skip to Main Content
Sandvik Aims To Lead In Premium Solid Round Tools With New Acquisition

Sandvik Aims To Lead In Premium Solid Round Tools With New Acquisition

Sandvik has signed an agreement to acquire 67 per cent of Chuzhou Yongpu Carbide Tools Co., Ltd, a China based premium solid round tools company, with a call option to buy the remaining part in three years’ time. Chuzhou Yongpu Carbide Tools Co., Ltd is mainly focused on global and local OEMs and connected suppliers operating in China. Its capabilities include the full solid round tools manufacturing value chain with an offer covering blanks, cutting tools, reconditioning and coating services. The company will be reported in Sandvik Coromant, a division within Sandvik Manufacturing and Machining Solutions.

Stefan Widing, President and CEO of Sandvik, says, “The acquisition of Chuzhou Yongpu Carbide Tools Co., Ltd is part of our strategy for our machining solutions business to increase our market share and take a leading position in solid round tools, and at the same time expand further in the Asian market. We are looking forward to welcoming Chuzhou Yongpu Carbide Tools Co., Ltd to the Sandvik Group.”

Chuzhou Yongpu Carbide Tools Co., Ltd will continue to operate under its own brand and focus on developing its offer and market share with the ambition to become a leading premium provider of solid round tools in China. The combined expertise and footprint of Sandvik Coromant and Chuzhou Yongpu Carbide Tools Co., Ltd will drive further geographical expansion in the region, particularly for cutting tools.

“We have long-term strategic commitment to strengthen and develop our business. China is a fast-growing market for solid round tools, and the acquisition of Chuzhou Yongpu Carbide Tools Co., Ltd will further strengthen our presence and enhance our offer to customers in this important region. With its premium position and strong customer focus, Chuzhou Yongpu Carbide Tools Co., Ltd is a great fit for Sandvik Machining Solutions“, says Nadine Crauwels, President of Sandvik Machining Solutions.

Chuzhou Yongpu Carbide Tools Co., Ltd is headquartered in Chuzhou, China, and has around 500 employees. It had revenues of approximately SEK 400 million for the twelve month period Q2 2020 to Q1 2021, an EBIT margin slightly dilutive to Sandvik Manufacturing and Machining Solutions. Impact on earnings per share will initially be neutral.

The transaction is expected to close during the third quarter of 2021.

 

Artificial Hip Joint Manufactured For Precision Fit

Artificial Hip Joint Manufactured For Precision Fit

Artificial hip joints must be manufactured with high precision, especially in the area where the hip stem and the ball joint connect. CERATIZIT has developed an economical production solution for precise interface between hip stem and ball joint.

If a hip joint is affecting quality of life by restricting movement and causing chronic pain, and if conservative treatment methods are no longer helping, the only option is to have an artificial replacement joint implanted – over 200,000 such operations are performed in Germany-alone each year. Those who take this route are hoping for long-lasting improvements. In order to make this hope a reality, as well as a good surgeon and first-rate care, the highest quality ‘spare parts’ are needed.

Prosthetics like this usually consist of a hip stem with ball joint, a hip socket and an intermediate piece to ensure movement is as smooth as possible. Particular attention must be paid to the connection between the hip stem and the ball joint. For the conical surfaces to fit together perfectly, they need to be produced with the highest precision and surface quality. Therefore, the tools used play a crucial role when manufacturing these components. 

“An artificial hip joint consists of difficult-to-machine materials, which not only need to be machined within the narrowest tolerances but also as economically as possible. Ultimately, an artificial hip replacement should be affordable for as many people as possible. We work with great dedication to find suitable tool solutions for these tasks,” explained Dirk Martin, Application Manager Medical at CERATIZIT and member of Team Cutting Tools. 

Meeting Machining Requirements

CERATIZIT is a full-range provider in the machining sector that has a wide range of standard and specially-made tools as well as in-depth machining expertise at its disposal. “With our huge product range and the expertise of our application specialists, we are extremely well equipped for tasks like machining the area where the hip stem and joint ball connect,” stresses Martin. “With our range of tools, we can test all manner of approaches to ultimately find the optimal solution.”

In the case of the artificial hip joint, the customer has particularly demanding and varied requirements. For the hip stem, made from high-strength titanium alloy Ti6Al4V, an angle tolerance of just +/-5‘ must be achieved in the conical connection area. Other tolerances are 3 µm for straightness, 8 µm for roundness and 60 µm for the diameter. It is also important that the specified contact ratio for the cone is achieved and a precisely defined groove profile produced.

The ball joint is made from a cobalt-based alloy (Co-Cr-Mo). Its conical hole must have the same shape, angle and dimension tolerances, as well as the specified contact ratio. However, there must be no marks, ridges or grooves made during machining. Martin mentions another crucial factor: “We need a production solution that is suitable for mass production. This means the machining must be process-secure and require as little monitoring as possible.”

Flexible u-Axis and Special Conical Reamer

To produce the conical outside profile, CERATIZIT’s application specialists opted for pre-machining with a solid carbide conical milling cutter. The subsequent roughing and finishing are then completed using a CERATIZIT u-axis system. 

“This is an interchangeable, freely programmable NC axis for machining centres, which can be used to machine contours or for turning.” explains Martin. 

“Attachment tools and indexable inserts can be used to create contours in holes and external machining work. This usually means that production times can be reduced considerably, while providing optimal surface quality and higher shape accuracy than usual,” he continued.  

This means the desired groove structure can be produced on the stem cone even on a machining centre. This has the benefit that all machining processes can be done on a single machine. Using the conventional process, a lathe and a milling machine would be required, which means additional clamping, aligning, time and money.

To make the conical hole in the ball joint, CERATIZIT’s solution involved the following steps being carried out on a lathe: First, the part is faced to provide a flat surface for the subsequent special solid carbide 180 deg drill with four cutting edges. This is then used to make a hole with a flat bottom. After this an EcoCut Classic drill and turning tool is used to produce the cone with close-contour boring, while a special solid carbide conical reamer ensures the ideal contact pattern and perfect surface quality and tolerance is achieved. The regrinding capability also saves the user further production costs. 

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Walter Strengthens Tool Offering With Acquisition Of Melin Tool Company

Tungaloy Adds Longer Flutes To Popular TungMeister Exchangeable-Head End Milling System

Seco Tools Acquires QCT’s Cutting Tool Division

CNC Machining & 3D Printing: A Mixed Approach To Precision Manufacturing

A Look at Walter’s Two-in-One Machining Concept

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Orthopaedic Implant Grinding Takes Off As Elective Surgery Resumes

Orthopaedic Implant Grinding Takes Off As Elective Surgery Resumes

Growth in the global orthopaedic devices market offers an attractive diversification strategy for the CNC tool cutting industry. Article by ANCA. 

The global impacts of COVID-19 are numerous and continue to affect people in ways that are unexpected. Stemming from this, the crisis response from the healthcare system in many countries was the necessary decision to stop all non-emergency procedures in order to direct resources towards tackling rising COVID cases. While the health system continues to face the challenges of the pandemic, many institutions are looking to ramp up elective surgery to address the backlog with careful planning. 

Growth of the Orthopaedics Implant Market

In the UK, it is estimated that nearly 10 million people are waiting for surgical procedures, including joint replacement surgeries* while one recent study in the US predicts that the post-pandemic backlog will exceed one million cases in orthopaedic surgery alone.* Compounding these backlogs is the steady growth in orthopaedic surgery due to an ageing population, with osteoarthritis being one of the most disabling diseases in developed countries.

The macro-economic challenges of the pandemic are also being experienced worldwide. For the tool grinding industry many traditional sectors are characterised by uncertainty. Now more than ever, diversification for tool and cutter grinding companies is a smart strategy. Diversification that follows opportunity is a proven method to protect and grow your business. 

The global orthopaedic devices market size was valued at US$53.44 billion in 2019 and is expected to reach $68.51 billion by 2027 returning a CAGR of 6.6% between 2020 and 2027*, with joint reconstruction leading the market. For these reasons, the field of medical orthopaedic implant grinding is an attractive diversification strategy for the CNC tool cutting business. Joint reconstructive surgery is largely dominated by knee, hip and shoulder procedures, all of which involve orthopaedic implants and associated instruments that typically require grinding during the manufacturing process. 

Grinding For Orthopaedic Applications

Grinding applications for the medical industry are characterised by high levels of customisation and complexity. Growth and technological advances in this area are opening doorways of opportunity to enter a lucrative market with strong historical and projected growth. Investment in the right machine tool coupled with industry-leading CAD/CAM software is crucial to remain competitive in this evolving market. 

Grinding routines for orthopaedic applications, such as knee implants and bone rasps, are commonly produced using CAD/CAM packages such as Siemens PLM NX. Machine NC programs are generated using an NC Post-Processor for a specific machine target and are then used to manufacture the part. The post-processor forms an integral part of the integration between the CAD/CAM software and the machine. It is therefore important to ensure that this integration allows maximum flexibility during the design and production process.  

Satisfying geometry and surface finish requirements when grinding orthopaedic-grade alloys for medical implants can prove challenging. Integration between the CAD/CAM software and machine should ideally allow for easy and flexible programming of wheel-dressing routines as well as freedom to select various roughing and finishing grinding wheel geometries. A clear distinction should exist between the role of the CAD/CAM system and machine to avoid inefficiencies that arise when grinding-process changes require NC program regeneration from the CAD model. 

To continue reading this article, head on over to our Ebook!

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

 

 

CNC Machining & 3D Printing: A Mixed Approach To Precision Manufacturing

CNC Machining & 3D Printing: A Mixed Approach To Precision Manufacturing

Peter Jacobs, Senior Director of Marketing at CNC Masters shares how a meaningful combination of CNC machining and 3D Printing can help manufacture even the most intricate parts and boost overall productivity.

The advancing 3D printing capabilities have made it convenient for manufacturers to use additive manufacturing to develop parts from a wide variety of materials. These materials include polymers such as ABS, PLA, TPE, and carbon fibre composites, polycarbonates, and nylon.

Alongside 3D printing, precision CNC machining also enjoys a crucial role in the additive manufacturing process, with a new process called hybrid manufacturing quickly assuming its hold in the industry.

Combining CNC machining and 3D printing can meet all crucial design requirements and eliminate limitations in these individual domains. 

Benefits of Combining Machining and 3D Printing

Here’s why the combination of CNC machining and 3D printing is relevant and the benefits that will follow:

  • Conservation of Time

The process of 3D printing a part and then having it delivered to the next section for CNC machining involves too many steps; however, this process is relatively less time-consuming relative to injection moulding.

In Injection moulding, the design and development of a specialised tool must go through every workpiece in the moulding process, making it more time-consuming.

While we can alternatively use 3D printed injection moulds to reduce production time, incorporating the potential of CNC machining can be more fruitful.

We can seamlessly tweak the digital files that end up getting 3D printed as prototypes rather than making alterations to an existing injection moulding machine tool.

  • Higher Tolerance Rate

3D printing has encountered hindrances in its progress due to the tolerances of modern 3D printers. Many end-use parts have specific tolerances and other vital requirements that are only feasible by incumbent manufacturing methods.

Unlike 3D printing, CNC machining is consistent. It offers a more refined product because its equipment does not exhibit sensitivity to heat as a 3D printer, which might warp and distort the product and result in uncertain runs of products.

Merging the two domains provides us with the perks of rapid prototyping brought to the table by 3D printers. It also enables us to dial in the tolerance from 0.1 mm to 0.3 mm as anticipated from a DMLS or SLS 3D printer to about 0.025 to 0.125 mm rendered by CNC Milling Machines.

  • Use a Bigger Workpiece

A congregation of these two domains involves 3D printing a part and then forwarding it to CNC milling to balance the final tolerances and providing it with the desired finish.

There has been excitements about merging these two technologies into one machine. This scenario could result in something that resembles the industrial-scale hybrid milling machines.

Such machines are speculated to harbour a build volume of about 40 feet in diameter and 10 feet in height. These hybrid 3D printing-milling machines can mill the surface of a new 3D print while the operation would still be underway.

With state-of-the-art CNC Benchtop Milling Machines, you can enjoy peak performance while occupying a minimum floor.

Likely Mergers of CNC Machining and 3D Printing

Some of the cases where we can successfully implement the merger of 3D printing and CNC machining for the manufacturing process includes:

  • Plastic Manufacturing

If we intend to develop a component from plastic, it is essential to consider that additive manufacturing might not adequately deliver the needed precision as we would require high tolerances.

In such cases, employing 3D printing to manufacture the component and then bring in CNC machining to trim it to the desired dimensions could be beneficial. This gesture can help dispose of any shortcomings that may have surfaced due to the additive manufacturing hardware.

To continue reading this article, head on over to our Ebook!

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

On High RPM

On High RPM

Andrei Petrilin, Technical Manager of ISCAR discusses the importance of high-speed spindle and the requirements in high-speed machining (HSM). 

High-speed machining (HSM) has not only led to a significant difference between machine tools but has also brought awareness to the high-speed spindle; perhaps, the most important and central component of high-speed machine tools and a key factor for the success of HSM.  

High Speed Machining

Operating a spindle with high rotation speed and gaining the optimal balance between the provided speed and torque is the main task of high spindle engineering.  The spindle’s performance depends on several different factors. One of the main factors relates to the design concept of a single- or combined twin-motor bearing system, seal components, and a tool retention method.

When machining, the spindle is not in direct contact with the workpiece but interacts with it through another technological system – the cutting tool. This connection acts as a conductor and should transform the impressive capabilities of a high-speed spindle into improved machining results. Another element between the cutting tool and the spindle is the toolholder which is fitted into the spindle. The poor performance of this small assembly, the cutting tool and toolholder, may reduce the function of the spindle to zero. Therefore, HSM toughens the accuracy, reliability, and safety requirements for the assembly of the spindle extension.  

High-speed rotation generates centrifugal forces. In HSM, when compared with traditional machining methods, these forces grow exponentially and turn into a significant load on a cutting tool which determines the tool’s durability. In indexable milling, high centrifugal forces may cause insert clamping screws to break, inserts to loosen and a cutter body to fail. Formed fragments can not only damage a machine and a machined part but can be very dangerous to the operator.

In such conditions, cutting tool manufacturers are compelled to consider the design and technological means necessary to ensure appropriate reliability of their products. Hence, the focus on indexable milling cutters should consider secure insert mounting and a robust body structure.

Reliable Milling

Let us start with a clamping screw, the smallest and weakest element of a whole technological system with a great impact on the system’s reliability.  The same can be said about the clamping screw in relation to a high-speed indexable milling cutter.  Applying dynamometric keys controls the tightening of the clamping screw. (Fig. 1). However, ensuring the torque is tightened sufficiently is not enough to reliably operate the cutter. Intelligent design is directed to minimise the dynamic load on the clamping screw.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Burgsmuller: WM 250-8000 Whirling Machine

Top 5 Articles In 2020: COVID-19, Fast-Fab & Machining

The Essential Guide To CNC Milling Machines

New Dimensions In Deep-Hole Drilling With Walter

Changing Times In The Metal Cutting Industry

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

 

Tool Craft For Aircraft

Tool Craft For Aircraft

Andrei Petrilin, Technical Manager of ISCAR showcases its new developments for aircraft machining of tomorrow.  

In machining aerospace components, the main challenges relate to component materials. Titanium, high-temperature superalloys (HTSA), and creep-resisting steel are difficult to cut and machining is a real bottleneck in the whole aircraft supply chain. Poor machinability of these materials results in low cutting speeds, which significantly reduces productivity and shortens tool life. Both these factors are directly connected with cutting tools. 

In fact, when dealing with hard-to-machine typical aerospace materials, cutting tool functionality defines the existing level of productivity. The truth is, cutting tools in their development lag machine tools, and this development gap limits the capabilities of leading-edge machines in the manufacturing of aerospace components.  

Modern aircraft, especially unmanned aerial vehicles (UAV), feature a considerably increased share of composite materials. Effective machining composites demand specific cutting tools, which is the focus of a technological leap in the aerospace industry.

Aircraft-grade aluminum continues to be a widely used material for fuselage elements. It may seem that machining aluminum is simple, however, selecting the right cutting tool is a necessary key to success in high-efficiency machining of aluminum.

A complex part shape is a specific feature of the turbine engine technology. Most geometrically complicated parts of aero engines work in highly corrosive environments and are made from hard-to-cut materials, such as titanium and HTSA, to ensure the required life cycle. A combination of complex shape, low material machinability, and high accuracy requirements are the main difficulties in producing these parts. Leading multi-axis machining centers enable various chip removal strategies to provide complex profiles in a more effective way. But a cutting tool, which comes into direct contact with a part, has a strong impact on the success of machining. Intensive tool wear affects surface accuracy, while an unpredictable tool breakage may lead to the discarding of a whole part. 

A cutting tool – the smallest element of a manufacturing system – turns into a key pillar for substantially improved performance. Therefore, aerospace part manufacturers and machine tool builders are waiting for innovative solutions for a new level of chip removal processes from their cutting tool producers. The solution targets are evident: more productivity and more tool life. Machining complex shapes of specific aerospace parts and large-sized fuselage components demand a predictable tool life period for reliable process planning and a well-timed replacement of worn tools or their exchangeable cutting components.

Coolant jet

In machining titanium, HTSA and creep-resisting steel, high pressure cooling (HPC) is an efficient tool for improving performance and increasing productivity. Pinpointed HPC significantly reduces the temperature at the cutting edge, ensures better chip formation and provides small, segmented chips. This contributes to higher cutting data and better tool life when compared with conventional cooling methods. More and more intensive applying HPC to machining difficult-to-cut materials is a clear trend in manufacturing aerospace components. Understandably, cutting tool manufacturers consider HPC tooling an important direction of development.

ISCAR, one of leaders in cutting tool manufacturing, has a vast product range for machining with HPC. In the last year, ISCAR has expanded its range by introducing new milling cutters carrying “classical” HELI200 and HELIMILL indexable inserts with 2 cutting edges (Fig. 1). This step brings an entire page of history to ISCAR’s product line.

The HELIMILL was modified and underwent changes which led to additional milling families and inserts with more cutting edges. The excellent performance and its close derivatives of the original tools ensured their phenomenal popularity in metalworking. Therefore, by adding a modern HPC tool design to the proven HELIMILL family was a direct response to customer demand and the next logical tool line to develop.

In Turning, ISCAR considerably expanded its line of assembled modular tools comprising of bars and exchangeable heads with indexable inserts. The bars have both traditional and anti-vibration designs and differ by their adaptation: cylindrical or polygonal taper shank. A common feature for the nodular tools is the delivery of internal coolant to be supplied directly to the required insert cutting edge (Fig. 2). The efficient distribution of coolant increases the insert’s tool life by reducing the temperature and improving chip control and chip evacuation; substantially increasing this application line in the aerospace industry.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Autodesk and Airbus Demonstrate Impact Of Generative Design On The Aerospace Industry

Round Tool Concepts: Indexable, Solid or Both

Sandvik Coromant Expands Digital Machining Division In Southeast Asia And Oceania

Pulsed Micro Arc Welding for Coil Terminations Increases Line Throughput

Optimising Aerospace Parts Manufacturing

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Hydraulic Expansion Toolholders With Cool Flow For Optimised Machining

Hydraulic Expansion Toolholders With Cool Flow For Optimised Machining

SCHUNK breaks down the development of its Cool Flow technology—a highly efficient cooling system which feeds coolant directly through the tool mounting, with the help of a model, tool and mould-making company from Germany. 

At the model, tool and mold-making company KRIEGER, standardisation is a key success factor. Within a decade, the variety of machine control systems, tool mountings and tools that had been developed were systematically analysed, structured and overhauled. 

Today, all machines come with standardised control systems, a uniform interface and specific tool pools. Even for special and customised tools, an in-house tool catalog has been drawn up in order to cut down on uncontrolled growth. This creates clarity and makes it easier to detect and eliminate even the smallest of deviations in processes. 

This includes deviations such as vibrations that can occur, in particular on machines with large traverse paths (2500 mm x 2000 mm x 1000 mm). Although the vibrations had been kept in check by changing the cutting parameters, there had long since been dissatisfaction with the overall process. 

Technological Progress with Hydraulic Expansion Toolholders

KRIEGER first deployed the TENDO Slim 4ax vibration-damping hydraulic expansion toolholders in a milling test to replace the previous standard heat shrinking mounting which was susceptible to vibrations. They found that the machines absorb the vibrations considerably better and no longer come to a standstill during demanding processes if they are equipped with the toolholders. 

Particularly on machining centers that lack stability due to their design and size, the effect has been enormous. The toolholders could simply be replaced without any reprogramming or collision check. 

It made sense for the 40-person company to deviate from what was hitherto tried-and-tested and the company was convinced.

Simple Replacement Via Plug & Work

Test series have proven that mounting with the vibration-damping characteristics of hydraulic expansion toolholder technology results in significant process improvements, especially during drilling, as well as demanding finish milling. Users benefit from shining surfaces, long tool service live, and efficient metal cutting. 

Unlike heat shrinking toolholders, the TENDO Slim 4ax can be seamlessly integrated into SCHUNK’s tried-and-tested hydraulic expansion program, with a constant run-out accuracy of < 0.003 mm at an unclamped length of 2.5 x D and a balancing grade of G 2.5 at 25,000 RPM. 

Since precision mountings can replace conventional heat shrinking toolholders by means of Plug & Work without having to reprogram the outside contour, its advantages can be immediately tested in real applications and used in the long term – just like at KRIEGER.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

ST Engineering’s Cybersecurity Solutions Gains Global Recognition

Meeting the Need for Speed

SCHUNK Launches VERO-S NSP 140

Continuing the Automation Legacy

TRUMPF Acquires Lantek And Expands Software Business

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

Changing Times In The Metal Cutting Industry

Changing Times In The Metal Cutting Industry

Today, workpieces need to be machined using multiple tools and fast tool change systems are becoming the norm. Article by heimatec. 

Today, workpieces generally need to be machined using multiple tools, which in turn means that tool changes are required during the machining process. In order to keep the changeover and adjustment times as short as possible, the use of fast tool change systems has become the norm. Here, heimatec, manufacturer of high-precision static and driven precision tools for lathes and machining centers, introduces its wide range of solutions for fast tool changing. 

Flexible System

Efficient manufacture is made significantly easier in two aspects. If machine downtimes can be reduced, the productive time increases automatically. By using flexible universal tools, the tool inventory can also be reduced, resulting in cost savings. 

heimatec developed the flexible heimatec.u-tec tool change system for this purpose, which allows machining companies to utilise different adapters for a wide variety of machining tasks. The driven heimatec.u-tec tools are designed with a collect chuck mount according to DIN 6499, allowing the user to use the driven tools without additional tool adapters. A special feature of the heimatec u-tec change system is the short mounting length which ensures exceptionally stable clamping of the cutting tool with low cantilever forces, leading to excellent machining results and a long service life of the cutters.

Reducing Machine Downtimes

The company has developed the easy-quick HT series specially for fast changes in the area of driven and static tools. This means different tool change inserts with market-standard tool mounts can be preset outside the tool machine and when required, can be simply, safely and quickly installed by the machine operator with one hand. With this series, machine downtimes are reduced significantly. In addition, the overall tooling costs are reduced thanks to the multiple and flexible use of the easy-quick base tools. 

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

Sandvik Coromant Expands Digital Machining Division In Southeast Asia And Oceania

Heimatec To Expand Production At Renchen Site

The Logic of Development

Choose Digital, Choose the Right Drill

First Mitsui Seiki Blue Arc Machine Installed At Aerodyn Engineering

With Additive Manufacturing To More Productivity

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

A New Approach To Aircraft Titanium Machining

A New Approach To Aircraft Titanium Machining

Makino introduces a new approach to overcome the challenges in titanium parts machining for aerospace manufacturers. 

The appeal of Titanium is no mystery. Its material properties of toughness, strength, corrosion resistance, thermal stability and light weight are highly beneficial to the construction of today’s aircraft.

However, aerospace manufacturers producing titanium parts quickly discover the difficulty these material properties present during the machining process. The combination of titanium’s poor thermal conductivity, strong alloying tendency and chemical reactivity with cutting tools are a detriment to tool life, metal-removal rates and ultimately the manufacturer’s profit margin.

Producing titanium parts efficiently requires a delicate balance between productivity and profitability. However, in standard machining practices these two factors share an inverse relationship, meaning greater productivity can come at a higher cost due to rapid tool degradation, while the desire to increase profit margins by extending tool life may result in decreased metal-removal rates and extended cycle times.

Overcoming this issue requires a new approach by Makino in which all components of the machining process are developed and integrated specific to the material’s unique challenges—requiring a reassessment of even the most basic machine tool design considerations. This was the concept for the new T-Series 5-axis horizontal machining centers with ADVANTiGE technologies, and the results speak for themselves—four times the productivity and double the tool life.

Changing the Rules

In the past, and even in some shops today, titanium is typically machined using multi-spindle gantries and machines with geared head spindles. While these technologies have been effective, the growing complexity of part geometries and required accuracies have brought forth several limitations, including machine and spindle vibration, poor chip removal and limited tooling options.

In support of the aerospace industry’s demand for titanium, Makino established a Global Titanium Research and Development Center, managed by a select group of engineers with knowledge and experience around titanium in both academic and industrial backgrounds. 

The company’s breakthrough, ADVANTiGE, is a comprehensive set of technologies that includes an extra-rigid machine construction, Active Damping System, high-pressure, high-flow coolant system, Coolant Microsizer System and an Autonomic Spindle Technology.  Each technology is designed specifically for the titanium machining process, providing dramatic improvements in both tool life and productivity.

Creating a Rigid Platform

Rigidity of a machine tool is one of the single most important components in titanium machining, heavily influencing the equipment’s stable cutting parameters. 

Machines designed with low rigidity offer limited stable cutting zones, dramatically reducing the maximum level of productivity that can be achieved across all spindle speeds. To increase the productivity of a low-rigidity machine, manufacturers have only one option: taking lighter cuts and increasing spindle speeds, resulting in dramatic reductions in tool life.

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

3D printing And Titanium — A Life-Changing Combination

Machining Aluminium Components Economically

Iscar: High Speed Spindle

Hexagon Enhances Its Smart Manufacturing Solutions Portfolio With Acquisition Of D.P. Technology Corp

Sandvik Coromant Expands Digital Machining Division In Southeast Asia And Oceania

EMO MILANO 2021: Meet “The Magic World Of Metalworking” In October 2021

Universal Robots Reaches Industry Milestone With 50,000 Collaborative Robots Sold

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

 

When XXL Machines Get Even Bigger

When XXL Machines Get Even Bigger

DMG MORI gantry machines utilise igus energy chains with guidelok system.

For 100 years, DECKEL MAHO Pfronten has stood for precision machinery and tools. The company’s monoBLOCK, duoBLOCK, Portal and Gantry series cover all industries and dimensions—from the smallest component to XXL parts. The XXL Centre in Pfronten precisely manufactures workpieces that are up to 10 m long and weigh up to 150 tonnes. In the future, even longer ones should be achievable, since the modular design allows the X dimension to be extended.

DECKEL MAHO’s XXL Centre is where they manufacture the DMU 600 series large-part gantry. The hall has to be big because the machines have to be XXL, so that they can produce XXL components. The DMU 600, with its traversing gantry design, was originally developed for press tool construction. DMG MORI has enjoyed global success with this machine series and is currently planning an even bigger one.

Dr. Kai Gümperlein, head of XXL machine design and development, says, “We’re planning to expand the modular design so that we can work on components that are up to 20 m long.”

But he wants to retain the flexibility that is unparalleled at this size: the DMU 600 gantry has great cutting performance during roughing while at the same time achieving very fine, accurate surface finishes. This is advantageous when large tools are manufactured for plastic injection moulding.

New Solution for Flexible Energy Supply Systems

As part of the design revision, the gantry’s energy supply was re-designed. It is also XXL because it has to transport the motor cables for the traversing drives; powerful tools and media cables for cooling lubricant, hydraulic oil and compressed air; and a large number of signal cables.

Reverse XXL Chains with Upper Run guidelok Guidance

In the future, two reverse chains with centre infeed will supply energy. The advantage here is the reduced chain length, which reduces pressure drop in the media cables. Both chains are also very accessible, and the defined interface allows easy installation of the chain packages, which are also XXL: the R4.112 chain with its 400-mm inner width is among the largest that the very extensive igus range has to offer. Another advantage of the new solution is that the guide trough is placed in a raised position on the control cabinet. This reduces the installation space required and allows transport to the set-up point in a guide cage as a unit. This saves time during on-site installation.

Central Advantage: The Modular Principle

The central advantage from DMG MORI’s point of view is the new solution’s modular principle. Gümperlein says, “Now we can use the same basic design for all previous variants with six, eight or ten metres of installation space and for even bigger machines in the future. All we need to do is extend the travel and the chain.”

To continue reading this article, head on over to our Ebook!

 

Check these articles out:

A.I. Engineering Pioneer Hyperganic Raises $7.8m Funding For R&D Expansion In Singapore

Technical Revolution In Automatic Turning

Frost & Sullivan: Welding Vendors Focusing On New Technologies And Energy Efficiency

Accelerate Mould Design-to-Manufacturing Processes to Stay Ahead

Advantages of Collaborative Development

igus Coating Technology Makes Abrasion-Resistant Metal Components

 

For other exclusive articles, visit www.equipment-news.com.

WANT MORE INSIDER NEWS? SUBSCRIBE TO OUR DIGITAL MAGAZINE NOW!

FOLLOW US ON: LinkedIn, Facebook, Twitter

 

 

 

Back To Top