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EDITION
102011
TECHNONEWS
AND
INFORMATION
Solutions formany applicationsColgar has developed during the
last years different new machine
concepts and in the meantime it
has performed existing machine
according to customers requests.
Every final machining process
needs the right kind of machine
configuration with high flexibility
since the beginning and the
possibility of upgrading in future
with additional special heads or
tables.
OPERATOR’S SUPPORT
Every Colgar boring and milling
machine is equipped with the last
market products in particular for
the NC where all the machine
parameters are stored and where
we study and load the machine
software in house. Colgar with
the “in house” strategy makes
itself the entire main electrical
board of the machines, the wiring
on board, the main software
and all the additional interface
softwares for accessories,
for probing and for testing.
Diagnostic and teleservice are
always integrated.
In this edition
66 years of Colgar P.1
FV line – new line P.2
FRAL line – USA case History P.4
FVG line – the vertical way P.6
Press brake line – Solution for tube P.8
World activities and Bric P.10
Every year the market gives us the possibility to
choose new products or new relies of existing
product. The reason of this fast development is
to be input 100% to the final user. The final users
of the boring and milling machine are like all the
other users and for this reason in order to stay in
market for a long time with a good reputation, we
think and plan new machine components or entire
new machines
This happened to Colgar in its history too. At first, with
the manual shears and the manual press bending
machines to the first automatic machines, and later on
with a new product branc: the horizontal and hydrostatic
boring and milling machines floor type at the beginning,
and table type later with the clear target to offer to the
market flexibility with boring spindle and head changer
in easy way. From the horizontal boring and milling
machine to the vertical gantry machine the step has
been short and easy. During the last 10 years Colgar has
been entering into the market: big machining centres
with pallets from 15 ton. to 45 ton capacity and 4500 Nm
torque and max. power of 60 KW duty rates; big floor
type with vertical travel of 7.000 mm and 100 KW; new
table type and floor type machine with linear motion and
head in the centre of the column available from spindle
diameter 130 mm up to 160 mm, and vertical travel up-
to 5000 mm; vertical hydrostatic gantry machines with
a good combination of power torque and speed 1000
KW, 4000 Nm, 4500 rpm available with fixed crossbeam
and travelling crossbeam and with maximum opening
range between the column of 7.000 mm; vertical linear
motion gantry machines with fixed crossbeam, travelling
crossbeam and the configuration with fixed portal and
movable table is coming soon.
All these Colgar products are sold with minimum two
accessory heads for each machine and one rotary
table at least. The accessory heads have always been
projected and assembled at Colgar’s, and today just
several of them are standard while all the other ones
are customized, as well as the big tables up to 200 ton.
loading capacity.
NEW OPPORTUNITIES EVERY YEAR
After sales support
Colgar is supporting its worldwide
customers directly from Milan
but also from local Colgar teams
already present in Germany,
in Russia, in India, in China, in
Brazil, in USA, in Mexico.
TechnoNews Edition 10 2011
Next Main Event in 2012
•Metav@Dusseldorfforboringandmillingmachines
Colgar will be at Metav from 28/02 to 03/03 with its own both and its technical and sales team.
•Lamiera@Bolognaforpressbrakeandshears
Colgar will be at Lamiera from 09/05 to 12/05 with its own both and its technical and sales team.
•IMTS@ChicagoforbothColgarproducts
Colgar will be at IMTS from 10/09 to 15/09 with its technical and sales team and local area support.
•AMB@Stuttgartforboringandmillingmachines
For the second time Colgar will at Stuttgart to be part of this important appointment of the machine tools. From 18/09 to 22/09
•BIMU@MilanforbothColgarproducts
The largest machine tool event in Italy from 02/10 to 06/10
•BLECH@Hannoverforpressbrakeandshearsmachines.
Like every two year this will be again the most important event in the world for metal forming machine. From 23/10 to 27/10
Via Marconi, 6320010 San Pietro all’OlmoMilanoPh. +39 02936151 www.colgar.it
Colgar Quarto d’Altino Ph. +39 0422 824483
Colgar Germany Ph. +49 (0) 8231 – 9171-40
Colgar ChinaPh. +86 10 84720758
2 3
Linear motion Linear guideways achieve high
precision linear motion by using
recirculating rolling elements
between the rail and the guide
block.
Advantages of Linear Guideways:
High positional accuracy
Long-life with high motional
accuracy
High speed motion with low
driving force
Equal loading capacity in all
directions
Easy installation
Easy lubrication
Interchangeability
FV - Fast milling machines
The machining performance
achieved by Colgar customers
with the fast milling machines
of the FV line has confirmed the
high performance anticipated
during the design stage.
As always, the steel structure
represents a strong point typical of
and differentiating Colgar machines.
With its extensive experience in the
deformation sector, where Colgar
is one of the world leaders in the
construction of bending machines of
up to 3000 tons, the FV remains one
of the few boring milling machines
on the market to have monolithic
uprights with an integrated base,
a central head and angles folded
with an extensive range and not
welded. The axis movements are
made by means of roller guides
which have, by now, become an
imperative for machining centres
for three advantages which can
be summarised briefly as follows:
speedy, rigidity and simplicity which
make it possible to use them for
both rough machining and finishing
and boring.
automatically. These heads can
have mechanical transmission
up to 6000 rpm in S1 100% or
electro-spindle.
The new FV line becomes a
palletised work cell with a tool
magazine in the form of a rack
with space for 500 tools while in
the floor type version the length
of the X-axis makes it possible to
manage more than one working
area in pendulum mode.
The floor type
of the FV line
is divided into
two families, the
family FV101 and
its bigger sister
FV301, the new entry in Colgar’s
production range. While they
retain the same motorisation, the
two machines have different size
structures to guarantee different
travel along the axes.
Like all other FV models, the
FV301 has two recirculating ball
screws one on front and one on
rear side but it also has a ram
with 1500mm travel with thermal
The FV line has two versions, one
with a floor type and one with a
table type upright. The starting
point for the description of the
main characteristics of this line
of machines is the dimensions
of the structures calculated on
the basis of the frequency of the
“maximum removal” cut that they
can support combined with the
FEM analyses. Thus dimensions
are not chosen solely on the
masses to be machined but also
on the dynamics of
the masses during
machining. Indeed,
by checking mass
dynamics while
also maintaining
the concept of the
machine with a central head, the
colum of the table type machine is
significantly different from that with
a floor type upright. The boring
mill has always represented
Colgar’s core business thanks to
the spindle transmission with: two
gear ranges; the spindle cartridge
lodged inside the ram; and the
possibility of being able to replace
accessory universal indexed or
continuous heads quickly and
FV - New line and good performances.
We decided to develop this new line following the continuous development of tool manufacturers.
“Patented system
for the
management
of spindle extension”
FOCUSWIKIPEDIAA linear-motion bearing
or linear slide is a bearing
designed to provide free motion
in one dimension. There are
many different types of linear
motion bearings and this family
of products is generally broken
down into two sub-categories:
rolling-element and plane.
Motorized linear slides such
as machine slides, XY tables,
roller tables and some dovetail
slides are bearings moved
by drive mechanisms. Not all
linear slides are motorized,
and non-motorized dovetail
slides, ball bearing slides and
roller slides provide low-friction
linear movement for equipment
powered by inertia or by hand.
All linear slides provide linear
motion based on bearings,
whether they are ball bearings,
dovetail bearings or linear roller
bearings. XY Tables, linear
stages, machine slides and
other advanced slides use linear
motion bearings to provide
movement along both X and Y
multiple axis.
management of the extensions
and boring spindles between
150mm and 180mm.
The FV line has adopted
a patented system for the
management of the extension
of active feedback and an anti-
tailing system for the mills.
All full optional FV machines
are easy to manage during
production both in terms of
maintenance and operation while
also guaranteeing high levels of
precision.
It is clear that the versatility
offered by the FV line remains the
same as that offered by Colgar
with the FRAL and FVG lines: the
possibility of choosing between
the Siemens and Heidenhain
NC, interchangeable indexed
or continuous heads as already
mentioned above, chain or rack
tool magazines, tool breakage
or wear adaptive control systems
and multi-media diagnostics.
Linear motion – FV line
Horizontal type witH roller guide waysColgar type Floor type “t” typeColgar name FV 101 FV 301 FV 101 t FV 201 t
dati tecnici – Campo di lavoro specifications – Capacite d’usinagetechnical features – work range technische daten - arbeitsbereich
Corsa longitudinale Course longitudinaleHorizontal travel Längsverschiebung
mm No limits No limits Max5000
Max5000
Corsa verticale Course vertical Vertical travel Vertikalverschiebung
mmMAX 3000 5000 3000 3000
Corsa testa Course poupéeHeadstock travel Verschiebung des Spindelstockes
mm 1250 1500 Column2500
Column2500
dimensione testa Section poupéeHead dimension Querschnitt des Spindelstockes
mm 480x495 500x500 Fixed445x445
Fixed445x445
Corsa mandrino di alesatura Course brochespindle travel Bohrspindelverschiebung
mm 700 900 700 700
diametro mandrino Diamètre brochespindle diameter Spindeldurchmesser
mm 130 150÷160 130 150÷160
performances
potenza mandrino Puissance de brochespindle power Spindelmotor Leistung
kW S1 41 41 41 41
kW S6 40% 61 61 61 61
Coppia mandrino Coupletorque Drehmoment
Nm 1700 2300 1700 2300
giri mandrino Vitesse brochespindle speed Spindeldrehzahl
rpm 4000 3000 4000 3000
spinta assi Puissance de travailworking thrust Axialkraft
kN 15 30 25 25
rapidi assi Déplacement rapideFeed rates Vorschübe
m/min MAX 30 25 25 25
Components
equilibratura EquilibrageBalancing Ausgleich
HYDRAULIC
Cambio gamma velocità Change gamme vitessesgear box speeds Drehzahlbereich-Wechsel Getriebe
n° 2 2 2 2
guide Glissièresguydeways Führungssystem
LINEAR MOTION
testa automatica intercambiabile Tête automatique échangeable automatic interchanging head Automatischer austauschender Kopf
YES YES YES YES
Le caratteristiche possono essere variate e quindi non sono impegnative Specifications can be changed without notice.
Customer SupportOrder
Management
Sales & Discovery
Installation &Training
4 5
For a better project managementColgar has a big team of project
engineers, everyone focused on
different machine components
and this team is not the same of
R&D team.
After many years of work and
after many experience exhanges
with leading companies also
from other fields different
from machine tools, we have
discovered that is better to split
the idea of project. The engineer
who works on new project
cannot be influenced by other
internal problems concerning
application of valves, of switches
or other small components.
In a separate office out of Colgar
but in the same location, a new
Colgar R&D team works on new
projects perfoming the machine,
its components and calculating
the material stress using the
FEM system and other kinds of
testing softwares.
By using the 3D software the
project can be finally uploaded
and performed by each Colgar
engineer.
COLGAR USAColgar USA located in Cincinnati
offers today a very strong after
sales support with spare parts
and service.
Periodic Preventive Maintenance
is the most appreciated after
sales service for the USA
customers. The machines are
always under the control of
Colgar’s engineers also for the
geometric and laser set-up.
Colgar USA provides for entire
transport, insurance and
customs duties.
SOFTWARENewsAlready since
different months
Siemens is
pushing on its
840Dsl control where “sl” means
solution line and replaces the
“pl” version or power line. The
big difference is mainly for the
manufacturer than for the end
users who will continue to use
the control on the machine in
the same way and with the
same pages and subroutine.
Many applications from Colgar.
Every kind of material needs the right machine performance to obtain accuracy after its transformation
Hydrostatic – FRAL line
Customized solution
Maximizing
Machine Performance
Whether gaining insight into
machine conditions or precisely
controlling processes, advanced
sensors and other electronics
provide crucial information to
operators.
Asset management is a phrase
that has come to mean a number
of things. Sometimes it means a
formal and comprehensive software
solution, but it can also refer to
preventive maintenance of expensive
equipment, efforts to save energy,
and use of high-tech instrumentation
to guide machine performance.
Big equipment equals
big challenges
Smart management of industrial
machinery is essential to LeTourneau
(formerly LeTourneau Technologies,
www.letourneau-inc.com), a Longview,
Texas-based manufacturer of machines
and fabricated components for large
rubber-tired loaders used worldwide by
the mining industry, as well as jackup
rigs that drill for oil and gas offshore in
places such as the Gulf of Mexico, the
Persian Gulf, and the North Sea. The
company also makes drilling equipment
used on offshore and land-drilling rigs.
1970, has become a leader in the
manufacture of a variety of high-
quality machinery, including boring
machines. In 1999, Colgar became
ISO 9001 certified. In use at the
LeTourneau facility are two Colgar
FRAL 401 Floor Type Horizontal
Boring Mills. They are equipped with
107 HP (80 kW) spindle motors and
have 196-inch (5m) of Y axis travel.
“When researching machine tool
manufacturers for a machine that
could machine a gear box of this
size in one setup, we found very few
OEM providers,”
Le Tourneau said.
“There were none in
North America. The
Colgar FRAL 401
model seemed to fit
our need, and their
delivery was within
our expectations.”
LeTourneau purchased the first
one, a 5 meters by 10 meters, and
another, 5 meters by 10 meters, two
years later.
Exceptional reduction in
process time
A stunning benefit that the company
realized was drastically decreased
machining process time for the gear
boxes on the Colgars. Compared with
the older, smaller machines that the
“Our major structure that we machine
is a gear box for the jackup rig,”
LeTourneau machine shop manager
said. There are 12 such gear boxes
required per rig. There are four
different models, ranging in size from
up to 12 feet high to 20 feet; these
weigh up to 100,000 pounds.
“Once machined, we assemble all
the subcomponents and ship the
assembly to various shipyards such
as Vicksburg, Miss., and Brownsville,
Texas, where they are installed onto
the jackup rig. Once a jackup rig is
constructed and
moved on location,
these gear boxes
push the legs down
to the ocean door
and ultimately,
once settled in on
the bottom, raise
the drilling platform
to a working height of approximately
50 feet above the water.”
LeTourneau has five rig models
designed to operate in harsh
offshore environments, drilling in
depths that range from 300 feet to
550 feet of water.
Italian expertise plays into this
challenging production process:
Colgar S.p.A. (www.colgar.it ) based
in San Pietro all’Olmo, Italy, is a
66-year old company that, since
company had used, time was reduced
from 200 hours to 120 hours on the
largest gear box and from 60 hours to
32 hours on the smallest.
“We had expected to reduce process
time,” Shop Manager said, “but
certainly not by this amount.” Computer
numerically controlled (CNC) software
programs track production stats,
timelines, tool life monitoring, and
maintenance reminders (e.g., 1,000
hour hydraulic filter service needed),
along with fault history.
The company’s equipment has been
at work for about 100 hours per week
since installation. In order to manage
their assets and maintain that kind of
production level, LeTourneau employs
a preventive maintenance (PM)
system for weekly and monthly checks
on the Colgar machines. Additionally,
factory representatives come in
annually to perform a more thorough
check-up.
“Our shop, being 60-plus years old,
is not a controlled environment, so all
our machine tools must operate in a
rugged environment,” Shop Manager
said. “Both Colgars perform well and
have met our expectations to date.
When considering future capital
needs, additional Colgars are certainly
on the list.”
“We had expected
to reduce process time,
but certainly not by
this amount”
Machine Shop Manager,LeTourneau
Horizontal type witH HydrostatiC guide waysColgar type Floor type “t” typeColgar name Fral 401 Fral 501 Fral 601 prog 401 t
dati tecnici – Campo di lavoro specifications – Capacite d’usinagetechnical features – work range technische daten - arbeitsbereich
Corsa longitudinale Course longitudinaleHorizontal travel Längsverschiebung
mm No limits No limits No limits Max5000
Corsa verticale Course vertical Vertical travel Vertikalverschiebung
mmMAX 5000 6500 6500 3500
Corsa testa Course poupéeHeadstock travel Verschiebung des Spindelstockes
mm 1500 1500 1500 Column2500
dimensione testa Section poupéeHead dimension Querschnitt des Spindelstockes
mm 410x505 450x550 500x540 Fixed450x550
Corsa mandrino di alesatura Course brochespindle travel Bohrspindelverschiebung
mm 900 1000 1400 900
diametro mandrino Diamètre brochespindle diameter Spindeldurchmesser
mm 150-160 180-200 225-260 150-160
performances
potenza mandrino Puissance de brochespindle power Spindelmotor Leistung
kW S1 60 85 110 60
kW S6 40% 90 125 138 90
Coppia mandrino Coupletorque Drehmoment
Nm 4700 6250 15000 4300
giri mandrino Vitesse brochespindle speed Spindeldrehzahl
rpm 3000 2000 1500 3000
spinta assi Puissance de travailworking thrust Axialkraft
kN 35 40 50 35
rapidi assi Déplacement rapideFeed rates Vorschübe
m/min MAX 20 15 15 20
Components
equilibratura EquilibrageBalancing Ausgleich
MECHANICAL HYDRAULIC
Cambio gamma velocità Change gamme vitessesgear box speeds Drehzahlbereich-Wechsel Getriebe
n° 2 2 2 2
guide Glissièresguydeways Führungssystem
HYDROSTATIC MOTION
testa automatica intercambiabile Tête automatique échangeable automatic interchanging headAutomatischer austauschender Kopf
YES YES YES YES
Le caratteristiche possono essere variate e quindi non sono impegnative Specifications can be changed without notice.
6 7
Double set-upA long axis is always an
advantage for double set-up
and pendular machining.
The cost of investment is high
but the difference to extend the
X axis does not influence a lot
the final price.
When the double set-up is
available on gantry machine
the fixed floor plates are divided
in two areas using electrical
switches and phisical wall.
The switches are used to delimit
the working area and the wall
with windows is used to ensure
the set-up area. The operator
from his cabin decides the
working areas and, by removing
manually the wall, can use the
entire length of the floor plates
as a 3° area.
5 axisAerospaceThe 2 axes continuos head in
combination with the 3 axes
machine gives the possibility
to work form and special angle
surface.
The aerospace industries are
familiar with this application
for composite, aluminium and
titanium. In the first and in the
second case, the main customer
request is the accuracy, but in
the third case the accuracy is in
combination with the rigidity.
A subsidiary company of China
Aviation Industry Corporation
selected Colgar for its final
performances.
Solution
Gantry or notgantryGantry is a machine fitted in
a hoist trolley and can move
horizontally on a rail or pair of
rails fitted under a beam through
columns. At top of the column
the beam is the floor and it can
also move in vertical direction
changing the gap to the floor.
Not gantry is a similar machine
but the portal is fixed to the
floor and configurated with the
table which is moving under the
beam with longitudinal travel.
This machine is better called
Plano Mill.
Milling, turning or multitaskingThe multitasking machine
or better the apparent
simultaneous performance of
two or more tasks, is always
more and more requested.
The large components located
under the gantry machines can
be milled and turned using the
same machine, reducing the
set-up time. However in this
configuration the main spindle
is the machine spindle when the
milling operations are requested
and it changes into table spindle
when turning operations are
requested.
At least two different heads
will be used and double tool
changer for high flexibility.
The “mechanic world” is moving fastinto big sizecomponents.
Machine like the vertical FVG Colgar gantry joints together a lot of functions and quality.
Gantry – FVG line
Easy work piece set-up
HydrostatiC gantry typegantryFVg 40 Colgar type gantry
FVg 60gantryFVg 80
dati tecnici - Campo di lavoro Specification - Capacite d’usinagetechnical features - work range Technische Daten - Arbeitsbereich
6000÷30000 mm Corsa longitudinale del portale - asse X Course longitudinale du portique - Axe Xgantry travel - X axis Längsverfahrweg des Portals - X-Achse mm 6000÷30000 6000÷30000
3500÷5000 mmCorsa trasversale utile del carro sulla traversa - asse y Course transversale utile du chariot d’usinage sur la traverse - Axe Y useful transversal travel of machining saddle - y axis Querverfahrweg des Querschlittens auf dem Querbalken - Y Achse
mm 4000÷5400 5800÷8800
1500 mmCorsa verticale della testa - asse z Course verticale de la poupée - Axe Z
Vertical headstock travel - z-axis Vertikalverfahrweg des Spindelschlittens - Z-Achse
mm 1800 2000÷2500
1500÷2500 mm OPTIONtraversa mobile - asse w Traverse mobile - Axe W
Movable saddle - w-axis Beweglichem Querbalken - W-Achse
OPTION mm 1500÷2500 2000÷3500
2700÷4200 mm passaggio tra i montanti Passage entre les montantsdistance between columns Durchgang zwischen des Ständern mm 3700÷6200 4300÷7300
2000÷3500 mm larghezza dei piani di staffaggio Largeur des taques porte piècesFloor plate width Breite des Aufspannplatten mm 2500÷5000 3000÷6000
8000 Maxmm OPTION tavola mobile Table mobile
Movable table Beweglichem Tisch OPTION Maxmm 8000 8000
1500÷2000 mm passaggio sotto mandrino Passage sous brocheClearance under spindle Durchgang unter Spindel mm 2000÷2500 2000÷5500
500x500 mm sezione testa Section broche Headstock Spindelstock mm 420x420 580x580
performance
45 kW S1potenza motore mandrino Puissance moteur de broche
spindle motor power Leistung des Spindelmotors
kW S1 60 80
60 kW S640%
kW S640% 90 100
2300 Nm Coppia massima Couple maximum Max. torque Max. Drehmoment Nm 3300 8000
3÷5000 rpm Max velocità di rotazione del mandrino Vitesse de rotation de la broche maxMax spindle rotation speed Spindeldrehzahl max rpm 3÷4500 3÷3000
15 kN spinta - asse z Poussée - Axe Z thrust - z-axis Vorschubkraft - Z-Achse kN 30 40
25 m/min rapidi assi X-y-(z) Déplacement rapides X-Y-(Z)Feed rapid X-y-(z) Eilgänge X-Y-(Z) Achsen m/min 20 15
Components
HYDRAULIC equilibratura Equilibrage Balancing Ausgleich HYDRAULIC
2 n° Cambio gamma velocità Change gamme vitessesgear box speeds Drehzahlbereich-Wechsel Getriebe n° 2 4
LINEAR MOTION guide Glissières guydeways Führungssystem HYDROSTATIC MOTION
YES testa automatica intercambiabile Tête automatique échangeableautomatic interchanging head Automatischer austauschender Kopf YES YES
Le caratteristiche possono essere variate e quindi non sono impegnative Specifications can be changed without notice.
“Colgar uses
FVG 60 to work
with high degree
of precision”
The purchase of technologically
advanced products is today a
business imperative irrespective
of the reference market involved.
The solutions adopted by
Breton are of the highest quality
available in its industrial sector.
To maintain its advantage over
its competitors, Breton uses
Colgar’s FVG60 vertical gantry
type milling machine.
Guaranteed precision
The precision required in some
markets segment such as, for
example, aerospace, means that
machine tool manufacturers are
required to use the greatest possible
care and attention in machine
construction. We are always talking
about machines manufacturing other
machines.
Who is at the first step of this supply
chain has often to face with orders
making demands in terms of quality
and precision which are almost
unthinkable.
Sharing skills
This is the situation Breton found
itself in, where Colgar has recently
installed a Gantry machine FVG 60.
Already a market leader in the sector
for the production of machines for
online analysis of the force of the
ram during its working stage and
the third for viewing the area where
the work is being effected. All the
tools are stored in a magazine rack
running along the entire length of
the machine’s X-axis, 250 tools each
weighing 50 kg with Big Plus flanges.
The automatic accessory head
replacement system allows the
machine to be ready to possible
changes in production with great
speed. One of the
most advanced
features of this
FVG60 is the
hydrostatic support
along all sliding
guides which, thanks
to the 0.02mm film
of oil controlled by thermal-regulators,
allows it to reach a maximum speed of
25m per minute. This is the maximum
that can be achieved with hydrostatic
machines, maintaining precision over
the years without exerting too much
force on the machinery. The ram is
also hydrostatic, entirely wrapped on
its four corners and so completely
guided in its outwards movement up
to its maximum extension of 1,800mm.
A 60 kW motor, through gear box,
machining stone, in recent years it
has also experienced success in the
machine tool sector.
Colgar’s FVG60 is a machine able to
achieve a level of performance which
would otherwise be impossible.
Colgar uses this machine to work
with a degree of precision, reliability
and positioning times which are still
extremely competitive and can be
set up with a mobile cross-beam, a
rotating table and many accessory
heads for rough
milling, finishing and
grinding.
The FVG60
installed in Breton
has a wide passage
between columns
combined with a considerable
working length along the X-axis.
The working area made with floor
plates cover a surface measuring
3,500 x 18,000 mm, all levelled
with a tolerance of one hundredth
of a millimetre. The space between
columns is 4,700 mm with the
distance under the spindle of 2,200
mm. The machine is also fitted with
a high-performing control panel with
three monitors, one for viewing the
currently-running program, one for
makes possible to reach 4500 rpm
both on the main spindle and on the
accessory heads with a maximum
torque of 2500 Nm.
A device compensating the central
curve of the cross-beam has been
installed in order to correct the portal
structure based on the temperature.
Important details
On machines of this size with a weight
of 100 tons, Colgar guarantees
that the axes in movement will
be perpendicular to a precision
of 0.05mm per 500mm and that it
will maintain a straight line with a
precision of 0.01mm per 1000mm.
The maintenance of such precision
over time can also be attributed to the
technical solution used by Colgar and
immediately appreciated by Breton: a
safe and clean working area thanks
to the covering of the foundations on
the X-axes beds with self steel tapers
specifically and securely fixed at their
base to the foundations.
The machine seems to float on
the floor, the milling chips are
easily removed and the hydrostatic
elements are further guaranteed
by an additional folding protection
which slides over the beds under the
telescopic protection.
8 9
Synergies and support for growing
Either in case of chip removal
or of sheet metal working, the
solutions proposed by Colgar
are based on technology and
services aimed at improving
the quality and the productive
process of the user.
FEMallows detailed visualization of
where structures bend or twist,
and indicates the distribution
of stresses and displacements.
FEM software provides a wide
range of simulation options for
controlling the complexity of
both modeling and analysis of
a system. Similarly, the desired
level of accuracy required and
associated computational time
requirements can be managed
simultaneously to address
most engineering applications.
FEM allows entire designs to
be constructed, refined, and
optimized before the design is
manufactured.
Flash
Once the positionof the material is acquired by
the back gauges, the bending
cycle starts with the automatic
calculation of the bending
distances for the Y1 and Y2
axes based on the thickness
of the material, the angle to be
obtained and the tools utilized.
A “tandem” for bending 18 msheet metal
Colgar has built an impressive bending installation composed of two synchronized PIS 160.71/91 TAC hydraulic bending presses placed in tandem, each of 9,100 mm, for a total of 18 m maximum bending length.The machines have been installed at the largest Chinese train manufacturer’s facilities for bending sheet metal for carriages in a single piece.
Press brake – 1600 Ton. Tandem
“The Dalian
bending parts
requires high
structures machines”
For some time now, Colgar has
been concentrating its efforts
on largescale bending presses
as part of its production range;
complete installations built ad hoc
for the specific needs of users. The
success of the strategy has been
demonstrated by the impressive
bending installation that the
company from San Pietro all’Olmo,
Italy, has manufactured for the
Dalian Locomotive & Rolling Stock
Works, the main Chinese train
manufacturer.
Carriage components
in a single piece
The installation concerned is composed
of two synchronized PIS 160.71/91 TAC
hydraulic bending presses placed in
tandem, each of 9,100 mm, for a total
of 18 m maximum bending length and
a force of 3,200 t. A length that will allow
Dalian Locomotive to make carriage
components in a single piece (from 10
to 18 m), thereby reducing machining
times and production costs.
Optimal bending results
from the very first piece
Returning to the specific application,
the greatest problems were related to
handling the sheet to be bent in front
of the presses, which, as seen, are of
such size and weight as to require the
use of front support lays to move the
automatic control of the bending angle
provides the possibility of changing
the material’s characteristics relatively
easily because the numerical control
unit automatically up-dates the related
data so as to be able to compensate
the elastic return
detected by the three
laser sensors that
form the automatic
system.
FEM technology
is at the base of the “intelligent
structure”
The Dalian bending parts requires high
structures machines.
During design development we made
use of innovative FEM technology
(the checking of structural calculations
using the finite element method) to
establish the dimensions of the folding
press. In this way we were sure of its
behaviour under stress, a decisive
aspect for the control, and automatic
compensation, of deformation”.
The structures of both the PIS160.71/91
material up against
the sensor-equipped
back gauges with
the use of motorised
pushers; the back
gauges then provide
input to the numerical
control unit, which
acquires the starting
data and starts the bending cycle.
Each of the two bending presses is
equipped with a back gauge with two
independent turrets, each with 3 axes
(X/Z/R), so as to ensure maximum
flexibility of use, including the possibility
of using the machines
individually.
The most prominent
characteristic is
represented by the
utilization of a laser
control system for the
bending angle, which assures optimal
bend results right from the first piece,
eliminating unnecessary bending tests
and, above all, substantial economic
losses considering the importance, also
in cost terms, of the sheet to be bent.
Once the position of the material is
acquired by the back gauges, the actual
bending cycle starts with the automatic
calculation of the bending distances
for the Y1 and Y2 axes according
to the thickness of the material, its
physical characteristics, the angle to
be obtained and the tools utilized. The
TAC bending presses have been
designed with the aid of finite elements
technology and built with a “multilayer”
construction method, in which the
thickness of the structure varies from
one point to another according to the
work stresses acting on it.
A perfect knowledge of how the
machine deforms under load and
its critical points has allowed the
designers to create a “made-to-
measure” structure, modulating the
thicknesses on the basis of a high
overall rigidity closely linked to its
use. The result is two heavyweight
machines (each with an approximate
mass of 228,000 kg) and, above all,
“optimized rigidity”; one can rightly
speak of “intelligent structure”.
The independent pumps
calibrate the flow of oil
during bending
Another constructional characteristic
of these folding presses (which can
each exert a force of 16,000 kN and
with a space of 7,100 mm between
the uprights) is the synchronized
hydraulic system (Colgar patent)
with two variable-flow servo-
assisted pumps with greater than
95% efficiency and a structure built
according to the “TAC” method, based
on the use of profiled bars with variably
inclined planes positioned directly
below the die table, allowing automatic
compensation of flexure during bending.
The machines are equipped with a
automatic correction of bending flexures.
Long-term precision and reliability are
guaranteed, while the installation has
been conceived to allow high flexibility,
particularly appreciated by operators
involved in processing different materials
every day.
The ram down stroke, work and up
stroke speeds are 80, 8 and 80 m/min
respectively. The ram can be inclined
with respect to the bed plane by up to
±30 mm and has a maximum travel of
800 mm, while the gap in the uprights
is 1,010 mm.
The variable-opening “die table” system
is quite innovative. It is composed of a
“container” made of high-grade steel
and a series of blocks and spacers
that, opportunely employed, determine
the width of the slot to be used. The
minimum and maximum slot widths
are determined on the basis of the
processing requirements; in this
case, 60 mm (minimum) – 250 mm
(maximum).
The integrated safety systems include
laser barriers to ensure that personnel
are not present in the working area
during the sheet-bending phase.
3000 ton. 16 meters
10 11
Large Press Brake and STEEL TUBE application.
The main Colgar business has
today moved into large size of
press brakes up to 4000 ton
stand alone machine or even
more in tandem.
THICKNESS: 50,8 mm.
DIAMETER: to be defined.
LENGTH: 12.200 mm.
MATERIALS: Duplex – Super
duplex – AISI – Titanium
Colgar and BRIC
BRIC is a grouping acronym
that refers to the countries
of Brazil, Russia, India and
China, which are all deemed
to be at a similar stage of
newly advanced economic
development.
Colgar is working on BRIC with
different strategy according
the local rules and habit. The
presence of Colgar is always
direct and include minimum first
line after sales service support.
COLGAR WEB
Just online, it is new, friendly
and usefull to check what Colgar
does, where Colgar is.
The new web page of Colgar
includes a lot of information,
photos and videoclips of
machines applications and
single components. In an easy
way all the Colgar activities can
be visualized on your computer
with a simple double click.
The new web page includes
also the application for iPhone
in order to be always connected
everywhere and every
minute. You can send us your
request through the webmail
and customers will have the
possibility to download or check
with personal ID and PSW their
order summary and their lay-out.
CRMCustomer relation management
is also a new internal Colgar
instrument to improve
chronology of customers
activities, offers, requests for
new machines and spare parts.
Huge installation of big machining centres
Colgar – Brazil
With a great support of a local
customer and partner MAUSA,
that has decided to come into the
business of machine tools with Colgar
technology and its total support,
the business of boring and milling
machines are increasing. Only 30%
of each machine manufactured in
Mausa is imported from Colgar.
The advantage for the end user is
now to become more competitive
buying a last boring and milling
machine tool technology available
on the world market without paying
the high import taxes. The financing
of COLGAR- MAUSA machines
is made through the line of credit
Finame BNDES (Banco Nacional
do Desenvolvimento) regarded as a
thermometer of the economy; it has
increased by 146% in the first two
months of this year compared with
the same period of 2009.
Colgar – China
Colgar China in Beijng is growing
every year more and more.
Actually an Italian Team for sale
and after sales is living in China
for a direct connection with the
customers.
The orders for Colgar are coming for
both the divisions of metal cutting
and metal forming. The Chinese
customers often have new buildings
to fill in with every kind of machine
tools and both Colgar divisions
became interesting for them. Actually
all the product range is installed in
China for every kind of application
energy, aerospace, automotive –
trucks, mining, chimical. The decision
of Colgar to improve the local
support has given the possibility to
consolidate its tournover despite the
negative world market situation of the
last years. Colgar has signed also
an agreement to supply stand alone
technology components.
Colgar – Europe
Europe and mainly Germany is
still the strategic market for high
technology machinery as Colgar
manufacturers.
Colgar Germany in Koenigsbrunn
has been the first Colgar experience
out of Italy. Colgar learnt how to
manage the sales activities and how
to support the customers during
the warranty and after the warranty
period often proposing the preventing
maintenance programs.
Liebherr, Voith, SEW, Sennebogen,
Weir, Bucyrus, Ruukki, are just a
few of the main important Colgar
customers. Thanks to the future
visions and the production managers
ideas, Colgar boring and milling
machines have added every day
small details that finally make the
difference between high quality and
standard quality machines. More than
90% of Colgar machines in Europe
are with boring bar.
Colgar – Italy
Domestic market is always an
important market because the
Italian industries are still keeping
the desire to be a world leader in
their field.
With the increasing tournover coming
from the boring and milling machine
business Colgar is still investing mainly
in training for all the internal division
and in new projects. The old building of
Colgar located in Quarto d’Altino near
Venice is now 80% autonomous for
assembly and testing the boring and
milling machines of the FV line. With
the support of Cimsa also, a subsidiary
Colgar company near Milan for the
production of automatic punching
lines, the division of accessory heads
is growing for Colgar proper use and
for future support of other company.
The Colgar headquarters in San
Pietro all’Olmo, in the middle of small
village, is always open to you!
Colgar – Russia
Since beginning of 2000 Colgar
started to improve its presence
on the Russian market.
A lot of press brakes and shears
are now installed and the boring
and milling machines are now
more requested with different
configurations. Colgar has its own
team Russian speaking to support
and easy follow the commercial,
the transports and the imports
phases of the orders . It is expected
that by 2013-2014, the majority of
Russian machine tool equipment
will “turn into scrap.” According
to the Russian government, it is
estimated that the growing demand
will require procurement of 700,000
new machine units by 2015. Industry
experts say that Russian end users
are appreciative of new advances in
technology to optimize and facilitate
production processes.
Colgar – India
Punj Lloyd signed a big order
for gantry type machine with
movable crossbeam, two 5axis
continous head one for roughing
and one for finishing operation
opening the right way for Colgar
into this market.
Punj Lloyd is an engineering and
construction group in India providing
integrated design, procurement and
project management services for
energy and infrastructure sector
projects. Punj Lloyd operations
are located in the Middle East,
the Caspian, the Asia Pacific, the
Europe, Africa and South Asia. Punj
Lloyd has 50+ subsidiaries and has
executed upwards of 200+ projects
in 20+ countries. Its main offices
are in Gurgaon, Haryana and its
stock is listed on the Bombay Stock
Exchange and also on National Stock
Exchange.