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Technical Revolution In Automatic Turning

Technical Revolution In Automatic Turning

igus develops energy supply solution for rotational and linear motion for DMG Mori.

For installation of the harnessed cables in the energy supply chains and the metal guides, the technicians in Cologne need approximately 2.5 days. (Source: igus GmbH)

After only two years of development time, DMG Mori ushers in a new era of automatic turning machines with the release of the Multisprint series, which support multiple spindles. But, behind its development is igus, which provided a special energy supply solution for both rotational and linear motion.

The readychain

The ‘readychain’ harnessed energy supply system from igus and the spindle drum were first brought together in April 2017, when many processes and manual procedures were not yet routine and demanded maximum attention from the people involved. Does the 750 kg and almost 2 m wide energy chain system from igus fit into the housing of the machine? Everything was put together in a way that is an absolute innovation in production technology for DMG Mori subsidiary, Gildemeister Italiana.

Upon installation of the readychain and its connection to the spindle drum, the engineers and technicians continued working for a further three months until midsummer 2017 to assemble the machine completely, test it and send it on its travels. Destination: EMO Hannover. Here, the Multisprint was presented as a revolution in mechanical engineering. After all, it is the first machine to combine a multi-spindle automatic lathe with SWISSTYPE technology. And all this with a Y-axis on each spindle position.

Maximum Flexibility Due to New Technology

Due to globalisation and market dynamics, customer requirements for modern turning machines have changed and now demand the following: shortened processing and tooling times, reduced amount of effort needed for process development and integration, and the ability to handle the increasing degree of complexity. Multisprint meets all these challenging requirements. Nozzles for fluid power equipment, implants for dentistry, and shafts for motor vehicle manufacturing are just three examples of complex components that can be made on the high-tech machine. The result is a manufacturing solution for scalable requirements from initial series production to the high-volume production of complex workpieces.

The combination of three types of machine technology enables the customer to engage in completely new forms of production, providing them maximum flexibility for the mass production of components with diameters up to 50 mm.

Heavy Drum Turns with Extreme Precision and Maximum Speed

The heart of the machine is the spindle drum with six spindles for simultaneous machining of several workpieces. The main spindles in the drum have a travel of up to 180 millimetres. The drum moves the workpieces to the tools quickly and very precisely—taking only 0.65 seconds for one of the six spindles to travel to the next position.

For spindles to return to the starting position after machining has been completed in the six stations, the drum must turn 300 deg in reverse. For this, the unit, which weighs over three metric tons, only needs one second. The rods are pushed out of the loader through the drum to get into position for machining. 

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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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Kennametal Introduces KCS10B For Superalloy Applications Used In Aerospace

Kennametal Introduces KCS10B For Superalloy Applications Used In Aerospace

Kennametal has introduced its newest turning grade, KCS10B, for nickel, cobalt and iron-based superalloys used in aerospace and other high temperature applications.

KCS10B, which features a revolutionary coating applied to an ultra-fine grain carbide substrate for superior layer adhesion, delivers up to 50 percent greater tool life, more predictable processes, and improved productivity when working with difficult to machine superalloys. KCS10B overcomes the most common challenges encountered in turning superalloys—cratering and depth-of-cut notching—two wear modes that often lead to unexpected and even catastrophic tool failure.

Special Sputtering

Rather than the light rain of droplets that fall on cutting tools during traditional PVD coating processes, Kennametal’s High-Power Impulse Magnetron Sputtering (High-PIMS) technology generates a fine mist of AlTiN, building a series of “extremely thin, smooth, and wear-resistant layers.”

Beating wear

Metals such as Inconel 718 and Stellite 31 are notorious for causing rapid wear and unpredictable tool life, KCS10B is proven to reduce DOC notching and extend tool life from three minutes to upwards of five minutes in roughing operations. Tool life in finishing operations fares even better, with visible cratering and subsequent tool failure often delayed by a factor of two or three compared to competitive brands.

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Tungaloy Revs Up Turning Efficiency In Heat-Resistant Superalloys With New Ceramic Insert Grades

Tungaloy Revs Up Turning Efficiency in Heat-Resistant Superalloys With New Ceramic Insert Grades

Tungaloy has unveiled two new ceramic insert grades: TS200 and TS300 that are developed for performing high-speed, high-efficiency turning operations of heat-resistant superalloys. The company has also introduced dedicated turning toolholders with a T-style insert clamp that are designed to securely hold the ceramic inserts to withstand demanding operations.

TS200 and TS300 are both SiAlON ceramic grades that are designed to perform high-speed turning operations of HRSAs common in aerospace, power generation and oil and gas industries. The TS200 is suitable for finishing processes; while the TS300 is ideal for removing oxide layer and other roughing operations.

The dedicated turning toolholders feature a unique T-style insert clamp with a carbide plate attached. This plate holds the ceramic insert securely in place in the seat to provide process security during demanding operations.

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Enabling More-accurate Measurement In The Micron Range

Enabling More-accurate Measurement in the Micron Range

This technology has enabled myonic to do machining even more accurate than before, and achieve even more measuring points to be recorded in a shorter space of time. Article by Blum Novotest.

The range of precision bearings, which are still a key sales-driver at myonic, has since been enhanced by a number of other products.

Precision hard turning is a key production process in the machine tool bearings unit at myonic GmbH in Leutkirch im Allgäu/Germany. Pieces are directly turned to the final dimension with extremely tight tolerances in the micron range. Using a probe solution from Blum-Novotest, key workpiece dimensions are now measured in-process, while still clamped. The result: greater measuring accuracy, improved manufacturing process, shorter cycle times.

myonic’s machine tool bearing activities are concentrated at a fully air-conditioned facility in Leutkirch, Germany. “The high-precision roller bearings are employed, for example, in rotary and swivel tables, milling heads and swivel spindles in machine tools,” explains Christoph Sauter, who, as Production Manager, is responsible for the manufacture of these precision bearings. “The bearings are double-direction, screw-on and installation-ready precision bearing units and part of the AXRY bearing range at myonic.”

The axial-radial-bearings consist of three rings: inner ring, outer ring and axial washer. Additional components include the cylindrical rollers, axial and radial cages, lubricants and retaining screws that hold the assembled bearing together. The rings are made of chromium steel, which has proven highly successful in bearing rings and rolling elements and which is hard machined at myonic exclusively on turning centres.

The hard-turning process occurs on different machines in two stages: roughing and finishing. Depending on the actual size, fine finishing to the final dimension, with extremely tight tolerances in the micron range, takes place on a horizontal or vertical turning machine in one setup and without any reworking. Cutting is conducted in a wet condition (cooling lubricant), while the workpieces are clamped on special magnetic chucks. Important dimensions in Z-direction are measured in-process, in other words while still clamped on the machine. An innovation that has significantly contributed to improving the production processes. This high-precision task is performed by the TC52 touch probe from Blum-Novotest, which transmits the measured values to an infrared receiver inside the machine room. The TC52 is positioned on the Hembrug horizontal hard-turning machines via the tool turret.

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Walter: Vibration-Free Machining In Difficult Conditions

Walter: Vibration-Free Machining In Difficult Conditions

With Accure·tec, Walter provides a damping system specially for turning and milling using tools with a long projection length. The vibration damping provided by the axially and radially flexibly positioned damper element is preset at the factory. The tools can therefore be used immediately without any time spent on adjustment.

Turning operations up to 10 x D can be manufactured with high process reliability and with very good surface finish quality using the A3000 boring bars. Examples include H7 engineering tolerances and the counterboring of generator shafts to Rz 6.3. The equally new QuadFit quick-change heads enable rapid tool changes and increase repeat accuracy (±2 µm). When milling, Accure·tec AC001 adaptors up to 5 x D can be used with cutting data up to three times higher than conventional tools.

Accure·tec AC001 adaptors are ideally suited to the Walter milling cutter range. This applies in particular to high-feed milling cutters, which have their main cutting force in the direction of the spindle. This means that the system is highly versatile: For example, for components with deep cavities in aircraft construction, as well as in mechanical engineering, the aerospace industry and the automotive industry. With turning applications, the focus is on the energy sector (e.g. valves for the oil industry) and/or on the aerospace industry (e.g. landing gear). Users benefit from good vibration damping and a system with low noise levels. Accure·tec promises longer tool life, productivity and process reliability and protects tools and machine spindles – despite higher cutting data. Walter offers Accure·tec AC001 (milling) and A3000 (turning) with all popular machine interfaces: Walter Capto, HSK/HSK-T, SK, MAS-BT and parallel shank.


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Kennametal Makes Hard Turning More Cost-Effective

Kennametal Makes Hard Turning More Cost-Effective

Kennametal introduces it latest innovation in hard turning-KBH10B and KBH20B PcBN grades, double-sided inserts for materials up to 65 HRC.

The new grades are specially designed to deliver higher productivity and longer tool life when turning tool steels and other hardened materials.

“Kennametal’s new KBH10B and KBH20B grade inserts are an excellent choice for high-volume production of hardened gears, shafts, bearings, housings, and other drivetrain components, where tooling cost per part is an important metric”, said Robert Keilmann, Product Manager, Turning.

Polycrystalline cubic boron nitride (PcBN) mini-tipped inserts have long been recognised as a great option for reducing part cost when turning hardened steel components. Kennametal’s new grades of PcBN inserts improve upon that value proposition by delivering increased productivity with a lower cost per part. Features include:

-Patented ceramic binder structure and TiN/TiAlN/TiN coating that provides extreme wear resistance even at elevated cutting speeds.
-A gold PVD coating makes it easy to identify when an insert needs indexing, while the numbered corners assure that a machine operator won’t inadvertently switch to a used edge.
-Two edge preparations in a “trumpet” style hone for heavier and interrupted cuts, and a light hone for continuous turning. Both are free-cutting, further extending tool life and generating surface finishes down to 0.2 Ra.
-The PcBN mini-tips are offered in four insert shapes—three rhomboidal and one triangular—which means up to six cutting edges per insert.


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