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Doosan Machine Tools Launches DBM 2030/3050 Series Machining Equipment

Doosan Machine Tools Launches DBM 2030/3050 series Machining Equipment

Doosan Machine Tools Co., Ltd will release more DMB Series line-ups, a double column of 2,000mm and 3,000 effective width, which consists of the multi-purpose double column machining center that is suitable for machining both large size workpieces and moulds. DBM Series supports various workpiece shapes and demonstrates a wide range of machining performance and high-precision mould machining, by applying the maximum specification in its class. This Series also maximises convenience in using the double column machining center for 5-sided machining, by applying convenient machining functions.

Supporting Various Shapes and Wide Range of Machining Performance

DBM Series is a specialised machining equipment for machining large size workpieces that offers a wide range of machining areas (effective column width – 2000mm, 2500mm, 3000mm, passage height- 1300mm, table length – 3000, 4000, 5000, 6000, and 8000mm), and can load a workpiece up to 35,000Kg. DBM Series guarantees machining precision that does not change easily even under machining loads for a long time. In addition, DBM Series can machine the mold and five sides, as well as various complex shapes such as freeform slope machining by one degree minimum split, by applying the auto-replaceable attachment that is differentiated for each machining characteristic. DBM Series also contributes to user’s productivity improvement because the head attachment replacement time can be minimised by installing two types of head attachment (dummy and 90 degree angle) by applying the automatic attachment changer (AAC) as a standard.

High Precision/High Speed Mould Machining Performance

The DBM Series structure minimises the impact of vibration even under heavy-duty cutting machining loads in the horizontal and vertical directions that occur while machining all five sides, as well as a M-type casting structure to maintain machining precision. The DBM Series also supports stable and precise machining for an extended period of time by minimising heat displacement by applying spindle and structure thermal displacement. This product can maintain heavy-duty cutting performance under any machining loads in the horizontal direction by applying a ram spindle with a maximum output of 55kW that can perform strong heavy-duty cutting, high stiffness quadrilateral box guideway that is stable against thermal strain, and ram cross-sectional area of 380 x 380 mm that is largest in its class. In addition, a more effective high-precision, high-speed contour control can be performed by setting the machining conditions by selecting the DSQI/II/III function.

Improved Operation Convenience and 5-sided Machining Support Program

Considering the screen layout of ergonomic usability, such as feed axis setting and magazine tool setting, improved convenience of operation is established. The DBM Series supports 5-sided machining of the large size workpiece in an easier and more efficient way, by using the 5-sided machining support system that is convenient for machining large size workpieces (packaged function that is available when selecting a 5-sided machining head attachment option), easy pattern cycle, variable control of workpiece load, AFC function, and machining monitoring function.

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Growth Opportunities In Singapore’s Precision Engineering Sector

Growth Opportunities In Singapore’s Precision Engineering Sector

Despite the ongoing pandemic, Singapore’s Precision Engineering (PE) Sector has offered close to 1,500 job opportunities from more than 270 companies since April this year, according to the Ministry of Manpower (MOM).

The PE industry is an integral part of the global manufacturing economy. It supplies critical products and expertise to manufacture complex components and equipment used in industries such as semi-conductors, medical technology, marine, offshore and aerospace. In Singapore, the PE industry employs more than a fifth of the 473,000 workers in the manufacturing sector and contributed approximately $38 billion in total output in 2019.

Furthermore, the industry continues to see pockets of growth—the PE cluster grew 11.4 percent in the period January to July 2020 compared to the same period last year. Companies which performed better includes the Medical Technology and Semiconductor sectors which saw an increase in demand of COVID-19 related products like ventilators; companies that supply machinery and systems as well as precision modules and components that make up tech appliances to facilitate remote working; companies that provide digital solutions.

The government will also be enhancing its Scale-up SG scheme with funding raised from 70 to 80 percent until September 2021. The scheme which was launched in July 2019 has helped 42 businesses develop and execute growth plans and aims to help another 50 companies in the next two years.

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The Next Big Thing In Wire EDM

The Next Big Thing in Wire EDM

Despite the many important and critical machine improvement points over the years, wire EDM machining speeds have remained relatively flat over the past decade… until now. Find out more in this article by Makino.

Wire EDM machining technology has seen continuous development to improve the reliability and efficiency of the process. These efforts have nurtured this non-traditional machining process to grow in use to become a mainstream method of manufacturing for an increasing number of industries. From its humble beginnings that revolutionized the tool and die building process, wire EDM has matured and expanded its use to direct parts production, especially in the medical and aerospace fields.

The latest generation wire EDM machines are better in almost every way compared to their predecessors, which has helped elevate the wire EDM process to become a daily relied upon manufacturing method. In recent years, many wire EDM manufacturers have focused developments on items that address and enhance the reliability of the process. This includes items such as simplifying the control interface, improving automatic wire threading capabilities, reducing machine maintenance requirements, and reducing wire consumption costs. While these are all important and critical machine improvement points, Wire EDM machining speeds have remained relatively flat over the past decade… until now!

Makino has introduced a new wire EDM machine, the U6 H.E.A.T. Extreme, that has been developed to take machining speeds to new levels of performance and efficiency. At the core of these new capabilities is the use of a larger diameter wire—0.016” (0.4mm)—elevating the U6 H.E.A.T. Extreme as the fastest wire EDM machine on the planet.

Is Bigger Better?

The key benefit in using a larger diameter wire is that it allows higher power levels to be applied, which result in increased machining speeds. There is a physical limit to how much power a particular wire size can withstand (spark density—the maximum amount of power that can be applied to the electrode over a specific area), as exceeding this level will result in a wire break; although there are other factors that contribute to wire breakage. Comparing 0.016” diameter wire to the traditionally used 0.010” diameter wire, the cross-sectional area is 265 percent larger.

Comparison of Wire Size

Using a larger diameter wire alone will not necessarily achieve higher performance. A larger wire supports higher power levels, but the 0.016” diameter wire size exceeds the power output capability of most machines, as wire EDM generators are commonly configured and optimized for 0.010” diameter operation. Stated differently, a standard wire EDM generator does not have a sufficient amount of additional/reserve electrical power to apply to the cut to operate at optimum levels with 0.016” diameter wire and will therefore starve and impede the process from achieving faster speeds.

To achieve faster cutting speeds using 0.016” diameter wire, the U6 H.E.A.T. Extreme machine is configured with an additional generator booster that increases the maximum average machining power from 30 A to 60 A. This booster unit increases the machine’s kVA power consumption by about 50 percent over the base U6 H.E.A.T., but this increase in power consumption is fully justified and offset by the gains in rough machining speed.

More Enhancements

The U6 H.E.A.T. Extreme builds and expands on the existing U6 H.E.A.T. machine and retains all the standard machining capabilities to achieve high accuracy and fine surface finish with wire sizes down to 0.004” (0.100mm) diameter. The “Extreme” portion entails special enhancements that focus on the operation of 0.016” diameter wire. Beyond the need for increased machining power, additional development and modifications are necessary to achieve reliable automatic wire threading with 0.016” diameter wire, which represents a severe technical challenge.

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ESCO Tool Enables Easy Modular Tooling

ESCO Tool Enables Easy Modular Tooling

A new clamshell style, O.D. mounted split frame machine that features fast, accurate, and easy to setup indexable tooling to part and bevel tube and pipe from 51 mm TO 1220 mm dia. is being introduced by ESCO Tool of Holliston, Massachusetts, U.S.A.

The Esco COHOG Split Frame Machine has a robust stationary ring machined from 7075 aluminum alloy that is hard coated and supports a custom steel forged, heat-treated and nickel-plated rotating ring using precision tuned eccentric bearings.  Featuring indexable tooling with slides and trip mechanisms and a marked locating system, this clamshell style machine can be precisely aligned and quickly attached without shims or guesswork.

Providing vibration-free operation, Esco COHOG Split Frame Machines have sealed construction to protect bearings and bearing races from debris.  Modular tool slides use tool steel blades or inserts with multiple cutting edges that offer more cuts per blade, and come in a variety of sizes for space-restricted applications.  Motor options include pneumatic, hydraulic, and electric power that can be mounted in different orientations.

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Aircraft Turned Parts Market To Reach US$ 1.9 Billion In 2025 Amid COVID-19

Aircraft Turned Parts Market to Reach US$ 1.9 Billion In 2025 Amid COVID-19

The aircraft turned parts market is expected to reach an estimated value of US$ 1.9 billion in 2025, impacted by COVID-19 according to Stratview Research market report.

Turning is a machining process used to obtain highly finished cylindrical parts with the help of single point cutting tools. Through turning, both solid, as well as thin-walled cylindrical parts, can be formed.

Impact of COVID-19 on the Aircraft Turned Parts Market

The rapid spread of COVID-19 exacerbated the existing aerospace industry challenges, hampered by the B737 max approval process. The pandemic left no options for aircraft manufacturers but to curtail their key aircraft production rates. For instance, Airbus announced to curtail its production by 1/3rd for 2020 with the revised rate of 40 A320s per month, 6 A350s per month, and 2 A330s per month, owing to a sudden collapse in air passenger traffic in the wake of complete travel ban imposed by several advanced and emerging economies.

Supply chain disruptions, huge cash burns, remote and adjusted work schedules, and huge COVID-19-related costs sacking the profitability are other noticeable effects of the pandemic.

However, strong fundamentals of the market, such as market entry of new aircraft programs; A321XLR, B777X, C919, and MC-21 coupled with a huge pile of order backlogs of Boeing and Airbus (12,816 commercial aircraft backlogs translating 7+ years at continuous production rates), and accelerated demand for replacing iconic aircraft such as A380 and B747 with A321, A350XWB, and B787, are some relieving factors for the entire aerospace community including the aircraft turned parts manufacturers.

It is estimated that the market is set to rebound from 2021 onwards after a nose-dive in 2020, the biggest collapse in the past two decades, and then will maintain a healthy growth pattern in the coming five years.

Asia-Pacific is expected to be the fastest-growing region in the years to come, driven by high long-term growth potential of the region. Commercial aircraft is likely to gain momentum in the region in the long run with the expected growth in the air passenger traffic and upcoming indigenous aircraft program (COMAC C919).

Military aircraft is also subjected to register a noticeable gain in the coming years, primarily driven by increasing defense budget of key economies, such as China, India, and South Korea.

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Mühlhoff Starts Production On Large Presses After Fire With Help From Schuler Service

Mühlhoff Starts Production On Large Presses After Fire With Help From Schuler Service

What a shock: at the turn of the year an arsonist sets fire in the production halls of Mühlhoff Umformtechnik on its site at the border with the Netherlands. The column of smoke can be seen for miles, resulting in damage in the high double-digit million euro range, including loss of production. But just six months later, the automotive supplier can start up again with its large presses: Schuler Service has already repaired two of the four damaged presses, and a new 2000-ton system from the TSD series is scheduled to go into operation in early 2021.

Mühlhoff managing director Markus Wermers had only been in office for three months when the fire broke out: “Just a few days later, Schuler Service was on site with nine employees.” Together, the decision is made to first repair the machines with 800 and 1,300 tons of press force that were only a few years old. In order to do this, the specialists have to replace the entire electrical and control system, and also remove several mechanical parts in order to have removed the contamination with soot and extinguishing water manually.

Mühlhoff can send some of the dies to the Schuler site in Erfurt so that parts production can continue there on a 1,600-ton press with TwinServo technology. “Other suppliers have also stepped in to process our orders,” recalls Wermers, who is currently running the business from a container in the parking lot – the administration building was also damaged by the major fire. He is grateful to his competitors for being able to continue to supply customers from the automotive industry with parts: “Everyone has helped so that everything can now gradually start up again.”

Mühlhoff Umformtechnik goes even further and is also investing in a new press from the TSD series with ServoDirect technology and 2,000 tons of press force. In addition, the system features the camera-based system “Visual Die Protection” and the “IIoT Connector” from Schuler, which enables numerous other Industry 4.0 functions such as process monitoring or predictive maintenance. “This means that we are optimally positioned for the future,” says production and project manager Christian Pennekamp with conviction. Pennekamp has been responsible for the configuration and project planning of the complex press systems at Mühlhoff for more than ten years.

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Driving Industry Forward With Intelligent Technologies

Driving Industry Forward With Intelligent Technologies

INTERMACH and MTA Asia 2020—ASEAN’s leading international industrial machinery and subcontracting event—is proud to showcase intelligent industrial machinery and technologies that drive the industry forward with timely manufacturing solutions such as automation, robotics and artificial intelligence (AI). 

The event offers a platform that will provide countless opportunities for entrepreneurs to gain access to advanced technologies and knowledge in a variety of industries. 

This year, more than 50 items will be launched for the first time in Thailand and ASEAN. There will also be a full range of sheet metal fabrication technology from 150 of the world’s leading brands, as well as additive manufacturing technology.

The event to be held from September 23–26 at the Bangkok International Trade & Exhibition Centre (BITEC) in Thailand, will feature cutting-edge manufacturing technologies and intelligent technology showcases from over 1,200 brands and 45 countries, over an exhibition area of 38,000 sqm. It will include major pavilions from South Korea, China, Japan, Taiwan, and Singapore. It will also feature an interesting line-up of conferences and forums, such as the following:

  • INTERMACH Forum: “SMEs, Transformation to Smart Manufacturers”
  • Future Automotive Forum: “Disruption of the Future Automotive in Thailand”
  • System Integrator (SI) Forum
  • Thai Subcon Seminar

In particular, the 4th INTERMACH Forum is designed for entrepreneurs in small and medium enterprises (SMEs). The forum will feature leading speakers and experts from both private and public sectors, who will share overviews and their insights in options and challenges on technology and workforce transformation for smart manufacturing. There will also be over 50 SME Empowerment Seminars and activities for SMEs related to future automotive, medical device, robotics, aerospace, and other ground-breaking industries.

Apart from these, the event will feature the Industrial Automation and Robotic Show 2020 (iAR), ASEAN’s leading exhibition on automation and robotics technology. The show, part of INTERMACH, provides a platform for advance automation and robotic technology and solutions enablers who are looking to upgrade their manufacturing, gain first hand updates on industry trends and developments, and grow their businesses in the market.

Co-located Events

SUBCON Thailand 2020 is the 15th Edition of ASEAN’s leading industrial subcontracting and business matching event. This is the only event jointly organised by the BOI Unit for Industrial Linkage Development (BUILD) – Thailand Board of Investment (BOI), Informa Markets and the Thai Subcontracting Promotion Association.

The show is designed to present business opportunities to more than 4,000 industrial part makers and help exhibitors negotiate business with major industrial part-buyers and manufacturers from Tier 1 and Tier 2. This year’s show is projected to be attended by more than 25,000 buyers from industries such as automotive, electric, electronic, machinery, as well as future industries including aviation, medical equipment, robotics automation and digital are all expected to take part in the event.

SHEET METAL ASIA 2020 is the 20th edition of Thailand’s largest international sheet metal fabrication and machinery event. The show brings together comprehensive technologies such as fibre laser machinery, CO2 lasers, press brakes, punching machines, water jet technology, and more, from over 300 major brands from 25 countries. The advanced technologies in sheet metal fabrication will cover industries such as automotive, electronics, electric equipment, construction, interior and furniture, medical devices, and agriculture.

For more information or immediate pre-registration, visit www.intermachshow.com.

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Schuler Appoints New Head Of Service

Schuler Appoints New Head Of Service

Torsten Petrick has been appointed as the new Head of Schuler Service as of July 1, 2020. Previously, he built up and managed the company’s global procurement. Graduating from the Technical University of Braunschweig and until 2008, Petrick worked in various management positions in the Maintenance, Repair and Overhaul (MRO) division of MTU Aero Engines AG. Graduating from the Technical University of Braunschweig

“The service is available to customers around the world around the clock to ensure the productivity and safety of both Schuler systems and third-party products,” emphasises Petrick.

Digital solutions are now intended to further improve the flexibility and agility of the Schuler Service. With the camera-based “Visual Die Protection” or the “IIoT Connector” for presses in the era of Industry 4.0, Schuler offers several products for networking forming technology.

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Accurate To The Micrometre

Accurate to the Micrometre

Here’s how readychain energy chains help Friedrich Vollmer Feinmessgerätebau GmbH achieve micrometre-accuracy in its measurement devices. Article by igus.

With the VLTG, Vollmer has developed the new “standard” for strip thickness measurement in cold rolling mills. (Source: Friedrich Vollmer Feinmessgerätebau GmbH)

Cold rolling mills operate at speeds of up to 2,000 metres per minute. A uniform strip thickness is a very decisive quality criterion, wherein the micrometre really matters. The more valuable the material is, the more precisely it must be rolled. This is because precious metals are cold-rolled and an oversize in this case is not only a quality defect, but also expensive from the manufacturer’s point of view. 

More than 50 years ago, Friedrich Vollmer Feinmessgerätebau GmbH developed a method for micrometre-accurate tactile strip thickness measurement of cold strip. The devices quickly became the worldwide standard in rolling mill technology and were subsequently expanded to include control units that can readjust the process at high speed.

The company has retained this unique selling proposition over the decades and has carried out intensive research work to develop a contactless measuring method with extreme accuracy to the point where it is ready for series production, thereby again gaining a development lead for the coming years. The Vollmer design engineers have chosen laser measurement as the measuring method. Since conventional lasers do not yield exact results under the ambient conditions of the rolling process with high temperatures, steam, humidity and oil mist, a proprietary laser technology was developed, and launched in 2014: the VTLG .

The VTLG has two laser distance sensors arranged opposite each other. The laser beams are in a common axis. A cumulative distance measurement enables the recording of the thickness of a material positioned in the beam path. The measuring rate is up to 80 kHz. This works with a resolution of 0.05 µm, whereby a measuring accuracy of +0.5 µm is achieved. This opens up completely new possibilities for the rolling mill operator to produce strip and foil with reproducible thickness. According to Elke Roller, sales manager at Vollmer, the VTLG became the new standard for strip thickness measurement. In fact, since its market launch, Vollmer has already sold around 90 units of this design in 17 countries. 

The mechanical structure of the C-frame in which the sensors are located must also meet the highest standards. The frame is made of Invar, a special steel with a minimum coefficient of thermal expansion. The sensor units move within the frame by means of a precision linear drive. The Sales Manager says: “For most users, a measurement of the strip thickness at the centre line position is sufficient to control the thickness. The sensor system then moves to the centre line position and is thereby adjusted. Other users continuously move the measuring device across the width of the strip to measure the thickness at different positions.” For this reason the energy and signal supply must be movable in the C-frame.

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The Benefits Of Composites For Milling Tools And Spindles

The Benefits of Composites for Milling Tools and Spindles

In this article, Dr. Humphrey Carter of CompoTech explains why CFRP tools are a feasible option for machinery manufacturers.

Shaft displacement with temperature. (Credit: Professor Matsubara, Kyoto University.*)

The use of carbon fibre-reinforced plastics (CFRPs) is very widespread in motorsports and the aerospace industry. The exceptional stiffness and lightweight of these materials make them ideal for enhancing the performance of Formula 1 cars and high-speed jet aircraft.

Less widespread is the use of CFRPs for the production of machine tools. The same properties that make these materials so popular in high performance applications can impart significant benefits in this arena too, especially for load-bearing and structural components, or for precision movements.

In particular, the use of CFRP parts can help to improve the speed and acceleration and deceleration of a machine tool, especially over extended distances. The accuracy and repeatability with which, for example, a tool set can be returned to exactly the same location, operation after operation, can have a significant impact on productivity and, through a reduction in weight, operating life.

 

Steel-composite Hybrid Milling Tool

To highlight the benefits of the use of CFRPs in such applications, CompoTech recently developed a steel-composite hybrid milling tool that, in testing, has been shown to perform faster and machine more accurately than conventional options. The tool also imparts improved surface roughness meaning that, in certain circumstances, it can perform the job normally requiring two steel tool sets, for rough and final machining. This increases milling productivity, decreases machining time and reduces machining cost.

The hybrid milling tool is produced by depositing carbon and graphite fibre onto a steel part using a process called robot assisted filament laying (RAFL). The steel body acts both as a mandrel and as a means of connecting the tool to the tool holder and the tool holder to the spindle. It also provides a means for the attachment of the tool to the milling teeth.

After fibre placement, the part is cured at room temperature to reduce the likelihood of any thermally induced stress. It is later machined to its final shape.

The reduction in weight, up to 40 percent, and the increased stiffness provided by the use of graphite and carbon fibres enhances the damping properties. As well as increasing the natural frequency of the tool, reducing unwanted vibrations in the machining process, it gives the tool greater stability.

The low weight of the milling tool means that less energy is used in non-loaded positioning, while the lower inertia reduces peek energy in acceleration. Fortunately, this can also reduce wear on parts of the machine, meaning that the lifetime of the machine and the durability of the tool tip can be increased.

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