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Shot Blasting, Mass Finishing And Cleaning Solutions From One Single Source

Shot Blasting, Mass Finishing And Cleaning Solutions From One Single Source

Perfectly adapted to the requirements of a job shop operation.

Article by B+S Metallbearbeitung GmbH.


The services offered by the B+S Metallbearbeitung GmbH include all kinds of mass finishing operations like deburring, polishing, etc., as well as shot blasting, part cleaning and packaging. The company handles a broad range of work pieces with different shapes, made from different materials, requiring different finishes and coming from all kinds of industries. To ensure continued excellent quality and on- time deliveries in a cost-effective manner, this service company is counting on well- trained employees and utilises modern equipment and consumables from Rösler.

The beginning of the B+S Metallbearbeitung GmbH dates back to the year 1959. The company, founded by Herbert Bickel, specialized early on in jobshop services in the field of mechanical surface treatment, such as mass finishing. In 1991 Mustafa Sahin became an employee of the B+S Metallbearbeitung GmbH located in Murr in Southern Germany. Since 2004 he held a 50% share in the company. When the founder decided to withdraw from the business in 2007 for health reasons, Mustafa Sahin became the general manager. He recognized quickly that in order to remain competitive and run the business successfully in the future, the outdated equipment had to be replaced with modern machinery. In addition, to strengthen the company’s competitive position in the market he decided to expand the service portfolio with additional finishing operations. An important aspect of this expansion strategy was to process the customer’s work pieces safely and consistently and to use high-quality equipment that could be operated round-the-clock.

Full Article On B+S Technology >> https://bit.ly/3mhnWPv

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Joining Forces For Continuous Operation

Joining Forces For Continuous Operation

How polymer knife-edge rollers are making maintenance-free conveyor belts and packaging systems possible, enhancing performance.

Article by igus.


Krones AG produces systems and machines for making, filling, and packaging beverages and liquid food. The industry never sleeps. So it is hardly surprising that Krones systems have to break their own speed records again and again. This becomes a problem when a part cannot withstand the pressure and there is no alternative that can perform better. That is why igus GmbH developed knife-edge rollers made of tribo-polymers for Krones, helping them achieve new records. In 2005, Krones faced a challenge with the Variopac Pro, a fully automatic all-round packaging system: the system’s performance had to be increased by 20 packs per minute. There was therefore an urgent need to change the conveyor belt deflection. Originally, metal rollers with needle roller bearings were used here, but they couldn’t meet the higher performance requirements and were cost-intensive. Looking for an alternative, Krones Design Engineer Jürgen Werner came upon igus GmbH products.

Full Article Available >> https://bit.ly/39VLJig

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Espirit Keeps The Success Flowing For Wet Design

Espirit Keeps The Success Flowing For Wet Design

Founded in 1983 by former Disney Imagineers, Southern California’s WET Design creates water features that are quite a few cuts above the fountains you might see at your local mall or city park. Their expansive portfolio is an impressive showcase of what’s possible when water, light, music, and human ingenuity come together. 

Article by WET Design.


If you’ve ever scrambled for a prime spot to watch the Fountains of Bellagio in Las Vegas, booked a once-in-a-lifetime experience at The Dubai Fountain at Dubai’s Burj Khalifa skyscraper (the tallest building in the world), or stopped to rest at the fountains at Salt Lake City’s City Creek Center, you’ve enjoyed WET’s work. WET installations can be found on three continents and have even made an appearance in the opening and closing ceremonies of the 2002 and 2014 Winter Olympics.

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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. 

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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. 

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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.

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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.

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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.

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