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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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Heimatec Discusses Market Opportunities, Challenges And Strategies

Heimatec Discusses Market Opportunities, Challenges and Strategies

Karl Moessmer (left), regional manager for Singapore, and Dirk Hund (right), sales manager, at Heimatec, speaks with Asia Pacific Metalworking Equipment News (APMEN) about the opportunities in the market, the challenges they are seeing, and their strategies to navigate these issues. Interview by Stephen Las Marias.

Established in 1987, Heimatec GmbH manufactures precision tools for turning and milling centres. The company is headquartered in Renchen, Germany, and has subsidiaries in Moscow, Russia; Chicago, Illinois, USA; and Pune, India; and has a representative office in Singapore.

At the recent MTA Vietnam 2019 event in Ho Chi Minh, Karl Moessmer, regional manager for Singapore, and Dirk Hund, sales manager, at Heimatec, speaks with Asia Pacific Metalworking Equipment News (APMEN) about the opportunities in the market, the challenges they are seeing, and their strategies to navigate these issues.

For those who may not be familiar, please give us a quick background on Heimatec.

Karl Moessmer (KM): Heimatec manufactures static and live tools for turning and milling centres, as well as machine centres. Static tools are the most basic kind of additional accessories for machine tools, whereas live tools give manufacturers a greater flexibility to manufacture, let’s say, more complex components. In this sector, we face substantial competition from Europe, especially, Italy and Germany, and to a certain extent, from Japan. Our participation in this show underscores our focus on the Asia Pacific market. And we have Vietnam in mind as we can see more and more foreign direct investments flowing into the country. That means more sophisticated machineries are being placed in various industries in the region.

What opportunities are you seeing?

KM: The number of machineries—machine tools, turning centres, machining centres—is increasing. And with it, the demand for the tools. Of course, Vietnam might be at the early stage for this kind of industrialisation, but it will grow like any other country did in the past. We don’t want to step in when all the positions are occupied already. We want to be part of it from the very beginning. This is where we see an opportunity.

Dirk Hund (DH): I agree with Karl. I am in close contact with him about the market situation here in Southeast Asia, and not every country has this big potential. But we definitely see one in Vietnam, Thailand, Philippines, and South Korea. These are the main regions we are looking at.

What are the industry drivers in the markets you are involved in?

DH: Investments. Government regulations or government programmes supporting various industries drive the region and investments. And for sure, bigger brands, bigger companies, when they come to the country and they start a production facility, they need to get third party suppliers. Those who will manufacture parts for those companies are potential customers for us, as long as they have such types of machines.

KM: The investment is also driven by whoever is supporting it—for instance, car manufacturing. We see a lot of potential in this area, but car manufacturing has been shifting all over the place. Right now, maybe the biggest chance remains in Thailand. But we also see part of production in this area shifting to the Philippines.

We always have to be on our toes to follow where the market is. The market is changing, depending on how strong the government is supporting a certain industry. Maybe around 5 to 10 years ago, it was disk drive manufacturing, they are using a lot of machine tools. But this production has been shifting all over the Asia Pacific. We have to open our eyes and travel a lot so that we can get first-hand information from the market. And in exhibitions like this, the feedback we receive will tell us how to change our attitude toward the market potential.

What challenges are you seeing?

KM: The biggest challenge is the different types of language. It is not enough that you can say ‘Hello’ or ‘Good morning’; you have to be able to explain the technical product.

DH: Finding the right partner. Not everybody, or not every company, can afford to open up their own facility here, or sales or service department. I believe it’s necessary to be successful in the country. If it is Vietnam, or Thailand, or whatever, you need to have good partners. And as Karl said, language is another barrier. It’s hard to find people who can speak English, even at least a few words.

Also, while one challenge is the technical part, which Karl described, the other one is the economic part. If you want to become successful in this market, you have to follow a strategy. In Europe, we use a lot of time just to think about how we can approach our customers, and follow a specific route just to have a clear picture about the country or market, find out where the business clusters are, like automotive, medical device businesses—maybe Hanoi is automotive, and Ho Chi Minh is aerospace—and you need to follow up once you find the machine tool builders.

You have to contact them, try to find possibilities to get in there, and then identify your customers. And do it like a sniper. This is sometimes hard to explain to some partners here in Asia, if you have found one. Sometimes, it’s difficult to deliver the message.

KM: One technical aspect to consider is that all the advanced machine tools require advanced and stable power supply. In the instance there are brownouts, when you don’t have a stable supply of power, you are in big trouble when you have highly advanced machineries—enormous damage can be caused when there are power interruptions. Therefore, the infrastructure is also important.

Also, when it comes to shipment of goods. For instance, when you ship a machine tool to Singapore, within the next couple of hours, it is already in the factory. But when you ship to other places, there might be flooded roads when it rains, and all the while the machine is hanging somewhere. Infrastructures must be stabilised and properly developed.

What are your goals and outlook in the Southeast Asian market?

DH: For the next two years, to have a solid base and partnerships here in Vietnam. Whatever the outlook will be, for sure, we want to grow with the market. We know we have to invest a lot of time and patience to develop it the right way, and every single euro we can make as a turnover will be perfect.

As long as we can do some turnover in the region, I can support our management back home, to be patient and do this more in the region. Because it has a potential. The challenge also is for the management of companies to stay focused on the Southeast Asian region. It has different cultures, different nationalities, different behaviours, and all these doesn’t make it easy.

Finally, what would be your advice to customers when it comes to their tool selection?

KM: My advice is not to focus on the initial price offer primarily, but to look at quality, reliability and durability. Cheap products come at a cheap price. Some investors have this sort of a twisted concept: they buy a machine costing half a million dollars, and then try to save money on the tool on the lower end of investment. This is where they try to save. What if the tool does not perform? Then the whole machine will be idle just to change an endmill—on which they saved a dollar.

This is a big challenge in some of the markets. When you buy cheap machines, you buy cheap tooling, cheap cutting tools, and then you save on the materials, but then you want to produce a top-class product… How can it be? If you want to sell to markets that are able and willing to pay a good price, then you have to supply top quality products. These products cannot be produced with cheap machines, cheap tools, and cheap materials.

 

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Addressing Temperature Effects In Turning

Addressing Temperature Effects In Turning

One of the most serious enemies of carbide inserts is the high temperature of the materials that results from the machining process. Here’s how high temperatures in machining are being addressed through the latest insert technologies. Article by ISCAR.

Cooling is essential to the machining world, where appropriate cooling can significantly increase insert life and reduce manufacturing costs, due to the changes in chip shape and the resulting temperature during the machining process.

In the last few years, the concept and implementation of cooling solutions for cutting tools has enjoyed a surge of popularity and enthusiasm as if it had never existed before. CNC machine manufacturers throughout the world have invested time and resources to develop solutions that can supply coolant at high pressures and today all new machines are supplied with a high-pressure coolant option.

Manufacturers from industries such as aerospace, automotive, and large part production appreciate the immense advantage of supplying coolant directly to the cutting edge and are only ordering machines for milling centers or turning centers with high pressure coolant capabilities—minimum 70 bar and up to 300 bar. Mass production manufacturers are also benefiting from the integration of ISCAR’s JETCUT tools into their processes.

One of the most serious enemies of carbide inserts is the high temperature of the materials that results from the machining process. Temperatures vary, depending both on the properties of the metal that is being machined and on environmental work conditions. The average temperature during machining can range from 300 deg C to 900 deg C.

As the temperature rises, the lifespan of the inserts is shortened. Increased wear can damage workpiece quality and negatively affect machining properties: the heat generated between the insert and the workpiece can cause a change in chip shape and plastic deformation of the insert.

High pressure starting at 70 bar can be effective in breaking chips and, in cases when it is difficult to break chips and the chip formed is long and curled, coolant applied correctly and under high pressure can solve this problem.

Judicious application of coolant can prevent the workpiece materials from deformation and can act as protectant for the machine. In many cases, effective and efficient cooling can actually mean the difference between profit and loss.

Cooling Technology

Cooling has a major influence on machining exotic materials such as Inconel, Titanium, Hastelloy, Monel and other alloys, which are all used in the aerospace industry. These workpiece materials are difficult to machine as they have a very high nickel level and possess a tendency to stick to cutter edges due to their elastic, sticky and ductile properties – which is one of the reasons that parts for the aerospace industry are extremely expensive. Machining these types of materials without coolant is almost impossible, as the high temperatures and stickiness cause instantaneous wear and premature failure for carbide inserts.

In addition to reducing temperatures for exotic metals, the use of coolant creates a shielded area between the insert and the workpiece material, so preventing material from sticking to the cutting edge – which is a major factor in premature failure for inserts.

In groove turn operations, it is particularly important to select the right grade for chip breaking. An incorrect choice of grade or chip breaker can spell disaster for the manufacturer. In addition, cooling has a significant effect on chip breaking effectiveness and correct coolant application can mean the difference between success and failure.

After researching and studying the influence of coolant on its inserts, ISCAR applied the scientific knowledge acquired to the successful implementation of new and groundbreaking cooling technologies in turning operations. The company developed and integrated external and internal tools to deliver coolant directly to the cutting edge, including the JETCUT range. This has succeeded in increasing tool lifespan and productivity and, even at low pressures such as 10 or 20 bar, the advantages of directing coolant flow straight at the cutting edge can be seen in the reduction of temperature during machining.

Manufacturers engaging in high volume machining have noted a substantial increase in tool life and productivity after integrating JETCUT tools to pinpoint coolant directly to the cutting zone. This is because lowering the temperature in this way facilitates longer tool life, increasing cutting conditions such as speed and feed.

Manufacturers who work with problematic exotic materials such as Inconel, titanium and stainless steels have also managed to achieve higher productivity by incorporating JETCUT tools. Pinpointing high pressure coolant straight onto the cutting zone prevents a sticky edge, consequently extending tool life.

In response to the growing demands of many industry sectors, ISCAR expanded its jet high pressure line by adding turning tools fitted with the JET-R-TURN hollow rigid clamp, which also acts as a coolant nozzle. Until now, ISCAR’s ISOTURN range of tools featuring a jet high pressure cooling option were designed with a lever clamping mechanism, as an upper clamp would obstruct the coolant jet from reaching the cutting edge.
The new design enables jet high pressure coolant to reach the cutting edge without any obstacles.

ISCAR offers tools with JET-R-TURN Rigid Clamp mechanism for the most popular standard CNMG, WNMG and DNMG insert geometries. It features strong and reliable clamping mechanism, which prolongs tool life; directs the coolant jet directed to the cutting edge; and has excellent corner location repeatability and performance in heavy cut machining.

The new external tools feature three coolant connection options: rear threaded inlet, bottom threaded inlet, and bottom inlet for adjustable shank overhang, as in ISCAR’s JHP-MC tools.

All external tools are equipped also with a frontal bottom coolant outlet directed to the insert flank, which enhances the cooling effect. The through-tool coolant provides improved tool life, chip control and productivity advantages when high pressure coolant is induced. In addition, the 10–15 bar standard pressure provides better performance when compared to external cooling results.

Every Second Counts

What is a second in our life? Every second can be multiplied and translated to millions of seconds when considering mass production of standard parts. Saving a single second times a million parts is equivalent to a whole working month, which represents a major savings and is the dream of every mass production manufacturer.

And ISCAR’s wide range of JETCUT tools for a variety of applications, from turning and grooving to parting, helps manufacturers achieve this, and more.

 

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Seco Tools Releases New Duratomic TM Grades For Stainless Steel Turning

Seco Tools Releases New Duratomic TM Grades for Stainless Steel Turning

Seco Tools has announced the release of three new grades specifically for stainless steel turning featuring the company’s latest Duratomic generation and its Used-Edge Detection technology. The new TM grades TM1501, TM2501 and TM3501 secure operations and improve productivity in materials ranging from austenitic stainless steel to high-alloyed, super-duplex stainless steels. The expanded range of 479 total TM insert configurations also includes three new geometries with chipbreakers optimised for finishing and medium-roughing applications in stainless steel.

TM1501 is designed for the highest level of speed, productivity and wear resistance in stable continuous cut applications for austenitic stainless steel components. The first-choice grade for any low to medium-alloyed stainless steel, TM2501 excels as a general grade that provides long tool life and toughness across the widest application area. And a brand-new grade for the toughest high-alloyed stainless steels, including duplex and super-duplex stainless steels, TM3501 also offers good performance across all stainless steel applications.

The addition of the unique FF1 chipbreaker for the TM3501 grade provides superior chip control in stainless steel finishing, while the new MR3 and M3 complements MF4 and M5 in medium-roughing applications. These three Duratomic grades feature innovations based on world-leading coating chemistry developments adapted to manufacturers’ application needs. In addition to offering superior mechanical and thermal properties, this coating also provides the chrome-colored Used-Edge Detection technology, which makes every edge count and reduces potential waste.

 

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