capable of stock
removal rates up to eight times those
achievable when grinding nickel alloys using
a plated CBN wheel. Broaching, milling and
turning operations could also be eliminated
and consumable costs were drastically
reduced.
The original Makino machines deployed
for VIPER grinding were versions of its
horizontal machining centres with modified
guarding to accommodate the very high
volumes of coolant that are necessary to
prevent burning of the nickel alloy. Small,
aluminium oxide grinding wheels in
standard 40-taper back ends were housed in
the tool magazine along with milling cutters,
drills and other tools, allowing additional
operations to be performed in-cycle.
An ingenious, programmable nozzle
assembly was developed to maximise
coolant delivery to the point of cutting. A
further development was continuous
dressing of the wheel during grinding as an
alternative to intermittent dressing using
table-mounted rolls.
A large Makino A99e was shown at the
recent NCMT Open House with a 1,250 x
1,100 x 1,250 mm working area, with this
modified VIPER configuration. It was
devoted to demonstrating in-process
Makino A99e with Delcam OMV software
NCMT EasyGrind Max PC – new CAD screen
inspection software from another Open
House partner, Delcam. A Renishaw probe
was programmed using Delcam OMV
(on-machine verification) software to
complete an inspection routine around a
guide vane and its fixture. The latter’s
location points were verified to pick up any
clamping issues.
Measurements on the component itself
avoided having to remove it from the A99e
to check dimensions on a coordinate
measuring machine, only to find that further
metal removal is necessary. Putting the part
back in the fixture accurately would require
a lengthy manual clocking process using
gauges, so avoiding this saves time and
eliminates the chance of introducing
inaccuracies. Measured results from
in-process probing were downloaded to a
Delcam engineer’s laptop, where they were
correlated with the CAD model of the vane.
Following the success of VIPER grinding
and its worldwide acceptance by
manufacturers in the aerospace and land
turbine supply chains, Makino
produced its first purpose-built,
5-axis machine in 2008, called
iGrinder G5, designed specifically to
exploit the technology to the full. As
with all VIPER grinding platforms, it
is available through Makino-NCMT
Grinding Division, a company
formed to market the turnkey
manufacturing systems across
Europe and Scandinavia.
The iGrinder G5 is 10 percent
quicker at machining nickel alloy
components than the modified
Makino A55e machining centre that
preceded it. Metal removal rate is of the
order of 80 cc/min and the machine accepts
parts nominally up to 300 mm in diameter.
The enhancement in grinding efficiency
comes from a number of factors, including
an increase in linear rapid traverse rate from
40 to 48 m/min. Work head speed more
than doubled to 100 rpm, which is especially
beneficial when grinding smaller
components.
Probably the most critical improvement,
however, is in the design of the
programmable coolant nozzles. They are
more versatile on the iGrinder G5, as they
may be positioned by two rotary NC axes
anywhere through 360 degrees around the
periphery of the grinding wheel, rather than
through just 180 degrees, as was the case
with the A55e. To achieve this greater
degree of freedom, power and coolant
supplies are built-in, rather than being
delivered through an umbilical cord. Nozzle
positioning speed is faster and therefore
more responsive when changing position to
direct coolant accurately towards the point
of cutting.
At the Open House, the iGrinder G5 was
shown roughing and finishing the tooth
profile of an involute gear and the front and
back diameters in a single set-up. It was an
aerospace actuator gear machined from a
stainless steel blank. NCMT has identified
gear production as a good prospect for
increased business and has a number of
enquiries pending, including for the
manufacture of racks.
Related technologies that have been
AEROSPACE REPORT
developed by Makino-NCMT to achieve
world class process capability and
throughput include EasyGrind Max PC, a
new release of software that, unlike its
predecessor, integrates CAD and
computerised cycle simulation capability,
creating powerful stand-alone functionality.
While the G5 accepts parts nominally up
to 300 mm diameter, with increasing aircraft
engine size some bigger vanes fall outside
the machine's working envelope.
Consequently, the larger iGrinder G7 was
introduced in early 2012 to address the
problem, bringing the smaller end of
industrial gas turbine components within its
scope. The machine, with a capacity of 730
mm in X by 650 mm in Y and 730 mm in Z,
has a similar specification to the G5,
complete with programmable 2-axis coolant
nozzles, but differs in having dual rolls to
dress the bigger grinding wheels.
The Open House event showed this
machine equipped for VIPER grinding of
turbine blades from gamma titanium
aluminide. The material has excellent
mechanical properties including lightweight
and oxidation and corrosion resistance at
temperatures of over 600°C, making it a
viable replacement for traditional
PO 900 BF
nickel-based superalloy components in gas
turbines.
NCMT has been carrying out exhaustive
trial machining of the material by VIPER
grinding and traditional metal cutting. For
confidentiality reasons, it is unable to
comment at this stage on the metal removal
rates achieved, the mechanical properties of
the machined parts or the customers for
Makino iGrinder G5 machining an involute gear
which the applications engineering is being
carried out.
NCMT Ltd
Tel: 020 8398 4277
www.ncmt.co.uk
PRECISION ELECTRO-CHEMICAL-MACHINING
Turbine components manufactured to the highest precision...
EMAG ECM GmbH: Complete solutions, design and development, prototyping, consultancy and sub-contract manufacturing.
Your contact for all Electro-Chemical-Machining enquiries.
» EMAG UK Ltd
Chestnut House
Kingswood Business Park
Holyhead Road
Albrighton
Wolverhampton WV7 3AU
www.emag.com
Phone
Fax
eMail
01902 37609-0
01902 37609-1
[email protected]
Manufacturing Systems for
Precision Metal Components
21
GSF PRODUCTION GRINDING 22-31_ES CONTENTS 4-5 20/08/2015 15:23 Page 22
Production Grinding
GrindTec 2016 looking to break previous records
16th to 19th March - Augsburg Fair Centre
and India, is growing, as is the interest
shown by US companies. They all have a
high opinion of GrindTec as an important
platform for interesting global contacts.”
Research into the effectiveness of
GrindTec 2014 clearly show that 75 percent
Only three months after mailing the
of exhibitors declared their participation at
documentation for participation at the next the show as “very good” or “good” with a
GrindTec, organisers AFAG report stand
further 17 percent expressing their
bookings of 42,000 m2, 5,000 m2 more than
satisfaction. Figures also indicate the
2014. Never before have so many
outstanding quality and professional
companies ordered their exhibition space so competence of the GrindTec visitors, with
early and is a strong indicator that the 10th
88 percent sole or co-decision makers or
GrindTec exhibition will sustain the
involved in an advisory capacity. This leads
continuous growth of this meeting place for to a large number of orders being placed;
the grinding technology sector.
900 or so at the last event.
This has led to the organisers planning the
layout of the halls early, with halls 1, 3, 5 and The perfect platform for premieres
7 virtually fully-booked. There are currently
For some time, the exhibitors’ marketing
still large stands available in halls 2 and 4.
experts have been choosing GrindTec for
Joachim Kalsdorf, GrindTec project
the premieres of important innovations.
manager is not really surprised: “GrindTec
With regard to production grinding, it has
has established its position as the leading
reached the pole position, overtaking even
international platform for grinding
the major event EMO. For this reason, any
technology. The participating companies
conflicts with simultaneously scheduled
regularly confirm excellent results. In
events with the same subject matter are no
addition we see that the larger machinery
problem for GrindTec exhibitors. As a result
manufacturers continue to need more
there will be no leading European grinding
space. As we can also see from the
technology company that is not present at
applications received, the interest of Asian
the GrindTec.
companies, particularly from China, Korea
“Tool-grinder of the year” competition
VOLLMER WERKE Maschinenfabrik
GmbH is a competent partner for the
“Tool-grinder of the year” competition
at GrindTec. For the sixth time in a row,
the trade journal “fertigung” and the
FDPW-Akademie are looking for the
best cutting tool mechanic in Germany,
Austria and Switzerland. Apart from
upgrading the image of this highly
demanding high-tech profession, the
intention is also to interest young
people in this trade, with its great future
prospects. Once again the finale will take
place during the GrindTec 2016. The five
finalists from the earlier heats will work on a
complex tool in public view against each
other and against the clock.
The planning of the exhibition halls will
begin earlier than in the past. Any
companies interested in taking part in the
trade fair should therefore contact the
project management as soon as possible,
especially if they are hoping for particular
positions. The information and the
application forms can be downloaded from
the GrindTec homepage at
www.grindtec.bde.
The project management team urgently
reminds exhibitors to list all their planned
exhibits in the application form. Without this
information, participation at GrindTec 2016
will not be possible.
For further information, contact:
AFAG Messen und Ausstellungen GmbH
Tel: 0049 821 589 82 390
www.grindtec.de
Great companies a single objective …
Jones & Shipman
Kellenberger
Hauser
Tschudin
Voumard
Usach
Working together to achieve
grinding excellence ...
Jones & Shipman offer Europe’s most
comprehensive grinding solutions from a
single source.
Manufactured in the UK, J&S machines offer
precision cylindrical, surface/profile and
creep feed grinding machines with partner
Hardinge Grinding Group companies offering
internal and jig grinding. Their capabilities
cover the spectrum from high precision
toolroom applications to volume production
environments.
All of these technologies from seven well
respected companies and all from a single
source.
If you are thinking grinding
… think Jones & Shipman
Jones & Shipman Hardinge Ltd,
Murrayfield Road, Leicester LE3 1UW
Tel: +44 (0) 116 201 3000
E-mail: [email protected]
Web: www.jonesshipman.com
Production Grinding
Universal grinder fulfils multiple role
Precision finish grinding to demanding
tolerances in some of the hardest workpiece
materials available has led to investment in a
seventh Kellenberger grinding machine by
Milton Keynes-based The Engineering
Quest.
The Engineering Quest offers a
comprehensive range of realisation
assessment, prototyping, product
development and manufacturing services,
working with customers across a diverse
range of industries on products ranging
from high pressure diesel pump parts to gas
and oil components, prosthetics and oil field
equipment.
Common denominators across Quest’s
activities are meeting very high tolerances,
sub-micron accuracies and challenging
materials which can include HSS steel
grades with a hardness in excess of 70
Rockwell, polycrystalline diamond and
aluminium-silicon castings.
The company has a long history of
operating Kellenberger manual and CNC
internal and external grinders, which are
supplied and supported in the UK by Jones
& Shipman Hardinge, based in Leicester.
Delivered in December 2014, the latest
machine, a high specification Kellenberger
Kel Vista with triple wheel head options
fitted, has been initially dedicated to
development work on 3000 psi capability
high pressure diesel injector pumps. The
Engineering Quest has developed these
with Woodward Diesel Systems for use on
mid-range diesel engines used in
marine and construction
equipment applications, and, with
the capability to undertake
medium batch production work,
the grinding machine will now be
applied in this area.
The Kel Vista is a highly
productive and capable universal
grinding machine with a
programmable B axis indexing to
1º as standard to allow up to two
external and one internal grinding
wheel to be used in the same setup.
Micro-adjustment of the tailstock and
semi-automatic balancing of the grinding
wheel are just two more of its many features.
Its construction features linear guides on
the X-axis, a classical side arrangement on
the Y-axis, a grinding length between 600
and 1000 mm and a swivelling work head
suitable for grinding between centres or
chucking work, with thermally optimised
bearings to guarantee highest roundness
and dimensional accuracy.
These features and others were
instrumental in The Engineering Quest’s
purchasing process, as managing director
Steve Matheron explains:
“We offer a very different range of
services to those offered by other
subcontractors. We actively encourage
customers to see us as their product
development partner offering component
manufacture, process expertise and cost
Steve Matheron (right), managing director of The Engineering Quest, believes the recently acquired
Kellenberger Kel Vista universal grinder can work on any number of projects in the firm’s Milton Keynes
factory
The Engineering Quest’s recently acquired
Kellenberger Kel Vista universal grinding machine
is used on both product development and
production volumes
avoidance planning,” he explains. “Specifically we added the Kel Vista to our
grinding inventory because of the diesel
injector project and the move into the
production manufacturing phase. But of
course it has great all round capabilities and
will complement any number of other
projects we are working on.
“Having worked through the
development and proving stages on the
diesel pump components it was important
to have the capability and capacity to
progress into production volumes.
“This in turn necessitated we have a
grinding machine offering absolute
repeatability bearing in mind the tolerances
of 2 micron geometric and 5 micron linear
while maintaining production speeds,” he
explains.
Winterthur Technology is the preferred
grinding wheel supplier to The Engineering
Quest and, coupled with the qualities and
grinding process flexibility offered by the
Kel Vista, the company feels it is achieving a
good balance between high precision,
excellent repeatability and productivity for
production capacity.
For further information on Kellenberger
grinding machines and other Hardinge
Grinding Group machines available in the
UK through Jones & Shipman Hardinge,
contact:
Jones & Shipman Hardinge Ltd
Tel: 0116 201 3000
www.jonesshipman.com
Production Grinding
MFP 50
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Solutions for safe
& efficient working
Systems to protect staff, reduce
environmental impact and realise
financial gains
Extraction & filtration
(dust, fume, gas, oil mist)
Cleaning
(wet, dry, explosive)
Production recycling
(inc cutting fluid & coolants)
Resource & waste management
(metal, paper, wood)
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(air, power, fluids)
Please contact us to arrange a free site survey
v
www.nederman.com
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www.nederman.co.uk
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25
Production Grinding
The Perfect grinder for gear manufacturer
Established in 1920, what is now Muffett
Gears went through various stages before
identifying the manufacture of precision
gears as an area of manufacturing that it
could become a specialist in. Ever since
1950, gear design and production has been
the core competency of the Tunbridge
Wells-based company. Now in its third
generation as a family-owned business, its
focus is firmly on maintaining its reputation
and continuing to invest in the latest
machine tool technology to deliver the
quality and service that this reputation has
been built on.
ISO 9001 and aerospace BS EN 9100
compliant and accredited, Muffett Gears’
specialism is in the design and manufacture
of gears and gearboxes, with a capability to
produce prototype and first batch
production for customers, as well as
production of a range of standard products,
including spur, helical, bevel, racks, worm
and wormwheels, internal gears and
moulded gears, with batch quantities
ranging from 1 off to 1000 off.
With a customer base that covers
aerospace, medical, mining, defence and
construction, it is called upon to
manufacture gears of all shapes and sizes,
from minute gears that are used in artificial
hands through to large shafts for industrial
pump systems. Other projects have
included manufacturing components for
medical scanners and camera mounts to
supplying gearboxes that end up in the
latest commercial aircraft designs. To
achieve the five micron accuracies that some
of their work calls for, Muffett Gears has an
extensive plant list capable of cutting any
form of gear. It also has a capacity list of
more conventional machine tools, one of the
more recent being a Perfect PFG-D4080AH
surface grinder from RK International
Machine Tools. The Perfect grinder is NC
controlled and was purchased to replace an
ageing manual grinder, with one specific
component in mind, spur gear filler plates
used in an oncology radiotherapy machine.
The old machine was becoming inconsistent
and required constant manual intervention
to maintain size, which was impacting on
productivity.
The Perfect PFG-D4080AH is improving productivity at Muffett Gears through its consistency and table
capacity
Having researched the market, the Perfect
PFG-D4080AH stood out from the crowd
due to its simplicity of operation and cost:
“Many of the surface grinders that we
looked at were over-specified for what we
wanted, which in turn meant that they were
more expensive,” explains Muffett Gears
works engineer Alan Kennard.
“Our requirement is pretty
straightforward: we needed a grinder that
would be consistent and accurate, without
all the bells and whistles, but would give us
some level of automation, while at the same
time allowing manual operation for when we
needed to use it as a toolroom grinder.”
Another advantage of the Perfect
PFG-D4080AH for Muffett Gears is the table
size, which at 400 mm by 800 mm allows
three components to be ground in a single
setup as opposed to two on the old
machine. This has an immediate impact on
lead times and productivity giving a 40/50
percent improvement with around a 90
percent reduction in input from the
operator. Shift supervisor, Rob Hudson
adds: “We had no previous experience of
NC surface grinding, but setting the Perfect
machine couldn’t be simpler. We simply
touch down on the work dial in the amount
of material to be removed and set the
number of passes. We tend to work on 50
micron roughing passes with a 25 micron
finishing pass. After that it is case of pushing
the button and waiting for the cycle to finish.
The machine grinds to size every time and
we have never had a scrap part from it in the
time it has been installed. Compared to the
old machine we have total control of sizing,
Production Grinding
if we want to remove another five micron, we simply dial it in and the
machine will remove exactly five micron.”
The consistency and accuracy of the Perfect PFG-D4080AH is due
to its construction, with the column and base manufactured from
CNC
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high quality castings, slideways coated with Turcite B to ensure
smooth movement and long-term accuracy. The cartridge-type
spindle is assembled using class P4 precision angular contact
bearings, giving a runout accuracy of < 2 micron. In addition to the
large 400 mm by 800 mm table, the grinder also has a 550 mm
distance between the wheel and table surface (optional 650 mm).
The wheel itself is 405 mm by 50 mm by 127 mm in size.
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“The Perfect PFG-D4080AH is part of an extensive range that
encompasses saddle, column and cantilever designs, with the
option of manual, NC and full CNC machines across the range,”
says Dick Aldrich, sales director of RK International Machine Tools.
The machine chosen by Muffett Gears is a fantastic example of
the value for money that the Perfect range provides. The
alternatives were either more expensive, more complex machines,
or to refurbish their existing machine, which would involve lost
production time and cost a similar amount to the new machine that
they bought.”
RK International Machine Tools Ltd
Tel: 01322 447611
www.rk-int.com
Cylindrical
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grinders
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27
Production Grinding
Flexible, individual solutions from Klingelnberg
Klingelnberg recently presented its first ever
in-house exhibition at its Hückeswagen
plant. During the two-day event,
Klingelnberg experts presented their
innovative product developments and
solutions to numerous customers and
business partners.
The event afforded a live view of many
new developments, with a number of
interesting presentations demonstrating just
how fascinating machine designs in gear
technology can be. The show's highlights
included presentations of the advanced
vertical concept on the new C 30 and G 30
bevel gear machines, the new P 16 precision
measuring centre designed to measure
small workpieces, the new BC 12 measuring
device for precision measurement of stick
blades, as well as a presentation of new tool
systems.
Klingelnberg covered a broad range of
topics in interesting lectures, in which the
significantly less load on the drive
components and a stiffer design of the
overall system. A major new feature of the
machine series is the innovative operating
concept with state-of-the-art control
technology: The touchscreen display with a
newly-developed operator guidance
facilitates intuitive machine control
compared with standards typically seen in
the marketplace.
company’s experts reported on current
challenges in drive technology and the
company's unique Closed-Loop concept for
gear manufacturing, among other topics.
ARCOFLEX innovative tool system
Klingelnberg is a leading manufacturer of
gear cutting tools in addition to machine
tools and precision measuring centres and
as such it is only fitting that the company
also presented a new tool system at the
in-house exhibition. The newly developed
ARCOFLEX system is ideal for producing
individual gear sets and small batch sizes.
This is due to the fact that only one cutter
head setting is needed to produce pinions
and ring gears of different sizes.
Founded in 1863, the family-owned
Klingelnberg company is one of the leading
companies in the gear industry. Thanks to
numerous innovations in the areas of
New standards in bevel gear machining
Built on the same design concept, the C 30
bevel gear cutting machines and the G 30
bevel gear grinding machines are setting
new standards in the gear machining
industry. All bevel gear machines in this
most recently developed series are
equipped with a heat-stable,
vibration-damping machine bed. Thanks to
the optimised axis arrangement of the
machines, reduced traversing paths ensure
Precision measuring centres – reliable
down to the last detail
In the area of gear measuring technology,
Klingelnberg presented its trendsetting P 16
precision measuring centre, designed to
measure small workpieces. The P 16 owes its
compact size to an innovative modification;
thanks to a newly developed workpiece
clamping system which is optimally adapted
to accommodate small workpieces, there is
no need for a counter support.
calculation, production, and measuring
technology, Klingelnberg maintains its
leadership position in this sector. With its
acquisition of Höfler Maschinenbau GmbH's
core business in 2012, Klingelnberg has
addedmachines for machining cylindrical
gears to its range of products, reinforcing its
position as a complete system provider.
Headquartered in Zürich, the machine
manufacturing firm develops and
manufactures today at its sites in Zürich,
Hückeswagen and Ettlingen, and Győr,
Hungary. The company also maintains a
presence with Sales and Service offices and
numerous marketing agents all over the
world. Klingelnberg solutions can be found
in the automotive, commercial vehicle, and
aircraft industries, as well as in shipbuilding,
the wind power industry and the general
gearbox manufacturing industry.
Applications range from vehicle drives to
aircraft turbine engines and cement mill
gear units, through to drive systems for
ships and oil rigs. With over 100 patent
grants, the company continuously
demonstrates its capacity for innovation.
Above and beyond this, its 14001
certification and participation in the VDMA's
Blue Competence initiative give credence to
Klingelnberg's sustainable, environmentally
sound business practices.
UK Agent:
Micronz
Tel: 01352 758840
[email protected]
www.micronz.co.uk
Production Grinding
Precision grinding with graphical monitoring
Precision machine tools in the manufacturing industry keep getting faster and
more precise. However, at the same time,
the technologies are also becoming more
complex, for example in the aviation,
aerospace and marine industry or the
automobile industry. Nevertheless, the use
of these precision machine tools must
remain simple and MIKROMAT, a
world-leading manufacturer of precision
machine tools, relies on the controls of
Schleicher Electronic Berlin in its thread
grinding machines.
In the domain of precision manufacturing,
CNC machines have replaced manually
operated machine tools for a long time.
These days, operation is achieved via an
electronic box and computer programs,
rather than manually with levers, cranks and
handwheels. In this way the machines can be
adjusted and monitored with considerably
more precision. The truth is that the classic
CNC programming via G-Code is
complicated and cumbersome as each
program step must be entered individually,
manually, in the input screen of the HMI
device. Up to 1,000 lines of hand-typed
commands quickly come together. In
addition, the classic CNC control panel is
confusing, as it is composed of countless
buttons with various letters, numerals,
characters and symbols.
This is the reason why MIKROMAT
adapted its thread grinding machines 26
years ago. Here, the handling of the user
interface was a decisive criterion.
“Simple operation is important for our
customers, so that a smooth flow, in
addition to a high-precision result, is
guaranteed”, comments Gerd Schäfer, sales
manager at MIKROMAT and the person
responsible for the thread grinding
application technology.
Until 2009, MIKROMAT, just like the other
industry giants, still ran on a DOS-based
system, including the G-series grinding
machines, because it was a proven
operating system. However, this offered no
future-proof use in the long run, as it was
outdated and no longer able to run on
today’s computer systems.
“We therefore switched to a
Windows-based system”, says
Gerd Schäfer. “It is only thanks to
this system that the common
graphic user interface standards
that exist today are achievable.”
However, given the new
generation of the system,
MIKROMAT has also had to find a
new and reliable control system.
After all, grinding machines are
required to meet especially high
standards regarding dimensional
accuracy and complexity. In order
to meet the specified basic size and the
required accuracy in the manufacturing
process, and to prevent erroneous grinding
processes, a clear and easy-to-understand
control operation is required. However, the
user interface of the new CNC technology is
a major challenge for inexperienced users in
particular as they need to be trained in how
to use the machine first. For this reason, in
order to ensure a quick and easy
incorporation, MIKROMAT placed special
emphasis on monitoring, whose user
interface works via insertion in a drawing
template. As many tools as possible have to
be created and the user needs to find these
understandable and easy to operate.
Another important criterion was the
implementation within an open system.
Gerd Schäfer adds: “We have clients in
various industries and with various
requirements. With an open system, we can
program the monitoring individually,
according to our customers’ visions.”
With these requirements for the new
monitoring system, the search began for an
appropriately potent supplier. The choice
was control manufacturer Schleicher
Electronic Berlin GmbH. A decisive criterion
for the decision against large, well-known
competitors was the open system which
Schleicher can enable with its monitoring
system XCA 1277. This is something which
provides MIKROMAT with an enormous
range of design freedoms: the user interface
can be modelled on the drawings of the
technologies with the end client. The control
functions are thus precisely limited to its
requirements. To date, no other controller
manufacturer for thread grinding machines
can offer such creativity freedom.
In addition, the XCA 1277 is extremely
easy to use: all grinding and access data can
be easily inserted in the screens, without any
need for programming skills. Any language
barriers will be undermined by
internationally understandable imagery.
“Our grinding machines are used in
Russia, China and Europe, but many of our
end clients don’t speak English”, says Gerd
Schäfer. “For this reason, we use graphics,
and as little text as possible.”
Schleicher Berlin GmbH
Tel: 0049 30 330050
www.schleicher.berlin
29
Production Grinding
Customised CNC upgrade simplifies
railcar axle grinding
A comprehensive upgrade of classic high
power centreless grinding machine tools is
helping a leading railcar axle manufacturer
to greatly simplify precision grinding
operations on axle forgings. A key element
of the project, which has been managed by
APeC Integration Services, Inc, is the retrofit
of the customised CNC control based on
NUM’s powerful Flexium platform.
Based in Wattsburg PA, APeC is an
electrical systems integrator specialising in
upgrading machine tools with modern PLC
and CNC control systems. Established in
1989, the company has built a reputation for
enabling clients to maximise the longevity
and performance of their machine
investments. Key retrofit services include
upgrading servo and spindle motors and
drives, PLC integration and custom machine
controls, and complete CNC replacement.
Extensive mechanical and electrical upgrades to
this Landis centreless grinding machine include a
new Flexium CNC system from NUM
The machine tools in this particular
project are high capacity Landis centreless
grinders, which utilise a dressable grinding
wheel and a plunge grinding cycle to create
precision profiles on railcar axle journals.
During grinding, both the axle workpiece
and the grinding wheel rotate in the same
direction, which means that the two surfaces
are moving in opposite directions at the
point of contact, resulting in smoother
operation. Once the machine is up to speed,
the grinding wheel is fed or ‘plunged’ into
the workpiece and makes continuous
contact with a single point along its length.
The plunge action is controlled by a
servo-driven axis grinding at several feed
rates, with transition points monitored by
in-process gauging. A built-in automated
2-axis dresser system with a diamond tipped
tool is used to dress the grinding wheel
whenever necessary.
This is the second time that APeC has
improved the performance of these grinders
with control systems based on NUM CNC
kernels. The original machines were
hydraulically actuated and equipped with
tracer type wheel dressing systems. In the
mid 1990’s, APeC performed a full
mechanical and electrical upgrade on each
machine that included retrofitting a modern
CNC system and in-process gauging
instruments. On that occasion, the company
based the upgrades on NUM’s Power 1060,
which at the time was regarded as one of
most flexible and user-friendly CNC systems
on the market.
After a further 20 years’ full-time service in
a busy production environment, the
machines became due for another
mechanical and electrical upgrade. APeC
had supported the machines and worked
closely with their operators throughout this
period, during which time it had also
developed a number of ideas for making the
machines even easier to operate and more
productive. The upgrade program offered
the ideal opportunity to put many of these
ideas into practice.
To expedite machine upgrade and
minimise the impact on its customer’s
production schedules, APeC managed a
three-way development partnership. All
major mechanical re-design, hydraulic,
lubrication, and geometrical rebuilding
aspects of the project were handled by
EURO Machinery Specialists Inc, a company
with some 45 years’ experience of
refurbishing and modernising high value
metal cutting machine tools. On the control
side, APeC collaborated with NUM USA to
develop a unique and intuitive human
machine interface (HMI). This enables
The machine’s plunge grinding cycle is controlled
by a servomotor-driven axis, utilising feedback
from a linear encode
operators to learn how to use the machines
very easily and quickly – even if they are
unfamiliar with these types of grinders.
Customer benefits include improved worker
satisfaction, less need for training and
increased machine productivity.
Dave DeCoursey of APeC says: “A key
project goal was simplifying machine
operation as much as possible. NUM’s open
Flexium CNC platform provides the control
flexibility and HMI customisation facilities
that we needed to develop individual,
task-oriented screens. The user interface is
consequently now much more ergonomic.
Most operations, such as offset calculations,
calibration, dressing and automatic grinding
cycle initiation, are now performed using
single, virtual pushbuttons that are only
displayed when appropriate.”
Each machine upgrade uses several NUM
products, including the CNC kernel,
touch-sensitive operator panel, servo drives
and motors. The Flexium CNC system uses
EtherCat I/O communications, making it
Production Grinding
simple for APeC to implement an advanced
plunge depth control architecture. The
in-process gauging instrumentation
previously used for this aspect of machine
operation has been replaced by a linear
encoder, which facilitates fast and accurate
depth control, as well as providing real-time
feedback to the operator throughout the
grinding cycle. The main control screen
features two large analog-style dials,
supported by digital displays, which derive
their input data from separate measurement
probes located along the length of the axle
journal, allowing the operator to monitor
taper tolerance very easily.
The client- and application-specific HMI
software that APeC has developed for the
grinding machine upgrade is task oriented.
It uses individual screens that are tailored to
the application, with clear context-sensitive
functions that help to prevent human error.
By using the Extended NCK Access (ENA)
facilities of the Flexium CNC controller, each
custom PLC-driven visualisation can control
and monitor the CNC functions directly. This
form of control approach is especially useful
for automated teach-type functionality, such
as guiding an operator through machine
start-up and preparing for automatic cycles.
For example, the start-up screen
initially displays only the status of the
CNC system and a single ‘Shutdown’
button. As soon as the CNC system
indicates that it is ready, the start-up
screen displays two additional buttons:
Home Screen and Manual Operation.
When the operator touches a displayed
button and causes a change of screen, the
software automatically alters the CNC
mode accordingly and selects the
corresponding part program if applicable.
By confining the operator’s available
options to just those that are appropriate at
the time, the software helps to ensure
consistent and efficient machine use.
Another major advantage of this type of
control approach, with extended access to
the NCK, is that it can be used to help the
operator with tool offsets and adjustments
to part program dimensions. When the
grinding wheel or dressing tool is replaced,
the operator can manually position the tool
on the desired surface of the wheel, access a
password-protected screen and then simply
press a button. The offsets are calculated
and pushed into the dressing program
automatically, using the ENA facility. This
same facility allows the operator to alter
During grinding, the main control screen displays
two large analog-style dials which allow the
operator to monitor the tolerance of axle taper very
easily and accurately
dressing dimensions and spark out set
points simply by adjusting a value up or
down. These are then pushed into the
corresponding part program.
For further information about NUM, contact:
NUM (UK) Ltd
Tel: 0871 750 4020
www.num.com
New for the price of old
When sourcing additional cylindrical
grinding capacity, the first option for many is
to look at buying refurbished machines due
to the perceived cost of new machines. With
one of Western Europe’s largest ranges of
conventional universal cylindrical grinding
machines, Italy-based Robbi has the ideal
solution with its cost-effective range.
Available through in the UK and Ireland
through RK International Machine Tools Ltd,
the Robbi R & E-series provide a
cost-effective alternative to sourcing and
refurbishing older machines, for a similar
cost. Not only that, but you will be getting a
European designed and built machine with
the reassurance of local support and a
manufacturer backed warranty.
“RK International Machine Tools has
extensive knowledge of both new and used
machine tools and we regularly see the
prices charged for refurbished conventional
cylindrical grinders. Customers are being
quoted prices for refurbished machines that
are equal if not greater than the cost of a
brand new Robbi Omicron 600R machine,”
says sales director, Dick Aldrich.
The Robbi Omicron range is
divided into the R and E series, with
between centre distances ranging
from 600 mm on the Omicron 600R
through to 2030 mm on the
Omicron 2000E, with centre height
ranging from 160 mm up to 230
mm. All Robbi grinding machines
are manufactured to be within the
ISO 2433 specification and typical
features include table movement
linearity being guaranteed to a
maximum deviation of 0.002 mm/m, surface The Robbi Omicron 600R provides a cost-effective
finish achievable to 0.2 Ra m and roundness solution to increasing cylindrical grinding capacity
of 0.3 micron (between centres) and 0.4
micron using a live spindle. The Robbi
new, European-built grinder, with all of the
Omicron R series machines are equipped
added security that this brings for the
with a two-axis digital readout, with axis
equivalent cost of sourcing and refurbishing
movement controlled by incremental linear a machine that may be 20 or 30 years old,”
encoders for micro-positioning of the
concludes Dick Aldrich.
wheelhead and centesimal table movement.
“With the high specification and value for RK International Machine Tools Ltd
money provided by the Robbi range of
Tel: 01322 447611
universal and cylindrical grinders customers Email: [email protected]
looking for this type of machine now have a www.rk-int.com
clear choice between purchasing a brand
31
GSF MACHINE SAFETY 32-33_ES CONTENTS 4-5 19/08/2015 14:34 Page 32
Machine Safety
One fire every week on grinding machines in the UK
Kraft & Bauer, whose automatic fire
extinguishers are fitted as standard by many
of Europe’s leading machine tool
companies, has developed a new range of
systems specifically designed to protect all
types of machines. However, protecting
grinding machines is the major application,
with many of Kraft and Bauer’s fire
extinguisher systems particularly being
found protecting tool grinding machines
from well known manufacturers such as
Jones & Shipman, Walter, Schneeberger,
Rollomatic, Haas, Saacke, Ewag, Vollmer,
Anca and Schutte. There are now some
17,000 K&B systems protecting machine
tools in Germany alone.
Louise Boraston, MD of Kraft & Bauer UK
explains why tool manufacturing and
regrinding companies commonly face an
increased risk of fires on their tool grinding
machines:
“Modern CNC tool grinding machines
commonly have at least five CNC axes that
interpolate all at the same time to generate
the ever more highly complex forms that are
needed in the design of today’s cutting
tools. In terms of programming alone, this
need for special form grinding means that
the manufacture and regrinding of cutters is
one of the most complex disciplines that
production engineers face.
“All of the leading tool grinding machine
manufacturers have developed software
packages that make programming both
faster and easier than ever before. However,
the room for operator or programming error
remains high. For example by making a
small error in inputting data to the grinding
wheel specification page or tool length
and/or diameter entry can easily cause a
collision between the wheel and tool during
grinding, or result in a very heavy cut taking
place, either of which will cause an
enormous amount of heat to build up within
seconds.
“There are also many other ways in which
unwanted intense heat can be generated
during tool grinding, such as coolant failure
or more commonly coolant not quite being
directed to exactly the right point as the
grinding position changes during complex
grinding cycles. With solid carbide cutters
demanding the use of oil as a coolant during
grinding, as opposed to water based
emulsion that can be used for other grinding
tasks, this combined with the risk of heat
being generated means that there is an ever
present and real risk of fire on CNC tool
grinding Machines. The 5-axis movements
of the grinding head and workhead and use
of higher pressure coolant generates a lot of
oil mist that even with the fitment of suitable
electrostatic mist extraction equipment
means that the machine cabinet is, during
the grinding process, full of oil mist vapour
and a single grinding spark will easily ignite
that leading to a major health and safety
risk.
“There is seemingly no pattern to the
occurrences of fire on CNC tool grinding
machines, although obviously the more
machines in use and the more hours they are
ran for vastly increases the risk for any
particular user. The trend for automated
production using autoload/unload systems
increases the threat still further and the part
or total absence of operators who would
otherwise be able to intervene in the event
of an incident further compounds the
problems. We have customers with one or
two machines that have never had fire
incidents, but equally have others who
experience several every year, then none for
a long time, and then again have a major
problem. Accidents are accidents and
cannot be forecasted but when companies
carry out risk analysis on production
machines it’s usually tool grinding machines
that head up that list!
“To protect their customer’s investments,
leading machine tool companies such as
Walter, Schneeberger and Rollomatic, to
name just three, fit our systems as standard
and each year Kraft & Bauer sell well over
750 fire protection systems to tool grinding
machine manufacturers alone. However
afterwards many end users do not consider
the servicing of the fire systems and we
regularly come across systems that have not,
for a variety of reasons, been functioning
correctly for some time. Believe it or not we
actually find several every year that whilst
functioning correctly have previously been
used but have not been refilled with CO2.
“Some of the UK’s leading tool grinding
companies are very much health and safety
conscious and protect their workers and
indeed their business’s by ensuring that
their tool grinding machines are well
serviced with a high degree of fire
protection but many others are simply
taking huge gambles by not doing so.
“Many grinding machine users believe
that the automatic fire prevention systems
are serviced by the machine tool
manufacturer’s engineers along with a
regular annual routine machine service.
However, this is simply not true. Our
systems must be serviced by us and if
grinding machine end users are not in
possession of a validated K&B certificate
that demonstrates the systems have been
serviced in accordance with our procedures
then any insurance policy that is in place is
almost certainly going to be invalid in case
of a fire incident.
GSF MACHINE SAFETY 32-33_ES CONTENTS 4-5 19/08/2015 14:34 Page 33
Machine Safety
“Other machine users rely upon
independent fire extinguisher companies to
service machine tool fire systems, but these
services are almost always limited to simply
weighing the bottle to see if it is full and no
independent UK based service companies
have received the necessary training and are
simply not authorised to service our
systems. These companies are used to
looking after simple hand held fire
extinguishers of the type that is used to
protect offices and all end users are warned
to be sure the correct procedure are being
followed.
“These companies are leaving themselves
wide open to legal action in the event that
the mandatory H&S laws are not being
followed, with fire risk assessments being
carried out and preventions not only being
put into place but also subsequently being
routinely checked by validated and fully
certified experts. Often engineering
companies don’t take into account the
affect of a single fire on a machine can have
on production and that it is not only highly
dangerous to operators it can also easily
result in the loss of the machine, a complete
production line, or even the entire factory.
Users need to ask themselves if, with new
tool grinding machine build times being
between 6 and 12 months, their customers
would still be around when machines
damaged by fire, although possibly insured,
can subsequently be replaced.
“Anyone thinking machine tool fires are a
low risk occurrence that rarely happens,
needs to think again. Last year there was at
least one fire incident every week on
grinding machines in the UK and these are
only the ones that we know about, as the
fires were prevented from leading to
extensive damage or loss of life by our
systems.”
Kraft & Bauer only manufactures specialist
systems for machine tools, all of which are
IP55 certified against ingress of coolant, and
offers various options, including fire
detection via Infra Red (IR) temperature
radiation detectors and Ultra Violet (UV)
sensors, as well as the most basic of usual
temperature based detection. CO² (or
Argon) bottles of various sizes from 2 kg to
20 Kg may be fitted, although for the very
largest of machine tools more than one can
be used to ensure total protection.
Initial detection and automatic activation
of the fire security systems is catered for by
IR or UV sensors, or in some cases a
combination of both, with instant reaction
times of under a second being possible. In
the case of the fastest UV radiation sensors
that operate within a wave range of 185-260
nm, a short activation check of between 1-2
seconds is usually set to avoid systems being
accidentally set off by flash-light
photography etc. Automatic secondary
backup fire detection is then catered for by
temperature sensors set to between 30 and
140 degrees that are integrated into the
machine cabinets; usually adjacent to a mist
extraction point that would draw flames in
the event of a fire. A further final means of
detection is visual by an operator and
manual system activation is always possible
by using emergency button switches
mounted to the front of the machines or by
pulling the emergency toggle pins mounted
onto the systems themselves.
When a fire is detected the machine tool
is automatically shut down and the fire
extinguished before any major damage can
occur. Warning to operators is taken care of
by both high powered 125 db acoustic
sirens and high visibility warning lights
mounted on the top of the machine. It is
often the case that machines can be back in
action within minutes of an incident
occurring.
The latest micro-processor technology is
employed, along with self contained
emergency power supply back-up devices
to ensure that even in the event of loss of
electrical power the fire protection systems
can still function. A further recent
development is the use of fully automated
CO2 cylinder check systems to ensure that
machines cannot be ran if a bottle is empty.
Kraft & Bauer UK offer a full sales, service
and installation facility from their base in
Coventry and systems can be fitted to new
machine tools or to any existing machine of
any type as a full retrofit service is also
offered.
Kraft & Bauer UK Ltd
Tel: 024 76 229477
www.kraftandbauer.co.uk
33
GSF GWD 34-43_ES CONTENTS 4-5 19/08/2015 14:34 Page 34
3M Winterthur wheels give GB
Precision a competitive edge
Birmingham-based GB Precision is a
quality-focused, precision engineering
company that has earned an enviable
reputation for itself by specialising in the
supply of highly complex precision
components and sub-assemblies to
customers ranging from large corporations
to small and specialised companies, both in
the UK and overseas.
A private limited company, GB Precision
recently celebrated its 40th anniversary, no
mean achievement in today’s highly
competitive world, and the direct result of
the company’s on-going strategy of
investing in the very best technology to
meet its customers’ increasing demands in
terms of accuracy and precision.
Director Paul Turner explains: “We are
constantly looking for new ways of
improving our productivity and capabilities.
This often results in the development of new
procedures or methods of working to meet
specific engineering challenges. In other
words, genuinely thinking “outside the box”
to achieve meet our customers’
requirements.
“We aim to get the absolute maximum
from our machining technology, not only by
achieving the best performance from each
particular machine, but by using technology
in the optimum way for each job. What’s
more, we further increase productivity
through our investment in an off-line,
presetting and palletisation system which
enables us to reduce setting times, increase
machine utilisation, achieve better surface
finishes and increase reliability.”
The company’s recently extended,
purpose-built 8000 sq ft facility houses a
range of the latest CNC machining
technology. However, the cornerstone of
the company’s activities remains its
precision grinding capabilities, with
no less than three CNC Studer
machines, two S21s and an S31,
making GB Precision one of only a
handful of companies in the UK with
the capability of offering
out-of-round grinding.
These Studer machines have the
ability to grind high-accuracy,
bespoke thread forms, which can
be required for top-end mould tool
assembly work, as well as to cut
tapered polygons on the end of otherwise
cylindrical geometric forms. They also
handle the whole range of high-precision
grinding tasks, including the creation of
external and internal spherical forms, where
the surface finish across the whole part, and
the form accuracy, is of critical importance.
Naturally, to help ensure the quality of its
subcontract work and to obtain maximum
productivity, GB Precision’s investment in
the best technology is matched by its use of
the best grinding consumables, which is why
the company has for many years purchased
3M Winterthur high-accuracy grinding
wheels.
Paul Turner explains: “For us, the most
important thing is the adaptability of the 3M
Winterthur wheels, which means that we can
rationalise the number of wheel grades we
keep on the shelf. Being a subcontract
company, we have to grind whatever the
customer gives us, from stainless steels,
toughened steels, surface-treated, for
example nitride, through to hardened tool
steels, and we find these wheels give us
really good grinding performance across the
board.
“We have been using 3M Winterthur
wheels for getting on for 13 years, since we
bought our first Studer in fact. That machine
was delivered with 3M Winterthur wheels,
which we used very successfully. When
those wheels needed replacing, we
originally reverted to the wheels we had
been using on our manual machines. They
proved to be quite inadequate for the job
and we have been buying 3M Winterthur
ever since.”
“We dress accurate, small, complex forms
into our wheels and in our experience they
hold the form extremely well, without wear
at the edges. We find they give us a stable
process capability, so that we can reliably
repeat a process and achieve exactly the
same, correct size as on previous parts, a
vital benefit to us and our customers.
Mike Denton, national sales manager for
3M Abrasives Sytems Division, Precision
Grinding & Finishing, concludes: “Given its
demanding quality requirements, GB
Precision makes use of the premium 54A
grinding wheel range from 3M Winterthur.
The high quality wheel range includes
grades designed for OD and ID cylindrical
grinding, surface and profile grinding and
gear grinding, across materials including
soft steel, hardened steel, case hardened
steel and Inconel.
“In addition to providing excellent surface
finish characteristics, 54A grinding wheels
help to ensure the efficiency of GB
Precision’s grinding operations as they
exhibit exceptional flexibility and
outstanding stock removal capabilities.
3M Winterthur UK
Tel: 0114 243 7180
www.winterthurtechnology.com
KREBS & RIEDEL
Schleifscheibenfabrik GmbH & Co. KG
Grinding Perfection for
Every Process
4 Percy Street, Coventry
West Midlands. CV1 3BY
02476 22 66 11
• CBN and Diamond Wheels in Vitrified Bond
• Grinding Wheels in Vitrified and Resin Bonds
KREBS & RIEDEL
Schleifscheibenfabrik GmbH & Co. KG
Bremer Str. 44
34385 Bad Karlshafen, Germany
Phone:
Fax:
E-Mail:
Web:
+49 5672 184-0
+49 5672 184-218
[email protected]
www.krebs-riedel.de
js01gsf15
I n n o v a t i v e G r i n d i n g Te c h n o l o g y s i n c e 1 8 9 5 !
Gearing up for the UK market
Advanced Grinding Solutions is reporting
excellent results obtained from the latest
Krebs & Riedel grinding wheels when used
for the machining of gear components, as it
continues to supply more UK-based gear
manufacturers with the Krebs range of
Multo grinding wheels.
One area where Krebs & Riedel excels in is
the supply of very special wheels for gear
and thread grinding applications and special
wheels are available to suit machines
manufactured by Gleason-Pfauter, Oerlikon,
Kapp- Niles, Hofler, Maag, Samputensili and
Reishauer etc. Krebs is also a member of the
“Gear Research Circle” at Aachen University
and is heavily involved in developing
advanced wheels for the latest production
technologies employed by leaders in the
field of gear manufacture.
For specially profiled wheels for gear
production Krebs keeps customers blank
wheels in stock and upon order will profile
these to suit and then supply within just 2
days.
Advanced Grinding is able to supply
wheels in large quantities at pre-decided
call off times for next day supply from its
base in Coventry, but equally is supplying its
UK gear manufacturing customers with just a
single specialist wheel to suit a specific
grinding task that they have, as well as
supplying wheels pre-profiled to any desired
form.
Krebs & Riedel is just completing the
installation of further kilns that will increase
production and throughput times allowing it
to decrease usual delivery times from
around seven to eight weeks to around five
weeks, although many standard wheels are
available “off the shelf”.
The newly developed V86 and V87
bonding systems are the latest addition to
the highly successful V84 and V85 from the
MULTO line. The new low-fired bonding
system allows increased processing speeds
(vc = 80 m/s) and optimum grain bonding at
high or very high porosity gives an increased
wheel life time without thermal damage to
peripheral zones. The low bond share (due
to cool grinding) results in less abrasion of
the dressing tool.
The Multo Pink classic V84 bonding
system remains the best seller as a more
universal grinding wheel for a wide
spectrum of grinding applications, while the
Multo blue V85 system with sintered
aluminium oxide is used for increased metal
removal rates for faster cycle times on
demanding materials.
Meanwhile, the Multo Green V86 grade
has been developed for external cylindrical
angular plunge grinding when the grinding
wheel must work under light pressure. The
use of this wheel is proven at speeds in
excess of 63 m/sec. The final new
development to the Krebs & Riedel range of
Multo wheels is the Multo Yellow V87
wheels that offer increased retention of the
wheels form when very high wheel porosity
is also called for at the same time. To reduce
dressing tool wear sintered micro crystalline
aluminium oxide is not used for this
particular wheel.
As a manufacturer of conventional, CBN
and diamond and ceramic bonded wheels
Krebs & Riedl has observed an increasing
trend for several years towards dressable,
ultra-hard grinding wheels. New materials
such as powder metallurgy steels as well as
very strong spray-on materials take
conventional grinding agents to the limits of
their performance and the range of
demanded part tolerances is also getting
ever tighter. At the same time machine
production times and down time should be
reduced and here extremely hard CBN and
diamond grinding agents offer significantly
more potential to reduce production costs.
The substrate of a grinding wheel is also an
essential building block in the grinding
wheel system and substrates made of
fibre-reinforced composite materials do
offer advantages for special applications.
Apart from reducing the weight by up to 70
percent, they provide good damping while
providing a very strong substrate.
Krebs and Riedel are pioneering the use
of carbon fibre wheel hubs and tests have
shown significantly faster cycle times are
obtained as well as improvements in surface
finishes generated by these special types of
grinding wheel. It is developing new wheels
all the time and they are added to the
existing collection of over 60,000 different
wheel types already available.
As Krebs & Riedel gears up its support for
its growing UK customer base that’s
become an important marker for them it’s
announced its commitment to again exhibit
at the MACH 2016 exhibition on the AGS
stand.
Tel: 024 76 226611
Jason Industries widens its finishing portfolio
DRONCO joins Osborn as members of the Jason Finishing Group
Jason Industries Inc., parent company to a
global family of manufacturing leaders in the
finishing, seating, automotive acoustics and
components markets, has announced that it
has completed a transaction to acquire
DRONCO GmbH, one of Europe's leading
manufacturers of abrasives. DRONCO
becomes an integral part of Jason Finishing
Group, a Jason business unit and the
leading global producer of technical and
maintenance brushes, polishing tools and
compounds.
The Jason Finishing Group portfolio
includes well-recognised brands such as
Osborn, the only truly global player in the
industrial brush and polishing market,
JacksonLea, Lippert-Unipol and Sealeze.
The deal allows Jason Finishing Group to
enter a targeted and faster growing
$6 billion abrasives market segment and
solidifies the company's position as the
complete surface treatment and finishing
solutions provider.
DRONCO's full range, which includes
cutting, grinding and abrasive discs,
diamond tools, ceramic abrasives,
sandpapers and technical brushes, is the
ideal complement to Jason Finishing
Group's product portfiolio. The acquisition
opens Jason Finishing Group products to
customers and distribution channels where
it currently has a limited presence, while
allowing the company to become a
"one-stop shop" within the finishing
industry. Under its new ownership,
DRONCO will be positioned for continued
growth. DRONCO products will be
immediately embedded into Jason Finishing
Group's well-established, global sales and
logistics network, thereby making the
DRONCO line available to a much broader
market. Geographically, DRONCO's strong
product portfolio will be distributed to
global markets, with a focus on further
expansion in Europe and North America. To
support North American sales growth,
logistics and distribution of DRONCO
products will be added at
Jason Finishing Group's
Richmond, Indiana facility
by the end of 2015. In
2016, DRONCO will be
expanded into emerging
markets to meet increased
demand for abrasives in
developing and growing
economies.
"DRONCO is an
outstanding strategic fit
for our organisation and
we are excited to welcome
the company and its
employees into the Jason family," says
David Westgate, chief executive officer at
Jason. "With DRONCO in our portfolio, we
reinforce Jason Finishing Group's status as
the leader in finishing. Our customers will
benefit from access to DRONCO's line of
quality products, while those of DRONCO
will benefit from the availability of Jason
Finishing Group's extensive line of brushes
and polishing tools from brands they
recognise and may already trust for their
surface treatment and finishing needs."
"By leveraging the numerous inherent
synergies between DRONCO and Jason
Finishing Group brands, like Osborn, we
expect to achieve considerable long-term
growth that will benefit each company in our
portfolio," says Dr. Florestan von Boxberg,
president of Jason Finishing Group.
"DRONCO has earned a privileged
reputation as an innovative, well-run
company that produces high-quality
products. We are proud to add this
organisation to our portfolio and are excited
about the value this acquisition brings to our
joint customers."
Jason intends to maintain DRONCO's
Wunsiedel, Germany site as the primary
manufacturing and R&D centre for bonded
products. In addition to this site, DRONCO
has three subsidiaries in UK, Sweden and
France. Jason Finishing Group has therefore
acquired a global abrasives company that is
recognised for quality and product
innovation. In fact, DRONCO recently
introduced a next-generation line of cutting
and grinding discs with a lifespan that is
three times that of its counterparts. Through
the acquisition of DRONCO, Jason Finishing
Group expects there to be a sharing of
technologies that will lead to the
development of innovative new products for
Osborn and other brands within the Jason
Finishing Group portfolio.
DRONCO is one of Europe's leading
manufacturers of abrasives and sells its
products in approximately 100 countries.
The company's range of products, including
cutting, grinding and abrasive discs,
diamond cutting tools and ceramic
abrasives, is recognised for outstanding
quality among professional tradespeople
and discerning DIY users alike. DRONCO
was founded in 1962 and is headquartered
in Wunsiedel, Germany, with subsidiaries in
France, UK and Sweden.
All Jason companies utilise the Jason
Business System, a collaborative
manufacturing strategy applicable to a
diverse group of companies that includes
business principles and processes to ensure
best-in-class results and collective strength.
Headquartered in Milwaukee, Wisconsin,
Jason employs more than 4,400 individuals
in 14 countries.
Osborn Unipol (UK) Ltd
Tel: 01291 643200
www.osborn-unipol.co.uk
3M™ Abrasive Systems Division
3M Spindles,,
th smaarrtt wayy
the
f work
to dress for
www.3M.com/precisiongrinding
3M Winterthur
Unit 1, M1 Distribution Centre
Vulcan Road. Sheffield S9 1EW
Phone: +44 (0)114 243 7180
email: [email protected]
©3M 2015. All Rights Reserved
J306033
39
Keeping up with abrasives technology in the foundry
Special Metals Wiggin, part of the PCC
Group of companies, has been a feature of
the industrial heritage of Hereford since
1950. Set over 45 acres and with over 600
employees covering three shifts, the
company is constantly working to update its
processes and take advantage of the latest
technologies to optimise its output.
So how do you ensure your processes are
being completed as efficiently as possible in
a fast-paced environment where priorities
can change in an instant? Principal buyer
John Anderson says: “The foundry will
always try to sell up to capacity and take
orders which will often need to be fulfilled at
short notice. This means our suppliers need
to adopt a pro-active and totally flexible
approach.”
Special Metals Wiggin supply a range
nickel-based alloys to a number of industries
from aerospace and automotive to oil, gas,
petrochemical and medical; in fact any
industry which requires nickel alloy.
In 2009 a decision was made to try to
consolidate suppliers and streamline the
supply chain, thereby optimising processes
and ultimately reducing costs. The first area
the company targeted was the supply of
abrasives on site. In 2009 abrasives were
supplied by five manufacturers and a
number of distributors in order to fulfil the
requirements of a challenging environment.
Manufacturers were invited to review the
cut-off and grinding applications on site and
to put forward a proposal to supply
abrasives on an on-going basis.
One of these manufacturers was TYROLIT,
a supplier of abrasive products and technical
support services across the world. TYROLIT
application engineer Paul Carson and two
colleagues from TYROLIT’s headquarters in
Austria visited Special Metals Wiggin to
begin the process of reviewing the cut-off,
and grinding applications.
Paul Carson says: “The first application we
looked at was the chopping of 80 mm solid
bar. The company was using a competitor’s
wheel to cut the bars which was causing
cracks and discolouration which ultimately
caused a shell like appearance in the heat
effected zone”.
TYROLIT introduced its SECUR range of
wheels, which proved a cost-effective
alternative to the competitor’s wheels. The
results were very favourable. John Anderson
comments: “Once we changed to
TYROLIT’s cut-off
wheels we had no more
burrs or blueing. The
discs also cut quickly
and neatly and they’re
so effective the factory
cuts two bars together
at the same time.” This
ultimately halved
process time and
doubled capacity on
one machine.
The next application
to be reviewed was a
tube reducing line.
Rubber bonded wheels
were being used to cut
tubes and bars
causing severe
problems with smell,
sharp burrs and resin
deposited on the cut
edges and inside the
tube. Coupled with
supplier inconsistency
and poor lead times
for supply, the process
was in urgent need of
an over-haul.
Paul Carson looked
at the process and
introduced a TYROLIT
resinoid wheel from
the company’s SECUR
range: “The wheel cut
with no burrs and no smell, while the
elimination of resin deposits means that
there was no ingress of dirt in to the tubes
and secondary work like filing the burrs off
and manual buffing has reduced
significantly. Our wheels were marginally
more expensive than the previous supplier’s
products. However the overall cost-per-cut
was greatly reduced.”
TYROLIT then moved on to look at other
applications which could be improved.
Wheels were trialled with the aim of
reducing cost-per-cut or per-part. Paul
Carson continues: “We basically moved
through the factory to different cells to look
at each process in turn. We slowly built up
trust and goodwill with the personnel on the
shop floor and based on their positive
experience with Tyrolit, they recommended
us to other departments. Over the next five
years we reviewed the majority of cutting &
grinding processes on site and were able to
improve each one using TYROLIT wheels.”
TYROLIT has been supplying Special
Metals Wiggin since 1976. In 2009 its share
of the abrasives business with the company
was between 15 and 20 percent. Now it’s
around 80 to 85 percent. It supplies the
TYROLIT range of grinding wheels for every
grinding process on site and the vast
majority of cut-off wheels. So why is the
partnership so successful? John Anderson is
convinced it’s the all-round partnership
approach: “TYROLIT are responsible for
managing supply of wheels to us but they
are also pro-active on site as a whole,
looking at processes and where things can
be improved. They have a pro-active
presence which helps us to keep improving
on what we’re doing.”
A comprehensive stock arrangement is
also in place to ensure smooth supply of
wheels. Stock is held on-site in Hereford and
also at TYROLIT’s warehouse in
Northamptonshire and stock levels are
reviewed weekly. John Anderson says: “We
keep around a month’s stock here in the
foundry but we can call stock from TYROLIT
whenever we need to. The arrangement
works very well indeed.”
The next task for Paul and TYROLIT is to
look at the supply of hot pressed wheels and
how new technology may be able to provide
an advantage. John Anderson says: “Our
relationship with TYROLIT has definitely
improved things. Rationalisation of the
supply chain has made things easier and
because of our stock arrangement we get
what we need quickly. It’s excellent having
someone with technical awareness on-site
and TYROLIT’s product development is very
good. They have built a total resource
centre and are supplier of choice for the
majority of our applications. Although we
operate an open-door policy for trials, it’s
only open to suppliers we know and trust so
we invite Paul and TYROLIT to review our
applications and see how continued
development can improve things.”
Ultimately, consolidation of the supply
chain has benefited Special Metals Wiggin
in a number of key areas: supply lead times
have been reduced, cost-per-part is lower
and time is saved for both the shop floor and
buyers thanks to comprehensive procedures
and stock arrangements, all the result of a
relationship built over 39 years.
TYROLIT Ltd
Tel: 01788 824500
www.tyrolit.com
NEW
CR 116 (ceramic grain)
MERCURIT BW 590
NEW
MERCURIT RB 595 Y
www.hermes-abrasives.com
Finished Stainless Steel
Hermes quality abrasives for flat grinding stainless steel
HERMES ABRASIVES LTD. • Wyncolls Road • Severalls Park • Colchester/Essex CO4 9LW • Phone 01206 754444 • Freefax 0800 614473 • [email protected]
41
Mirka invests in major new engineered surface finishing initiative
Mirka is committing significant investment
to a new 20,000 square metre factory at its
headquarters in Finland, specifically
designed to produce high tech
microfinishing abrasive film technology.
The new advanced patented
manufacturing process produces high
quality abrasive film that offers users cost
efficient, consistent and higher quality
finishes. Customers are from a variety of
industries including industrial roller
manufacture and refurbishment, glass
repair, automotive engineering, computer,
communication and consumer electronics
(3C).
Mirka’s innovative microfinishing film
technology effectively distributes the
micron sized abrasive particles evenly and
consistently across the quality backing film.
The range is available in a selection of
abrasive types, including: aluminium oxide,
silicon carbide, ceramic coated and
diamond. Various film roll lengths and
widths are available as well as different
thicknesses of backing materials.
To complement the ESF film products,
Mirka’s ground breaking Abranet has also
been developed further. Abranet Max is a
versatile net finishing product in both roll
and belt form to support higher stock
removal as well as fine finishing
requirements.
Mirka’s objective is to work with
customers to develop the correct
configuration of abrasive, abrasive
distribution and machine operating
parameters to optimise processes and
provide substantial cost savings.
The abrasives create consistently fine
surface scratch patterns during use and the
even grain distribution on the film allows for
even stock removal without clogging,
achieving a high quality finish faster and a
reduction in film usage. The products have
been designed for use on a variety of
materials including hardened steels,
chrome, copper, rubber, aluminium alloys,
titanium, composites, plastics,
polycarbonates, painted surfaces and glass.
Craig Daycock, managing director of
Mirka UK, says: “The dedicated ESF factory
highlights our continued commitment to
investing in cutting-edge abrasive
technology that introduces innovation into
an established marketplace. Our ESF
microfinishing solutions have been designed
by our R&D team to offer customers
products that will lower costs, deliver
efficiency and process improvement, and
provide consistency of finish in many
industries such as paper, print, industrial,
automotive engineering, glass polishing and
3C industries.”
Mirka (UK) Ltd
Tel: 01908 866100
www.mirka.com/microfinishing
Grinding, sanding and power tools from Aerotech
Aerotech Group’s unique product range has
evolved to become the unparalleled
portfolio that’s available today. Each and
every item that’s sold has been examined
and reexamined to ensure it meets the
company’s strict quality control standards.
Previous experience in the metalworking
industry clearly showed that there was never
enough customer service to accompany
production. That’s why Aerotech has
worked hard on making sure that every
aspect of its service reflects what its
customers have come to expect. That’s an
honest, quick, efficient and reliable service
with a high-quality product to match.
Aerotech Group’s abrasive solutions allow
businesses to work safely, efficiently and
increase productivity on a scale of their
choosing. The company’s philosophy is
resolute, never wavers and is instilled
throughout our business: we don’t stop
working until we’ve provided our customers
with products that meet each and every
single one of their requirements.
Aerotech Group sources products from all
over the world to provide its clients with the
widest choice at the most competitive
prices. Customers include metal, stainless
steel and tank and vessel fabricators plus
steel casting and trailer manufacturers, rail
industries (rail track maintenance),
aerospace and manufacturers of catering
equipment.
From the initial enquiry through to
technical backup and advice, the team is
available Monday through to Friday (07:00
to 16:00) via email and telephone to answer
every one of your queries. Aerotech Group
endeavour to make every aspect of the
transaction as seamless as possible, and that
includes support after you’ve received the
product.
The aftercare service has been designed
to make sure you’re completely happy with
your product and Aerotech Group as a
company.
Aerotech is well aware that not every
specification for an item or product can be
taken ‘off the shelf’. That’s why it works
closely with customers to provide the
perfect abrasive solution that lives up to
expectations. For example, if there’s an
abrasive belt that doesn’t match the size
that the customer requires, then it will make
one that does. Is there a Typhoon zirconium
flap disc that the customer needs that
doesn’t match up to the size and grit that’s
required? No problem, Aerotech will create
a solution for them. It’s as easy as that.
Aerotech Group
Tel: 01423 202811
www.aerotechabrasivesgroup.com
Precision diamond dressing roll plus the profiling of grinding wheels
With a working width of
0.6 to 1.5 mm, the new
wheel design of the
drebojet® diamond
dressing roll plus is the
ideal truing tool for
CNC dressing of
conventional grinding
wheels.
Another application
area for drebojet-plus is
the dressing/profiling
of ceramic bond
diamond and CBN
grinding wheels during
serial production.
For example, when
camshaft grinding,
The drebojet-plus precision dressing roll profiling a
conventional grinding wheel
LACH DIAMANT drebojet-plus
precision dressing rolls feature
increased tool life and absolute profiling precision compared to
conventional dressing rolls for CNC profiling.
Regrinding service for natural diamond dressing tools
LACH DIAMANT is a manufacturer of diamond tools in Hanau, a
town that in the past was well known for precious jewellery,
emphasises how important the “little things” really are, for example
the repairing, resetting and
regrinding of natural diamond
dressing tools.
It offers a resetting and regrinding
service for single point diamonds
and polished profile diamonds of all
systems (Fortuna, Schaudt, Jung,
Diaform and others).
This service goes back to an old
tradition, when until the outbreak of
World War II, LACH employed
almost 600 grinders of natural
diamonds.
The special service is offered to all
metal grinding shops and toolmakers and is also provided for third-party brands.
LACH DIAMANT’s head office is in Hanau, with a plant in
Lichtenau near Chemnitz, Germany, while LACH DIAMOND INC.,
based in Grand Rapids/Michigan, USA, specialises in service for
PCD, PCBn and CBN tools.
LACH DIAMANT
Jakob Lach GmbH & Co. KG
Tel: 0049 6181 103822
Email: offi[email protected]
www.lach-diamant.de
43
GSF DEBURRING 44-49_ES CONTENTS 4-5 19/08/2015 14:39 Page 44
DeburringEXPO – innovative solutions
for efficiently optimised surfaces
1st Trade Fair for Deburring and Polishing Technology from 13 to 15 October 2015
In nearly all of today’s manufacturing
industries, deburring, rounding and
polishing are required production steps.
Due to continuously increasing demands for
product quality, precision and surface
finishing with simultaneously rising cost
pressure, companies are facing new
challenges to an ever greater extent.
DeburringEXPO will present innovative
solutions for meeting these challenges at
the Karlsruhe Exhibition Centre from the
13th through the 15th of October, 2015.
The exhibitor list for the deburring and
polishing trade fair already includes more
than 70 exhibitors from eight countries
(status as of 25 June 2015). The
supplementary expert forum additionally
offers a great deal of valuable knowledge.
Whether parts are manufactured by
means of machining, metal forming or
master forming, deburring, rounding and
polishing don’t usually belong to the core
competencies of manufacturing companies
from the fields of automotive,
aviation, medical technology,
machinery manufacturing, drive
technology, precision
engineering, microsystems
technology, casting, hydraulics
and other industry sectors.
However, in order to fulfil today’s
typically exacting demands placed
on product quality, functionality
and service life, undesired
“production remnants” have to be
removed. In particular, deburring
processes are still frequently
executed just like they were in
days of old, with all of the
associated disadvantages
including a lack of reproducibility
and high costs.
Companies are therefore on the
lookout for efficient and innovative
solutions for deburring, rounding
and polishing. These can all be found at
DeburringEXPO.
This is substantiated by the exhibitor list
for the technical trade fair for deburring and
polishing technology which already includes
more than 70 companies.
“Positive feedback, coming from
companies outside of Germany as well, is
confirming our concept for an independent
trade fair aligned to the fields of deburring,
rounding and polishing”, stresses Hartmut
Herdin, managing director of event
promoters fairXperts GmbH & Co. KG.
There’s plenty of visitor interest in the new
trade fair too.
“An initial mailing to potential expert
visitors also resulted in excellent feedback.
In addition to market leaders from the
automobile industry, automation
technology, drive and transmission
technology, aviation, machinery
manufacturing, mechanical engineering, the
sanitary industry, clock making and the
tooling industry, numerous highly capable
suppliers for various other industry sectors
have already announced that they will visit
the trade fair”, adds Hartmut Herdin.
Innovative solutions for enhanced value
creation and a sharper competitive edge
Numerous market and technology leaders
are already amongst DeburringEXPO’s
exhibitors. This ensures that comprehensive,
representative offerings for deburring,
rounding and polishing processes and
technologies will await the visitors. These
will encompass various innovative processes
and further developments which not only
assure the fulfilment of current requirements for process reliability
and economic efficiency. Depending on the utilised technology,
they also make it possible to furnish processed surfaces with special
characteristics. Amongst others, these include reduced friction and
wear, minimised noise levels, increased internal compressive stress,
longer service life and energy savings. Issues covered by
DeburringEXPO which also address the areas of product
development and design engineering include burr avoidance and
minimisation, as well as burr-free production of contours, structures
and even non-cylindrical drill holes. The deburring, rounding and
polishing production steps can thus contribute to enhanced value
creation as well as a sharper competitive edge.
Expert Forum – value added through knowledge and an exchange
of experience
Exhibitor offerings presented at DeburringEXPO will be
complemented by an integrated expert forum. A practically
oriented transfer of knowledge concerning deburring and polishing
technologies, as well as examples of best practice and a direct
exchange of experience, will be the centre of attention. This will
make it possible for visitors to gather targeted information on
various issues in the field of deburring and polishing technology.
The DeburringEXPO exhibition offering covers equipment,
systems and tools for belt grinding, brushing, abrasive flow
machining, vibratory grinding, blasting with solid and liquid media
such as high pressure water jets and CO2 snow jets, abrasive
water-jet blasting, magnetic-abrasive deburring, ultrasonic
deburring, chemical bath deburring, electrochemical machining
(ECM), precision electrochemical machining (PECM), electron beam
machining, thermal energy machining (TEM), mechanical deburring,
buffing, polish honing, electrolytic polishing, plasma polishing, laser
polishing, immersion and brush polishing, as well as measuring, test
and analysis systems, deburring, rounding and polishing in the form
of services, research, training and literature.
Further information can be found at www.deburringexpo.com
fairXperts GmbH & Co. KG
Tel: 0049 7025 84340
www.fairxperts.de
45
Ellesco puts a shine into summer
Many capital equipment vendors will admit that seasonal trends
often lead the summer time sales figures being a little sluggish.
However, Ellesco is clearly bucking this seasonal trend with four
Timesavers-Grindingmaster rotary brush machines installed in the
last couple of weeks.
The popularity of the Timesavers-Grindingmaster 42 Series WRb
and Rb surface finishing, deburring and edge radiussing machines
has soared in recent months with sales across the length and
breadth of the UK. The most recent installations have been made at
Had-Fab Ltd in East Lothian, Bridmet Ltd in Bridport, Dorset,
Welland Power Ltd in Lincolnshire and Syspal Ltd in Brosely,
Shropshire. All these manufacturers are new customers to Ellesco
and the Timesavers-Grindingmaster brand.
Commenting on the surge in orders, Ellesco managing director,
Guy Newton says: "Each of these new customers is manufacturing
completely different products from a variety of materials for very
diverse industry sectors. These applications range from heavy duty
surface finishing with 40 grit abrasive belts through to the polishing
of laser cut sheet metal and even the fine graining of wide sheet
stainless steel for the production of toilets, basins and cooking
equipment in the hygiene and catering sectors. Whilst these
customers specified the 42 Series WRb and Rb machines for edge
radiussing, two customers specified the Timesavers-Grindingmaster
42 Series for deburring and surface finishing, such is the capability
scope of the machines."
A Common Goal
The one thing all these new customers have in common is the desire
to improve productivity, quality and consistency whilst reducing
costs. Guy Newton continues:
"All of these customers were previously finishing parts by hand and
were to an extent unaware of the entire capabilities and benefits
offered by the Timesavers-Grindingmaster range. By reducing, and
in some instances eliminating, hand finishing, these customers are
obtaining greater throughput, reduced lead times and above all a
consistent surface and edge finish. This is resulting in improved
quality of the finished components and also a reduction in reject
rates.
"In addition, the easy-to-use Timesavers-Grindingmaster
machines and Ellesco’s team of nationwide service & commissioning
engineers, ensure immediate operational benefits and support.
They can then swiftly run a batch of components through the WRb
or Rb machine in a fraction of the time of hand finishing. This is
freeing up man hours for the end user. What's more, we are
witnessing more employers becoming aware of the latest Health &
Safety 'trigger directive'. The key to this new directive is that no
employee should be using hand tools for more than 1.5 hours a day,
to restrict the potential for RSI. Employers conscious of employee
health & safety are instigating change in line with the regulations
and Ellesco has just the answer with the Timesavers-Grindingmaster
range of deburring, edge & surface finishing machines."
Ellesco is a leading supplier of deburring, polishing and finishing
machines in the UK & Eire. Its core purpose is to supply machines to
companies and accompany this with support equipment, service,
consumables, installation, training and commissioning.
Ellesco has been supplying machines since 1975 and currently has
almost 3,000 installations in the UK and Ireland. Founded from the
recognition of the advantages to production of wide belt abrasive
machinery from Grindingmaster, Ellesco has grown its portfolio of
suppliers in line with listening to customers’ other requirements.
These suppliers are the best in their field, offering machinery which
is proven, reliable and technically excellent.
Ellesco has a support team of engineers and product support
people who can handle service contracts, parts and repair,
consumable supplies as well as upgrades and sales. The sales team
have all experienced the operational benefits of the suppliers,
received factory training and carry a real world approach to
delivering a solution to your business.
A founding principle of Ellesco is to deliver better finishes
consistently through real world trials. Regular visits to supplier
factories to process components, with or without the customer,
have proven the benefits of the machine. A new Demonstration
facility at our Christchurch base is open to every customer for trials
and training.
Ellesco Ltd Tel: 01202 499400
Email: [email protected] www.ellesco.co.uk
Brush deburring with the AC microLine
Lapmaster Wolters is a unique manufacturer
of double-side brush deburring machines.
The successful AC microLine® product line,
with its applications in fine grinding,
polishing, lapping and honing, is now
complemented with the application of
double-side brush deburring. Most
conventional linear brush deburring
machines have the disadvantage of an
expensive flip-over device with high space
requirement, particularly for non-magnetic
work pieces. The AC microLine deburring
machines, however, process simultaneously
both surfaces of the workpieces in one
production step. Thus, no expensive
flip-over devices are necessary which leads
to significant cost savings and a smaller
footprint of the system. Furthermore, the
magnetisation and de-magnetisation for
magnetic workpieces is not necessary
anymore.
With an AC double-side deburring
machine, the workpieces are transported in
workpiece carriers, so that batch machining
can take place. The planetary kinematics of
brush wheel, pin ring and work piece carrier
rotation enable a steady and high quality of
deburring and edge rounding. This is
ensured because of the movement of the
work pieces in epicycloid and hypocycloid
trajectories.
Customer benefits with AC microLine
deburring machines include: double-side
brush deburring in one production step
without the need of flip-over device;
significant smaller space requirement
compared to conventional deburring
systems with flip-over device; suitable for
non-magnetic workpieces; reliable Peter
Wolters AC microLine technology; easy
automatic interlinking of an AC microLine
fine grinding machine and deburring
machine in the same size, because both
machines are equipped with the same
epicyclic workholder drive system; handling
of the workpiece carriers; conversion to an
AC microLine fine grinding machine
possible; outstanding synergy with other
Lapmaster Wolters machines: e.g.
high-precision double-sided grinding and
deburring machines.
There exists a high amount of different
brush deburring wheel specifications. For
every customer application, Lapmaster
Wolters will design and specify the brush
deburring wheels according to the specific
customer requirement for its workpiece
range.
Lapmaster Wolters
Tel: 01752 893191
www.lapmaster.co.uk
Airfield Road, Christchurch, Dorset, BH23 3TG
01202 499 400
[email protected] [email protected] [email protected]
www.ellesco.co.uk
With One Simple Operation On The Timesavers
Through-Feed Machines You Can:
• Deburr
• Edge Finish and Radius Even On Complex Forms & Holes
• Graining/Surface Finishing
Benefits:
•
•
•
•
Consistent Finishing Every Time
Improved Component Quality
Improved Productivity & Efficiency
Reduce Health & Safety Risks
Selecting the correct deburring method
to optimise efficiency
Nigel Willcock, technical specialist at 3M Abrasive Systems Division looks at how deburring has
evolved and how metal finishers can ensure they are selecting the correct deburring method to
optimise efficiency
The science of surface finishing is one that
continues to present many challenges for
engineers, part manufacturers, technicians
and fabricators every single day. One such
challenge is the method of deburring. A
process that is typically defined by removing
a ‘burr,’i.e. a raised edge of excess material
or area of roughness produced in cutting or
shaping of metal, which is carried out by
chamfering the edge of the metal to create
two smaller sharp edges. The intricacy of the
part coupled with demanding material
properties are both key obstacles that can
make it difficult to find a deburring method
that is efficient, both in terms of cost and
process.
Most surface finishers carrying out a
deburring process, whether it be in a
pattern/tool makers or in an aerospace
manufacturing workshop, are looking for
precise edge finishing with increased speed
and reduced side effects. For example some
manufacturers will require a deburring
process to be completed in a specific
timeframe, such as CNC machines which
need the mechanical parts to be deburred in
the cycle time specified to match the overall
production line rate, and others will be more
focused on the precision and geometry.
One example would be turbine blades
where it is critical that the manufacturers
produce a specific deburred radius.
Deburring can be required wherever
there is turning, milling, drilling, boring,
lapping, shaping, machining, surface
grinding and abrading. All these machining
and cutting operations produce a burr. It is
the process of completely removing the
burrs from a workpiece, leaving a slightly
radiused edge, without any modification to
the part shape and geometry.
There are many reasons why deburring is
necessary, not least for safety. When a piece
of metal is cut in a workshop, the sharp edge
can present a danger of injury. If the
stainless steel used to manufacture tanks
and vessels, professional kitchens or other
food and beverage equipment is being cut
to shape from a larger section then this can
cause a burr on the underside of the
material. The sharpness also predominantly
poses a material handling risk as well as the
end-product safety for the user.
Additionally it can cause mechanical
damage to the assembly if a burr breaks, for
example on pistons, gears, textile machinery
or computer hardware. Again, in the
assembly of gears or parts in the power
generation industry, they may not fit
together if the burr is still intact. It can also
be an important factor in maintaining a
product’s aesthetic appearance, such as the
front panel of radios, DVD players, furniture
cabinets or building equipment. Finally, it
can play a major role in electrical
applications where a broken burr could
create a short circuit in printed circuits,
electric motors or generators.
What are the options?
Deburring is an ancient practice but its
process has evolved throughout history,
therefore there is a plethora of traditional
methods available including: files; mounted
points; bonded wheels; scalpels; abrasive
rolls; wire brushes; abrasive belts; rotary
burrs; flexi hones and rubber wheels.
However, it is a solution for an absolute
deburr that many manufacturers seek.
At 3M, we have developed a variety of
abrasive solutions for deburring that ensure
increase efficiency and productivity in all
metal and wood applications. For example,
Scotch-Brite Products leave a much
smoother surface after deburring and there
is no undercutting or gouging of the surface.
Unlike most other products, they also
deburr both the sides and surfaces of the
workpiece. Scotch-Brite Deburring Wheels
and Scotch-Brite Radial Bristle Brush create
an ideal deburr with a rounded edge as
there is no secondary burr created by the
process, the corners are rounded, there are
no geometric changes and it keeps the
tolerance.
Let’s take a look at some of the traditional
methods compared with the new
technology incorporated in the Scotch-Brite
Deburring Products:
Using hand files and wire brushes on a
buffing stand can provide results that are
inconsistent and time consuming. Should a
workshop or production line receive an
increase in orders, another method would
be required.
Furthermore, coated belts can generate
flats and change the geometry of the
workpiece as well as leaving secondary
burrs.
Scotch-Brite Deburring Wheels and
Scotch-Brite Bristle Brushes by 3M
overcome these issues as they help prevent
undercutting and gouging through their
controlled abrasive action. They last longer
and are easier to use which means less
downtime and operator fatigue, offering a
more consistent, controlled result and they
work much faster. They also offer a better
alternative to wire brushes because there
are no flying wires, making them far safer.
Selecting a deburr based on application
Heavier deburring
Some applications require a heavier
deburring tool where the nature of the
material or the type of cutting tool produces
a heavier burr than normal. Unitised wheels
such as Scotch-Brite Wheels offer
non-directional, soft deburring without
making a large radius. An additional benefit
to using this method is that the wheels can
be used on any metal. However, they have a
shorter life and lower cut than convolute or
moulded wheels so are best suited for larger
burrs where more aggression is needed. The
Scotch-Brite Unitised Wheels by 3M are
made from a non-woven web interspersed
with resin and mineral, which is then cured
under pressure to form a slab from which
the wheels are cut.
Lighter deburring
For lighter burrs convolute wheels offer a
better solution than the unitised wheels
mentioned above. Convolute wheels are
wound onto a fibreglass core with a resin
layer to form a “bun” which is then cured in
the oven. This offers a finer cut, softer
density and a more even finish.
Brushes by 3M more efficient. Generally
speaking, the finer more conformable bristle
products are used for decorative finishing
they will conform more readily to surface
contours along with generating a more
uniform finish. The coarser less conformable
bristle products are therefore used for more
difficult blending, cleaning, and deburring
operations. Pressure and speed can also
influence product life as well as
performance. Lower pressure and speed
means a lower cut and longer life and higher
pressure and speed means a higher cut and
shorter life. Too-high a pressure increases
wear drastically.
When used in automated processes,
lubricants or coolants are advised whenever
possible to reduce heat and extend product
life. All Scotch-Brite Products can be used
with coolants such as water and some
water-soluble oils - most reduce surface
Stock removal and shaping
A replacement for rubber
bonded wheels is moulded
wheels, suitable for stock
removal and shaping. For
example they would be
used to remove milling
marks and taking out small
mismatches from the
machining process. They
are more aggressive than
unitised wheels and run
more smoothly than rubber
and bonded wheels with
the result that they can
produce the result more
quickly with less vibration.
Light deburring, cleaning and surface
preparation
Bristle brushes offer the most effective
solution for applications such as cleaning
rust and contamination in maintenance
repair and operation (MRO), removing
coatings such as painted surfaces, weld
cleaning, deburring complex shapes such as
gears and turbine blade roots, and cleaning
and/or deburring of threaded bolts.
The Scotch-Brite Bristle Brushes by 3M
are designed to offer additional safety
benefits due to the abrasive-filled plastic
brushes eliminating the risk of flying wires
and conforming to contoured parts.
Compared to wire or filament brushes, they
can cut faster and more effectively meaning
an overall increased production rate. The
fresh mineral is exposed as it wears meaning
there is a constant cut rather than the
peening effect produced by the other
products, making Scotch-Brite Bristle
roughness. The higher viscosity lubricants
produce lower surface roughness and
grease produces a finer surface finish than
oil.
Whether it be to match a prodution line
rate, or find a more cost-effective method
that offers an absolute deburr, choosing the
right method or tool and matching it with
the right abrasive product is absolutely
critical.
For more information on Scotch-Brite
products for deburring applications,
contact:
3M Abrasives
Tel: 0870 60 800 90
www.3M.co.uk/abrasives
49
GSF FTR POLISHING & LAPPING 50-53_ES CONTENTS 4-5 20/08/2015 11:26 Page 50
Feature -
Engis lapping plate selection, care and maintenance
Superabrasive specialist, Engis Corporation
has been engineering superior lapping
systems, from machines and plates, to slurry
and compound, for more than three
decades, creating and tailoring solutions to
meet the demands of lapping applications
including the processing of metals,
ceramics, glass, semiconductor substrates
and electro-optical materials.
As designers of complete lapping
solutions, Engis completely understands the
importance of each component in the
system and firmly believes that one of the
best ways of maximising the efficiency of the
lapping operation is the selection of the
appropriate lapping plate and its ongoing
care and maintenance.
For each application there is an optimum
lapping plate; for example for aggressive
stock removal, composite iron plates, often
used as an alternative to cast iron plates,
provide excellent flatness, longer service life
and refined surface finishes, particularly on
metals and ceramics.
For moderate stock removal one option is
the use of composite tin plates which offer a
lead-free working environment and provide
superior surface finish, while working with
coarser diamond slurries for fast stock
removal, long service life and low
reconditioning requirements. An alternative
would be Engis widely used Hyprez HY
copper plate, suitable for lapping virtually
any solid material and which minimises
fracturing and chipping tendencies when
lapping crystal components.
On the other hand, for applications
requiring very low stock removal a
tin-antimony plate may provide the best
answer, being resistant to temperature
variations during lapping and also
preventing changes in lubricant viscosity
during continuous lapping.
Whichever plate is selected, the key to
achieving good surface finish and flatness
relies on its correct maintenance. The
cleanliness, flatness and texture of the
lapping plate directly affects the process
results.
It is important that plates are cleaned at
appropriate intervals by rinsing them, Engis
recommends using DI water, and using a
squeegee and vacuuming away the excess
residue, taking care not to introduce
contamination to the plate during the
process.
Lapping plate flatness is of course also
critical. If a lap plate is excessively concave,
the parts will be convex and
vice-versa. It is important
therefore to periodically check
plate flatness and make
necessary adjustments. As a
general rule a good starting point
is a slightly concave plate (2.5 –
5.00 microns).
During the lapping cycle itself,
the use of ceramic conditioning
rings is recommended. If the
lapping plate starts to become
concave, the conditioning ring
should be positioned towards the
outer edge and conversely, if the
plate starts to become convex,
the ceramic conditioning rings
should be positioned towards the
centre.
If the lapping plate is out of flat and/or has
lost texture, it should be re-conditioned.
Engis recommends that, for composite
lapping plates, a diamond plated
conditioning ring (PCR) is placed in one of
the roller yokes, while for cast iron or pure
metal plates, a cast iron conditioning ring
and a non-diamond abrasive such as
aluminium oxide should be used.
The ring should overlap both the ID and
the OD of the lapping plate to ensure that a
ridge is not formed during conditioning; the
plate should be sprayed with enough
lubricant to keep it wet and it is also
important to use lubricant throughout the
re-conditioning cycle.
To correct the flatness of a plate that is
too concave, the PCR should be positioned
toward the OD of the plate and to correct a
plate that is too convex, the PCR should be
positioned toward the ID of the plate. Bear
in mind that it is much easier to make a plate
more convex than to make it more concave
and for this reason it is important not to let a
plate become too convex.
Whatever your lapping and polishing
requirements, a member of the technical
team at Engis UK, will be delighted to
discuss your specific needs, helping you to
make the optimum choices to obtain the
best results from your lapping technology,
meet your technical objectives and exceed
your customers’ expectations.
Engis (UK) Ltd
Tel: 01491.411117
www.engis.uk.com
Cougar stalks the UK and Ireland
With the advent of small machines, which
can remove weld oxide on stainless steel
electrochemically, the market place is now
flooded with an array of such functioning
machines. One disadvantage has been
reliability, which gave Anopol cause to seek
out a machine which was robust, extremely
reliable and, importantly, straight forward to
use. For these reasons, Anopol chose to add
the Cougartron machines to its range of
products for cleaning weld oxide discolouration from stainless steel.
The company has long been marketing its
Weldkleen and Minikleen units for cleaning
welds. These machines operate by pumping
a cleaning fluid to a pad at the end of a
touch. The electrochemical action between
the pad and the fluid produces an
electrochemical action, which in turn
removes the weld burn (oxide) from TIG
welded seams and joints. Whilst operating,
there is a continuous flow of solution to the
pad.
The operating principle for the
Cougartron range of weld cleaners is rather
different. Instead of a pad, a carbon fibre
brush is
employed. This brush is dipped continuously into the cleaning fluid, which is
then applied to the weld burn areas. The
elevated power (amps) of this machine
results in very rapid oxide removal, not only
on TIG but also on MIG welds.
The Cougartron comes in two versions.
The standard ‘Cougartron Plus’ cleans TIG
and MIG weld oxides, whilst the
‘Cougartron ProPlus’ can also be used for
electropolishing small stainless steel areas.
With over 40 years’ experience, Anopol
are a leader in chemical and electrochemical
processing of stainless steel, and other
metals, for a wide spectrum of industrial,
decorative and functional applications.
In addition to offering sub-contract
services, plant and chemicals, Anopol can
also supply an extensive range of pickling,
passivating and general cleaning products
for stainless steels. These are suitable for for
use by companies who wish to carry out
their own processing.
Anopol operates from 2 sites, one in
Birmingham and the other in Bordon,
Hampshire.
Anopol Ltd
Tel: 0121 632 6888
www.anopol.co.uk
Kemet
Precision Lapping
pp g | Polishing
g | Cleaning
g | Materialography
g p y
Not Everyone
Understands
Lapping Like Us
With over 75 years’ experience we have the knowledge to
provide a complete process for all your surface finishing needs.
A comprehensive range of lapping, polishing and cleaning
machines that can be adapted to most geometries and processes
The widest selection of diamond and conventional abrasives,
lapping plates, flatness measuring equipment and polishing pads.
Free trials with reports, recommendations and demonstrations to ensure
that you have the optimum lapping and polishing package for your components.
Kemet International
International Ltd,
Ltd, Parkwood Trading Estate,
Estate, Maidstone,
Maidstone, Kent, ME15
ME15 9NJ,
9NJ, UK
UK
Tel:
T
el
e : +44 (0) 1622 755287 - Fax:
Fax: +44 (0) 1622 670915
5 - www.kemet.co.uk
www
w.kemet.co
.
.uk - [email protected]
[email protected]
51
New investment at PPS
Professional Polishing Services Ltd announces its latest investment
As the first UK free-issue polishing company
to process wide sheet and plate via a 2000
mm wide dull and satin polishing line,
Professional Polishing Services is expanding
this department with the purchase of a new
double-headed line from Costa Levigatrici
SpA in Italy. The new line will polish plates
up to 2000 mm wide and 20 mm thick, with a
maximum piece weight of two tonnes.
This additional capital expansion builds on
the company's ethos of dedicated growth
and re-investment to secure success for the
future and to give the best possible finish
and service to industry.
Alberto Burtini from Costa explains why
their machine was the right choice for
Professional Polishing Services "We were
proud to demonstrate our build and
engineering quality during their visit to our
three factories in Italy. The machine is
designed by the latest generation 3D CADCAM technology and the
software is uniquely developed by our engineers thus allowing us
the control of every single machine function and create also tailor
made solutions for special needs"
Kirsty Davies-Chinnock, managing director of Professional
Polishing Services Ltd was impressed with the trials carried out in
Italy. "It's an exciting period for PPS, this investment is a fantastic
opportunity for us to grow to the next level and to cement our
position as the UK's market leader in stainless steel mechanical
finishing."
The investment itself is the largest ever made by the multi-award
winning Professional Polishing Services in its thirty two year history.
The new plant is due to arrive and be commissioned during
December 2015.
Professional Polishing Services Ltd
Tel: 0121 555 6569
www.professionalpolishing.co.uk
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Better plate than ever
New Kemet lapping plates
technology, specifically
developed for applications that
Following the success of Kemet
make high demands on the
International Ltd’s Copper SP2 composite
lapping process. These can be
plate released in 2014, the development
tungsten carbide coated gate
laboratories of this 75 year old UK company valve lapping where the parts
have come up with two more new
are large and heavy, or high
composite plates which will be added to
volume 24 hour production
their offering by the end of 2015.
scenarios where there is little
Kemet’s Copper SP2 was the first
time available for plate dressing
composite lapping/polishing plate to truly
or flatness maintenance. The
provide both good stock removal and final
specially formulated Iron SP2 is a low
Ra value, all achieved with the same plate.
maintenance, highly stable composite
This means that a single Kemet
designed for applications like these.
lapping/polishing machine fitted with a
For the polishing end of the process
Kemet Copper SP2 plate can now do what in spectrum, Kemet’s labs have also developed
the past had required two machines.
the new Kemet XL polishing plate. Two
But this is not the priority with all lapping
years in development the results have been
and polishing processes. Many high volume worth the wait. Primarily a general purpose,
applications need multiple machines in
super finishing plate for medium to super
order to meet the throughput demands of
hard metals and alloys, its performance on
their businesses. In these circumstances, it’s hard aluminium oxide and silicon carbide
the stability of the lapping process that
ceramics takes it beyond industrial polishing
becomes a priority.
into the realms of optical finishing.
The new Kemet Iron SP2 composite plate
Kemet are not resting on their laurels,
is a breakthrough in diamond lapping
however. They continue to work hard,
pushing the boundaries of what is
achievable in lapping and polishing,
embracing and adapting to new
technologies as they develop and grow.
Keen to work with all industries they
encourage engineers to throw their finishing
challenges at their R&D/process
development departments to come up with
a solution.
Kemet International Ltd
Tel: 01622 755287,
www.kemet.co.uk
Engis facing device maintains lapping plate flatness
Engis innovative FastLap Plate Facing
Device enables customers to maintain
lapping plate flatness by using a single point
turning tool, replacing the use of traditional
conditioning rings which require considerable operator skill in their accurate
positioning.
Plate flatness is, naturally, critical to the
productivity of lapping systems, as the
shape of the plate influences the geometry
of components being processed and
contributes not only to final surface finish,
but also to the lapping rates which can be
achieved. Increasing control over the
groove pattern (macro texture) and lands
(micro texture) of the plate surface ensures
greater consistency in removal rates and
surface finishes.
With Engis unique system, when plate
reconditioning becomes necessary, the
Plate Facing Device uses a diamond tool bit
to remove the top layer of the plate and
then machines in a groove pattern in a
second pass. When not in use, the device
retracts out of the work zone.
The Plate Facing Device, used in
combination with the pneumatic pressure
heads of Engis FastLap machine, can
consistently achieve accurate plate
conditioning, controlled surface geometry
and texture as well as fast, predictable stock
removal. This results in a lapping process
which is easier to manage, with more
repeatable results.
Engis (UK) Ltd. is part of the Engis
Corporation, a world-wide organisation,
established in 1938, which manufactures
and markets superabrasive finishing systems
for operations that demand precision
surface polishing and close tolerance
requirements. Engis provides products,
services and technological advances in
several key areas including: diamond flat
lapping/polishing, diamond and
CBN-plated tools, bore finishing tools and
machines, tool room products and
accessories and R&D and technical support.
At Engis, teams have extensive expertise
in the fundamental science of industrial
diamond and related superabrasives. This
knowledge, coupled with three process
development labs, permits the company to
develop leading edge superabrasive
products of superior quality such as
diamond slurries, engineered diamond
compound and electroplated grinding
wheels. Engineering staff also design and kit
out machine tool systems which go
hand-in-hand with the consumables. Engis is
unique in this capability.
Engis (UK) Ltd.
Tel.01491.411117,
www.engis.uk.com
53
GSF HONING 54-55_ES CONTENTS 4-5 19/08/2015 14:44 Page 54
Honing
Achieve flow tuning excellence
Proprietary MICROFLOW technology key to improved quality
New EXTRUDE HONE PROGRESS
Fuel system manufacturers seeking the best
fuel performance require flexible high-flow
grinding and high-flow test capabilities to
achieve finely tuned orifices in numerous
design variations.
To this end, Kennametal Precision Surface
Solutions® is announcing EXTRUDE HONE
MF PROGRESS™, the next generation of
flow tuning and flow measurement featuring
a flow targeting accuracy to +/-1 percent
aimed at orifices 100-350 ?m in parts less
than 30 mm in diameter and flow rates up to
5 L/min. “Additionally, MF PROGRESS
delivers another exclusive added value that
we call flexibility through modularity,” says
Sharath
Shankaregowda, Kennametal Precision
Surface Solutions MICROFLOW product
manager. “Customers benefit from a
self-contained modular construction for
each process (grinding, flush, flow testing,
etc.) and configurable hardware (manifolds,
frequency drives, etc.)”
Customers are saying adding such
advanced process options can help ensure
components meet ever more stringent
government regulations. From CAFÉ in
North America, EURO6 and expected
EURO7 in Europe, and PRC standards in
Asia, all focused on reducing CO2
emissions, EXTRUDE HONE MF PROGRESS
provides the perfect next step in upgraded
manufacturing and finishing. In addition, this
all takes place in a 25 percent reduced
machine footprint, 50 percent less tool wear
compared to previous-generation
equipment, and depending on the
application the output can be increased by
up to 100 percent.
affected).MICROFLOW processing involves
pressure drop, flow rate, geometry, and
fluidproperties; machine design and
dynamics; workpiece characteristics; media
properties and processing procedures.
Exclusive range of standard and customised
MICROFLOW media with specific properties
perform a step beyond classical hydro
erosive liquid.
EXTRUDE HONE MF PROGRESS is
available in various inside station layouts:
flow tuning, media reclaim, flush module,
test module, marking, thanks to the system’s
modular design and construction. It is easy
to configure and easy to fit into modern
production lines ready for robotic or other
handling system automation. The machine
also comes with expanded on-screen
maintenance capabilities and improved
filtration to further pump and valve life.
Reliability being at the heart of production
control requirements, EXTRUDE HONE MF
PROGRESS provides for online monitoring
and control of all relevant parameters. The
MICROFLOW explained
online feature is also beneficial in delivering
MICROFLOW is the real-time monitored
remote process demonstrations and
flow of abrasive media through small
gathering resulting data.
passages, such as fuel-injector spray holes. It
Celebrating more than 75 years as an
achieves specific, repeatable processing
industrial technology leader, Kennametal
results, including edge radius, micro-hole
Inc. delivers productivity to customers
size and surface finish. These changes to
seeking peak performance in demanding
small-hole geometry improve part function
environments. The company provides
and performance. Media flows in one
innovative wear-resistant products,
direction, similar to part operation.
application engineering and services backed
Increased flow is attributed to subtly
by advanced material science, serving
changing the geometry of the opening
customers in 60 countries across diverse
entrance (opening exit usually is not
sectors of aerospace, earthworks, energy,
industrial production, transportation and
infrastructure. With approximately 14,000
employees and nearly $3 billion in sales, the
company realises half of its revenue from
outside North America, and 40 percent
globally from innovations introduced in the
past five years. Recognised among the
"world's most ethical companies"
(Ethisphere); "outstanding corporate
innovator" (Product Development
Management Association); and "America's
safest companies" (EHS Today) with a focus
on 100 percent safety, Kennametal and its
foundation invest in technical education,
industrial technologies and material science
to deliver the promise of progress and
economic prosperity to people everywhere.
Kennametal UK Ltd
Tel: 01384 408060
www.kennametal.com
GSF HONING 54-55_ES CONTENTS 4-5 19/08/2015 14:45 Page 55
Honing
New all-electric tube hone is just the job
Automatic bore geometry
correction, overload protection
and size lock minimise operator
involvement. Tool stroke
position repeatability of 0.1
mm/0.004" is ideal for
close-tolerance work in blind
bores. Handles both rotary- and
push-feed tools.
Sunnen’s new HTR all-electric
job-shop tube hone combines
servo precision and
cycle-automation features with
constant spindle power and 0.1
mm (0.004") stroke
repeatability to efficiently hone
blind bores or correct tight
spots in a bore without operator intervention. Designed and
equipped to hone the wide variety of parts encountered in a job
shop, the machine handles bore I.D.'s up to 900 mm (35.41"). Its
modular design can be configured for stroke lengths from 2.5 m to
14 m (8' to 46.2').
Critical for job-shop versatility and productivity, the HTR's 12 kW
(16-hp) spindle motor, combined with a four-step gearbox,
produces a constant power band through the entire speed range of
10-470 rpm for fast metal removal. The standard servo rotary tool
feed can also function as a push-feed system with an optional drive
shaft that converts rotary to linear motion, allowing the machine to
handle the full range of Sunnen heavy-duty and two-stage tools.
Tool overload monitoring ensures optimal stock removal rates,
while protecting the tool and workpiece. Precision stroke position
and repeatability are ensured with a servo rack-and-pinion stroking
system. It drives the spindle carriage at speeds of 0.1 to 48 m/min
(4" to 157' per minute) on hardened and ground ways with a 10.2
kW (13.6 hp) servomotor, giving the machine plenty of power to
handle superabrasives for fast material removal.
The HTR's design eliminates all hydraulics to vastly reduce
maintenance, noise, leakage and heat, as well as system hysteresis
due to hydraulic oil heating up. The machine's 305-mm (12")
Windows® touchscreen PC control manages all machine functions,
including stroke speed/position, tool feed, spindle speed, stone
wear compensation and cutting pressure. Standard control features
include size lock, automatic bore geometry correction,
recommended setups, tool overload protection, spark out, spindle
jog and short stroke. The control can store up to 900 different part
programs and be configured for 13 languages.
The HTR's optional easy-to-setup fixturing is available in two
ranges for parts 40 to 600 mm (1.6" to 31.8"), and parts 50 to 810
mm (2" to 31.8"). Part weight capacity is 6,000 kg (13,230 lb) and
8,000 kg (17,640 lb) respectively. The fixtures ride on a linear
bearing system to allow easy positioning. Multiple coolant system
configurations are available to tailor for process requirements.
Other options include in-process gaging, tapered-bore capability,
various coolant systems, part rotation device, moving steady rests
for 2-m and 4-m models, two-stage honing, air conditioned
electrical cabinet and CE compliant safety system.
The HTR is the latest addition to the Sunnen HT tube hone series,
which includes nine models suited for every job.
Sunnen Products Ltd
Tel: 01442 393939
www.sunnen.com
55
GSF FILTRATION & LUBRICATION 56-57_ES CONTENTS 4-5 20/08/2015 15:28 Page 56
A clean performance across the entire process
As a leading provider of complete systems in the field of
cleaning and pre-treatment, Henkel presents sustainable
solutions for the entire metalworking value added chain.
Cooling lubricants have become an essential part of
metalworking. They reduce friction losses between the
tool and the workpiece, dissipate heat and guarantee
long tool lifetimes. However, what is important after
machining is not just that the parts are produced
error-free, but also that they are clean. MQL operations
produce residues on the parts and in the holes/threads
that are very difficult to clean, and they can also create
tramp-oil layers in the subsequent water miscible process
steps, which is also not helpful. For this purpose, Henkel
provides customers with an integrated product solution.
In this way, the water-miscible cooling lubricants from
the Bonderite L-MR range convince customers through
their ideal combination of high lubrication and rinsing
performance in one product. They are not only free of
bactericides, but also permit, due to their high hard water
stability, a long bath-life. Thanks to the excellent washing
and lubrication capabilities, particularly good rinsing
behaviour and therefore very low drag-out of the product
concentrate, Bonderite L-MR cooling lubricants are highly
economical. Due to the properties of the finely dispersed
Bonderite L-MR emulsion, tools, machines and processed
parts consistently remain clean during the production
process, have a long tool-lifetime and produce
outstanding good surface finishing. Downstream cleaning
steps are thus substantially more efficient.
Another innovation is that the pure concentrate of the innovative
2 in 1 cooling lubricant Bonderite L-MR 21972 can be used as a
minimum quantity lubricant. In this way, parts processed with the
product as a minimum quantity lubricant (MQL) can be cleaned
more easily.
Maximum cleanliness in the production process
The high-quality, aqueous, generally neutral or slightly alkaline,
cleaning fluids in the Bonderite C-NE and C-AK product series have
been specially adapted to the cooling lubricants. They ensure
efficient process, parts and maintenance cleaning, even at low
temperatures. Biostable formulas ensure that the biological, easily
degradable wetting agents do not lose their effective properties,
even when used at low temperatures. This means that components
of any material can be optimally prepared for further production
processes such as bonding, coating or painting. A selection of
special cleaning agents are available for sensitive light metal alloys,
which, in addition to the removal of the processing agent, also
activate the surface for the subsequent processes. Under the
designation Bonderite C-AD, additives which are essential for the
optimisation of the cleaning process complete the range of
available products.
An overview of the entire process
In order that the metal pre-treatment process takes place quickly,
error-free and effectively, Henkel has developed a complete,
programmable control system called Lineguard. It provides the
perfect support for maintenance of the process parameters.
Aligned to the Bonderite L-MR cooling lubricants and the various
cleaning agent types in the Bonderite C-NE and C-AK product
series, this modular system gives excellent results in quality,
efficiency and process reliability.
Due to this integrated production solution, Henkel represents a
strong system partner for all metalworking companies which place
great value on safe, clean and effective overall processes.
Henkel operates worldwide with leading brands and technologies
in three business units: Laundry & Home Care, Beauty Care and
Adhesive Technologies. Founded in 1876, Henkel holds globally
leading market positions, both in the consumer and in the industrial
businesses, with well-known brands such as Persil, Schwarzkopf and
Loctite. Henkel employs almost 50,000 people and reported sales
of 16.4 billion euros and adjusted operating profit of 2.6 billion
euros in fiscal 2014. Henkel's preferred shares are listed in the
German stock index DAX.
Looking back on nearly 140 years of success, Henkel’s vision is to
become a global leader in brands and technologies. Henkel holds
strong market positions both in the consumer and industrial sector
today and is well known for brands such as Persil, Schwarzkopf and
Loctite.
Henkel Adhesive Technologies
Tel: 0049 2117975672
www.henkel.com
GSF FILTRATION & LUBRICATION 56-57_ES CONTENTS 4-5 21/08/2015 11:06 Page 57
New emulsion mist collectors
Offering high efficiency, low operating costs and 24/7 performance
A new line of Handte EM Profi emulsion mist
collectors from Camfil Air Pollution Control
(APC) offers the highest available collection
efficiencies, plus the ability to run "24/7" for
reduced maintenance, service ease and
lower operating costs. The units can handle
the heaviest loads encountered in industry
to clean up contaminants generated during
milling, drilling, tapping, turning, grinding
and other machining processes that utilise
emulsion mist coolants.
The EM Profi collector uses long-life
coarse and fine filter demisters followed by a
final-stage HEPA filter with combined
efficiencies of 99.9 percent on particles of
0.3 micron and larger. This is much higher
than capture efficiencies achieved with
fiberglass V-bag filters, which lose efficiency
as media becomes saturated. A patented
automatic sprayer counteracts emulsion
clumping, ensuring that the separators can
operate "24/7" almost maintenance-free.
During routine annual maintenance, the
unit is easily serviced from the ground by a
single technician, eliminating extra
manpower and lift equipment. Service life
between change-outs is up to six years for
demister filters and two years for HEPA
filters. Large maintenance doors and
quick-clamping elements facilitate fast,
tool-less filter replacement. Due to these
features, Handte EM Profi collectors achieve
substantial savings through reduced
downtime, longer change-out cycles and
increased productivity and reliability.
Sturdy modular construction is another
benefit. Basic modules can handle air
volumes from 1,700-8,000 cfm, with a wide
range of accessories and configurations for
optimum flexibility. Modules can be
combined to accommodate larger airflow
requirements. Small space-saving models
are also offered for low airflow applications
of 500-1,400 cfm.
Last year, U.S based Camfil APC acquired
Handte, the leading German provider of
mist collectors, wet scrubbers and other
environmental products, with over 120 years
of experience and worldwide automaker
references. Handte's offerings complement
the equipment offered by Camfil APC, a
leading global manufacturer of dust and
fume collection systems and part of Camfil,
the world's largest air filtration company.
Camfil Ltd
Tel: 01706 238000
Email: uk.filtersales@camfil.com
www.camfil.co.uk
Competitive market?
Then EVERY team member has to perform
Oelheld Metalw
Metalworking
orking Fluids - P
Performance
erformance enhancing capabilities
57
GSF SURFACE MEASUREMENT 58-59_ES CONTENTS 4-5 19/08/2015 14:49 Page 58
Surface Measurement
Shorter wavelength leads to very stable signals
2D/3D blue laser sensors now enable high precision profile measurements on shiny, highly
polished surfaces
Designed specifically for shiny, highly
polished surfaces, as well as transparent
materials such as plastics, glass, optical
components and film/substrates, a new
range of 2D/3D blue laser profile sensors
(laser line scanners) are now available from
precision sensor manufacturer MicroEpsilon. The sensors are designed for high
precision profile and dimensional
measurements on a variety of materials
where red laser diode sensors do not
perform well.
The scanCONTROL BL series of blue laser
profile sensors operate using blue (violet)
laser technology rather than red. The special
characteristics of the blue wavelength laser
light make the scanners suitable for
measuring against shiny, highly polished
metals, as well as red-hot glowing metals
and silicon-based materials. All the controls
and electronics are integrated in an
extremely lightweight, compact sensor
design, enabling the scanners to be installed
in locations where there may be little space
available for mounting. The scanCONTROL
BL series offers a range of interfaces and
flexible installation options.
Chris Jones, managing director of
Micro-Epsilon UK, comments: “Unlike a red
laser, the blue laser operates at a shorter
wavelength of 405 nm, which is far from the
red part of the visible spectrum. This means
it is unaffected by the emitted infrared
radiation from hot or glowing targets, due
to implementing a simple optical filter,
which ensures very stable signals.
Additionally, when measuring on shiny
surfaces or highly polished metals, where
red lasers tend to suffer from higher noise,
the high precision optics and shorter
wavelength of the scanCONTROL blue laser
profile sensor performs extremely well,
providing much lower noise levels, typically
by a factor of two or more compared to red
laser sensors.”
The scanCONTROL BL series is available
with measuring ranges up to 265 mm in the
z-axis (distance/profile height) and up to
143.5 mm in the x-axis (laser line
length/profile width). Output of
measurement data is via Ethernet (UDP,
Modbus) or serial interface (RS422,
Modbus). In addition, analogue signals or
digital switching signals can be output
directly to a PLC. Profile frequencies of up to
2,000 Hz and a measuring rate of up to
2,560,000 points/sec enable the sensors to
be used in high speed applications.
Easy integration and connection to PLCs
All scanCONTROL series sensors (blue
and red) are equipped with a Gigabit
Ethernet interface for transferring profile
data, as well as a multi-purpose connector
for RS422, Digital In (HTL/TTL), power
supply and synchronisation. The sensors
support Power-over-Ethernet (PoE), which
reduces the need for an additional power
cable.
Micro-Epsilon has also released a new
LabVIEW driver for scanCONTROL series
sensors. The LabVIEW instrument driver 2.4,
available as a 32-bit or 64-bit version, is a
convenient interface between sensor and
LabVIEW test and measurement
environments. As well as updating existing
modules, further ones have been added that
enable faster, easier set up and
configuration of scanCONTROL sensors. In
addition, the driver includes several
example programs that illustrate the
ease-of-use of these modules.
Chris Jones states: “A major selling point
for the scanCONTROL series is how easy the
sensors are to set up and configure for
applications. The software programme
supplied as standard with the scanner
enables the user to configure the device to a
unique IP address. A Modbus protocol,
which is supported via Ethernet and the
RS422 interface, also enables direct
connection between the sensor and a PLC
and other control systems. We also supply a
software development kit and
comprehensive command library as
standard with the sensor. This provides the
user with a communications platform that
offers maximum flexibility and performance
via direct integration with most common
programming languages.”
Multi-scanner applications
All scanCONTROL series sensors (blue and
red) are designed with a high-speed
external profile trigger input. In this way, the
data rate can be optimised and measurements can be triggered at a specific event in
GSF SURFACE MEASUREMENT 58-59_ES CONTENTS 4-5 26/08/2015 09:02 Page 59
Surface Measurement
time. This is particularly beneficial when
several systems are operating
synchronously. Together with its compact
design and simple wiring, scanCONTROL is
ideally suited to multi-scanner applications.
As with all scanCONTROL series sensors
(including red laser line scanners) from
Micro-Epsilon, the scanCONTROL BL series
is available in three classes: COMPACT,
HIGHSPEED and SMART.
COMPACT scanCONTROL 2900/BL
sensors are suitable for both static and
dynamic measurement tasks. These
compact sensors offer a profile frequency of
up to 200Hz and act as profile data
providers.
HIGHSPEED scanCONTROL 2950/BL
sensors offer everything for advanced
high-speed and 3D profile applications. A
profile frequency of up to 2,000Hz can be
acquired using these sensors, which also
serve as pure profile data providers.
SMART scanCONTROL 2910/BL series
offers a ‘plug & play’ solution with
integrated controller that is suitable for
simple-to-complex measurement tasks. The
design of the sensor is identical to the
COMPACT and HIGHSPEED classes. The
scanner evaluates recorded profiles and
outputs the measurement values.
Application Finder
The new web-based ‘Application Finder’
intelligent software tool allows users to
search for the appropriate laser profile
sensor from Micro-Epsilon’s comprehensive
scanCONTROL series by considering a
number of application-related search
criteria. On accessing the Application Finder
(http://www.micro-epsilon.co.uk/laser-scan
ner/applications/index.html) users are
presented with three main search criteria: by
Material, by Measurement or by Industry.
Within each of these sections, users can
further refine their searches by clicking on a
variety of filters.
Micro-Epsilon is a major global
manufacturer of sensors, headquartered in
Germany. The company’s range of
displacement sensors measure everything
from to distance, position, vibration,
dimensions and thickness, using both
contact and non-contact measurement
techniques. These techniques include 1D,
2D and even 3D laser-optical sensors and
systems, eddy-current, capacitive, LVDT &
inductive, potentiometric and draw-wire
principles. In addition, Micro Epsilon has
developed its own range of non-contact
infrared temperature sensors that can
measure virtually any target temperature
from -40 to +3,300°C. The company also
manufactures a comprehensive range of
colour recognition sensors.
For more information on the scanCONTROL
BL series, contact:
Micro-Epsilon UK Ltd
Tel: 0151 355 6070
www.micro-epsilon.co.uk
Form and roughness.
In one system.
By Alicona.
That's metrology!
InfiniteFocus is based on the technology of Focus-Variation.
Users measure form and roughness in the µm and sub- µm area.
With the new generation of InfiniteFocus, Alicona supplies
the fastest optical sensor in its class.
Optical 3D surface measureme n t
59
GSF FTR TOOL & PROFILE GRINDING 60-69_ES CONTENTS 4-5 20/08/2015 15:29 Page 60
Feature - TOOL & PROFILE GRINDING
Vollmer develops new side grinding machine
With innovations rolling off the production
line at Vollmer, the latest new addition to its
extensive product line-up is the new
CHF840 and CHF1300 machines for
grinding the tooth sides of carbide-tipped
circular saw blades.
This new generation of TCT saw blade
sharpening technology uses five
CNC-controlled axes to machine the tooth
sides of carbide-tipped circular saw blades
with precision, productivity levels and
capabilities beyond anything available from
alternate vendors. All commonly used
angles are ground in only one cycle, even on
saws with group toothing. This makes
processing of complex blade geometries a
simplistic process for the end user.
The new CHF840 has been introduced to
deliver a solution for the processing of
circular saws from 80 to 840 mm diameter
whilst the larger CHF1300 is capable of
finishing saws from 80 to 1300 mm
diameter. Offering versatility that leaves
nothing to be desired, the new CHF
machines provide oscillation grinding as
standard to remove maximum material rates
in a single cycle. The 5-axis kinematics
delivers maximum flexibility and optimal
movement coordination for short grinding
times and to reduce non-production times
with an adjustable cam for the ideal tooth
positioning.
All this makes the new CHF series suitable
for side grinding saw blades for the saw mill
industry, woodworking, plastic and
aluminium processing and also the metal
cutting industries. The machines from the
CHF series adjust the angles without
assistance and even the hook angles and
tooth pitch are automatically detected. To
further simplify processing for the end user,
the CHF makes it possible to machine
convex tooth flanks and it has an optional
tooth pitch up to 180 mm, which is credit to
a second feed pawl for greater flexibility.
Additionally, saw changes are possible
without adjusting the mounting carriage, so
there is no need to set a blade up a second
time.
The new CHF840 and CHF1300
incorporate a multi-functional hand-wheel
that makes operation faster and more
simplistic. The axes can be selected and
controlled by only one module to avoid the
possibility of incorrect operation. This
hand-wheel can also be used as a
potentiometer in order to carry out speed
adjustments in automatic mode. With
operator convenience built into every
aspect of the new CHF line, there is no need
for manual adjustment of radial and
tangential clearance angles. This means that
operator errors are eliminated and values
can be entered as angles or absolute values.
With an intuitive Windows based CNC
control, the multi-function hand-wheel and
the storage of up to 4000 programs that are
accessed via a 10-inch LCD colour display,
Vollmer has truly covered every angle from
the perspective of user friendliness.
"For our new sharpening machines, we
provide numerous services such as
consultation and training, as well as
financing options. We also support our
customers throughout the entire service life
of the machines, with services for
maintenance and corrective repair, for which
we operate twelve of our own Sales and
Services branches worldwide," says Jürgen
Hauger, head of the Sales Division at the
Vollmer Group.
Vollmer UK Ltd
Tel: 0115 949 1040
www.vollmer-group.com
Sharp and precise
Hunt down cost, time and resource savings with the Darex
XT3000 Xpandable sharpener system from 1st MTA
• Faster and more accurate regrinding of drills
up to 21 mm diameter
• Consistent results, regardless of operator
skill levels
• Precise control of drill set up,
sharpening loads and cycle times
• Faster payback and ongoing savings
• Resharpening to international
aerospace standards
• Modules to suit all types of drilling operation.
Sharpen up your operations
the UK’s leading machining
accessory supplier.
St
Email: [email protected] Freephone: 0800 783 0510
Fax: 0800 783 0517
www.1mta.com
MTA
MACHINE TOOL ACCESSORIES
with the Darex XT3000 from 1st MTA,
TOOL & PROFILE GRINDING
Wear parts specialist invests in Rollomatic
Situated in Hartlebury, Worcestershire,
Hartmetall UK was established 12 years ago
as a distributor of tungsten carbide wear
parts. Two years ago it moved to new
premises in order to expand and offer a
blank preparation service to manufacturers
of tungsten carbide rotary tools across the
UK.
Mark Turton began his involvement with
tungsten carbide wear parts 20 years ago at
Artisan Sintered Products in Manchester,
eventually moving to Bohlerit where he was
introduced to rod products and new
methods of manufacturing. Always looking
for an opportunity to set up on his own he
moved into consultancy work and was
introduced to Hartmetall AG of Switzerland
whose products he successfully distributed
for ten years, until they were taken over and
rod production was no longer an important
part of their business. Fortunately Extramet,
with whom he had already had some
dealings, was happy to appoint him as its UK
distributor and together they have gone
from strength to strength. Son Matt joined
the company seven years ago after finishing
his apprenticeship as a dental technician and
like his father was looking for a new
opportunity.
Hartmetall UK provides tungsten carbide
wear parts across the whole spectrum of
manufacturing with an emphasis on rod
products and a particular interest in
aerospace and medical tools. Having
comprehensive stocks held in the UK
ensures customer satisfaction, in-stock items
are shipped for next day delivery and stock
is replenished on a weekly basis, ensuring
that a high level of service is maintained.
Mark Turton says: “When Matt joined me
it soon became evident that we needed to
grow the business and we soon decided that
blank preparation was the way forward for
us. We spent over a year studying what
other European distributors were doing and
more importantly how they were doing it
successfully.”
In order to provide a high level of service,
Hartmetall UK invested in a CNC slitting
machine (soon to be two) a dedicated
chamfer machine and eventually a
Rollomatic NP5 and associated ancillary
equipment.
“We have become a capacity multiplier.
By having us prepare blanks, it allows our
customers to reduce preparation time and
grinding time allowing them to produce
more tools with their existing machines.”
One particular customer Hartmetall UK
has worked very closely with since
establishing this service has seen a 20
percent reduction in material cost and a
substantial increase in profit (he’s not saying
how much) by using his machines more
efficiently.
“Of course we would like to do what we
do even better and we have a plans for
expansion and to offer new services to a higher
level, but self-financing relies on market
conditions. By the end of 2015 we will have
invested £500,000 in machinery plus £30,000 in
infrastructure,” adds Mark Turton.
“Having this facility in-house allows for
preparation of blanks to customers specification
at short notice, producing from one off to a
thousand off steps, tapers, ball noses, back
tapers is all in a day’s work.
“What we will never do is produce cutting
tools. We strictly make wear parts,” concludes
Mark Turton.
The Rollomatic ShapeSmart NP5 is a precision
cylindrical grinding machine with five CNC axes
and a grinding capacity up to Ø25.0mm. The
peel grinding method is well proven by
Rollomatic providing extreme/length diameter
ratio as well as complex profiles. Furthermore the
rigid design of this machine with its powerful 8.5 kW spindles motor
and a wheel diameter of 250 mm, allows for the grinding of parts
requiring high stock removal. The ShapeSmart NP5 has a fast and
reliable 3-axis integrated tool loader with capacity up to 1,000
pieces.
The ShapeSmart NP5 can also be fitted with end probing for
length referencing of blanks before grinding. This option is
particularly suited to grind the neck and taper on milling tools and
form cutters that have already been flute ground.
Hartmetall UK
Tel: 01299 253882
www.hartmetalluk.com
Rollomatic SA
UK Contact:
Alec Dummer
Tel: 07949 120431
It’s here!
The tool grinder
you’ve been waiting for
Visit us at EMO
Hall 14, Stand
Stand N10
www.anca.com
www.anca.com
63
ANCA grinder gives Prima Tooling the
cutting edge
Formed in 1979 by three partners, each with
extensive experience in the design and
manufacture of high quality Tungsten
Carbide (TCT) and High Speed Steel (HSS)
tools, Prima Tooling specialises in the
production of highly efficient tooling for the
woodworking Industry.
Prima’s comprehensive tool range
includes TCT dowel drills, router cutters,
PCD profile router cutters, profile spindle
tooling and saws. In addition to providing a
wide range of standard TCT and HSS also
Prima Tooling also design and manufacture
one-off, cost-effective specials that are
tipped with Polycrystalline Diamond (PCD).
To help accommodate the growing
demand for the company’s products, in
1987 Prima relocated from the company’s
original Romford, Essex-based factory to a
new, larger facility in Brentwood. Reflecting
the continued growth of the business, since
the relocation Prima’s Brentwood facility has
doubled in size.
Paul Wiggins, Prima Tooling director
explains: “Our impressive success in the
manufacture and sales of tooling has been
brought about by ensuring that each of our
products is designed to deliver maximum
efficiency and long life usage to our
customers. We don't just manufacture and
sell tools, we offer expert advice on what is
the right tool for a particular application.
Also, if potential customers have a problem,
we'll help them to solve it.”
To keep pace with its growing output,
Prima Tools’ management recently
researched the available tool and cutter
grinders that would enable the manufacture
of high volumes of premium quality tooling.
Paul Wiggins continues: “Even though we
were aware of the excellent reputation of
ANCA tool and cutter grinders, we did
consider a couple of other brands.
Although, after a successful demonstration,
we were certain that ANCA’s advanced MX7
machine would give us with the kind of
flexibility we need for the efficient
production of high quality tools and would
also help in the manufacture of our PCD
tooling.
“The very adaptable nature of the MX7
was a key factor in our decision to buy the
grinder and its level of flexibility provides us
with a real competitive advantage. Features
such as a ten-second wheel and tool
changeover time means that, as well as
undertaking high-yield, relatively long
production runs, we are now also able to
make quick changeovers to accommodate
our smaller batch sizes. To make the MX7
even more productive and to enable us to
keep up with increasing demand, we
purchased our new grinder fitted with an
ANCA FastLoad-MX, tool loading system.
“The excellent service and training we
have received from ANCA UK, in addition to
the ease of use of ANCA’s system, has
allowed our operators to quickly become
proficient in the MX7’s operation and to
produce the required quality and quantity of
tools. We consider the ANCA MX7 and
FastLoad-MX combination to be
‘future-proof’. Together they have the
ability not only to handle our current
production requirements, we are also
confident that the ANCA grinder and loader
combination will be able to cope with all of
the demands placed on them in the
foreseeable future.”
The ANCA MX7 is a versatile CNC
grinding machine that was designed to
meet the challenging demands of high
volume production grinding. Described by
ANCA as a next-generation machine tool,
the state-of-the-art grinder incorporates a
range of advanced features that render it,
not only ideal for today’s grinding tasks, but
also capable of adapting to the need of an
ever evolving marketplace.
The robust, rigid design of the MX7, along
with its range of unique features has
resulted in the creation of a flexible, highly
productivity machine package that is
capable of handling high-precision work and
varied batch size production with minimum
setup time.
Driven by global tool manufacturers’
demands for precision grinding at lower unit
costs, the highly efficient MX7 focuses on
the area of greatest demand and is
optimised to grind tools of up to 25 mm
diameter.
Designed specifically to meet the
demanding needs of tool production
facilities that seek maximum output while
remaining adaptable to customers’ needs,
the flexible MX7 delivers outstanding
spindle performance across the entire
spindle working range. A permanent
magnet spindle provides high torque at
lower rpm, this is particularly suited for
carbide grinding.
With six HSK wheel packs, the MX7’s
efficient wheel pack changer increases
machine productivity and flexibility by
enabling a 10-second wheel change time. In
addition, the spindle returns to the same
index position when changing arbors,
The mounting of a wheel dresser roll onto
the MX7’s high-speed headstock allows
in-cycle dressing of grinding wheels – a must
for any unmanned high-performance
operation. Customised wheel shapes can
also be imported in the form of DXF files and
automatically dressed and used in any
grinding cycle.
The ANCA FastLoad-MX system, as used
alongside Prima’s MX7 grinder, is a reliable,
cost-effective loader. As an ingenious
solution for automatic tool loading, the
FastLoad-MX is has been designed to
increase the productivity and profitability of
the ANCA MX range of machines by
increasing output and by enabling the MX7
to run unmanned for extended periods.
FastLoad-MX uses the machine’s existing
axes for movement and makes automation a
feasible, affordable option for companies
that cannot justify the investment in more
complex systems. The loader’s movements
are kept simple, resulting in an economical
solution for customers producing or
regrinding tools in medium to small batch
sizes.
Creating Tool Performance
ANCA (UK) Ltd
Tel: 024 7644 7000
www.anca.com
A member of the UNITED GRINDING Group
SYSTEM AND SOLUTION PROVIDER
FOR TOOL MACHINING
Insert production or manufacturing
and resharpening of rotary tools, HSS,
CBN or super-hard materials, grinding,
EDM, laser or measuring – WALTER
and EWAG offer all technologies from
a single source! Together with software and services we provide the best
fit for your requirements – you can
feel secure with the competence and
precision of the experienced partner!
Creating Tool Performance
www.walter-machines.com · www.ewag.com
65
OSG UK looks to Walter to underpin growth
A battery of Walter Helitronic tool grinders
and Walter Helicheck tool measuring
machines are playing a key role in the
continued success and growth of tooling
specialist, OSG UK.
The Basildon (Essex) based company is
using its four Helitronics, including the more
recently installed Helitronic Vision tool
grinder and Helicheck Pro tool inspection
machine, to maintain its leading reputation
for tool regrinds, primarily of own-brand
tools, to a wide customer base throughout
the UK, Ireland and Europe.
Importantly too, the Walter tool
regrinding and measuring technology is also
helping to ensure OSG’s superlative levels
of back-up for its market-leading range of
own-brand tooling, in particular its
high-precision carbide tools for the
aerospace industry.
Based on OSG’s worldwide technical
relationship with Walter, the Helitronic
Vision tool grinder with robot loader and
Helicheck Pro tool measuring machine are
the latest additions (installed in 2012) to the
UK company’s portfolio and these form an
integrated cell.
The multi-axis Helitronic Vision features a
mineral cast machine bed and gantry
design, and provides a massive 30 kW of
spindle power. Coupled with sophisticated
drive technology plus synchronous linear
motors for its linear axes and synchronous
torque motors for the rotational axes, the
machine generates unrivalled grinding times
and superior surface finishes.
The machine’s Fanuc LR Mate 200iC/5L
robot loader can handle workpieces 250 mm
OSG UK's Walter Helitronic Vision also has a robot loader and four-pallet system
long and weighing 1.5 kgs and it operates in
conjunction with a four-pallet system that
provides a storage capability of up to 1,500
workpieces. Capacity can be optionally
increased to 3,500 workpieces with eight
pallets.
This is coupled with the 4-axis Helicheck
Pro measuring machine which has a repeatability of +/- one micron and a measuring
resolution of 0.25 micron. The machine can
accommodate tools measuring 200 mm
diameter by 300 mm long.
The Vision-Pro cell is used mainly for
processing small batches of specials and is
linked with the Helicheck for immediate
feedback of measurement data and, where
appropriate, real-time corrective action.
Supplied by Walter Ewag UK, part of the
United Grinding group, these machines sit
alongside a Helitronic Power Regrinder and
two Helitronic Powers, all fitted with
cylindrical pallet loaders able to
accommodate 280 tools, depending on
diameter.
“The loaders are a big asset,” says
production manager, Mick Brown. “We can
put several different batches of parts on the loader. All we do is
instruct the machine where each batch is located and the rest is
automatic. It means we can run the machine overnight and
therefore make savings.”
Fully utilising the robot/loaders, the Walter machines constantly
run unmanned and through the night producing batches of up to
30-off. Around 5,000 tools are reground every month.
“Lots of people can easily go wrong with regrinding, where
repeatability is everything,” continues Mick Brown. “It’s therefore
key that the right machining technology is operated by suitably
skilled operators to ensure that the reground tool matches the
customers’ demands exactly. Our strength as OSG is that we have
access to all our original geometries, which means when we regrind
tools we can get back to 100 percent tool life. At least that is always
our aim.
“This is where OSG UK continually scores,” he adds. “Because we
successfully combine high-technology machining on the Helitronics
with our in-house tooling expertise, we are confident that in many
cases our regrinds are even better than many other alternative
originals.”
OSG UK’s continual progression ( it currently employees 45
people, including two apprentices) also depends heavily on its
ability to immediately supply a comprehensive range of
cost-effective tooling from an extensive in-house stock.
Indeed, orders for standard tools taken up to 5 pm are
despatched on the same day. The whole operation is underpinned
by a sophisticated ERP system.
The company has also recently acquired PN Tools of Atherstone,
Warwickshire, an established manufacturer and regrinder of carbide
and HSS tools.
The renamed OSG PN Tools is already investing in its future with
Walter Ewag UK via a Walter Helitronic Mini Automation multi-axis
tool grinder being ordered at the behest of Tony Cooper, OSG UK’s
sales director and a director of OSG PN Tools.
“To meet increasing demand, the new Helitronic will reinforce the
quality of PN Tools’ production to customers in industry sectors that
include aerospace and automotive,” he says.
WALTER EWAG UK Ltd
Tel: 01926 485047
www.walter-machines.com
EFFICIENCY SQUARED.
THE NEW VOLLMER
VGRIND 160
The one-of-a-kind, multi-level machining of the
Vgrind 160 uses two vertically arranged grinding spindles to provide the highest standard of
efficiency for the production of solid carbide
tools. Further highlights include its sophisticated wall design for optimum accessibility and
clear viewing, flexible automation solutions
and tried and tested operating software. Are
you ready for precision at its best?
www.vgrind.com
VOLLMER UK LTD. // Orchard Park Ind. Estate // Town Street
Sandiacre // Nottingham NG10 5BP
[email protected] // Phone: +44 115 9491040
67
Moving forward with a new management team
ISOG Technology restructures its upper management
In order to help move the company forward
on its new course, grinding machine
manufacturer ISOG Technology GmbH &
Co. KG in Weilheim, Upper Bavaria is
restructuring its management team. A new
five-member executive board under the
leadership of CEO Martin Sackmann intends
to get the traditional company ready for the
future.
The Weilheim company has had two
directors since the end of 2013, who helped
the company back on its feet after some
hard times: Martin Sackmann, who was
responsible for sales and all business
aspects, and Thomas Seyßler who was in
charge of all technology matters. Thomas
Seyßler's contract has ended and he has left
the company.
"We need to develop some new
momentum for the realignment which we
started two years ago", explains Martin
Sackmann. "This is why we are now putting a
team of experts in place." Together with the
new management team, Martin Sackmann is
planning to make the strengthened
company even more modern, active and
responsive in the future.
The new management team will include
both familiar and new faces. Dr. Georg
Mörsch will join ISOG on August 1st. The
50-year-old with a PhD in physics will lead
the technology department in the role of
CTO. His responsibilities will include
development, manufacturing and quality
management. The longstanding HR
manager Johanna Jarosch (49) will
contribute her expertise as CHRO. Supply
chain expert Bernd Weisgerber has been
with ISOG since January. As COO of the
new team, the 42-year-old with a Master of
Business and Engineering is driving
improvements to business operations. He is
looking after supply chain management and
logistics, as well as managing the
manufacturing orders and assembly. All
financial topics will continue to be managed
by Richard Blau (52), who joined ISOG one
year ago as interim manager in order to
restructure the finance department. He is on
the management team in the role of CFO.
CEO Martin Sackmann (50) continues to
be in charge of sales, project management,
service and application technology.
Together with the technology specialist
Mörsch, he is planning to further the
targeted expansion of the service and
application technology departments. ISOG
is planning to grow in these two areas in
particular:.
"The customer is always at the centre of
everything we do", that is and will continue
to be Martin Sackmann's motto.
"We work for our customers, and we work
with our customers. Because we can only
benefit from ensuring that the dialogue with
our partners is as direct and friendly as possible. Nobody knows the
ISOG machines as well as someone who works with them every day.
We want to acquire and incorporate their knowledge and their
experiences."
The changes to the management structure will be reflected
throughout ISOG and the new drive is expected to be felt even in
everyday operations. Every member of the management team is
assuming responsibility for their own area of the company and will
be working closely with their respective teams. Weekly coordination
meetings will ensure that ideas are implemented quickly and that
any problems are tackled and solved in a targeted manner.
"The industry has already noticed that we are stepping it up",
states Martin Sackmann. "Soon it will become clear that we are
stepping it up even more, something I'm looking forward to."
FOR
PERFECT
TOOLS WZS 70
FOR VERSATILE
APPLICATION
MID RANGE PERFORMANCE
SMALL BATCH SIZES
ALL GEOMETRIES
A farewell to the last ten S11 machines
It is time to say goodbye to the S11. It will close a chapter in ISOG
Technology's records. For 38 years, the company has been building
the legendary S11 a manual grinding machine that used to be a
leader in the market. During this period, about 2,500 of them have
been sold all over the globe, most of them still in use.
No matter whether producing special tools or single pieces, the
S11 is simply ideal for specific tasks and will remain so for good. This
is why there will be a last opportunity for those who know their
onions. ISOG has decided to build another ten S11 models as a
"final edition" and whoever is quick enough may have a chance to
grab one of them.
UK Sales Agent:
Tel: 01908 675434
www.nlmtc.co.uk
TOOL GRINDING MACHINE WZS 70
THE ENTIRE PROCESS CHAIN – FROM THE BLANK TO THE PRECISION TOOL:
END PROFILE GRINDING
CONTOUR / CYLINDRICAL GRINDING
TOOL GRINDING
WWW.WERKZEUGSCHLEIFEN.DE
69
GSF COMPONENT CLEANING 70-75_ES CONTENTS 4-5 19/08/2015 14:58 Page 70
Component Cleaning
Meet high cleanliness requirements efficiently using solvents
In many applications, the cleaning of
components is a production step that is
critical to quality and an optimal solution to
this problem requires a suitable product and
expertise. When removing non-polar and
partly as well polar impurities, solvents such
as chlorinated hydrocarbons and modified
alcohols are able to achieve high cleanliness
requirements in a reliable, efficient and
sustainable manner. When it comes to
choosing and using the right solvent,
SAFECHEM offers not only a complete
product portfolio for solvent cleaning, but
also comprehensive services, from
consulting, laboratory services, service
elements and training to an innovative
chemical leasing model.
“Equal solves equal”
According to this principle, solvents such as
chlorinated hydrocarbons and modified
alcohols are the preferred choice for
non-polar impurities such as machining oils,
greases, waxes and resins. They are
characterised by good material
compatibility, so that parts made of virtually
any metal can thus be cleaned. At the same
time, cleaning is carried out without
corrosion, oxidation, chemical burning,
matting or other alteration of the surface.
But which solvent is best suited for a
particular application? To answer this
important question, SAFECHEM Europe
GmbH, a subsidiary of The Dow Chemical
Company, considers the entire production
environment on the one hand because
substances carried into the solvent bath play
a crucial role, while on the other hand, the
CHEMAWARE laboratory services including
solvent analyses and oil compatibility tests
support the decision process and the
optimal combination of the service
elements.
Cleaning using chlorinated hydrocarbons
As a result, DOWPER MC is being used at
Gebrüder Kunze GmbH, an important
German automotive supplier. This solvent is
a virgin, specially stabilised
perchloroethylene which has been
developed for difficult cleaning tasks and for
degreasing metal parts that have a high
degree of soiling. The company produces
millions of net shape parts made of steel,
stainless steel and aluminium; during their
cleaning and degreasing process, a lot of oil
is carried into the solvent bath, including
The cleaning of complex sandwich and
monolithic composite structures prior to bonding
is critical to the quality at Aircelle Ltd., a member
of the SAFRAN Group. Therefore, DOWPER MC
perchloroethylene is used.
chlorinated oils. Due to the distillation
process, acids can be formed over time,
which may result in corrosion of the cleaning
equipment and a reduced solvent lifetime.
To prevent this, SAFECHEM conducted oil
compatibility tests with various stabilisers.
The stabilisers used are thus optimally
aligned to the oil, so that the solvent can
achieve a lifetime of several years. DOWPER
MC is also certified for many cleaning
applications in the aerospace industry.
Aircelle Ltd, a member of the SAFRAN
Group, uses this solvent for example to
clean complex sandwich and monolithic
composite structures prior to bonding when
manufacturing engine nacelles. The
company decided for DOWPER MC based
on extensive cleaning tests.
chlorinated hydrocarbons, hydrocarbons as
well as aqueous cleaners. This includes, for
example, the cleaning of complex heat
exchanger components at HS Marston
Aerospace Ltd, a UTC Aerospace Systems
company. HS Marston produces innovative
heat exchangers and fluid management
systems, which are used in commercial and
military aircraft as well as in motorsport and
in the electronics industry. The decision for
DOWCLENE 1601 was based on extensive
cleaning tests and laboratory analyses. Due
to its special formulation the solvent can
reliably and reproducibly remove both,
non-polar impurities such as oils and greases
as well as polar substances such as cooling
emulsions and solids like salts and abrasion
particles. In addition to the approval for
cleaning applications in the aerospace
industry by well-known companies, parts
cleaned with DOWCLENE 1601 have been
certified by the Fraunhofer Institute for
Interfacial Engineering and Biotechnology
(IGB) to be biocompatible for medical
applications in accordance with DIN ISO
10993-5, 2009.
Modified alcohols – a versatile alternative
With the distillable solvents from the
DOWCLENE 16 series SAFECHEM and Dow
have developed modified alcohols which
have lipophilic and hydrophilic properties.
They are used as an alternative to
When cleaning parts used in the medical industry,
DOWCLENE 1601 achieves biocompatible
surfaces in accordance with DIN ISO 10993-5,
2009
DOWCLENE 1601 and the COMPLEASE Chemical
Leasing model are the optimal solution for the
cleaning of components for manufacturers of
innovative heat exchangers, such as HS Marston
Aerospace Ltd., a subsidiary of UTC Aerospace
Systems
DOWCLENE 1611 is a solvent based on
modified alcohols with stronger hydrophilic
properties. Applications include for example
the cleaning of lapped and sintered parts,
the removal of adhering polishing pastes,
abrasion, and the cleaning of aqueous
cooling and lubricating emulsions. The
DOWCLENE 1621 cleaning medium was
developed for flood and vapour degreasing
in combined solvent/aqueous cleaning
processes. It is used, for example, by
Germany’s leading contract hardening shop
Schwäbische Härterei Ulm GmbH (SHU) in a
hybrid cleaning system. SHU often misses
information about the type and amount of
Component Cleaning
The DOWCLENE 1621 cleaning liquid was
developed for flood and vapour degreasing in
combined solvent/aqueous cleaning processes
and has been used successfully in Germany's
largest contract hardening shop, Schwäbische
Härtetechnik Ulm GmbH (SHU)
Virtually emission-free operation
Fresh solvent is supplied in the SAFETAINER System and used solvent is taken
back for professional recycling. In combination with closed cleaning equipment,
this safety system developed by SAFECHEM
is considered to be the Best Available
Technology (BAT) for the safe and sustainable transport, storage and handling of
solvents. Special accessories enable
practically emission-free solvent cleaning.
Chemical Leasing – a future-oriented
solution
Companies from different industries such as
the aerospace industry, automotive
the contaminants on the parts to be
suppliers and contract cleaners, value the
cleaned. At the same time, the demands for COMPLEASE Chemical Leasing model
cleanliness are very high, especially in
developed by SAFECHEM as a
thermo-chemical diffusion processes such as future-oriented alternative for solvent
nitrifying and nitrocarburising.
cleaning. It focuses on the performance of
SAFECHEM offers additional service
the solvent which is optimised by
elements, such as test kits, for all chlorinated accompanying services in order to meet the
solvents and modified alcohols. These
high cleaning requirements of customers
enable to easily control the quality of the
towards quality, environmental
solvent on site. If necessary, suitable
responsibility and efficiency. Customers
stabiliser concentrates for the
benefit by using less solvent and stabiliser
re-stabilisation of solvents are available.
while the cleaning process and the results
are being optimised. At the same time users
CHEMAWARE Solvent Analyses and Oil
Compatibility Tests assist in the thorough
selection of the right solvent and contribute to
process reliability and cost-effectiveness
get support from specialists who have
long-time experience and deep knowledge
about the cleaning process. Due to the fixed
monthly leasing fee, COMPLEASE
customers can exactly calculate their
cleaning costs.
SAFECHEM Europe GmbH
Tel: 01384 296613
www.safechem-europe.com
www.chemaware.org
The Powerful Force in Component Cleaning
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TURBEX CLEANING TECHNOLOGY CENTRE
Unit 1 Riverwey Industrial Park, Newman Lane,
Alton, Hampshire GU34 2QL
T: 01420 544909 F: 01420 542264. E: [email protected]
Component Cleaning
Innovative dry cleaning without compressed air
Intermediate cleaning of powertrain parts with over 50 percent energy savings and high
process reliability
Machined powertrain components undergo
intermediate cleaning to safeguard the
quality of subsequent process steps. This is
typically done by means of compressed air,
which must be generated at a high expense
of energy. With the new EcoCVac, Dürr
Ecoclean offers an effective dry cleaning
system that eliminates the need for
compressed air. Apart from delivering
enhanced process reliability, the system can
provide energy savings of more than 50
percent. As maintenance of the working
chamber is minimised it also improves the
machine availability.
Modern engine and transmission
manufacturing lines are designed for
maximum productivity and economic
efficiency. Accordingly, any cause of
interference with a downstream process
must be eliminated. This makes it
mandatory that engine and transmission
parts such as cylinder heads, engine blocks
and transmission housings undergo cleaning
operations between machining steps. Such
intermediate cleaning is often performed by
cleaning machines using compressed air. A
benefit of this method is that the part is
cleaned 'dry'. On the downside, however,
generating the compressed air supply is very
costly. Moreover, the chips and machining
fluid residue that adheres to the product are
merely blown off, i.e. allowed to spread
around in the work chamber, which will
therefore become contaminated quickly.
This, in turn, increases the risk of
re-contamination of the product, with the
possible result of impairing the next
processing step.
Vacuum suction without compressed air in
short cycles
With its innovative EcoCVac pre-cleaning
and intermediate cleaning system, Dürr
Ecoclean has overcome these drawbacks.
The equipment relies on the newly
developed vacuum suction technology. This
ensures that contaminants will be removed
not just from the part but also from the work
chamber within a mere 1.5 to 3 seconds of
process time.
The EcoCVac system comprises a
pressure vessel in which a vacuum is
maintained permanently. This vessel is
connected by a pipe to the vacuum chamber
in which the part is placed. Once the
chamber is closed, a powerful airflow is
directed through it, thereby 'entraining' the
chips sticking to the part and taking them
into the vacuum vessel. A chip clean-out
device integrated nearby separates chips
and emulsion, allowing both to be
discharged separately via a collecting bin
and a flume, respectively.
More than 50 percent energy savings
In the development of the EcoCVac
system, resource efficiency was a prime
concern. As a result, the system affords
much-reduced energy consumption when
compared to compressed-air type
equipment. Assuming a compressed air
Dry cleaning without compressed air can
yield energy savings of more than 50
percent in addition to process reliability
gains.
consumption of 2.5 Nm³ per part at a price
of 1.26 euro cents per Nm³, the cost of one
compressed-air blowing cycle amounts to
3.15 euro cents per part. With the new
vacuum dry cleaning process, an electric
power input of 0.139 kWh per part is
needed. At an estimated electricity price of
10.88 euro cents per kWh, power costs of
1.51 euro cents per part will thus be
incurred. This is equal to a cost reduction by
more than 50 percent.
Optimised process reliability and
availability
In addition to the obvious cost benefits, the
EcoCVac shines with its improved process
reliability. As the chips are removed not only
Component Cleaning
from the part but also from the work
chamber, the risk of re-contamination is
minimised. The chamber must hence be
cleaned less often, and at a clearly reduced
cost and effort. Moreover, unlike
conventional compressed-air systems, there
are no nozzles to be aligned relative to the
part, for example during commissioning or
after a collision. The system's availability
rate is thus further improved.
As a leading supplier, Dürr Ecoclean
supplies automotive manufacturers and
suppliers, as well as the broad industrial
market, with the latest cleaning technology
and systems for surface activation and
treatment. With individually tailored
technology from Dürr Ecoclean, customers
can exploit potential savings for example in
unit costs, energy consumption and process
time. Dürr Ecoclean is part of the Dürr
Group worldwide and has over ten sites in
eight countries with approximately 800
employees.
The Dürr Group is one of the world's
leading mechanical and plant engineering
firms. Products, systems and services
offered by Dürr enable highly efficient
manufacturing processes in different
industries. Business with automobile
The parts are cleaned in a vacuum chamber
through which a powerful airflow is passed. This
airflow not just reliably removes contaminants
adhering to the part, but also conveys them out of
the work chamber
takeover of HOMAG Group AG in October
2014, the woodworking industry. Dürr has
92 business locations in 28 countries. With
14,200 employees, the Group plans to
generate sales revenues of € 3.4-3.5 billion
in 2015. The Dürr Group operates in the
market with five divisions:
Paint and Final Assembly Systems - paint
shops and final assembly systems for the
automotive industry; Application
Technology - robot technologies for the
automatic application of paint as well as
sealants and adhesives; Measuring and
Process Systems - balancing and cleaning
systems as well as testing and filling
technology; Clean Technology Systems exhaust-air purification systems and
energy-efficiency technology;
Woodworking Machinery and Systems
-machinery and systems for the
woodworking industry.
Dürr Ecoclean UK & Ireland
Tel: 01926 474080
manufacturers and their suppliers accounts
for approximately 65 percent of Dürr's sales. www.durr-ecoclean.com
Other market segments include the
mechanical engineering, chemical and
pharmaceutical industries and, since the
Charles Butler reaps the rewards of ultrasonic cleaning
Family run motor engineer Charles Butler
has reduced cleaning times for gear boxes
by 25 percent by using the very latest
ultrasonic cleaning equipment , giving the
business an edge over its competitors.
Ultrawave, a leading British manufacturer
of precision ultrasonic cleaning systems,
supplied Charles Butler Motor Engineers of
Forfar in Angus with a state-of-the-art
ultrasonic cleaner, which has revolutionised
the speed at which the business can turn
around jobs and improved the quality of its
work.
Jeff Butler, owner of Charles Butler Motor
Engineers, says: “It’s a competitive industry,
so speed and accuracy is more important
than ever. Our customers want a fast, quality
service.
The new Ultrawave cleaner has made a
big difference to what we can offer. No
other machine could achieve the same level
of cleanliness, especially in the intricate
internal parts of the gearbox. We can turn
jobs around faster so it has improved
productivity too. We now have a greater
capacity to take on new work.”
Stephen Noyce, sales coordinator of
Ultrawave says: “In response to its specific
needs to improve cleaning quality and
speed, we supplied Charles Butler with an
IND265D, an industrial grade, heated
ultrasonic cleaner with a large capacity of
265 litres.
“The company had previously used an
ultrasonic cleaner from another
manufacturer, but found it could not reach
tough oil and metallic contaminants in the
intricate parts of the gearbox, making the
process difficult and time-consuming.
“We are delighted that the new cleaner
has given them such strong results and
helped them to move the business forward.”
Founded in 1990 and this year celebrating
its 25th anniversary, Ultrawave are one of
the largest manufacturers and exporters of
precision ultrasonic cleaning equipment in
the UK. They have designed, manufactured
and supplied over 50,000 ultrasonic
cleaning systems for a wide range of
industries across the world.
Ultrawave’s customers include
automotive manufacturers, hospitals and
dental practices, medical device
manufacturer, engineering companies,
aircraft maintenance operators, Formula 1
racing teams, the Ministry of Defence, food
manufacturers and many more.
Established in 1975, Charles Butler Motor
Engineers provides a range of garage
services to domestic, light commercial,
marine and industrial customers.
Ultrawave Precision Ultrasonic Cleaning Equipment
Tel: 0845 330 4236
www.ultrawave.co.uk
73
Component Cleaning
Elevance Clean 1200 now commercially
available in Europe
Elevance Renewable Sciences Inc, a
high-growth specialty chemicals company
that creates novel specialty chemicals from
natural oils, announced during The Cleaning
Show 2015 in London that its superiorperforming, bio-based and safe-to-use
ingredient, Elevance Clean™ 1200, is now
commercially available in Europe.
Elevance Clean 1200 is highly compatible
across a range of aqueous and organic
solutions while being used at neutral pH in
cleaning products for a wide range of
applications such as metal cleaning,
industrial and institutional degreasing,
transportation, oil field, textiles, and food
processing.
“Elevance Clean 1200 is designed for
cleaning applications where superior
performance and an improved environmental profile is desired,” says Andy Corr,
Elevance senior vice president, Consumer
and Industrial Ingredients. “Customer
response to Elevance Clean 1200 has been
positive and we are pleased that we’re now
able to bring this product to the European
market.”
Elevance also named Equilex Chemicals
BV as a European distributor for Elevance
Clean 1200. Equilex combines a team of
sales and logistics professionals that will
provide enhanced service and support
capabilities for customers in Europe with an
interest in Elevance Clean 1200.
“We are delighted to team up with
Elevance Renewable Sciences and
participate in the launch of Elevance Clean
1200 in Europe. This novel solvent fits well
with our strategy to introduce new, biobased chemicals into our current markets
and will nicely complement our existing
range of products,” says Patrick Elie, Equilex
commercial director.
Equilex Chemicals will use the broad
international experience of its commercial,
technical and logistics teams to support
development of the European market for
this exciting new product.
Elevance Clean 1200 can be used directly,
blended with other ingredients or emulsified
with the addition of surfactants. Its specific
product attributes include: strong solvency
characteristics surpassing that of
d-limonene, dibasic esters, vegetable esters
and isoparaffins as measured on the Kauri
butanol (Kb) scale; formulating compatibility
across a range of organic and aqueous
cleaners, providing a boost in cleaning
performance that surpasses other solventbased and surfactant-based cleaning
formulations; excellent performance across
a broad range of cleaning applications,
including metal cleaning, industrial and
institutional degreasing, transportation, oil
field, textiles, and food processing;
outperforming standard cleaning
formulations in the market at neutral pH
(6-9), eliminating the need for highly caustic
cleaning products, demanding and
time-consuming personal protective
equipment (PPE) requirements, and the
need to preserve sensitive metal substrates.
Produced from natural oils, Elevance
Clean 1200 meets increasingly restrictive
environmental requirements, a key benefit
as industries continue to come under
pressure to reduce greenhouse gas (GHG)
emissions globally. Further, it is
non-flammable for easier handling,
improving worker safety while providing
excellent grease removal at neutral pH,
allowing for much safer and easier handling
than highly caustic and acidic cleaners.
Elevance Clean 1200 is also: VOC exempt
(Directive 2004/42/CE of the European
Parliament and the Council); REACh
registered; readily biodegradable (by OECD
method); free of components listed in the
EU Dangerous Substances Directive
(Regulation No. 1272/2008).
Elevance Clean 1200 was recently named
the Bio-Based Product Innovation of the
Year at the WBM Bio Business Awards 2015
for its ability to boost the cleaning
performance of formulations by rapidly
penetrating the most challenging soils.
Headquartered in Woodridge, Ilinois,
Elevance Renewable Sciences Inc. is a
high-growth specialty chemicals company
that creates novel specialty chemicals that
perform better from renewable feedstocks,
making the products that industry and
consumers use every day better. Using a
proprietary technology called olefin
metathesis, the company helps industry
deliver products that exceed the
performance of existing products while
leaving a smaller environmental footprint for
use in personal care products, detergents
and cleaners, engineered polymers,
lubricants and additives, and other specialty
chemicals markets.
With its headquarters in Schiedam, the
Netherlands, Equilex Chemicals bv is a 100
percent subsidiary of Equilex BV, a
chemicals and refinery feedstocks
distribution company having business
activities in Western and Eastern Europe,
Asia and the Americas. The company
distributes a range of intermediates,
specialty chemicals, base oils and waxes,
and differentiates itself by providing
marketing, commercial and technical
assistance to its supply partners.
For a full list of Elevance’s high-performing,
bio-based products, visit
www.elevance.com/products
Equilex bv
Tel: 0031 725214 0731
www.equilex-chemicals.com
Component Cleaning
New UK agency for multi-stage washing
IWM (Industrial Washing Machines) has
recently announced that it will be expanding
its offer to include TEIJO top-loading,
single-stage and multi-stage component
cleaning machines. By becoming a UK
distributor for TEIJO products, IWM is
adding to its portfolio general-purpose
industrial cleaning machine systems as well
as machines that are specifically optimised
for use in the automotive and industrial
manufacturing sectors.
TEIJO machines use water-based
technology, obviating the need to use
expensive and potentially hazardous
solvents. They are ideal for pre-cleaning of
components before welding, removal of
anti-corrosive treatments before machining,
cleaning of engines and engine parts,
descaling of cylinder heads and many similar
applications.
Eco-friendly and robust, TEIJO machines
are designed with a closed cleaning fluid
system which filters and reuses fluid,
creating significant water and energy
savings. The fluid normally consists of water
and 1 to 5 percent detergent, depending on
the application. The machines achieve
excellent detergent economy, as the wash
liquid can be reused for up to several
months, depending on the degree of
soiling.
Multiple-stage alkaline cleaning,
descaling and rinsing, wax removal and
rinsing, phosphating and rinsing, are just a
few of the many functions offered as
standards with the TEIJO multi-stage
cleaning machines.
To reduce energy consumption, the
maximum temperature of the washing fluid
is set at 80 degrees C. The short heating
time and large fluid tank ensure that even
the most soiled components are easily and
reliably cleaned every time.
“Becoming a TEIJO distributor means
that IWM has added another important
family of product options for our
customers,” explains managing director
Carl Hollier. “The TEIJO range of
component washing machines
complements our own food manufacturing
and processing ranges. This collaboration
will raise the profile of TEIJO machines here
in the UK and it will help IWM to supply
efficient and cost-effective solutions to suit
an even wider range of customer
requirements.”
Industrial Washing Machines Ltd
Tel: 0121 459 3241
www.indwash.co.uk
Turbex to present surface treatment lines
Automated lines for surface treatment,
including anodising and chemical cleaning,
are sold in the UK by Turbex as a result of an
agreement with Finnish company, Galvatek,
whose equipment will be highlighted at this
year’s Surface World show (Stand 150).
Established for over 30 years, the
manufacturer has designed, delivered,
installed and continues to service more than
600 turnkey installations in over 35
countries.
Galvatek is especially well known in the
aerospace industry, as its lines for chemical
cleaning, anodising and etching are used in
factories manufacturing aircraft parts and
engine components, as well as in the
maintenance, repair and overhaul (MRO)
sector. Supply of anodising plant forms a
large part of the business. Such facilities
comprise one or several lines and typically
use sulphuric acid or a TSA (tartaric sulphuric
acid) mix.
Chemical cleaning lines are built either for
one specific purpose or as part of a larger
package where it prepares parts for other
surface treatment phases. Turnkey solutions
are regularly supplied, complete with waste
water purification and recycling systems.
Turbex will additionally promote its
extensive programme of aqueous cleaning
machines, which range from small,
bench-top cleaning units to bespoke,
multi-tank, automated cleaning and drying
lines, often with ultrasonics.
Some involve a patented system in which
the movements of the holding basket and
spray jets are individually adjustable to
enhance processing efficiency. Others are
aimed primarily at high-precision cleaning
applications in the optics, medical,
aerospace, automotive, nuclear and
electronics sectors, with the possibility of
simulated clean room conditions.
For processing larger components, the
heavy duty Turbex AC range of
front-loading, spray washing and rinsing
machines are the preferred choice. They are
especially popular for degreasing,
phosphating, paint removal, de-rusting and
descaling. Manufactured from stainless
steel, the AC programme comprises singleand multi-stage units with options for one,
two or three process tanks. Standard sizes
range from one to two metres in diameter,
although larger machine sizes are available.
Turbex Ltd
Tel: 01420 544909
www.turbex.co.uk
75
GSF METAL FINISHING 76-81_ES CONTENTS 4-5 20/08/2015 15:37 Page 76
Metal Finishing
Gear maker invests in vibratory finishing
Descaling and deburring as well as superfinishing of motorsport gears are the latest
subcontract services being brought in-house
Since the mid-1980s, All Gear Services has
been making high quality gears and related
products for motorsport gearboxes and
commercial applications. A variety of
materials is processed, from case hardening
steel through stainless steels for marine use
to aluminium for pulleys. Small to large
batch production is undertaken, from a
one-off repair for a broken-down machine to
volume manufacture for the motor industry.
As business grew, Steve Cooper and his
co-directors found themselves turning and
gearcutting in-house but subcontracting out
most other work. It included heat treatment,
grinding, milling and superfinishing, which
polishes gears to reduce vibration,
extending the life of a race car gearbox.
The approach to finishing the gears
changed at the MACH 2014 machine tool
exhibition in Birmingham, when Steve
Cooper visited the PDJ Vibro stand and
discussed alternative options with one of the
directors, Paul Hurley. The meeting was
prompted by the demise of an old
drum-type rumbler that was used to clean
heat-treated steel parts at All Gear Services’
factory in Finchampstead, Berkshire.
Initially, the gears were sent to PDJ
Vibro’s technical centre in Bletchley for
descaling, deburring and edge breaking in
vibratory bowls operated by its subcontract
division. This service is a major part of the
firm’s business and more than 35 million
parts are processed annually, in most cases
within in a 24-hour turnaround, for
customers that prefer to outsource the
function.
However, Steve Cooper’s policy was to
bring in-house as many processes as
feasible, so a 300-litre capacity vibratory
bowl finishing machine from PDJ Vibro’s
economy range was installed at
Finchampstead towards the end of 2014.
Filled with a ceramic medium supplied with
a recirculating, filtered mixture of water and
metal finishing compound, it has reduced
processing time from 10 hours in the old
rumbler to just four hours and has drastically
improved the finish on component surfaces.
Moreover, due to the generous size of the
vibratory machine, up to 80 parts can be
processed at a time, reducing the previous
daily rumbling operations to one or two
vibratory processes per week. Around 75
percent of heat treated components at the
Finchampstead factory are finished in this
way. Only clutch shafts and drive shafts too
long for the bowl are cleaned by hand.
Of the gears and shafts that are not heat
treated, accounting for around 40 per cent
of production, some are put through the
bowl for a shorter period for deburring and
surface improvement.
A further recommendation from PDJ
Vibro is the imminent addition of a switch on
the economy bowl that will reverse the
toroidal action of the ceramic medium. It will
bring the components to the surface after
processing, making them easier to remove.
Superfinishing on the increase
That is only part of the finishing story at All
Gear Services, however. Of the components
supplied to motorsport customers, which
accounts for around half of the company’s
business, 60 percent are currently
superfinished. That proportion is increasing
as race teams become more aware of the
benefits of reducing friction in transmissions, namely increased speed and lower
maintenance costs.
Steve Cooper previously sent gears and
shafts to a firm specialising in the
acid-isotropic superfinishing process. While
PDJ Vibro sells new machines that employ
the process and offers it in the subcontract
department, it tends to be aggressive,
eroding metal surfaces and affecting the
accuracy of components.
So the company normally recommends
the porcelain and paste option for
superfinishing, which polishes surfaces
efficiently but without removing any
discernible amount of metal. Steve Cooper
sent sample parts to PDJ Vibro for trial
processing using the method and was so
impressed that all superfinishing is now
done that way in the subcontract
department at Bletchley. It is also less
expensive than the isotropic method.
Superfinishing will be transferred to
Finchampstead during 2015, for which All
Gear Services will buy a second, similar
300-litre bowl filled with the requisite media.
PDJ Vibro Ltd,
Tel: 01908 648757.
www.pdjvibro.co.uk
',$-."(3' /-!-2)
444."(3' /-!-2)
/1-, -" *#1!&*#5 2!)',%&+0&'/# see us at Surface World Exhibition, NEC,
Birmingham. 23rd & 24th September
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Metal Finishing
Aluminum for blasting aluminum
At the recent Gifa exhibition held in
Dusseldorf, Germany, Walther Trowal
displayed its new continuous feed tumblast
machines, which have been specially
adapted for shot blasting of light metals like
aluminum or magnesium. For weight
reasons these two metals are increasingly
replacing steel as the material of choice for
the production of a wide range of
components. The soft and, therefore, gentle
aluminum media has proven to be the most
suitable blast media for treating
components made from light metals.
The continuously increasing sales of the
Walther Trowal THM shot blast systems
show a clear trend toward aluminum blast
media becoming more popular for blast
cleaning of die-cast and forged aluminum
and magnesium components. Its obvious
advantage over stainless steel media is the
drastic reduction of the overall operating
costs due to the wear rate of the blast
turbines in particular and the machine in
general trending to nearly zero.
Of course, because of the lower mass of
aluminum media, the turbines must throw a
much larger media quantity to achieve the
same processing results. For this reason,
Walther Trowal re-engineered the THM
troughed belt shot blast machines to ensure
that they can easily cope with the higher
media quantities. A highlight of the new
THM shot blast machine range is the
innovative electric media dosing system,
which will be presented to the public at Gifa.
These machines were specially adapted for
gentle blast cleaning of aluminum and
magnesium. But of course, they also
produce excellent results on steel, zinc and
brass components.
Troughed belt continuous shot blast
machines
The THM continuous troughed belt
machines can handle large quantities of bulk
produced small parts as well as large,
delicate single workpieces with complex
shapes. Because of the much simpler and
gentler workpiece handling they frequently
replace conventional batch tumblast
machines. THM continuous feed machines
are especially advantageous for treating
very delicate components: Contrary to
batch tumblast machines, where the parts
are continuously tumbling over each other
with a high risk of nicking, in the Walther
Trowal THM machines the workpieces are
spread out throughout the length of the
trough, ensuring a gentle, nick-free
processing. The workpieces are not
tumbling over each other but gently roll
over the polyurethane coating of the
transport rods. This is extremely important
for highly complex thin-walled parts, which
must increasingly undergo an intensive blast
cleaning process. The results are perfectly
cleaned parts without any nicking or other
damage.
Compared to spinner hanger machines
the THM continuous shot blast systems have
also significant technical advantages:
Because the workpieces are gently tumbling
through the troughed belt, they are
exposed to the blast stream from all sides
and, especially, always at the same distance
from the turbines, ensuring all around, even
shot blasting results.
Aluminum: The gentle shot blasting media
Generally the blast cleaning of die-cast or
forged aluminum components, for example,
steering knuckles, requires a relatively soft
blast media. But there is also an increasing
trend towards the use of aluminum blast
media for processing magnesium
components, especially in the automobile
industry. Many structural automotive
components, for example, dashboard
mountings, are made from magnesium. This
material has not only a low weight, but at the
same time, is also very tough.
Due to the fact that in the Walther Trowal
THM shot blast systems the distance
between the workpieces and the turbines is
very short, the aluminum blast media,
despite its low density, has still a very high
kinetic energy when hitting the workpieces.
This is ideal for processing components
made from aluminum and magnesium. The
THM continuous shot blast machines can be
equipped with a different number of
turbines. For example, for forged aluminum
components the THM 700/4/E with four (4)
turbines with 15 kW each offers an optimum
performance.
A design that is totally adapted to
aluminum
To ensure the proper handling of the
aluminum shot blasting media, the Walther
Trowal engineering team has completely
Metal Finishing
redesigned many key equipment
components like the media dosing system
and the blast turbines. Just one of the many
details: Since a rough surface on the
throwing blades would quickly wear down
the aluminum blast media, the surface of the
blades is smoothed in a vibratory finishing
machine before they are installed in the
turbine. The result is drastically reduced
media consumption, lower dust emissions
and a significantly higher uptime of the
turbines.
Continuous feed or batch processing
For integrating the THM systems into
automated manufacturing systems Walther
Trowal offers a range of part feeding and
handling systems like, for example, vibratory
conveyors or angled belt conveyors. Many
customers link the Walther Trowal blast
cleaning systems directly with their forging
line or die-casting machines.
But the THM systems can also be
operated in batch mode. In such cases the
workpieces arrive at the blast machine in
special part bins and are transferred into the
machine with lift & tip loaders. Large
workpieces are placed manually on a special
belt conveyor.
Safety comes first
Since aluminum and magnesium dust is
flammable and can be highly explosive, it is
of utmost importance that the dust
concentrations generated by shot blasting
of light metal components with aluminum
remain low.
In numerous design details the Walther
Trowal engineers made sure that only small
dust quantities are produced during the
shot blast operation and dust deposits in the
machine are prevented. One example are
vibratory conveyors for transporting the
blast media, which totally preclude the
formation of dust pockets. In addition, the
dust-loaded air is cleaned in special
explosion protected dust collectors, and the
air speed in the machine and the ductwork is
constantly monitored.
Walther Trowal GmbH & Co. KG
Tel: 0049 2129571209
www. walther-trowal.de
ABRASIVE
SIVE BL
BLAST
AST CABINE
CABINETS
TS
dǁŝŶĐĂďŝŶĞƚǁŝƚŚƌŽůůĞƌƐĨŽƌĐǇůŝŶĚƌŝĐĂůƉƌŽĚƵĐƚƐ
dǁŝŶĐĂďŝŶĞƚǁŝƚŚƌŽůůĞƌƐĨŽƌĐǇůŝŶĚƌŝĐĂůƉƌŽĚƵ
• Pressure or ^ƵĐƟŽŶĐĂďŝŶĞƚƐ
ĐĂďŝŶĞƚƐ
• /ůůƵŵŝŶĂƚĞĚŚŝŐŚͲǀŝƐŝďŝůŝƚǇĐŚĂŵďĞƌ
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of work chamber sizes
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Choice of
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ƐƚDĂĐŚ
Metal Finishing
Riley Surface World wins large order
Riley Surface World has recently won a
six-figure order for the supply of pre-owned
nickel plating, anodising, cleaning and water
treatment plants from a specialist metal
finishing company in Mexico.
The equipment had all been declared
surplus to requirements by a large,
international provider of safety products to
the nuclear power generation sector. Riley
Surface World was selected to dispose of
the plants due to its specialist knowledge of
the global surface finishing industry. The
various items have now been shipped from
their original home in Birmingham, UK to
their new location in Toluca, near Mexico
City.
The new owner is Ecoplating SA, part of a
group of eight companies that comprises
the largest metal finishing organisation in
Mexico. It was formed 70 years ago by
Ramon Pages Snr who is still active in the
company. It has a workforce of 1550
employees and two of the companies have
joint ventures in the USA and Germany. Its
services include nickel, copper, zinc,
chrome, tin and precious metal plating,
passivation, phosphating and other ancillary
activities.
Ecoplating enjoys an excellent strategic
location in one of Mexico’s most vibrant
manufacturing areas, with neighbouring
companies that include: Chrysler, Mercedes
Benz, BMW, Nissan, Honda, Valeo,
Schneider and Siemens. It supplies the
automotive, electronics, oil and gas and
consumer products sectors. Future
expansion plans include new factories in
Monterrey and Queretaro to support the
expansion of the Mexican automobile
industry.
The equipment supplied by Riley Surface
World comprised an 8-stage nickel plating
line with two rectifiers, four modern 4-stage
anodising lines with rectifiers, fume
extraction and product suspension, two
cleaning lines including transporters and
drying ovens and a 5m3 demineralised water
generation plant.
future expansion plans, as it stands to
benefit from the expected upturn in the
Central and North American economies
over the next few years. He also paid tribute
to the professionalism and technical
expertise of all the staff at Riley Surface
World, who worked very hard to complete
the project on budget and on time.
Riley Surface World is a trading name of
Riley Industries Ltd. The company was
founded in 1966 as Barry Riley and Sons.
The original premises were located in
Central Birmingham, UK, close to the
world-famous Hockley jewellery quarter.
Barry Riley started by trading in recycled
nickel during the great nickel shortage of
the late 1960s, supplying the large number
of nickel plating companies that existed at
that time.
This steady income allowed the company
to diversify into a much wider range of
second hand surface finishing plant and
machinery. It eventually moved to larger
premises at Perry Barr to the North of
Birmingham city centre, where the business
flourished throughout the 1980s and 1990s.
Riley Surface World in the 21st century
Today, Riley Surface World occupies a large
5000 square metres headquarters at
All of the machinery is in immaculate
Aldridge on the outskirts of Birmingham.
condition and can be easily re-configured
This modern facility has space for over 1000
for other process finishing and cleaning
items of used surface finishing plant &
applications.
machinery.
The current CEO of Ecoplating SA, Ramon
The warehouse has industrial-sized
Pages Jnr says that the purchase of such
loading and unloading bays, overhead
valuable and versatile equipment will make
cranes throughout and substantial repair
an important contribution to his company’s
and refurbishing facilities. There is a
prestigious showroom and ample
conference and meeting areas.
Riley Surface World is staffed by a team of
fully experienced surface finishing
professionals, who are able to provide
advice and technical support to assist with
machinery purchases.
The company also have the expertise to
evaluate all of the machinery that they buy in
the marketplace and are always prepared to
pay the market value price for good quality
used surface finishing machinery in working
order.
Riley Surface World
Tel: 01922 458000,
www.rileysurfaceworld.co.uk
Metal Finishing
George Koch process line installation helps Gestamp Tallent
The Gestamp Tallent plant at Newton
Aycliffe in the north-east of England has now
been enhanced by a purpose-designed
acid-etching process line installed by
George Koch Sons Europe Ltd. The facility,
developed in response to the specific
requirements of one of Gestamp Tallent’s
major automotive customers, has been
installed in conjunction with an upgrade of
the company’s existing effluent plant to
accommodate increased throughput and,
significantly, sees the first use in the UK of
the new Koch Rejuvenator filtration system.
With initial testing having proven the
installation performance, the line is now fully
operational, accommodating a range of
suspension, chassis and axle components
manufactured by Volvo.
Mike Fisher, environmental manager at
George Koch, explains how the new facility
is meeting developing needs in the sector:
“Ever-increasing quality standards within
the automotive industry have highlighted
the need to eradicate silicon-based deposits
that can appear on the welds of subassemblies, potentially causing defects to
the finished, electro-coated
product,”
“Removal with an alkaline
degreaser followed by acid-etching
at 50°C using a product based on 10
percent sulphuric acid has proved to
be particularly effective in addressing
this issue,” The fully-automated plant
processes manually-loaded parts
suspended from an overhead
conveyor through nine stages
including spray and dip cleaners,
rinse stages, the acid-etch and the
application of an inhibitor ahead of product
storage.
Because the new installation also means
an increase in the amount of wastewater
that needs to be handled at the site, with a
particular requirement for treatment prior to
sewer discharge, George Koch’s expertise in
this area too has been utilised by Gestamp
Tallent. “The original need had been
addressed by a precipitation plant for more
than 20 years but the new acid-etch plant
pointed towards an upgrading of the facility
to enhance the customer’s environmental
performance while handling the larger
volumes involved,” says Mike Fisher.
He highlights the fact that George Koch
was able to remove the existing plant and
install the new facility within just a nine-day
summer shut down period to ensure that
loss of production was avoided.
George Koch Sons Europe Ltd
Tel: 01543 444001
www.kocheurope.com
For all your vibratory finishing
equipment and materials
• New and used vibratory finishing
machines and systems
From 2litres to 4000litres
• Finishing media; Ceramic, Plastic,
Wood, Steel and Maizorb
• Liquid/powdered/paste compounds
• Abrasive finishing wheels
• Vibratory separators/sieving machines and
re-meshing service
• Repairs and relines
• Effluent water treatment systems
• Subcontract finishing and industrial sieving
services
• Redundant machines purchased
• Consultancy
• Experienced Engineers
• After sales technical support
• Nationwide deliveries
SHARMIC FOR FAST, FRIENDLY SERVICE
Sharmic Engineering Ltd
Baldwin Road, Stourport-on-Severn, Worcestershire, England, DY13 9AX, UK
Tel: +44 (0)1299 822135/878123/4/5 Fax: +44 (0)1299 879409
Email: [email protected] www.sharmic.co.uk
Tel: 0208 339 7370
Fax: 0208 339 7371
Unit 5 Russell House, Molesey Road, Email: [email protected]
Walton-on-Thames, Surrey KT12 3PE www.blackfast.com
81
GSF AT YOUR SERVICE 82-84_GSF PRODUCT FOCUS 73-76 19/08/2015 15:08 Page 82
To advertise in this section please call John Barber on
AT YOUR SERVICE
GUYSON FINISHING EQUIPMENT
*X\VRQPDQXIDFWXUHDZLGHYDULHW\RILQGXVWULDOÀQLVKLQJHTXLSPHQWLQFOXGLQJEODVWFDELQHWVXOWUDVRQLFEDWKV
DQGWDQNVDQGFRPSDFWVSUD\ZDVKHUV0DQXDODQGIXOO\DXWRPDWHGRSWLRQVDUHDYDLODEOHDQGWKHUHDUHUDQJHV
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DQGVHUYLFHFRQWUDFWV)RUIXUWKHULQIRUPDWLRQFRQWDFW*X\VRQ·V&XVWRPHU
www.guyson.co.uk
6HUYLFH'HSDUWPHQWRQRUHPDLOLQIR#JX\VRQFRXN
‘The Complete Package’
Precision Engineers in CNC Grinding Turning and Milling
- Centreless Grinding
- Surface Grinding
- Universal Grinding
- CNC Grinding
- CNC Turning
- CNC Milling
Telephone: 01923 721 011 Fax: 01923 777 915
E-Mail: [email protected] Web: www.multigrind.co.uk
Finishing Techniques is the UK Agent for OTEC drag finishing,
disc finishing and stream finishing machines
Looking for
honing
excellence?
T: 01242 525868
[email protected]
www.apperleyhoning.co.uk
Micro metal
surface finishing
Super finishing
Super-fast
High quality
micro deburring
and honing
FINISHING TECHNIQUES LTD
Tel: 01706 825819
Fax: 01706 825748
www.fintek.co.uk
on 01403 242803 or email:[email protected]
AT YOUR SERVICE
Global leaders in surface
preparation and finishing
solutions
• Air Blast
• Wheel Blast
• Wet Blast
• Shot Peening
• Vibratory Mass Finishing
• Deburring and Surface
Finishing
• Washing and Degreasing
• Open Blast
• Effluent Treatment
• Ultrasonic Cleaning
Wheelabrator Plus Surface preparation services
• Service and Maintenance
• Spare Parts and Consumables
• Equipment Modernisation
Programmes (EMP)
Contact us:
T: 0161 928 6388
E: [email protected]
www.wheelabratorgroup.com
NEW DIAMOND AND CBN
GRINDING WHEELS CATALOGUE
LACH DIAMANT considers its new catalogue the
industry standard for solutions of grinding tasks in
metal machining.
The German manufacturer emphasises the fact that
it will still manufacture special types for specific
applications. “Made in Germany” is mandatory for
LACH DIAMANT and proves to be a strong
indicator of quality and reproducible performance.
The new catalogue for diamond wheels is available from:
LACH DIAMANT Jakob Lach & Co KG
Tel: 0049 6181 103822
Email: office:lach-diamant.de
www.vixen.co.uk
Market leaders in the
manufacture of wet
blasting cabinets
• Dust-free process
• Cleans by flow, not by impact
• Simultaneously blasts and
degreases
• Water acts as a lubricant between
abrasive and component
Maesteg Business Centre
Maesteg, Mid-Glamorgan CF34 0BQ
t: (+44) 01656 738566
m: (+44) 07990 514937
www.pulse-pr.co.uk
The UK’s leading PR Agency
for the manufacturing & technical industry sectors
• High quality cabinet construction
• Suitable for a variety of blasting
applications
t:01642 769333
e: [email protected]
83

Sept 2015 - Roger Barber Publishing Services

Transcription

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HTC Superprep - HTC Superfloor

7.1 Grinding