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Blum: TC64-Digilog Wireless

Blum: TC64-Digilog Wireless

The primary area of application of Blum’s TC63-Digilog is on large milling, turning and turning/milling machines, in which the system must be used together with extensions and elbows in order to reach the various measuring points.

The wireless probe has a maximum probing speed of two m per minute, and approach directions are in the X, Y and Z axis.

The probe’s measuring mechanism means that during the scanning process, the integrated face gear produces a defined deflection direction at constant deflection forces. Any torsional force that may occur is absorbed by the face gear and thus has no effect on the measuring result.

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Starrag: Dorries Contumat VCE 2800

Starrag: Dorries Contumat VCE 2800

Starrag’s Dorries Contumat VCE 2800 single column vertical lathe is suitable for turning.

With additional units, it can also be used for drilling, milling and grinding, meaning that full machining operations are possible on the machine. Hydrostatic guide rails are designed to damp vibrations. The table diameter is 2,490 by 2,640 mm, with a maximum workpiece weight of 25,000 kg. Swing diameter is 2,800 mm.

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Okuma LU7000 EX CNC Lathe

Okuma LU7000 EX CNC Lathe

Okuma LU7000 EX CNC Lathe two-saddle is designed for applications with large work envelopes. The machine’s turning capacity is 10 sq mm and can cut oil-well pipes in one chaser threading.

The Okuma LU7000 EX CNC Lathe machine also has a 45-degree box bed with all box way construction, which provides support for the carriage and cross slide.

The Okuma LU7000 EX CNC Lathe machine’s end milling capacity is 120 cubic cm per minute with maximum working diameter of 900 mm and 200 mm long Y-axis travel. Simultaneous turning with upper and lower turrets can achieve faster cycle times.

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Sandvik Coromant: GC2220 Turning Insert

Sandvik Coromant: GC2220 Turning Insert

Sandvik Coromant’s GC2220 turning insert is made for stainless steel materials. It is available for CoroTurn 107 inserts, CoroTurn TR for external profiling and T-Max P for general turning applications, and is suitable for the aerospace, automotive, and oil and gas industries.

The Sandvik Coromant GC2220 Turning Insert offers better resistance to plastic deformation and provides better edge line security.

The insert has a CVD-coated gradient sintered carbide that is designed for semi-finishing to rough turning under stable conditions where higher wear resistance is required.

Its Inveio coating provides unidirectional crystal orientation in the alumina coating layer, increasing tool life and wear resistance.

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Tornos: Swiss DT 26 Turning Centre

Tornos: Swiss DT 26 Turning Centre

The Tornos Swiss DT 26 turning centre has two C axes and five linear axes that can accommodate eight rotating tools and a maximum of 22 tools.

It has a liquid-cooled guide bushing with a built-in motor and the guide bush can be removed to give a maximum workpiece length of 45 mm on the machine, which takes 15 minutes to convert to a different direction.

The Tornos Swiss DT 26 Turning Centre machine has a 10.5 kW motor on both its front and rear spindles that delivers speeds of 10,000 rpm. It has a modular four-position counter operation station which can be used for main operations, enabling tasks such as polygon turning or thread-whirling processes.

Tornos Swiss DT 26 Turning Centre Designed to machine bars of up to 13 and 25.4 mm in diameter, these simple and easy-to-use machines allow you to achieve measurable production improvements. Thanks to advanced technical features and its efficient five-axis kinematics, the DT range is perfect for all your turning and milling tasks.

 
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WFL: M200 Millturn

WFL: M200 Millturn

The M200 Millturn can machine workpieces of up to two m in diameter, 14 m in length and 60 tons in weight.

The a new dimension in complete machining M200 MILLTURN WFL Millturn Technologies machine is built in different turning lengths and nominal centre distances, making the range of applications correspondingly diverse: large landing gear extensions, large crankshafts, shafts for turbines and for generators, large manifolds as well as shafts and rollers for heavy industry.

The turning-boring-milling unit can work on difficult-to-machine materials, and at up to 80 kW of power and 1800 Nm of torque with minimal vibration. The machine can work on any type of inclined machining due to its B-axis; it also supports WFL M200 MILLTURN 5-Axis CNC Lathes interpolation.

 
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Process Knowledge Makes Machining More Efficient

Process Knowledge Makes Machining More Efficient

Complete machining solutions at component level are improving cost-efficiency for the aerospace industry. By Lim Gan Shu, Southeast Asia marketing manager, Walter AG

Although the topic is not new, it appears as a new item on the agenda on a daily basis: The demands made on manufacturers in the aviation and aerospace industry are becoming increasingly more demanding and complex. And what applies to production businesses, also applies to the machining industry that provides them with the tools they require.

In order to be more cost-efficient, manufacturers need to not only use tools that perform with a long tool life, but also continuously optimise their machining solutions and processes. In this area in particular, Walter provides support for its aerospace customers.

Creating Complete Solutions

The goal is to create complete solutions that address the complexity of the task and help to increase productivity and cost-efficiency.

“Today, customers expect their tool supplier to have a high level of expertise in all key operations that are carried out using its tools. This reduces the increasing cost pressure and compensates for the loss of expertise which arises as a result of outsourcing a large number of tasks.”, explained Thomas Schaarschmidt, director business and application development at Walter.

This means that, in addition to the tools required for the relevant machining solutions and the associated comprehensive service, suppliers also have a recycling and reconditioning program.

Technical support is provided, and simple order processing is integrated into the customer’s workflows. The supplier programs the machining systems (or helps the user’s staff to do so) and trains the customer’s employees, among other requirements that are neded.

Crucial Beneficial Effects

In addition, the tool specialist develops complete machining concepts, including all process steps which arise during the production of a component. These concepts are individually tailored to the customer’s needs and contain detailed recommendations regarding which tools are used in which step.

Mr Schaarschmidt said, “We have taken our customers’ list of requirements and developed it further. In other words, we have been systematically building on the comprehensive expertise that our customers need to take on the problems and challenges associated with the production of their components. We make this expertise and the discoveries which result for the production process available to our customers. We are thereby actively helping them to use our tools as efficiently, and as cost-effectively, as possible.”

First, Mr Schaarschmidt’s team defined specific components that are frequently used in the aerospace industry: Structural parts made from titanium aluminium alloys, for example, or engine and landing gear components. Complete machining solutions for these components are then developed in close collaboration with technology partners from the sector: Key customers, machinery and software manufacturers, suppliers, universities and research institutes.

Practical Development

“For every component for which we develop a machining solution together with the customer, we analyse the features and look at which and how many variations exist for each component. Then we map the entire process chain as it is implemented at the customer, in-house or at technology partners. This means that we know every detail that is relevant for machining the customer component,” said Mr Schaarschmidt.

In the next step, a roadmap is created that defines which steps are to be taken to the finished solution. The specialists identify what they can do where, which processes they have already mastered, where there is need for development and how this should be covered most effectively and in the quickest way possible.

The creation of machining concepts involves tool specialists who bring their expertise in machining turning, drilling, threading or milling using a wide range of different materials. The process also involves component experts who know which challenges associated with the manufacture of specific components need to be overcome.

To enable them to tailor their solutions as closely as possible to the specific requirements of the user, the company’s component managers visit their customers on a regular basis.

“Our component managers are deeply involved in the topic; they speak the language of our customers and know exactly where the problem areas lie,” explains Mr Schaarschmidt.

Their task is to keep up to date with what the users of the cutting tools are currently doing, and what optimisation measures or open topics they are looking at. They also gather feedback on recommended machining solutions.

A Competitive Advantage

The solutions that Mr Schaarschmidt’s team develops with customers have the purpose of creating competitive advantages for customers. It is therefore not uncommon for one machining concept to include hundreds of pieces of detailed information, machining steps or more. This includes numerous variant-specific machining solutions for every component.

Mr Schaarschmidt stated that his team’s goal is to offer a complete solution for 80 percent of the different variants of a component—all documented, partly standardised and accessible to specialists at all times.

The result: recommendations of which tools, machining parameters and processes can be used to produce a certain component with costs. This information is passed on to their customers via technology days together with technology partners, via roadshows, using training videos or animations on YouTube and, in the future—to deal with the trend in digitalisation—via the company’s homepage and augmented reality.

Knowledge about future products and requirements also flows into the development processes.Mr Schaarschmidt explains the benefits for customers:

“Forward-looking planning and development enables us to offer our customers a completely new type of machining solution, often right at the start of production of a new product, which is precisely tailored to them.

He adds that his team is able to support their customers with new component-specific cutting material solutions with immediately. Along with reduced start-up costs, the time between development and series production (time-to-market) is considerably accelerated and that this has a positive impact on cost-effectiveness.

Porcupine milling cutter for roughing titanium alloys

Porcupine milling cutter for roughing titanium alloys

Landing gear mounts are complex structural components that are situated horizontally in the wing structure above the landing gear. These elements connect the wing and the landing gear and act as a shock absorber in conjunction with the main cylinder of the landing gear

Landing gear mounts are complex structural components that are situated horizontally in the wing structure above the landing gear. These elements connect the wing and the landing gear and act as a shock absorber in conjunction with the main cylinder of the landing gear.

Wing ribs are structural components inside the wing. Together with the longerons, they form the frame for the wing skin. Wing ribs are predominantly manufactured from aluminium wrought alloys. These are light, have a high load-bearing capacity and are extremely robust

Wing ribs are structural components inside the wing. Together with the longerons, they form the frame for the wing skin. Wing ribs are predominantly manufactured from aluminium wrought alloys. These are light, have a high load-bearing capacity and are extremely robust.

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Green Light For Accelerated Automotive Turning

Green Light For Accelerated Automotive Turning

An interesting approach towards Accelerated Automotive Turning the external turning of steel parts in high volume offers opportunities for manufacturers in the automotive industry. By Håkan Ericksson, global product specialist at Sandvik Coromant

Manufacturing engineers in the automotive industry have tried almost everything to extract the last drops of productivity from their conventional turning processes. Although these processes are evolving by making small gains on an almost constant basis, a different approach looks set to help turning shops take a step forward.

With a different take on turning conventions, PrimeTurning from Sandvik Coromant offers opportunities for manufacturers tasked with the external turning of steel parts in high volumes. The methodology can not only address many of the common challenges faced by automotive original equipment manufacturers (OEMs) and suppliers, but also provide potential gains.

Automotive Turning Predominance

Steel turning dominates many automotive applications, including the production of transmission shafts and shift sleeves, and flange and post ends on engine crankshafts, for instance. Hub units, constant-velocity joint components and drive pinions are among further examples. In a market as notoriously competitive as automotive, all of these parts share a common requirement: To maximise productivity without compromising quality.

The question is how can this still be achieved? Turning is a mature process that has been edging forwards for a number of decades but without a major step-change of note. Sure enough, more rigid machines have been matched with ever-improving workholding and cutting tool solutions, but the methodology of turning itself has not evolved.

The upshot is that turning has become a bottleneck in comparison with many other manufacturing processes which have advanced at a faster rate.

Turning On Its Head

In contrast to conventional longitudinal turning, the new turning methodology allows the tool to enter the component at the chuck and removes material in the opposite direction. Turning “backwards” in this manner allows a small entering angle to be applied, which in turn can provide productivity gains.

Experienced operators are aware that small entry angles permit increased feeds, but in conventional turning are restricted to around 90 deg in order to reach the shoulder and avoid the long, curved chips that small entering angles characteristically generate. In contrast, the new process provides reach at the shoulder and allows for entry angles of 25-30 deg, with chip control and maintained tolerances.

Of course, some machine shops have already tried turning from chuck to part end with small entry angles, but the problem has always been chip control. With the new methodology, however, there are chip breakers, edge preparation and a machining strategy that can account for chip thickness and a gradual release of cutting forces when entering the workpiece. As a result, speed and feed rates can effectively be up to doubled Accelerated Automotive Turning.

The small entry angle and higher lead angle create thinner, wider chips that spread the load and heat away from the nose radius, resulting in increased cutting data and/or tool life. Furthermore, as cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming, a common unwanted effect of conventional longitudinal turning.

This is good news for automotive manufacturing engineers under pressure to reduce cycle times and cost per part in order to stay competitive. The methodology also has additional benefits to offer, such as reducing downtime through fewer set-ups. This is because the new process allows for all-directional turning, which means that turning conventionally from component end to chuck can be performed using the same tools. This is supported by newly developed inserts that have three edges/corners: one for longitudinal turning, one for facing and one for profiling.

The specialised insert is designed for light roughing, finishing and profiling Accelerated Automotive Turning

The specialised insert is designed for light roughing, finishing and profiling

Efficient Edge Utilisation

Conventional longitudinal turning uses the corner radius and a small part of the insert side to create the chip, whereas the new methodology uses just the side to create a thin and wide chip. For facing operations, conventional methods continue to rely on the corner radius, thus further increasing wear. In contrast, the new methodology uses the other side of the insert, delivering edge utilisation and longer tool life.

Traditional turning methods always use the corner radius when turning, which leads to concentrated heat, excessive wear and unfavourable chip forms that are difficult to break, while the new methodology generates the heat in a wider and different area so that heat can move away from the cutting zone. The chip is also straight and easier to form.

All-directional turning presents possibilities for automotive shops to perform existing operations in a more optimised manner. Tests show that the new turning process is typically best suited to short and compact components, although all-directional turning inserts mean that slender parts can also be processed (conventionally) using a tail stock. With specialised Coroturn inserts, feed rates up to 1.2 mm per revolution and depths of cut up to 4 mm can be achieved, depending on the application.

Turning Code Generator

To Automotive Turning highlight the potential gains on offer to automotive manufacturers through a combination of the new methodology, specialised inserts and a new code generator. Numerical control code changes can be viewed as problematic to many machine shops. With the aim of simplifying adoption of the new process, the specially-developed code generator facilitates changing from conventional toolpath programs to the new methodology.

Furthermore, it helps to maximise output through the application of optimised parameters and variables, and ensures process security with suitably adjusted feed rate and entry radius data.

Turning Hubs

The Automotive Turning new methodology is suitable for use on CNC turning centres and multi-tasking turn-mill machines, and early customer tests have yielded results. For instance, when turning a hub made from cast steel (SAE/AISI 1045) on a Gildemeister CTV 250 CNC turning centre, a machining company in Brazil was able to achieve significant benefits.

Using the same cutting speed (300 m per min), the adoption of the specialised inserts allowed feed rates to be increased from 0.25 mm per revolution to 0.4 mm per revolution, and depth of cut from 1.5 mm to 3 mm. The result was a 59 percent increase in productivity and 55 percent more tool life. With over 120,000 hubs a year being produced, the overall impact on profitability is expected to be considerable.

The new methodology will thus appeal to automotive OEMs and their tier 1, 2 and 3 suppliers that know their cutting data and its current limitations.

As cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming Accelerated Automotive Turning.

As cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming.

 

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