Large or small precision laser cutting from the team …engineeringsubcontractor.com/wp-content/uploads/2018/11/...Large or small precision laser cutting from the team you can trust

Large or small precision laser cutting from the team you can trust

t: 0115 944 3428 e: [email protected] FC Laser, Unit 8, Lows Lane, Stanton by Dale, Ilkeston, Derbyshire. DE7 4QU www.fclaser.co.uk

From intricate precision bespoke laser cutting to large format commissions; FC Laser, the fastest growing precision laser company in the Midlands has an unrivalled experienced team to deliver your project from initial design and development right through to delivery.

Shift your expectations up a gear on what you expect from a precision laser cutting company - contact FC Laser at: [email protected]

• State-of-the-art manufacturing with three of the very latest Bystronic 10 kilowatt Bystar Fiber Lasers.

• Dedicated account managers who understand our customers’ unique requirements.

• We can provide you with a quotation typically within two hours of receiving your email request.

• ISO 9001 Quality Management System accreditationand EN1090 Execution Class 2 standard.

HORN TOOLS HORN stands for winning technology at the cutting edge, plus outstanding performance and reliability. Our precision tools make the difference – so we can put you on the road to success.

www.phorn.co.uk

THE DIFFERENCE BETWEEN THE WHEELS COMING OFF AND STAYING ON

CONTENTS

NEXT ISSUE JANUARY 2019• SOUTHERN MANUFACTURING PREVIEW• MOTORSPORT REPORT • AUTOMATION

• FASTENING & ASSEMBLY • METAL MARKING• WATERJET MACHINING

VOLUME 15 | No.10 ISSN 1742 -5778

AMB REVIEW 4MEDICAL REPORT 10FEATURE - EDM 12METAL CUTTING 18

FEATURE - DEEP HOLE DRILLING 24CUTTING TOOLS 30

FEATURE - AUTOMATION 36WORKHOLDING 46

FEATURE - CADCAM 50MEASUREMENT & INSPECTION 60

FEATURE - LASER CUTTING 64SAWING & CUTTING OFF 74

FEATURE - WELDING 76CLASSIFIED SECTION 82

With a keen focus on delivering excellence in customer service,FC Laser can be relied upon as a top-quality provider of precisionlaser cutting services. Based in Derbyshire, it provides customerservice second to none. Established by managing director DannyFantom in 2012, FC Laser has seen impressive growth over the pastsix years and now proudly boasts a team of 55 highly-skilled teammembers. FC Laser uses the very latest Swiss made Bystroniccutting and folding machines, housed in a specially designed20,000 sq m state-of-the-art unit, making it Europe's largestinstallation of three 10 kW Bystronic Bystar fibre lasers. The star ofthe show is the Bystar Fiber, fitted with a Bytrans auto-sheet loader.Providing customers nationwide with the highest parts outputavailable and yet still retaining an unmatchable premium cuttingquality, all at highly competitive prices.

With a culture of ‘quality first’, teamwork, training and staffdevelopment are high on the agenda at FC Laser. The same is truewhen it comes to relationships with the company’s supply chain, aclose group of loyal and reliable suppliers of raw materials and

equipment ensure that FC Laser always delivers on time and tobudget. As they say, ‘failure is not an option’ and the hardworkingteam at FC Laser work around the clock, seven days a week toproduce the premium quality products that its loyal customersdemand. From intricate and sophisticated laser cutting on a widerange of metals through to highly resilient fabrications andinnovative folding, FC Laser makes light work of the mostcomplicated customer requests.

Caring for staff welfare and customers alike the managementteam at FC Laser also take responsibilities for the environment veryseriously. With regular team meetings and input from the settersand engineers on the shop floor, the business has one of the besttrack records in the industry when it comes to the energy efficiencyof its Bystronic Bystar fiber lasers, using up to 30 percent lessenergy than traditional 6 kW CO2 machines.

Working with its tried and tested ‘5S’ continuous improvementstrategy, the management team ensures that production error ratesare as low as possible and any improvements that can be made aredone within a very short timescale. Working closely with theproduction team, the highly skilled account management team is anessential link between the company and its customers.

FC Laser Tel: 0115 944 3428Email: [email protected] www.fclaser.co.uk

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COVER STORY

Top quality precisionlaser cutting services

Engineering Subcontractor � NOVEMBER 2018 3

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AMB 2018 REVIEW


AMB 2018 proved to be the most successfulever with the organisers claiming anincrease of 20 percent on the first day alone.The exhibition not only met all expectations,it also broke all previous records. Kromervon Baerle, spokesperson for themanagement team, says: “We had 1,553exhibitors over an exhibition space of, whatis now, more than 120,000 gross squaremetres, plus 91,016 visitors. These arerecord figures for the Stuttgart trade faircentre. We have started drawing visitorsfrom further afield: Eighteen percent of thevisitors came from 83 countries to attendAMB.” The exhibitors and partners in theten fully booked halls were very happy andhave been convinced of the importance ofthe metalworking exhibition for the industry.

According to Kromer Von Baerle, thissuccess has confirmed Messe Stuttgart'sintention to push ahead with expansionplans it has announced as part of its 2025master plan, such as the construction ofadditional parking spaces, a new Hall 11 anda second convention centre towards thewest of the trade fair site.

Impressed by high visitor quality andeagerness to investThe quality of visitors was impressively high.Around three quarters of visitors said theywere involved in purchasing andprocurement decisions, while 78 percentcame to the exhibition with specificpurchase and investment intentions.Mechanical engineering accounted for the

largest proportion of visitor industries at36 percent. This was followed by themetalworking and processing industry at27 percent, the automotive/vehiclemanufacturing industry at 18 percent, toolconstruction and mouldmaking at12 percent and metal constructionenterprises at 10 percent. More than onethird of visitors said that AMB was the onlyevent which they attended. Over half thevisitors were certain that AMB wouldbecome more important in future.88 percent of visitors said that they wouldrecommend AMB to others.

Dr Wilfried Schäfer, executive director ofthe German Machine Tool Builders'Association (VDW), says: “The responsefrom the membership of the VDW hasshown that investment is ongoing withinGermany and in the European market, andthis is reflected in the quality of visitors at

AMB. Meanwhile, digitalisation inproduction is becoming an increasinglycentral topic. Using umati, a standardisedtool for connecting machines with existing ITstructures, it is possible to meet the currentdemands of suppliers and customers. For us,AMB was the right place and the right timefor us to launch umati onto the market.”

“The atmosphere was excellent, and wesaw a flow of visitors of exemplary quality.This was by far the best AMB of all time.”enthused Lothar Horn, chairman of theTechnical Association for Precision Tools inthe German Mechanical EngineeringAssociation (VDMA). The new Paul Horn Hallwas received with the highest enthusiasm.

Exhibitors are delightedIrene Bader, director of global marketing atDMG MORI, says: “We are extremely happywith AMB 2018. We were in Hall 10 for thefirst time, and we were very impressed withour stand location. The whole trade fair sitewas buzzing, and people were flooding infrom entrance west, which was near to us,from 9 am on the first day.”

Irene Bader added that the quality ofvisitors was also exceptional. After onlythree days, the number of quotationsrequested was far ahead of the previousAMB. Visitors to the trade fair mostlydirected their questions towards topics thatwere focal points at the DMG MORI tradefair stand: digitalisation, automation andadditive production processes. Trade fairdiscussions about digitalisation becamesignificantly more substantial. In addition,almost half of all machines on display werealready equipped with automationsolutions, a trend that Irene Bader isconvinced will rise dramatically at the next

AMB 2018 sets new standards

AMB 2018 REVIEW

Engineering Subcontractor � NOVEMBER 2018

AMB trade fair in two years' time. There wasalso much interest in the combination ofadditive production processes withmachining, which DMG MORI has offeredfor many years.

The Yamazaki Mazak trade fair stand wassimilarly “fuller than full, with even moregoing on than at the last AMB.” statesMartin Engels, managing director ofYamazaki Mazak Germany. As he points out,there is often a lack of personnel to operatemachines, which has made automation a keytopic. He declares himself a "huge fan ofAMB". His reasons for this include thecompactness of the trade fair, the proximityof the airport and the location, right in theheart of Europe's leading region formachinery.

“Demand is high for complete solutions,”reports Christian Jung, managing director ofGF Machining Solutions. He goes on topoint out that his company offers completesolutions in this sector and notes that manycustomers came with very specific questionsand a concrete remit.

According to Christian Jung, GFMachining Solutions also used the AMBtrade fair to grow its customer groups. Heconcludes: “AMB is ideal for us. It is exactlythe right size, so our customers can lookaround all of the stands they are interestedin and be back at work the next day. Theshort distances between different areas ofthe trade fair site are a contributing factor.” Philippe Selot, manager of marketingcommunication at the grinding machinespecialist United Grinding, praises theflawless organisation of the AMB trade fair.“AMB is a wide-ranging trade fair. Itsgeographic location in the south ofGermany, near to Switzerland and Austria, is

ideal for us. The short distances andexcellent transport connections are a realadvantage for visitors. The fact that theAMB trade fair can be visited in one day isattractive to our customers. The new,thematic organisation of the halls makes iteasier for visitors to find their way around,and to find what they are looking for.” Thishas all played a part in United Grinding'sincrease in qualitative leads, which,according to Philippe Selot, is “a clearindication of the outstanding quality of ourvisitors.”

High interest in tool innovationsDr Jochen Kress, managing director ofMapal Dr. Kress in Germany, says: “Thequality of the discussions was significantlyhigher than at the last AMB, we had moredecision-makers come to our stand.Discussions were steered towards completesolutions for projects. He says another focalpoint was electro-mobility, for which Mapalhas developed a special new milling range.

“This trend will continue to develop, just likenetworking and automation and will play abig part at the next AMB in 2020.”

“Excellent business, continuedinvestments,” says Claude Sun, divisionmanager for machining in Europe atCeratizit. He continues: “The flow of visitorsat AMB has risen again compared toprevious trade fairs, overall, visitors wereextremely interested in innovative products.He also observes that noticeably moreIndustry 4.0 solutions were showcased bythe exhibitors this year than at AMB 2016.Toolscope is one such solution, developedby the Ceratizit Group to monitor machinesand tools, and to optimise productivity.

Markus Horn, managing director of PaulHorn, says: “After the trade fairs of the lastfew weeks, we arrived in Stuttgart with highexpectations, and they have been exceededonce again. We had more discussions at ourstand than at previous AMBs.” He believesthat very concrete projects are to thank forthis. Many of the highly technology-orientedcompanies want to know precisely howcertain solutions work in order to get themost out of their projects and processes.New technologies such as out-of-roundturning, a dynamically adjustable side andface cutter, or speed forming, areinterpretation of the familiar planingprocess, were of particular interest.

Oliver Gühring, managing director ofGühring, concludes: “This was the best AMBwe have ever attended. We set a new visitorrecord every day and the mood among ourcustomers was very positive.”

Messe StuttgartTel: 0049 711 185600Email: [email protected]/amb

5

AMB 2018 REVIEW


The CERATIZIT Group has become strongerthan ever with the integration of theBesigheim-based precision toolmanufacturer KOMET. It now employs 9,000people across the Group. The Groupshowcased its new, dynamic structure atAMB 2018.

KOMET has become one of the fourflagship brands in the Group’s machiningportfolio, alongside Cutting Solutions byCERATIZIT, KLENK and WNT. This newaddition has enabled CERATIZIT to becomea full-service provider in all areas ofmachining. This was clear to see for visitorsto the group’s two stands at AMB.

Visitors to this year's trade fair had theopportunity to see comprehensivemanufacturing expertise on both CERATIZITstands. In Hall 1, the company presentedexciting live shows and innovative productlaunches, concluding with the reveal of atechnical world first in turning applications.

In Hall 3, CERATIZIT presented its toolingand manufacturing expertise in a variety ofsectors, including the automotivepowertrain sector. Across three areas,visitors experienced how the latest tooltechnology can increase productivity andquality in cylinder head/engine blockmachining, turbocharger manufacturing andin the machining of common rail andcrankshafts. CERATIZIT and its flagshipbrand KOMET demonstrated its expertiseand introduced its latest solutions for theautomotive industry.

The 100th anniversary drill, KUB 100, wasanother of the highlights waiting to bediscovered for visitors. The KUB 100 was theresult of a joint development project byCERATIZIT and KOMET and it demonstrateshow the team has been successfullyintegrated in a short period of time. It is safe

to say that the tool, produced as a result ofthis project, represents the cutting edge inindexable insert drilling, providing excellentperformance, handling, process capabilityand efficiency.

The tool developers at Cutting Solutionsby CERATIZIT also presented the MaxiMill491 at AMB. The double-sided 90° shouldermilling system impressed with its incrediblystraightforward handling and inserts thatcan be changed quickly on the machineitself. The system has become a best-sellerand with good reason. It is the only systemthat, with eight useable cutting edges perindexable insert, can create a precise 90°profile on the workpiece. The addition of the9 mm size means the system now offers evenmore flexibility.

WNT, another flagship brand of theCERATIZIT Group, also presented itsinnovative machining solutions in theJacques Lanners Hall. The most notableinnovations were found among the newtools for hard machining. As well as aprofessional tool for trochoidal roughmachining in hardened materialapplications, WNT also has the perfect toolfor finishing, plus new drilling tools and amultitool for drilling, countersinking andthreading in hard machining applications.However, WNT has also raised the stakes insliding head tooling and presented newtooling solutions to significantly increase theproductivity of sliding head lathes.

Last but not least, KLENK, the fourthflagship brand, also exhibited on theCERATIZIT stand. As a specialist in tools formachining CFK, titanium, aluminium andsteel, its focus is mainly on industry-specificsolutions for the aerospace sector. As well asan innovative countersink, KLENK alsopresented many other high-quality specialtools that were of interest to companiesoperating in the aerospace industry.

CERATIZIT UK & IRELAND LtdTel: 0800 073 2073Email: [email protected]

Machining experts united at AMB

Yamazaki Mazak UK Ltd

Badgeworth Drive, Worcester

Worcestershire, WR4 9NF, UK

T +44 (0) 1905 755 755

F +44 (0) 1905 755 542

E [email protected]

It’s show-time

AMB 2018 REVIEW


GROB demonstrated a first-generation5-axis G350 universal machine at its debutappearance at AMB ten years ago. Thegreat success that universal machines haveenjoyed since the market launch isparticularly due to the fact that the universalmachine range has been consistentlyexpanded and refined. The complete seriesnow comprises a G350, G550, G750, and asecond generation G1050. With theexception of the G1050, all machines arealso available with turning/milling features,as well as with automation. This year,GROB's exhibition highlights once againturned the spotlight on furtherdevelopments in its second generation ofuniversal machines, as well as on the futureof automation and digitisation.

Trade show highlights in the area ofmachining and automationAt this year's 19th edition of the AMB inStuttgart, GROB presented its 5-axisuniversal machines, all designed to feature aSIEMENS control system, to demonstratethe very latest technology. A G350 universalmachining centre, second generation with aHSK-A63, 16,000 rpm motor spindle, is alsoequipped with a highly dynamic rotary tablefor enhanced stability, precision and greaterefficiency in workpiece machining. A steelblisk segment is being machined. Anotherexhibit, a G350 second generationproduction cell with a rotary pallet storagesystem and TM200 additional toolmagazine, was used to demonstrate theoptimum flexibility, even with smallmachining centres. They are the ideal pointof entry into automated and high-efficiencyproduction. The machine is equipped with aHSK-A63 motor spindle, rotating at a speed

of 16,000 rpm, and was used to mill analuminum Eiffel tower and a steel demo partlive on site.

The family-run business is geared up forthe trend towards automation. This isevidenced by the GROB engineers with asecond generation G550T 5-axis milling/turning universal machining centre,designed with an HSK-T100, 14,500 rpmmotor spindle. It is used for milling andturning parts made of steel with powermachining performance.

GROB also unveiled a new developmentin the G-series of system machines with thesixth generation of G520 double spindlemachine. The G520 is equipped with anoptional double pallet-changing system andan HSK-A63 motor spindle, which rotates at18,000 rpm. Its capability for being set up inparallel with workpiece machining wasdemonstrated at the show by two pallets,each with one blank part and one finishedpart of a lateral arm, as well as oneturbocharger each. The G520double-spindle machine with pallet changeris specially designed for machiningworkpieces such as oil pumps, wheelcarriers, valve and steering housings, as wellas brake callipers, steering knuckles andturbine housings.

Trade fair highlights in the area ofdigitisationDigitisation was one of the key themes ofthis year's AMB, especially in the context ofthe increasing significance of Industry 4.0.GROB-NET4Industry software technologyuses web technology to create transparencythroughout the entire production processon a cross-plant basis. Visitors to the GROBstand in the new technologies were able tosee how this works in practice. Furthermore,

the new GROB4Pilot control panel, which isavailable for SIEMENS and HAIDENHANcontrol systems, was also unveiled.

DIAHON Werkzeuge was a GROB partnerat the showIt has become a tradition at AMB for variousmachine applications not only to beshowcased at the GROB stand, but also tobe demonstrated at partner booths, such asat the DIAHON Werkzeuge GmbH & Co. KGstand this year. A cylinder block made ofcoated aluminum was demonstrated toonlookers with in-process measurement ona G350 second generation.

GROB’s worldwide production facility isgeared up to meet the standards set by itsgerman headquarters. Extensive qualitytests are integral to every production andassembly step and ensure that thecompany‘s machines and systems strictlymeet its customers' requirements andproduce parts reliably and economicallyover the long term.

GROB Machine Tools UK LtdTel: 0121 366 9848Email: [email protected]

From the universal machine to theautomated production system

AMB 2018 REVIEW


One year ago, the Hoffmann Grouppresented its first general-purposeGARANT solid carbide barrel milling cuttersfor the Parabolic Performance Cutting (PPC)process. Since then, the product family hasbeen extended to cover machining ofaluminium and a new milling cutter versionhas been added: The first GARANT PPCstub point conical solid carbide barrelmilling cutter for machining flat faces at thebottom area of the workpiece.

When used in conjunction with otherGARANT PPC milling cutters, the new toolallows the finishing of even more complexgeometries and offers the option to eitherbenefit from shorter production processtimes or better surface finishes. Thecomplete GARANT PPC tool family wasexhibited at AMB.

Parabolic Performance Cutting (PPC)represents a further development ofball-nosed slot drilling and is used above allin machine tool building, toolmaking anddie making. The particular feature of PPCtools is the main cutting edge in the profile

of an arc of a circle. Compared to a ball-noseslot drill this permits significantly largereffective radii. The result is a line skip up tonine times larger, or a surface quality up to80 times better. To allow finish machining ofeven more complex geometries, theHoffmann Group has now extended itsrange to include a new stub point conicalversion for machining flat faces at thebottom area of the workpiece. Theprecondition for PPC is a 5-axis milling

machine and CADCAM software whichallows the tool geometries to be processedas a data model.

The new PPC milling cutter range foraluminium and the new stub point conicalGARANT PPC solid carbide barrel millingcutter can be ordered immediately via theHoffmann Group eShop and via the2018/2019 catalogue.

Hoffmann GmbH Tel: 0870 4176111Email: [email protected]

Hoffmann Group extends its product family for Parabolic Performance Cutting (PPC)

In the field of digitisation DMG MORI offersan integrated digitalisation strategy at alllevels of value creationAs a pioneer of digitalisation in the area ofmachine tool manufacture, DMG MORIcontinues to consider it a strategicfuture-oriented field. The companypresented pathways towards Industry 4.0 atAMB under the catchphrase integrateddigitisation. Core fields include theAPP-based control and operating systemCELOS, new software solutions forproduction planning, exclusive technologycycles as well as CADCAM and simulationsolutions. Complemented by NETservice,for simple and direct remote service andWERKBLiQ for digital maintenance, DMGMORI also offers a digitalisation strategy atall levels of value creation. With this broadportfolio, it is able to support its customerswith end-to-end solutions for digitalisation.

Digitalisation for the user is all aboutoptimising internal value-creation processesin an integral way. DMG MORI has set itselfthe goal of offering its customers integratedand universal digitalisation solutions to

enable step-by-step entry into networkedproduction. Integrated digitisation by DMGMORI begins at the planning and jobpreparation phase extending through to themachine and follows the vertical companyorganisation upon this basis. It can beclassified into three levels as Dr. HolgerRudzio, managing director of DMG MORISoftware Solutions, explains: “At the first,we offer machine-specific apps in theCELOS environment and, at the second,upstream and downstream processesthroughout the entire productionenvironment. The multi-vendor digitalplatforms are located at the third level. Theyform a type of open marketplace, accessibleto everyone, which supports users duringservice and maintenance, for example.”

Digital monitoring of productionWith its APP-based control and operatingsystem CELOS, DMG MORI has created abasis to offer long-term support tocustomers on the pathway to Industry 4.0with the aid of integral workflows, both atthe machine level as well as for upstream

processes. CELOS is installed on all newDMG MORI high-tech machines and one ofits features is the capability of digitallymonitoring production. CELOS DigitalMonitoring is made up of the appsMESSENGER, CONDITION ANALYZER andPERFORMANCE MONITOR, amongstothers.

DMG MORI UK LtdTel: 0247 651 6120 Email: [email protected]

Integrated digitisation

Product range extended with new stub point conical milling cutter

The GARANT PPC solid carbide barrel millingcutters are available immediately for machiningaluminium

Parabolic Performance Cutting (PPC) is particularlyeffective when the tool profile exactly matches theworkpiece surface contour

MEDICAL REPORT


Global engineering company Renishawoffers QuantAM Dental software whichautomates additive manufacturing (AM)build preparation for hundreds of dentalframeworks in a single operation. Thesoftware, which was launched in March2017, can cut preparation time from twohours or more with existing buildpreparation software to around 30 minutes.The 75 percent reduction allows dentalproduction facilities to producepatient-specific frameworks with a reducedworkload for staff, enabling cost reductions.

Dental production facilities typicallyreceive hundreds of custom design filesdaily from multiple customers. Previously,the industry lacked a single suite of softwarethat could handle all the operations requiredto prepare files for production. Instead,manufacturers were forced to use multiplesoftware applications to prepare for a build.

Ed Littlewood, marketing manager atRenishaw’s medical and dental productsdivision, says: “QuantAM Dentalconsolidates the number of softwarepackages required to produce batches offrameworks, helping to reduce licensingoverheads, decrease training requirementsand reduce build preparation times daily.

“Being able to start builds later in theworking day allows more time for designs tobe received from customers, leading to afuller build plate and better productionefficiency, whilst still allowing the build tocomplete before the next working day.”

QuantAM Dental automatically importshundreds of dental frameworks, repairs thestereolithography (.stl) files if necessary andautomates the orientation so that

framework cavities face upwards, avoidingsupports on the fitting surfaces. It alsoautomatically adds an identification tag toeach framework to allow reconciliation todesigns and finally, generates supports.

The software then groups frameworktypes according to manufacturingrequirements. For example, frameworks thatrequire heat treatment, such as bridges, aregrouped separately from those that do not.Frameworks not requiring heat treatmentcan quickly and easily be identified beforethat step in the process is completed.

Finally, QuantAM Dental reviews the filesand gives a list of potential errors for anysub-optimal frameworks. The systemsoperator can then slice the build files readyto transfer them to the AM system. For moreinformation about QuantAM Dental and tosee how quick and easy it is to use, watchthe video and visit www.renishaw.com/dental.

Renishaw showcases innovative implantsto maxillofacial surgeonsRenishaw showcased its additivelymanufactured craniomaxillofacial (CMF)implants at this year’s British Association ofOral and Maxillofacial Surgeons (BAOMS)annual scientific meeting.

Every year, the event provides leadingoral and maxillofacial surgeons and traineesthe opportunity to share recent findingsfrom their clinical practice. Presentations,workshops and exhibition stands allowattendees to learn about new research,

outcomes, experiences and techniques thatare helping to improve the standard ofmaxillofacial surgery.

Renishaw showcased a range of itsmaxillofacial products at the event, with afocus on its additively manufactured CMFimplants. Additive manufacturing enablesthe company to use computed tomography(CT) data to produce patient-specificimplants (PSIs).

Ed Littlewood says: “PSIs help to reducesurgery time and provide a better fit for thepatient. Also additive manufacturingremoves some of the geometric constraintsof traditional manufacturing, meaning morecomplex structures can be produced, whichis highly beneficial for patients.

“Our design options can be adapteddepending on the hospital’s needs. We canhelp hospitals realise the design of theirimplants or, if they prefer, we can handle themanufacturing only.”

2018 marks the fourth consecutive yearthat Renishaw has attended the BAOMSannual scientific meeting. As a UK-basedsupplier, it is an important opportunity forthe company to meet with surgeons todiscuss the application of its products.Renishaw also hopes its learnings fromthe event will help inform its nextdevelopments.

For more information about how additivemanufacturing can be used to improvesurgical outcomes for surgeons andpatients, visit www.renishaw.com/en/medical-and-healthcare--32082.

Renishaw reduces dental framework buildpreparation time by up to 75 percent

MEDICAL REPORT


Renishaw exhibits at CanadianNeurological Sciences FederationCongressIn June the company also attended theCanadian Neurological SciencesFederation’s annual congress. The event,held at the Halifax Convention Centre, NovaScotia, provides multidisciplinary coursesrelevant to all neuroscience specialities.Renishaw presented its neuromate®

stereotactic robot and neuroinspire™, itssurgical planning software.

The neuromate robot has been used inthousands of electrode implantationprocedures including deep brain stimulation(DBS) for Parkinson’s disease andstereoelectroencephalography (SEEG), aprocedure used in epilepsy diagnosis. Therobot provides consistent, rapid and precisetargeting in neurosurgical procedures andremoves the need for a stereotactic frame.

Renishaw’s neuroinspire surgical planningsoftware provides the tools to assist with theplanning of most stereotactic procedures. Itintegrates with the neuromate stereotacticrobot and provides the ability to carry outperi-operative verification.

Adrian Gut, global sales and marketingdirector of Renishaw’s Neurologicalproducts division, says: “The Canadian

Neurological SciencesFederation’s annual congressis a great opportunity forRenishaw to meet bothexisting and potentialcustomers. Renishaw alreadycontributes to the AdditiveDesign in Surgical Solutions(ADEISS) Centre in London,Canada as a result of itspartnership with WesternUniversity and the London MedicalNetwork. However, there is considerablepotential for further collaborationin Canada.

David A. Steven, associate professor ofNeurosurgery at Western University, says:“The robot totally changes how weapproach insertion of SEEG electrodes. It isnoticeably faster and more accurate thanthe previous system. In addition, it allows usto plan trajectories previously impossiblewith a standard frame, making surgery saferand more accurate.”

For more information on Renishaw’sneurological product range, visitwww.renishaw.com/neuro.

UK-based Renishaw is a leadingengineering technologies company,supplying products used for applications as

diverse as jet engine and wind turbinemanufacture, through to dentistry and brainsurgery. It has over 4,500 employeeslocated in the 36 countries where it haswholly-owned subsidiary operations.

Throughout its history Renishaw has madea significant commitment to research anddevelopment, with historically between 13and 18 percent of annual sales invested inR&D and engineering. The majority of thisR&D and manufacturing of the company’sproducts is carried out in the UK.

Renishaw plcTel: 01453 524524Email: [email protected]

SOUTHERN MANUFACTURING & ELECTRONICSis an ETES event organised by European Trade & Exhibition Services Ltd

Tel 01784 880890 · email [email protected]

Pre-register online now for your freeentry badge and show preview atwww.industrysouth.co.uk

Meet over 800 national and international suppliers under one roof in the brand

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labeling & marking, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment.

Free industry seminar programme online @ www.industrysouth.co.uk

The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 5th February.

5th – 7th February 20199.30am – 4.30pm (3.30pm close Thurs)

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Feature - EDM


Following an exceptional 12 monthsbusiness, with repeat and new customerorders and enquiries for the range of highperformance, cost-effective Excetek CNCwire cut machine tools, Warwick MachineTools will go forward concentratingexclusively on providing pre- and post-salesand service support for the brand in the UKand Eire. However, existing UK customerswith ONA EDM machines will continue to besupported with the usual, reliable technicalbackup and service care they are used to.

Andrew Kilshaw, national sales manager,explains the rationale behind the decision:“We have had an exceptional long-termrelationship with ONA, supplying andsupporting customers in many advancedindustry sectors and we will not abandonthose customers with older and more recentONA EDM machines as we have the mosttechnical experience and expertise tosupport them in the UK. However, thecontinued growth of Excetek demands ourfull focus and the tough decision wasrecently taken to end the businesspartnership amicably.”

Dudley-based Electro-Discharge Ltdprovides a perfect example of customersreturning to WMT for further wire EDMcapacity from Excetek. From its impressivefacilities the specialist subcontract CNC wireand spark erosion provider supports adiverse engineering customer base. It hasleading quality accreditations and a plantcapacity list that features over 30 wire andspark erosion machines. These now includean additional three of the latest generationExcetek CNC wire cut machines, installed tooperate automatically at speed, to closetolerances in a ‘lights out’ environment.

Originally established in 1980,Electro-Discharge initially targetedengineering businesses in the WestMidlands. However, continued growth,especially in the aerospace sector, meanstoday its customer base is spread across theUK, and its knowledge and services are alsoprized by international manufacturingcompanies. To support this global businessbase the company has added two newExcetek V650Gs and a smaller V400G CNCwire cut machine.

Rupin Vadera, general manager at

Electro-Discharge, says: “Although we wereaware of the Excetek range we didn’tinitially fully appreciate the capability andfunctionality offered. We arranged ademonstration at Warwick Machine Tools’showroom near Kenilworth and everyonewas impressed with both the build qualityand performance. The price-to-performanceratio is exceptional. The three new ‘VG’series machines are in addition to twolarger V850G machines we installed lastyear (2017).”

Andrew Kilshaw concludes:Electro-Discharge is typical of the type ofcustomers that WMT is supplying Excetekmachines to, as they have seen the benefitof the value-to-performance ratio that thesemachines offer. Couple this to the reliableand friendly support they receive fromWMT, and it just goes to prove that Excetekand WMT are a very viable proposition. Onethat our existing Excetek users come back totime and time again.”

Established in 1978 as the exclusivedistributor of ONA EDM products in the UKand Ireland. Warwick Machine Tools Ltdgrew into a highly experienced and reliablepartner supporting its customer base with avariety of complementary machines over theyears.

In October 2012, Warwick Machine Toolsbecame the exclusive UK and Ireland agentfor an exciting new range of EDM Wire Cutmachines, manufactured by ExcetekTechnologies.

The range of Compact Excetek Wire Cutmachines provide increased performance,productivity and maximise productioncapability while reducing operating costs.Large modular and customised wire EDMmachine’s are also part of the range and thisenables Warwick Machine Tools to offer asolution that fits with customers’requirements and budgets.

The company seeks to create partnershipswith its clients to provide a bespoke tailoredEDM technology solution which best suitscustomer needs. This is backed up with a fullafter sales service and support programmewhich is supported by factory trainedengineers and a comprehensive range ofgenuine consumables. This ensures that theEDM machine maintains its accuracy andquality of finish during its working life.

Warwick Machine Tools LtdTel: 01676 534534Email: [email protected]

Warwick Machine Tools to concentrateits efforts on Excetek EDM

Take the long viewSodick EDM - an investment for today and tomorrow

Sodi-Tech EDM sole UK distributor of Sodick EDM technologyRowley Drive, Baginton, Coventry CV3 4FG Tel. +44 (0)24 76 511 677 Email [email protected] www.sodi-techedm.co.uk

A Sodick EDM LINEAR motor machine offers you a whole lot more

All Sodick EDM machines incorporate LINEAR DRIVE TECHNOLOGY

trademark features, such as ceramic components, user-friendly software and

EDM


HLP Engineering Solutions, a specialist in press tools for theautomotive industry, has invested in another Sodick wire erosionmachine from Sodi-Tech EDM. The large Sodick AQ750L Premiumnot only provides more size and time capacity, but greaterprecision and around 25-30 percent more speed than themachine it replaced.

Based in Halesowen in the West Midlands, HLP Engineeringsupplies a number of Tier 1 automotive suppliers with multi-stageprogression tools. Founded in 2009 by experienced toolmakersLuke Hobbs and his business partner Phil Littlewood, HLP hasquickly grown to become a respected industry name inpresstool manufacture.

Luke Hobbs says: “We started with no premises, machines ormoney, and would simply cold-call to get work. A friend offered ussome space in his unit and we bought a few pre-owned Sodick wireEDMs from auction. We were familiar with Sodick machines fromprevious employment and they are tried and tested as far as we’reconcerned. We also know the guys at Sodi-Tech and the level ofsupport they provide.”

Progress at HLP soon accelerated. After a brief stint in a rentedunit the company acquired its own premises in Halesowen, withthree pre-owned Sodick wire EDMs in place. However, faced withyet more demand for its services, the company recently sought toexpand its capacity even further.

Luke Hobbs says: “We needed to extend the size envelope ofwhat we could offer customers. In addition, we knew that bringingin another Sodick would also release capacity on some of ourother machines.”

HLP was particularly interested in a AQ750L Premium atSodi-Tech EDM, a machine that was developed by Sodick inresponse to growing demand for large dies. The AQ750L Premiumcan handle a maximum workpiece 1,050 mm long, by 750 mm deep,by 400 mm high. In addition, up to 3,000 kg can be accommodatedon the work table.

Luke Hobbs continues: “Along with the size, the AQ750LPremium has introduced us to new-generation technologies such aslinear drives, which compare favourably against our other machinesthat feature ballscrews. It means that surface quality is enhancedand energy consumption is reduced. The machine has become theshowpiece of our facility.”

Installed in February 2018, the AQ750L Premium has been set towork producing parts for automotive press tools, such as formingand cutting steels. All are one-off items, with most manufacturedfrom D2 tool steel to micron-level tolerances. Run times vary from30-45 minutes for smaller parts, up to 20-30 hours for a largepunch block.

Luke Hobbs explains: “The Jumbo feeder on the AQ750LPremium means we can load large spools of wire and run some ofour longer jobs unmanned, out of normal working hours, which weare insured to do. This is one example where the new machine hasmoved us on the next level, along with precision and speed. I wouldestimate the new machine is 25-30 percent faster than the machineit replaced.”

Upon installing the AQ750L Premium, HLP ‘retired’ one of itsolder models leaving three Sodick wire EDMs operational. Beyondpress tools for the automotive industry, today the company hasdiversified into the manufacture of jigs and fixtures, as well assubcontract wire EDM work and general subcontractCNC machining.

Today there are eight employees at the company, which says ithas not had to advertise for work since 2009, such has been thesatisfaction and repeat orders from existing customers.

Luke Hobbs concludes: Quality and customer service are ourUSPs. With the Sodick machines we know the parts will be first class,which supports our ethos of ensuring the press tools we makefunction as intended by the customer. There is an intensive toolingbuy-off process involved with every press tool that involvesproduction rate trials from coil at both our premises and thecustomer facility. There is nowhere to hide if the tool doesn’t workcorrectly, which is why we work hard to ensure full satisfaction withpress tools manufactured by HLP.”

Sodi-Tech EDM LtdTel: 024 76 511677Email:[email protected]

HLP enjoys 30 percent more speed andgreater accuracy with latest Sodick EDM

EDM


GF Machining Solutions’ latestAgieCharmilles Cut P Series of wire EDMmachines provides users with precisepositioning and contouring capabilities thatensure high part quality and unrivalledproductivity.

The Cut P 350/550/800/1250 machinesare equipped with efficient powergenerators and feature robust design andbuild, intuitive human-machine-interfaces(HMIs) as well as several automation optionsfor lights-out/unattended operations. WithIntelligent Power Generator (IPG) digitaltechnology, the EDM machines deliverultra-fine surface finishes (Ra 0.10 μm) andcan improve cutting speeds by up to20 percent.

Several Expert systems further optimisethe IPG’s cutting performance, especiallywhen undertaking demanding andchallenging applications.

POWER-Expert monitors and changes thepower levels required to machine parts withvariable heights. The system protects theparts from unstable conditions and themachine maintains high cutting speeds.

Simultaneously, this system controls thespark parameters during finishingoperations to provide high-quality surfacefinishes on variable-height parts. Thismaximises part finishes and significantlyreduces the need for secondary benchwork.

Regardless of workpiece height,WIRE-Expert dynamically controls wire wearto achieve continuous geometrical accuracyfrom all directions.

For part profile accuracy, PROFIL-Expertautomatically adapts the machiningparameters and the cutting path for roughand skim passes. This provides excellentcontrol of fine details and ensurespositioning and contour accuracies of±2 μm. TAPER-Expert technology cutsangles from 0 to 30 degrees, 45 degreesoptional, to maximum Z heights.

TAPER-Expert corrects shifts of the Zreference position in real time, even whenthe taper angle is changing. The taper angleis also held to within 10 seconds on average,providing taper accuracy and geometryreference accuracy throughout thetaper cut.

Fixed tables on the machines providerigidity and stability that ensure accuracywhen machining heavy workpieces.Integrated temperature regulation systemsconsistently maintain temperatures within±0.2 degrees centigrade, which guaranteesrepeatability over long periods of time.

GF Machining Solutions Ltd Tel: 02476 538666Email: [email protected]/uk

A new benchmark in wire EDM performance

Makino is the world leader in EDM technology, providing faster processing times and superior surface finishes for even the most complex and involved part geometries. WIRE EDM machines combine a diverse mix of high performance capabilities, low operating costs, and advanced user-friendly operation that provide optimum efficiency on the production floor. By combining innovative Makino machine tools and software with NCMT’s world-class specialist applications knowledge and expertise, shops of every size are competing and winning the kind of work that matters on the global EDM stage. All Makino EDM products utilize the modern Hyper i control system that delivers new levels of user-friendliness, with its high definition large 24” touch screen interface that makes use of Pinch, Swipe, and Spread touch functions similar to smartphones and tablets.

WHAT MATTERS TO YOU? FASTER PROCESSING, SUPERIOR SURFACE FINISHES, LOWER COSTS

EDM

www.ncmt.co.ukTel 020 8398 4277

EDM


Located on the outskirts of Glasgow nearHamilton, The Spark Erosion Centre is asubcontract manufacturer that, as the namesuggests, specialises in EDM machining. Tobe a dedicated specialist generally requirestwo things; staff expertise and the latesttechnology. Luckily for the Scottishcompany, it has both in abundance and it isrecognised as FANUC UK’s largestcustomer of EDM machine tool technology.

The company has been in business forover 30 years and it has employed FANUCmachine tools from almost day-one.Commenting upon this relationship, BillBright, managing director at the SparkErosion Centre, says: “We bought our firstFANUC machine back in 1984 and we havestuck with FANUC ever since. This isbecause we find the machines to be veryaccurate and reliable products that we pushto the limit on a daily basis.”

“By pushing the limits, I am referring tothe type and quantity of work that comesthrough the door. We are stretching whatthe machines should and shouldn’t be ableto do, such as increased tapers that are waybeyond what the machine is supposed to becapable of. We have learnt tricks down theyears and how to best exploit thecapabilities of the FANUC machines and thisgives us a major competitive edge.”

Not just a one-trick-pony, The SparkErosion Centre is a precision machiningcompany that undertakes tool making,injection moulding, tool and jig design andmanufacture as well as spark and wire

erosion for the offshore, automotive,aerospace, electronics, academic and toolmaking industries. This diversity is a criticalfactor for success considering the industriallandscape in Scotland.

Bill Bright explains: “The oil & gas industryis a key sector in Scotland but there is still alot of automotive and tool making workgoing on. A lot of the local work is overspillfrom the offshore work in Aberdeen and inrecent years most engineering companiesfelt the impact of the oil & gas downturn.Many companies only worked in the oil &gas industry and when it took a downturn,many companies went under whilst othershad to fight for whatever they could.Fortunately for us, we operate in a variety ofsectors and we have niche areas of expertisethat ensure a stable business.”

An example of this expertise can be notedon an oil & gas industry cylinder that wasturned by a customer of the Spark ErosionCentre. The turned cylinder is intended tobe an offshore collet and the customerapproached the Spark Erosion Centre tosplit the cylinder via wire EDM processes tocreate a collet assembly. Bill Bright recalls:

FANUC adds the spark for ScottishEDM subcontractor company

EDM


“We received the first component and itwasn’t stress relieved. This is where wireerosion is a benefit, as it has no forcesinvolved in the process. We wire cut the firstpart and it sprang quite badly. On futurecomponents, we recommended stressrelieving the parts and the customer askedus to handle the entire process.” It is thisexpertise and capability that has made theISO: 9001 company such a success.

Bill Bright continues: “We utilise the corestitch function to machine from the centre ofthe part to the outside. However, we do notmachine all the way through the part,leaving a ‘tag’ like on an Airfix model. Thiskeeps the cylinder in an assembledcondition and allows the customer to justbreak-off the parts during final assembly.”

Referring to the FANUC relationship, BillBright says: “We have a range of machinesnow and we tend to trade-in as we get newmachines, but we still have machines up to10 years old that still perform extremelywell. The reliability is there, and we havebeen working with FANUC machines for solong that we can now undertake a lot of ourown maintenance and repairs, but thesupport from FANUC has always been thereas soon as we need it.”

Categorically a major believer in FANUCtechnology, the company has once againinvested in FANUC with the recent arrival ofa ROBOCUT C600 iB wire erosion machine.Bill Bright says: “This machine is right on thesweet spot for us, we have both smaller andlarger machines and as a new machine, thisgives us the X- and Y-axis capability wewanted. It has an extra 100 mm in the Z-axis,which takes the Z-axis to 400 mm and thisgives us a niche. There is certainly work thatcomes to us that cannot be done by anyoneelse in the area and this is credit to thegenerous Z-axis capability on the FANUC.”

Sitting alongside a previous generationFANUC ROBOCUT C600 A-Series, the newC600 B-Series addition has a multitude ofnew features that are not integrated intoprevious generation machines. Bill Brightcontinues: “The new touch-screen CNCcontrol unit is a new feature that is very easyto work with as ‘touch-screen’ has become afamiliar part of everyday life, who doesn’thave a touch-screen phone nowadays?Added to this, the control unit is also farmore capable than previous generations.”

FANUC has made significant strides downthe route of machine efficiency, powerconsumption rates, automation and

precision in recent years. Bill Brightconcludes: “Our customers are verydemanding and they want parts back assoon as possible, so energy efficiency isn’tthe top of our consideration list. However,when it comes to precision, we have done alot of intricate R&D work and the machineshave been spot-on. Additionally,automation is a core factor, so our machineshave to be auto-wire fed. This is somethingwe now take for granted because in themodern competitive market, we have tomaximise the running time of ourmachines.”

FANUC UK LtdTel: 02476 518 449 Email: [email protected]

Mitsubishi Electric used MACH 2018 as theplatform to introduce its groundbreakingnew CNC control unit on its established MVSeries of EDM machines. The MitsubishiEDM stand at the exhibition was furnishedwith the MV1200S and the MV2400R Seriesof EDM technology that introduced thelatest advancements in Industry 4.0 andpower supply technology.

The compact MV1200S machine with its400 by 300 by 220 mm, X, Y & Z axes, traveloffers cost-effective production in a smallfootprint while the larger MV2400R boastedMitsubishi's V350-V AEII Power SupplyDMX-S, Digital Matrix Sensor, that shapeseach spark to reduce electrode wearconsiderably and the world's first LinearShaft Drive System XYUV. This combinationdelivers smooth, highly controllablemovements and unparalleled precision andproductivity levels.

Quality is in the DNA of the Mitsubishibrand and the MV-R and MV-S Series atMACH both demonstrated the pre-installedCrash Protection System, Intelligent AutoWire Threading, the latest Power Master

Control for process stability and a host ofadditional innovative features. Central toboth machines on the stand was therevolutionary new CNC control system.Globally launched at EMO 2017 andreceiving its UK exhibition premiere atMACH, the new control system incorporatesIndustry 4.0 features in abundance.

Advanced technology and a new userinterface can be a daunting prospect for anymachine operator. Mitsubishi Electric hasovercome this by offering both the new andestablished interface in a single control.With the flick of a switch, the new CNCinterface can revert to either type, offeringexisting and experienced users the familiarinterface whilst providing all the benefits ofthe new technology. The machine operatorhas a large screen monitor and moderngesture controls that boost comfort with aconfigurable interface that supports the userby allowing the main function elements tobe freely arranged for daily work.Furthermore, the step-by-step dialogueguidance pilots less experienced operatorsthrough the entire process with checklists

taking operators from programmingthrough to machining.

Completely tailored to the needs of theend user, the Natural User Interface has aneasy-to-grasp display with all the machiningparameters in configurable form to makeeverything visible. For scheduling, support isprovided with an overview of remainingwire, filter cartridge state and otherparameters.

Mitsubishi EDMTel: 01788 577288Email: [email protected]

Mitsubishi introduces new control unit

METAL CUTTING


XYZ Machine Tools remains a leader in thesupply of small to medium capacity CNCmachining centres and lathes, but is also amajor player when it comes to large capacitymachine tools. 12 machines are part of itssuper-heavyweight machining centre,travelling column machining centre, XL andOil Country lathe range.

The super-heavyweight machiningcentres are the XYZ 2010 HD, XYZ 2510 HDand XYZ 3010 HD, which have X-axis travelsfrom 2,000 mm through to 3,000 mm. Allthree machines have 1,000 mm Y-axis and800 mm Z-axis movement. Machine rigidityand exceptional vibration damping isprovided by the solid Meehanite castingwith box slideways, with six guideways aloneon the Y-axis to provide total support for themachine table. Adding to the machiningcapability is the standard 8,000 revs/minspindle which has 30 hp (23 kW) of poweravailable on a continuous basis. It has 36 hpand 56 hp available for 30 minutes and 2.5minutes, in every 10-minute period,respectively, when more power is required.Control on these super-heavyweights isprovided by the Siemens 828D Shopmillsystem with 15-inch touch screen fittedas standard.

XYZ’s four-machine travelling columnrange features X-axis travels of 4,000, 6,000,8,000, and 10,000 mm with Y and Z axistravels of 800 mm and 600 mm, respectively,with all axes using linear rail technology. Thestandard continuous 15 hp spindle has aspeed range of 60-8,000 revs/min withpower available up to 38 hp, 28.5 kW, forshort periods of heavy-duty cutting. Bothrapid traverse and cutting feed rates are amaximum of 24 m/min in all axes, with the

X-axis controlled by a backlash-free gearboxcombined with a GUDEL, Swiss-made, highprecision gear rack. Ranging in weight from22,000 kg to 32,000 kg, the TCM range fromXYZ is truly heavy-weight and provides theagility required for the machining of highlycomplex components often found in theaerospace sector.

When it comes to turning, XYZ MachineTools has an extensive range of XL and OilCountry lathes. The XL series goes from theXL 780 with 780 mm swing over the bed and3,000 mm between centre distance to theXL 2200 with 2,200 mm swing and up to12,000 mm between centres. Across therange the headstock features a gearboxwith precision ground gears for quiet andprecise power transmission as well ashigh-precision taper roller bearings foradded accuracy and spindle rigidity.Spindles range from 43 hp, 32 kW, on the XL780, through to 94 hp, 70 kW, with spindlespeeds from 4-1,300 revs/min with up tothree gear ranges dependant on machine.All machines in the XL series feature a solidribbed cast construction bed with a widevee and flat bed ways, which again add tothe machine’s stability under heavy cuts.

The XYZ Oil Country lathe features aswing over the bed of 1,100 mm with3,000 mm between centre distance asstandard, although this can be specifiedbetween 1,500 mm and 16,000 mm to suitspecific customer needs. Spindle bore is420 mm as standard, with larger diametersavailable. The spindle is rated at 85 hp(63.3 kW) continuous and when specifiedwith the 420 mm spindle bore comes withthree gear ranges taking spindle speedsfrom 5 to 250 revs/min. Componentsweighing up to 1,000 kg can be machinedusing just the chuck for support. This rises to4,000 kg when the tailstock is applied, and7,000 kg can be machined when the chuck,tailstock and steady are used incombination.

Nigel Atherton, managing director of XYZMachine Tools, concludes: “XYZ MachineTools has always supported machiningacross the size range and our large capacitymachines are ideal for applications inaerospace, oil & gas, and power generation.A number of these large capacity machinesare held in stock at our Devon headquarters,ready for quick delivery, with the assurancethat machines are subjected to rigoroustesting procedures prior to deliver tothe customer.”

XYZ Machine ToolsTel: 01823 674200Email: [email protected]

XYZ’s heavyweights offer largecapacity machining for all

METAL CUTTING


At the Barnoldswick factory of bicycleaftermarket component manufacturer HopeTechnology, nearly all parts are machinedfrom aluminium. Due to the relatively lightmetalcutting involved, it is not surprisingthat nimble, 30-taper machining centres arefound on the shop floor alongside morepowerful but relatively ponderous machineshaving a 40-taper tool interface.

Indeed, works and production managerLindley Pate has started to replace some40-taper machines with 30-tapertechnology, although there is no consciouspolicy to do so. Each machine is purchasedon its merits for the intended applications.

A case in point occurred earlier this yearwhen a Japanese-built Brother R650X130-taper, 3-axis, vertical machining centre,VMC, with 650 x 400 x 305 mm travels andtwin pallet changer, 2APC, was delivered byWhitehouse Machine Tools. It replaced anageing, 40-taper VMC/2APC model with asimilar working envelope and the benefitshave been far-reaching.

First, the Brother machine is much moreproductive. For example, Op 2 on threetwin-piston brake calipers fixturedside-by-side now takes 19 minutes whereasit previously took 32 minutes, representing a40 percent reduction. Time savings of thisorder are typical across the expandingrange of parts being transferred across tothe more agile machine.

Secondly, the footprint occupied by theR650X1 is 20 percent smaller, which ishelpful in a busy factory requiring more andmore machine tools to service a businesswhose recent annual percentage turnovergrowth is well into double digits.

A third advantage is that, as any 30-tapermachining centre draws less power than a40-taper machine with equivalent workingenvelope, there is an ongoing reduction inenergy consumption that not only savesmoney but is also appropriate in a companythat makes equipment for carbon-freetransportation. The R650X1 additionallyprovides power regeneration from spindledeceleration, while the Brother CNC-C00control minimises the power consumed bymotors, pumps and lights by putting theminto standby when not in use.

Lindley Pate explains: “We use ten30-taper machining centres on ourproduction floor and fifteen prismaticmetalcutting machines with 40-taperspindles, a mix of VMCs andhorizontal-spindle machines. Half of the40-taper machines are in multi-pallet cellsand that will not change; in fact at MACH2018 I ordered another 5-axis modelequipped with a 32-pallet pool.

“Where there is scope for swapping to30-taper is in respect of our single-table andstand-alone 2APC 40-taper machines. Thebenefits are compelling due to the higheroutput that is possible using the smaller toolinterface, while accuracy and repeatabilityare just as good.

“In fact, they are fantastic on the Brothermachine. We hold down to five microns totaltolerance on some components such ascassettes, which have to mate with anothersprocket set produced on a differentmachine to provide the higher gear ratios.”

He points to the use of a BIG Plus spindleon the latest R650X1, which providesface-and-taper contact with the tool's backend, leading to extreme rigidity. It allows,for instance, a 32 mm diameter face mill toskim components to achieve a fine finish on

some surfaces, cosmetic features that aremuch appreciated by customers in morethan 40 countries that use Hope's high-endbicycle parts.

The manufacturer's first encounter withKenilworth-based Brother agentWhitehouse Machine Tools was five yearsago when two 30-taper TC-2RB 3-axismachining centres were purchased to copewith increased workload. At the time Hopeused, and still does, six 30-taper machiningcentres of a different make, some equippedwith manual pallet change.

Brother TC-2RB machines were selectedowing to their superior speed, productivityand also due to the compact design of theautomatic pallet changer that both increasesproduction efficiency and saves space.

Brother calls this a QT (quick turn) table,which is essentially one large pallet rotatingaround its centre, so no time is lost byhaving to temporarily disengage pallets for180-degree indexing into and out of themachine's working area.

Two years ago, the first R650X1 arrived onthe shop floor at Barnoldswick, again tocope with steeply increasing demand forHope bicycle accessories. The machine wasconsiderably faster in-cut than the TC-R2Bs,as well as offering similarly short idle times.It also provided a larger table, 800 x 600 mminstead of 600 x 300 mm, and at acompetitive price. The extra table areaenables more parts to be fixtured for longerrun times, which is especially useful forlights-out machining during 24-houroperation, currently from Monday throughto Thursday. A single shift is operated onFriday and weekend working is according todemand.

Further benefits of the R650X1 are theoption of 22-tool storage capacity ratherthan 14 positions on the TC-R2B, 15 bar

30-taper machining centre is 40 percent quicker

METAL CUTTING


coolant delivery through the 16,000 rpmspindle, notably with a 30 m/min cuttingfeed rate in all axes instead of 10 m/min inX and Y and 20 m/min in Z on the TC-R2B.The inherent speed of all Brother machiningcentres derives from fast tool changes andAPC time as well as 50 m/m rapids, all ofwhich happen at the same time so that thetool is in position to cut the next partinstantaneously after pallet changeover.

Larger memory capacity in the Brothercontrol is useful, as two dissimilar Hopeparts can be fixtured and machined on theR650X1's pallets. In contrast, on the old40-taper machine, a relatively complex part

had to bemachined two at atime due to lack ofcontrol memory.The ability toproduce differentparts on onemachine is usefulto Lindley Pate,who sees partnumbers formachining newcomponentderivatives arrivingall the time fromthe design officebut very few beingdeleted.

He concludes: “There is a greater varietyof 30-taper milling centres around now andmore tooling is available to use on them.They are extremely compact, helped by thecarousel style oftool magazine.

“We use two major makes of 30-tapermachine here. Brother machines have theedge in terms of speed, compactness, valuefor money and reliability, and they providegood access for loading and unloading parts

so are popular with our operators.Whitehouse also provides excellentafter-sales backup and service.”

Whitehouse Machine Tools LtdTel: 01926 852725. Email: [email protected]

A leading manufacturer of thermoformingmachinery has made its biggest ever capitalinvestment to help it target new business inthe food and medical sectors.

Shawpak, which is a division ofDerby-based Riverside Medical Packaging,has spent £600,000 with EngineeringTechnology Group (ETG) by purchasing a5-axis Chiron 1250 vertical milling machinethat will help it almost halve cycle times onthe 80-off customer tools it will produceover the next 12 months.

The high-speed spindle, rotating bed andbespoke workholding from Hyfore meansthe company can machine up to twentyparts at any one time, with production setto take just 40 hours, instead of theprevious 80.

This is a major breakthrough for the firm,that will now be able to make more tailoredmachinery for food customers that couldgenerate in excess of £2 m of new businessover the next 12 months.

Alan Wade, works and engineeringdirector at Shawpak, says: “Demand for ourthermoforming technology is growing

rapidly, which means we need tomanufacture more parts withinthe same amount of time to keepup with demand.

“Our existing equipment couldjust about cope, but the time ittook to manufacture parts wouldbe so long our lead times mayhave gone out and we may havemissed out on opportunities inthe marketplace. That’s when wedecided to renew our strategicpartnership with EngineeringTechnology Group and ask it to come upwith some options.

“The support we received was nothingshort of outstanding. We initially hired aXT630 and that showed us the type ofperformance we could get out of a 5-axismachine. However, we knew we needed aneven better solution and that’s when ETGsuggested the state-of-the-art Chiron 12505-axis machine and tapping into thebespoke workholding expertise of Hyfore inCoventry. It’s our largest-ever singlepurchase, but one that has the potential to

really help us drive forward within the foodsector.”

Shawpak is expecting orders to trebleover the next 18 months after stepping-upthe roll-out of its new thermoformingmachinery, which has the benefit of a smallfootprint over traditional alternatives, whilststill delivering the same levels of quality.

Engineering Technology GroupTel: 01926 298128Email: [email protected] www.engtechgroup.com

Chiron investment seals Shawpak’s future growth

METAL CUTTING


Cogsdill-Nuneaton Ltd, a specialist toolingsolutions supplier, has recently invested in anew high-performance Doosan verticalmachining centre from Mills CNC.

The machine, a DNM 6700, was installedat the company’s 27,000 sq ft facility in May2018, where it is being used, primarily tomachine precision components forCogsdill’s range of ZX facing and contouringhead tooling systems. These componentsinclude different sized front-mounted crossslides, with slide ranges from 200 mm to900 mm, which are machined from nitridedand carbon steel.

The decision to invest in the new DoosanDNM 6700 machine followed an internalreview undertaken by Cogsdill into itsexisting CNC machine tool capabilities and,in particular, whether current millingmachining capabilities were adequate tomeet the growing demand from customersworldwide for its large-capacitytooling solutions.

Lee Donaldson, executive director ofCogsdill UK, says: “We invest regularly inadvanced CNC machine tool technologiesand the audit and review highlighted apotential improvement opportunity withinour existing CNC milling capabilities.”

With global demand for its larger toolingsolutions on the increase, it became clear tomanagement and production staff atCogsdill that an investment in a new, reliableand large-capacity vertical machining centrewas required.

Lee Donaldson explains: “To ensure weacquired a vertical machining centre thatmatched our needs and expectations we didour homework and created a ‘key criteria’checklist before investigating the market.”

In addition to the working capacity of thenew machine, other requirements includedthe machine’s cutting performance, itsavailability and price as well as the scopeand scale of the technical back-up and

after-sales support services providedby the machine tool supplier.

Lee Donaldson continues:“Although we hadn’t invested in aDoosan machine tool previously, weknew that Doosan machine tools havea good reputation in the market andthat Mills CNC, the exclusivedistributor of Doosan machines in theUK and Ireland, is a successfulcompany with a significantmarket presence.”

Cogsdill also had direct experience ofworking in collaboration with both Doosanand Mills CNC as a technical partner,supplying advanced tooling solutionto both.

A recent example of this involved Cogsdillworking in partnership with Doosan andMills CNC to deliver a turnkey process forauto-loading facing heads, boring tools andsplining tools, into a Doosan horizontalboring machine, a DBC 130, for a US-basedoil and gas customer. Following anextensive search into the market, Cogsdillultimately decided on investing in a newDNM 6700 vertical machining centre.

The DNM 6700 is a large-capacity verticalmachining centre equipped with a generoussized worktable, 1,500 mm x 670 mm, aswell as impressive axis travels, X-axis1,300 mm x Y-axis: 670 mm x Z-axis:625 mm. The machine also features apowerful, high-torque, 118 Nm direct-drivespindle, 18.7kW/12,000 rpm.

Lee Donaldson says: “The workingenvelope of the machine was of criticalimportance and the DNM 6700large-capacity working envelope enables usto machine larger components, as well assmaller components, in a single setup. Thismeans faster production and reduced partcycle times. Similarly, the cuttingperformance of the machine was importantand the DNM 6700’s powerful anddirect-drive spindle technology gives us theability to achieve high-volumetric removalrates when required as well as fine finishes. Itis a very versatile machine.”

To increase the machine’s flexibilityfurther Cogsdill, as part of its investment inthe DNM 6700, also ordered a 4th/5th axisunit to be supplied with the machine.

Mills CNC has at least 70 new Doosanmachines, at any given time, in stock at itstechnology campus facility in Leamington.

A significant proportion of these machinesinclude its best-selling DNM verticalmachining centres.

Since being installed at Cogsdill’s facilityin Nuneaton, the DNM 6700 has been usedto machine front-mounted cross slides usedin the company's ZX facing and contouringhead tooling systems. These cross slides arerough machined from solid on the machineprior to stress relieving, and are thensemi-finished, heat treated and groundbefore final finishing operations occur. Onaverage machining times for roughing,semi-finishing and finishing are 60 minutes,90 minutes and 30 minutes respectively.

Mills CNC LtdTel: 01926 736736Email: [email protected] www.millscnc.co.uk

Leaving nothing to chance

METAL CUTTING


The award-winning Victor Vturn-26HD haslong been a firm favourite amongmanufacturers with a need for a mid-sizedturning centre that delivers power, precisionand uncompromising levels of reliability.Now, Victor CNC has added to this line withthe arrival of the new Vturn-S26 (CM).

Complementing the existing Vturn-26 HDand VT-A26CM, the new arrival has beenre-engineered to provide a host of newfeatures that include the option of a servopowered C-axis to offer driven toolingstations. This new facility gives end users theoption of the cost-effective 2-axisVturn-26HD workhorse or the equally costeffective, more flexible 3-axis Vturn-S26.

As with all Victor CNC machine tools, thefoundation for the new Vturn-S26 is a largesturdy single-piece slant-bed. Thesingle-piece design eliminates thepossibility of coolant leakage whilst the30-degree design lowers the centre ofgravity to enhance rigidity and performance.In addition, this innovative newconfiguration provides a large swingdiameter that enables end-users to load

larger billets. The performance of the newVturn-S26 is encapsulated in its 18/24m/minrapid feed rates and high thrust force of1,441 kg/f that reduces chip-to-chip timesand ensures that productivity levels arebest-in-class. Further contributing to theproductivity level of the new Vturn-S26 is the12 station live tooling turret.

Despite its nimble and productiveperformance, the new Vturn-S26 offers amassive spindle output of 22 kW with574 Nm which permits heavy duty cuttingunder the most challenging conditions andmaterials. End users can rest assured thatsurface finishes and tool life are optimisedwith the unparalleled rigidity and machinestability that are the hallmark of the VictorCNC brand.

The latest addition to the Victor CNCstable has an increased swing over the bed.The Vturn–S26 has a swing of 600 mmcompared to the 520 mm on previousVturn-26HD models and this increases themaximum turning diameter from 410 to430 mm. The Vturn-S26 also incorporatesthe latest FANUC 0iTF CNC control with a

large 10.4-inch colour screen display andintuitive manual guide.

For end users looking to upgrade to thiscompact new powerhouse, Victor CNC canalso offer a host of optional accessories thatinclude a manual or auto tool pre-setter,part catcher, power-chuck, high pressurecoolant, bar-feed interface, auto-door,tailstock centre and of course the C-axisconfiguration.

Victor CNC Tel: 01706 648485Email: [email protected]

Victor CNC adds to its Vturn marque

Pipeline & Drainage Systems, based inSheffield, ensures the high-end productionof its Envirokerb kerb drainage system byusing a Hyundai-Wia vertical machiningcentre to produce the numerous holes/slotsrequired. The system is described as “thelightest, strongest and greenest” kerbdrainage solution available.

Manufactured from recycled materials,the composite kerb has the appearance ofconcrete and its wide appeal is also helpedby the fact that it is a one-part kerb system,as opposed to conventional two-partconcrete alternatives, which means nobreakages and faster installation.

Part of the USL Group, a leader in theprovision of specialist civil engineering andconstruction solutions, Pipeline & DrainageSystems needed to replace an ageingvertical machining centre for producing therequired holes/slots in each section of drain.These range from six to 20 mm diameter/width and vary in height/length, dependingon product variety. They are machined in astraightforward sequence along the lengthof each kerb section.

The company turned to local machinesupplier, T W Ward CNC Machinery (WardCNC), knowing that a suitable machinewould be in stock. Ward CNC is the UK andIreland exclusive supplier of a wide range ofmachines, with many representative modelsbeing held in stock.

Glyn Jones, operations manager atPipeline & Drainage Systems, says: “TheHyundai-Wia F600D was selected due to anumber of reasons. First, it had the capacityto accommodate all kerb lengths and,secondly, it had the capability to reliablyproduce the holes and slots day in, day out.”

With a 900 mm x 650 mm twin table

configuration, that is able to accommodateloads of 400 kgs per table, plus X, Y and Zaxis travels of 800 mm x 600 mm x 600 mm,the F600D has the ability to have acontinuously running (in-cut) spindle due tothe twin-table arrangement enabling aload/unload procedure while the machine isin-cycle. This feature, when coupled with apowerful 15 kW, 8,000 revs/min spindleand 24-tool automatic toolchanger, offereda machine with all the features thatGlyn Jones required.

Glyn Jones concludes: “The kerbs areproduced in varying batches and are ofdifferent sizes. The Hyundai-Wia is provingto be much quicker and a lot better atconsistently producing the holes which are,after all, key to the success of the drainagesystem.”

T W Ward CNC Machinery LtdTel: 0114 276 5411Email: [email protected]

Capacity and capability from TW Ward

Feature - DEEP HOLE DRILLING


JB: Firstly, can you tell us a little aboutTibo, it’s history and its areas ofexpertise?

JE: Since 1994, the name Tibo stands forhighly sophisticated process solutions indeep hole drilling. Based in the town ofPfullingen, in Germany, the permanentpursuit of quality and refinement has alwaysbeen the hallmark of Tibo’s reputation.

As one of the leading suppliers ofsingle-spindle, or multi-spindle deep holedrilling machines, TIBO TiefbohrtechnikGmbH provides sophisticated solutions forsophisticated tasks. The excellence of Tibodeep hole drilling machines is recognised ina wide range of industries throughout theworld including hydraulics, pneumatics,aerospace, automotive, renewable energiesand medical technologies.

JB: At AMB, I was excited to discover thatyou now have a UK distributor for yourproducts. Could you reveal who thisdistributor is and how the relationshipwas first formed?

JE: Our UK distributor is MaydownInternational Tools, which has a strongregional sales force in all areas of the UK. Itssales team is supported by three regionaltechnical sales managers and groupmanaging director Carl Griffiths who hasmore than 30-years’ experience in thedesign, manufacture and installation ofdeep hole boring, turning and specialpurpose machine tools. Carl and his teamare exceptionally well equipped to translatecustomer needs to the Tibo sales, technicaland commercial departments, ensuring thefull modular concept is matched toindividual customer needs providing theoptimised solution for the customers.Additionally, through his machine toolbackground, Carl and his team can providefirst line support for Tibo in the UK.

We think this exciting new era, with ournew partner in the UK, will allow the UKdeep hole drilling industry to benefit fromTibo’s unrivalled simplicity, performanceand service, effectively delivering our coreprincipals of modularity, performance andprecision. The relationship was first formedsome years ago when carl purchased some

components from Tibo, for machines thenbuilt in the UK. Discussions were held atEMO last year, renewing the relationshipand we started formal cooperation again inMay of this year.

JB: What makes Tibo deep holedrilling machines stand out in acompetitive market?

JE: Our core principals, utilising leanmanufacturing and the best of Germantechnology and quality, have focused ourbusiness on delivering what the customerneeds. Our modularity ensures we havecommon components and sub- assembliesacross our entire range ensuring we arecompetitive, but more importantly it meansthat we can often build to short lead times,using stock components andsub-assemblies. This ensures that customersindividual needs are met precisely andconsistently with a very high-performancelevel.

JB: In terms of service, what can youoffer to your customers?

JE: We offer the highest service levels inthe industry with remote diagnostic andsupport utilising the latest technology andwe are always available for our customers. Inthe UK, we have the added benefit of having

support from Carl and his team withlocations in the midlands and Yorkshire.

JB: How important are trade shows, suchas AMB, for Tibo?

JE: Trade shows, as well as trademagazines, are a very good platform todemonstrate the latest technicalimprovements, presence in the market andcoverage. The company participates in allmajor trade shows.

JB: In the era of industry 4.0 anddigitalisation, what solutions can thecompany provide?

JE: We already offer totally integratedmachines with robotic loading, in processinspection and data capture, continuing todevelop and integrate the latest digitaltechnologies, across our range of machines,offering remote diagnostic and support asstandard. Our R&D department are alsoworking on artificial intelligence and theopportunity to deploy this in our machines.

Our latest software utilises digitaltechnology to visually display, capture andstore critical deep hole boring parameterssuch as: spindle load, axis load, oiltemperature, oil-flow, oil pressure, cycletime, batch quantities and chip flowinformation in real time. These areas of

Sophisticated solutions for sophisticated tasksJohn Barber met with Jost Eppinger, CEO of Tibo at AMB in Germany, to discuss the latestexciting developments at the deep hole drilling specialists

DEEP HOLE DRILLING


functionality digitally enhance the machinesand simplifies what can be a harsh and verydemanding process.

JB: Looking ahead, can you envisageexpanding into new areas that couldbenefit from your products?

JE: In addition to deep hole boring’straditional sectors in the UK, such as oil andgas, medium and heavy engineering, thereis a very strong casting, foundry, steelprocessing industry operating in the UK. Aswe know, from F1 and continuingcompetition of our top drivers and the closecooperation of F1’s best constructers, the

UK is very well respected and is known to beleading innovators in high performancemotor sport, aerospace and defenceindustries. We believe these sectors can alsobenefit from Tibo’s quality, reliability andphilosophy.

JB: Could you explain why the McLarencar has been such a prominent feature ofyour stand at AMB?

JE: We are delighted with thecooperation of McLaren Stuttgart, ensuringwe could bring this fine example of thelatest technology in high performancemotor sport within reach of engineers andvisitors at AMB. We also feel this helps todevelop our links with the UK, as well asbeing a huge focal point and we hope thiswill be the continuation of a long andsuccessful relationship between our twocountries

JB: Do you have any personal highlightsor success stories that you would like toshare from your time with the company?

JE: Tibo has spent a huge amount indeveloping state-of-the-art-machines, witha high level of automatisation, in R&Dactivities and a bunch of software

modifications related to industrie 4.0.Furthermore, the relocation to our newplant in Pfullingen in 2016 has providedbetter efficiency in manufacturing as well asan ideal platform for presentation.Therefore, Tibo has won many newcustomers in all industries.

JB: Finally, what can your customers lookforward to in the future?

JE: Tibo will ehance its position as one ofthe leading manufacturers of deepholedrilling machines and will continue to serveits customers with short lead times, due toour very successful modular systems.Customers that use our machines will becompetitive in the market.

TIBO Tiefbohrtechnik GmbH Tel: 0049 7121 994260 Email: [email protected] www.tibo.com

UK Agent:Maydown International Tools LtdTel: 01827 309709 Email: [email protected]

www.tibo.comTIBO Tiefbohrtechnik GmbH | Benzstr. 5 | 72793 Pful l ingen | Germany

Innovative deep hole drilling technology,

intell igently engineered from modular

system components – that’s what Tibo

Tiefbohrtechnik is all about. Get to know

our high-performance BTA and gundrill-

ing machines and discover the amazing

possibilities for your specific deep hole

drilling applications.

Visit us at our headquarters and production

site in Pfullingen, Germany or experience

our website at www.tibo.com

Modularity. Performance. Precision.

Experience Tibo deep hole drilling machines.

DEEP HOLE DRILLING


The BTA or STS self-piloting drilling processfor larger holes is able to create bores fromØ18 mm up to 100 or more timeslength-to-diameter ratios. MollartEngineering and its tooling partner Botek isable to provide application engineeringsupport involving drill heads up toØ1,000 mm.

Chris Barker, director of tooling atMollart, explains: “The BTA drilling processoriginated from the Boring and TrepanningAssociation formed through a group ofEuropean manufacturers in the 1940s. TheBTA process is also known as the single tubesystem, STS, covering deep hole solid drillheads, pull boring and counter boringheads, step and form boring tools andtrepanning heads.”

Due to the different tool head types, eachproviding a more effective deep holeproduction solution over conventionaldrilling and boring, they need to beconfigured and applied to optimise results.In order to provide this level of support,Mollart Engineering has created its BTAApplication Centre based in Chessingtonwith two ‘local’ regional specialists in theMidlands and North of England to alsoprovide direct support to customers inScotland. The new centre is also able todraw upon Mollart’s international expertisein advanced deep hole machine tooldevelopment and build, tooling andsubcontract manufacture.

Due to its configuration and hole sizecapability, BTA drilling requires more powerthan gundrilling. Both drill from solid usinghigh pressure coolant to directly lubricatethe cutting zone and importantly, efficientlyevacuate chips away from the head ofthe drill.

There is a marked difference in the designof a gundrill and BTA tool. Gundrilling uses a

solid carbide tool head brazed to a tubethrough which coolant is pumped underpressure to the cutting edge of the toolhead. Chips are evacuated via a deep veeshaped flute in the drill head which extendsback along the exterior of the tubebetween the drill and the drilled portion ofthe workpiece.

The BTA system has a rigid drill head,secured to a support and feed tube, witheither brazed carbide or indexable insertswhere coolant is pumped under pressure tothe cutting edge between the outside of thetube, the cutting head and the newlycreated bore in the workpiece material. Thispressure forces the chips to be efficientlyflushed back through the drill head, tubeand machine spindle for collection. In bothBTA and gundrill systems, guide pads in thedrill head support the cutting actionenabling continuous feed rates to beapplied to achieve straight, round andaccurately sized holes with high degrees ofsurface finish.

As chips are evacuated through theinternal bore of the BTA drill head and tube,fluting or grooving is not required. Thisenables a greater cross-section of tool thatincreases rigidity and hence stability undercutting conditions with the ability tomaintain geometry and performance overextended hole depths.

Pull boring is a BTA-based process used

to accurately enlarge existing through boresto maintain, for instance, a constant wallthickness, tolerance or surface finish. Theprocess uses a tensioned BTA boring headbut with the wear pads set ahead of thecutting inserts in order that the cutting toolcan be drawn or pulled-back through theworkpiece.

Counter boring is a very effectiveoperational use of the BTA process to openup existing pre-bored holes where the BTAdrill head can achieve a more precisediameter, or concentricity of a bore, orprovide an additional feature such as abearing or oil seal diameter.

While gundrilling can be used for creationof micro bores as small as Ø0.5 mm, BTAholes start at Ø18 mm due to the sizerequired for the drill tube but its designcriteria is able to create bore lengths inexcess of 100 times depth-to-diameter ratio.In addition, the use of a trepanning stylehead extends the BTA concept to machinebore diameters up to Ø1,000 mm. However,while the trepanning operation createschips from the cutting action, it alsoproduces a central core of material whichcan be used for further production and isespecially economic on high value materials.

BTA drill heads comprise a series ofsupporting guide pads and can be fittedeither with brazed carbide inserts that canbe reground or carry a series of carbide

Mollart engineers BTA drilling solutions

DEEP HOLE DRILLING


indexable inserts which enable greater efficiency due to themultiple cutting surfaces. The drill head is larger than the tube andis screwed into the end of the rigid drill tube. This construction ofthe tool means it is ideal for difficult materials such as exotic alloysteels and stainless steels and is able to support and maintain drillpenetration rates several times faster than more conventionaldrill types.

As a result, the BTA system has been widely adopted by the oiland gas, nuclear and defence sectors as well as generalengineering. Indeed, with certain sectors having demandingcomponents, such as premium precision tube for use in hostile orextreme environments, BTA drilling is the chosen process to createthe standard of bores demanded.

Recent applications at Mollart Engineering, involving the BTAdrilling process, included a second order from a Europeanaerospace contractor for producing a series of deep and blind holesin a range of aircraft actuation devices. Ian Petitt, managing directorof Mollart, says: “The success in our application engineering for thefirst machine, won against intense world competition, put us veryquickly on the shortlist for the follow-on order.”

The Mollart HD1-1500 BTA machine, with 22 kW drive, has acapacity from Ø18 mm to Ø50 mm by 1,500 mm depth. It isprocessing a series of blind and through holes between Ø20 mmand Ø47 mm in 15-5PH stainless steel bar where holes can be up to1,200 mm deep. Geometric tolerances are within 0.2 mm forstraightness, 0.05 mm TIR for concentricity and 0.025 mm forroundness with surface finish within 0.8 micrometres.

Mollart Engineering’s Acubore deep hole drilling centre, installedat its Chessington subcontract facility, was used to produceØ63.5 mm bores from solid using BTA tooling technology indemanding oil industry Super Duplex materials. The parts wereproduced from Ø250 mm by 2,180 mm long, 13 percent chromiumSuper Duplex stainless steel bars with each component weighingsome 900 kg.

The design of the Acubore machine incorporates the flexibility todrill both on-centreline as well as off-centre using either orcombinations of gundrills and BTA tooling. This extends theflexibility of the process and drilling capability to suit the workpieceand the level of accuracy required.

The Acubore machine was developed by Mollart for powerdrilling with a 30 kW motor able to create up to 666 Nm of torquewith a top speed of 5,000 revs/min. This enables the machine toaccommodate both large and smaller hole sizes with the power todrill exotic materials and higher speeds for machining materials.

Mollart LtdTel: 0208 391 2282Email: [email protected] www.mollart.com

27

Subcon Drilling Ltd Unit 6, The Heron Business Park, Eastman Way, Hemel Hempstead, Hertfordshire HP2 7FW

Tel: 01442 205960 Fax: 01442 205961

www.subcondrilling.co.uk Email: [email protected]

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DEEP HOLE DRILLING


When the manufacturing engineering teamat medical device manufacturer ConMedneeded to find a way to pull significant costsout of production, they saw an opportunityto bring bone drill holemaking in house. Theparts, however, presented a significantchallenge, with small diameters, thin partwalls and approaching depth-to-diameterhole ratios of 100:1. Manager Kevin Burchand his team were unsure if gundrillingcould hold required tolerances and givethem the control of accuracy thatthey needed.

Medical tooling components and similarapplications with extremely small diametersare on the edge of what is possible withsmall diameter deep hole drilling. Thesediameters are produced with gundrilling, aprocess which uses a single effective cuttingedge to produce deep holes with highpressure coolant and effective chip removal,reaching depth-to-diameters that otherprocesses cannot handle. Typically,counter-rotation of the tool and workpieceis used for maximum concentricity of thefinished hole. This is performed on adedicated gundrilling machine, equippedwith smart controls, to take any guessworkout of the process.

Holes in the extremely small rangepresent additional challenges compared tomore common depths and diameters.Often, workpiece dimensions and shapesresult in thin walls and non-uniform sectionswith extreme precision requirements. Thisdemands a consistent, reliable process inorder to produce successful parts. Gundrillsin this range of diameters require additionalsupport to sustain rigidity and processdevelopment is essential for developingideal drilling speeds and feeds. Control andfeedback of the operation is critical.

Kevin Burch and his team considereddifferent solutions for their in-houseproduction. When they began their search,they had no experience with gundrilling andwere looking to confirm that the processcould hold tight tolerances, ultimatelyfinding a solution that wouldn’t upset theirproduction.

Kevin Burch says: “The processcollaboration with UNISIG gave usconfidence that we could produce this partand hold the runout. The team at UNISIGsaid ‘There shouldn’t be any reason we can’tdo it the way you want’ after evaluating our

process and demands. They madeit happen.”

He ultimately decided on the UNE6gundrilling machine, designed specificallyfor the extremely small hole diameters thathis parts required.

ConMed worked with UNISIG’sengineering and technical teams to developa solution that fit demands withoutcompromise through detailed processcollaboration. The result was a standardUNE6 machine, with additional tooling andaccessories to ensure the accuracy of theprocess and in-depth training with ConMedoperators and engineers. This enabled themto confidently begin productionimmediately following installation.

UNE6 gundrilling machines are compact,accurate and have intuitive operation forparts requiring holes up to 0.25 in (6 mm) indiameter, using the counter-rotatinggundrilling process. To maintain the optimaldrill speeds and feeds for the operation, themachine uses a high speed, integral motor

spindle, reaching 20,000 rpm, to provideample power while also reducing vibrationsat sustained high speeds. A high-pressurecoolant system is required to manage therequired 3,000 psi of coolant needed to flowthrough the extremely small tool.Additionally, application specific supportand fixtures were developed to supportshort drills and clamp on the outsidediameter of the part for veryhigh repeatability.

Capable gundrilling for extremely smalldiameters has opened up a whole new realmof possibility for medical manufacturers suchas ConMed, who face similar challenges inboth accuracy and production. Using aproven gundrill process after turningenables a profitable, reliable solution in thechallenging small diameters of medicaltooling and components.

Kevin Burch and his team use processmonitoring on the machine’s interface tokeep an eye on the drilling process, ensuringtheir accuracy is upheld, while keeping updemanding production. The machinehandles two families of products with over30 individual part numbers and enablesConMed to keep up with demand, whileproducing competitive parts for the medicalindustry. They currently run two shifts,alongside a screw machine, to keep up withdemand while maintaining confidence intheir parts. Kevin Burch states that theircycle time has been cut in half, saving themsignificant costs and providing a controlledsolution: “It’s so easy for our operators touse, the machine basically runs itself.”

UNISIG is one of the largest producers of

UNE6 gundrilling machine from Unisig

DEEP HOLE DRILLING


deep hole drilling machines and a leader intechnology, innovation, support and servicethat its customers rely on to be competitive.Its customers include small job shopslooking to expand their capabilities, to largeOEM’s that need to drill millions of holes.

The company offers an entire deep holedrilling solution that consists of machines,tools and automation. It provides technicalexpertise, training and remote, as well ason-site, service to its customers to helpmaximise the value of their investments.

UNISIG machines are engineered andmanufactured in the USA for its globalcustomer base. The machines can beinstalled and supported anywhere in theworld. It has installed machines in theAmericas, Europe and Asia and offerstechnical support and service to itscustomers in order for them to stayproductive through the life of theequipment.

The company believes that its successstems from a very strong understanding ofthe deep hole drilling process, drilling toolsand their applications. It has a long history ofachievement, regardless of the technicalchallenges.

This experience comes from solving

problems with itscustomers andlearning what theyneed from theirmachines to achievetheir deep holedrilling goals. It thenapplies what it learnswith its impressiveengineering andmanufacturingcapabilities whilesetting newstandards forperformance from deep hole drillingmachines. This in turn drives toolingdevelopment to the benefit of the industryas a whole.

UNISIG often helps customers, with littleor no deep hole drilling experience, to bevery successful when launching new projectsthat are critical to manufacturing needs.More experienced customers also value thepower, precision, and control that thecompany’s machines offer them.

Its products cover the full range of deephole drilling applications. It can offerstandard models that drill holes less than1 mm, 040, diameter in titanium medical

components. On the other end of thespectrum, it builds machines that can drillholes 500 mm, 20” in diameter, over 10 m,30 ft, deep in massive high strengthforgings. Its experience goes beyonddrilling with its 5-axis CNC milling anddrilling machines. UNISIG’s sales andapplication team will customers to find theright solution.

UNISIG GmbHTel: 0049 71259687590Email: [email protected]

PRV Engineering prides itself on being aprecision engineering company that deliversa complete, customised service with theability to manage customers deep holedrilling and engineering requirements. Why PRV for deep hole drilling?

PRV not only offers superiorworkmanship, but it also providesoutstanding customer care from the start tothe completion of projects.

As a company, it has many years of deephole drilling experience working with a widerange of customers. Its personnel areknowledgeable and possess the experienceand skills to deliver high levels of accuracy,in terms of hole position, diametricaltolerance, surface finish and straightness.

How can PRV help with deep hole drilling?Using its 10 deep hole drilling machines

and related equipment, it has developed afull range of supporting processes. It canoffer deep hole drilling as a stand-aloneservice or the complete manufacturingpackage, providing component processesto whatever stage that is required.

Deep hole drilling capabilities at PRV

The company providesnon-cylindrical components:Holes from 5 mm diameter upto 100 mm diameter, in anyposition, Up to 3,000 mmcentres dependent on weightand overhang, maximumweight four tonnes. It alsoprovides on-site drillingservices up to 75 mm diameterand 3,000 mm in length.

For cylindrical components itprovides: Holes from 5 mm dia up to200 mm dia, in any position, up to 5,000 mmin length, maximum weight four tonnes.

It also has an extensive range of gun drills,ejector drills and counter boring heads forthe above capabilities and uses itsknowledge and experience to provide thetechnical assistance that customers require.

The company’s commitment to qualityand service helps to make it truly stand out.As well as investing in the best machinery, ithas pioneered its ethics and ideals towardthe attainment of excellence, which is whatits client’s value the most.

Simon Jones, managing director at PRV,concludes: “We boast years of deep holedrilling experience and have worked closelywith a wide range of customers. Our staffare knowledgeable and possess the skills todeliver high levels of accuracy in terms ofhole position, diametrical tolerance, surfacefinish and straightness.”

PRV Engineering LtdTel: 01495 708971Email: [email protected]

Deep hole drilling and precision engineering from PRV

CUTTING TOOLS


At Dormer Pramet, the process of creating anew tool begins with its productmanagement department that identifies themarket needs and gaps in the company’scurrent assortment. Karel Tiefenbach is thecompany’s product manager for indexablemilling and he created a concept brief andclear objective for the development team.

Dormer Pramet’s aim was to create anassortment of tools for its double-negativecutters, which allowed high feed rates forincreased productivity. The design neededto be for double-sided inserts to maximisethe economic value, four-edges, andprovide good chip control, allowing for ahigher ramping angle.

At the same time, the tool needed to offerprocess security and a versatile range formould and die operations, coveringroughing to finishing.

Design conceptsJan Bittner began the process with JanVlcek, from the company’s product design &information department, responsible for all

aspects of tool development. This includescreating high quality data on every toolproduced, the design of products andsupporting manufacture.

The department’s first task in designing anew high feed milling tool, later known asSBN10, was to research what products werealready available in the market from

competitors and how Dormer Pramet couldbe different, while still meeting the needs ofcustomers.

Jan Bittner says: “We started with a seriesof preliminary studies and initial prototypedesigns, putting a number of ideas forwardbefore we could start to produce samples.There are always difficulties and challengesto overcome, but some small changes at thisstage can have a big impact.

“For example, with one of the firstsamples created, we realised there was aconflict with an existing patent from acompetitor. With many companies creatingnew inserts all the time, it is a very crowdedmarket.

“However, we worked with the designerto modify our concept to make it unique,whilst still fulfilling the original brief. This ledus to liaise closely with colleagues in Swedenand North America to make sure our designsdid not conflict with any patents.

“We discussed with colleagues inIntellectual Property, IP, how we can makeour design unique and this was a newexperience to me.

“At each stage, we were in discussionswith IP over the design and any slightchanges being made. We needed to confirm

Creating a new cutting tool

Global manufacturer Dormer Pramet tasks its product management and development department with creating new tools every year.A member of the team is product and development engineer Jan Bittner. In January 2015, he joined Dormer Pramet and became partof the company’s project to develop an assortment of high feed milling tools. Almost three years later, a new range of SBN10 cuttersand BNGX inserts were launched into the global market.

The time taken to introduce a product is an indication of the investment a manufacturer makes to create a new product which willadd value to customers for many years. This is Jan Bittner’s story:

New cutting tools are continuously being introduced to the market, but what is the processto get a product from concept through to the spindle?

CUTTING TOOLS


we were within patent pending at everypoint and not conflicting with others alreadysubmitted. Eventually we were given the okto proceed.

Product testingJan Bittner continues: “At the start of theprocess in 2015, we had a schedule to followand aimed to launch the BNGX inserts byNovember 2017. We had pressure from oursales teams who wanted it earlier. Our aimwas to keep the process going as fast aspossible and we kept to schedule.

“By the second quarter of 2016, we wereable to start the testing stage. This includedseveral on-site tests with customers as this isthe best way to check how good a productreally is.

“We were confident it was a goodproduct, but no amount of in-house testingcan match trying it out in the real world. Welearned so much from these tests whichallowed us to identify areas of furtherimprovement.

“A test we did, with a customer in France,involved machining a titanium-bearing,austenitic, chromium-nickel, stainless steel.It is an extremely tough and ductile material.It requires a powerful machine, capable ofheavy feeds and slow spindle speeds. Weput it up against a competitor’s high feedmilling tool with similar features to ourSBN10.

“After machining three parts, the cuttingedge of the competitor’s insert was worn,forcing the operator to index the cuttingedge to proceed production. Aftermachining eight parts with the SBN10 cutterand BNGX inserts, the cutting edge showedminor flank wear and was still in a goodcondition to continue cutting.

“In addition to significant longer tool life,the metal removal rate was 20 percenthigher. The customer was so impressed, heimmediately bought one cutter andpre-ordered seven more by early 2018. Wedid more than 20 tests with customers inFrance, Brazil, Poland, China, Italy, CzechRepublic and Germany. Altogether, five of

these tests did not match our expectationsso it allowed us to go back and look at whatneeded improving. This is an importantprocess and can only help improve productperformance and reduce limitations.

“The crucial part is to react quickly duringthe testing process, speed is crucial. Anyissues need to be eliminated and the designof the tool improved as soon as possible,before putting it back in for more tests.

“In July 2017, we returned to Germany toa customer where one of the tests did notgo as well as the others. Going back to thesame location meant we could perform theexact same trial in the same conditions asbefore. This was important to verify if theimprovements we made had worked. Theapplication ran very successfully, and it wasgreat to show the customer the new andimproved version.

“We realised at this stage, we were readyto launch the product into the market. Wehad further discussions with IP to make sureour patent was in place and everything wasprepared.

“This led to meetings with production toensure enough inserts were manufacturedfor the time of launch and liaising with themarketing and communications departmenton creation of all the support material, suchas brochures, images, videos, press releasesand online content.”

Launching product to marketDormer Pramet launched its range of BNGXinserts and SBN10 cutters in November2017, almost three years after the initialdesign brief was prepared.

During 2018, the company willmanufacture more than 30,000 BNGXinserts, comprising of different sizes andchip breakers, alongside 450 cutters, inthree different variants; end mills with

threaded shank, end mills with parallel shankand shell mills.

Jan Bittner concludes: “Productdevelopment is very much a team effort.There are many people from around theworld involved in the creation of new cuttingtools. From product management to design,to the technology team, production, testing,through to sales and marketing.

“Each department is not independentfrom the rest. We are all connected and onearea cannot be successful without thesupport of the rest. They all must worktogether to get a product to market.

“Also, any new product created willbecome the future work for our productiondepartment. Sometimes we can be focusedon today and what is new now, but it is ourjob to look at the future and what will beimportant in five to ten years’ time.”

For more information regarding the highfeed milling SBN10 and BNGX range, visit:https://www.dormerpramet.com/en-gb/newssite/pages/2017-2_high-feed-milling-cutters-and-inserts.aspx

Dormer Pramet is a global manufacturerand supplier of tools for the metal cuttingindustry. Its comprehensive productprogram encompasses both rotary andindexable drilling, milling, threading andturning tools for use in a wide variety ofproduction environments. An extensivesales and technical support service operatesfrom 30 offices, serving more than 100markets worldwide. These are supported bydedicated production facilities in Europeand South America and a highly developeddistribution and logistics network.

Dormer PrametTel: 0870 850 4466Email: [email protected]

31

CUTTING TOOLS


Sandvik Coromant now has a completeoffering for hard turning operationsCutting tool and tooling system specialistSandvik Coromant has released two newgrades for interrupted hard-part turningoperations, CB7125 and CB7135. Thegrades will complete the company’s offerfor hard-part turning, complementing theexisting CB7105 and CB7115 grades.

The latest Sandvik Coromant gradesprovide the ability to perform medium toheavy interrupted cuts and remove thehardened layer, depth of cut up to 2 mm, incase- and induction-hardened steelcomponents, typically for the automotiveindustry. Here, CB7125 and CB7135 offerlonger and more consistent tool life, goodlevels of surface finish and consistentdimensional tolerances.

Torbjörn Ågren, product manager forgeneral turning at Sandvik Coromant, says:“For everyone working with transmissionand other hard-turned components, there isa reason to choose these CBN grades. Notleast because adding value in speedcapabilities and providing a more secureedge line and consistent tool life meanslower cost per component. This isparticularly the case when aiming for aone-cut strategy, namely a single cut withlarger chip thickness, at high speed.”

CB7125 and CB7135 are optimised forturning steel materials with a hardness of58-62 HRC. Designed for mediumintermittent cutting, CB7125 features a newPVD coating that provides improved wearand fracture resistance for extended toollife. This grade, which contains mediumCBN content, is ideal for turning of shaftsplines and shafts with chamfered oil holesor pockets. Further applications include thefacing of gears, the hard-to-soft turning ofcrown wheels, and the removal of hardenedlayers.

The CB7135 grade is pitched at the

efficient longitudinal turning of gears andshafts with unchamfered keyways orpockets, as well as CV joint componentssuch as the inner/outer race and cage.Featuring a high CBN content, the gradeoffers high fracture resistance andpredictable machining results.

Available for T-Max P, CoroTurn 107 andCoroTurn TR tooling systems, the newgrades come in both positive and negativebasic shapes, with various edgepreparations. Cutting datarecommendations for CB7125 include acutting speed of 100-200 m/min, 328-656ft/min, a feed rate of 0.05-0.45 mm/rev,0.002-0.018 in/rev. For CB7135, a cuttingspeed of 80-160 m/min, 262-525 ft/min a

feed rate of 0.05-0.4 mm/rev, 0.002-0.016 in/rev, should be achievabledepending on the specific application.

With the introduction of CB7125 andCB7135, Sandvik Coromant now offers acomplete hard-part turning solution, alongwith the existing and complementaryCB7105 and CB7115 grades, which aresuitable for continuous or continuous tolight interrupted cutting operations.

Sandvik CoromantTel: 0121 5045400Email: [email protected]/uk

Top grades for hard-part turning

Delivery next day not some dayOrder by 6:30pm and we guarantee next day delivery on over 55,000 tools with 99% ex-stock availability.

It means, with WNT Tool-Xpress, you could deliver the job before other suppliers deliver the tool.

CERATIZIT UK & Ireland [email protected] \ Free phone service number: 0800 073 2073www.ceratizit.com \ www.kometgroup.com \ www.wnt.com \ www.klenk-tools.de

CUTTING TOOLS


For manufacturers tangled in the process ofdeciding which solid carbide tool to buyfrom a supplier, NTK immediately doesaway with the legwork of finding the mostproductive or cost-effective solution. Thenew Ceramatic Series of solid ceramic endmills for heat resistant super alloys from NTKoffers productivity levels 10 times that ofsolid carbide equivalents.

Manufactured from NTK’s durableSiAlON SX9 grade, the new Ceramatic line isavailable with the option of a four or six flutevariant. Ideal for manufacturers in the oil &gas and aerospace industries, whereInconel, Rene, Hastelloy, Waspalloy andother materials are the daily challenge, NTKhas introduced a completely new geometryfor the Ceramatic line with an optimisedhelix angle and cutting-edge design. Itprovides an astounding level of toughnessand wear resistance when machiningparticularly challenging heat resistant alloys.

Not only does the new Ceramatic linedeliver unsurpassed performance, it alsoprovides flexibility with the four-flute variantcapable of conducting slotting, pocketing

and ramping operations.Complementing the four-fluteend mill, the six-flute variantgenerates superior toughnessfor face milling, side milling,profiling and rampingoperations.

The ability to conduct ultrahigh-speed machining underthese conditions is credit to theCeramatic geometry, that isparticularly resistant to cuttingforces under high loadoperations. This is the result of a geometrydesign that evacuates chips at speed whilstgenerating a smooth cutting action thatminimises the cutting forces on both theCeramatic end mill and the machine spindle.

The composition of the Ceramatic endmill and the innovative geometry designenable the exciting new end mill to run atcutting speeds from 300 mm/min to 1m/minon the most challenging alloys that machineshops are likely to encounter. Massivelyoutperforming solid carbide end mills, theCeramatic can machine at a depth of cut up

to 2 mm for face milling and slotting and adepth of 6 mm for side milling.

Both the four and six flute variants areavailable with a choice of 8, 10 and 12 mmdiameters with imperial dimensionsincluding 3/8 and ½ inch diameter.

NTK Cutting ToolsTel: 01442 281072Email: [email protected]

NTK launches ceramic end mills for 10 times faster machining

For the efficient turning of high hardenedsteel, Mitsubishi Materials has an extensiverange of coated CBN insert grades, theBC8100 series. Four grades make up thecomplete range:

BC8105 for the highest speeds and finesurface finishing. This grade can providelong tool life and fine surface finishes of Ra0.6μm or better due to the improvedlubricity of the CrAlN and TiAlN layeredcoating.

BC8110 is the first choice for continuoushigh speed and light interrupted machiningup to 310 m/min cutting speeds.

BC8120 is for general applications and itdelivers a substantially better wearresistance and cutting-edge toughnessthrough use of a substrate with a newmicro-particle binder that prevents crackdevelopment. This micro particle binder isalso adopted across the whole 8100 series.

BC8130 is for the toughest workpiecesand for heavily interrupted cutting. Peelingof the coating, usually caused by the impactof interrupted machining, is prevented bythe adoption of a high CBN contentsubstrate and a customised ceramic coating.

All grades incorporate next generationadvanced ceramic coating technology thatprovides outstanding wear resistance andimproves productivity. All the differentcoatings include a TiAlN layer that improvesadhesion between the base layer and theCBN surface whilst also generatingexceptional peeling resistance. Each coatinghas similarities, but also has specificcharacteristics that makes it ideally suited toeach application.

Serious research resulted in the innovativenew substrate technology used across thewhole BC8100 series. Micro and mediumgrain CBN particles are bound together byan ultra-micro particle binder material. Thisprevents linear crack development andsudden fracturing by dispersing the impact

and cutting forces radially. The result is aconsistently high performance for theend user.

To extend the potential of these CBNgrades, Mitsubishi now has available a widerange of ISO insert geometries, with anextensive choice of standard honing types,for small depths of cut through to heavyinterrupted applications. Additionally, twochipbreakers are available for removingcarburised layers and for intermittent hardsoft material machining.

MMC Hardmetal UK LtdTel: 01827 312312Email: [email protected]

BC8100 CBN insert series for hardened steel applications

CUTTING TOOLS


Achieving precise and consistentadjustment of fine boring tools has longbeen a challenge. Manual adjustment isopen to many vagaries, with individualoperators able to interpret data differentlyand provide incorrect adjustments thatcreates potential for scrap parts and losttime. The Smartbore solution from Rigiborede-skills the whole process to guaranteeaccurate and consistent fine adjustment ofboring bars.

Smartbore from Rigibore is a digitalsolution to an analogue problem thatelectronically measures the real-timemovement of the insert to an accuracy ofone micron on diameter. Smartbore canoperate over a wide range of diameters withSmartbore Nano covering bore diameters of0.5 mm to 16 mm. Smartbore Plus currentlycovering bores from 15 mm to 31 mm andSmartbore Cartridges takes care of boresfrom 28mm upwards. There is also an optionfor every fine-boring application. Usingpatented digital technology, Smartbore is acombination of the cutting tool, boring baror cartridge, along with the hand-heldSmartbore Adjuster, which contains arechargeable power source, together withthe control electronics necessary to displaythe adjustment reading on the LCD. Thiscombination allows boring tools to beadjusted in the spindle, without the need tounclamp and clamp the cutting edge. Thelarge and clear digital readout on theSmartbore Adjuster confirms the new size,allowing production to carry on withminimal disruption.

Eliminating the potential for human erroris a major advantage when working with finetolerances and Smartbore delivers on thisfront as there can be no ambiguity with thedigital measurement that it provides.

This is particularly important on smalldiameter bores, where Smartbore Nanoboring head plays a vital role. Unlike otherdigital boring heads, the delicate and bulky

display electronics are kept out of themachining environment with all theseelements contained within the SmartboreAdjuster rather than the boring head itself.Only one adjuster is required for multipleSmartbore installations.

The Smartbore Plus modular system hasincreased flexibility with the advantage ofcoarse and fine adjustment capabilities. Thisallows tools to be set quickly and accuratelyacross a range of bore sizes across anadjustment range of 3.5mm on diameter.Once the coarse adjustment has beenmade, the Smartbore Adjuster completesthe process delivering micron adjustment

Smartbore cartridges provide the samemicron level of adjustment as the other twoSmartbore systems, but also add versatility

as they can be integrated into specialtooling solutions. Rigibore’s in-house designsoftware enables them to create multiplecutting edge solutions, allowing multiplebores to be machined simultaneously, all ofwhich can be quickly and easily adjustedusing a single Smartbore Adjuster. Theresult is increased process efficiency andreduced rework/scrap levels. All achievedwithout removing the tool from the machinespindle.

Rigibore LtdTel: 01736 755355Email: [email protected] I

Smartbore delivers guaranteed precision performance

CONSTANT RELIABILITYPerformance you can trustwww.dormerpramet.com

Top left: Smartbore Nano can adjust bores from 0.5 mm to 16 mm to the micron levelTop right: Smartbore Plus allows coarse and fine adjustment of bores between 15 mm and31 mm diameterBottom: Smartbore cartridge adds versatility of multiple diameters in a single boring bar

CUTTING TOOLS


Now available from Industrial ToolingCorporation (ITC) is the new Base MasterRed and Base Master Mini high-precisiontouch sensors from BIG KAISER. Theimpressive new high-precision touch sensorfamily can rapidly determine workpieceoffsets and tool lengths to improveprecision, repeatability and reduce setuptimes whilst providing end users withconfidence in the precision of processes.

The new Base Master Red from BIGKAISER, a leader in premium high-precisiontooling systems, is part of the popular BaseMaster family. The Base Master Red can beused with all types of machines andmaterials. This also includes non-conductivecutting tools, workpieces and machine tools.The Base Master Red allows the operator toquickly touch a tool with zero risk of damageor breakage, saving time and money.Additionally, the body set and measuringsensor are independent of each other andthis makes maintenance particularly easy ascustomers can simply replace the measuringsensor, in the event of any issue everoccurring. This allows users to avoid

expensive repair costs and long deliverytimes.

The Base Master Red has an extremelyprecise repeatability level of only ±0.001mm. For maximum flexibility, the system hasa solid magnetic base that mounts vertically,horizontally or at any angle the operatordesires.

The Base Master Red is complemented bythe Base Master Mini. This new Innovationhas a compact design that makes it very fast,flexible and easy to use. Generatingextremely accurate results, the main featureof the Base Master Mini is the very slimheight of only 10 mm. This makes the MasterMini perfect for small turning centres, slidinghead lathes and other machine tools thathave an extremely compact work envelopewhere working space is very limited.

For rapid reference point detection, boththe Base Master Red and Base Master Miniare fitted with a bright green LED light andthis identification is compatible with allworkpieces. With a battery life of 10 hours ofcontinuous use, the sensor will notdisappoint when most needed. For more

details on how you can improve yourprocess reliability and precision, pleasecontact your local ITC representative formore information.

Industrial Tooling Corporation LtdTel: 01827 304500 Email: [email protected] www.itc-ltd.co.uk

New ITC touch sensors deliver accurate pinpoint precision

MaxiMill HFC-TUR ideal for roughingturbine bladesTraditionally button-style milling insertshave been the method of choice when itcomes to rough machining turbine blades.The one limiting factor has always been theachievable feed rates are relatively low forthis style of insert. The development byCutting Solutions by CERATIZIT, thecompetence brand for innovative toolingsolutions at the CERATIZIT Group, of theMaxiMill HFC-TUR milling system hasovercome this, achieving feed rates doublethose achieved with button inserts.

At the heart of the MaxiMill HFC-TUR isthe insert itself. It comes in 09 and 12 mmsizes with four indexes per insert. With thelarger of the inserts, cutting depths up to5 mm can be achieved and angled rampingof 2.6 degrees, 2.3 for helical ramping, canbe achieved. Process security is ensured byuse of a larger than typical screw and, alsothe extensive mating faces in theinsert pocket.

The insert design, with its large effectiveradius, makes it ideal for a variety of 3D

machining applications and general facemilling. Its soft cutting action assists in thecutting of components with thin sectionsand large unsupported areas, such asturbine blades. A further advantage is thatthe MaxiMill HFC-TUR cutters can be usedon lower powered machines, that would notbe suitable for high-feed milling stylecutters. The cutter bodies for the HFC-TURseries are available in sizes between 32 and63 mm, with all dimensions matching theexisting button insert cutters, ensuring thatCAD programming is exactly the same.Cutter body life is extended by use of nickelplating and insert life is enhanced withthrough tool coolant on cutter bodies.

With depths of cut up to 5.0 mm andfeedrates up to 1 mm/tooth, the MaxiMillHFC-TUR cutters dramatically reduce cycletimes with Ceratizit’s M50 geometryenhancing these performance benefits. In atypical example, the machining of a forgedturbine blade in Martensitic heat-resistantsteel in unstable machining conditions, partclamped at both ends, using Ceratizit’sbutton-style cutters feed per tooth was

0.4 mm, switching to the MaxiMill HFC-Tursystem this was increased to 0.8 mm. In bothcases the surface speed was 320 m/min anddepth of cut 3 mm.

CERATIZIT UK & IRELAND LtdTel: 0800 073 2073Email: [email protected]

A milling revolution for turbine blade machining

Feature - AUTOMATION


Debunking the myths of robotsreplacing workersAs explained in the McKinsey report,Artificial Intelligence (AI) can play a key rolein improving the global economy and is anopportunity that the UK must grasp.McKinsey suggests that there is likely to be aperformance gap between companies thatadopt AI tools and ‘non-adopters’, meaningbenefits will be disproportional.

According to the IFR, there are just 71industrial robots per 10,000 workers in theUK. That positions the UK behind 14 otherEuropean countries and, alarmingly, theonly G7 country with a robot density belowthe world’s average (74 units). In contrast,Germany, Europe’s most automatedcountry, has 309 units whilst the CzechRepublic, the closest European country tothe UK, has 101 units per 10,000 workers.

It’s clear that change is needed. Onepossible reason for the UK’s lowperformance could be linked to the stigmaattached to the use of robotics andunemployment. If the UK is to catch up withthe rest of the world, it’s going to need toadopt more automation in its manufacturingfacilities and therefore shift this viewpoint.

We have found that the use of industrialrobots goes hand-in-hand with upskilling,which can lead to an increased productivityrate. This helps remove the perceived threatto unemployment and also addresses thewidely-reported skills gap, both of which areconcerns shown by the Government andindustry.

Earlier this year, Engineering UK reportedthat 265,000 skilled entrants are requiredeach year to meet business demand. Bybringing in robotic technology, engineerscan be trained to learn how to programme aFANUC machine, a process that can betaught and understood in as few asfour days.

Is automation the affordable solution to UKmanufacturing?Given the findings from both reports, it hasbecome clear the UK needs to increaseautomation through manufacturing. Inaddition to the impact on employment, theassociated costs with industrial robotics isalso quite often a sticking point for UKmanufacturers.

When discussing industrial robotics,affordability and pricing is more

often-than-not going to be the first questionasked by manufacturers. However, industrialrobots aren’t as expensive as first thoughtand, on many occasions, are paid off in aslittle as 18 months.

Thanks to their ability to bereprogrammed, industrial robotics offer along-lasting solution that go beyond theirfirst use. And if more people are upskilledand become trained on programming,there’s even more benefits thatmanufacturers can and should be takingadvantage of.

What does the UK need to do next?It’s clear that manufacturing is a going to

be a key asset for the UK if it is to maintain acompetitive edge after Brexit. The UKcannot become a service industry andchange is required before it slips furtherbehind its global counterparts. Therefore, aculture change in the views and perceptionof automation and robotic technology isneeded.

The stigma attached to industrial roboticsneeds to be removed: it’s simply a tool formanufacturers to use that helps increaseefficiency. The opportunity for upskilling isone that should be grasped and willeventually help address the skills gap,alleviating concerns people have towardsthe use of robots.

Ultimately, technology is alwaysimproving and we need to ensure we aren’tcaught falling further behind. Positivelypositioning automation will not only benefitmanufacturers’ capabilities, but it will alsoclose the gap between the UK and theleading nations.

FANUC UK LtdTel: 02476 518 449 Email: [email protected]

Upskilling is the key for UK manufacturingIt’s no secret that the UK is behind many of its European counterparts when it comes to UK manufacturing andproductivity. A recent report by the International Federation of Robots (IFR) highlighted the extent of thecountry’s lack of industrial robots, whilst McKinsey & Company has reiterated the benefits of automation to theeconomy in its discussion paper. The UK needs to offer a solution sooner rather than later if it is to maintain acompetitive edge, but how can industrial robots play a key role in UK manufacturing?

Tom Bouchier, managing director of FANUC UK, offers his thoughts on the two reports and discusses what theUK needs to change in order to compete with other nations.

Managing director, Tom Bouchier, FANUC UK

DUGARD Automation

• Affordable automation - up to a third less than regular industrial robots

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Hanwha Collaborative Robot (Cobot)

HCR Series

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with operator collision protec• User friendly Graphic User I• 0.01mm positional accuracy• Compact and light body - in

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Hanwha Co

Meet your new team member

www.dugard.com [email protected] 01273 732286DUGARD

One of Korea’s largest corporations

Dugard are now the exclusive UK dealer for

AUTOMATION


To streamline and speed deliveries of longstock to customers, a Unicompacthigh-performance storage and distributionsystem from KASTO has been installed in anew, purpose-built unit in Ellwangenoperated by Friedrich Kicherer GmbH, oneof the largest steel stockholders in Germany.Three KASTOwin F bandsaws have beenintegrated into the system.

Employing more than 350 staff, Kichererships 210,000 tonnes of steel per year. Sixpre-existing automatic storage systems fromKASTO and 44 cranes in the original steelcentre optimise the operation. The firstKASTO store was installed in 1995, whichover the years was supplemented by rackingsystems for tubes, stacking cradles forstructural steel profiles, angles and boilertubes, and a Uniline 3.0 sheet metal storewith 610 cassettes. These investments weremostly driven by the objective of expandingthe range and providing faster deliveries

KASTO was selected for the latest projectto supply the new bar storage system withcentral loading station linked to thestockholder's IT system. The solution isbased on a 115 m long, 15 m high,automatic honeycomb storage system withspace for more than 10,000 cassettes. Eachcan accommodate material up to six metresin length and carry 3.4 tonnes. Fast storageand retrieval of stock is achieved with fivecranes travelling at up to 180 m/min alongthree aisles of racking.

To transport picked materials to theloading station automatically, KASTO hasinstalled two manipulators on separate rails.From these, the bar stock travels to one of

25 loading stations via a conveyor. A stationwith a packaging machine is provided forstretch film wrapping. The IT departments atKicherer and KASTO have jointly modelledall components of the new logistics systemin unified software within the KASTOlogicwarehouse management system. Kicherertracks its steel profiles through the storeusing QR codes.

Automatic storage system ensures efficientsheet metal processingTo create space and capacity for growth, anew 4,000 sq m plant has been built on a25,000 sq m site in the German town ofHettenleidelheim by Blum GmbH, acompany that specialises in sheet metalworking and switch cabinet manufacture. Itsupplies anything from individual partsthrough small and large batches tocomplete assemblies.

The company holds raw sheet materialand finished parts in a high density Unilinesheet storage system supplied by KASTO. Itensures safe and reliable material handlingand efficient supply to connected flat-bedsheet metalworking machinery. Bending

and folding as well asmanual and roboticwelding are also carriedout on site.

At its previousfactory, mild steel,stainless steel andaluminium sheet werestored in a warehouseserved by forklifts.Machine operatorsmoved material to theproduction machineryby hand, which wastime-consuming and

laborious. To cut costs, the companydecided to streamline and automate theseoperations but wanted to do soindependently of the metalworking machinesuppliers.

KASTO installed an 8 m high Uniline inlinestorage system with space for up to 686pallets that can hold sheets measuring up to3 x 1.5 m. They enter the warehouse via astation with a longitudinal carriage, fromwhere they are transported automatically toa free location by a storage and retrievalmachine. It is equipped with dynamic drivesfor fast, direct material handling.Integrated KASTOlogic warehousemanagement software allows Blumoperators to identify the position of everypallet and the stock it holds, as theinformation is keyed in at the control panelusing an intuitive graphical user interface asthe material is stored.

At the front of the warehouse are sevenstations with lateral transport carriages forremoving and returning material. There arealso two metalworking machines, includinga pre-existing laser cutting machine fed by amanually operated overhead crane.However, when new material is needed,employees can request it by simply pressinga button and the pallet arrives automaticallyin a matter of seconds.

A newly purchased punch press and lasercutting combination machine capable ofunattended operation is connected directlyto the storage system. KASTOlogic softwareinterfaces with any control system,regardless of manufacturer.

KASTO LtdTel: 01908 571590Email: [email protected]

KASTO builds large distribution centrefor steel stockholder

Intelligent workpiece handling

The UK’s leading machining accessories supplier.

For all your workholding requirements

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The answer’sYESEngineering Data takingautomation to the next level with the new generation of palletisation

AUTOMATION


In this article, Mike Wilson of ABB RoboticsUK, provides advice about how to approachsmart manufacturing and why robots canoffer a good first step for any companylooking to automate its processes. Imagine if there was a way for the UK’sproductivity to become world-class in underfive years. Imagine if our factories couldproduce goods quickly, efficiently and withminimal waste and be able to respond tochanges in customer demands with minimaldisruption. Imagine if we had a highlyskilled, adaptable workforce using the latesttechnology.

You may be surprised to know thatmodern automation technologies can helpmake all of this achievable, provided wemake the changes now to make it happen.

Evidence for this includes the findings of astudy of automation, labour productivityand employment by Copenhagen BusinessSchool. It found that if the UK was tobecome as automated as the world’s mostautomated countries, which includes Japan,Germany and Sweden, productivity wouldincrease by 22.3 percent. Not only that, butthe improvements it would bring would helpto yield a projected increase in employmentof at least 7.4 percent as new jobs arecreated to keep pace.

In the International Federation ofRobotics’ (IFR) World Robotics report 2017,the UK ranked fifteenth compared to otherEuropean countries with 71 robots per10,000 employees. Compare our robotdensity with a country like Germany, whichhas 309 robots per 10,000 employees andthe potential impact of continuing to trailbehind becomes clear.

The problem is that many small tomedium-sized UK companies lack the time,

experience or technical skills needed to planand implement automated productionsystems. Despite the proven ability of robotsto deliver benefits such as increased output,higher quality and lower wastage, manybusinesses still tend to view them as toolsfor mass production processes, with little orno idea about their wider applicability forbespoke or low volume processes.

Part of the problem can arguably beattributed to the confusion around exactlywhat smart manufacturing means and whatit is. The principle behind smartmanufacturing is straightforward enough.Essentially, by digitally linking all equipmenton a factory floor, data can be gathered,analysed and used to help deliverimprovements throughout the productionline.

While such a scenario should undoubtedlybe the ultimate goal, it is one that isnevertheless still some way off for a lot of UKmanufacturers, with many wondering whereto start.

The important thing to remember aboutsmart manufacturing is that there is nosingle ‘out of the box’ solution that can beuniformly applied to every process.

As a production tool that can be usedstandalone or as part of a complete cellintegrated into a digital production line,robots offer a good starting point for anycompany that wants to take the first stepstowards smart manufacturing throughautomation.

There are many applications within afactory that can be readily automated withrobots to help deliver improved efficiencyand productivity. To decide where to start,the following factors should be considered:

What are you currently making? Is the quantity or type of products you aremaking likely to change? What thoughtprocesses are involved in its manufacture?Could they be automated?

What will you make? Is the product design subject to change?What processes would be involved then?How would they need to change from howthey currently are? Developments in robottechnology mean that robots can now makemost things however, sometimes it mightstill be better for a manual worker to handlecertain tasks.

How long are you going to make it for? Contrary to popular belief, robots areequally as suited to one-off or shortproduction runs as they are to massproduction processes, with their flexibilityallowing them to be used to handle a varietyof different products.

How will you justify the investment? Robot automation provides many benefits,but these need to be quantified in financialterms to gain the support of the financialdirector. This can include calculating

Why robots should be the first step inthe smart manufacturing journey

AUTOMATION


potential cost improvements for benefitssuch as: increased production throughput;reduced scrappage and associatedreworking; reduced capital costs associatedwith inventory and work in progress.

What areas in your current process couldbe improved? It is useful to think about improvements interms of aiming for lean manufacture,focusing on reducing overproduction andexcessive movement of people orequipment throughout a process. Leanmanufacturing also removes delays betweenproduction steps, reduces excess inventoryand over-processing of parts, helping to findand fix defects.

What are the strengths and weaknesses ofyour current process? How could the strengths be made evenstronger? How could the weaknesses berectified?

Is there scope for collaboration? Traditional production lines are designedaround humans and machines working inproximity, so when planning an installation,it is still necessary to include the human

variable. Modern collaborative robots offera raft of exciting new opportunities forcloser working relationships betweenhumans and robots that can yield higherlevels of productivity.

What size will you need? A small robot may fit the space available,but will it have the appropriate payload tobe able to lift the materials?

What type of tools would the robotrequire? It pays to think carefully about what youwould like your robot to do and to equip itaccordingly. A metals fabricationapplication, for example, may require awelding attachment, whereas a machinetending application would require grippers.

Don’t put off until tomorrowWe realise that for most UK manufacturersenvisioning a factory that runs itself is a faraway prospect and a steep hill to climb.Ignoring it though will only make it steeperand increase the distance needed to catchup with competitors that are alreadyembracing the technology.

Where robots are concerned, thecomprehensive range of proven solutions onoffer, together with the help and supportavailable from robot manufacturers such asABB and specialist systems integrators, canhelp to remove much of the uncertainty andcomplexity around the design anddeployment or robot-automated systems.

Are you interested in making the firststeps towards smarter manufacturing?Register for our upcoming Switch to Robotsseminar by visitinghttp://bit.ly/S2RFeb18.

ABB LtdTel: 01908 350300www.abb.co.uk

We make automation simple

THE FACTORY AUTOMATION COMPANY

more than

100,000 FANUC industrial robots installed in Europe

Get in contact today! 02476 053 000 [email protected]

AUTOMATION


Cost-effective and quick and easy to implement, the new Deltarobot from igus is available directly from stock as a kit or deliveredpre-assembled ready to install. Its maintenance-free belt drive units,lubrication-free link rods, encoders and stepper motors combine tocreate a lightweight, low-cost automation solution for automatedtasks such as pick and place. The typical ROI period for the Deltarobot is estimated at just six months, this compares favourably tothe industry’s rule-of-thumb target of two years.

The Delta robot is based on three maintenance-free drylin ZLWtoothed belt axes, lubrication-free igubal link rods and matchingadapter plates. NEMA stepper motors and encoders ensure fasthandling of up to 1 kg with a precision of ±0.5 mm. The completesystem has an installation space of up to 420 mm in diameter andcan carry up to 5 kg at lower speeds. The lightweight design,consisting of aluminium and plastic, makes the Delta robotextremely cost-effective at a price from as little as £5,000 andensures high speeds with a pick rate of at least 60 per minute.

Matthew Aldridge, managing director of igus, says: “The opendesign of the Delta robot enables manufacturers to use their owncontroller. We estimate that with the usual integration costs, eachDelta robot installation will be around £10,000 to £15,000, whichmeans that it will pay for itself after a few months.”

There are many other benefits inherent with Delta robotdeployment, the higher the production rate the lower the cost perunit will be. If a company can make twice as many widgets as itscompetitor in the same amount of time, the advantage is obvious.There are also opportunities to reduce scrap and rework, increasequality and consistency, and improve overall safety.

Depending on requirements, the Delta robot can be delivered asa kit in a box within 24 hours of receipt of order. Comprehensiveassembly instructions are included, and an assembly video isavailable online at: www.igus.co.uk/deltaassembly.Alternatively, the delta robot can be delivered pre-assembled on atransport frame ready for installation. The machine builder is free touse its preferred software and controller or, as an alternative, it canopt for the intuitive and easy-to-use dryve D1 controller from igus.

The Delta robot is particularly suitable for simple assembly tasks,pick and place tasks, as well as applications in test and measuring.

Based in Northampton and with global headquarters in Cologne,Germany, igus is a leading international manufacturer of energychain systems and polymer plain bearings. The family-run companyis represented in 35 countries and employs 3,800 people aroundthe world. In 2017, igus generated a turnover of 690 million euroswith motion plastics, plastic components for moving applications.

With plastic bearing experience since 1964, cable carrierexperience since 1971 and continuous-flex cable since 1989, igusprovides the right solution based on 100,000 products availablefrom stock with between 1,500 and 2,500 new productintroductions each year. igus operates the largest test laboratoriesand factories in its sector to offer customers quick turnaround timeson innovative products and solutions tailored to their needs.

The UK subsidiary has also analysed new methods of packagingand recycling materials, which have led to quicker dispatch timesand increased environmental friendliness.

A dedicated readychain® assembly area, where energy chains are

fully harnessed as complete systems for customers and configuredwith all requisite cables and connectors, means a system can besupplied, ready-made to customer specifications, fully tested andwith an igus guarantee. This initiative reduces cost and time for thecustomer and also reduces the number of suppliers the customerhas to deal with. igus employs a highly trained workforce of skilledelectricians in this department to ensure the highest standards. Aworkshop area is also designated to the installation team, who arequalified to install these complete systems on site.

igus (UK) LtdTel: 01604 677240Email: [email protected]

Automation at your fingertipsigus introduces fast low-cost robots for less than £5,000

AUTOMATION


Industry 4.0 combinesproduction with the latestmodern informationtechnology and automationsystems. This is based onintelligent, digitally linkedsystems that connect plantand machinery. KUKA andKEB Automation havedeveloped a solution thatdemonstrates how this worksin practice.

In this field, KEBAutomation is offering a newsolution for implementing connectivity to KUKA robots in variousapplications. With the C6 HMI LC, KEB now offers the possibility toboth exchange data and to control and program the KUKA robot.The KEB system combines display, using an HMI, and control, via aPLC, in a single machine. This simplifies the complexity of thesystem and reduces costs. EtherCAT, as a powerful fieldbus, alsofacilitates connection to the robot.

Working from individual customer requirements, KEBoffers several implementation solutions to suit a wide rangeof applications:

Visualisation Using the C6 HMI LC, the user is able to display information, suchas the current position of the robot, via a corresponding displayconcept and can exchange data between the robot and the HMI.

ControlThe function module library “mxAutomation” from KUKA, which isbased on PLC open standards, allows programming, diagnosis andmanual operation of the KUKA robot via FB modules of the PLC.The library introduces almost all KUKA programming languagecommands into the PLC. Motion control of the axes is thenperformed by the robot itself.

SafetyIn addition, the KEB solutions enable integration of safety controlsto the system. The C6 Safety PLC from KEB uses“Safety-over-EtherCAT” as a secure fieldbus protocol for datatransmission and communication with the robot, whereby safetyfunctions can be implemented via the robot.

To view an example of KEB and KUKA systems working together,please visit: https://www.youtube.com/watch?v=DiSuYRue7qc

KEB provides a complete Automation Solution from gear shaft toHMI screen, including motion control up to CNC level, safetysystems with FsoE (Failsafe over EtherCAT) and visualisation. KEB’saim is always to find the optimum drive and control solution tailoredto suit a customer’s precise requirements.

KEB (UK) Ltd Tel: 01933 402 220Email: [email protected] www.keb.co.uk

Safe communicationwith KUKA and KEB

43

— Transform your productivity with a Switch to Robots

Our Switch to Robots events give you all you need to help you decide whether robots are right for your shop floor. Over one day, we cover everything from how to identify whether you need a robot through to how to justify an investment. We’ll also show you how today’s robots are easier than ever to set up and program, with a hands-on training session.

Visit http://bit.ly/S2Rinfo to sign up for our next free, no-obligation Switch to Robots event at our Milton Keynes training centre.

AUTOMATION


Within the last year, new company PurpleRobotics developed an innovative vacuumgripper, the world’s first specifically forcobots. Purple Robotics has now beenacquired by OnRobot, one of the trulysignificant robot industry endeavours. Theacquisition takes place a mere two monthsafter the OnRobot merger of three roboticscompanies from the USA, Hungary, andDenmark to create one global player with astrong focus on the market for industrialrobot accessories.

OnRobot in Odense, Denmark, hastherefore added another trail-blazingtechnology to the product mix. With theacquisition of the company Purple Robotics,OnRobot can now offer its partners theworld’s first dual vacuum gripper. Thegripper attracted international robotindustry attention when presented by theinventors at Automatica, the world’s largestrobotics fair, in Munich in June this year.

Purple Robotics was established by thethree Danish “super-nerds” Lasse Kieffer,Henrik Tillitz Hansen and Peter NadolnyMadsen, all of whom have a background asproduct developers at the company behindthe world’s first cobot, Universal Robots.OnRobot is now fusing this valuableexpertise with its existing R&D departmentat its headquarters in Odense. Lasse Kieffer,Purple Robotics CEO, looks forward tojoining the OnRobot organisation togetherwith his colleagues:

“It has been really good fun to create abrand-new robotics company and to disruptthe market for vacuum grippers with ourinvention. It makes a lot of sense and creates

significant synergy to join forces withOnRobot who have already created astrong, global sales organisation. Thismeans that we can focus 100 percent ondeveloping the world’s coolest roboticsproducts. Together, we can go far,” saysLasse Kieffer.

Since entering the market, PurpleRobotics has experienced a veritableonslaught from partners worldwide wishingto be able to offer the product to theircustomers. Already three months afterlaunching the product, 40 partners in 25countries have concluded partnershipagreements with Purple Robotics for thepatented innovation.

The Purple Robotics dual vacuum grippercan, so to speak, give a robot arm two“hands” and thereby the ability to handleseveral items simultaneously and solvingmultiple tasks in one movement.Additionally, it has an electric pumpintegrated in the gripper itself, meaning thatusers need not worry about hoses,compressed air, and cables as withconventional vacuum gripper solutions.

The vacuum gripper meets a clear need inthe global industry for efficient and flexiblerobot solutions which are simple and quickto commission. It takes less than 30 minutesto install the Purple Robotics gripper on arobot and start it up. The vacuum gripper isable to gently and efficiently handle items ofmany different dimensions, weights,materials, and shapes. The lifting capacity is10 k and the robot gripper is designed foruse on a wide range of light-weight robotsfrom all robot manufacturers.

The acquisition of Purple Robotics meansthat the Vacuum Gripper could be

presented to robot equipment buyers at theIMTS fair in Chicago in September. After thespring merger of the three roboticscompanies OnRobot, Perception Robotics,and OptoForce, the OnRobot productrange now features a wide assortment ofrobot equipment, including electricgrippers, force-moment sensors, geckogrippers, and tactile sensors.

“We are now one step closer to our visionof offering “one-stop-shopping” for buyersof robot accessories. Purple Robotics willdefinitely not be our last acquisition. Wehave our eye on a number of other,interesting companies around the world,”says Enrico Krog Iversen, CEO of ONRobot.

OnRobot has also recently welcomedanother strong, international investor to theownership roster, the American venturefund Summit Partners.

OnRobot is located in Odense and offerstechnologies, hardware as well as software,used for solutions involving collaboratingrobots, cobots. OnRobot develops grippers,sensors and other cobot equipment whichmakes the use of technology easier in areassuch as packaging, quality control, materialshandling, machine maintenance, assembly,and welding. In addition to the head office inDenmark, OnRobot also has sales offices inGermany, China, USA, Spain, Malaysiaand Hungary, and now has more than100 employees.

OnRobot A/STel: 0045 5353 5757Email: [email protected]

OnRobot acquires Purple Robotics

AUTOMATION


The MOTOMAN® GP series of robots fromYASKAWA has recently been extended toinclude options which are suitable forapplications with heavier loads up to 600 kg.Renowned for being one of the mostcompact and efficient range of robots forhigh-speed assembly, packaging andgeneral handling applications, theMOTOMAN GP600 is designed for heavierhandling and general applications wherepayloads weigh up to 600 kg.

Thanks to this latest addition to the rangethe current GP, General Purpose, modelsare successfully replacing the handlingrobots of the proven MH series. Thesepowerful, 6-axis GP600 robots are designedas true productivity drivers offering a widemotion range, up to 2,942 mm, for safeand efficient handling of large andheavy workpieces.

Other important features include theirultra-compact design which enables therobot to be positioned closer to machinesand fixtures helping to save valuable floorspace. They also feature a parallel-linkconstruction for strength, rigidity andstabilisation of high inertia loads, along with

heavy-duty bearings that will ensure asmooth arm rotation.

In addition to the capability ofhandling heavier loads, these newmodels also offer the benefitsassociated with MOTOMAN robots,such as optimum productivity withhigh payloads and speeds. They alsoallow for a wide variety of products tobe transferred with different grippersto ensure greater allowablemovement. Speeds of all axes havebeen increased, whilst accelerationand deceleration control has beenimproved to achieve maximum reduction ofacceleration/deceleration time for all robotpostures.

YASKAWA has been a leader in theworld’s industrial robot market since the firstrelease of its all-electric industrial robot“MOTOMAN” in Japan in 1977.

Since that time, it has successivelycommercialised and marketed optimumrobots for various uses, cantering on arcwelding, one of its areas of expertise, andincluding spot welding, handling, assembly,painting, transfer of liquid crystal panels,

and transfer of semiconductor wafers.Recently, it has been enhancing its efforts inthe food, pharmaceutical, cosmetic, andbiomedical markets. Also, the companycontinues to take on new challenges tofurther expand the fields where robotsare applied.

YASKAWATel: 01295 272755 Email: [email protected] www.yaskawa.eu.com

New MOTOMAN GP robots for easy handling of heavier loads

REM Systems Ltd, Runway Farm, Honiley Road,Kenilworth, Warks, CV8 1NQT: 01452 750 [email protected]

Increase the productivity of your machines stepby step with the help of EROWA‘s tooling systems,setting-up and presetting stations, AutomationRobots and Job-Management Software Systems.

Tooling Systems with highestaccuracy and stability.

Job-Management Softwarefor easy control of complexautomation cells.

PreSetting and QualityControl with a high level ofmechanical precision.

Robotic Systems for smalland large workpieces upto 500 kg.

WORKHOLDING


Located close to the UK’s motorsport valleyin Bletchley, near Milton Keynes, DowseEngineering offers a comprehensive rangeof engineering services, including themanufacture of precision components andthe machining of micro mass-producedcomponents across a range of materials andfinishes. In addition to the motorsportsector, the company undertakes work for awide variety of clients, across the aerospace,defence, telecommunications, electronics,automotive and medical Industries, sectorsthat demand the supply of high-qualitycomponents that are manufactured to themost challenging of specifications, often totight deadlines.

To help ensure the efficient andcost-effective delivery of premium qualitycomponents, over the past 25 years, DowseEngineering has continually invested in thelatest computer technology and precisionmachinery resulting in the company’simpressive 11,500 sq ft manufacturingfacility now being stocked with a wide rangeof advanced machine tools. To enable thefull productive potential of the company’smanufacturing plant to be realised and toensure the consistent production ofpremium quality components, DowseEngineering use a range of workholdingequipment from Thame Workholding.

Director Trevor Dowse explains: “DowseEngineering holds the highest level

precision engineering accreditationfrom the NQA awarding body. Assuch, we are fully compliant withaerospace and defence qualitystandards and we deliver all ofour components to theequivalent standard.

“Our highly skilled engineeringstaff cover a wide spectrum ofengineering disciplines and wecontinually invest in advanced 5-axisand CNC engineering machinery.Given our diverse assortment ofhigh-performance machine tools, weare able to produce complexprecision manufacturedcomponents, from single prototypesup to large batch runs. In addition,we are capable of manufacturingparts that feature the mostdemanding of dimensional tolerances. Asour customers often challenge us withextremely tight deadlines, we are alwayslooking to find ways of improving ourflexibility and increasing the efficiency of ourmanufacturing systems.

“Just as we work in partnership with ourmachine tool suppliers, we also work closelywith the staff of Thame Workholding. Thedepth and diversity of Thame Workholding’srange means that whenever we haveexplained our needs to the company’stechnical staff, an efficient, cost-effectivesolution has been supplied to us. Given thedemanding nature of our customers and thecomplexity and challenging dimensionalspecifications of many of the parts wemachine, the use of Thame Workholdingproducts has helped enable us to achievethe required precise results. Also, the use ofThame’s products has allowed us tosignificantly reduce our machining times. Anexample of the many advantages we havegained through the use of ThameWorkholding’s products is our recentlypurchased InoGrip system.

“Now, dependant on the application,before loading a billet onto an InoGrip vicefor a milling operation, we stamp theworkpiece in our InoGrip stamping station.The applied four precise depressions allowthe specially shaped ends of the InoGripvice’s three jaws to lock into the last 6 mm ofthe workpiece. This positive fit makes itpossible to securely clamp the workpiecewith just a fraction of the previously

necessary clamping force. In addition, thisarrangement provides an absolutely precisereference point for re-inserting workpiecesin the vice with a high degree ofrepeat accuracy.

“The much-reduced machining times,improved precision and substantial costsavings on materials we have achievedthrough the use of the ingenious InoGripsystem means that we anticipate a rapidreturn on our investment.”

The patented InoGrip Stamping systemsupplied by Thame Workholding results inthe need for a much reduced workholdingclamping force to be applied to workpieces,whilst at the same time delivering maximholding forces across both turning andmilling applications. In addition, only 6 mmclamping depth is required, compared tothe 20-25 mm of clamping depth usuallyneeded when using conventionalgripper jaws.

The advanced InoGrip system uses ahigh-pressure hydraulic press tosimultaneously apply four precise cruciformindentations to the last 6 mm of the billet tobe machined. The system allows all materialswith a value of up to 1,400 N/mm² to bestamped. Following the rapid stampingoperation, when transferred to the InoGripchuck, the male cruciform features, locatedon the end of each of the chuck’s jaws,accurately engage with the workpieces’indentations. The ingenious systemproduces a positive, secure fit with animpressive holding force that is up to 10

Gripping tale of workholding efficiency

WORKHOLDING


times higher than that produced byconventional gripper jaws.

InoGrip chucks can be used on allstandard power chucks and deliver a widerange of advantages. When employed inturning operations, users are able to achievethe best possible roundness results ondeformable workpieces. Also, whenemployed on milling applications, thesystem provides the ability to machineprismatic parts with the application ofmaximum cutting values. If the billet to bemachined is solid, the higher clampingpressure that can be applied by the use ofthe InoGrip stamping technique means thatthe workpiece can be securely held whilstboth roughing and finishing operations areperformed. Also, if secondary machiningoperations are to be performed, thepre-stamped InoGrip indentations ensureexcellent repeatability of location from onemachine tool to another. Last but not least,the ingenious InoGrip system’s ability toclamp on just 6 mm ensures thatconsiderable material savings are made.

Based in Long Crendon,Buckinghamshire, Thame Workholdingdesigns, manufactures and supplies a widerange of cost-effective standard and

bespoke workholding products to its globalcustomer base. Complementing its ownproducts, the company also provide a rangeof highly efficient workholding solutionsfrom leading global manufacturers, such asLang Technik, Horst Witte, Samchully andHWR Spanntechnik, on an exclusive UKagency basis.

To ensure the in-house production ofcost-effective, high-quality ThameWorkholding products, the company uses arange of modern 3-, 4- and 5-axis machinetools with multi-pallet and automatedloading for unmanned machining. ThameWorkholding’s impressive manufacturingfacilities are supported by a high-accuracyCMM inspection provision and 3D CAD andCAM modelling facilities.

With a high proportion of products beingdesigned and manufactured in-house,Thame Workholding has developed into aleading international provider of practicalworkholding solutions that are suitable forall categories of machining, in both standardand special applications. The company isaccredited to Quality Standard ISO9001:2015 with the scope of design,manufacture, assembly, supply andmaintenance of workholding equipment.

Thame WorkholdingTel: 01844 208050Email. [email protected]

Clamping specialist HAINBUCH is nowoffering users of its Mini Series, or the earlierToplus or Spanntop chucks, a cleverinnovation that saves time and money. TheVario Part and Vario Quick end-stopsystems, already in its product portfolio,have now been joined by a third variant, theVario Flex.

The pneumatic workpiece ejector pushesthe workpiece from the chuck automatically.The pneumatic workpiece ejector depth canbe adjusted flexibly by means of a cleverretaining mechanism and it can bepositioned in the machine exactly as

required for the workpiece. This automatedfunction increases process security andreduces cycle times. The Vario Flexworkpiece ejector can also be used as abasic end-stop for coolant wash or air flush.To do this, the pneumatic spring is removedand a feed tube is attached. The optionalworkpiece-specific end-stop with holes forthe wash and air-flush can then be mounteddirectly on this flexible interface.

Two systems & more flexibilityValuable time can be saved using thestandardised end-stops. Setup times are

drastically reduced, and theuser always has the rightend-stop ready to hand.Whether to use Vario Quickor Vario Part is just a matterof preference. For precise,rigid clamping, HAINBUCHrecommends using the VarioPart system. It works on thesame principle as a gaugeblock, and its height can befinely adjusted in 1 mm steps

with gauge discs. With an axial run-out of< 0.02 mm at the part of the end-stop thattouches the workpiece, Vario Part is ideal formachining finished parts. The Vario Quickvariant is intended for fast, flexibleclamping. It has a precise, trapezoidalthread screw to allow the clamping length tobe adjusted quickly. A half-turn is equivalentto an axial adjustment of 1 mm. Thecompany also offers end stop blanks forworkpiece or front-end stops.

More than 65 years ago, HAINBUCHstarted in a small garage in Germany. Overthe years its customer family has grown toinclude manufacturers in industries asdiverse as automotive, aerospace, medicaltools and appliances, energy, andpure research.

HAINBUCH UK LtdTel. 01543 278731Email: [email protected]

Cost-effective new pneumatic workpiece ejector

WORKHOLDING


“With the production of single pieces andsmall series, there is still a great deal ofpotential today that is going to waste at themoment” says Stefan Maas, owner of MaasFrästechnik. Primarily when it comes tochoosing the clamping devices, there is agreat deal of potential that is not being usedin his opinion. Together with MartinSchultheis from Qmax Plus Tooling +Engineering and SCHUNK, he hassuccessively trimmed his own operation tomaximise productivity.

Stefan Maas is a doer through andthrough. Sitting still is simply not his thing.His gaze permanently detects where there isa need for action and where potential foroptimisation lies. He began two years agowith a single milling machine and expandedhis operations over the past two years from12 to 32 employees today. The fact that hewas never satisfied with the current statusquo led to a close collaboration with MartinSchultheis from Qmax Plus Tooling +Engineering, a supplier claiming tospecialise in the optimisation of metalcutting processes. The two are constantlyfiddling about with processes, their own andwith those that are developed on behalf oftheir customers. They tinker with theprogramming, the tools and the clampingdevices until the maximum level ofproductivity has been reached andsophisticated processes have beenimplemented into their own operations orcan be handed over to the customers readyto go. Here, the production of Maas alsoserves as a showroom and training centre,

because some of the strategies that thecompany has successfully established overthe past few years can be used as blueprintsfor the customers' processes.

Direct comparisonMartin Schultheis procured a 5-axis machinefor the development of customer processes.It was equipped with SCHUNK VERO-Squick-change clamping modules andoperated in Stefan Maas's productionfacility.

Stefan Maas explains: “We alwaysconsidered using quick-change clampingtechnology in single-item production. But itwas always a case of if we didn't make astart, nothing would happen.” Within a briefperiod of time, the tables turned. In dailyoperation, side by side with conventionalclamping devices, it became clear how greatthe advantages of the quick-changeclamping system were. While theconventionally equipped 5-axis millingmachine, which for a long time was thebottleneck on the Maas production line,would have to be laboriously retrofitted, theDMU 50 ecoline from DMG Mori had longsince been up and running again.

For Stefan Maas, this was a clear signal, ifthey were to invest in a new 5-axis centre,then it would only be with the quick-changepallet system and a consistent clampingtechnology concept. Besides the DMU 50,today one Hermle C30 U and one HermleC42 U machining centre are equipped withthe SCHUNK quick-change technology andsupplemented with an extensive clampingdevice pool, meaning the majority of allconceivable customer requests can becovered straight away.

Stefan Maas continues: “We havecomponents in the size of a little finger andothers are equipped with a 500 mm baseplate. This means we are required to map allpossibilities in very quick succession andmust often put out fires for our customers. Ifa vise with six clamping claws has to beclamped up and down every time, it is tootime-intensive, because the customer doesnot pay for the setting up.”

The key element of the clamping solutionis SCHUNK VERO-S NSE plus 138quick-change modules, with which all

machine tables are fitted in a consistentgauge for bore holes of 200 mm. This allowsvarious clamping devices to be switchedbetween the individual machines with just afew actions.

Stefan Maas enthuses: “I don't need totighten any screws, look for any washers orkeys. All clamping devices are precisely andfirmly connected to the machine. Theclamping situation is always identical,without anything having to be aligned. Andthe flexibility is simply sensational.”

Clamping pyramids facilitate efficientmultiple clampingRadially arranged clamping slides retractand self-lock the clamping pin with theSCHUNK VERO-S via a spring assembly thatuses form-fitting clamping. Clamping andpositioning is carried out via a short taper,that ensures a repeat accuracy of< 0.005 mm. Due to patented dual strokesystem, each module achieves pull-downforces of 7,500 N. With activatedturbo-function, the proven pull-down forceis 25,000 N. The retention force is 50,000 N.Due to the special geometry of the SCHUNKVERO-S clamping pins, an eccentric andtherefore particularly simple loading of themodules is also possible without theclamping pins being tilted. In order toincrease service life and process reliability,all functional components of the VERO-Smodules are made of hardened stainlesssteel, making them absolutely corrosionresistant. In addition to this, the modules arecompletely sealed and thus protectedagainst contaminants and coolant. StefanMaas makes particular use of the clampingpyramids from the more than 1,000 variantsof the modular SCHUNK VERO-S system.

Stefan Maas says: “If you want to reach allsides during 5-axis machining, then you can

Clamping technology increasesproductivity for Maas Frästechnik

WORKHOLDING


essentially only clamp over the middle. Assoon as I clamp two components next to oneanother, there is always one componentdisturbing on one side.”

“I am relatively free when it comes toaccessibility and can turn the visesdepending on the situation around 90° forinstance. So, I have a multiple clampingsystem and use the advantages of multi-sidemachining at the same time.”

This allowed several parts to be machinedone after the other, without userintervention being necessary. At the sametime, the times for tool change are reducedas four parts can always be machined oneafter the other with one and the same tool.

Stefan Maas continues: “With the pyramidit is irrelevant whether I machine fouridentical parts in series or four individualparts as I can bundle similar individual partstogether on the pyramid at any time.“

The only requirement is the programmingin the CADCAM system and a reliablesimulation.

His idea goes one step further: “My visionis to have four different zero points onthe pyramid one day, and to be ableto machine completely differentcomponents.”

Flat vices with jaw quick-change The VERO-S clamping pyramids arecombined with manually actuated SCHUNKKONTEC KSC 125 clamping force blocks, inthe lengths 160 mm and 300 mm. The highlyefficient all-rounders for raw and finishedpart machining combine high clampingforces, convenient operation, and shortsetup times. As the clamping takes placeunder tension, the bending load on the basebody and thereby the lifting up of theclamping vice are minimised, which adds tothe accuracy and rigidity of the clamping. Apre-tensioned centre bearing withoutspindle reverse clearance and speciallyadjusted slides ensure an excellent repeataccuracy of +/- 0.015 mm. The fullyencapsulated drive and an integrated chipoutlet ensure particularly high processstability and minimum wear. Due to a jawquick-change system, workpiece-specificchuck jaws can be changed in next to notime and a wide range of workpieces canbe covered.

Standardisation is the recipe for successFor urgent orders that Stefan Maas has tocarry out, the clamping pyramid isexchanged on the spot. This allows parts of

up to 800 mm in length to be machined inSCHUNK KONTEC KSC vices directly on themachine table. Alternatively, cylindrical orflat components can be clamped using theSCHUNK collet chuck mounting or theSCHUNK SPM clamping fixture on the fifthside of the pyramid.

Martin Schultheis concludes: “It is muchmore efficient to use current clampingtechnologies, like those from SCHUNKintelligently, even if they require a slightlyhigher investment at the outset. We havethe most modern machines which bringprecisely that which is simultaneouslyavailable on the market in a 5-axis machine.We have completely achieved the maximumtool rack and the standardisation of thetools. We have mastered the SCHUNKquick-change system and a pyramid toachieve multiple clamping and fully use themachine room. We have hereby achievedthe maximum. The fact is that most of thisinvestment will have paid for itself within ayear, maybe even less.”

SCHUNK Intec LtdTel: 01908 611127Email: [email protected]

A new vice with intelligent sensors thatenable safe clamping of workpieces onmachine tools and real-time productionmonitoring has been developed byRoemheld, which presented a prototype onits stand at the recent AMB show inStuttgart. The HPC machine vice can beoperated intuitively via an associated app.

It is the second Roemheld clamp withintegrated sensors, following theintroduction of a similarly equipped swingclamp in 2017 that measures, for example,clamping pressure, temperature and thecutting forces on the workpiece. Thegroup’s goal is to develop Industry 4.0compatible workholding equipment thatincreases manufacturing quality.

The latest innovation, which extends thefunctions of the proven Hilma NC 125machine vice, incorporates electronics thatmeasure clamping forces in real time andcompares them with pre-set target and limitvalues. The results are transmitted wirelesslyto stationary or mobile receivers on whichthe associated app Hilma ProcessControls installed.

If the clamping force values approach oneof the limits, a warning is transmitted. Thedata can also be communicated to themachine control for automated interventionin the production process. In addition towireless transmission to the app, theindustry 4.0 standard OPC-UA softwareinterface is used for data transmission.

Current values are transmitted wirelesslyto the app, where they may be read and arelogged. They can also be controlled via anoptical traffic light system in the app,whereby the operator conveniently entersthe clamping force limits. Green indicatesoptimal production. As soon as a force valueis measured at the edge of a set minimum ormaximum, the light switches to yellow andthe operator can intervene. If a limit value isexceeded the light turns red, in whichcase the machine can be set to switchoff automatically.

With the current version of the app, theoperator can differentiate between, andcontrol on-screen, up to four HPC vicessimultaneously. In addition, they can easilybe calibrated via the app.

The monitoring system, which can bebattery or mains powered, essentiallyconsists of a circuit board and a batterymounted within a housing on the clamp toprotect them from swarf and coolant toIP67. It will be available as an option on themechanical-hydraulic and fully hydraulicversions of the Hilma NC 125 machine viceand further sensor projects will follow.

Roemheld UK LtdTel: 01462 459052Email: [email protected]

Industry 4.0 vice monitors clamping force

Feature - CADCAM


At the Seco ‘Inspiration Through Innovation‘event last month, OPEN MINDTechnologies presented the latest version ofits hyperMILL® CADCAM suite throughtechnical and live demonstrations. Thecompany’s presence focussed on thehyperMILL MAXX Machining performancepackage that brings together highlyefficient machining strategies that makethe most out of the options for therespective machine tool.

hyperMILL MAXX Machining incorporatesinnovative methods for roughing, finishingand drilling, all of which werecomprehensively demonstrated on a GROBmill/turn centre and a 5-axis Hermlemachining centre at the event. The MAXXMachining demonstration on the Hermlesaw OPEN MIND produce a portion of anannulus filler aircraft engine part fromaluminium with innovative CAM strategiesthat will apply the latest Seco conical barreltools to achieve incredible cycle times.

Highlighting the benefits of hyperMILLMAXX Machining rough, finish and drillingstrategies that can deliver cycle timereductions in the region of 90 percent,OPEN MIND UK’s managing director,Adrian Smith says: “The annulus filler willshowcase the combined benefits of MAXXMachining‘s rough and finishing strategiesand the cycle time savings with Seco conicalbarrel tools. The demo part will alsointroduce technology like our MAXX drillingfeature that interpolates milling tools tocreate holes at speeds significantly fasterthan conventional drilling. Similarly,trochoidal milling is not necessarily thefastest route to material removal as thecontinual direction change doesn’t alwaysallow the machine to achieve maximum feedrates. The optimised MAXX Roughingstrategy undertakes intelligent straight-linetool paths, and this permits the machine toreach the maximum acceleration and feedrates. In contrast, the GROB demonstrationwill be undertaking B-axis turning, which is agenuine eyecatcher on a mill/turn centre.“

OPEN MIND also provided some sneakpeeks at pending expansions to itsperformance package that will beintroduced in the soon to be arriving Version2019.1. For instance, in the not too distantfuture, hyperMILL MAXX Machining will beavailable for 3D-optimised roughing as wellas for turning. Meanwhile, 5-axis tangent

machining is available forcorner filleting and thisfunction guarantees simpleradius programming atsurface boundaries with anexcellent surface finish.

Stepping into theworkspace virtuallyThe highly developedhyperMILL Virtual Machinesimulation functions alsomade an appearance at theSeco event. Visitors wereable to delve into themachining area through a 3D machinesimulation on a virtual reality station. Visitorscould also view the clamps, holders, tools,toolpaths and even view simulations fromany desired perspective. End users wereable to observe complex processes viavirtual machining. Hidden processes will bemade visible and it will be easier to detectcollision risks.

OPEN MIND is one of the world’s mostsought-after developers of powerful CAMsolutions for machine and controllerindependent programming.

OPEN MIND develops optimised CAMsolutions that include a high number ofinnovative features, not available elsewhere,to deliver significantly higher performancein both programming and machining.Strategies such as 2.5D, 3D, as well as 5-axismilling/mill turning, and machiningoperations like HSC and HPC, are efficientlybuilt into the hyperMILL CAM system.hyperMILL provides the maximum possible

benefits to customers thanks to its fullcompatibility with all current CAD solutionsand extensive programming automation.

OPEN MIND strives to be the best andmost innovative CADCAM manufacturer inthe world, helping it become one of the topfive in the CAM industry according to theNC Market Analysis Report 2017 compiledby CIMdata. The CADCAM solutions ofOPEN MIND fulfil the highest demands inthe automotive, tool and mouldmanufacturing, production machining,medical, job shops, energy and aerospaceindustries. OPEN MIND is represented in allkey markets in Asia, Europe and America,and is a Mensch und Maschine company.

Open Mind TechnologiesTel: 01869 290003Email: [email protected]

Highlights from hyperMILL at Seco event

T: 020 3893 2211 | e: [email protected]

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CADCAM


ModuleWorks, a leading supplier ofCADCAM software components formachining and simulation, has announcedit has collaborated with BobCAD-CAM on anew NC Editor that provides an enhancedG-code editing and verificationenvironment.

ModuleWorks and BobCAD-CAM workedclosely together to design an editor thatfulfills the needs of the full spectrum of userswho require G-code editing and verificationsoftware. The ModuleWorks NC Editor ispart of the ModuleWorks product line and isavailable now to all ModuleWorks partners.

BobCAD-CAM Version 31 is the firstcommercially available CADCAM softwareto use the powerful new ModuleWorks NCEditor for editing, simulating, back plottingand verifying G-code for multi-axis CNCmachining.

The ModuleWorks NC Editor has anintuitive interface with step-through codeediting and automatic colour highlighting offunctions to simplify and speed up theediting process. For improved machinesafety, there is instant 3D simulation whileediting the program to enable users todetect programming errors and potentialcollisions between the tool and stock at aglance and to instantly verify any changes tothe code. Integrated Job Setup for fast andflexible tool creation, including holders andadapters, and built-in support for multipleCNC machines further accelerate andsimplify the editing and verification process.

Greg Myers, director of softwaredevelopment at BobCAD-CAM, says: “Wewanted an editor that would meet theG-code editing needs of all our customersand we are delighted with the result of ourcollaboration with ModuleWorks. We cannow offer our customers a comprehensive,cost-effective and easy-to-use G-codeediting and verification system thatoptimises the quality and efficiency of theirmachining processes.”

David Plater, technical director atModuleWorks, says: “We are very pleasedthat the NC Editor has become the systemof choice for BobCAD-CAM. It’s great to seehow our specially designed G-code editingenvironment is helping users quickly andeasily optimise the quality of their G-codefor safer and more cost-effectivemachining.”

ModuleWorks release 2018.08CADCAM componentsModuleWorks has released the latestrelease of its CAM components,ModuleWorks 2018.08, the second majorupdate of 2018.

ModuleWorks is at the forefront of 5-axismachining and simulation technology,providing the toolpath and simulationtechnology that powers many of the leadingCAM systems around the world today. Thislatest release includes new features for5-axis and 3-axis machining, machinesimulation and the MultiXPostKinematic Solver.

5-axis machiningThis new option improves the quality andaccuracy of toolpaths by smoothing sharpcorners and replacing them with splines.Users enter the spline distance and theminimum detection angle. The smoothingdistance is automatically adjusted to avoidcollisions with adjacent slices.

Barrel section and double barrel toolThe barrel tools have a circular section onthe tool flank. A new feature enables usersto define the centre of the circular sectionfor creating asymmetric shapes. As well as

specifying the radius of the circular section,users can enter an upper and lowerblending radius.

The double barrel tool has a secondcircular section on the front, enabling walland floor machining without changingthe tool.

ContouringThe new contouring feature is a highlyautomated and efficient way of creatingedge trimming operations onthin workpieces.

3-axis machiningTo improve the quality of toolpaths, thecorner radius of the tool is now taken intoconsideration when generating the adaptiveroughing toolpath. This results in fewercusps in the final toolpath.

Machine simulationA new machine coordinate system has beenadded to the Machine Simulator interface.The coordinate system is based on themachine definition and uses an internaldetection algorithm for the mainmachine axis.

MultiXPost Kinematic SolverThe new Retract and Rewind AdvancedSettings dialog provides enhanced controlover all available functionalities. The newMulti-Step Retract provides greaterflexibility and control over retractingmovements and users can now retractevents in a single step or in two steps. Forthe second step, users can also selectthe direction.

BobCAD-CAM & ModuleWorkscollaborate on new NC Editor

CADCAM


First unified CADCAM solution for ultra-precision machining ofoptical partsModuleWorks and ZEISS, an internationally leading technologyenterprise operating in the fields of optics and optoelectronics,have combined conventional CAM features and the requirements ofultra-precision machining in a single CADCAM software solution.

Ultra-precision machining is used for parts that need to bemachined to an accuracy of just a few μm and a roughness in therange of Nm. Optical parts require both types of machining,ultra-precision machining for the optically effective areas of the partand conventional machining for the non-optical areas.ModuleWorks has developed CAM software components thatenabled ZEISS to combine both types of machining in a single,integrated solution. Integrating all machining relevant processes ina unified system accelerates process programming for cuttingcomplex freeform surfaces and improves the quality andcost-efficiency of producing ultra-precision optical parts.

6-axis toolpath modelThe new software is powered by the ModuleWorks 64-bitultra-precision kernel. The kernel is based on the industry provenModuleWorks 5-axis technology for toolpath generation and hasbeen specially developed to meet the growing demand forhigh-precision machining of increasingly complex geometries in theoptics industry. The ModuleWorks ultra-precision kernel supportspoint clouds, NURBS surfaces and parametric geometries and usesmulti-threading for fast toolpath generation with radial, spiral andparallel patterns for slow and fast tool kinematics. The freelyconfigurable machine model supports all machine tool types forgrinding and diamond turning applications as well as grindingpatterns for roughing, drilling, chamfering, slotting and contouring.Full 3D machine and material removal simulation software can alsobe applied with the high resolution of ultra-precision machiningrequirements. The high-performance CNC posting frameworkprovides scriptable CNC data output at a rate of 50 K points persecond and supports multi-threaded cloud posting.

3D Machine simulation with material removal“We developed a system to address the needs of UPM andintegrated this into a unified CADCAM solution for improvedefficiency”, explains Lothar Glasmacher, project director for processtechnology at ModuleWorks.

The software is the result of research and development projectsbetween ZEISS, ModuleWorks and Fraunhofer IPT. It was presentedat the euspen 2018 International Conference & Exhibition and isavailable now as a software library that can be integrated intoexisting CADCAM systems.

ModuleWorks is your Go-To partner for CADCAM software. Fromstandard products to exclusive development projects, it worksclosely together with you as a partner to bring your own vision ofIndustry 4.0 to life. With its comprehensive product portfolio andcutting-edge software components, you can optimise yourCADCAM solutions and successfully connect to CNC/MTB systemsto rapidly increase your competitiveness.

ModuleWorks GmbHTel: 0049 241 9900040Email: [email protected]

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Vero Software is a world leader in CAD CAM

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CADCAM


Over 60 people from 50 of the UK’s leadingadvanced manufacturing and technologycompanies attended CGTech’s latest VUE(VERICUT Users’ Exchange) event, heldduring October, at Williams F1 ConferenceCentre, Wantage, Oxfordshire. Thetechnical team from CGTech used the eventto provide customers with a feature reviewof VERICUT 8.2, the latest release of theworld’s most advanced independent CNCmachine tool simulation and optimisationsoftware. The focus was on highlighting newconvenience features that improvesimulation visibility, speed workflow, andstreamline each user’s verification process.

The event marked CGTech’s 30thanniversary and attendees were welcomedby Tony Shrewsbury, CGTech UK’smanaging director. He emphasised that thecompany now “has a global customer basewith 7,000 customers in 55 countries usingaround 20,000 seats of VERICUT to supportthe drive towards ever-increasingly complexcomponents, produced on multi-axismachine tools and using advancedprocesses such as material depositionadditive manufacturing.

“Advances in VERICUT match the pace ofthe needs of the customers, providing anopportunity for VERICUT to supportindustries’ goals for efficiency andproductivity. Representing an accumulationof thousands of customer requests, thislatest release of software has more userconvenience features, such as continuedmodernising of the user interface; additional

additive manufacturing functions; OptiPathand Force data sharing and manyenhancements to those products, along witha plethora of detailed enhancements.”

Scott Ravenscroft, sales engineer, thenwent on to highlight these new features inthe latest release: “A configurable Head-UpDisplay (HUD) improves simulationmonitoring and visibility by showing the NCprogram, or machining and cutting statusinformation, overlaid on top of VERICUT’sgraphical views. It provides constant accessto important details about the machiningprocess, while keeping simulation views aslarge as possible for optimal viewing. Acustomisable Right-Mouse-Button Ribbonputs favourite VERICUT functions just asingle click away, providing convenientaccess to external applications thatprogrammers find useful, such as NCeditors.”

He also explained the new NC ProgramAlert symbols and colours used to highlighterrors and warnings found in NC programs,making it faster and easier to identifyproblem sources.

Scott Ravenscroft continued: “Theseenhancements make it much easier toidentify where problem lines are withouthaving to click on the message in the logger.Highlighting lines with Errors/Warnings inNC Programs the software now has‘Quick-tip’ hover messages and isdynamically linked to the Message Logger.While the Forward/Back search is great forusing in review mode.”

VERICUT’s Additive module simulatesmaterial added to a part, materialdeposition via powdered metal deposition,wire additive welding, gasket or sealantapplication, and other ‘additive’ processes.

“An updated deposition algorithm offersspeed improvements of up to 50 percentfaster for multi axis applications and up to85 percent for 3-axis 3D print types,”Scott Ravenscroft stated.

He continued: “The main reason for doingthis was in preparation for simulating ‘BigArea’ additive builds. It also opens the doorwider for simulating 3D print build files thattend to have a lot of code and huge filesizes, within a reasonable amount of time.New features for additive tools are beingincluded as we learn more about theprocesses and important items usersrequire, and VERICUT also warns aboutmaterial added under ‘bad’ conditions fortighter process control.”

Building on the additive manufacturingtheme was a presentation on the DRAMA(Digital Reconfigurable AdditiveManufacturing facilities for Aerospace)Project from the MTC, home to the NationalCentre for Additive Manufacturing. Theproject includes ATS, Autodesk, GrantaMaterial Intelligence, Midlands AerospaceAlliance, NPL, Renishaw and the Universityof Birmingham, and aims to build a strongerAM supply chain for UK aerospace bydeveloping a digital learning factory. Theentire AM process chain will be digitallytwinned, enabling the cost of processdevelopment to be de-risked by carrying itout in a virtual environment. The facility willbe reconfigurable, so that it can be tailoredto fit the requirements of different users andto allow different hardware and softwareoptions to be trialled.

CGTech LtdTel: 01273 773538 Email [email protected]

VERICUT V8.2 users get the heads up

CADCAM

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What do you need for machining complexcomponents? Are you looking for thebest in 5 axis CAM software? Tebis hasthe solutionDuring the Seco event last month, a A350fuel connector for the aerospace sector wasproduced using Tebis CADCAM softwareon a Hermle C30 U 5-axis machine. PhilSmith, applications engineer at Tebis,explains how the component was machined:“The complex design of the part matchedour latest 5-axis functionality perfectly suchas 5-axis adaptive roughing, port machiningand surface machining. This allows thecomponent to be produced in a singlesetup, rather than multiple setups with ahigh-quality surface finish.

These cycles in addition to our virtualmachine technology, which is used in threestages of the process for planning,programming and verification, allowsoptimal collision free toolpaths oncomplex parts.”

Phil Smith also explains that the mainbenefit of Tebis uses a variety of options forfull cut handling and for full cut avoidance. Infull cut handling, feed rates areautomatically reduced in full cut areas andthey are machined in a trochoidal method. Inadaptive roughing, the path layout isautomatically adapted to the geometry.

When it comes to rough and finish cycles,when carrying out multi-sided machining ofundercut areas, key and ball cutters can beused to achieve very high surface qualitywith the shortest possible tools. The partcan be completely machined in a singlesetup and the operations on millingmachines can very easy planned andcalculated without collisions. This machiningmethod is also suitable for 5-axissimultaneous milling of undercut pocketsand breakthroughs, as well as for flowpassages and impellers.

Easy-to-useNC programming of 5-axis simultaneousmilling paths is easy-to-use with Tebissoftware. Research shows that Tebisprogrammers, that previous created 3-axistoolpath, also learn to easily program with5-axis milling. This is because each functionis tailored to special machining tasks andonly includes the parameters that areactually necessary for the respective task. If

you previously used 3- axis, it shouldn’t be aproblem to update to 5-axis with Tebis.

Reliable and efficient Tebis CADCAM5-axisBenefits include: Precisely adaptedfunctions for manufacturing preparation,such as for guide and centre curves; Optimaluse of circular segment cutters with barrel,oval, taper or lens geometry; All roughingand finishing strategies integrated; Shortprogramming times; Analyse andinteractively optimise tool tilt direction;Reduce machining times and machine idletimes.

For over 30 years, Tebis has ensuredprocess efficiency and a technological edgein international die, mould and modelmanufacturing, in industrial design, inmachinery and equipment. The companyworks responsibly and follows clearprinciples, wholly in the interest of itscustomers. It offers support on-site, aroundthe world, as a process provider.

Your company is right at home in theworld of design and industrialmanufacturing. No matter if you have two,2,000 or 200,000 employees, your processesare becoming increasingly digitised,automated and networked. In this era ofIndustry 4.0, the fourth Industrial Revolution,how can you improve your competitiveadvantage, increase your profitability andsecure your value creation?

Tebis is the ideal partner to optimally

prepare and orient your company for thefuture. It shortens throughput times andeffectively utilises cost-intensivemanufacturing equipment and increases theefficiency of all processes. It providescomplete software solutions andhigh-efficiency processes with which you candevelop, design and manufacture models,moulding tools and components morequickly, at higher quality and with greatervalue creation.

Tebis simplifies customer processesradically and improves competitiveness as asupplier and as a manufacturer, in theautomotive, mechanical engineering oraerospace industries.

Tebis (UK) Ltd Tel: 02476 15 8178 Email: [email protected] www.tebis.com

Take off with Tebis New function within Version 4.0 Release 6

CADCAM


NCCS, the developer of NCL multi-axis machining software, usedextensively in the aerospace, automotive and turbo-machineryindustries, has announced the release of NCL 2018. The new versionadds programming shortcuts and productivity features such asenhanced forms and videos that demonstrate each Form’s function.These features help speed up programming. They give even themost novice programmer the ability to program with confidenceand relative ease.

NCL 2018 offers a unique blend of automated anduser-controlled tool path generation techniques that saveprogramming time and increases quality. NCL’s combination ofpower, flexibility and tool control give users a distinct advantageover the competition by allowing users to quickly produce any part,reduce machine time, improve quality, and increase profits.

It also offers motion interface enhancements controlled byeasy-to-use menu driven commands. All NCL motion, geometry,and program control commands retain the power and flexibility thatis inherit to the NCL language-based system. All commands, thatare now output using a menu driven interface, can still be usedwithin loops, macros, etc. just as in previous versions of NCL.

NCL 2018 includes many new form options. For example,Waterline Roughing routine, an automatic routine used for highvolume material removal of roughing a part in multiple levels.

These key features of NCL will help companies get the most outof their software investment by increasing programming proficiencyin addition to improving the quality and accuracy of theirNC programs.

Don Schultz, president of NCCS, says: “NCCS is dedicated toconstantly improving our software technology, giving the end userwhat they want. The latest release of NCL is yet another example ofthe entrepreneurial spirit that has made the company successful.”

Numerical Control Computer Sciences (NCCS) has been aninternational supplier of Computer-Aided Manufacturing (CAM)software and services for over 40 years. A recognised leader insoftware solutions for multi-axis machining applications, its flagshipproducts NCL and PostWorks are used by leading manufacturingcompanies throughout the world. For more information, visitNCCS’ website at http://www.nccs.com.

NCCS EuropeTel: 01656 785050Email: [email protected]

NCCS releases NCL 2018

57

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“Some complex mould tools used to takeme nearly a week to design. But when weinvested in VISI that immediately camedown to a couple of days. And it’s evenquicker now.”

Those are the words of Mark Chapman,company secretary and mouldmaker atfamily-run business Sharnold Ltd. Designingtheir moulds in VISI, and machining themwith toolpaths generated by WorkNC,ensures that the tight tolerances they needto achieve are met first time, every time.

The company was established as asubcontract mould maker in 1957, movingto its current 3,500 square foot premises inNorthamptonshire, in 1970, with tenemployees. Nowadays it is run by just fourpeople: Maurice Chapman, his two sonsMark and Stephen, and Stephen’s wifeTracy. Maurice bought into the business in1982, eventually taking sole ownership.

While making tools for plastic injectionmoulders remains an important part of thebusiness, it set up its own mouldingoperation in 2000, and now has sevenmoulding machines; two Boys, twoBattenfelds and three Arburgs. Themachines mean the company has a lockingforce of between 22 and 100 tonnes, givingit the ability to supply moulded plastic partsup to 230 grams.

While the company has used WorkNC,from Vero Software, to machine its mouldsfor at least 15 years, VISI, also from the Verostable, is a relatively new investment.

Mark Chapman says: “It’s already provingto be vital for us. CAD designers areproducing increasingly more complex parts,but VISI gives us the ability to meet thosedemands quickly and easily. It’s now simpleto achieve aspects that we struggled withbefore. For example, producing split lines ismuch easier, as is slide generation. VISIhas speeded up the whole designprocess considerably.”

The combination of mould design withVISI, and WorkNC driving a 3-axis HurcoVMX machining centre along with a HurcoHawk and XYZ bed mills, means thateverything Sharnold produces is within therequired tolerances sometimes down to+ or -0.05 of a mm.

Mark Chapman continues: “Every mouldwe manufacture goes through bothsoftware packages. Using the Hurcomachines and VISI means that in terms ofdesign and cutting the forms, we save atleast half the time and the overall time takento produce the complete tool is reduced byaround a third.”

He says their process begins with theplastic component, whether they areproducing the tool for another moulder, orto run on their own moulding machines.

Mark Chapman explains: “A bigadvantage of VISI is that we can check themodel’s integrity before we start. It’s got avariety of tools to ensure that all surfacesmeet up, because if we’re trying to workwith a poorly designed model, the mouldtool won’t work.

“I check the features with the draft

analysis function, making sure it has relevantdraft tapers, and then move on to thedesign. As VISI has a large library ofmaterials, with all their specs andcharacteristics, it’s simple to apply shrinkageto the particular plastic I’m working with.”

He says core and cavity separation is quickand easy, even with varied split lines, as aresliding block and tricky shot out areas:“I make either the fixed half or moving halftransparent onscreen, so I can look insideand ensure the faces are touching, and thateverything fits and works properly.”

Once he is happy with the split hesubtracts the part out of the inserts andestablishes the insert size around it. WhileVISI automatically picks the mould basewhen the insert and part are complete, he isparticularly impressed with the speed andaccuracy it can be manually tailored ifrequired.“ When working on multi-cavitytools VISI lets me literally copy a completedinsert into the next position, and when thatoperation’s finished it automatically selectsthe bolster and again there are manualediting tools if necessary.”

He says the feed gate generator and

VISI cuts mould tooling time by half

CADCAM


library of ejector pins all help to move thedesign along at a fast pace. Transferringfrom VISI’s CAD process to WorkNC forCAM is also fast and seamless. “I put eachplate on a different layer, so l have my clampplate, the fixed half form plate and themoving half form plate all saved as individualparts in native VISI files. As WorkNC readsthe VISI files, I simply move them across. Ican pull a finished plate design out of VISI,and WorkNC is generating toolpaths for itwithin a minute.”

Sharnold’s moulded parts are largely forthe automotive, security door, electronics,conveyor belt, licensed trade, and airportindustries. They include a brewery “Python”strap, and a pulley wheel system for aconveyor belt.

The Python strap is used for securingpipework leading from pub cellars to thetaps on the bar. It comprises regroundplastic waste from other manufacturingprocesses. Once the company had beenbriefed on the project by Dirk Parker, fromits Leicestershire-based customer L’isolanteK-Flex, they used VISI to create the mouldtool from an existing part which waspreviously manufactured using adifferent method.

The contract for the pulley wheel systemcame about after producing a smallclamping block for Axiom GB.

Mark Chapman says: “We made around5,000 parts, which was their first venture intomoulding. It was so successful that theyasked us to work on the wheels for theirconveyor system. We designed the fullmould in VISI and transferred the files toWorkNC for machining the bolster, formsand electrodes.”

Overall, Sharnold makes around a dozenmould tools a year, ranging from 75 mmsquare bolster plates up to 445 mm square,and ship around 40 different moulded

products totalling 100,000 piece partsevery month.

“Not bad for just the four of us” concludesMark Chapman. He and Stephen, along withtheir father Maurice, work on the design andtoolmaking operations, and Tracy handlesthe administration work.

Vero Software LtdTel: 01189 756084Email:[email protected]/

MEASUREMENT & INSPECTION


If you speak to anybody from the world ofmotorsport about engines andtransmissions, there is one name that isimmediately associated with casting designand rapid prototyping, Grainger & Worrall.Its unrivalled experience in F1 and WRCchampionship engine and transmissionprograms can be demonstrated by the factthat all 20 cars on the LMP2 grid at Le Mansin June 2018 were using Gibson GK428engines, cast by Grainger & Worrall.

However, motorsport is only one part ofits expertise, as it offers clients extensiveknowledge in casting design andengineering, tooling design, machining andprototyping. Grainger & Worrall’s specialistprototype aluminium foundry approachesproduct development by adding value,delivering successful high integrity precisionsand castings for automotive engines,aerospace components and other industrialmarkets. The world is demandingever-lighter, ever more efficient means ofpropulsion, resulting in increased prototypedemands and increased quality controlrequirements. To meet the demands ofapproximately 300 new productintroductions, including niche volume andmotorsport supply annually, Grainger &Worrall recently purchased a CreaformHandySCAN 700 from MeasurementSolutions.

Time saving accuracyAlthough already equipped with traditionalgantry CMM’s, Coordinate MeasuringMachines, advanced industrial CT scanning,Computed Tomography, and white lightscanning systems, the increasing complexityand persistence to push the limits ofpossibility has driven a need for bothincreased capacity and capability. Therequirement to spend time preparingsurfaces of castings with powder spray, thathas always been difficult with projected lightscanners, all served to drive its decision topurchase the Creaform HandySCAN 700.David Lang, who was integral to thedecision-making process, comments: “TheHandySCAN ticks many boxes for us. Notrequiring powder spray is an obvious benefitin terms of time savings, both before andafter scanning. We were spending severalthousand pounds annually on spray, which isan inefficient and unnecessary cost and addto that the associated costs incurred during

the ‘shot blasting’ process to clean thecastings after scanning.”

The HandySCAN 700 utilises 14 red laserlines which offers a large field of view and acapability to capture data extremely fast.David Lang continues: “After testing theHandySCAN it was obvious to us the 14 laserlines feature allowed for very fast datacapture, with the addition of a single laserline to capture areas within deep pockets.We also found the HandySCAN to be ofhigh accuracy and comparable to ourexisting equipment.”

In house quality management ensures theeffective design of processes that verify thecustomer’s needs. This has helped to ensurethat Grainger & Worrall are known globallyas a leading supplier of prototyping servicesin structural Powertrain Components and anexceptional supplier of castings andmachining for specialist low volume castcomponents. It is these evolving processesthat have provided Grainger & Worrall withopportunities to continually assess andupgrade its equipment needs.

As is often the case with newtechnologies, once in process, users get toexplore the full benefits on offer. David Langadds: “As we assessed the product further,additional benefits came to the forefront.The ability to scan with a ‘handheld’portable solution was significant. The factthe HandySCAN and all accessories fit into asmall carry case means it is quick and simpleto take to the shop floor and startinspecting. Whether it be a large piece oftooling or a sand mould-pack beingassembled, we can now take the scanner onlocation, set up and be finished within thehour. Before purchasing the HandySCANthis task would have been much morechallenging and usually resulted in movingcomponents to the metrology room, whichoften was impractical.”

As with any company, constantly investingin new technology, the availability oftraining, system implementation and aftersales support is a very significant part of anydecision to purchase. Aftersales support hasalways been a huge part of MeasurementSolutions DNA and a key to its success,having recently celebrated its20-year anniversary.

Measurement Solutions LtdTel: 01733 325252Email: [email protected]

Leading the way in motorsport innovations



Bowers Group has supplied CoMechMetrology with a range of measurementsolutions for the rail industry. Based inDerby, CoMech specialises in thecalibration, design, manufacture and supplyof safety critical measurement equipmentprimarily to the rail sector, but also to theautomotive, aerospace and generalengineering industries.

As part of CoMech’s calibration servicesfor gauges used in the rail sector, thecompany was keen to improve its level ofefficiency in order to keep up withincreasing customer demand. The gaugesare typically used for train maintenance,therefore decreasing the turnaround time ofcalibration services was a high priority, aswell as important for ensuring that trains aresafe, and the rail network runs efficiently.

Bowers Group provided CoMech with aTrimos V4 700 Height Gauge to aid in themeasurement of bespoke rail gauges. Thisvertical measuring instrument is universallyrecognised for its ease-of-use andhigh-quality manufacturing. The heightgauge has enabled CoMech to successfullyspeed up its measurement of rail gauges.

The CMM machine at CoMech is in very highdemand, therefore the Trimos enablesquick, simple measurement that takesdemand off the CMM machine for simplemeasurements requiring high levelsof accuracy.

Bowers Group also supplied CoMech witha Sylvac M3 Dial Gauge Calibrator which isused to calibrate gauges. Suitable fortesting dial gauges, plunger type and testindicators, the unit can be used in thevertical and horizontal position, providingdirect status from the instrument duringchecking and sending measured resultsdirectly to software.

The company also provided CoMech witha Baty R14 FT2-E Profile Projector toimprove its quality inspection capability ofwheel profile gauges for trains. This benchmount profile projector boasts a 340 mmscreen and combines high accuracynon-contact measurement and inspectionwith a large 175 mm x 100 mmmeasuring range.

The horizontal light path configurationmeans that CoMech can secure the wheelprofile gauges to the workstage and

measure their consistency and accuracy. Theprofile projector also enables CoMech tofree up the CMM machine, thereforecarrying out more measurements.

CoMech also uses the Baty FusionSoftware, which combines ease of use,advanced edge detection and graphicalreporting. Particularly useful for CoMech isthe profile scanning capability, whichautomatically traces the profile of a part.

Bowers GroupTel: 01276 469866Email: [email protected]

CoMech on track with measurement solutions from Bowers Group



VES Precision was established in 1991 to provide a range ofprecision engineering and subcontract machining services to localcompanies, such as Westland Helicopters, now LeonardoHelicopters, and Normalair Garrett, now Honeywell Aerospace,both of which are located in nearby Yeovil.

Prompted by customer demand, over the past three decades thecompany has considerably expanded its footprint and now operatesfrom a modern 14,500 sq ft production facility. Having considerablyexpanded its range of competences, VES Precision now offers anall-embracing machining service with a wide range of capabilitiesincluding CNC milling, turning, EDM Wire Erosion, grinding,lapping and surface blasting. VES is able to produce componentsfrom a broad range of materials, including plastics, stainless steel,high-speed steel, brass, copper, bronze, tungsten and aluminium.The company also has considerable experience in machining exoticmaterials such as Nimonic 90, Inconel, Stellite and MAR-M-247.

Recent substantial investments in advanced, high-yield machinetools have enabled VES Precision to significantly increase its output.As this rise in production had started to place a strain on thecompany’s inspection provision, VES quality assurance manager,Steve Trigg recently investigated the available, precise and fastacting CNC Coordinate Measuring Machines, CMMs. Afterevaluating the merits of CMMs from several leading manufacturers,an advanced, high-speed Axiom Too HS machine was purchasedfrom Aberlink.

Steve Trigg explains: “Most engineering subcontractors areeither geared-up for high-volume work or for one-offs and smallbatch work. Our success is based largely on our flexibility and ourability to offer complete, one-stop-shop machining solutions, fromone-off bespoke jobs, through to large, repeat order production.We use a wide range of techniques including 5-axis milling, 3- and4-axis mill-turning, dedicated CNC milling and CNC turning, EDMwire erosion, surface and cylindrical grinding, lapping and grit/glassbead blasting.

“Prompted by an ever-increasing work-load, several months agowe opened a new, purpose-built milling hall that includes anadvanced 5-axis machine with a pallet loader, 3- and 4-axis CNCmills and an overhead gantry crane. The additional capacity,provided by our new milling hall, has enabled us to considerablyincrease our output.

“Although our inspection system has been able to keep-pacewith our increased output, as it was working at full capacity we wereaware of the need to boost our measuring capabilities. Havingweighed-up the available fast acting CMMs against our list ofrequirements, we decided that Axiom Too HS CNC CMM was theideal machine for our needs, therefore, we placed an orderwith Aberlink.”

Available in several capacity variants, the cost-effective AxiomToo HS, from Aberlink, the largest UK owned CMM manufacturer,can truly be described as the complete, high-speed, high-precisioninspection centre. Impressive measuring accuracy and speed ofoperation is achieved through the use of the latest metrologytechniques and advanced in-house manufacturing methods.

The Axiom Too HS boasts an aluminium bridge with a very lowthermal mass, making it ideal for use either in controlledenvironments or within less than perfect shop-floor conditions.

Thanks to its use of advanced materials, the CMM’s reduced inertiaresults in class leading speed of operation. For increased accuracy,air bearings of optimised stiffness are employed on all axes, whilst agranite Y Beam allows preloading of bridge bearings in bothdirections. Borrowed from the aerospace industry, the CMM’ssturdy component support consists of an advancedgranite/aluminium honeycomb construction. This technologyprovides natural damping and further improves the machine’sthermal properties.

The Axiom Too HS utilises Aberlink’s famous, intuitive 3Dsoftware. A welcome bi-product of any Aberlink CMM inspectionroutine is that a simultaneous picture of the measured component iscreated on the computer screen. Dimensions between themeasured features, mirroring those that appear on the componentdrawing, are then picked off as required. In essence this ‘smart’software represents an intelligent measuring system that is able toautomatically recognise and define the various features beingmeasured. Aberlink 3D is claimed to be the easiest to use CMMsoftware currently available, as a result a complete novice is usuallyable to perform relatively involved measurement routines after justfive minutes training.

Aberlink Tel: 01453 884461Email: [email protected],ukwww.aberlink.co.uk

Aberlink provide VES with pace and precision



If manual inspection of two-dimensionalcomponents on a measuring machine,optical profile projector or measuringmicroscope is too time consuming or notsufficiently precise, the newQUADRA-CHEK 2000 from HEIDENHAINcan solve the problem. Equipped withembedded evaluation software and a highresolution, 7-inch, hardened colourtouchscreen, the unit has a built-in powersupply, rugged aluminium housing andfanless cooling. It is therefore ideal forapplications on the shop floor as well as inthe inspection room.

Neil Prescott, managing director ofHEIDENHAIN (GB), comments: "This is ahigh-quality hardware and software solutiondedicated to 2-D metrology applications,manufactured by our parent group inGermany and supported from our BurgessHill technical centre. For the user, thesystem offers a high level of functionalityand reliable operation combined withlong-term service back-up."

Point acquisition using X and Yhandwheels, and perhaps also stagerotation, is easy using crosshairs or via a

connected optical edge detector. The latter,operator-independent mode enables a highlevel of repeatability and significantlyreduces measurement uncertainty byeliminating subjective error. Predefinedgeometry tools record the coordinates oftwo-dimensional features such as points,lines, circles, slots and squares and measurethe distances and angles between them. A'Measure Magic' function simplifiesinspection further by using the acquiredpoints to recognise, select and fit thegeometry automatically.

When dealing with complex contours andrepetitive inspection, a user canautomatically record the measuring routineand run it at any time. QUADRA-CHEK 2000keeps track of the presets, sequence ofmeasurements, tolerances and data outputcommands. When the recorded program isexecuted again, the unit displays on-screenuser guidance detailing all of the features tobe measured.

The menu-driven software iscontext-sensitive, showing only thosefunctions that are available in the currentmeasuring situation. Results are captured

and displayed graphically. On completion ofthe inspection routine, an integratedreporting function makes it easy to create aPDF, CSV or printout of the measurementand tolerance results. Users can even createand import their own bespoke reporttemplates.

HEIDENHAIN (GB) LtdTel: 01444 247711Email: [email protected]

Manual 2-D inspection becomes faster and more accurate

Real time part rotation acceleratesinspection and design workflowsFARO has recently introduced the FARO8-axis FaroArm® system. After more than 30years of continuous innovation in portablemeasurement arms, FARO is once againdriving the industry forward. Thiscomprehensive solution combines either theportable Quantum FaroArm®, QuantumScanArm or Design ScanArm® portfolioproducts with a functionally integrated, yetphysically separate, 8th axis.

The 8th axis is a complete rotational axisidentical to and a natural extension of allFaroArm products. It plugs directly into theFaroArm and results in a seamlesslyintegrated, high accuracy additional axisthat requires no additional setup time oreffort. Moreover, unlike a turntable, the 8thaxis is completely transparent to themeasurement software, so no softwareupdates or upgrades are needed.

This innovative functionality enables thepart to be rotated in real time relative to theArm versus requiring the Arm to be movedaround the part. As a result, it is not only

easier to scan andmeasure typicallyharder to reach areas,but also bothmeasurement time andhuman measurementerror are dramaticallyreduced since the partitself rests on a stable,consistent platform.

The 8-axis system is ideal for addressing arange of non-contact measurement anddesign challenges, including point cloudcomparison with CAD, rapid prototyping,reverse engineering, and 3D modeling offree-form surfaces.

The extended reach of this system, via theeasy-to-use part rotation functionality,allows the user to scan, measure and digitisefeatures on both small and large parts with asingle Arm position. As a result, this processis up to 40 percent faster relative to astandard 7-axis Arm system.

The operator is now able to focus, withminimal distraction, on the actual scan ormeasurement of the part since reaching

around the part is no longer required. Also,this allows complex objects to be digitised,not only faster, but also morecomprehensively.

Due to reduced need to move the Arm todifferent positions around the part or movethe part itself into several positions in orderto capture all necessary features, a minimumnumber of scans need to be aligned. As aresult, post processing activities are bothsimplified and completed faster.

FARO Technologies UK LtdTel: 02476 217690Email: [email protected] www.faro.com

Breakthrough FARO 8-axis FaroArm sets new standard

Feature - LASER CUTTING


Yamazaki Mazak presented fivestate-of-the-art laser cutting machinesand two automation solutions atEuroBLECH 2018.

The standout machine was a new modelof the OPTIPLEX 3015 6kW DDL, DirectDiode Laser, a high-speed andhigh-accuracy machine that offers laserusers a step-change in cutting performance.

The OPTIPLEX 3015 is equipped with apowerful 6 kW DDL resonator, ideal forcutting medium and thick sheet metal. Theresonator, the most advanced of its kind,enables fast-cutting of stainless steel andaluminium and is up to 15 percent fasterthan its 6 kW fibre equivalent. This highlyefficient machine is also available as part ofthe OPTIPLEX 4020 series.

Most importantly, the new DDL machinedelivers stable cutting for both thin and thickmaterial, due to the use of Beam DiameterControl, along with Intelligent MonitoringFunctions (IMF) and Intelligent Set-upfunctions (ISF), all of which combine toproduce unsurpassed productivity of around15 percent compared to 4 kW machines.

In addition, the DDL delivers the highestlevels of cutting quality, particularly withthick mild steel, utilising its large cuttingsweet-spot to deliver a smooth cut edge.The DDL is equipped with a multi-controltorch and new MAZATROL PreviewG.

Alongside the DDL was the new FG-220DDL 4 kW, a new Direct Diode Laser versionof the company’s highly popular tube andpipe cutting machines. The machine isdesigned for maximum productivity utilisinghigh-speed approach piercing to improvecutting speeds on both thin andmedium-thick material by up to 20 percentcompared to CO2 lasers.

The FG-220 DDL is able to cut highlyreflective material, such as copper and brass

and is ideal for cutting long structuralmaterial, including round, square andrectangular pipe, along with H, I andL beams.

The machine is designed for maximumease-of-operation, with features includingQuick Programme Restart and reducedrunning costs due to its lower resonator,reduced chiller unit energy consumptionand the fact that no laser gas is required.The laser machine is equipped with theMazak FX CNC.

Also, on the stand were the 10 kW and8 kW versions of the OPTIPLEX FIBER IIIlasers. Specifically, the 8 kW version isequipped with a Mazak Smart Cellautomation system, developed tocomplement machines in the Mazak laserportfolio.

The Smart Cell system has a smallfootprint and compact layout along with anergonomic design for improved access andease-of-operation. The automation cell canbe programmed offline and, when inoperation, offers detailed reporting ofproduction status and operation, automaticparts separation detection and dynamickinetics to calculate weight andoptimise speed.

Most importantly, Smart Celloffers an Industry 4.0 readysolution for laser users and hasan open interface to aid furtherexpansion, along with an optionfor a robot solution.

The final machine on displaywas the 6 kW OPTIPLEX NEXUS3015 FIBER, equipped with aFasani CST automation system.

The 3015 FIBER is equipped todeliver higher productivity whencutting stainless steel and

aluminium and is also capable of thicker mildsteel nitrogen cutting. The machine isequipped with a range of monitoring andcontrol functions that improve productivityand cut quality, including stable beamcutting from thin-to-thick with beamdiameter control, optimised cutting with theIntelligent Monitoring Function and reducedsetup times with the IntelligentSetup functions.

The machine is equipped with a CSTautomation system, which consists of asingle tower mounted above the laserbench, with a maximum of 13 separatedrawers for the loading of raw material andthe unloading of processed workpieces. Theautomation system uses a suction system toload and unload workpieces with amaximum load capacity of 3,000 kgper drawer.

Gaetano Lo Guzzo, director for laserbusiness Europe at Mazak, concludes: “Ourtheme for EuroBlech this year was speed,specifically new technology, such as theOPTIPLEX DDL with its powerful 6 kWresonator and the ability to combine lasercutting technology with automationsolutions, to provide an integrated cuttingand machine handling solution that can takeproductivity to the next level.”

Yamazaki Mazak UK Ltd Tel: 01905 755755 Email: [email protected] www.mazakeu.co.uk

Automation and laser solutions from Mazak

Fiber laser cutting without compromises

Full power, wide range of applications, and extensive features. Whatever you cut in the future, our ByStar Fiber laser cutting system provides everything you need.

Cutting | Bending | Automationbystronic.com

LASER CUTTING


Carbon fibre composite materials arefinding their way into an ever-increasingnumber of products and applications. Theaerospace and motorsport sectors wereamongst the first to take advantage of thehigh-performance strength to weightration of these materials and today theyhave become an essential and integral partof many high-performance components.

Cutting and machining these materialshowever, presents many challenges whencompared to working with traditionalmetals and alloys. Conventional machiningmethods and cutting tools generallyperform poorly on composite materials,suffering from excessive tool wear andexerting significant stresses on thematerial, which can cause high levels ofde-lamination of the part.

So, are lasers the optimum solution formachining and cutting Carbon FibreReinforced Polymer (CFRP) Composites?In this article, TLM Laser’s Andy Tomsdiscusses how using multiple wavelengthscan help overcome the issues associatedwith cutting CFRP’s and create a clean lasercut edge with minimal heat affected zoneExperience has taught us that traditionalmechanical tools such as routers and evenultrasonic knives, can exert significantstresses on carbon fibres during the cuttingprocess. These stresses can often result indisplacement of the fibres and in severecases, delamination of individual layers.This in turn leads to significant degradationof the structural properties of theCFRP composite.

As a non-contact process, laser cuttingdoes not cause the kind of edge damagethat is characteristic of mechanical cuttingprocesses, however conventional lasercutting can still create excessive heatingnear the cut edge. For example, a 1.06 μmwavelength Yb-doped fibre laser can cutthrough a CFRP composite, however theresultant cut is not optimised because thepolymer matrix material is largelytransparent to this wavelength.

The carbon fibres absorb the 1.06 μmlaser energy, converting it to heat. The heatvaporises the carbon fibres cleanly, butresidual heat is conducted down the lengthof the fibres causing decomposition of thepolymer matrix material and leaving a largeheat affected zone (HAZ).

A CO2 laser, with a characteristic

wavelength of 10.6 μm, can also cut througha CFRP composite. Both the carbon fibresand the polymer matrix material will readilyabsorb the 10.6μm laser energy. However,the amount of energy needed to vaporisethe carbon fibres is usually much greaterthan the energy needed to vaporise thepolymer. This again leads to excessivedecomposition of the polymer matrixmaterial in the vicinity of the cut edge.

A unique solution to this issue can berealised by combining two laserwavelengths into a single, coaxial laserbeam. The hybrid laser beam is composedof a CO2 laser beam with a wavelength of10.6μm and an Yb-doped fibre laser beamwith a wavelength of 1.06μm. The 10.6 μmlaser wavelength cleanly ablates thepolymer matrix material while the 1.06 μmlaser wavelength simultaneous cuts thecarbon fibres. This leads to a superior cutquality with minimal Heat Affected Zone(HAZ) and, more importantlyno delamination.

This multiple wavelength concept wastested and proven through trials undertakenby Universal Laser Systems Inc. All laserprocessing was performed using anXLS10MWH platform from Universal LaserSystems. Two lasers were installed on theplatform, a 40 W Yb-doped fibre laser with awavelength of 1.06 μm, and a 75 W CO2

laser with a wavelength of 10.6 μm. The

XLS10MWH platform is equipped withMultiwave Hybrid™ technology, that allowsthe individual laser beams to be combined

Make light work of cutting carbon fibre

LASER CUTTING


into a coaxial beam with a common focalplane. The laser beams can also be operatedindependently.

Multiple wavelength laser cutting wasinvestigated using 1.5 mm thick carbon fibrereinforced polymer sheet stock, with thelaser cutting process optimised to providethe best balance between 1.06 μm laserenergy and 10.6 μm laser energy. Cutquality was observed microscopically usingan Opto-digital microscope.

A comparison was made between cuttingthe CFRP sheet with a CO2 laser, a Yb-dopedfibre laser and subsequently a multiplewavelength laser beam. The 10.6 μmwavelength of the CO2 laser was absorbedefficiently by the polymer matrix material,causing it to decompose and vaporise.However, it was not possible to cut throughthe carbon fibres due to their relatively highvaporisation threshold. It should be notedhowever, that it is possible to cut throughcarbon fibres with a 10.6 μm wavelengthlaser beam, but it requires significantlymore power than the 75 W used in thisspecific analysis.

The middle circle was cut using only the1.06 μm wavelength Yb-doped fibre laser.This wavelength is absorbed efficiently bythe carbon fibres. However, the polymer

matrix material is transparent to thiswavelength. The result is that the carbonfibres, that are directly in the path of thelaser beam, are vaporised efficiently. Thematrix material is vaporised indirectly,through conduction of heat down thecarbon fibers. This leads to significantdegradation of the polymer matrix materialnear the cut edge. The exposed carbonfibres shown in the figure can lead todelamination, and degradation ofmechanical properties.

The bottom circle was cut using bothlasers simultaneously. The benefit of thisapproach is that the carbon fibres areheated and vaporised directly by the 1.06μm laser beam and the polymer matrixmaterial is heated and vaporised directly bythe 10.6 μm laser beam. This minimisesoverheating of the polymer matrix material.A much better cut quality can be obtainedwith the multiple wavelength laser beamand the HAZ is significantly reduced.

Using the two laser beams simultaneouslyresults in an efficient process for cuttingCFRP. Each of the two laser beamwavelengths was selected to heat andvaporise the individual components of thecomposite sheet. By using this multiplewavelength laser cutting technology, the

CFRP can be cut cleanly using relatively lowpower lasers. This technology can beextended beyond CFRP, to other types ofcomposite sheets, through appropriateselection of the laser wavelengths.

TLM LaserTel: 01527 959 099Email: [email protected]

LASER CUTTING


FC Laser Ltd, the Derbyshire-basedhigh-quality laser cutting and fabricationbusiness, is building an enviable andgrowing reputation for innovative andintricate laser cutting services, after just 6years in business. This reputation isespecially impressive against a backclothwhere many of its competitors have beentrading for over 30 years. The hardworkingteam of directors and staff at FC Laser arenot exactly ‘new to the game’, themanagement team has over 60 years of

experience between them. Danny Fantom,managing director and founder of thebusiness, started his career in engineeringback in 1990 and worked his way up from ashop floor apprentice to managementretaining his characteristic ‘hands-on’approach to the business right to this day. Itis this practical, supportive and passionateapproach with his team that has helpedgrow the business from a turnover of£0.75 m in 2012 to more than £7 m today.With an expanding headcount of 55 teammembers, financial growth, whilst importantto the stability of the business, is not themain driving force of the management team.Innovation and dedication to customerservice are the key drivers behind the team’ssuccessful track record in laser cutting, CNCfolding, fabrication and welding.

Having Europe's largest installation ofthree 10 kW Bystronic Bystar Fiber Lasers,up to 4 m x 2 m bed size, the business is atthe cutting edge of technology. Whateverthe material and however complicated thecut, the ByStar Fiber provides the highestparts output available and at an

unmatchable premium cutting quality. Thisimpressive piece of kit can cut far greaterthicknesses than any other machinecurrently available in the U.K. Making lightwork on a wide range of materials, theBystar Fiber easily cuts through 25 mm mildsteel; 30 mm Stainless Steel; 30 mmaluminium; 15 mm copper and 12 mm brass.

FC Laser also employs continuousimprovement techniques that moreestablished competitors find hard to match.One such innovative example is the recent

introduction of digital feedback ‘kiosks’ onthe shop floor, where team members cangive immediate feedback and suggestimprovements to work processes. FC Laserbelieves that this digital feedback system isunique within the industry.

Customer service is at the very heart ofeverything that the team at FC Laser does,utilising its ‘5S’ continuous improvement

process. Steve Connolly, general manager,explains the benefits of this to both thebusiness and its customers. “ Since theintroduction of ‘5S’ we’ve seen a bigreduction in errors in production due tomisinformation. There has been improvedteam working and it helps engender a morepositive attitude to work, enabling us to geteven the most challenging jobs out of thedoor, on time and to budget. With ‘5S’ inplace, we have a platform on which to buildour future growth, based on quality, serviceand value for our customers.”

Everything FC laser does is about makingthe process of laser cutting, folding andfabrication as efficient and asenvironmentally friendly as it can. In fact, theBystronic Bystar Fiber uses 30 percent lessenergy than traditional 6 kW CO2 machinesand therefore helps to reduce the business'scarbon footprint.

The layout of the new 20,000 sqmstate-of-the-art production unit in Ilkeston,conveniently located just off Junction 25 ofthe M1 motorway, has been meticulouslyplanned for maximum efficiency; helping toreduce customers’ manufacturing and shopfloor handling time. Everything has itsspecific place within clearly marked baysallowing for safe and efficient forklift dropoff and collection points with a continuousworkflow ensured, no matter how busy thefactory is throughout its 24 hours a day,seven days a week shift pattern. Combinedwith its innovative ‘lean’ working practicesthe company has a unique offering thatcustomers seem to appreciate. Workinghand-in-hand with customers and rawmaterial suppliers, FC Laser’s

FC Laser experiences impressive growth

Managing Director, Danny Fantom, FC Laser Ltd

LASER CUTTING

knowledgeable account management team help to achieve thecompany's ISOQAR UKAS ISO 9001 accreditation.

Despite rising raw material prices, FC Laser prioritises deliveringvery competitive pricing for its customers by providing a quickerand more efficient cutting, folding and fabrication service. This isdue to the sophistication and technical excellence of its Swiss madeBystronic lasers and presses.

FC Laser’s unique approach to account management means thatits designers, engineers and production operatives can concentrateon the job in hand without having to worry personally aboutcustomer deadlines, cost estimates or delivery schedules, whilstworking towards the highest levels of customer service and productquality. The FC Laser ‘OTIF’ (On Time in Full) measurements aresome of the highest in the country and is one of the most importantKPI’s that the whole team focus on.

The business is on a rapid growth trajectory, despite an uncertaineconomic outlook in the U.K. and Europe. FC Laser has seen littlestaff turnover, in fact with numbers steadily increasing beyond thecurrent 55 workers, the business is keen to take on more staffespecially apprentices who can benefit from FC Laser’s unique stafftraining and development programme. Part of this growth is due inno small part to the care and attention that is put into staff welfareand development. From internal ‘quality forums’ to regular financialperformance presentations, the management team work hard tokeep everyone well informed and fairly remunerated, with regularperformance bonuses no matter what level they operate at withinthe business.

The future growth of the business is just as reliant on financial

investment in its people, as it is in having the very latest high-techmachinery. A strategic growth plan over the next few years will seeFC Laser expand its operation at the Ilkeston site with extraproduction capacity within the main unit. A new Mezzanine floor hasrecently been constructed to house the ever-increasing list of theplant to service its customers in the architectural metalworking,shop fitting, general sheet metal work, stainless metalwork andautomotive industries. The production site has ample potential forexpansion should space become a premium in the current unit overthe coming years, a nice problem for the team at FC Laser to have.

FC Laser Tel: 0115 944 3428Email: [email protected] www.fclaser.co.uk

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LASER CUTTING


Established in 2010 by Dave Mawer andMike Barratt, D & M Design & Fabricationhas seen dramatic progression since thejoint owners started running the businessfrom the former's bedroom and the latter'sgarage. At the time, neither thought thatseven years later they would buy one of themost advanced fibre laser cutting centres onthe market, a Bystronic 10 kW ByStar Fiberwith automated sheet handling.

In May 2017, the machine was installed inone of the firm's factory units in KirkbyMalzeard, in the Yorkshire Dales near Ripon.Capable of processing 3 m x 1.5 m sheet, itemploys the highest power fibre lasercurrently available on a cutting machine.According to Mike Barratt, it is about 10times faster at processing 10 mm thickmaterial than D&M's previous Bystronic3.3 kW CO2 fibre laser machine bought fiveyears earlier. A sheet can be completedtypically in less than 40 minutes, rather thansix hours.

Mike Barratt says: “We were previouslystruggling to keep up with laser-profilingour material, despite running the CO2

machine around the clock, six days a week."With the speed of fibre technology, we

are easily processing more material per dayin a single shift and now only work five daysa week. The fibre machine stands idle forsome of the time at present, as it finishesall the work going through the shopso quickly.”

Dave Mawer adds: “With an eye to thefuture, we specified the machine with aninline ByTrans Extended handling system toautomate supply of material to the machineand return of laser-cut sheets.”

Between 2014 and 2016, annual growth inturnover of the company was 10 percent.

This jumped to 20 percent in 2017 due tothe efficiency of fibre laser cutting and thisrate of increase is continuing through 2018.Work is flowing in from a broad spread ofsectors including automotive, constructionand food and involves cutting mainlystainless steel, mild steel and aluminium.

Additionally, fibre laser technology allowsreflective materials like copper and brass tobe cut without damaging the optics, unlikewith CO2, so expands the range of work thatD&M can take on. For the same reason, fibrealso helps when cutting aluminium.

The two company directors had access toa lot of advice before they bought their firstlaser cutting machine in May 2012, as untilthen they had been putting this work out tosubcontractors. Visits to their factoriesrevealed the makes of laser cuttingequipment commonly in use and one of themost popular was that supplied by Swissmanufacturer, Bystronic. At the time, therewas not much to choose technically betweenthe different CO2 offerings. However,Bystronic was selected due to the UKsubsidiary's more personal sales approachand the level of service offered.

This was again the case when the ByStarFiber 3015 was purchased. Dave Mawer hadwitnessed its launch during the BLECH 2016exhibition in Germany and subsequentlyvisited the Bystronic factory in Niederönz tosee the machines being built. Impressed bywhat he saw, he was finally convinced by the

10 kW laser source, higher power than onother machines offered and capable ofcutting material up to 30 mm thick.

Both D&M partners regard the onsitetraining provided by the supplier ascomprehensive. They also think the BySoft 7software is efficient for nesting and easy touse, especially when transferring designsfrom their SolidWorks CADCAM seat intothe Bystronic control to create the cuttingroutines. Cut pieces are invariably folded onD&M's six press brakes and powder coatedon-site before delivery to customers.

Such is the success that D&M is enjoyingthat expansion plans are already under way.The unit housing the fibre laser machine isbeing extended and by mid-year will includea deburring facility. Later in 2018, the shopcontaining the company's press brakes willalso be enlarged to accommodate a newpowder coating plant. Overall, the factoryarea will increase from 20,000 to28,000 sq ft.

Bystronic UK LtdTel: 0844 848 5850Email: [email protected]

Fabricator doubles growth rate withfibre laser cutting

LASER CUTTING


Lasered Components Ltd, a Braintree-basedspecialist in laser-profiled sheet-metal parts,has recently installed three TRUMPFTruLaser 5030 fiber machines. Replacingmachines of a different make, the trio ofTRUMPF models provide 10-20 percentmore speed across all materials, along withhigher levels of machine reliability,ease-of-use and product consistency.

With over 20 years’ experience in lasercutting, Lasered Components is owned andmanaged by father and son team, Kevin andKarl Willett. The company has a growingreputation serving a wide range ofindustries, including construction, retail,automotive and ducting, both locally andnationwide. As a result, LaseredComponents today employs 31 people andhas registered some impressive growth inrecent years. The company has just finishedits financial year, recording a 27 percentincrease on the previous 12-month period,which in turn was 40 percent up on theyear before.

At the heart of Lasered Components’operation is its desire for continuous

improvement, which is achieved throughambitious, structured investment in plant,processes, premises and people.

As a result of trials at TRUMPF’s facilitiesin both Luton and Germany, along with anappreciation of TRUMPF’s large UK supportteam, the company opted for TruLaser 5030fiber machines. Two were installed in 2017,with the third arriving in March 2018.

Lasered Components uses its profilingmachines to process mild steel from 0.5 mmto 25 mm thick, and aluminium and stainlesssteel from 0.5 mm to 20 mm, with batchsizes ranging from 1-offs to 200,000 in someinstances. There are two weekday shifts inoperation at the company, as well as apartial lights-out shift of 2-4 hours where theTRUMPF machines run unmanned.

As stated the TRUMPF models are 10-20percent faster across all materials than themachines they replaced. Moreover, themachines are equipped with the TRUMPFHighspeed Eco capability which canincrease sheet throughput by 100 percent.Additionally, Highspeed Eco reducescutting gas consumption by up to 70percent.

All three TruLaser 5030 fiber machines atLasered Components were secured with thehelp of TRUMPF Financial Services, and thecompany was more than impressed with theoutcome.

Karl Willett concludes: “TRUMPF FinancialServices were easy to deal with and offeredmore competitive rates than we could findelsewhere. In addition, they provided somegood flexible options should they berequired in the future.”

TRUMPF LtdTel: 01582 725335Email: [email protected]

Lasered Components boosts output 10-20 percent

LASER CUTTING


Laser cutting systems were initially poweredby assist gases, with CO2 hybrid machinestaking the industry by storm. The hybridelement allowed the cutting head to movein one direction and the sheet of metal tomove in the other, but on average a CO2

machine would take around 10 to 15minutes to reach the right energy level to beable to start cutting.

CO2 lasers, while effective, also consume aconsiderable amount of electricity. Theyalso use many working components such asturbo-blowers to produce the cutting laserlight. I remember installing 200 KVA to ourfirst industrial unit, at that time it was onlyenough to power two laser machines.

Prior to 2000, punching machines werethe method of choice. Using multiple punchtools, it would essentially punch shapes andprofiles into a sheet of metal. Punchmachines were more economical than CO2

lasers, however, the tools became blunt veryeasily and would be costly to replace.

Sheet metal cutting was beginning itsrevolution by the year 2000, and lasers werestarting to gain traction. The concept ofusing just one tool, a single focused laserlight, with the main consumables beingnozzles and lenses took the industry by

storm. These machines proved much morecost-effective too when compared topunching due to the no contact features. Aswell as offering this precise and quick cut,these machines are much quieter than othermachines. Our productions managerthreatened to leave if we ever buy a punchmachine as they’re so noisy.

Lasers quickly outsold punches in the early2000s. It was these successful sales thatfuelled a technology battle between someof the world’s leading machinemanufacturers with Japan’s AMADA,Germany’s TRUMPF and Switzerland’sBystronic leading the way. Each companycompeting to meet the demands of themarkets and to win the next machine order.

In the meantime, there was a new playeron the field, fibre lasers.

Fibre lasers use diodes to produce laserlight. It sends light down a fibre optic cablestraight to the cutting head with the abilityto start up and shut down instantly.

Just two years after they appeared on themarket, in 2012, fibre lasers wereeverywhere offering unheard of results.Capable of processing 0.6 to 20 mmjob-shop thickness and the ability to cutmuch faster, electric consumption wasreduced to a third. In the space of two years,these revolutionary machines had becomemainstream and over the next six months, 80percent of manufacturers’ books were filledwith orders for fibre laser systems.

Our fibre laser arrived in May of 2014 and

completely revolutionised the company.Imagine a machine capable of performing atthree times the capacity with a third of therunning cost of the previous machine.

The profits from this created an industrygiant. This giant, based in Russia, spentyears creating a unique laser source. When itfinally launched this revolutionarytechnology, it was leaps and bounds aheadof any other sources on the market andbecause of this, almost every laser cuttingmanufacturer began purchasing it to use intheir machines. Hundreds of new lasercutting machine manufacturers appeared onthe market in a short space of time followingthis introduction.

The technology advancements in such ashort space of time have had a significantimpact on the industry. It has enabledmanufacturers to not only reduce energyconsumption and cut costs, but it has alsoled to an increase in productivity andbetter-quality output. When we look to thefuture of laser cutting, what’s on thehorizon? Light is the fastest thing in theworld and we’ve managed to capture itwithin a machine and focus it to a point,what could advance on this? We’ll have towait and see.

Malton LaserTel: 01653 697770Email: [email protected]

The evolution of laser cutting systems Laser cutting has been a metal cutting method for almost 60 years. During this time, the processes and technology have changed anddeveloped drastically and there’s a number of options on the table for a company looking to invest in a laser cutting system.Charles Corner, managing director of full-service sheet metalwork manufacturer, Malton Laser, discusses the evolution oflaser cutting

LASER CUTTING


Gratnells Engineering exhibited at theAdvanced Engineering Show last month atthe NEC in Birmingham.

As a member of the AILU, GratnellsEngineering featured in the Laser Hub in thecentre of the exhibition. In 2018, thecompany invested in a new state-of-the-artBLM LT Fiber machine, allowing theHarlow-based company to expand itscapabilities and ensure clients benefit fromeven faster turnaround times.

This brand-new machine now sits next tothe existing LT5, a laser tube cuttingmachine designed to cut from small tomedium diameters and thicknesses of metaltubular sections. The LT Fiber allows tubesof any shape to be cut, process of specialsections and even open shapes without anyadditional special equipment required.

Tube laser cutting was of keen interest tomany visitors at this year’s AdvancedEngineering Show, with the technologycontinuing to grow in popularity as it offers aquick route to a precise finish, eliminatingconventional, time-consuming stages suchas marking out, sawing and finishing whilstdelivering significant cost savings.

Investing in the latest laser technologyavailable has increased GratnellsEngineering’s factory efficiency by allowingunloading to various positions, with finishedparts from one machine being unloadedwhilst production continues uninterruptedon the other. The need to manually separateparts from different orders has also nowbeen eliminated.

The Gratnells Engineering factory cannow turn around tube laser cutting jobswithin 3-5 days from receipt of order and,using sophisticated software, can processparts from a variety of media including 3Dmodels, xt files and solid works. This isparticularly beneficial for bespokeautomotive and point-of-sale components

where the minimum quantities can startat one.

Operations director Loic Jones concludes:“Gratnells Engineering decided to invest instate-of-the-art laser technology to enableus to offer fast production runs with the bestquality finish, to our customer base. Wewere delighted to be exhibiting at this yearsAdvanced Engineering Show and enjoyedsharing our latest developments with themanufacturing and supply chainprofessionals in attendance.”

Gratnells LtdTel: 01279 401550Email: [email protected]

Gratnells Engineering showcases laser technology developments

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SAWING & CUTTING OFF


To realise its ambitions of being the UK’sleading independent profiling andprocessing company, The P.P. Group hasconsolidated its business interests bybringing its three manufacturing facilities inSalford, Gorton and St Helens, under oneroof in the form of a brand new 110,000 sq ftsix acre site in Oldham. Moving to its newfactory in 2017, the £9 m investmentincluded a 36 m oxy-fuel and plasma cuttingcell from Kerf Developments.

This significant investment is testament tothe success of a business that has a fivepercent 'book debt' limit on its client base.By limiting and spreading the risk ratio of itsclient base, the company has continuallyevolved to a position that it is now profiling,processing, fabricating and welding beyond12,000 tonnes of steel every year. Toemphasise how central the Kerf RUM4500goxy-fuel and RUM4500p high-definitionplasma cutting machine has become to thestrategy for continued growth. The machineis processing over 400 tonnes of steel eachmonth. This equates to almost 40 percent ofthe material that passes through the doorsof the 100-employee company.

Discussing the installation of the KerfRUM4500 cell, P.P. Group managingdirector, Peter McCabe, says: “In ourprevious factories we had a 9 m by 4 mplasma cutting machine for processing steelup to 40 mm thick and a 22 m by 5 m flamecutting machine for materials up to 200 mmthick. The machines were more than 10years old, they were unreliable and this wascompounded by poor service and support.Additionally, the machines were expensiveto run, not particularly user-friendly and themachine configuration didn't suit pendulum

loading. We made the business decision notto bring the machines to the new factory.We looked at replacing them with a moreefficient, productive, cost-effective anduser-friendly solution. Kerf Developmentshad exactly what we were looking for.”

With plasma and flame cutting beingcentral to business activities, getting themost suitable machine was critical. Thebespoke production cell configuration,selected by The P.P. Group, was a 12 m by3.5 m bed with an RUM4500p single gantry400 A Lincoln Electric high- definitionplasma cutting head. It features Ultrasharpcut technology and a 24 m by 3.5 m tablewith two RUM4 500 g gantries, each withfour oxy-fuel flame cutting heads, all on asingle platform. This single bedconfiguration has streamlined workflow andimproved throughput, whilst the 8 oxy-fuelheads have improved productivity by morethan 35 percent.

Peter McCabe says: “Since we installedthe Kerf RUM4500 system, the cell has beenoperating 24 hours a day and six days a

week. It is a major contributor to our growth.If it's not burning, it's not earning. Prior tothe Kerf installation, we didn't have theconfidence to sell our capacity as the oldmachines were inefficient, unreliable andthe machine beds were too high. Ourbusiness has grown by 10 percent in the yearsince we moved to the new factory and theKerf cutting cell is a major contributor tothis growth.”

The height of the bed on the previousmachines made loading and unloading achallenge for staff. The Kerf RUM system hasa larger bed than the previous two machinescombined and is positioned at anergonomically suitable height that makesloading and unloading convenient foroperators. The large bed also allows thecompany to conduct pendulum cutting. The12 m bed section of the Kerf plasmamachine was designed purely for pendulumcutting, as carbon steel plates are suppliedin 6 m lengths as standard.

Peter McCabe continues: “The Kerfsystem has reduced cycle times by 50percent due to the facility for pendulumcutting. The Burny 10 LCD CNC control unitis very easy-to-use and it makesprogramming profiles fast and efficient. Thekinematics of the Kerf machine combinedwith the Burny 10 control and the Ultrasharpcutting technology, enables us to nest ourparts with precision and proximity thatwasn't previously feasible. This is reducingour waste material and allowing us to cutmore parts from each plate.”

Kerf Developments LtdTel: 01706 757 670 Email: [email protected] www.kerfdevelopments.com

P.P Group cuts route to success with Kerf

SAWING & CUTTING OFF

In its endless pursuit of excellence inbandsaw blade cutting performance,Bahco’s design and manufacturing team hasdeveloped a new blade, the 3858 SandflexP9000 PQ™.

Now available in the UK and Ireland, thisbi-metal blade is produced using highlyalloyed Powder Metallurgic HSS. It isdesigned for high-performance cutting of alldifficult materials, including hard andexotic materials.

This manufacturing technique improvesthe hardness and toughness of the blade,resulting in excellent tooth edgeperformance, improved wear resistance andlonger blade life.

The P9000 will cut a wider range ofworkpiece sizes and shapes thanconventional blades and deliver an excellentsurface finish on all materials. Moreconsistency in the hardness from batch tobatch increases blade reliability.

This remarkable new blade retains all thebenefits of a traditional PQ, thanks to aconsistently precise tooth height, enablingevery tooth to give the same chiploadwhen cutting.

This results in more even tooth wear,which extends tooth life. It also limitsthe risk of overloading a tooth,guarding against tooth breakage. Thetooth design improves cuttingperformance in special alloys with workhardening properties.

Alan Rankin, industrial tool specialistat Bahco, says: “Powder MetallurgyHSS provides an effective alternative toconventional HSS steels, delivering highhardness and toughness properties whichcan’t be obtained with traditionalhigh-speed steels.

“It also has the ability to use alloyingwhich is not possible in conventionallymelted HSS, allowing more advancedalloying while still having a superiormicrostructure and stability. This truly leadsto an excellent performance of thetooth edges.”

For detailed technical information,including test performance statistics, visit:www.bahco.com

SNA Europe is a premier pan-Europeanmanufacturer of hand tools and saws, part ofSnap-on Incorporated.

It designs and manufactures tools andsaws tailored to the most demandingprofessionals, focussing its design oninnovation, performance and ergonomics.As innovators for over 165 years, it hasintroduced the most advanced tools in theworld and sells through distributors withwhom it builds long-term partnerships.Bahco products are overwhelminglymanufactured in its own factories locatedacross Europe and offered by its partnerdistributors to professionals.

SNA Europe (UK & Ireland)Tel: 01709 731731Email: [email protected]

Bahco team develops new bandsaw blade

Oxy-fuel, Plasma, UltraSharp and Waterjet Cutting Technology

Machine sales, service, support and consumables

Call us on: +44 (0)1706 757 670www.kerfdevelopments.com | Email: [email protected]

Kerf Developments Ltd, Unit 1a Eagle Technology Park, Queensway, Rochdale, OL11 1TQ

For solid, reliable

down to earth advice,

contact Kerf today.

Feature - WELDING


Kverneland Group is a leading international developer,manufacturer and distributor of agricultural machinery and services.At its factory in Klepp, South West Norway the company producesploughs that are renowned for their longevity thanks largely tounique Kverneland steels and the company’s in-house hardeningprocesses. State-of-the-art automation ensures that productivity isvery high, and Kverneland Group Operations Norway AS continuallyinvests to ensure it remains a leader in plough production. Onerecent development has been the upgrading of six robotic weldingcells to use ESAB’s endless wire, which has resulted in improvedproductivity and significant cost savings.

The six welding cells are now consuming ESAB FILARC PZ6105R1.4 mm welding wire at a combined rate of 120 tonnes per year.Previously, Kverneland was using ESAB’s Marathon Pac bulk drumsof welding wire, which contain far more wire than conventionalspools, but the recently added ‘endless’ technology features aportable butt-welding device to join the end of one Marathon Pacdrum to the start of the next so the robotic welding operation isnever interrupted. Kverneland can now leave the robot cells runningovernight, unattended, which is saving the company approximately£10-15,000 per year. Furthermore, Kverneland no longer has toscrap the wire at the end of the Marathon Pac, which it previouslyhad to do sometimes in order to avoid the wire running outmid-weld; this elimination of waste results in another directfinancial saving.

ESAB FILARC PZ6105R is a metal-cored wire for robotic weldingof single- and multi-pass fillet welds in the downhand andhorizontal/vertical positions. As welded, the typical mechanicalproperties are 32 percent elongation, tensile strength of 558 MPa,yield strength of 453 MPa and a Charpy impact value of 55 J at-40°C. Depending on the welding parameters and wire feed speed,1.4 mm diameter PZ6105R can be deposited at rates of up to 7.2kg/h. Thanks to these properties and the wire’s excellent startperformance, arc stability and good feeding characteristics, FILARCPZ6105R has proved to be an outstanding choice for weldingKverneland’s ploughs.

To help maximise the productivity of its robot welding cells,Kverneland invited ESAB’s Value Added Engineering (VAE) team toundertake a study. Odd Lorentz Pettersen, team leader atKverneland Group Operations AS, explains: “The VAE teamanalysed the welding process for each segment of the welds andundertook tests at the ESAB process centre in Gothenberg. Theythen made recommendations for the robot welding speeds so thatwe could reduce the cycle time without compromising quality. Allsix robots are different and they all perform slightly differentwelding operations, so the VAE team had to look in detail at all sixrobot cells. As a result of the VAE project, we are now saving about£20,000 per year.”

There are some applications for which robotic welding isunsuitable, so Kverneland has recently invested in 20 ESAB Warriorwelding machines. These multiple-process welding machinesbenefit from inverter technology coupled with simple controls and abright, clear display. Importantly for Kverneland, the machines arealso very robust and have proven to be extremely reliable.Compared with the machines Kverneland previously had for manualwelding, the Warriors are easier to use and achieve higher-quality

welds. When welding with ESAB FILARC PZ6105R wire, themachines are easy to start, have good gap-filling capability andproduce a good finish.

Odd Lorentz Pettersen says: “ESAB machines are robust, reliableand produce high-quality welds. The welding wires are also verygood and we have made significant savings by switching to endlesswire for the robotic welding processes. ESAB is a great company todeal with, the people are always very helpful and the VAE teamachieved excellent results by optimising the roboticwelding processes.”

Kjetil Hansen, sales engineer with ESAB Norway, concludes:“Kverneland is always interested in looking at new ways to do thingsso as to remain at the forefront of plough production. And our VAEproject showed what can be achieved when you take a fresh look atan automated or robotic welding operation that you think isalready efficient.”

ESAB Group (UK) LtdTel: 0800 389 3152Email: [email protected] www.esab.com

Endless wire cuts cost of welding

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WELDING


The Fohnsdorf Training Centre is located inStyria, Austria. To train welders it uses avirtual welding system, the Virtual Weldingsimulator from Fronius. The simulatoremploys a virtual trainer to provide 1:1training for the centre’s students, anapproach that has a positive impact ontraining quality.

A young student carefully guides thewelding torch. The weaving motions shemakes as she welds the single-V butt weld infront of her appear very composed, animpression that is confirmed by theconsistently positive feedback from hertrainer. A colleague next to her practiseswelding a pipe, and he too has a trainerlooking permanently over his shoulder.Students on the welding training course atthe Fohnsdorf Training Centre have accessto five such “personal trainers”. However,these are not real people, they are alltotally virtual.

The Fohnsdorf Training Centre is one ofthe most modern and innovativeprofessional training establishments inAustria. Situated in Murtal in Styria, it hasbeen operating on behalf of theEmployment Agency since 1975 to providespecialist staff for commerce and industry.Its emphasis on practical experience andability to adapt to the requirements ofbusiness enable it to broadly fulfil itsobjective of integrating its students asquickly as possible into the country’s labour

market. A success rate of 53.4 percent, in2016, was the highest in Austria.

The training courses on offer cover themetal technology, electrical engineering,tourism and office/IT sectors, plus the moregeneric areas of CAD, languages, transportand logistics. Around 1,500 students passthrough every year and acquire newopportunities in the workplace throughtraining, higher qualifications andprofessional reorientation. They aresupported in their endeavours not only by170 highly qualified employees, but also bythe latest teaching methods. The FohnsdorfTraining Centre utilises various digital

approaches, such as e-learning, blendedlearning and e-testing, to provide thestudents with state-of-the-arttraining facilities.

Its desire to keep up-to-date with thelatest developments and maintain thehigh-quality of its training led to the additionof two welding simulators to the Centre’straining operations in 2010. Initially, VirtualWelding was primarily used to assess thesuitability of students interested in awelding course. Virtual Welding was thengradually introduced into the trainingprogramme and there are now five weldingsimulators in use at Fohnsdorf.

Learning to weld with a personal trainer

WELDING


The Fronius Virtual Welding system is awelding simulator that allows users to learnand practise the use of various weldingprocesses in a virtual reality (VR)environment. The processes currentlyavailable are: manual arc welding, gas metalarc welding (MIG/MAG) and tungsten inertgas welding (TIG). Single-V butt welds, filletwelds, square butt welds, pipe joints andoverlay welding can all be practised invarious positions using plastic workpiecesattached to the stand-up terminal. Awelding torch is used to create a seam that isdisplayed in real time on the simulator’stouchscreen display and the 3D glassesworn by the user.

“Ghost”, the virtual trainer, is a huge assetwhen learning how to handle the torch. Itshows the path the torch should take andindicates the correct speed, angle anddistance between torch and workpiece,giving direct, visual feedback when thestudent starts to drift away from one of theset values. At the more advanced levels,welding is unguided, in other words theGhost does not show the correct torch path.However, even here it offers support in theform of a playback function in which userscan see not only their weld, but also review

the complete welding operation.Feedback is provided by displaying thetorch path taken by the user and therecommended one at the same time, sothey can be directly compared.

The one-on-one training facility and theability to carry out “virtual practising” hastransformed welding training inFohnsdorf, as the highly material-intensiveearly stages of imparting the basic skillsand torch guidance can now be simulated,resulting in savings in resources and costs.The risk of injury is also reduced as studentsare trained in how to handle the torchbefore being confronted by high levels ofheat and a dazzling arc. However, the mostimportant aspect is the effect on learning.

Virtual welding helps save time, as there isno need for any pre- or post-processing ofworkpieces during the initial stages oflearning a new process. The FohnsdorfTraining Centre uses the time saved tointensify the training by providing moretime to practise and to weld moredemanding workpieces.

The students have generally respondedvery favourably to Virtual Welding.However, it’s when the rankings appear,which display the percentage points

awarded for torch guidance, that VirtualWelding starts to generate something of acompetitive atmosphere. Another didacticfeature observed by the head of departmentis that the learning process with VirtualWelding is highly intuitive.

The valuable experience acquired by theFohnsdorf Training Centre has made it animportant partner for Fronius in the furtherdevelopment of Virtual Welding.

Fronius UK LtdTel: 01908 512300 Email: [email protected] www.fronius.co.u

MacGregor Welding Systems hasintroduced the new MACGREGOR TR-16ATouch Retract Welding Torch. It is ideal forthe rapid design evaluation of electricvehicle battery pack concepts in researchand development settings, low to mediumvolume battery pack manufacturing, andbattery pack repair and rework applications.The TR-16A Touch Retract Welding Torch isa great choice for those scaling up from R&Dto manufacturing, offering ease-of-integration and automation.

The TR-16A Touch Retract Torch is alightweight, handheld tool that allows easymanipulation of battery cans and tabmaterials in a bench-top, R&D environment.The system can be used with typicalprototype tooling. The system has beenextensively tested for welding copper,nickel, and aluminium battery tab materialsup to a thickness of 0.5mm onto 18650 and2170 battery can material.

Compared to traditional resistancewelding technologies, the TR-16A TouchRetract Torch can achieve effective welding

of copper with relative ease. Its low voltageoperation also offers safety advantages forhand assembly applications compared tomany tungsten inert gas (TIG) systems.

At a lower cost than a typical laser system,the system is a more affordable option forlow volume battery pack prototyping, racingvehicles, and small to medium scale batterypack rework. The flexible TR-16A enablesbattery pack concepts to be quicklymanufactured and tested. It can also beincorporated into an automatedmanufacturing line, making the TR-16Aappropriate for low to medium volumeniche automotive production applications.

MacGregor Welding Systems is part ofAmada Miyachi Europe and provides provenresistance welder and micro arc weldertechnologies, with a long tradition as amarket leader in micro-connection. It is alsowell-known under its MACGREGOR brand.

MacGregor Welding Systems is at thevery forefront of the micro-joining industryand its continuous R&D programme enablesit to supply one of the largest choices of

micro-welding equipment availableanywhere. MacGregor Welding Systems isISO 9001:2000 approved and the businessoffers a full design, build and installationservice.

MacGregor Welding Systems LtdTel: 01638 510011Email: [email protected]

New TR-16A Touch Retract Welding Torch for electricvehicle battery pack applications

WELDING


Telsonic UK has established a reputation fordelivering robust technical solutions forchallenging welding and joining application,many of which are for automotivecomponents and sub-assemblies. In thislatest application for LAP Electrical, Telsonicwas called upon again to assist withdeveloping not only the tightly controlledprocess within a machine solution, but tohelp develop the underpinning joint designdetail required for a hermetic seal on crankcase ventilation valves.

The components in this application aremanufactured from glass filled nylon anddepending upon variant, have between fiveand six individual sub-component parts.The production solution also has to becapable of accommodating five productassembly variants.

Telsonic’s ultrasonic technology, suppliedfor this project, included a USP3000E Press,MAG-W020024-S 2.4kW welding systemtogether with a TCS-5 controller,touchscreen interface and a suite of Zappsteel sonotrodes, designed to suit thedifferent product types and incorporating aquick release tool change system. TheTelsonic controller uses individual weldrecipes for the different variants that includestaged pressure profiled electronic forcedelivery and weld collapse limits.

The ultrasonic welding system is fullyintegrated within a turnkey multi stationrotary indexing machine. The operatormanually places the loosely pre-assembledcomponents which are then welded,providing a repetitive, strong andhermetically sealed closure of the internalassembly components using the USP3000Esystem process control features.

Subsequent stations within the machineare used to perform flow and pressure tests

on the assemblies before all goodcomponents are laser marked, orientatedand unloaded from the machine by a pickand place unit. Any parts deemed as rejectby any of the station tests or the weldprocess are segregated at theunload station.

There were a number of technicalchallenges for Telsonic in this application.Different part colour, post mould part age,together with part supply from differentmoulders as well as sub-component parttolerances that required carefulconsideration when defining the joiningprocess parameters. Telsonic conductedprolonged tests with LAP at their UKlaboratory to develop the specific weldmodes and limits which would assure a

strong hermetic seal, capable ofwithstanding the rigorous airflowcharacteristics, leak test,mechanical shear and tensile testsrequired. Sonotrode design alsoplayed an important role indetermining the final solution,being carefully sized to achieve anear field weld across allcomponent variants.

The factors that resulted inTelsonic securing this business werethe company’s demonstration of adetailed understanding of the

process influences on the material and theproduct assembly and determiningrepeatable weld recipes for each variant.Finally, delivering a joining machine solutionin which LAP Electrical could have completeconfidence. As a result of this success, LAP isnow retrofitting Telsonic ultrasonictechnology to existing and older machinesas part of its upgrade programme.

Telsonic UK offers a comprehensive rangeof ultrasonic modules and systems for avariety of plastic and metal welding, cutting,sealing, cut’n’seal, food cutting andcleaning applications within a wide rangeof industries.

The company provides a full designfacility, using an FEA tooling package andjoint design recommendations as part of itsservice. Its range of plastic weldingequipment includes hand-held units, benchtop systems and bespoke welding systems.It has a range of equipment, aimed at theOEM market, to which it supplies actuators,generators, ultrasonic stacks, convertersand boosters, including tooling for specialistmachine builders to integrate into fullyautomated assembly systems.

Telsonic UK LtdTel: 01202 697340Email: [email protected]

Telsonic Ultrasonics seal the case for LAP Electrical

WELDING


K-TIG (Keyhole TIG) is a highly refinedversion of TIG/GTAW developed by theAustralian Government’s CommonwealthScience & Industrial Research Organisation(CSIRO). The patented technology is a resultof extensive, scientific study of thegas-tungsten-arc process and is the result ofmany innovations in arc characteristics, weldpool stabilisation, heat removal and processefficiency. This welding process has beenquietly adopted by some of the world’slargest and most productive stainless-steelfabricators and is also ideally suited to lowerconductivity materials such as duplex,super duplex, nickel alloys, titanium alloysand most corrosion resistant andexotic materials.

K-TIG has 8 x the penetration of GTAW,allowing it to perform x-ray quality welds inmaterials up to 5/8-inch, 16 mm, thick in asingle pass, without the need for edgebevelling. The resulting welds areperformed at up to 100 x the speed ofconventional TIG/GTAW. Gas consumptionis reduced by more than 90 percent and wireconsumption is reduced by in excess of90 percent or eliminated entirely.

The physics of the K-TIG processcreate high energy density in thewelding arc, allowing it to open upa ‘keyhole’ and fully penetrate thematerial being welded and weld athigh speed.

The minimisation of the surfaceenergy associated with the keyholegeometry and the relativelyunrestricted egress of the arcgases combine to produce anextremely stable and benign weldpool. The molten metal within theweld pool is prevented from falling from theroot face by surface tension created by theprocess.

The K-TIG torch is engineered to converta high current arc into a plasma jet whichfully penetrates the material and creates ahigh surface tension weld pool on theunderside of the material. By managing thesurface tension, K-TIG can hold and stabilisethe weight of the molten materialwhile welding.

The penetration capabilities of K-TIGvaries from material to material. It canachieve full penetration and single-pass

welding on austenitic stainless steel of ½inch, 13 mm thickness. A key advantage ofthis impressive penetration is that there is noneed for edge bevelling or a gap. All that isrequired is a simple square buttpresentation, and you’ll be ready tocomplete single pass stainless steel welding.

K-TIGTel: 0061 873246800Email: [email protected]

How to weld stainless steel with Keyhole TIG

The standards for the quality of orbitalwelding seams are extremely high. In orderto ensure they are met, a welding headorbits the round workpiece on a circularpath and this arc welding technology meetsthe required standards. The arc and weldingseam are protected against externalinfluences by inert shielding gases in thisprocess, guaranteeing a reduced failure ratefor the process along with very goodreproducibility of welding processes,thereby considerably improving theproduct quality.

Aside from the alloy composition, theelectrode geometry is also important heresince it has a significant influence on thewelding result. The Gesellschaft für WolframIndustrie mbH took this into account in thedevelopment of its two new ORBISTARelectrodes for orbital, tube and circularwelding, designed in close cooperation withusers. They set themselves apart withespecially good surface quality, accuratepoint grinding and a preciselongitudinal section.

Gesellschaft für Wolfram Industrie mbHhas been active in the fields of pure,thoriated, cerium and zirconium dopedW-electrodes as well as lanthanum andspecial electrodes for more than 100 years,incorporating this experience into the newelectrodes. Thanks to the use of rare earths,the ORBISTAR WS2 WITSTAR guaranteesgreat durability for all tube weldingapplications. As an alternative, Wolframoffers the ORBISTAR WLa 20 for workingwith frequent ignition sequences. It is idealfor the low-current range and for solutionswith thin-walled tubes. Process-specificalloys and dimensions, according toindividual specifications, are also possible,even angled electrodes up to a diameter of3.2 mm for interior welds in tubes.ORBISTAR is cost-effective, environmentallyfriendly and enables high quality. Shorter

production times make the electrode aneffective solution for all orbitalwelding tasks.

The company was originally founded in1911 as Wolfram Drahtfabrik GmbH for theproduction and processing of tungsten andmolybdenum in Berlin. The company wasrenamed to Gesellschaft für WolframIndustrie mbH in 1928. There are currently57 employees located at its Dachau locationand 63 in Traunstein.

Gesellschaft für Wolfram Industrie mbHTel: 0049 86198790Email: [email protected]

Orbital welding


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Laser Process help manufacturersto improve performance

• More than 20 years experience• Advanced, high speed laser systems• Project management• Technical advice• Highest quality standards• Nationwide delivery

Laser Process Ltd, Tel: 01543 495000Upper Keys, Cannock, Fax: 01543 495001Staffordshire WS12 2GE Email: [email protected]

www.laserprocess.co.uk

EDM WIREELECTRODE

MANUFACTURINGELECTRODE MATERIALS

ALL EDMCONSUMABLES

T: 01384 892011 F: 01384 897162s a l e s @ e r o d e x . c o m

w w w . e r o d e x . c o m

T H E L E A D I N G E D G E

CNC Lathes &Machining Centres

01706 648485victorcnc.com

Guyson International's advanced robotic blast systems for manufacturers of precision components

with demanding surface engineering topography requirements and any subsequent validation issues, typically medical implants and aerospace turbine blades.

with manual blast cabinets

Call Guyson now for a further information

Tel: 01756 799911 Email: [email protected] Web: www.guyson.co.uk

AUTOMATED BLAST FINISHING

CLASSIFIED SECTION

To advertise in this section please callJohn Barber on: 01403 266022

or email: [email protected]

Documents

Large or small precision laser cutting from the team …engineeringsubcontractor.com/wp-content/uploads/2018/11/...Large or small precision laser cutting from the team you can trust