Embed Size (px)
Citation preview
SWISS MACHINE TOOL INDUSTRY: Sector is becoming stable // Page 6
20years20years
2010
>
Sw
iss
Qu
ali
ty P
ro
du
cti
on
> MACHINE TOOLS
Automated manufacturingsolution for 5-axis machiningof complex pieces // Page 9
> CUTTING TOOLS
Two new coatings increasemilling performance by up to30 percent // Page 34
> DRIVE SYSTEMS
Shaft cooling improvesthe repeat accuracy of thetool centre point // Page 35
Swiss Quality Production
Ed
itio
n 2
01
0
01_Titel_CHe2010 07.07.2010 16:17 Uhr Seite 1
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
Meister AbrasivesInternationalwww.meister-abrasives.com
Make A Quality Decision
02_U2-U4_CHe10 07.07.2010 16:19 Uhr Seite 1
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
E D I TO R I A L
3
Slowly but surely, LIFE IS RETURNING to the machine tool industry. Some are already enjoy-
ing incoming orders on the level of 2005, others are still waiting for large orders and still others
are now faced with empty halls after shipping out long-running projects. Those who have sur-
vived are happy to be alive – although the forecast is: 30 percent of the machine tool manufac-
turers will not survive the crisis. The WORST RECESSION the industry has ever experienced
hardly cost taxpayers anything compared to the unimaginable sums that were required to res-
cue the financial sector. While companies are still struggling with the effects of the crisis – for
example, how to finance the economic upturn? – will the Swiss promotion of innovations sud-
denly run out of steam? Here it is a matter of an acute LACK OF INTEREST OF POLITICIANS,
although the machine tool industry in Switzerland is by far the world's most successful nation-
al industry, measured on the per capita value of machine production. And that despite compe-
tition with foreign companies with a development budget as large as the total turnover of the
Swiss companies.
Nothing would function without precision machine tool manufacturing. And nevertheless, it
receives insufficient attention from politics and society. Although TECHNOLOGICAL PROGRESS
is made possible in the first place by this industry. If we search for the reasons for the lack of im-
plementation of new technologies on the market, we often find: It is due to a lack of sufficiently
precise or sufficiently efficient production technology. Machine tool manufacturing in Switzer-
land must MOVE TOGETHER in every regard. Cooperation, joint development and joint repre-
sentation of our interests are the TOP PRIORITIES here.
Reawakening of the industry
The ideal material for tumbstonesAs the rapid traverse on modern horizontal machining centres is constantlyincreasing, the weight of the payload becomes obviously an importantpoint. Our tumbstones made of epoxy mineral casting are lighter in theirspecific weight than aluminium. In addition, vibrations are greatly reducedin a way that even in the upper end of the tumbstone high accuracy isguaranteed. In certain cases, as for instance when the fixture is designedwithout the base rail, that means directly mounted on the cube, the tumb-stone can be improved by a steel jacket. Triag customers are employingsuccessfully tumbstones with steel jackets since 2004. In most cases op-timal solutions can be found with standard Triag clamping devices.
Front Cover Advertisement>
Triag Precision Tools, Aussergrütstrasse 2, CH-6319 AllenwindenPhone +41 41 7272727, Fax +41 41 7272799> [email protected], > www.triag.ch
Prof. Dr. Konrad Wegener
03_SE810003_Editorial_CHe10 07.07.2010 16:21 Uhr Seite 3
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
C O N T E N T S
4
03 EDITORIAL
Reawakening of the industry
06 LEADING ARTICLE
Harbingers of the new age(Christoph Blättler)
09 MACHINE TOOLS
09 Two partners, a single aim
(Michael Hobohm)
12 When fractions of micrometrescount
14 Time gains thanks to innovativeprocessing possibilities(Robert Meier)
17 One for all(Dr. Tobias Schröder)
20 Kel-Vita with Kel-Portal
22 Close to the market(Michael Hobohm)
25 Cuts production times in half
26 CUTTING TOOLS
26 Conixs, B813 and the rollingwheel of the future(Thorsten Kaletsch)
29 Reaming: modular and easyto handle(Danijel Matosevic)
31 Easy presetting and longer tool life
32 Workpiece storage and chuckingtechnology in one
34 Off to new layers
35 DRIVE SYSTEMS
Cooling for the core(Rudolf Walter)
14
29
38
MACHINE TOOLS
Eight-spindle automaticlath reduces
throughput cycles
CUTTING TOOLS
Modular multi-edge reaming toolswith a high degree of precision
C-TECHNOLOGIES
›Joint competence‹ offers asoftware pool for all grinding tasks
Contents38 C-TECHNOLOGIES
38 Bundling core competences(Dietmar Ernst)
42 Full speed ahead(Christian Graber)
44 A software packagefor special tool solutions
45 OPERATING TECHNOLOGY
45 Good coating quality requirescleanliness
46 Swiss purity standard(Roman Bürge)
48 Precious metal hunts bacteria
49 From lubricant to liquid tool
50 ADVERTISERS' INDEXABOUT US
04-05_Inhalt_CHe10 07.07.2010 16:22 Uhr Seite 4
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
Worldwide uniqueEven the most complex work pieces can now be ground in one clamping. A new wheelhead
with two motor spindles for external grinding and an Internal grinding unit make this possible.
Now three wheels can be used to grind a workpiece to your individual requirements and
even faster than before – a complete machining in the extra class.
Fritz Studer AG
CH-3602 Thun
Tel. +41-33-439 1111 · Fax +41-33-439 1112
www.studer.com
S33 NEWThe reasonably pricedfor unrestricted grinding length & simplest programming.
04-05_Inhalt_CHe10 07.07.2010 16:22 Uhr Seite 5
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
L E A D I N G A R T I C L E
6
> The figures on the economic situationare quite clear: The Swiss machine, elec-trical and metallurgical (MEM) industryexperienced a severe setback during thepast year unparalleled by any other sinceWorld War II. The annual results for 2009of this industry highly dependent on ex-ports reflect the extremely low market ac-tivity in the various regions of the world.The machine tool industry as a classic rep-resentative of the industry was especiallystrongly affected by this development.
According to the quarterly reports of290 Swissmem member firms, there was adecrease in orders by one-quarter over the
entire year of 2009. If the individual quar-ters are considered, then the following canbe established: The clear downward trendhas slowed down in the course of the yearand has stabilised at a low level. With 27percent, the foreign demand decreasedmore strongly than the domestic demand,which dropped by 17.7 percent. However,the Swiss domestic market is considerablysmaller and therefore has considerably lessinfluence on the course of business. In cer-tain sub-industries, the dip in orders wasmuch more extreme and was in some cas-es 50 or even 60 percent.
The negative development for orders re-ceived has also had a major effect onturnover. It dropped by over 20 percent inthe past year – and for machines tools by
45.1 percent. Even if the demand shouldstabilise or even increase – as appears tobe the case for the orders received in themachine tool industry for the first quar-ter of 2010 –, it will be approximately twoquarters before it affects turnover.
Lasting low demand,
greatly reduced exports
The MEM industry, which is heavily de-pendent on foreign trade, was seriouslyaffected by the global recession that hashit every region of the world. Exportsdropped by 20.8 percent for the entire in-dustry, and for machine tools by 43.3 per-cent. Above all the major drop in demandfrom European countries, which are re-sponsible for approximately two-thirds
MEM industry looks with cautious optimism to the future
Harbingers of the new ageIn year one after the ›annus horribilis‹, the situation for the Swiss machine, electri-cal and metallurgical industry is becoming stable. Although 2009 proved to be a verybad year, a slow recovery with moderate growth is now expected.
BY CHRISTOPH BLÄTTLER
Figu
res:
Mik
ron
(lead
), S
wis
smem
/OZD
(1,
3, 4
), S
wis
smem
/KO
F (2
)
© Carl Hanser Verlag, Munich
06-08_SE110021_CHe10 07.07.2010 16:24 Uhr Seite 6
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
of all exports of the Swiss MEM industry,had a negative effect. The negative devel-opment of business was also intensifiedby the heavy decrease in exports to theUS. In comparison, business relations tothe Asian market held up best with a dropin exports of 11.4 percent over the entireyear (for machine tools it was even almostneutral). With minus 1.8 percent in thefourth quarter of 2009, the exports in thisregion were almost at the level of the pre-vious year.
As shown in figure 1, all product seg-ments showed a negative development.This was especially pronounced in themetal construction (-31.3 percent) andmechanical engineering (-25.9 percent)sectors, while the sub-industries of elec-trical engineering/electronics (-16.2 per-cent) and precision instruments (-7.2 per-cent) were not as heavily affected.
Low capacity utilisation,
cautiously optimistic outlook
The steep worldwide economic downturnabruptly followed a phase with extreme-ly high production levels and has led to adistinctly low utilisation of the capacitiesavailable in the Swiss MEM industry (fig-ure 2).With a quota of 77.5 percent, it wasapproximately 10 percent below the long-term average. This low capacity utilisationnot only negatively effects employment,but also the ability of the supply chain todeliver. At the moment, many companiesare still counting on short-time working.However, the recession has already had amajor effect on the labour market. In theMEM industry, approximately 21,000 jobswere lost within a one-year period. Nev-ertheless, in all probability employment inthe Swiss industry will not drop as low asin 2003.
If we want to believe experts on busi-ness activity, the worst is over for the SwissMEM industry. The situation has sta-bilised and a slow (!) recovery with mod-erate growth is expected. In fact, the esti-
mate of the companies surveyed by Swiss-mem has become more optimistic and acertain change in mood is noticeable.Over half the companies specified thatthey expect increasing foreign demand inthe near future; 35.5 percent are expect-ing a stagnating development. Neverthe-less, the situation will continue to be tensethis year, and the business prospects arelinked to great uncertainties. Even if theeconomic situation stabilises somewhatagain over the next several months, manycompanies will continue to work at re-duced capacity.
The figures
of the machine tool industry
With an output of Euro 2,182 million formachine tools including accessories, theSwiss machine tool industry achieved alow point worth remembering – or betteryet worth forgetting – in 2009. Almost allrelevant major markets, including the do-
mestic market, contributed to the de-crease with high two-digit percentages.Domestic turnover showed the secondlargest drop with 52.7 percent after thethird most-important export market Italy(-57.1 percent). Only markets like China,South Korea and India were able attractattention to themselves with barely neu-tral or even slightly positive figures. Thisin turn resulted in a reorientation of themost important sales markets. China hasjumped forward two places and is now thesecond most important export market ofthe Swiss machine tool manufacturers af-ter Germany (figure 3). It is interesting tosee the stabilising effect of sales in Germany,the US and France. It was possible to keepthe percentage of total sales stabile in thesemarkets. This means that Germany con-tinues to purchase one-quarter of Swissproduction or just under one-third of allmachine tool experts. As the volume inItaly dropped so sharply, this market
7
MANUFACTURERiSwissmemCH-8008 ZürichPhone +41 44 3844111Fax +41 44 3844242> www.swissmem.ch
Change in Swiss industrial exports in 2009 compared to the previous year by merchandise groups1
Change Export
Total
Mechanicalengineering
Metalconstruction
Precision-instruments
Electrical engi-neering/elektronics
Vehicles
-40 % -20 -10 0 10 20 30 40 50 60 bn./CHF 80
-20.8
-25.9
-31.3
-7.2
-16.2
-12.1
63.4
22.4
10.5
13.8
11.3
5.4
The ten-percent gap: Capacity utilisation of the Swiss machine, electrical and metallurgical industry at the end of 20092
Year
95
90
85
80
75
%
1997
Capa
city
util
izat
ion
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
06-08_SE110021_CHe10 07.07.2010 16:24 Uhr Seite 7
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
L E A D I N G A R T I C L E
now occupies fifth place among the ex-port markets – and will therefore soon beon approximately the same level as thepositively developing countries South Ko-rea and India.
Among the types of products sold,above all drilling and milling machines,parts and accessories and machining cen-tres have gained ground (figure 4). Partsand accessories meanwhile make up al-most one-third of total sales. However, theSwiss sheet metal working machines, orrather their manufacturers, experienced asmall Waterloo in 2009.With shrinking to-tal sales, they had to accept another ninepercent decrease.
The upward trend appears
to be mainly export-driven
If we look at the preliminary results of thefirst quarter of 2010 more closely, then thefollowing becomes apparent: Two sectionshave formed. The one with standard ma-chines and what tend to be short or medi-um delivery times,and the other with proj-ect-oriented machines and medium tolonger delivery times. For the first group,a considerable to strong upward trend isapparent, while for the second this can(still) only be seen in individual cases. Thepositive signs are not individual excep-
tions, id est we are not just talking about»one swallow in the sky«. Nevertheless, itshould still be noted: The upward trendfirst appears to be mainly export-driven,and several elements of uncertainty stillexist for the ›flight conditions‹. At thispoint I would like to point out three ofthese factors:■ The Euro/Swiss frank exchange rate
The relative instability in the Europeaneconomic/national structures – in par-ticular Greece – has led to a dispropor-tionate increase in the value of the Swissfranc. Not quite 50 percent of Swiss ma-chine tools are sold to customers in Eu-ropean countries. A fast and then per-sistent change in the exchange rate of 7to 10 percent can quite certainly decideon success or failure, existence or non-existence.
■ The supply chainIn the tough times of the past year, andin some cases even before that, stockswere reduced like crazy. Not only ma-chine builders,but also component man-ufacturers have occasionally rigorouslyminimised and even liquidated stocks.Now those machine tool builders are inthe lurch, who could show a strong in-crease in orders: Even without stocks,one would be happy to make greater use
of suppliers of parts and assemblies likeCNC controllers, connectors and a lotmore. This frequently leads to miscal-culations, as the manufacturer requiresseveral months to bring its productionup to speed and also has to struggle withminimal stocks of finished products.This is a challenge of a different kindwhich at least hinders the upward trend.
■ The capacity utilisation in the MEM in-dustryThe Swiss machine, electrical and met-allurgical industry itself is one of themost important customers for machinetools. At the end of 2009 the capacityutilisation of this industry reached itslowest value since the existence of theindicator. Many years of experience hasshown that companies with a capacityutilisation from approximately 85 per-cent make purchasing decisions for newinvestments. This means that here westill have to struggle with a gap of almost10 percent. This means: There are stillproduction capacities available, whichmust first be fully utilised.
Economy moves up and down with
the global situation synchronously
As a result, the environment often changesquite suddenly and the task is to adjust tothis in the proven Swiss way. With thatwhich we have and are capable of. Swissproducts are in demand,however the econ-omy – and that has changed with this cri-sis – now moves up and down with nu-ances in virtual synchronisation with theglobal situation. Therefore, the task is todeal with this and to make use of the greatinternational business experience gainedover many decades as a USP and a pointthat creates customer trust.And finally, wecan only hope that, after all it has experi-enced, the financial industry thinks betterof it and resourcefully makes credit avail-able for companies that create values andpreserve production jobs in our region. Sothat these companies can create the up-swing into a new age. ❚
8
Distribution of product types in 2009: Sales of machining centres and parts andaccessories showed an increase, however sheet metal working machines declined4
Machining centres 11 %Parts and accessoires 29 %
Other machines 4 %
EDM~ 4 %
Forming machines,Presses 7 %
Drilling and milling machines 8 %
Turning machines 4 %
Grinding machines 11 %
Gear cutting machines 4 %Sheet metal working machines18 %
Dipl.-Ing. (FH) Christoph Blättler is Director of the Professional Association ›Machine Tools and Production Engineering‹at Swissmem in Zürich/Switzerland> [email protected]
Something happened: Sales markets of the Swiss machine tool industry in 20093
Germany 25 %Others 23 %
Great Britain 3 %India 2%
Russian Federation 3 %
South Korea 3 %
Italy 4 %
France 5 %
Switzerland16 %
China 9%
USA 7 %
06-08_SE110021_CHe10 07.07.2010 16:24 Uhr Seite 8
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
M A C H I N E TO O L S
9
> The machine tool manufacturer Fehl-mann from Seon in Switzerland and theproducer of tooling, handling and processcontrol systems Erowa from Büron, alsoin Switzerland, have worked together since1992. The common aim has always beenthe provision of automatic manufactur-ing solutions that are tightly adapted toindividual customer requirements. Whatbegan in the nineties with the automa-tion of an initial Fehlmann system nowcovers a wide spectrum of products onboth sides.
»Strategically, Fehlmann in recent yearshas mainly pushed forward the concept ofmachine accessibility and turnkey inte-gration«,says Fabio Casteletti,Head of Mar-keting and Regional Sales Manager for themachine manufacturer. »Because of thephilosophy of complete turnkey systems,reliable suppliers are as important to us acontinuous cooperation. Of course we useexactly those components required by cus-tomers, although Erowa systems here havea high priority.« One reason for this is thewide spectrum of products enabling ahighly wide range of applications.The com-ponent size with end customers is only onecriterion, albeit an important one. »We al-
ways receive the right automation solutionfor the whole range of machines, from thesmallest one to the largest«, informs Caste-letti.»And the system approach from Erowanot only suits our philosophy of con-structing in a compact, accessible and lu-cid manner,but the physical proximity andstraightforward cooperation are highly im-portant factors for us.«
Designed for the 5-axis machining
of complex work pieces
A typical example of the collaboration be-tween both companies is the Picomax 825Versa 5-axis machining centre (figure 1).»Fehlmann contacted us at an early stage
5-axis machining centre with handling device and palletising system
Two partners, a single aimApplication-specific solutions are becoming ever more important with 5-axis machin-ing. Manufacturers of machine tools and automation solutions thus interconnectvia collaboration and at the same time make the most of their individual strengths.
BY MICHAEL HOBOHM
Figu
res:
Feh
lman
n (1
, 2, 3
), E
row
a (4
), H
anse
r (5
)
Automated manufacturing solution:the 5-axis machiningcentre Picomax 825Versa including RobotEasy handling device
1
09-11_SE110020_CHe10 07.07.2010 16:30 Uhr Seite 9
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
of product development in order to findout in which direction we were forcing ourautomation approaches«, remembersBernhard Steiger, Key Account Manager atErowa. »This knowledge was then takeninto account with the construction of themachine. The fact that Fehlmann turned tous in this phase of product developmentalso says something about the strength oftrust between the two companies.«
Designed with a portal construction,the Picomax 825 Versa was ultimately con-ceived as a 5-axis machine for the highestdemands (figure 2). The circular swivel-ling table is longitudinally integrated in-to the machine concept so that swivel op-eration is not influenced by the linear axes(figure 3).The table features a torque drive,mechanical clamps and direct positionsensors for both axes, giving the system aswivel range of 230° (±115°) and high dy-namics. Maximal loading of the high-rigidity table consists of 350 kg, the palletsize is 400✕ 400 mm and the parts diame-ter is 560 mm. The core of the Picomax825 Versa is an HSC spindle from Fehl-mann available in the variants HSK-A63with either 14,000 or 20,000 rpm and apowerful 120 Nm,or HSK-E50 with 30,000or 36,000 rpm and 33 Nm (15 Nm) torque.The tool changer with chain magazine in
the basic version offers capacity for 44tools to a maximum diameter of 130 mm,and an extension magazine with capacityfor up to 250 tools is optionally available.
»In accordance with our fundamentalproduct strategy, the Picomax 825 Versawas also designed as a flexible manufac-turing solution«, says Casteletti. »That'swhy we're able to approach a wide varietyof customers with the machine, rangingfrom single part manufacturers to seriesproducers within highly diverse industrysectors. In order to comply with our sys-tem approach we also have to provide allof these customers with automation solu-tions. Erowa in this regard offers us the re-quired bandwidth of services with a highlevel of product dependability.« The au-tomation is matched to specific customerrequirements in terms of pallet spaces andcapacity and design of the axes. At the endof it all this may consist of a solution withonly one or two machines or the construc-
tion of a complete linear automation sys-tem. The 5-axis machining centre can notonly be equipped with varying automa-tion concepts, but such concepts can beupgraded at any time. According to thenumber of pallets and parts diversity, thesystem is controlled and monitored via aclosed-loop pallet file or the flexible Fehl-mann MCM master computer system. Inthe latter case the MCM assumes completecontrol and monitoring of the robot andmachining centre. As a result of the highlevel of operator convenience of both themachine and MCM, the complete systemcan be implemented cost-efficiently bothfor series production and for small quan-tity runs.
»The automation of the Picomax 825Versa has been designed as either a linearor stand alone solution with the possibil-ity of flexible pallet change«, reports Caste-letti, who then immediately mentions thesecond aspect. »A high variety of different
10
The Picomax 825 Versa is designed forprocessing of complex components, shownhere with impeller milling
2 The Picomax 825 Versa's circular swivelling table with a range of ±115°3
MANUFACTURERiErowa AGCH-6233 BüronPhone +41 41 9351111Fax +41 41 9351213> www.erowa.com
MANUFACTURERiFehlmann AGCH-5703 SeonPhone +41 62 7691111Fax +41 62 7691190> www.fehlmann.com
09-11_SE110020_CHe10 07.07.2010 16:30 Uhr Seite 10
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
components can be clamped onto the pal-let and thus production prepared simul-taneously to manufacture.« In additionthe operator also has the possibility of en-abling the pallet system to be expandedupon. All Fehlmann machines are con-ceived so that automation can be added atany time. If for example the user has un-til a certain point benefited from the ad-vantages of manual pallet change, he cantake the step towards automationwithout having to forfeitinvestments madein pallets.
With Fehl-mann, two fun-damental tenden-cies can be seen withthe use of pallet systems. While automa-tion of a high level of work piece palletsdemands process control systems withwork piece identification, a low numberof pallets can be simply administered withintegrated pallet management via the ma-chine control. »That's the solution withthe Erowa Robot Easy«, says Steiger. »Withthis approach the Robot Multi is also usedas well, with 80 kg transfer weight, workpiece identification, potential gripperchange, dual machine operation and Ro-bot Dynamic for high parts diversity andhigh storage capacity.«
Thanks to monoblock construction, theRobot Easy is rapidly installed to the ma-chine and ready for operation (figure 4).With a transfer weight capacity of 250 kgit is optimally suited to moving Erowa MTSsystem pallets. The track path of the grip-per (x axis) consists of 1500 mm, and thehandling system offers magazine variantsfor all Erowa clamping systems, whetherfor ten UPC pallets (320✕ 320 mm) or sixMTS pallets (400 ✕ 400 mm). The inte-grated Erowa Manufacturing Control soft-ware ensures correct application flow, andalso controlling, managing and monitor-ing of the manufacturing cell, while at thesame time guaranteeing the consistency ofall production data.
»At present, the MTS, UPC and PC210systems are mainly implemented on thePicomax 825 Versa«, stipulates Urs Canon-ica, responsible for Marketing Services andPublic Relations at Erowa. »For one par-ticular customer application the MTS+ ze-ro-point system was considered that fea-
tures series monitoring for all conditionsin the clamping chuck.« Only two air ductsare required for controlling and monitor-ing conditions of the chuck such as ›Open‹,›Closed‹ or ›Pallet Present‹. For operatingthe MTS+, either a manual control boxwith monitoring display or an automaticsolution can be specified. And thanks to anew locking technology the systemachieves a high level of rigidity, backed upby a
repeat accuracy of three micrometres. TheMTS+ chucks achieve a clamping force ofup to 18 kN.
Added value via a partnership
between two companies
The MTS+ was adapted according to theconcept of a special complete system wherecustomer requirements were similarly spec-ified in detail:
■ Parts spectrumCubic components of (150 to 250)✕ 250✕ 250 mm, cast housing to maximum500✕ 500✕ 500 mm
■ Processing5-axis HSC
■ Lot sizesSmall series to 5 pieces (large parts, casthousings), series to 50 pieces (cubicparts),
■ Magazine capacityLarge parts to 12 pieces, cubic parts, atleast 50 pieces
■ Operating timesLarge parts 30 to 40 minutes, cubic parts10 to 20 minutes
■ Special parametersSimple prioritisation of orders, suffi-cient magazine capacity for the secondand third shift (optionally with week-end loads), simple and transparent eval-uation of orders and cell loads.
The solution approach drawn up by Fehl-mann based on these specifications con-sists of the Picomax 825 Versa with storagemagazine for 180 work pieces, the MTS+zero-point clamping system from Erowaand adaptation to PC210 pallets. Erowacompleted the production solution withthe Robot Dynamic featuring work piecemagazines for the large parts and cubiccomponents. As well as functioning as aloading station for infeed and outfeed ofthe work pieces, the Erowa ManufacturingControl software is used for control of thecell, evaluation of orders and the importof ERP and CAM data.
»Customers receiving such individualconfigurations gain additional benefits viaaccess to two professional, autonomous-ly active companies«, informs Casteletti.»With Fehlmann Erowa automation so-lutions, the customer purchases a com-plete solution that integrates customer-specific needs with the experience of along-term collaboration. Precise knowl-edge of the available machines and pe-ripheral devices in this regard enables thetargeted selection of an application-spe-cific technology that in turn generates op-timum results for customers.« ❚
11
Dr. Michael Hobohm is Editor-in-Chiefof Swiss Quality Production at Carl HanserVerlag in Munich/Germany> [email protected]
Diverse automation solutions with theErowa and Fehlmann product ranges: Bernhard Steiger, Fabio Casteletti and UrsCanonica (from left)
5
The Robot Easy can extend work pieceswith a transfer weight of 250 kg to a path of1500 mm
4
09-11_SE110020_CHe10 07.07.2010 16:30 Uhr Seite 11
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
> A new era has dawned on the banks ofLake Biel in Switzerland. Complex indi-vidual construction of the Mikron serieshigh-speed milling machines is com-mencing, consisting of the models HSM400, 400U and 500 LP Precision (figure 1),and the experts take advantage of hand-picked machine components with con-struction of the Mikron HSM LP Preci-sion. Each machine must prove its worthfor the future processing of sophisticatedwork pieces with extensive test cycles. Inaddition, the machine manufacturer GFAgieCharmilles, Nidau/Switzerland, has asolution at hand for process-safe toolmeasurement on the machine tool. The
potential of this functionality was recog-nised at an early stage, and evaluation ofintelligent alternatives was consequentlybegun several years ago. The result hasbeen named IntelligentToolMeasurement(ITM), and consists of optical tool meas-urement at full spindle speed. »Withoutthis technology, a Mikron HSM LP Preci-sion with its present features is practicallyunimaginable«, explained GF AgieChar-milles Product Manager Georg Scheiba.Because such technical progress also en-ables more efficient work strategies, eachcustomer receives specific technology train-ing dedicated to both the product andprocess control.
With the effects of high axial accelera-tions, tool paths must be precisely main-tained with minimal noise. Only in thisway is it possible to achieve the surfacequalities and contour accuracy of a MikronHSM LP Precision. Because heat loss oc-curs in all electrical machines, the drivegroups of a precision machine tool mustbe purposefully cooled. Each linear axis aswell as the circular swivel unit have theirown cooling circuit. The Opticool conceptwith spindle nose cooling ensures tem-perature stability, and the cooling man-agement prevents thermal flow from thedrive motors into the machine bed. Thisresults in a geometric stability that ensureshigh levels of repeat accuracy in the mo-tion control.
Precision with
tool geometry measurement
But what are the advantages for userswhen a Mikron HSM LP Precision is ableto implement minimal process steps of100 nanometres (1/10000 mm), but theimprecision with tool geometry meas-urement thwarts reproduction of this pre-cision class on the work piece? Anyonewho has attempted to precisely reprocessan overmilled surface using various tooldiameters is aware of the impossibility ofthis task. But precisely this must be en-sured if perfect transitions between sur-face sections processed with differenttools are to be achieved. One of the mainreasons for this can be found in the func-tional method of conventional laser toolmeasurement. Different tool geometrieslead to differing immersion ratios in thelaser beam and therefore to variations inthe absolute Z reference. Particles of dirtor oil drops adhering to the tool surfacemay lead to measurement results that de-viate from the actual tool contour. Whatis to do?
12
Producing specular surfaces on microstructures
When fractions of micrometres count
The Mikron HSM LP Precision machine series and intelligent ITM tool measurement– a formidable pair for high-precision processing.
The Mikron HSM LP Precisioncan implement minimal processsteps of 100 nanometres
1
Figu
res:
Mik
ron
Agi
eCha
rmill
es
12-13_SE310015_CHe10 07.07.2010 16:34 Uhr Seite 12
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
Tool measurement
in the micrometre range
The IntelligentToolMeasurement (ITM)method of tool measuring on the otherhand detects the complete tool tip to a di-ameter of 12 mm with image sensors (fig-ure 2). The digitally recorded tool geom-etry is digitally cleaned by software andonly then measured: ITM in this way en-ables tool measurement with an absoluteZ reference in the micrometre range. Thespectrum for high-precision processingranges from components for minimallyinvasive surgery and miniaturised flowparts to tool and mould making (for ex-ample for LEDs, reflectors and minimalform characteristics).
Exemplary for the precision class of theMikron HSM LP Precision machines arethe results achieved for example with a re-flector insert (figure 3). The basic materi-al to be processed consisted of high-alloy,powder-metallurgically produced CrVMosteel (C1.7 – Mn 0.3 – Cr17 – NiV3 – Mo1)with a hardness of approximately HRC 60.With average material abrasion in the fin-ishing process having an allowance of lessthan 10 μm,a mean roughness on the com-plete work piece surface of Ra=0.020 μm=20 nm=0.00002 mm was achieved. Themean roughness of Ra =0.020 μm corre-
sponds to the ISO roughness class N1.Thishigh-precision result was measured bothin advance direction and path infeed di-rection.
Performance limit is
approached by ›smart machine‹
In motorsport, vehicles only approachtheir limits when the pilot activates theelectronic support function, and in a sim-ilar way the high-tech milling machinesof the Mikron HSM LP Precision seriesonly draw near their performance limitwhen electronic software support in theform of the patented ›smart machine‹ OSSPrecision (Operator Support System) mod-ule is implemented. The machine opera-tor can influence the unit costs of thegoods produced with intuitive user guid-ance. Drive and control parameters areoverwritten by the control so that cus-tomers can exploit either the speed con-trol, surface quality or contour accuracyof the milling machine. ❚
Mikron AgieCharmilles AGCH-2560 NidauPhone +41 32 3661210Fax +41 32 3661239> www.gfac.com
The Intelligent-ToolMeasurement(ITM) methoddetects the completetool tip to a diameterof 12 mm
2
A specular reflectorinsert processed by aMikron HSM 400 U LPPrecision
3
ALESA Ltd.
CH-5707 Seengen
Phone +41 62 7676 262
Fax +41 62 7676 282
www.alesa.ch
POSITIVE
Sincegenerations
12-13_SE310015_CHe10 08.07.2010 15:42 Uhr Seite 13
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
14
> It's not only that lathed parts are be-coming ever more complex,causing greaterproduction expenditure in turn, but eco-nomic pressure on lathed parts produc-ers is increasing. Material prices and to agreater extent the manufacturing time perpiece represent some of the essential costfactors.
Because material prices are often deter-mined by the market, the only other way ofinfluencing costs is via production time.Multi-spindle automatic lathes such as theTornos Multi Sigma with 8×24 spindlesdemonstrate in such cases that today's tech-nical solutions are capable of achieving thedesired reduction in processing times (fig-ure 2).Eight dynamic motor spindles trans-form the automatic lathe into a highly pow-erful means of production, and because all
spindles have their own drive system, userscan assign the most suitable speed for thecorresponding process to each spindle. Afurther advantage of the motor spindles istheir rapid and precise indexing; all posi-tions are numerically defined via program-ming. No mechanical setting is required atthe machine itself, giving it a very high lev-el of flexibility.
Eight spindles give users the possibilityto separate processing operations on lathed
Multi Sigma 8 × 24 multi-spindle automatic lathe
Time gains thanks to innovativeprocessing possibilitiesLathed parts are becoming ever more complex and more difficult to produce, a challenge met by manufacturers of automatic lathes with more powerful machines.The effects of this are reduced lead times and lower manufacturing costs.
BY ROBERT MEIER
Lathed parts are becoming ever more complex in terms of form and functionality. A solution is production with multifunctionaland highly flexible multi-spindle machines1
Figu
res:
Tor
nos
14-16_SE110016_CHe10 07.07.2010 16:35 Uhr Seite 14
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
parts so that longer processing steps aresplit up into shorter ones, thus distinctlyincreasing the machine's part throughput.The possibility of several tools per spin-dle, in this case five, leads to even moreflexibility. Use of a counter spindle as withthe Multi Sigma is especially interesting.This is also equipped with five tools, al-lowing complete processing of the oppo-site side of the component. The result isnot only finished parts, but with the ex-tended processing possibilities, manufac-turing of ever more complex componentsis simplified with no surplus time invest-ed. Because the work steps on the count-er spindle may lead to bottlenecks in termsof time though, Tornos optionally offersa second counter spindle with five toolsas well for the Multi Sigma. This also en-ables splitting up of processing steps onthe opposite side, thus reducing through-put time of the parts.
The constancy of operating tempera-ture and the fact that the machine hasbeen designed for a high level of precisiontransforms the Multi Sigma into a high-performance means of production formedium-complex lathed parts in large se-ries. The automatic lathe's eight spindlesin addition also enable the production ofcomplex lathed parts. If on the other hand
simpler parts are required, the experi-enced operator will program the eight-spindle automatic lathe to 2× 4 and ap-proach the counter spindle with 2×2 toolsfor example. The increased efficiency thusachieved results in further distinct timegains for users.
High demands with the
production of bone screws
The processing of threads, especially withbone screws for medical technology (fig-ure 4), often proved to be a time-con-suming production step in the past. High-performance and economic solutions weretargeted here as well. Multi-spindle auto-matic lathes are fundamentally suitable forthis, but rational thread processing withsuch machines was hardly feasible untilnow because of the high complexity ofbone screw production. For a start, pro-duction quality demands prohibit burrs.As such, thread processing methods suchas thread rolling or thread cutting withturning tools are not tolerated, as these donot achieve the stipulated quality. In ad-dition, processing of materials such as ti-tanium and stainless steel place high de-mands on machines, tools and operators.Often screw heads also feature complexforms, making manufacture even morecomplex.
The method best suited to the produc-tion of threads is whirl threading. This isa time-consuming process though thatwas until now implemented with singlespindle automatic lathes. The Tornos en-gineers saw that transferring this manu-facturing technology from single to mul-
ti-spindle machines was relatively simple.And in fact such machines, designed forthe production of complex components,are indeed capable of producing not on-ly threads but in some cases highly com-plex screw heads as well. The Multi Sigmaautomatic lathe has eight independent mo-tor spindles for this purpose and one ortwo counter spindles, each with five pro-cessing tools.
The concept of reducing processingtime is based on implementing whirlthreading according to thread length, sep-arated into two to three work steps. Thechange of processing position from onethreaded section to the next was not to beunderestimated, and was a task that theTornos engineers were capable of solving.They in addition achieved the division ofthe whirl threading process without thisbeing detectable on the bone screw post-processing.
Processing time for a bone screw
five times shorter
The results speak volumes: the processingtime for a bone screw with a total lengthof 80 mm is five times shorter with a Mul-ti Sigma 8×24 than with a single spindleautomatic lathe. In addition, the bonescrew, as with other lathed parts, leaves theautomatic lathe as a completely finishedlathed part. Thanks to this process the re-sponse capability of the lathed part man-ufacturer is also increased; instead of hav-ing several single spindle automatic latheshe now needs to configure only one mul-ti-spindle machine for larger series. Qual-ity is impressive as well. Because the whirl
15
MANUFACTURERiTornos S.A.CH-2740 MoutierPhone +41 32 4944444Fax +41 32 4944903> www.tornos.com
The eight-spindle Multi Sigmafrom Tornos enables processing of lathed partswith differing complexity and with significantly reduced throughput cycles
2
14-16_SE110016_CHe10 07.07.2010 16:35 Uhr Seite 15
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
tool never leaves the processing zone, theoperating temperature during the com-plete series remains constant, thus in turnensuring uniform quality thanks merelyto the machine concept. With multi-spin-dle automatic lathes, lathed parts can to-day be produced that nobody even con-sidered five years ago.
Process smaller batch sizes
without stopping the machine
With bone screws the trend is currentlydistinctly heading towards standardisationand bringing larger manufacturing seriesin its wake. Although the customer regu-larly splits these lots into smaller quanti-ties, whereby series with identical screwtypes but different lengths are usually pro-duced. This form of order was also takeninto account by the Tornos engineers,which is why they equipped the automat-ic lathes with a CNC-controlled stopper.This solution enables users to programseveral lots of bone screws of the same typewith identical diameters but with differ-ent lengths in order that they can be exe-cuted in series. With machine infeed withidentical rod stock this allows the lathedpart manufacturer to process smaller batchsizes without stopping the machine,chang-ing the tool or installing a new program.
As such, flexibility in production is signif-icantly increased. In addition, productionis not interrupted so that all parts of var-ious series can be manufactured under thesame production conditions.The quality ofeach individual part is therefore identical.
Special customer requirements in thissector may mean that adapted peripher-al devices are necessary. Tornos has thus
a wide range of peripheral equipment forthe multi-spindle automatic lathes on of-fer that is adapted in each case to the spe-cific machine type. With bone screws forexample, palletising of the parts is fre-quently stipulated. The wide range ofTornos accessories naturally features suit-able equipment for the Multi Sigma. Thiscan be installed directly onto the machinewithout the need for special adaptationwork. If various lengths are produced inseries the palletising equipment imple-ments pallet changing with each newscrew type, which means that subsequentsorting of various screw lengths can be dis-pensed with.
An automatic lathe
for complete families of parts
With adjustment of the Multi Sigma towhirl threading, the multi-spindle auto-matic lathe retains all its capabilities.Thus other parts for medical technologycan also be produced as well. Examplesare polyaxial heads for the vertebral col-umn or orthopedic screws. The lathedparts manufacturer thus has an automat-ic lathe with which to produce completefamilies of parts. ❚
16
Robert Meier is a freelance technical journalist from Rupperswil/Switzerland> [email protected]
Manufacture of bone screws requires expertise. Quality demands are high, and materials are challenging to process4
The processing area of the multi-spindle automatic lathe is easily accessible3
14-16_SE110016_CHe10 07.07.2010 16:35 Uhr Seite 16
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
> Due to the constantly more demand-ing requirements for workpiece qualityand component properties, hard-fine ma-chining of gearwheels increasingly dom-inates industrial practice. Of the variousalternatives to fine machining of tooth-ing, above all hob grinding has establisheditself in recent years. The reasons for thiscan be seen in the diverse innovations fromReishauer which have been integrated inthe process and have dramatically reducedmachining costs while at the same timeproviding an increase in quality.
Innovations to reduce machining
costs and to increase quality
One example of this type of innovationsis shift grinding technology in which wear-ing can be compensated with continuousaxial shifting of the grinding screw. Withthe selected shift strategy, both uniformworkpiece quality over the entire dressingcycle and a considerably higher time cut-ting volume can be achieved. The tech-nology was developed in the 1990's byReishauer AG in Wallisellen near Zürich,Switzerland, and has led to widespread ex-pansion of continuous hob grinding in thelorry and larger passenger car toothingsegment (so-called ring gears).
Another example of innovation is theintroduction of a second workpiece spin-dle, which enables loading and unloadingof the workpiece parallel to the main time.With ever-shorter machining times, this
primarily minimises the unproductivetimes which in particular mainly make upa significant share of the cycle time. Theseinnovations were presented for the firsttime with the Reishauer RZ 150 hob grind-ing machine at the EMO 2003 in Milan,Italy. With this machine generation, theReishauer hob grinding process also be-came economical in the automotive in-dustry for cutting smaller gears like con-trol gears or planetary pinion gears. Due
to the resulting enormous market growth,the RZ 150 has since then held a perma-nent place worldwide in the production ofgearwheels for automotive gearboxes.
As additional innovations to the tech-nology of hob grinding ensure a continu-ous increase in productivity, Reishauer hasnow applied the principle of the RZ 150 toa larger line of machines. The new RZ 260line (figure 1), which enables the machin-ing of a larger range of workpieces,was pre-
17
Modular machine concept
One for allWith the RZ 260, Reishauer presents a new generation of machines for grindingtoothing. The modular concept realised enables users to individually adapt themachine to their own needs.
BY TOBIAS SCHRÖDER
Figu
res:
Rei
shau
er
As a modular machine concept, the RZ 260 hob grinding machine supplements theproduct line at Reishauer1
17-19_SE110017_CHe10 07.07.2010 16:36 Uhr Seite 17
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
sented for the first time at EMO 2009 inMilan, Italy. As a result, the machiningtasks of the grinding machine RZ 260 havealso become considerably more diverse.While the RZ 150 is clearly oriented to-ward large series production, the RZ 260must also be efficient for very small lotsizes and a wide variety of parts. For thisreason, a major focus during the develop-ment phase was placed on the adaptabili-ty to basic conditions at the plant of therespective customer.
A modular machine concept
with a broad range of options
To master this balancing act, a modularmachine concept resulted with which thecustomer can configure the optimum ma-chine for its plant with a broad range ofoptions. For example, the second work-piece spindle is only an option on the RZ260. If mainly large, wide workpieces aremachined, then the share of the workpiecechange time in the cycle time is relativelylow and the additional costs for the sec-ond spindle do not pay off. Dispensingwith the second chucking device also re-duces the tooling costs and the conversiontime, which is above all an important cri-terion for smaller lot sizes. Even with in-terlinked operation, e.g. if the machine isprimarily used together with other ma-chines which do not achieve the cycle timeof the grinding machine RZ 260 or if the
capacity of the machine cannot be fullyutilised, the investment can be reduced bydispensing with the second workpiecespindle. However, should it become ap-parent that the higher productivity of themachine is more efficient with a secondworkpiece spindle, then it can easily beretrofitted at a later time.
Like all Reishauer hob grinding ma-chines, the RZ 260 is also equipped withan integrated dressing device.For increasedflexibility during dressing, a CNC axis forswivelling the dressing tool can be installedas an option. This axis enables the use offlexible dual-cone wheels, which can notonly be used for cutting a single gearwheel,but instead very universally covers a cer-tain range of module and nominal pres-sure angles. This then enables the invest-ment costs for tools to be significantlyreduced even with a large range of parts.In addition, the C4 axis is a condition forthe TwistControl grinding technology usedfor the production of defined transposi-tions on the tooth flanks.
On the other hand, if only a limitedrange of parts is to be machined, set or full-profile rollers can be used. These are gen-erally especially designed for cutting onetype of gearwheel, however are more pro-ductive compared to dual-cone wheels. Inthis case, it is possible to dispense with theinstallation of the CNC swivelling axis toachieve lower investment costs. Here as
well, the C4 axis can be retrofitted if thisproves to be practical when operating themachine.
Both the dressing device and the work-piece spindle(s) are mounted on a rotatingspindle carrier (figure 2). During grindingthis carrier positions one of the two spin-dles with extreme high repeat accuracy,and during dressing it positions the dress-ing device relative to the grinding screw.Loading and unloading takes place out-side the machine work area, making theworkpiece optimally accessible for auto-mated or manual loading. With the two-spindle model, both spindles are arrangedon the spindle carrier offset by 180°.Whilea workpiece is ground on the first spindle,the workpiece can be changed on the sec-ond one and synchronised with the grind-ing screw using an inductive sensor. Dur-ing grinding the high-precision dressingdevice is positioned at the 90° position be-tween the two spindles and is protectedagainst cooling lubricant, grinding chipsand grinding grit during grinding.
18
The user candetermine thedegree of flexibilityand productivityitself: spindle carriers of the RZ 260 in four different configurations
2
Profile grinding of gearwheels with limited run-out using the Reishauer profilegrinding head
3
17-19_SE110017_CHe10 07.07.2010 16:36 Uhr Seite 18
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
To further increase the range of appli-cations of the RZ 260, intermittent pro-file grinding is also offered as an option.With very small lot sizes or annual quan-tities, profile grinding can be an econom-ical alternative to Reishauer hob grinding,despite the considerably lower produc-tivity, as the required grinding wheel canbe profiled with little effort. In addition,a large module range can be covered withprofile grinding (a factor of approx. 1.5).
If profile grinding wheels with a largeroutside diameter can be used, then only asoftware option is concerned, as all axesrequired for profile grinding are alreadyavailable in the RZ 260. In addition, it is al-so possible to use very small grinding wheelsfor profile grinding. In this case, the new-ly developed Reishauer profile grindinghead is used. Small grinding wheels areprimarily required when gearwheels withadjacent interfering contours must be ma-chined, for which there is not sufficientspace for the run-out of larger grindingwheels (figure 3). When developing thisattached grinding head, extreme impor-tance was placed on simple, fast mount-
ability. The conversion from hob to pro-file grinding therefore only takes a fewminutes more than conversion betweentwo different parts for hob grinding.
In contrast to previous Reishauer ma-chines, which are used exclusively for con-tinuous hob grinding with dressable grind-ing screws, a clearly expanded range ofapplications results for the RZ 260. Bothhob and profile grinding can be carriedout with dressable or galvanically boundgrinding tools – in the latter case also withcombined roughing and smoothing grind-ing wheels. Despite this wide variety ofusable technologies, the RZ 260 is a hobgrinding machine, which is specificallyand uncompromisingly optimised for themost demanding process, id est continu-ous hob grinding with dressable grind-ing screws. If no basic conditions existwhich prevent their application, then thistechnology continues to be the most ef-ficient process for hard-fine machiningof tooth flanks.
Two-spindle machine
minimises floor-to-floor time
Figure 4 shows an example of the effi-ciency of the RZ 260. The machined gear-wheel is a typical axle drive gear (alsocalled a ring gear), which is used in front-wheel drive passenger cars with a trans-verse engine. Due to the high ratio of thediameter to the toothing width and thethin-walled gear body, relatively heavy
hardening distortions frequently occur inthese components in industrial practice.As a result, these kinds of workpieces havealready been ground on Reishauer ma-chines for some time now. With the two-spindle RZ 260 it is now possible to ma-chine the ring gear with a floor-to-floortime of considerably under one minute(including time required for dressing andworkpiece change). The grinding resultsshow: The demanding requirements whichusers place on the quality of the groundgearwheels are easily met.
The combination of high performanceand modular design results in a very broadmarket. Customers include not only theautomotive industry with its suppliers, butalso manufacturers of lorry and industri-al gearboxes or producers of gearwheelsalone. In the process, the modular designoption has developed into an importantcharacteristic for the success of the ma-chine. The broad range of variants amongthe machines sold shows: Regardless ofwhether the customer uses all or only partof the options offered, it benefits in its ownspecific way from those options. And as aresult, innovations from Reishauer onceagain provide a tangible competitive ad-vantage for its customers. ❚
19
Dr.-Ing. Tobias Schröder is Director of Marketing and Product Managementat Reishauer in Wallisellen/Switzerland> [email protected]
When grinding a ring gearfrom the automotive industry, it was possible toreduce the floor-to-floor timeto considerably less thanone minute with a two-spindle RZ 260
4
MANUFACTURERiReishauer AGCH-8304 WallisellenPhone +41 44 8322211Fax +41 44 8322390> www.reishauer.com
17-19_SE110017_CHe10 07.07.2010 16:37 Uhr Seite 19
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
> For universal grinding as well, there isincreasing pressure to reduce the piececosts for small and medium-sized work-piece series. This trend motivated Kellen-berger in St. Gallen, Switzerland, to devel-op a flexible, cost-optimised, standardisedloading cell. Here the Kel-Vita machineseries serves as the basis for a mechanicaland control-related fully integrated load-ing solution for retrofitting existing sys-tems (figure 1).The solution offers the usera high degree of comfort when workingwith or without the use of a loading sys-tem. A broad range of parts up to a dia-
meter of 100 mm, a length of 400 mm anda weight of 5 kg is covered. The objectiveof the new development was a fully inte-grated loading cell which offers the cus-tomer a complete solution from a singlesource.
In the current version, Kel-Portal is de-signed especially for small and medium-sized lots and, thanks to the included soft-ware support,allows short conversion timesfor a broad range of parts.Additional high-lights include the low installation costs andeffort, the short-term initial start-up andthe need for only minimal operator train-ing. The loading cell with a portal designwas realised with alternating grippers in an
H-pattern. The NC axis in the longitudi-nal direction results in a high degree offlexibility not only in the machine, but al-so for loading parts. Both shafts and flangeparts can be picked up directly in a cyclingbelt and loaded. In particular the autono-my for small parts can be additionally in-creased within a cell without conversionwork by using standardised pallet systems.The NOK and PLC output are integratedas standard features via a drawer systemand a platform for additional functions.The advantages of the standard portalloader include:
■ Ability to operate multiple machines,■ Complete machining in one work fix-
ture including for chuck parts,■ Uniform temperature change during
several work processes, as sliding doorneed not be opened during a workpiecechange,
■ Optimum operating range for lot sizesfrom 20 to 5,000,
■ Maximum conversion time 15 minutes(excluding chucking device),
■ Good value for money thanks to per-fected, function-optimised design,
■ Individual parts can also be loaded andmachined manually without obstruc-tion and without a loading system.
The loader is controlled via the machine-side controller and is integrated in the userinterface (figure 2). The advantages of thecontroller are:■ Parameter programming,■ ICON programming,■ Selective help screens,■ Program memory,■ Settings for repeat orders,■ Continuation of sequence without ad-
ditional effort following error cancella-tion,
■ Low training effort for the operator,■ Reduced costs.
Thanks to a perfected gripper concept,workpiece diameters from 6 to 80 mm canbe picked up with just six gripping tongs.The required positions and gripping di-ameters are marked directly on the ele-ments. Additional advantages of the grip-per include the lower investment costs andshort conversion times. The prism se-quencer can be set up vertically and hori-zontally via an adjustment mechanism de-pending on the workpiece and adjusted toa workpiece length of up to 400 mm in theprocess. The autonomy covers:■ 27 parts up to a diameter of 38 mm,■ 13 parts up to a diameter of 75 mm,■ 9 parts up to a diameter of 100 mm,
20
Standardised, cost-optimised loading cell
Kel-Vita with Kel-Portal
A portal loader increases flexibility during universal grinding, supports multi-machine operation and enables fast conversion in the loading area.
Figu
res:
Kel
lenb
erge
r
Kel-Portal is a mechanically and control-related fully integrated loading solutionsuitable for retrofitting theKel-Vita machine series
1
20-21_SE310010_CHe10 07.07.2010 16:37 Uhr Seite 20
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
Standardised pallets can be laid on theprism sequencer. These are adjustable andavailable with various row and cycle spac-ings (figure 3). Examples of autonomy are:■ 312 parts with a diameter of
19 mm and a length of 60 mm,■ 84 parts with a diameter of
55 mm and a length of 60 mm,■ 42 parts with a diameter of
100 mm and a length of 60 mm.
With the Kel-Portal loading cell, the ma-chine tool manufacturer Kellenberger of-fers the greatest possible flexibility foruniversal use of the grinding machine.Weighty arguments nevertheless speak infavour of additional but one-time invest-ment costs for the portal loader solution.These are the support of multi-machineoperation with the loading buffer, shortconversion times in the loading area for
a large parts range and – not just with re-peat orders – the ability to integrate ad-ditional auxiliary cycles. ❚
L. Kellenberger & Co. AGCH-9009 St. GallenPhone +41 71 2429111Fax +41 71 2429222> www.kellenberger.com
The user interface is integrated in the machine-sidecontroller for the control of the portal loader2
Standardised pallets can be laidon the sequencer,which are adjustableand available withvarious row andcycle spacings
3
www.winterthurtechnology.com
SwitzerlandWinterthur Schleiftechnik AG8411 WinterthurPhone: +41 (0)52 234 41 41Fax: +41 (0)52 232 51 [email protected]
GermanyWinterthur Technology GmbH72766 ReutlingenPhone: +49 (0)7121 93 24 0Fax: +49 (0)7121 93 24 [email protected]
WENDT GmbH40670 MeerbuschPhone: +49 (0)2159 671 0Fax: +49 (0)2159 806 [email protected]
AustriaRappold Winterthur Technologie GmbH9500 VillachPhone: +43 (0)42 42 41 811 0Fax: +43 (0)42 42 41 811 [email protected]
GRINDING WHEELS FROM WINTERTHUR:PASSIONATELY PRECISE
20-21_SE310010_CHe10 07.07.2010 16:37 Uhr Seite 21
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
22
> With the manufacture of motor spin-dles the tendency is clear: in current timesall manufacturers are searching for spin-dles that feature high torque in the lowerspeed range and are without limits in termsof higher speeds. Based on a wide-range,continuously optimised product spectrum,this is also the aim of the manufacturer Alfred Jäger (see below).
High frequency spindles
with speeds of up to 100,000 rpm
At the company headquarters at Ober-Mör-len in Germany, Jäger has until now exclu-sively produced lifetime-lubricated highfrequency motor spindles that however aresoon to be supplemented this year with anair bearing spindle for the PCB industry.»Our current product portfolio consists ofspindles with external diameters rangingfrom 33 to 150 mm«, reports Uwe Krause,Head of Sales at Jäger. »That correspondsto a power spectrum of 80 W to 67 kW.«Beyond the limits of this spectrum Jägerdifferentiates between three product lines
(figure 1):while the blue Z series is equippedthroughout with asynchronous motors
enabling speeds of 30,000 to 100,000 rpm,the red Chopper series designed for costefficiency is limited to speeds of 30,000 to40,000 rpm. Jäger specifies concentricityfor this series at 2 µm, and 1 µm for the Zseries. »The new brainchild of our prod-uct range is the purple Power-Line«, in-forms Krause. »It's characterised by high-er performance and torques as well ascooler shafts and stiffer bearing systems.«When the unit quantities for these threespindle ranges are totaled,it is seen that Jägeroutputs about 3,500 to 4,000 spindles year-ly. The majority of this is the blue Z-Line.
Universal cylindrical grinding machine for high frequency spindle production
Close to the marketA good three years ago, a well known spindle manufacturer converted its grindingsystems to high quality CNC machines. In terms of complete manufacturing it todayprofits from shorter lead times, high quality and significant cost savings.
BY MICHAEL HOBOHM
Figu
res:
Jäg
er (
1), S
tude
r (2
), H
anse
r (3
, 4, 5
)
The Z-Line of one of three product series from Alfred Jäger, manufacturer of high frequency spindles1
USERiFounded more than forty years ago, thecompany of Alfred Jäger is characteri-sed by a high level of expertise in themotor spindle and application technolo-gy sectors. In 2000/2001 the originalpartnership was converted to become alimited company, and this transforma-tion went hand in hand with a great ma-ny technological advances. Today theglobally active spindle manufacturer has
approximately 60 employees, mostlyworking at the Ober-Mörlen headquar-ters, where all construction and manu-facturing is located.
Alfred Jäger GmbHD-61239 Ober-MörlenPhone +49 6002 91230Fax +49 6002 912340> www.alfredjaeger.de
22-24_SE110019_CHe10 07.07.2010 16:40 Uhr Seite 22
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
The spindles are implemented for allmilling, grinding, drilling, deburring andengraving applications.As such, diametersof 33,42 and 45 mm are used for small PCB,engraving and prototype constructionmachines, and also for dental technologywhere Jäger has 95 percent of the marketcovered. Spindles with 62 to 80 mm con-struction size for example are applied tolight mould making or are used in rotaryindex machines for the automotive indu-stry and in robotics.The largest Jäger spind-les are used in mid-sized mould makingfor example for steel processing.
Part of today's manufacturing
concept: three Studer machines
Production of the three spindle series inOber-Mörlen is characterised by a highmanufacturing depth.»After company lead-ership was handed over to the second gen-eration in 2000/2001, we strongly rejuve-nated the machinery and pushed forwardindustrial manufacturing of the products«,reports Krause. »As part of this we aimedat investing in the machinery of a singlemanufacturer, according to the individualproduction processes. As a result, we aretoday able to implement multiple machinework and use our employees flexibly.«
While sectors such as dental technolo-gy and special machine construction of-ten expect rapid responses to individualrequirements, Jäger has maintained theworkshop principle in addition to indu-strial production in specific areas. »Withthis hybrid form, our manufacturing ca-pacity is designed so that we can react toa wide variety of requests in a flexible way«,says Herbert Böning, Production Mana-ger at Jäger. »At the same time we've ap-plied a quality assurance screen across ourcomplete range of production processes toensure a high level of product quality.«
With the S21, S33 and S145, three Stu-der machines make up part of the indu-strial manufacturing at Jäger. These in-itiated conversion at the spindle producerto CNC grinding three years ago in orderto be able to respond to the more deman-ding requirements of the market and itsincreasing sensibility to pricing. »For A-parts such as housings and shafts wemainly needed the shortest lead times pos-sible to allow us to offer our spindles at at-tractive prices. And at the same time ofcourse quality had to be right as well«,Krause says. That the decision was taken
for Studer had something to do with thefavourable price-performance ratio of theSwiss machines according to Böning. Inaddition they are also a guarantee of highmanufacturing quality and production sa-fety, a fact noticed not only by the custo-mers but also by competitors.
As with the S21, the experts from Ober-Mörlen also decided on a universal grin-ding machine with the S33 and S145 in or-der to completely cover the wide range ofprocessing and also to respond flexibly tocustom requirements from the customer.»All three standard machines exhibited ahigh quality level and no compromises we-re made in terms of both hardware andsoftware«, says Rainer Krebs, Regional Sa-les Manager at Studer. This means for theS33 universal cylindrical grinding machi-ne for example: designed for centre di-stances of up to 1000 mm,for centre heightsof up to 175 mm and work piece weightsof up to 120 kg, and equipped with a tur-ret spindle head with motor spindle, an in-ternal grinding apparatus with automaticswivelling 1° Hirth and an external grin-
23
MANUFACTURERiFritz Studer AGCH-3602 ThunPhone +41 33 4391111Fax +41 33 4391112> www.studerag.ch
The S33 universal grinding machinefrom Studer is used in Ober-Mörlen for thecylindrical surface grinding of high-precision shafts
2
With the S21,equipped with a turret spindle headwith high resolution0.0001° B axis andC axis to the workpiece spindle head,motor and bearinghousings are cylindrically groundinternally and externally with highprecision to thenearest micrometer
3
With the complete machining of bearing housings with the S145, lead times andcosts were cut in each case by 20 percent4
22-24_SE110019_CHe10 07.07.2010 16:40 Uhr Seite 23
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
M A C H I N E TO O L S
ding spindle head with pivoting plate and0° and 30° stops (figure 2).The StuderWINsoftware enables simple programming ona Fanuc 0i-TD,and for the creating of grin-ding and dressing programs users can ta-ke advantage of the StuderGRIND pro-gramming software. At present the S33 inOber-Mörlen is used exclusively for the cy-lindrical surface grinding of shafts of vary-ing sizes.
The S21 and S145 (see below) universalcylindrical grinding machines on the otherhand are used for internal and external cy-lindrical grinding of motor and bearinghousings.For machining of centre distancesto 400 mm and centre heights to 125 mmthe S21 is equipped with a turret spindlehead, a B axis with precise 0.0001° resolu-tion and a C axis to the work piece spindlehead for moulding and thread grinding.Aswell as convenient work with StuderGRINDthe Studer Pictogramming software allo-ws simple programming (figure 3).
»In terms of quality standards we areconfidently able to maintain tolerances of± 1 µm with both internal and externalgrinding thanks to the Studer machines«,emphasises Böning. »In addition to theprecision of the machines this is mainlydue to the all-round manufacturing of ourparts that gives us not only significantlyshorter machining times but also enablesthe required processing quality to be mo-re easily determined.« While the machinestoday enable final dimensions to be moreclosely achieved and in some cases evenreached, processing steps such as honingcan be increasingly done without. And
employees have no problems switchingfrom one Studer machine to another orindeed operating several at once.
Processing times
and costs cut by 20 percent
An application on the S145 specificallydemonstrates the advantages.For the grind-ing of ball bearing housings of tool steelthe processing time could be shortened by20 percent. From centreless grinding to internal grinding the housing needed toformerly be machined with four conven-tional grinding machines. »Today we cansave a major part of the connected setuptimes and work with two instead of fivespans«, reports Böning. »That affects thequality and dimensional specifications ofcourse. In this way we can maintain thespecified 1 µm tolerance for axial and ra-dial runout for safe processing. The com-plete machining and shortened lead timesgives us cost savings of around 20 per-cent.« With multiple machine operationJäger also achieves more capacity. »At thesame time the dependence of productionon specific employees is lessened,« addsKrebs.»Whereas we needed an absolute topgrinder before, today's technology makessuch bottlenecks less dramatic.«
How will the collaboration between Jä-ger and Studer proceed? »Depending onthe economy in general, we want to investas soon as possible in another S33«, saysBöning. The aim is to replace a conventio-
nal grinding machine with the existingS33, transferring the tasks to this facilityas well.»S33 is not the same as S33 though«,emphasises Thorsten Sudler-Mainz, SalesEngineer with Sudler machine tools. »Be-cause in the meantime Studer has develo-ped this model further and equipped itwith new features. Its core is the new ex-ternal spindle head with two motor spind-les, to which two 500 mm grinding wheelscan be arranged collision-free. Togetherwith the internal grinding apparatus evenmore complex geometries can be machi-ned. And in terms of technology that willbring Jäger a whole lot forward.«
New aircushioned spindles
And that with the most fundamental ofrequirements, the manufacture of highquality products. »In this point both Stud-er and Jäger are very similar«, says Krebs.»We're also trying to make high qualitymachinery in a price-sensitive way.«Krause adds: »Both are flexibly organisedcompanies that with their products areclose to the market and respond to marketneeds. We'll soon be putting that to the testwith our new air-cushioned spindles thatthanks to synergy expertise are allowing usto make a completely new product.« ❚
24
Dr. Michael Hobohm is Editor-in-Chiefof Swiss Quality Production at Carl HanserVerlag in Munich/Germany> [email protected]
Keen to get the new S33 to Ober-Mörlen: Thorsten Sudler-Mainz, Herbert Böning,Uwe Krause and Rainer Krebs (from left)5
S145i
The S145 inner cylindrical grinding ma-chine is designed for grinding lengths ofup to 200 mm, swing diameters of up to448 mm, internal grinding diameters to200 mm and external diameters to180 mm. The spindle turret has up tofour spindles for combining both inter-nal and external grinding operations.The dressing can be implemented witheither stationary or rotating tools. In ad-dition the S145 also has a Q axis forautomatic swivelling of the work piecespindle head through ±30° and a C axisfor efficient mould machining and thre-ad grinding. In terms of software theS145 is equipped with Studer Picto-gramming and StuderGRIND as well.
22-24_SE110019_CHe10 07.07.2010 16:40 Uhr Seite 24
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
> Peripheral grinding machines for theproduction of indexable inserts are hard-ly a new invention. However, compared toconventional machines,the Insert Line fromEwag in Etzingen, Switzerland offers deci-sive advantages. These range from variablegrinding wheel diameters, which also al-low grinding of concave shapes, to opti-mal machine kinematics with hydrostaticguides to the quality of the cutting surfacesand reduced production times.
Top precision of shapes and
outstanding cutting edge qualitites
Grinding wheel diameters up to 500 mmsupport the new grinding technology ofthe Insert Line and reduce the productiontime by up to 50 percent compared to con-ventional processes. At the same time, thenew grinding process from Ewag guaran-tees top precision of shapes and outstand-
ing cutting edge qualities. When machin-ing the cutting surfaces of indexable inserts,a theoretical line contact results betweenthe indexable inserts and the grinding wheelwith the new peripheral grinding process.The thermal load in the contact zone is reduced accordingly, surface damage isavoided and the removal rates can be in-creased. In addition, the grinding tech-nology enables the machining of increas-ingly complex indexable insert geometries.
At the same time, Ewag has also opti-mised the grinding kinematics. The cen-tre of the C-axis therefore lies at the cen-tre of the B-axis swinging centre. As aresult, considerably reduced interpolationis required for the CNC axes. Magnetical-ly pre-clamped hydrostatic guides, a ma-chine bed made of Granitan and directdrives on all axes guarantee extremely highaccuracies and process safety while pro-
viding for unmatched dynamics. Torquedrives on the round axes and linear directdrives on the X and Y-axes eliminate wearand improve precision.
Automatic handling system
In classic indexable insert production oflarge tool manufacturers, lot sizes rangefrom 100 to 10,000 pieces. Ewag thereforeexclusively offers the Insert Line with an au-tomatic handling system.The integrated ro-bot cell optimally supplements the produc-tive grinding machine. In the process, the6-axis robot enables loading times of underfour seconds and can be excellently adapt-ed to different customer applications. ❚
Indexable-insert peripheral grinding machine with handling system
Cuts production times in half
Ewag AG, CH-4554 EtzikenPhone +41 32 6133131Fax +41 32 6133115> www.ewag.com
25_SE310009_CHe10 07.07.2010 16:42 Uhr Seite 25
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
Th
ma
The
the
Muc
The
vari
Dep
whe
The
W
SW
T
L. K
Hei
900
C U T T I N G TO O L S
Solutions custom tailored especially to customer needs
Conixs, B813 and the rollingwheel of the futureThe latest developments of Diametal include not only a hob cutter and a syntheticresin wheel, but also rolling wheels made of a special carbide and a standard fortoothing mills which guarantees shorter delivery times.
Equipped with a special type of carbide, the new diamondrolling wheels produce high surface qualities and are characterised by a long tool life
1
> Diametal, a company with a long tra-dition and headquarters in Biel, Switzer-land, has specialised in the development,production and sale of two product groups,id est precision grinding tools and hard-material tools and applications. By com-bining findings from both product groups,synergies repeatedly result which enableextraordinary innovations.Thanks to manyyears of research and development, the spe-cialists at Diametal possess a high level oftechnical know-how which they use to solvethe specific problems of their customers.On the market, developments of this kindstrengthen the high quality standard of thecompany, which is certified according toISO 9001/14001 and OHSAS 18001.
The Conix hob cutter is just such an in-house development. With small modules,the possibilities for producing high-qual-ity toothing on bevel gears and pinionswere limited in the past. But now the newhob cutter is a real alternative to expensivehelical wire erosion. As many companiesalready own a conventional gear cuttingmachine or a modern automatic lathe witha gear cutting module, Conixs is based onthe hobbing method and is designed es-pecially for conical tooth shapes.
The milling cutter can be provided withany desired profile, e.g. customer-specificor according to standard as per NIHS 20-25, NIHS 20-02, DIN 867, etc. It is availablefrom a module of 0.03 mm and a diame-ter of 8 mm. Diametal specifies the opti-mum number of hob teeth (two to seven)depending on the geometry and dimen-
sions of the profile on the pinion. The newmilling cutter consists of solid carbide; likea possible coating, the carbide type is de-fined based on the workpiece. Additionalfeatures are the cutting angle in the cen-tre, logarithmically relief-ground and leftor right-handed. Conixs is a new develop-ment which can achieve amazing perform-ance in the area of conical gear cutting (cy-cloid and involute profiles) and the purchaseof which pays off economically thanks toits high efficiency.
B813: high edge stability
meets optimum cutting capacity
A high level of efficiency is also guaran-teed by the new B813 synthetic resin wheels.This development is intended to solve a fa-miliar problem: If the cutting capacity isimproved during machining, then the edge
BY THORSTEN KALETSCH
Figu
res:
Dia
met
al
26-28_SE110023_CHe10 07.07.2010 16:44 Uhr Seite 26
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
The newest KELLENBERGER CNC universal cylindrical grinding
machine with a multitude of features.
The KEL-VITA universal cylindrical grinding machine with glass measuring devices on
the X and Z axes and the leading GEFanuc 310is controls.
Much additional equipment and many accessories expand your application possibilities.
The machine is available with distances between centers of 600 mm or 1000 mm, and
various wheelhead variations.The maximum diameter which can be worked is 349 mm.
Depending on the wheelhead, manual or automatic indexing is available. Grinding
wheel diameters from 300 mm to 500 mm can be selected.
The new KEL-VITA – simply perfect.
WHEN WE HAVE
SWISS MADE WRITTEN ON IT
THEN SWISS MADE IS ALSO INSIDE
L. Kellenberger & Co. AG
Heiligkreuzstrasse 28
9009 St.Gallen/Switzerland
Phone +41 (0)71 242 91 11
Fax +41 (0)71 242 92 22
www.kellenberger.com
stability worsens – and vice versa.There areno longer any compromises of this kindwith the B813 synthetic resin wheels fromDiametal. A new bonding system guaran-tees maximum edge stability with optimumcutting capacity.
The synthetic resin wheel impresses withoutstanding cutting performance. Evenlarge cutting volumes are easily tackled –for example when grinding certain rota-tionally symmetrical geometries. In theprocess, the wheel retains its shape. This
enables previously time-consuming dress-ing operations to be reduced to a mini-mum. And that guarantees a long tool lifeand a considerable increase in productiv-ity. Thanks to its convincing propertieswith regard to removal and wear, the newB813 synthetic resin wheel is an extreme-ly economical solution. It achieves out-standing results – and that regardless ofthe cooling medium used. The solution al-so attracts attention with regard to thetrueness of shape. Thanks to optimal wet-ting of the filling and grinding material,the developers of the B813 wheel set newstandards in this area. At cutting speeds ofjust 18 to 24 m/s, a convincing edge sta-bility or trueness of shape of the grindingcoating is achieved with the B813 wheelfrom Diametal.
Like all products from the Swiss man-ufacturer, the new synthetic resin wheelcan also be tested by the customer. Cus-tomer consultants and developers like topresent it to interested companies anddemonstrate its advantages.
The Conixs hob cutter from Diametal is available from a module of 0.03 mm and adiameter of 8 mm2
26-28_SE110023_CHe10 07.07.2010 16:44 Uhr Seite 27
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
C U T T I N G TO O L S
Carbide: combine high rolling
quality with long tool life
Outstanding results are also supplied bythe newly developed rolling wheels fromDiametal (figure 1). The basis for success-ful rolling is not only experience, a precisemachine, the right oil and exact dressing,but also the right rolling wheel. And it isavailable starting immediately. Togetherwith a carbide manufacturer, the engineersat Diametal developed a carbide type espe-cially for rolling after they had thorough-ly tested numerous carbide types from abroad range of different manufacturers.The reason: All standard types fulfilled therequirements for rolling only condition-ally or not at all.
Field tests at several customers, whichare active in the upmarket watch sector,resulted in outstanding results for the car-bide rolling wheels.For example,one com-pany reported, »We've never had such agood wheel.The surface quality of the parts
is perfect and the wheel also has an ex-tremely long life.« The new carbide rollingwheels from Diametal really are currentlyunmatched on the market, as the righttype of carbide guarantees excellent re-sults. Starting immediately the wheels areavailable from stock in five sizes. Both con-tact wheels with U-notches according tocustomer specifications and ceramic orcarbide rolling wheels are available.
Standard: quickly deliver
hob cutters
Diametal not only develops new productsand custom-tailored solutions for cus-tomers, it also simplifies entire processesthanks to innovations. A good example ofthis is the new standard for hob cutters,which Dévoïd Conseils has developed to-gether with Diametal. The production ofa complicated watch differs considerablefrom one of a basic calibre. There are few-er parts to produce, the time for manu-facturing a prototype is often short andthe rapid procurement of the componentstherefore becomes a competitive advan-tage.As a result, the procurement deadlinefor the hob cutter for pinion and gear pro-duction is usually critical.
To fulfil the need of the customer forshort delivery times, Dévoïd Conseils has
developed a new standard for hob cuttersbased on which Diametal can manufac-ture the tools in just a few days. The stan-dard defines basic hob cutters for cuttinggears which show reduced play in a broadtolerance range. As a result, only twomilling cutters per module are requiredfor cutting gears, and the number of teethcan be from eight to over 200. It is veryeasy to use the standard. The complica-tion is drafted by the designer while com-plying with the defined modules. Minordeviations are possible here. Then DévoïdConseils is commissioned with a study inwhich the toothing profiles, functionalcharacteristics and the reference numberof the hob cutter are determined. Basedon these results, the customer can then or-der the tool from Diametal.
In addition, the guaranteed short pro-curement time, the development time canalso be reduced with this standard. In ad-dition, the costs for prototype manufac-turing decrease due to the reduced needfor milling cutters. The functionality is se-cured with minimal play – this is other-wise frequently a critical factor for com-plications. Following the prototype phase,the profile optimisations are carried outto ensure subsequent series production.Thanks to the cooperation between DévoïdConseils and the company Diametal, newoptions with regard to flexibility, applica-tion technology and potential savings re-sult for customers from the watch mak-ing industry.
A reliable partner
for specialist companies
Whether it's a new hob cutter for cuttingconical gears, a new synthetic resin wheelfor machining, a rolling wheel made of anew type of carbide or a standard for hobgear cutters which simplifies prototypemanufacturing in the watch making in-dustry: Diametal continually develops so-lutions for customers which are special-ly matched to their needs. The developersand engineers are happy to take on allkinds of new challenges. Of course, dis-cretion is the a top priority here. ❚
28
Thorsten Kaletsch is a freelance specialistjournalist in Biel/Switzerland> [email protected]
The B813 synthetic resin wheel combines high edge stability with optimal cuttingcapacity and impresses with outstanding cutting performance3
MANUFACTURERiDiametal AGCH-2500 BielPhone +41 32 3443333Fax +41 32 3443344> www.diametal.ch
26-28_SE110023_CHe10 07.07.2010 16:44 Uhr Seite 28
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010 29
> The Dihart Reamax TS tooling systemmeets a broad range of requirements withwhich users define quality and efficiencyfor reaming. It reduces tooling costs, as ithas a modular design and can be used witheasy-change reaming heads for a broadrange of components. And it offers sur-prising performance which, for example,becomes apparent in a long tool life (fig-ure 1). And another thing that is appreci-ated at Hermesmeyer & Greweling, is theconcentricity integrated via the Dihart DAHZero alignable holder (figure 2).
»We've already worked with drillingtools from the Komet Group for manyyears now and have repeatedly made ajump forward with them«, says Karl-HeinzGreßmeyer, the responsible foreman inProduction at Hermesmeyer & Grewel-ing. The company based in Marienfeld,Germany, specialises in machining ofcomponents from plant, mould, machineand tool construction segments. Greß-meyer explains what he means by »a jumpforward« with the example of the new Di-hart Reamax TS multi-edge high-perform-ance reaming tools, which he purchasedfor machining large components for windpower plants (figure 3). One of these com-
ponents are torque converter bearingsmade of GGG40, for which the toolingsystem with a DST reaming head (Cer-met) with a 30 mm diameter is used. Toadapt the tool, a Komet ABS hydro-ex-pansion chuck is used and a Dihart DAHZero alignable holder is employed for theconcentricity adjustment. From a sport-
Efficiency from plug-'n'-ream toolbox
Reaming: modular and easy to handleWith the Dihart Reamax TS multi-edge high-performance reaming tools and theDihart DAH Zero alignable holders, a user takes a leap forward in the machining oflarge components for wind power plants. Technically and efficiently.
BY DANIJEL MATOSEVIC
Figu
res:
Kom
et G
roup
The Dihart Reamax TS modular tool system offers ahigh degree of system modularityand precision
1
MANUFACTURERiKomet Dihart AGCH-4657 DullikenPhone +41 62 2854200Fax +41 62 2854299> www.kometgroup.com
USERiHermesmeyer & GrewelingGmbH & Co. KGD-33428 MarienfeldPhone +49 5247 98680Fax +49 5247 986850> www.hermesmeyer-greweling.de
29-30_SE110015_CHe10 07.07.2010 16:45 Uhr Seite 29
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich 30
ing standpoint, Greßmeyer's jump froma previous 4,350 to approximately 40,000mm is virtually an Olympic one. As a re-sult, the high-performance reamers meeta central requirement via which efficien-cy is primarily defined. However, the tool-ing system offers additional advantages,which are also integrated in the calcula-tion in Marienfeld.
Changing instead of
adjusting and setting
The idea of the Dihart Reamax TS high-performance reamers is based on the prin-ciple of interchangeable reaming heads,like those familiar for many years now fromthe Dihart disposable head (figure 4). In-stead of setting and adjusting tool edges,it pursues the approach of simple inter-changeability, which considerably simpli-fies the handling of reaming tools.The con-ditions for this are interchangeable headsreliably produced to toleranced dimensions.
A in the true sense of the word centralelement is the high-precision separatingpoint with a short taper and flat contact.It ensures the proper transmission of thetorques resulting during reaming,and withit compliance with the concentricity re-quired for ultra-fine machining. In the Di-hart Reamax TS the separating point isstandardised, and therefore serves as thebasis for modularity, which provides anadditional advantage. As a result, reamingheads with different designs and diame-
ters can be adapted to one basic elementfor all applications. Suitable holder vari-ants are available for the required machineconnections and certain length-to-diam-eter ratios. All reaming heads can then beadapted to these holders.The heads are fas-tened to the respective holder with a radi-al clamping device which permits simplebut secure fixation and release.Thanks to thismodularity,the toolingsystem canbe used fora broadrange ofcomponents.
»Alone for the large compo-nents for wind power plants, var-ious diameters result. Due to the differentmaterials used, we cover these in each casewith specially manufactured reaming headsmade of Cermet or carbide, but alwayswith the same system,« says Greßmeyer. Inhis efficiency calculation, he clocks up notonly shorter adjustment and setting times,but also the reduced tool diversity as anadditional advantage.
Precise, controlled production
However, what likewise pays off in longertool life, but is also clocked up by foremanGreßmeyer on the quality and process re-liability side, is the adjustability of the mul-ti-edge tools. The demanding quality re-quirements, especially for components ofwind power plants, also necessitate exactsetting of the concentricity properties. AtHermesmeyer & Greweling the Dihart DAHZero alignable holders are used for thispurpose (figure 2). The holders availableas standard components in the plug-'n'-ream toolbox from the Komet Group en-able the exact setting of the concentricityproperties down to the micrometer. »Con-centricity errors can result on the machineor spindle side or can be caused by tool ex-tensions with which we must overcomeprojecting edges,« says Greßmeyer. Pre-mature damage such as micro-chippingcould result from increased loading. Thisdamage then above all quickly affects thedrilling quality and tool life travel in theultra-fine machining segment.
With the Dihart DAH Zero alignableholder, concentricity properties can beachieved with a precision of less than
three micrometers, which satis-fies even the most demand-
ing requirements.Setting can be car-ried out within oroutside the machinein just minutes, evenwithout experience.
Many advantages re-sult from the modular
Dihart Reamax TS toolingsystem and the use of theDihart DAH Zero alignableholders and cannot always
be exactly expressed in eurosat Hermesmeyer & Greweling.
However, with regard to the torqueconverter bearings alone, the consid-
eration of the tool life travel results in sav-ings of nearly Euro 10,000 a year in a one-to-one comparison.❚
Danijel Matosevic is Product Manager forthe Reaming Tools Division of the KometGroup in Besigheim, Germany> [email protected]
With the newDihart DAH Zeroalignable holders,a maximum concentricity of thereaming tools resultseven withunfavourablemachine or spindle-side conditions
2
The innovative reaming tools from theKomet Group fulfil the demanding qualityrequirements for components of wind powerplants at Hermesmeyer & Greweling
3
Instead of settingand adjusting tooledges, the Dihart-Reamax reaming heads aresimply replaced
4
C U T T I N G TO O L S
29-30_SE110015_CHe10 07.07.2010 16:45 Uhr Seite 30
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
> The new powRgrip toolholding systemfor lathes and Swiss Automatics of Rego-Fix,Tenniken/Switzerland,offers the sameadvantages as standard powRgrip pro-gram. These include better TIR, improvedtool dampening, easy presetting, longer
tool life and unparalleled clamping forces.The cylindrical toolholders CYL-T (fig-
ure1) are available in 25 mm, 32 mm, 40mm, 1”, 1.25” and 1.5” diameters in PG15 and PG 25 collet series. powRgrip VDIhas also been added to the Rego-Fix port-
folio. This new line offers options in VDI30, 40 and 50 mm also for the PG 15 andPG 25 collet series (figure 2).The standardRego-Fix Capto toolholders are also partof the program for turning applications.They are available in different sizes. Rego-Fix is also expanding its powRgrip turn-ing system to include a line of boring barturning collets. These new PG-T collets areavailable in metric and inch sizes from 5to 20 mm in the PG 15 and PG 25 colletseries. These collets feature an exact tim-ing method for the boring bar flat to en-able precise presetting.❚
Toolholding system for turning applications
Easy presetting and longer tool life
Figu
res:
Reg
o-Fi
x
The cylindrical toolholders CYL-T areavailable in 25, 32 and 40 mm1 The new line offers options in VDI 30,
40 and 50 mm also for the PG 15 and PG25 collet series
2
Rego-fix AG, CH-4456 TennikenPhone +41 61 9761466Fax +41 61 9761414> www.rego-fix.com
PRECITRAMEMACHINES SA
INNOVATIVEMACHININGSOLUTIONS
P R E C I T R A M EM A C H I N E S S AG r a n d - R u e 5CH-2720Tramelan
www.precitrame.com Tél. +41(0)32 486 88 50 Fax +41(0)32 486 88 51
THE MULTITALENTED MACHINES
PRECITRAME MTR400 Series
CNC rotary transfer machine for high volume production and high precision
5 faces machining, milling and turning in one clamping
Modular and extendable from 4 to 15 stations and up to 50 cutting tools
Hall 9Booth 9C11
28.09.- 02.10.2010 05.-09.10.2010
Metal Cutting PavilionBooth S-8966
13-18.09.2010
31_SE310011_CHe10 07.07.2010 16:49 Uhr Seite 31
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
C U T T I N G TO O L S
> The problem is well-known: The newmachining centre is here, and neverthelessthere is no jump in productivity. This usu-ally has nothing to do with the machine orwith the tools used, but instead with a lackof workpiece chucking technology andhandling.Even the fastest machine is worth-less if the workpiece change takes too longor no workpieces are available when theyare needed. The machines really begin tomake money with production in the sec-ond and third partially or unmanned shift.And that's why it's important to opti-mise the work organisation andmaterial flow. However, someworkpiece storage units and thefeed handling devices are expen-sive. In addition, the in-
terfaces are often not clearly defined. Thesuppliers of workpiece storage units andhandling systems are often simply not fromthe machining sector.And that's why manyof the requirements relevant there are notsufficiently taken into account.
The solution: chucking technology,
pallet storage unit and handling
Gressel, the Swiss specialist for chuckingtechnology, with headquarters in Aadorf,
Switzerland, takes a different route. Gres-sel has developed practical solutions formany chucking-related requirements. Aworkpiece storage unit with an integratedpallet feed handling device, id est a ready-to-operate plug-and play system, was builtin close cooperation with a handling spe-cialist. The workpiece storage unit bearsthe name P60R (pallet magazine,60 pieces,to be docked on the right-hand side of themachining centre). It is
32
Tool-chucking technology and handling
Workpiece storage and chucking technology in one
Work organisation and material flow can be optimized with a combination of a work-piece storage unit, a pallet feed handling device and workpiece chucking technology.
The ready-to-operateP60R workpiece storage unitis ready for docking on a machining centre
1
© Carl Hanser Verlag, Munich
Figu
res:
Gre
ssel
32-33_SE310012_CHe10 07.07.2010 16:50 Uhr Seite 32
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
supplied as a standardised unit. First thespace available at the machine must beclarified. Additional questions, for exam-ple with regard to an automatic door, willbe clarified by specialists.
The P60R workpiece storage unit is basedon a steel-sheet welded structure with arugged monoblock design. Vertical gridplates are installed in the basic unit, whichserve as carriers for horizontal mountingcross-members for loading with work-piece pallets. This height incrementing hasthe advantage that the mounting cross-members for the workpiece pallets can bequickly adjusted depending on the work-piece height, enabling the standard num-ber of 60 workpiece pallets to be expand-ed further for small workpieces.
At least 60 workpiece pallets
in an extremely small area
Another advantage of the concept is thatthe standard pallets for the magazine already form the base plate for holding theworkpiece chucking units.High-rise,space-wasting adapter plates are eliminated. Thestandard pallets and the chucking units areencapsulated so that they can easily becleaned and handled. Workpiece pallethandling in the workpiece storage unit andduring feeding is fully automated with ahigh precision telescopic handling deviceequipped with a horizontal swivelling device. It is designed for workpiece palletswith a total weight of up to 30 kg. Depend-
ing on the working program,the workpiecepallets are collected from the correspon-ding mounting cross-members, transport-ed into the zero-point chucking system onthe table of the machining centre and fixedin place there. Following machining, thepallet is collected and returned to storage.Then the next workpiece pallet is fed intothe machine. In addition, the telescopichandling device collects the workpiece pal-lets and transports them into the inte-grated pallet loading/unloading station ifnecessary. As a result, the operator can replace the workpieces on the workpiecepallets and carry out the necessary con-versions of the chucking devices parallelto the main time.
The experience of the workpiece chuck-ing expert Gressel has been integrated inthe considerations and designs. That iswhy the mounting points for the work-piece pallets are hardened. The residualfluids are removed from the pallets dur-ing handling by blowing them off in themachine room. The workpieces are easy tosee and accessible from all sides throughlarge doors of transparent, break and impact-resistant safety glass. Thanks to aspecial 45 ° arrangement, the workpiecepallets are not only easy to see, they can al-so hold longer workpieces.This makes it un-necessary to eliminate the respective neigh-bouring positions.
In the standard model the magazine supports and the workpiece pallets are
prepared for the Unilock zero-point chuck-ing system from Schunk, Lauffen/Germa-ny. All other zero-point clamping systemsare also available on request. The work-piece storage unit is controlled with a pal-let management system.
Change time for a
workpiece pallet is 20 seconds
Programming and operation are carriedout with a touchscreen monitor via an input dialogue. Several work orders can besaved simultaneously, enabling repeat orders to be started quickly and withoutwaiting times. The change time for a work-piece pallet is 20 seconds from the maga-zine position to chucking in the zero-pointsystem. Here all processes are automatic.The standardised workpiece pallets can beused flexibly for various workpiece chuck-ing units. Depending on the application,the pallets hold either simple clamps called›Solinos‹,centred clamps ›Centrinos‹,dou-ble clamps called ›Duogrips‹ or specialchucking devices. This reduces the costsfor chucking devices. ❚
33
Gressel AGCH-8355 AadorfPhone +41 52 3681616Fax +41 52 3681617> www.gressel.ch
The workpiece pallet handling system has mounting cross-members which arefastened in vertical grid pallets2
It is possible to work at theloading/unloading station parallel to themain time, id est during pallet handling andmachining
3
32-33_SE310012_CHe10 07.07.2010 16:50 Uhr Seite 33
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
The coating Balinit Alcrona Prohas proven itself for the applicationsgear cutting, end milling, punchingand forming
1
Milling cutter in use: The coatingsBalinit Alcrona Pro and Balinit Alnovacan increase milling performance by up to30 percent
2
© Carl Hanser Verlag, Munich
C U T T I N G TO O L S
> Oerlikon Balzers, supplier of coatingsfor tools and precision components, hasadded two new coatings to its product line.These are the all-round coating Balinit Al-crona Pro and Balinit Alnova for high-endend milling cutters. They promise a longertool life at higher cutting speeds, highprocess reliability and recoating without areduction in performance. Compared totheir predecessors, the AlCrN-based coat-ings are said to offer improved perform-ance and greater productivity. Importantfeatures, like hot hardness, thermal shockstability and resistance to abrasive wear,have been optimised to achieve better re-sults under the extreme conditions of cut-ting and forming machining.
The coating Balinit Alcrona Pro is basedon the coating Balinit Alcrona, which hasproven itself since its introduction in manyapplications, such as punching, forminggear cutting and end milling (figure 1). Byoptimising the process parameters andmodifying the coating structure, it waspossible to improve the coating's internalstress profile and its resistance to temper-ature change. Tools coated with Balinit Al-crona Pro proved to be especially well-suit-ed for wet machining of non-alloyed steelsand high-strength steels with a hardness
of up to 55 HRC in the field test. Depend-ing on the application, increases in per-formance of 20 percent and more can beachieved compared to the coating BalinitAlcrona.
High-end coating
for end milling cutters
The Balinit Alnova coating developed onthe Innova coating system is characterisedby a greater hot hardness and resistance tooxidation. The end milling cutters coatedwith Alnova achieved an average tool lifeup to 30 percent longer than tools with oth-er high-performance coatings (figure 2).Through the development of higher-per-formance coating systems linked with ad-justments to the cutting materials and toolgeometries, it was possible to increase thetime cutting volume for roughing by a fac-tor of 15. While 7.5 cm3 of material wasremoved per minute with high-perform-ance steel milling cutters coated with TiN,today carbide milling cutters coated withAlCrN achieve 120 cm3/min.
In spite of an unmatched drop in theturnover in the past year, Oerlikon Balz-ers was still able to show a positive oper-ating result before restructuring coststhanks to early cost-reducing measures.
The adjustment of the coating network tothe market shift was primarily decisive forthis development. For example, 2009 pri-marily saw an increase in production ca-pacities in Asia, and in March 2010 the firstlocation was opened in Russia. »For 2010we are expecting a noticeable stimulationof business and the return to profitablegrowth,« commented Dr. Hans Brändle,CEO of Oerlikon Coating. »We want tocontinue to contribute to increased pro-ductivity with our coatings in future. In ad-dition, our high-performance coatings areincreasingly used on components in en-gine construction, and therefore also con-tribute to reducing fuel consumption.«❚
34
Oerlikon Balzers Coating Germany GmbHD-55411 BingenPhone +49 6721 793125Fax +49 6721 793104> www.oerlikon.com Fi
gure
s: O
erlik
onB
alze
rs
30 percent performance increase for milling
Off to new layers
New AlCrN-based layers improve tool life and cuttingspeeds. Recoating is possible without reduced performance.
34_SE310013_CHe10 07.07.2010 16:53 Uhr Seite 34
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
> Innovation is of significant importancein the higher wage economies, securing oremphasising market advantages over coun-tries that are active in the global arena withlow wage overheads, and higher-perform-ance products are often associated with thephrase. Of equal importance for corporatesuccess though and a factor that is seldomrendered transparent is process innovation.
The spindle is often designated as thecore of a milling or grinding machine.Spin-dle innovation is therefore of importance
if machine manufacturers are aiming tosecure or expand on market advantages.With milling and grinding processes thedemands placed on spindles are not on-ly diverse but in individual applicationsalso sometimes significantly different,with a high level of precision and speedand low vibration being specifically re-quired.With aviation applications, torqueand power are of primary importance inorder to increase the removal capacity(cutting rate).Under consideration of suchframework conditions, the Fischer com-pany from Herzogenbuchsee in Switzer-land have developed spindles and spindle
features that aim to push forward existingperformance limitations.
Shaft cooling helps
to improve the repeat accuracy
Fischer shaft cooling is a product innova-tion that helps to distinctly improve therepeat accuracy of the TCP (Tool CenterPoint). It enables the cooling of the com-plete spindle shaft and therefore of the ro-tor and inner bearing rings as well. Thecooling is implemented via several chan-nels in the spindle shaft through which thecooling medium (water or oil) is routed(figure 1).
35
D R I V E SY S T E M S
Higher-performance spindles via shaft cooling
Cooling for the coreShaft cooling, a spindle feature of the Swiss company Fischer AG, enables cooling ofthe complete spindle shaft and therefore the rotor and inner bearing rings as well.This is of interest for the aviation industry and for tool and mould construction.
BY RUDOLF WALTER
Figu
res:
Fis
cher
Schematic diagram of the Fischer shaft cooling system (left) and housing and shaft cooling1
35-37_SE110022_CHe10 07.07.2010 16:55 Uhr Seite 35
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
D R I V E SY S T E M S
Direct cooling of the thermal sources ona spindle shaft reduces the temperaturegradients in a spindle in both the axial andradial directions.This positively influencesthe TCP repeat accuracy and the warm-up behaviour. Because of a low spindletemperature level, temperature stabilityis significantly improved and as a conse-quence the dependence of temperaturebehaviour on rotational speed is almostentirely eliminated. The completegrowth in height of a spindle canbe reduced by 70 percent with theuse of a shaft cool-ing system. In tooland in mould con-struction applica-tions, this improve-ment in precision isof decisive advantage.
What's new: water cooling is nowavailable for spindles with an HSK-E40 interface, whereas until nowthis was only available for HSK-E50 andHSK-A63 spindles. For this to be achieveda new design principle was required fortool output, for the internal process coolantprovision and supply of the shaft with thecoolant.
For titanium machining
and the aviation industry
Implementation of a shaft cooling systemis also advantageous for titanium cuttingin the aviation industry. Large-scale asyn-chronous motors create considerable pow-
er loss in the rotor, and cooling of the ro-tor via air turbulence is low because of thelow speeds involved with titanium cutting.The use of synchronous motors is in somecases difficult because of the requisite max-imum torque levels and the resulting rel-atively large field weakening ranges.
For example, speeds of 5000 rpm and arated torque greater than 600 Nm are re-quired with a rated speed of 500 rpm. This
corresponds to a ratio of anchor settingrange to field weakening range of one toten,whereas a ratio of one to three is mean-ingfully applicable for synchronous mo-tors.With current demands,asynchronousmotors would basically be the favourablesolution. Standard laminations for motorshave been constructed to generate the leastpossible heat in the rotor. If however ad-ditional losses in the motor are permittedvia adaptation of the lamination along with
simultaneous implementation of shaft cool-ing, torques can be achieved as with syn-chronous motors and significantly greaterfield weakening ranges in comparison toa synchronous motor.
Figure 2 compares the losses of an asyn-chronous,a synchronous and a shaft-cooledasynchronous motor. With 800 Nm it wasshown that with identical outer diametersthe blade length of the shaft-cooled asyn-chronous motor was only 15 percent larg-er than that of the synchronous motor,meaning that power densities were almostcomparable.
Rotary transmission
sets high standards
In tool and mould construction a standardrequirement is, in addition to cooling lu-brications and minimum lubricating quan-tities, to make air available via the inter-nal coolant infeed,and without limitationsin speed. The Fischer rotary transmissionmeets this requirement (figure 3).With themilling of deep cavities, supply of the cut-ters with air enables swarf to be blown outthat in particular for tools with small diam-eters disturbs the cutting process and insome cases may also lead to cutter break-ages.The rotary transmission system works
with a non-contact lossysealing system that func-
tions without wear.Wear to the sealingsystems of rotarytransmissions (pri-mary failure causewith rotary trans-missions) has beeneliminated with the
rotary transmission sys-tem. The sealing principleoutlined above enables
high pressure impact, which increases theachievable removal rates for titanium cut-ting with correspondingly identical toolwear. With a pressure of 150 bar, a toolwith two bores (each with 2 mm diameter)enables a flow of coolant volume of ap-proximately 40 l/min.
The Fischer MFM UniDrive grindingspindles offer high precision and goodgrinding performance, and are equippedwith various options such as rotary trans-mission or speed monitoring. But forsome applications however these are over-
36
Comparison of electrical losses and required blade lengths with constant motor diameters2
0 0.5 1 1.5 2 2.5
Eisenverluste Stator [kW]
Kupferverluste Stator [kW]
Kupferverluste Rotor [kW]
Bezogene Motorlänge [ ]
Synchronmotor Asynchronmotor Asynchronmotor mit Wellenkühlung
cos ϕ = 0,95cos ϕ = 0,75
cos ϕ = 0,80
Fischer rotary transmission with non-contact sealing system3
Synchronous motor Asynchronous motor Shaft-cooled asynchronous motor
Iron loss of the stator [kW]
Copper loss of thestator [kW]
Copper loss of therotor [kW]
Blade length of themotor
35-37_SE110022_CHe10 07.07.2010 16:55 Uhr Seite 36
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
sized and therefore uneconomical. Thenew MFL LeanDrive grinding spindle se-ries has been developed under considera-tion of modern manufacturing processesand new construction principles and aspart of internal process innovation. TheMFL series is a supplement to the MFMseries, and differs in its limited applicationrange and lower performance (figure 4).Development of the MFL spindles focusedupon the maxim of being as complex asnecessary and as economic as possible.Withthe best possible coordination betweenperformance and optimised construction,a cost-efficient, lower-price range was de-veloped without having to accept compro-mises in terms of quality. This proceduremarks the boundary between lean prod-ucts and low cost solutions.
In terms of design and construction anemphasis was placed upon reducing diver-sity, an aim that was facilitated by the lim-
itation of possible options. The new Fis-cher plant was also an important prereq-uisite for this. Lead times and therefore al-so unit costs could be reduced with thespecific selection of suitable productionresources,efficient processing methods anda minimisation of work stages.
Input of minimal quantities of oil or
grease near to the rolling contact
The grease lubrication of spindle bearingsreaches its limits compared to oil/air lu-brication systems in cases where a perma-nent operation of maximum speeds is re-quired, and the achievable service life issignificantly less. The reasons for this arediverse. A specific reason though appearsto be the absence of migration of base oilfrom the peripheral areas of the lubricantcollar into the races. Grease lubrication istherefore problematic for example for ap-plications in tool and mould making.Withthe processing of free-formed surfaces,tools with small diameters are used for thecomplete processing duration. The millingstrategies require high cutting speeds evenwith such small tools, thus resulting inhigh speed requirements.
Relubrication, id est the input of mini-mal quantities of oil or grease into the
greased bearings near to therolling contact where usedgrease (thickener withoutbase oil) is found, is accord-ing to initial tests an effec-tive method of achieving agreater service life with suchapplications. The problemhere is found in the selec-tion of suitable lubricatingintervals and the dosage ofthe grease or oil to be fed.First tests have demonstrat-ed that with the implemen-tation of relubrication, keyspeed values of 2.2 millionmm/min. seem sustainablyrealistic.
Constant temperature
– work-precise spindles
The aim is to prevent a sig-nificant increase of temper-ature in bearings via relubri-cation. With a specificationof more frequent lubricat-
ing intervals (every two hours for exam-ple) with use of small quantities of greaseor oil, the proportion of friction causedby relubrication is negligible comparedto other parts of overall friction in thebearings (rolling friction, drilling fric-tion, friction between rolling elementsand cage, friction between the cage andbearing ring, air friction). If a constanttemperature cycle exists, the longitudinalelongation of the shaft remains constant,which in turn excludes an influence up-on the work precision of the spindles.This is a precondition for use in tool andmould making applications. Researchdedicated to analysing the influence of re-lubrication is now the focus of productdevelopment at Fischer Precise in orderto gain secure knowledge over increasesin speed and service life. And indeed thefirst results show that relubrication willbe pushing the limits for grease lubrica-tion towards greater speeds and bearingservice life. ❚
37
D R I V E SY S T E M S
Rudolf Walter is Head of Sales and Marketing at Fischer Precise Groupin Herzogenbuchsee/Switzerland > [email protected]
Data comparison of the MFL and MFM series4
Drehzahl–LeistungsdiagrammSpeed performance diagram
Leis
tung
kW
Pow
erkW
8
7
6
5
4
3
2
1
0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000 110000 120000
Drehzahl min-1
Speed rpm
MFL
–102
4
MFL
–104
5
MFL–1075
MFL–10105
MFM
–102
2/45
MFM
–103
2/60
MFM–1090
MFM–10120
MANUFACTURERiFischer Precise Group AGCH-3360 HerzogenbuchseePhone +41 62 9562222Fax +41 62 9562200> www.fischerprecise.com
35-37_SE110022_CHe10 07.07.2010 16:55 Uhr Seite 37
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
C - T E C H N O LO G I E S
38
> Especially with expensive machiningprocesses like grinding, production ex-perts have to reach deeply into their bagof tricks today.Whether it's ›exotic‹ grind-ing processes like profile relief-grindingof conical dies or standard processes likegroove grinding – the tools and processesused must be developed further from thepoint of view of efficiency. Here the ob-jectives are clear: To manufacture tools withaccuracies which are only limited by thereproducibility of the process.Whether in-dividually or in combination, use of theprocesses should be as flexible as possible.These objectives can only be achieved withcorresponding software and simultane-ous, integrated process control. So it is apioneering idea when two specialists bun-dle their components for tool grindingand quality control for this product seg-ment. From standard milling cutters ordrill bits to indexable inserts to complexform-dependent milling tools and ›exotis‹for the production of any desired gears:The ›joint competence‹ products from Es-co and MTS offer complete solutions froma single source.
Thanks to the bundling and the joint ex-pansion of their product focuses, the Swisscompany MTS AG and the company EscoGmbH with headquarters in Aachen, Ger-many, meet the broad range of require-ments from precision tool manufacturing.
Two product families
for all grinding tasks
With Tool-kit professional,MTS covers themanufacturing and sharpening of milling,drilling and lathing tools, and blanking diegrinding has also just been integrated.Theintegrated visualisation and collision mon-itoring functions make use easy. Standardinterfaces to tool measuring devices com-plete the range of functions.
With the software products of the PTM(Precision Tool Manufacturing) family,Esco is well established in the productionof profile-dependent (special) tools. Aspecial species in this environment are, forexample, the gear cutting tools. All rele-vant processes for soft and hard machin-ing of these tools are available in the tooldesign and production simulation. Theexternal accuracy requirements for pro-file and gear cutting tools make it neces-sary to head in new directions in qualityassurance. Esco provides tool and pro-duction-oriented measuring and evalua-tion software with the Hawk quality as-surance module. ›Closed-loop‹ grindingwith the automated return of deviations
Two software manufacturers use synergies of ›joint competence‹
Bundling core competencesWhether it's a standard tool or a die, a thread-cutting or a gear-cutting tool: Thesoftware companies MTS and Esco offer a software pool for all grinding tasks. Andthey have already jointly developed three partner solutions for all areas of grinding.
BY DIETMAR ERNST
Profile relief-groundcutting edge
1
Figu
res:
Esc
o, M
TS
38-41_SE110014_CHe10 07.07.2010 16:57 Uhr Seite 38
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
measured in the process promises toolswith a high level of reproducible quality.The newest product of the PTM family isthe software module for ›near net shape‹blank production: The simulation of thegrinding process for the production of aprecision tool is provided by the produc-tion-realistic model as a 3D solid.
»The first three«
In the previous three joint-competence so-lutions, the cooperation partners showhow the user can benefit from the syner-gy effects. Any desired combination ofsheath bevel grinding and profile reliefgrinding not only makes grinding of com-bination tools considerably easier, it alsoserves as the basis for the modelling of anydesired standard and special tools. Closed-loop grinding provides good results for theentire range of tools addressed with possible access to the basic data for de-scribing the tool lip.
Tool-kit professional knows variousgrinding processes with which tool flankgeometries can be ground using standardgrinding wheels (linear grinding, bevelgrinding and radial relief-grinding). Toproduce profile sections with a high true-ness of contour, it is advisable to use pro-file wheels which are dressed accordingly.The tool can have any desired spiral shapeand a tool flank geometry with freely de-finable axial/radial clearance angles. Theprocess for calculating the profile wheelfrom a specified contour and a cutting-edge three-dimensional curve was devel-
oped by Esco and integrated in the Tool-kit professional grinding software fromMTS AG (figure 1). To produce a profilewheel, the software is equipped with a sep-arate dressing cycle, which can either beintegrated in the grinding machine or canbe run as an external dressing program forcontrolling a special dressing machine.
Closed-loop grinding
Grinding programs created with Tool-kitprofessional map the required tool geom-etry tolerance-compliant. However, realitythen often becomes apparent when meas-uring the tools: the grinding tool, tech-
nology and machine cause deviations. Theevaluation of these deviations and the pro-vision of specific correction data with theEsco Hawk software made it possible toproduce tools with accuracies which areonly limited by the reproducibility of theprocess.
The closed-loop process was developedby Esco and integrated in the MTS grind-ing software. The objective of the devel-opment was to avoid the time-consumingtrial-and-error methods for correctingshape deviations. To achieve the requiredprecision, even skilled tool grinders wereforced up until now to employ dogged cor-rection of the grinding wheels and, if nec-essary, of the calculated grinding pathwith corresponding correction parame-ters. This led to repeated test grinding re-quiring a great deal of time and materials.
The situation is quite a different onewhen working in a closed loop. Here thetool geometry is first designed and para-meterised in Tool-kit professional. Thesystem must be understood as a virtualmachine. Verification is carried out geo-metrically and with process engineeringhere. 2D and 3D simulations monitor andoptimise the process sequences,axis move-ments and grinding wheel interventions.The tool geometry is checked with inte-grated measuring and analysis tools andthe individual process parameters are al-ready set on the PC – and therefore out-
39
The tool contour is measured in the Hawk software tool2
The corrected grinding path is generated there from the correction data and a new CNCcode is transferred to the grinding machine3
SWISS QUALITY PRODUCTION 2010
38-41_SE110014_CHe10 07.07.2010 16:57 Uhr Seite 39
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
C - T E C H N O LO G I E S
40
side the actual machine room. Finally, thecalculated grinding and dressing programscreate a CNC code for controlling thegrinding machine used. Grinding is fol-lowed by the measurement of the toolgeometry in an (optical) coordinate meas-uring machine (figure 2).
Hawk ist the connecting link
between several machines
The Hawk software tool as a programming,evaluation and documentation system forthe digital measurement of geometricalvariables is the connecting link between themeasuring machine and the tool grindingmachine. It is tailored to the requirementsof precision tool manufacturing,and there-fore takes characteristic requirements fromthe tool geometry and the grinding processinto account.
The data exchange between Tool-kit pro-fessional and Hawk is optimised with acorresponding system interface.From here,Hawk is supplied with the data of the tar-get contour and the shape of the cuttingedge curve. At the same time, the meas-ured contour data from the measuringmachine are integrated as actual values. In
the first step, Hawk assumes the task ofdetermining the deviations in shape fromthe target-actual comparison (figure 2 be-low). In the second step, the results are then
automatically implemented in a correctionfunction (figure 3). The calculated correc-tion data are routed back into the Tool-kitprofessional grinding system. The grind-ing path corrected accordingly is generat-ed there from the correction data and anew CNC code is transferred to the grind-ing machine. Ideally, one-time correctivegrinding is sufficient to produce a toler-ance-compliant tool. Even with extremeaccuracy requirements, only a few correc-tive cycles are necessary to reproduciblygrind the tool with high accuracy.
Near net shape blank production
The term ›near net shape‹ is a fixed termfor blank production with primary and re-shaping operations. Considerable advan-tages of the strategy can be applied to theproduction of precision tools. The EscoPTM (Precision Tool Manufacturing) soft-ware tool with integrated functionalityfrom Tool-kit professional supplies thetool for blank production as a ›produc-tion-realistic‹ 3D solid model which re-sulted from a design chain developed froma freely selectable combination of the grind-ing processes for tool flank grinding (seefigure 1). Depending on the type, dimen-sions and material, a tool runs throughmore or less complex machining process-es within the respective process chain dur-
Production simulation in the PTM software tool begins with parameterisation andimporting of the tool geometry4
All individual operations are then carried out virtually in the subsequent modelling run5
38-41_SE110014_CHe10 07.07.2010 16:57 Uhr Seite 40
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
ing its production. Form-dependent tools– and if necessary secondary tools – arerequired for the soft machining of dies.These are profile cutters and/or relief cut-ters, which must in turn also be designedand manufactured. Following hardening,the ›decisive‹ part is ground. On theother hand, solid carbide tools areproduced by grinding from the car-bide blank, which is often only veryroughly matched to the final geom-etry. Grinding is the most expensiveprocess and involves the most eco-logical problems. This means thatthe closer the blank already is tothe final geometry, the shorter theprocess chain, the fewer resourcesare required and the better the pro-duction quality that can be ensured.
However, the blank must not on-ly be technically practical, it mustalso be inexpensive to produce. 5-axis machining centres with match-ing CAM software can achieve thesegoals. In contrast to groove millingor relief lathing machines, standardmachines with standard tools canbe used to mill a blank. Via a stan-dard interface (STEP, IGES), theCAM software processes blank da-ta imported as a solid like conven-tional data for describing a freeshape. This input is supplied byPTM in a form suitable for the re-spective interface. The productionsimulation begins with the para-meterisation and/or importing ofthe tool geometry in accordance withthe drawing data. For production,for example for relief grinding of afir tree cutter, the effective geome-try can be divided up into the areasto which separate partial grindingwheels are assigned. The next stepsare the selection of the machiningprocess and the parameterisation ofthe (individual) operations (fig-ure 4). Relief grinding can, for ex-
ample, be carried out with various radialand/or axial strokes. The results of the cal-culations are the tool geometries requiredfor machining and additional informationon the production results, for example theactual cutting angle curve. All individual
operations are then carried out virtuallyin the subsequent modelling run (figure 5).This then makes the results based on therespective production status available forthe derivation of the model for blank pro-duction. Depending on the tool type andthe tool dimensions, it can therefore befreely decided which production depth isassigned to the blank. ❚
Dietmar Ernst, Engineer, is CEO of Escoin Aachen/Germany> [email protected]
Can you finishprecise small bores?
The Micro Bore Sizing (MBS) system consists of:
* Example from the watch-and-clock-making industry
1 mm*
Microcut LtdRolliweg 21/P.O. Box 448CH-2543 Lengnau BESwitzerland
Phone +41 (0)32 654 15 15Fax +41 (0)32 654 15 16E-Mail [email protected] www.microcut.ch
· dimension and dimensional accuracy· roundness· surface roughness· cylindricity
Micro Bore Sizing is an ideal procedure for materials such asPCD, ceramic, tungsten carbide,steel, glass and plastics.
Details at: www.microcut.ch
Honing and internal cylindrical grinding reach their technical limits at bore diameters of 0.015 to 2.5 mm. The micro bore sizing offers economical finishing solutions for exactly this diameter range. Corrections of following quality criteria are possible:
MANUFACTURERiEsco GmbHD-52070 AachenPhone +49 241 182980Fax +49 241 1829829> www.esco-aachen.de
MANUFACTURERiMTS AGCH-4133 PrattelnPhone +41 61 8159130Fax +41 61 8159139> www.mtsag.net
SWISS QUALITY PRODUCTION 2010 41
38-41_SE110014_CHe10 07.07.2010 16:57 Uhr Seite 41
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich 42
> Renewable energies are an importantresource for dealing with the world we livein in a lasting, environmentally friendlymanner. Hydroelectric power still coversmore than half the electricity required inSwitzerland. Now the expansion of reser-voirs and river power stations will soonreach its limits. However, small powerplants still have development potential.It's worth it to use even smaller amountsof water for power generation. BunormAG, with headquarters in the Swiss townof Aarwangen, has supplied three smallturbines for this kind of power plant. Theywere manufactured and assembled com-pletely in-house.
Bunorm employs a staff of more than60, was founded in 1965 and originallyproduced items for civil defence and firebrigades. This was then followed by thetransition to a mechanical engineeringcompany specialised in welding tech-niques and the machining of large parts.The company is managed in the secondgeneration by Urs Morgenthaler. He says,»Our strength is the machining of work-pieces up to 12 metres in length on ourmachining centres. Our own engineeringdepartment enables us to take on ordersthat other suppliers are unable to fill.« Forexample, Bunorm offers self-developedworking platforms for tunnel construc-
tion, which are used by German and Nor-wegian road construction companies. Asa wage producer, Bunorm supplies Swissmachine builders and automation com-panies. It is in this context that the com-pany received the order mentioned at thebeginning.
From individual parts to delivery
of complete tubular turbines
Initially, Bunorm only supplied individ-ual parts. When these met up to its cus-tomers' expectations and the supplier wasunable to deliver the cast Kaplan bladeson schedule, Bunorm received the orderto mill these from solid material. The or-der was then expanded and also com-prised the delivery and installation of theentire tubular turbines, the constructiveproduction of which also entailed certainengineering tasks.
Digital models in the 3D step formatwere available for parts production onCNC machines and prior programming.The most demanding workpiece for tur-bines is the blade, which must be milledwith 3 to 5 axes. For their programming,Roger Knobel (figure 1), machine opera-tor and CNC programmer, used the Top-Solid’Cam CAM system from Missler Soft-ware. This system is sold in Switzerland byNCData AG in Zürich and in Germany byNCData GmbH in Öpfingen.NCData sup-plies the software, produces the post-processors and trains the users.
The case described concerned a supple-ment to the original basic training pro-gram in order to select the correct millingstrategies. NCData conducted local train-ing in 5-axis milling with TopSolid’Cam.Together with the programmer Knobel,suitable machining methods were devel-oped and checked using a model. The pro-totype of an aluminium blade was milledbeforehand to study the feasibility. To milla blade from solid material, most materi-al must be removed with 3-axis roughingcycles. Due to the limited working area ofthe DMU 100T 5-axis milling machinesfrom DMG, 3-axis roughing had to be car-
Complete in-house production of tubular turbines
Full speed aheadThe most demanding workpieces on turbines are the blades. A powerful programming system helps find the right machining methods, define working levels and check material removal.
BY CHRISTIAN GRABER
Roger Knobel,machine operatorand CNC programmerat Bunorm, at hisprogramming station
1
C - T E C H N O LO G I E S
Figu
res:
NC
Dat
a
MANUFACTURERiNCData AGCH-8047 ZürichPhone +41 44 7382727Fax +41 44 7382717> www.ncdata.ch
USERiBunorm AGCH-4912 AarwangenPhone +41 62 9192040Fax +41 62 9192049> www.bunorm.ch
42-43_SE110024_CHe10 07.07.2010 17:01 Uhr Seite 42
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
ried out from ten different directions.Herethe TopSolid’Cam programming systemhelped to define working levels and rough-ing cycles and to check the material removalcarried out. Programming and checkingwere carried out exclusively on a com-puter (figure 3). For example, this dyed ar-eas in the picture show the operator veryprecisely where it is necessary to cut awaymaterial and where material is still pres-ent for additional milling operations.
As a final step, the entire blade was fin-ish-smoothed with the 5-axis sweep methodto refine the surface and reduce the re-quired polishing effort. Here as well, it wasnecessary to proceed step by step with dif-ferent inclinations of the milling cutter rel-ative to the material due to the limited ma-chine room (figure 4).
The safety of milling collision-free
During all work steps the realistic machinesimulation from Top-Solid’Cam offeredthe safety necessary for milling the partcollision-free. Knobel was able to dependon the calculated collision check using allmachine and chucking elements. »With-out the extensive simulations and test func-tions of TopSolid’Cam, it would not havebeen possible for us to program and millthis blade,« he explains. »With the CAMfunction, which enables the exact behav-iour of the machine when changing levelsto be defined, saved and reused, it was al-so possible to program the approach dis-tance in accordance with reality, and there-fore to avoid all collisions in advance«.
All other workpieces of the turbinewere programmed with TopSolid’Camand milled or lathed on machining cen-tres from Bunorm. Finally, the turbine wasassembled and delivered for installation inthe power plant. In the process, it becameapparent that the pipe in which the rotorwas to be inserted, has been incorrectly de-signed by the customer and had to be rema-
chined to the right size by Bunorm. Thismeant dismantling and return to the fac-tory. One more argument in favour of acomplete supply from Aarwangen.
Bunorm uses TopSolid’Cam since 2006to program its CNC machines. Initially,relatively simple supplied parts were pro-duced, which could be machined with 5positioning axes. One year after these ini-tial steps, the first application for 5-axissimultaneous milling followed. NCDataproduced post-processors for all machinesand adapted them to the special needs ofBunorm. Since 2009 tubular turbines havebeen manufactured completely in-house.In response to the question of whether thesoftware has opened up new business seg-ments, Morgenthaler clearly replied »Yes«.The company's strategy is the supply of as-sembled modules and complete machines.These provide greater added value,and withits own Engineering department, Bunormhas created excellent conditions for sup-plying more than just the machined work-pieces. Morgenthaler explains, »Each ma-chine contains its own very complex parts.As we always program with TopSolid’Camand produce here at the factory, we cansupply everything from a single source andreceive an increasing number of orders.«
Bunorm trains two polymechanics a yearand also provides training in high-endCNC programming. A simple 2- and a 5-axis CNC machine are available to traineesfor this purpose. Public vocational schoolsand instruction at the professional associ-ation cannot offer this demanding training.Therefore, in future Morgenthaler wantsto have all trainees trained at the traineeboot camps offered by NCData. ❚
Christian Graber is a member of the management at NCData in Zürich/Switzerland> [email protected] Turbo-Separator AG / CH-9620 Lichtensteig
Sanborn Technologies Walpole MA 02081-2558800-343-3381 / 508-660-9050
Back-Flush Filterfrom Turbo-Separator
Protecting the environment
...and still universal applicability
at maximum cost savings
For more than 50 years innovations for an intact
environment
Turbo Clean TCL
- Innovative filtration concept- for carbide and oil- filter quality 2 – 5 micron- back-flush with oil (no commpressed air)- cost effective operation- simple maintenance- energy saving operation- optimized sludge conditioning- single supply and central systems
for an attractive price
We are present:IMTS 2010 / N7538
Material removal is checked with theTopSolid’Cam programming system:The dyed areas indicate which areas stillneed to be cut away
3
Milled from solid material: The machinesimulations in the CAM system ensure collision-free milling for all work steps onthe turbine blade
4
SWISS QUALITY PRODUCTION 2010
42-43_SE110024_CHe10 08.07.2010 15:39 Uhr Seite 43
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
C - T E C H N O LO G I E S
> Unimerco has built up an envious namefor itself on a global scale with the devel-opment of special tools. Unimerco expertsproduce custom-made tools for their cus-tomers within a very short period of time.The company with headquarters in Den-mark today has around 600 employees andhas been using CNC tool grinding ma-chines equipped with the Numroto grind-ing software for nearly 20 years. The serv-ice spectrum (with twelve subsidiariesacross the world) is characterised by closecooperation between the tool grindingmachine manufacturer Saacke and thesoftware experts from Num. Often newtool solutions are drawn up within a pe-riod of only eight to ten days, and the uni-fied quality concept has deep roots in thecompany's corporate culture.
As a part of today's operations, finaltool specifications are saved to the mainserver in the Danish Unimerco headquar-ters. From there these can be called up byany subsidiary via the company intranet.
Identical Saacke grinding machines areused (figure 1) at all manufacturing loca-tions in Europe and America, equippedwith Numroto packages. In this way Uni-merco is able to reproduce the most pre-cise aspects of tool construction exactlyaccording to original specifications, andindependently of when and where the
production of new tools or regrinding isrequired. The main focus of custom-madetools also demands the solving of highlycomplex problems, which is why the com-pany has built up a relationship to Saackeand Num in the past years. The startingpoint for many developments in CNCtechnology at the Saacke grinding centreswas often the requirements of Unimerco,an example being the first automatic andflexible workpiece changer on a tool grind-ing machine.
Rapid implementation
of new constructions
With tool construction and machine con-trol, Unimerco depends on highly devel-oped software. Many years ago, and fol-lowing an extensive evaluation process, thelittle-known solution from Num was se-lected. In the meantime, Unimerco em-ployees are convinced they have the bestpossible solution with Numroto. The soft-ware package's 3D modelling, simulationand optimisation environment plays animportant part in the rapid implementa-tion of new constructions, and the modellibrary is also a frequently used feature.This enables many constructions for spe-cial tools to be imported, adapted, simu-lated and optimised within a short spaceof time. Two of the virtual functions forprototype creation are toolpiece simula-tion and collision monitoring for Saacketool grinding machines, which allow Uni-merco to save much time that would oth-erwise need to be invested in testing. ❚
44
Numroto software used by special tool manufacturer
A software package for special tool solutions
With the production of special tools, the tool manufacturer Unimerco depends on theNumroto software package at its various production locations.
USERiOne of Unimerco's special applicationareas is the production of special tools forthe processing of hydraulic valves, andUnimerco has developed a number of toolconcepts for this market. An example isthe Grooving Land Tool, with enables allgrooves and control edges of a slide boreto be processed in one step (figure 2).Normally the production of such compo-nents requires several tools to be imple-mented, and often with machining fromboth sides. The Unimerco solution meansthat up to 15 grooves/control edges canbe processed in one work step.
Unimerco GmbHD-71634 LudwigsburgPhone +49 7141 6434755Fax +49 7141 6434756> www.unimerco.com
MANUFACTURERiNum AGCH-9053 TeufenPhone +41 71 3350411Fax +41 71 3333587> www.num.com
All-in-one solution: the Grooving LandTool profile tool (above) and the before (centre) and after (below) results on theprocessed workpiece
2
Unimerco uses identical grindingmachines sourced from the manufacturerSaacke for all production facilities worldwide
1
Figu
res:
Num
, Uni
mer
co
44_SE310014_CHe10 07.07.2010 16:59 Uhr Seite 44
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
> The Eifeler Corporate Group uses aType 4400 hydrocarbon system from thecleaning specialists at Amsonic in Biel,Switzerland, to condition shank tools forcarbide coating and to remove oil andgrinding dust residues, even from toolswith cooling ducts. The main businesssector of the Eifeler Corporate Group iswear protection of tools with PVD hardmaterial coatings. To fully unfold theirperformance, the coatings must adherewell to the tool surface.And this requiresa cleaned bare metal surface. Duringtesting with individual tools at the Amsonic laboratory it already becameapparent that good cleaning results canbe achieved, in particular even on cut-ting tools with cooling ducts.
Cleanliness in ducts
The excellent results of the tests are con-firmed in the application. All types ofshank tools were efficiently cleaned.Andthere were no problems on tools with a long working range and correspond-ingly deep ducts for inner cooling. Thesubsequent PVD coating also adheres inthe immediate vicinity of the outletopening of cooling ducts, enabling thesetypes of tools to be provided with a high-quality coating even without additionaleffort and expense.
In 2008 the staff at Eifeler wanted toimprove the situation when cleaningshank tools with a complex geometry.The systems of the Amsonic product linewere especially interesting here. Theirtechnology is based on the use of non-chlorinated hydrocarbon solvents at in-creased temperature in a sealed vacuum.
The corresponding cleaning systems havecertain advantages. These include highsolvent power for the most importanttypes of soiling, a pronounced metallicgloss following cleaning and an excellentecological balance and efficiency. At theend of a long series of tests at the Amsonic process laboratory, Eifeler de-cided on the system of the 4000 productline. A system of the type Amsonic 4400A3, the newest model of this series, wasinstalled the same year. The system fea-tures fully automatic control and a con-siderably higher throughput comparedto the test model (six batches per hourof 100 kg each), enabling Eifeler's needsto be met as required. ❚
SWISS QUALITY PRODUCTION 2010
Clean shank tools before coating
Good coating quality requires cleanliness
Figu
re: A
mso
nic Amsonic AG
CH-2504 BielPhone +41 32 3443500Fax +41 32 3443501> www.amsonic.com
SwissPrecisionTools
www.powRgrip.ch
More than clean: After cleaning in theAmsonic 4400 A3 fully automated cleaning system, the shank tools areexcellently prepared for coating
O P E R AT I N G T E C H N O LO G Y
45_SE310017_CHe10 07.07.2010 17:00 Uhr Seite 45
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
O P E R AT I N G T E C H N O LO G Y
46
MANUFACTURERiTurbo-Separator AGCH-9620 LichtensteigPhone +41 71 9877031Fax +41 71 9877029> www.turbo-separator.ch
> For over twenty years the Chinese com-pany SanHe Timberley in the province ofGuangxi has produced tools for the wood-working industry. In the past the parts –primarily profile and standard cutters –were produced on 32 Chinese grindingmachines. In recent years the managementhas decided to equip its production plantwith modern production machines. Theincrease in demand and the product qual-ity requirements made this step necessary.With the purchase of modern CNC grind-ing machines, it became necessary to re-place the magnetic filter process previous-ly used for oil cleaning.
Yuanhua Thielke-Qiu, Chief Represen-tative for Asia and CEO of Turbo FiltrationScience & Technology Co., Ltd. in Shang-
hai, a subsidiary of Turbo-Separator inSwitzerland, succeeded in presenting var-ious solutions for cleaning lubricants inWuzhou before the decision was made infavour of a certain machine tool manu-facturer. At SanHe Timberley the decisionwas made to purchase 40 CNC grindingmachines of the RX and GX series from theAustralian company Anca in Melbourne.As a result, the machine pool will be in-creased from the already existing 32 MHKmachines to a new total of 72 productionmachines. The management in Wuzhouthen searched for an effective method forprocessing the grinding oil. With its newdevelopment Turbo- Clean TCL, the teamat Turbo-Separator in Lichtensteig suc-ceeded in presenting a technical realisationwhich matched the requirement profile inmost points. The Turbo-Clean TCL clean-ing system (figure 3) is designed to separate
carbide from low-viscosity grinding oil and,like all cleaning solutions from Turbo-Sep-arator, functions without additives. Thesystem combines the filtration methods offine filters with a back-flushing processwith the turbo centrifuge technology. Themodular design enables step-by-step ex-pansion with a cleaning performance of120 l/min.
Production machines
divided into two blocks
Yuanhua Thielke-Qiu made sure that nolanguage misunderstandings could creep inwhen exchanging data,dimensions,sketch-es, drawings and details between Wuzhouin China and Lichtensteig in Switzerland.Ruedi Bannwart (figure 2),CEO of the Tur-bo Group, explains, »The cooperation asa team in Switzerland and on-site in Chi-na functioned well. If planning and proj-ect problems occurred,either Management,Sales or Engineering jumped in whenev-er necessary to suggest a solution as quick-ly as possible.« As a result, the project plan-ning group was able to present the TechnicalDirector Pirmin Sieber with a completeplan within three months. This was thencoordinated with the features profile fromChina and accepted by SanHe.
It was important during the realisationphase to maintain the greatest possible in-
Additive-free cleaning solution for Chinese tool manufacturers
Swiss purity standardNow that's global cooperation: The Chinese tool manufacturer SanHe Timberleyprocesses grinding oil and other process fluids from more than 70 grindingmachines with two systems from the Swiss manufacturer Turbo-Separator.
BY ROMAN BÜRGE
Figu
res:
Tur
bo-S
epar
ator
YuanhuaThielke-Qiu, ChiefRepresentative forAsia and CEO ofTurbo FiltrationScience & Technology Co.,Ltd. in Shanghai,a subsidiary ofTurbo-Separatorin Switzerland
1
»If planning and project problemsoccurred, either Management, Salesor Engineering jumped in to suggesta solution as quickly as possible«,explains Ruedi Bannwart, CEO of theTurbo Group
2
46-47_SE110025_CHe10 07.07.2010 17:02 Uhr Seite 46
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
SWISS QUALITY PRODUCTION 2010
dependencewithin the produc-tion line. For this rea-son,the companies San-He and Turbo-Separatordecided to divide the pro-duction machines into two blocks.The40 new Anca CNC grinding machineswere supplied with four Turbo-CleanTCL group systems with an output of800 l/min. The back-flushing fluid isprocessed with two AZF-T40 auto-matic centrifuges. Block 2 is formedby the already existing 32 grinding ma-chines of Chinese origin. Here clean-ing is carried out with two group sys-tems with an output of 480 l/min, andthe fluid is processed with an auto-matic AZF-T40.
The soiled cleaning fluid of the toolgrinding machines is pumped throughthe back-flushing unit. The fluid flowsthrough five filter tower units simul-taneously, however these are back-flushed consecutively. This guaranteesthe continuous supply of the produc-tion machines. The solid particles arereliably held back in the Turbo-CleanTCL. Following back-flushing, the oilsaturated with carbide is pumped in-to the catch container of the AZF-T40automatic centrifuge. This centrifugeprocesses the oil with a low flow rate,and the cleaned oil is pumped back tothe system. The removed carbide isautomatically collected in the sludgecatch container.
The connected machining systemsare supplied with the cleaned mediumthrough a closed circular pipeline withfrequency-controlled pumps. The en-tire pumping system is redundantly de-
signed and therefore guarantees a highlevel of protection against failure. Thesystem operates without compressedair, making it suitable for use in geo-graphical areas with high humidity.
Cleaning quality
ranges from 2 to 5 μm
The cleaning quality of these systemsranges from 2 to 5 µm. The high degreeof cleanliness of the medium achievesa considerable increase in product qual-ity.The major advantages of the systemslie in the increased service life and theability to reuse the recovered carbide.The virtually dry, pure carbide sludgeis also purchased in China by dispos-al companies and routed to recycling.The TCL lines are equipped with a tele-maintenance tool, enabling possiblemalfunctions to be eliminated.
With this project, the team at Tur-bo-Separator was able to bring itsstrengths to bear. SanHe now process-es its soiled fluids according to theprinciples of economy and ecology.These include increased quality, re-duction of the machine downtimes,reduced purchasing and disposal costsfor the media used and recovery of theraw materials used. ❚
Roman Bürge is Sales Directorat Turbo-Separator in Lichtensteig/Switzerland> [email protected]
The Turbo-Clean TCL
cleaning system is designed to separate carbide
from low-viscosity grinding oil
3
46-47_SE110025_CHe10 07.07.2010 17:02 Uhr Seite 47
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
© Carl Hanser Verlag, Munich
O P E R AT I N G T E C H N O LO G Y
> Employees working at machine tools canbreathe easy. No more hazardous chemi-cals like boron, amines, bactericides orfungicides, but now instead bioactive pre-cious metals can put a stop to bacterialgrowth in the machining fluid.At the sametime, the machining performance andlong-life stability of the Motorex TresorPMC cooling lubricant from the Swisscompany Motorex is excellent.
A cooling lubricant without
bactericides and fungicides
When industrial companies machine met-al, the machine tool, the tool and the pieceof metal to be machined must be heavilycooled.This task is assumed by the so-calledcooling lubricant.The Swiss company Mo-torex has long been a global player in thissector. Now the lubricant specialists fromLangenthal have brought a new productonto the market, id est a cooling lubricantthat requires no bactericides or fungicidesthat pose a problem for people and the en-vironment.Actually, the performance spec-ification for the chemists and engineers sayssomething completely different. To marka quickly biodegradable hydraulic oil, mi-cro-small paint balls (luminescent poly-mer beads) are to be added to the formula.In brainstorming with external specialists,not only coloured pigments, but also anentire range of other substances were thenhidden in these beads. Including, for ex-ample, active precious metals, which can
float like little submarines in themachining fluid of machinetools. According to the man-ufacturer's specifications, ithas been scientifically proventhat precious metal ions have aradically eliminating effect on undesirablebacteria and fungi – as is also the case inoily machining emulsions.
Several questions had to be answeredbefore Motorex Tresor PMC was ready forthe market:■ How can precious metal ions be dis-
persed in an oil-water emulsion so thatthe beads do not clot and precipitate atthe bottom?
■ How can the beads be prevented fromreacting to the metal chips from ma-chining?
■ How can precious metal hunters creepup on mobile bacteria?
This question caused the Motorex chemistsmany a sleepless night. Neither a dialysissystem in a separate circuit nor special fil-ter candles led to success. Finally, it was theright size of the precious metal beads thatprovided the breakthrough.
A polymer plastic matrix absorbs theactivated precious metals and forms thebasis for the antibiotic catalyst. Small partsin the micro-range of this plastic floatalong in the cooling lubricant.When PMCsurfaces meet up with the bacteria alongthe way, they are catalytically destroyedwhen they contact the bacterial cell mem-
brane. Then an undesirable bacterial population cannot result in the first place.As precious metal remains precious, thecatalyst does not lose its effect – as in cars– and the service life is extended.
Green and efficient
The technology patented for Motorex Tresor PMC claims to be pioneering forthe future development of cooling lubri-cants. The researchers from Langenthalhave taken a great step with the replace-ment of toxic chemicals for bacterial con-trol. They have succeeded in eliminatingan important problem and a potential hazard for people and the environment.The new technology does not affect themachining performance, and the coolingperformance can draw even with the performance of the Motorex Swisscoolfamily. ❚
48
Bioactive precious metals in cooling lubricant
Precious metal hunts bacteria
A new cooling lubricant technology completely dispenses with bactericides and fungicides, and is therefore agreeable for people and the environment.
Motorex SchmiertechnikCH-4901 LangenthalPhone +41 62 9197575Fax +41 62 9197595> www.motorex.com Fi
gure
: fot
olia
The MotorexSwisscool
Tresor PMCcooling
lubricant promises excellent
machining performance and a
long bio-stability
48_SE310018_CHe10 07.07.2010 17:03 Uhr Seite 48
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
> In Hasle-Rüegsau, Switzerland, head-quarters of Blaser Swisslub, the compa-ny's cooling lubricant experts have set upa new technology centre. Equipped withtwo 3-axis high-speed machining systems,Blaser offers machinists the ability to con-duct extensive testing of cooling lubricantsthere with regard to their performanceand behaviour during use. Blaser coolinglubricants are in use at customers' plantsworldwide for the production of every-thing from extremely small parts – in thewatch and clock making industry or med-ical technology – to huge structural partsin aircraft construction. As a compara-tively small Swiss firm, Blaser must holdits own against the large oil corporations,
and therefore offers more than just prod-ucts alone. Today the customer expectsmeasurable added values, whether it is intool life or in the number of parts pro-duced per unit of time. ❚
SWISS QUALITY PRODUCTION 2010 49
Testing performance and behaviour during use of cooling lubricants
From lubricant to liquid tool
Blaser Swisslube has committed itself to machining with a newly set up technologycentre for testing cooling lubricants.
Figu
res:
Bla
ser
Blaser Swisslube AGCH-3415 Hasle-RüegsauPhone +41 34 4600101Fax +41 34 4600100> www.blaser.com
Max Zuber is Head of Production Engineering at Blaser Swisslube in Hasle-Rüegsau, Switzerland
Mr. Zuber, how is it that BlaserSwisslube is the first manufacturerof cooling lubricant in Switzer-land to set up its own technologycentre?MAX ZUBER: For a long timethe machine tool manufactur-ers were the engine for newtechnologies in the metalworking industry. Today it's the
tool manufacturers and thematerial developers. New sub-strates, coatings and geome-tries now enable machiningparameters which were stillconsidered utopian just twoyears ago. Naturally, this hastriggered a dynamic situationon the market. With our tech-nology centre, we have not on-ly reacted to the rapid changeson the market, we are also ac-tively participating in progress.
What does that mean in specificterms?MAX ZUBER: With our twohigh-speed machining centresand the infrastructure custom-tailored to our requirements,we are capable of testing theentire range of cooling lubri-cants with regard to perform-ance and behaviour duringuse. The findings from thetests lead to a continuous expansion of knowledge on thecomplex interaction of chemi-
cals and mechanical systemsin the machining zone. Thisknowledge is integrated in thedevelopment of new productsand in the further develop-ment of existing cooling lubri-cants.
Can't the same objective beachieved with tests at the customer's plant?MAX ZUBER: The intensive cooperation between develop-ment chemists and machiningexperts under one roof and theimmediate implementation ontheir own machines result inan extreme shortening of thetime between a product ideaand the field test at selectedcustomer plants. The tests canbe reproduced in a very smalltolerance range and sources oferror in the test matrix can bereduced to a minimum. As weconduct basic research, thisreproducibility is an absolutemust. The machining condi-
tions at the customer's plantcover a much broader range.
Everyone is talking about in-creased productivity. What doesthat mean to Blaser Swisslube?What are the benefits for the customer?MAX ZUBER: Increased pro-ductivity must result in addedvalue for the customer. Howthis added value is generated,can only be decided in meet-ings with the customer andfollowing an on-site analysis.This requires us to speak thecustomer's language and toknow its processes. In closecooperation with the customer,the specialists at Blaser canoptimise its productionprocess with the cooling lubri-cants best suited for this pur-pose. As a result, Blaser cus-tomers receive a liquid tooland can therefore increase the efficiency of the entiremachining process.
QUESTIONS AND ANSWERS?
Customers canthoroughly test therange of Blasercooling lubricantsat the technologycentre in Hasle-Rüegsau,Switzerland
49_SE310016_CHe10 07.07.2010 17:04 Uhr Seite 49
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
EDITORIAL BOARDProf. Dr.-Ing. Konrad WegenerETH ZurichChristoph BlättlerSwissmem
PUBLISHING DIRECTORDipl.-Ing. (FH) Michael Himmelstoß
EDITORSDr.-Ing. Michael Hobohm (responsible)Kolbergerstraße 22, D-81679 MunichPhone +49 89 99830682Fax +49 89 99830623E-Mail [email protected]
Claudia JäkelPhone +49 89 99830254Fax +49 89 99830623E-Mail [email protected]
PUBLISHERCarl Hanser Verlag GmbH & Co. KG
Kolbergerstraße 22, D-81679 Munich or
P.O. Box 860420, D-81631 Munich
www.hanser.deIn accordance with § 8 of the BavarianPress Act, we herewith state the owner-ship structure as follows: Carl HanserVerlag GmbH & Co. KG, Kolbergerstr.22, D-81679 Munich, seat and registrycourt: Munich HRA 49621, Sharehold-ers: Carl Hanser Verlagsleitungsges.mbH, Kolbergerstr. 22, 81679 Munich,seat and registry court: Munich HRB40463; Ruth Beisler, housewife, Munich;Getraud Bracker, book seller, Weilheim;Wolfgang Beisler, managing director,Munich; Ulrike Beisler, publisher, Rome;Christoph Beisler, artist, Munich.
MANAGING DIRECTORSWolfgang Beisler, Stephan D. Joß,
Michael Krüger
ADVERTISEMENT MANAGERDietmar von der Au (responsible)
Phone + 49 89 99830214
E-Mail [email protected]
ADVERTISEMENT PLANNINGAnnette AnthonyPhone +49 89 99830218Fax +49 89 99830623E-Mail [email protected]
PRODUCTION MANAGERHadrian Zett (responsible)Phone +49 89 99830420E-Mail [email protected] and Production:Nina CoppPhone +49 89 99830158E-Mail [email protected]
GENERAL REPRESENTATIONRico DormannMedia Consulting MarketingMoosstraße 7, P.O. Box 574CH-8803 RüschlikonPhone +41 44 7208550Fax +41 44 7211474E-Mail [email protected]
PRINTSellier Druck GmbHAngerstraße 54, D-85354 FreisingPrinted in Germany
COPYRIGHT AND PUBLISHING RIGHTSThe publication and all individual arti-cles and illustrations contained hereinare protected by copyright. Upon an arti-cle being accepted for publication, therights of puplication, as well as rights oftranslation, of granting reproduction li-censes, of storage in electronic retrievalsystems of producing special impres-sions, photocopies and microcopies aretransferred to the publisher. Any utilisa-tion thereof outside the limits of thecopyright act is forbidden without writ-ten permission of the publisher.
DESCRIPTIVE NAMESThe use of general descriptive names,poprietary names, trade names, com-mercial designitions or the like in thispublication in no way implies that suchnames may be used freely; these are oftenlegally protected, registere‚d trademarks,even if not designated as such.
© Carl Hanser Verlag, Munich 2010
Swiss Quality Production 2010
IMPRESSUM
Alesa Ltd.,CH-Seengen 13
Hanser Verlag GmbH & Co. KG, D-Munich
inside back coveroutside back cover
Imoberdorf AG,CH-Oensingen 47
Kellenberger & Co. AG,CH-St. Gallen 27
Lehmann AG,CH-Bärau between 34/35
Meister Abrasives AG,CH-Andelfingen
inside front coverMicrocut AG,
CH-Lengnau 41
Platit AG,CH-Selzach 25
Precitrame Machines SA,CH-Tramelan 31
Rego-Fix AG,CH-Tenniken 45
Studer AG,CH-Thun 5
S
R
P
M
L
K
I
H
ATriag AG,
CH-Allenwindenfront cover
Turbo-Separator AG,CH-Lichtensteig 43
WST WinterthurSchleiftechnik AG,CH-Winterthur 21
W
T
ADVERTISERS’ INDEX
›Prodex'10‹, the international exhibition for machine tools, tools
and production measurement, will take place in the Exhibition
Center Basel from 16th to 20th November 2010. At the same
time ›Swisstech 2010‹ – Europe's central fair for the subcon-
tracting industries – will be organised by MCH Messe Schweiz
(Basel) AG.
Compact fair package
Figu
re: E
ntze
roth
ProdexExhibit and More AGCH-8117 FällandenPhone +41 44 8063344, Fax +41 44 8063343> www.prodex.ch
SwisstechMCH Messe Schweiz (Basel) AGCH-4005 BaselPhone +41 58 2002020, Fax +41 58 2062189> www.swisstech2010.com
S E R V I C E
Swiss Quality Production
>
50_Impressum_CHe10 07.07.2010 17:04 Uhr Seite 54
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
CO M P U T E R | P L A S T I C S | E NG I N E E R I NG | M A N AG E M E N T & B U S I N E S S
This book has established itself as a
standard reference for everyone dea-
ling with statistical problems in
industrial production.
Accompanying the book you can down-
load a statistical software demo
version.
The focus is put on the application of
the procedures required for machine
acceptance and process qualification
as well as interpretation of the calcu-
lated results.
Great value is also set on the visuali -
zation of results in many different
variations. This helps the practitioner
to quickly gain insight into the situa-
tions he has to evaluate.
Your Survival Kit in the World of Statistics.
Especially the included company guidelines are proof of the practical appli -
cation and the benefit of the discussed topics in daily practice.
The 6th, completely revised edition takes the latest developments in inter-
national and national standards (i.e. DIN ISO 21747) into account.
Dietrich/Schulze, Statistical Procedures for Machine and Process Qualification
760 pages, 500 figures, 61 tables · € 129,90 [D]
More Information on: www.hanser.de/technik
Fax-Hotline: +49/89/998 30-157Please send me the following books:
Statistical Procedures for Machine and Process QualificationISBN 978-3-446-42249-0
€ 129,90 [D] (Recommended retail price)
First name Name
Company Department
Address
Country / ZIP / City
� Please send me a proforma invoice. VAT No.
� Please charge my credit card. Total Amount €
� Eurocard / Mastercard � Visa / Diners Club � American Express
Card Number Exp. Date
Shipping costs will be charged via your choice of delivery: � Airmail � Surface mail
Date / Signature
FW-4
2206
0 Please inform me by e-mail on following subjects:� Plasticse-Mail
Or click www.hanser.de/newsletter
Carl Hanser Verlag · Kolbergerstraße 22 · 81679 Munich/Germany · Tel.: +49/89/9 98 30-0 · Fax: +49/89/9 98 30-157 · [email protected] · www.hanser.de
02_U2-U4_CHe10 07.07.2010 16:19 Uhr Seite 2
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
Carl Hanser Verlag · P.O. Box 86 04 20 · 81631 Munich/Germany · Tel.: +49/89/998 30-0 · Fax: +49/89/98 48 09 · www.hanser.de
T E C H N I C A L M AG A Z I N E S | T E C H N I C A L BO O K S | O N L I N E S E R V I C E S | S E M I N A R S
Seminars
Technical Books
Technical Magazines
Online Services
Profound Knowledge in a Flexible Multi-Media System:
Since 1928 Hanser Publishers have established themselves as
competent providers of information. With 21 professional
magazines, some 200 new book publications and reprints
annually as well as about 2,000 titles in stock, Hanser ranks
amongst the 10 largest German specialist technico-scientific
publishing houses. Specialist seminars and conferences as well
as branch services on the Internet supplement what is being
offered in the way of information. Read more at www.hanser.de
02_U2-U4_CHe10 07.07.2010 16:19 Uhr Seite 3
© 2
010
Car
l Han
ser V
erla
g, M
ünch
en
ww
w.h
anse
r.de/
sp
Nic
ht z
ur V
erw
endu
ng in
Intra
net-
und
Inte
rnet
-Ang
ebot
en s
owie
ele
ktro
nisc
hen
Ver
teile
rn.
