Turkey industry magazine 41 issue

Robotmaster at EMO 2015!

New generation Leroy-Somer LSA 46.3 & LSA 49.3 alternators launch

Seco increases copy milling capabilities via three product expansions

Starrett shows its cut and thrust at EMO

Maximum Speed and Energy Efficiency with Hybrid Design

Inline technique for the selective removal of contaminants generated by assembly and joining processes

First in Turkey in the field of Plastic Injections, Tisse and Kollmorgen have together developed an electric-hydraulic Hybrid Machine. The Hybrid Machine can manufacture difficult and sensitive products at high speeds; its power and quality eliminate problems like ejection errors and high quantity of wastage. It also increases the production rate and provides energy efficiency up to 35-40% compared to the competition.

Assembly and joining processes, such as screwing, pressing or welding, generate unavoidable contamination. These particles or smoke residues often have an adverse effect on product quality or downstream manufacturing steps. This can be avoided using an integrated precision-cleaning solution, such as the quattroClean system from acp. Featuring a minimum footprint and short cycle times, the system cleans components in a dry, selective process; it is also easy to automate.

Targeted “surfing� in a bed of finishing media

CLOOS at SCHWEISSTEC 2015 The perfect solution for every requirement

World's first: Additively manufactured hydraulic chuck

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Automation 4.0 toolcraft and PCam reinvent the automation era

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September - October 2015

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CONTENTS

Realizing the Internet of Things 4

September - October 2015/4 Vol.41 Publication Type

: Local/Periodical

Yay›n Türü

: (Yerel/Süreli)

Targeted “surfing” in a bed of finishing media 12

Chairman

Ahmet Pelit

Seco increases copy milling capabilities via three product expansions 14

Editorial Director

Berusmak Metal Working Machinery 15

Editors

Maximum Speed and Energy Efficiency with Hybrid Design 8

‹mtiyaz Sahibi

Selver Pelit

Sorumlu Yaz› ‹?leri Müdürü

Erdem Ça€layan

Yazı ‹flleri

Flexible Label Feeder for SMT lines brings affordable traceability to any

Advertising Sales Staff Reklam Grubu

Emel fienyüz Fahriye Ziyade Hafise Ergün

Rego-Fix to exhibit at the EMO trade show in Milan 18

Design & Graphics

AjansMik Co., Ltd.

CHIRON at EMO 2015 with World and Trade Show premieres for more

Graphic Designer

business 16 Hazırlık & Tasarım

Mehmet Can Pelit

Grafik Tasarım

Data Processing

Ali Birim

efficiency, precision and dynamics 20

Bilgi ‹fllem

hyperMILL® 2016.1 - Machining with better performance 23

Print by

fian Ofset

Baskı

Ayazağa Mah. Kemerburgaz Cad. No:13 Şişli-- ‹stanbul

First milling cutter with HX blades of PcBN 24 Inline technique for the selective removal of contaminants generated by assembly and joining processes 26 WITTENSTEIN bastian at EMO Milano 2015 28 Automation 4.0 toolcraft and PCam reinvent the automation era 30 SHW Werkzeugmaschinen shows a spectacular array of novelties at the EMO 32 Starrett shows its cut and thrust at EMO 33

Head Office / Yönetim Merkezi AjansMik Publishing Advertising Org.& Tourism Industry Trade Co., Ltd. Perpa Ticaret Merkezi B Blok Kat:11 No:1928 Okmeydanı - fiiflli 34384 ‹stanbul / Türkiye Phone : +90 [212] 222 93 71 Pbx Fax : +90 [212] 222 93 74 E-mail : info@ajansmik.com Web : www.ajansmik.com

World's first: Additively manufactured hydraulic chuck 36

Representative of Germany

BIG KAISER announces fastest air turbine spindle at 120,000rpm 37

WELCKERSTR.22 D-53113 BONN Germany

EISENACHER MEDIEN Phone: +49 0228 24 99 860 •

Ionbond at EMO 2015 38

Fax: +49 0228 65 00 76 e-mail:info@eisenacher-medien.de

CLOOS at SCHWEISSTEC 2015 The perfect solution for every requirement 39

Representative of Italy

RPS Endurance inverters with new parallel operation feature – available in

Via Cardano 81 - 22100 Como (Italia)

CASIRAGHI INTERNATIONAL ADVERTISING

20 ft “ICON ND” stations up to 2.25 MWac 40

Tel. +39 031 261407 Fax +39 031 261380 www.casiraghi.info

NSK products make debut at Agritechnica 2015 41

Representative of Taiwan

Athlonix 22DCP Brush DC Motors deliver speed-to-torque performance in a

9F-2, No. 200, Zhongming Rd., North District,

cost-efficient package 42

Tel: +886 4 2329 7318

Ringier Trade Media Ltd. Taichung 404, Taiwan sydneylai@ringier.com.hk

Emerson Presents Elevator Drive&Motor Solution at Interlift 2015 43 New generation Leroy-Somer LSA 46.3 & LSA 49.3 alternators launch 44 Robotmaster at EMO 2015! 46

www.industrymagazine.com.tr info@industrymagazine.com.tr ISSN 1303-636X©Turkey Industry Magazine Publication Date : 01 October 2015 ‹stanbul - Turkey Baskı Yeri&Tarihi: 01 Ekim 2015 ‹stanbul - Turkey

Plastron Hot Runner Systems Co LTD 46

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All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording, without the written permission of the publishers.

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Realizing the Internet of Things Oxford school has online control of heating, ventilation, water, lighting etc. At the EF International Language Centre in Oxford, system integrator Global Electrical Solutions Ltd. has installed a building management system to keep track of heating, ventilation, water, lighting etc. By connecting Netbiter Remote Management gateways to Rockwell control panels in the building, users can see current temperatures, levels, and consumption online. They can even turn on lights or open windows remotely – truly realizing the Internet of Things.

Global Electrical Solutions (GES) is a UK-based system integrator specializing in assembling highly efficient control panels used in buildings, power & energy, manufacturing etc. At one of their recent installations at the EF International Language Centre in Oxford, they have used the Netbiter Remote Management solution to remotely monitor and control the building premises.

The Netbiter Argos web interface works as a front end towards the user displaying current values from the building and also allows users to generate reports and get alarms whenever certain thresholds are reached.

A Netbiter gateway is connected to the controlling Rockwell PLCs. Users access the premises at www.netbiter.net.

GES and the building owners can log in to www.netbiter.net to see current values and even start or stop equipment, open windows and turn lights on or off from their Netbiter Argos dashboard. Furthermore, they can get alarms via email if certain values are reached (for ex-

ample if CO2 levels are too high). It is also possible to generate reports on consumption and performance over time.

“It works really, really well,” says Mark Jenkyns, Managing Director at Global Electrical Solutions. “It is

How it works A Netbiter EC310 gateway is connected to the Rockwell Micro800series PLCs which control the different systems in the building. The Netbiter gateway sends data to the cloud-based Netbiter Argos service where it is stored and accessed.

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Real values, real pictures. GES have used pictures from the actual premises in the school when creating Netbiter dashboards. In these dashboards, users can see exact values in real-time and control heating and ventilation remotely.

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ers costs for maintenance as costly service trips can be reduced to an absolute minimum. Since the price of a remote management gateway usually equals the cost of a service visit, the return on investment is usually just a couple of months.

easy for us to create graphical dashboards in Netbiter Argos, so we basically use it as the front end for our Building Management System.”

Fewer service visits means quick ROI The remote management solution has been well received by Global Electrical Solution’s customers as it gives both better control and low-

Mark Jenkyns explains: “When the customer reports a heating problem, there is a good chance it’s a sensor failure which would normally require an engineer visiting site with test equipment. With the Netbiter onsite we can now log in to any one of the buildings controllers and inspect the real time values to determine if the sensor is faulty or not without leaving the office. A new part can be ordered and installed within a fraction of the time.”

Mark Jenkyns experienced one of the benefits himself when installing the remote monitoring solution in one of the rooms of the school: “When I got back to the office, I realized that I had forgotten to turn the hot water back on. But since the room now had Netbiter installed, I could easily go in and turn it on with a click of the mouse. Many service trips and maintenance issues are usually simple fixes like this, so with Netbiter we can save a lot of time and money for both us and our customers.”

GES has now installed Netbiter at two schools and a hotel in the Oxford area and can see many other applications for Netbiter connected to their control panels. “It really gives our offering an edge as it provides customers with an easy-tograsp overview of their systems and keeps costs for maintenance down” finishes Mark Jenkyns.

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Newly developed transfluid solution for combined pipe forming chines are furthermore also now CNC controlled and it is possible to very effectively form pipes with bends in excess of 90°.”

Axial/rotary CNC controlled pipe forming machine offers tool-independent forming of contours The technical challenges of modern pipe processing are constantly increasing, driven by ever more demanding applications of high grade piping. Just one manufacturing process often does not suffice to perfectly and effectively form pipe ends to suit the requirements. This was made possible only by effective interaction between combined axial and rotary pipe forming techniques.

The transfluid Maschinenbau GmbH engineers have developed a new range of their tried and tested combination machines to achieve this. In the course of this, they have set new benchmarks for technology and machine design.

Increased options and chipless cutting methods CNC control of the new transfluid machine enables tool-independent forming of contours.

Producing your perfect pipe with combined axial and rotary forming.

Effectively forming pipes even with bends in excess of 90 degrees Managing Director Stefanie Flaeper explains more about the improvements and novelties incorporated in transfluid’s ‘new one’: “There are actually five fundamental changes. For a start, our combination machine is now externally more compact. All the drives are electrical and CNC control enables synchronous axial and radial movements. And we have once again made significant improvements to rotary forming techniques. For the first time, these techniques now enable forming of contours virtually independent of the tool. Our ma-

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Effective interaction between combined axial and rotary pipe forming opens up many options.

These new features of the combination machines now open up additional pipe forming options. The swaging unit can accommodate, for instance, an intermediate chuck, despite the electrical drive. A wide variety of tools may be used for various rotary forming tasks and the machines can also cut chipless – from the inside out and vice versa.

Newly introduced CNC technology – as with the transfluid stand-alone rotary forming machines – for the first time also allows contour forming irrespective the tool. With their new combination machine, our South-Westphalian machine builders are now in a position to offer their customers the perfect solution for their pipes and the challenges of a dynamic market.

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Maximum Speed and Energy Efficiency with Hybrid Design First in Turkey in the field of Plastic Injections, Tisse and Kollmorgen have together developed an electric-hydraulic Hybrid Machine. The Hybrid Machine can manufacture difficult and sensitive products at high speeds; its power and quality eliminate problems like ejection errors and high quantity of wastage. It also increases the production rate and provides energy efficiency up to 35-40% compared to the competition. eS-Drive450 Tisse is the result of the cooperation between Kollmorgen engineering and Tisse Plastic Injection Molding Machines Company. It is the first hybrid plastic injection molding machine, whose injection part includes an electric system and a hydraulic system comprised of clamping and conveying as well as an ejection unit. The hybrid de-

sign provides speed and energy saving in manufacturing. The entire software of the machine was written by Kollmorgen, in house, from scratch.

The injection part of the hybrid machine consists of 2 servo motors, whereas clamping, conveying and ejection parts form the hydraulic system. However, because the pump of the hydraulic system is driven using servo motor, the machine may be called a full electric hybrid.

The reason why servo motors were used in the injection part was to provide crucial acceleration and sensitive pressure balance, making it easy and quick for the liquid plastic to be injected in to the mold..

Speed is of great importance especially for molding thin-walled packaging products. For instance, be-

cause products, such as the lids of yoghurt pots cool very quickly, the process is required to be completed immediately.

Seref Karaoglan, project manager of Kollmorgen Turkey, speaks about the machine performance: “We often witness that manufacturers have difficulty in manufacturing such products. We designed the hybrid not only to provide energy efficiency but also to increase speed. People think it is not easy to manufacture such machine because, for instance, we apply 10 different speed stages and 10 different pressure stages in accordance with the type of mold in order to make a movement of 90mm (P/Q). It is really not easy to do this just with any servo motors but we used Kollmorgen’s S600 drives and PDMM controllers.”

eS-Drive450 Tisse machine, the first Hybrid Machine in plastic injection molding: speed and energy saving

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Ömer Sengelen, Production Manager – Tisse Machine Omer Sengelen, Production Manager of Tisse Machine, summarized their position in the sector: “We are endeavoring to add remarkable features even to typical machines. Actually, we quit manufacturing injection molding machines in 2000. In 2008, however, we noticed that

there was a need for blow molding machines and we started manufacturing again. With the expertise and high product quality that we developed through our partnership with Elsim Kollmorgen, we have become capable with very high-level injection molding machinery. ”

Clamping systems in normal injection molding machines are usually problematic. The injection molding might be fast but the clamping is the negative side. The compression ratio is less, but they cause great expenses at high speed. The clamping part in hydraulic injection machines is always as per specifications, but complaints about the injection speed predominate. Their maximum speed is between 100mm/h and 200mm/s. This hybrid machine has the best side of those 2 systems. While it enables the clamping and other parts of the machine which require power to run fast, it is also able to reach a speed of 300mm/h by getting the injection system to work with servo motors.

In addition to these advantages, it provides energy saving in the pump of the hydraulic system by using servo motors.

Project manager of Kollmorgen Turkey, Seref Karaoglan says, “The reason why electric machines are liked is that they are energy efficient unlike AC motors, in the hydraulic part of old machines, that keep cycling even while the machine is off and consume energy even if you do nothing.”

Special Valve Technology Regeneration is provided through the special valve used in the hydraulic system of the machine. Suppose that the grease taken from the tank and injected into the system, supplies 100 units of energy in the classical systems. Thanks to this valve, the grease coming out of the system is re-injected into the system, instead of transferring it into the tank. Thus, you obtain extra power up to 60%. According to Seref Karaoglan, you get extra speed as well as extra power, and

Kollmorgen Automation Suite Machine Automation Solution

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Special Pump Software There are 2 important elements in grease-powered systems: Speed and Pressure. The software developed for this machine, ensures the desired pressure at the desired speed.

Seref Karaoglan says, ”We can use 10 different PQ distances.

We are also using this advantage on the clamping system.

Thanks to the servo motored pump software, we reach the desired speed within 150200ms and despite this speed, we provide the desired pressure on an error band of 2 or 3 bars.”

Kollmorgen Automation Suite Machine Automation Solution “It is like the generator of a car charging the accumulator. We could have used standard valves for the clamping parts because we had acceleration in the injection part. But thanks to this special valve, we use the clamping system as if it is electrically operated, and increase the speed thanks to regeneration.”

Parallel Power through Two Different Motors Another stellar feature of the machine is that 2 different motors are used in the injection process, getting parallel power through each other. The motors are connected by very special screws that run synchronously. These screws enable the motors to cycle with high-precision in less than 1/10mm, and they provide stable running even at high speed.

Efficient Communication System The speed doubles because the injection nozzle in the machine is pushed and pulled by twin motors.

Seref Karaoglan says, “Kollmorgen communication systems allow the

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synchronous work of two motors on the same mechanical system but running independently. If one of the motors runs at a speed slower than 1/10mm, it might damage the screws, which are very special and expensive. The communication time and synchronization of the motors takes less than 1 m/s.

High-Tech Braking The motors used in the machine are quite heavy and powerful. “We took all kinds of measurements in the event of any communication problems between each other.

6.5kW of braking resistance is used in the system because the flywheel effect comes out while the screws and balls gain acceleration.” Seref Karaoglan also points out that it gets really difficult to control the speed and says,”The products we use here are those developed by Kollmorgen and include plates providing stepped braking. It would have been impossible for me to succeed in this project with standard braking resistances.”

High Kollmorgen Engineering Kollmorgen’s machine automation solution brings highly integrated and intuitive software programming platform, top of the range movement components and extraordinary co-operated engineering services in order to create highly differentiated machines and more profitable business organizations. It has been proven that Kollmorgen Automation Suite™ accelerates the development process, raises the machine manufacturing, reduces wastage and increases hardware efficiency (OEE).

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Targeted “surfing” in a bed of finishing media Fully automatic processing, extremely short cycle times, high process stability, repeatability and finishing of precisely targeted surface areas – these are the many benefits of the new Rösler “Surf” Finishing technology for deburring, surface grinding, smoothing and polishing of delicate, high-value work pieces with complex geometries.

Growing demands for improving the quality of finished surfaces, for sta- The innovative Surf Finishing technology allows single component surface finishing of bility & repeatability of delicate, high value work pieces with extremely short cycle times. the finishing processes toing and many other industries pieces into a rotating processing gether with the need for further inwhere precise deburring, surface bowl filled with grinding or polishcreased cost efficiencies, requires grinding, smoothing and polishing ing media. This process allows eiinnovative technologies for treating are essential. Multiple component / ther all-around surface finishing of high value components with more part specific processing programs the work pieces or the selective complex geometries. Röslers Reare stored in the system controls treatment of targeted surface arsearch & Development has met this from where they can be quickly reeas. The simultaneous “surfing” of challenge head-on with the newly trieved by the operator. the work pieces through the grindcreated “Surf Finishing” technology. ing media and the rotation of the The treatment process can be augIt allows fully automatic dry or wet processing bowl generate an exmented by material handling and processing of delicate work pieces tremely high grinding pressure. The other auxiliary equipment such as to be accommodated, which, to result is a very intensive process component / part transport sysdate, could only be finished with and a perfect surface finish, in atems and part washers. Therefore, highly unreliable and costly manual mazingly short cycle times. the Surf Finishing equipment can be methods or with very expensive easily integrated into complex, auEasy integration into manufacturmechanical systems. tomated manufacturing lines. ing lines The ideal combination of robotic Surf Finishing guarantees very handling and special media motion high process stability and repeataDepending on the finishing applibility and is, therefore, the ideal cation, the Surf Finishing technolotechnology for single component gy uses either one or multiple 6-axtreatment in the aerospace, autois robotic arms to lower the work motive, hydraulic, energy generat-

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Seco increases copy milling capabilities via three product expansions Seco recently added new offerings to its MinimasterŽPlus replaceable cutting tool system, Combimaster™ milling cutter system and Round 12 button insert line to further extend the capabilities of these copy milling products.

The company has optimised the cutting parameters of its popular Minimaster Plus system via a new four-flute head for larger helix angles. The head joins the system’s existing three-flute design. Both cutting heads provide high metal removal rates in roughing and semi-finishing operations. The fourflute head, however, features shorter 0.7xD flute lengths for increased stability in aggressive metal removal applications and 5-axis machining where cutter ends are used more frequently than entire flute lengths.

The industry-leading Combimaster milling cutter system encompasses an array of shank types, lengths and interchangeable cutter heads that offers maximum flexibility over a wide range of applications. Seco takes the versatility and stability of this system into the 40/42-mm diameter (50-mm diameter in ballnose) cutter arena with the new M20 connection. The M20 thread ensures the strongest connection possible between the shank and the cutter body. In most instances, the

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Combimaster M20 allows users to increase both metal removal rates and depths of cut by as much as 15 percent to improve overall machining performance. Seco has adapted the M20 connection to more than 30 new holder styles and over 50 types of milling cutters.

Seco has advanced its range of Round 12 button inserts with the addition of indexing capabilities that provide fast, precise insert positioning. The anti-rotation indexing system provides absolute insert security, especially during demanding material removal applications.

Round 12 inserts have indexing

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local Seco representative or visit www.secotools.com/minimasterplu, www.secotools.com/combimaster and www.secotools.com/round12, respectively.

notches that correspond with cutter body alignment marks, both of which ensure perfect insert positioning into the cutter body pocket seats and make the system extremely easy to use. For the new system, Seco incorporated advanced geometries with the Round

12 inserts and designed all the diameters of the cutting bodies with new differential pitches to reduce vibration and chatter.

For more information on the Minimaster Plus, Combimaster and Round 12 inserts, please contact a

Headquartered in Fagersta, Sweden and present in more than 50 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, turning, holemaking and toolholding. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments, please visit www.secotools.com

Berusmak Metal Working Machinery Berusmak, as manufacturer of sheet metal processing machines, offers to the world market keeping customer satisfaction high quality and cost-effective products are more than 13 years. Our company has ma naged to become a brand at the same time producing high-level professional services and network solutions with sales representatives located about 43 world countries.

Berusmak Metal Working Machinery, Quality Policy: At each stage of production to follow and implement international quality standards With proper planning to comply with the delivery time Services to meet the needsof our customers and to offer the right pruducts Time with a strong service network and reach a solution. www.berussa.com.tr

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Flexible Label Feeder for SMT lines brings affordable traceability to any business

Worldwide identification specialist Brady, and Germany based AMS Software & Elektronik, have signed a partnership to offer high tech, automated and affordable traceability label feeders to electronic manufacturers throughout Europe, Middle East and Africa. “The combination of the flexible AMS ALF14 label feeder series with Brady’s advanced traceability labels offers users a highly efficient labelling automation solution for SMT lines in PCB manufacturing”, says David Walmsley, EMEA Business Development Manager at Brady.

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Traceability “The need for traceability has never been higher”, Walmsley continues. “Gone are the days when it was driven and executed by the largest companies. These days, traceability demands are driven by industries and are driven down the supply chain, meaning relatively small companies are requested to comply. We believe that affordable, quality label feeders will form part of the solution that brings cost-effective traceability to the entire supply chain.”

Various sizes The AMS ALF14 Label Feeder Series has a very competitive cost structure and a durable design that can easily be adjusted to common label sizes and tape widths ranging from 5*5 mm to 53*53 mm. “The ALF14-25, ALF14-40 and ALF14-55 drive down cost and increase quality because label liners do not need to be cut to size and because the feeders are not limited to one label size.” says Ivan Bajic, General Manager of AMS Software & Elektronik GmbH. “Supporting the needs of various industries, the

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er can dispense a range of labels which enables fast and easy handling in daily operations”, says Mr. Bajic.

Specialised PCB Traceability Labels

ALF14 Label Feeder Series handle label material up to varying maximum label sizes and are the top choice for electronic manufacturing and special purpose machinery”. Moreover, all ALF14 models are modular label feeders which negates the need to replace the entire feeder if or when you replace your pick and place machines. Only the feeder machine adapter needs changing, at maximum 20% of the cost of a new feeder.

Easy to use All three label feeders in the ALF14 Series are supplied with adapters for common SMT pick-and-place systems, making it an extremely flexible

tool with a very short set-up time. To fit it to another machine, simply attach the corresponding adapter to the feeder and your traceability system is back up.

The label feeders’ fully automated label guidance system ensures reproducible label positioning for pick-and-place systems. Their simple and fast sensing and dispensing keeps up with the demands of modern pick equipment, while its compact design minimises occupied space in your feeder rack.

“The easy exchange of consumables, even with different label sizes, is a challenging industry request AMS focused on during product design. Every ALF14 Label Feed-

Brady UltraTemp™ Label Series can all be supplied in either blank or pre-printed form to your specifications and ready for dispensing by the ALF14 Label Feeders. UltraTemp labels will stay intact and legible throughout the printed circuit board manufacturing process and can resist a range of chemicals, temperatures and high pressure while maintaining material and print integrity to enable complete traceability throughout the supply chain. Moreover, these labels are specifically designed to meet the needs of modern day automation.

“Brady spent many years developing materials that are easy to dispense”, says David Walmsley. “Although only a label, if it doesn’t dispense properly, a production line stops and your traceability can be lost. Brady solved common problems when auto-applying labels and developed materials to overcome these issues.”

More flexibility Brady UltraTemp Labels can even be printed on-site using a Brady printer coupled to the AMS ALF14 Label Feeders. If you need many different prints, adding a Brady label printer to your automated traceability solution enables you to print any barcode, QR-code or serial number in highly resistant ink on blank traceability labels for maximum flexibility that meets the demands of a modern day SMT line.

For more information, or for a free ALF14 demo, please email emea_request@bradycorp.com.

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Rego-Fix to exhibit at the EMO trade show in Milan During the EMP trade show to be held in Milan from October 5 to 10, 2015, visitors to Swiss manufacturer Rego-Fix’s booth will have a chance to experience for themselves the benefits of the PGU 9500 automatic tool clamping unit.

Several operational units will be available to try out. Those interested can thus see for themselves how the simple and reliable powRgrip tool clamping system from Rego-Fix works. Customers can also schedule appointments to test the tool at their own facilities.

The PGU 9500 clamping unit is perfectly compatible with the highly precise powRgrip tool clamping system. At the press of a button, it clamps drilling and milling tools ranging in diameter from 0.2 to 25.4 mm in less than 10 seconds. To do so, the operator just has to select the matching clamping adapter, then insert the tool with the toolholder into the clamping unit. Toolholders are available in all standard market spindle interfaces, such as SK, HSK, BT, BT+ and Capto. On the clamping adapter selected, the PGU 9500 clamping unit automatically recognizes the right clamping pressure for the toolholder and the tool.

The particular benefits of the powRgrip clamping system include outstanding vibration damping thanks to two interfacing surfaces, the optimal T.I.R. of the clamped tools of less than 3 µm – which is still intact after more than 20,000 tool changes – as well as the exact

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0.01 mm default setting of the tools to be clamped against an adjustable length stop. This contributes to long tool service life. With a very high transferrable torque of much more than 1000 Nm (PG 32), the powRgrip clamps tools made of solid carbide and HSS with cylindrical tool

shanks – also Weldon and Whistle Notch toolholders – for an h6 tolerance or also thread taps and thread forms for an h9 tolerance. The clamping system therefore functions purely mechanically without heat. When clamping tools, this ensures the highest process reliability without waiting times. Tools clamped with powRgrip are suitable for challenging HSC and HPC highspeed machining.

A few weeks ago, the PGU 9500 automatic clamping unit was honored with the “Red Dot Award 2015” in the “industrial design” category. Its well-thought-out design and its particularly comfortable handling impressed the jury.

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CHIRON at EMO 2015 with World and Trade Show premieres for more efficiency, precision and dynamics At the EMO exhibition from October 5 to 10 in Milan, CHIRON is presenting a series of new, high-efficiency machining centers featuring live demonstrations and supporting its claim to give users the "Seconds ahead" lead. Together with other companies in the group, CHIRON is exhibiting in Hall 11 at Stand E04.

As far as new products are concerned, CHIRON is presenting its completely revised 12 series for the eco-nomical machining of complex work pieces and offering a significantly larger tool magazine; the new FZ08 MT Precision+ for optimum accuracy; the MILL 2000 high dynamics with new dynamic package and the strong and robust DZ18 W MAGNUM for large component machining. The company is also showing the pre-configured "baseline" entry level models.

high-efficiency, automated, twinspindle turning and milling of cylinder head components for injection pumps.

A VDZ 100 DS SCHERER vertical lathe can be seen in combination with a CHIRON DZ12 W machining center with work piece changing device and integrated FlexcellUno robot automation. The robot operates the two machines connected via a feed belt. The lathe is supplied with the raw parts from a pallet storage and after turning, they are transported by a conveyor belt to the milling center, then milled and stored as a finished part again held in the pallet storage.

The new FZ08 MT precision+ turning/milling center is the efficient solution for high-precision, flexible and economical machining of parts.

The stand will be shared with SCHERER Feinbau, featuring vertical lathes and shaft lathes, CMS, the retrofit specialist in machining centers and machine builder STAMA. Automation: SCHERER - CHIRON show a compact integrated system As a highlight and world première, CHIRON and SCHERER Feinbau are showing a highly productive and compact integrated system for

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CHIRON and SCHERER Feinbau show a compact complete system, for example, for the high-efficiency, automated and twin-spindle turning and milling of cylinder head components.

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Due to its rapid feeds of up to 75 m/min and accelerations of up to 2g, the machining center is very dynamic. The tools are also changed at high speed within 0.9 seconds, so that chip-to-chip times as low as 2.2 seconds can be achieved.

More precise than ever before: Trade show innovation FZ08 MT precision+

In Milan, CHIRON is presenting a new dynamic package to improve performance of the MILL series.

World première: Complete manufacture of complex components: The new generation of the CHIRON 12 series.

With the FZ12 FX, CHIRON is showing a single-spindle representative of the new generation of 12 series for the economical machining of complex work pieces. At the stand, visitors can see a five-axis center with new Heidenhain TNC 640 control manufacturing an aluminum distributor as a demonstration..

machining center with a 2-axis rotary table and five simultaneously controlled axes is a high precision, universal machine. Tools with diameters up to 125 mm can be used without any problem and spindle speeds of up to 30,000 rpm open up numerous application possibilities.

Highlights of multi-functional 12 series machining centers include improved milling and drilling capacity for series production with low costs per unit, the very rigid and robust construction, stronger ball screws and the low floor space requirement of five square meters.

For efficient, complete machining, 128 HSK 50 tools are available in two magazine shafts – without needing an additional background magazine.

The single-spindle 5-axis FZ12 FX

Extended traverse paths, greater axis speeds and a more dynamic acceleration are the outstanding characteristics of the new double-spindle DZ18 W Magnum.

The new FZ08 MT precision+ turning/milling center, with its space requirement of only a three square meters footprint, is the efficient, ready-made solution for highly precise, flexible and economical parts machining. In spite of the small footprint, it offers traverse paths (XY-Z) of 210 mm, 200 mm and 360 mm, an integrated swivel head, a turning spindle and a counter spindle. In addition to the standard reliable ball screws, linear direct drives are also available upon request. The FZ08 MT precision+ is perfectly suited to meet the highest demands for workpiece surfaces – for example, in medical engineering or in the watch and jewelry sector.

Thanks to numerous equipment options, the FZ08 MT precision+ turning/milling center is a real allrounder and can be used for many different applications. The highly precise swivel head works with a torque drive which has a swivel range of -10° up to +100° and delivers speeds of up to 54,000 rpm. The pick-up magazine accesses 96 tools in a very short time and even complex shapes can be conveniently machined from six sides through the use of the counter spindle.

Thanks to the turning spindle with a bar capacity of 32 mm and a speed of 8,000 rpm, full-value turning is possible.

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dle DZ18 W Magnum. Larger bridge dimensions and traverse paths for the efficient machining of large components are now available: up to 630 mm in X, 530 mm in Y and 450 mm in Z. The axis velocity is increased from 60 m/min to 75 m/min – with noticeably greater dynamics: The acceleration values in X go up to 1.0 g; in Y to a maximum of 1.4 g and in Z optimized at 1.6 g.

With the FZ12 FX, CHIRON is showing a single-spindle representative of the new 12 series for the economical complete machining of complex workpieces.

World première: Dynamics package for the MILL series In Milan, CHIRON is presenting a new dynamic package for the MILL series to improve performance that is based on a rigid and weight-optimized machine structure and highly dynamic drives. With axis acceleration up to 1.7 g and a rapid traverse rate of 75 m/min, the "MILL 2000 high dynamics" clearly demonstrates the highest productivity during both machining and non-machining times. With live demonstrations on its stand, CHIRON will be showing that MILL is the ideal machining center for companies wishing to manufacture lightweight body and structural components even faster and more productively.

It can be used both as a proven s-

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ingle-spindle machining center in the vertical travelling column design, with NC swivel head for stepless programmable positions ±110° for 5-axis machining, as well as in the long-bed production with pendulum mode.

An automatic tool change is available with the pick-up procedure starting from 1.5 seconds to a maximum of 60 tool stations of the type HSK 63 or a background magazine, doing this during productive time with up to 163 tools.

New at the trade fair: Faster, more robust and dynamic: the new DZ18 W MAGNUM Extended traverse paths, greater axis speeds and a more dynamic acceleration are the outstanding characteristics of the new double-spin-

The direct position measuring systems in all axes ensure the highest precision when machining. Workpieces can, depending on the machine, be powerfully cut with a speed of up to 16,000 rpm or a maximum torque of 180 Nm. A contribution to the high dynamics of the machining center is provided by the shortened 2.2 second chip-to-chip times. The HSK-A63 tool taper permits tools with diameters up to 140 mm, a maximum length of 380 mm and an individual weight of 8 kg.

The low-cost introduction with "baseline" As a low-cost introduction into successful and proven CHIRON technology, the machine tool manufacturer has developed its new "baseline" product series of singlespindle machining centers. These mainly meet to the needs of producers of small and medium batch components with all machines preconfigured, flexible in use, and available in five-axis versions with optional controls from Heidenhain or Siemens.

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hyperMILL® 2016.1 - Machining with better performance

OPEN MIND Technologies AG is set to exhibit at this year’s EMO, the world’s leading metalworking trade fair, from 5 to 10 October.

At Booth C10 in Hall 4, the developer of CAM/CAD software and postprocessors will be offering a sneak peek at the upcoming release of version 2016.1 of its hyperMILL® CAM solution. A particular highlight of the new version is the finishing strategy from the new hyperMILL® MAXX Machining performance package. ‘Tangent plane machining’ makes it possible to achieve machining time savings of up to 90 per cent.

Extended functions for 3D and 5axis machining tasks, new cycles for mill-turning and numerous innovations in hyperCAD®-S round out the range of functions available in the new version.

‘Tangent plane machining’ offers users a major boost in efficiency for finishing planes and free-form surfaces. Using conical barrel cutters allows for larger path distances for the same theoretical scallop height.

The OPEN MIND machining strategy takes advantage of the extremely large radius of the barrel shape, which allows for optimal inclination to the faces. This makes it possible to achieve considerably shorter machining times and a high level of surface quality. The innovative strategy is easy to program, highly efficient and reliable thanks to the collision check performed on the toolpaths.

Toolkit with special strategies Version 2016.1 sees OPEN MIND showcase the modular hyperMILL® MAXX Machining performance package. It offers a range of optional high-performance strategies for

roughing and finishing. The package includes the HPC roughing module, currently called hyperMAXX®, that is powered by Celeritive’s Volumill kernel.

Mill-turning with more performance The mill-turning innovations and optimisations also promise better performance. The user interface is now even more transparent for making inputs easier. The new cutting edge position management feature makes it possible to better define the tool cutting edge and its position.

More CAD for CAM – hyperCAD®-S hyperCAD®-S, the CAD system for CAM, is packed with many innovations and extensions, including extended associativity with hyperMILL® and the new surface command for support during 5axis swarf cutting.

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First milling cutter with HX blades of PcBN The HX blades have established themselves for reaming operations. Thanks to the hexagonal form they have six usable cutting edges and thus ensure very good cost-effectiveness during machining. MAPAL has now succeeded in making the HX blades available also for milling operations. Whereas to date only brazed PcBN blades with one cutting edge could generally be used for face milling during the finishing of cast iron and hardened steel it is now possible to use the six cutting edges of the HX blade.

With 63 mm diameter, for example, the newly designed milling cutter has five PcBN milling inserts.

The use of proven adjustment and clamping systems guarantees the optimum backlash-free mounting of the HX blades. Since six cutting edges can be used with each indexable blade and both adjustment and changing is very simple, the new milling cutter is extremely cost-effective.

The costs per part are significantly reduced.

The new milling cutter with PcBN blades shows its strengths particularly in the automotive sector and

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in mould making where the extremely good surface finishes are demanded that the new milling cutter produces. Furthermore, the central coolant supply is directed straight at the inserts to ensure an optimum chip flow.

During face milling of a part of GJL25, for example, surfaces are produced with Rz = 3 µm and Ra = 0.4 µm at a cutting speed of up to 2000 m/min and a spindle speed of 10,110 rpm (d = 63 mm). The maximum cutting depth that can be achieved with the new milling cut-

ter is 1 mm in cast materials.

In hardened steel with a hardness of HRC58 ± 2, the maximum cutting depth is 0.2 mm. During machining, surfaces are produced with Rz = 1.3 µm and Ra = 0.16 µm at a cutting speed of up to 250 m/min and a spindle speed of 1400 rpm (d = 63 mm).

The HX milling cutter with PcBN blades will be presented at the EMO 2015 in Milan.

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Inline technique for the selective removal of contaminants generated by assembly and joining processes Assembly and joining processes, such as screwing, pressing or welding, generate unavoidable contamination. These particles or smoke residues often have an adverse effect on product quality or downstream manufacturing steps. This can be avoided using an integrated precision-cleaning solution, such as the quattroClean system from acp.

Featuring a minimum footprint and short cycle times, the system cleans components in a dry, selective process; it is also easy to automate.

In numerous branches of industry, such as the automotive, supplier, mechatronics, precision engineering, hydraulics and aerospace industries, components have to be really clean. Accordingly, technical cleanliness requirements in component manufacturing are strictly defined. To uphold them, enormous technical and financial efforts are necessary. Despite this, functionally-critical contamination is still found in systems that are constructed from parts manufactured in compliance with cleanliness specifi-

cations. Most of the contaminants originate from assembly processes.

This is because tiny burrs, chips, flakes, abraded material and filmy contamination are unavoidably generated during tumbling, caulking, screwing, pressing, punching and bending processes. To ensure the function, quality and long-term reliability of the subassembly or product, these contaminants have to be selectively removed – ideally immediately after their formation.

In serial productions, the efficient

Fitted with two nozzles, the quattroClean system simultaneously cleans the inner and outer surfaces of a product in an inline assembly process.

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Critical particles or flakes (left) generated during the assembly process are selectively removed by a jet of CO2 snow. quattroClean snow-cleaning system from acp – advanced clean production GmbH, is the ideal solution. It reliably removes filmy and particulate contaminants in the assembly line’s one-piece flow – even from delicate and finely-structured surfaces. The system uses a dry cleaning method and, depending on requirements, whole components or just specific areas thereof can be cleaned. The space-saving device can be integrated into an assembly or joining process and is easy to automate.

More effective than compressed air and highly versatile Environmentally-neutral carbon dioxide, which has an unlimited shelf life, is used as a cleaning medium. It is produced as a by-product in the chemical industry as well as in the generation of energy from biomass.

Liquid carbon dioxide is guided through the patented two-component ring nozzle and expands on exiting to form fine CO2 crystals. This core jet is then bundled by a jacketed jet of compressed air and accelerated to supersonic speed. The easy-to-focus jet of snow and com-

pressed air has a temperature of minus 78.5°C as it exits the nozzle.

On impacting on the surface to be cleaned, a combination of thermal, mechanical, sublimation and solvent effects occur. These four means of action not only ensure that particulate contamination, such as chips, abrasion and tiny flaky burrs are reliably removed, but also filmy contamination, for example residues of lubricants and pastes, smoke traces from laserwelding processes and flux residues from soldering steps. Consequently, the system can clean off contaminants that compressed air would be unable to remove. The cleaning process is also gentle on materials, therefore enabling quattroClean to be used for cleaning components with delicate, finely-structured surfaces.

The aerodynamic force of the jet of snow and compressed air also ensures that detached contaminant particles are transported away from the component and sucked into the system’s work chamber. The crystalline carbon dioxide converts fully to gas during the cleaning step, meaning that the cleaned component is dry straight away.

Compact, easy to automate and individually programmable Thanks to its modular construction, the quattroClean system from acp can be easily adapted to customer requirements, even in cases where space is limited: a jet unit fits into a space of approximately 20 x 20 cm, including an extraction device for detached contaminants.

This allows even geometricallycomplex components to be cleaned in the one-piece flow of an assembly line or rotary indexing table. To achieve optimum results with a minimum of effort, each snowcleaning unit can be programmed to clean a specific component or subassembly. The programs are filed in the controller of the line control system. Workpiece carriers can also be cleaned selectively.

Its efficient cleaning ability, compact construction and easy automation capability enable the quattroClean system to eliminate critical contamination from assembly and joining processes. It therefore improves functional reliability and product quality, and that at an affordable price.

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WITTENSTEIN bastian at EMO Milano 2015

WITTENSTEIN bastian GmbH, the quality and technology leader for innovative gearing components and special gearheads, will be represented at the EMO Milano from October 5 to 10, 2015 (Hall 3, Stand H14) with a broad array of optimally meshed solutions. From automotive to racing cars and from machine tools to CNC machining centers and robots - WITTENSTEIN bastian's gearing technology excels in terms of design, production and durability.

The product portfolio chosen for WITTENSTEIN bastian's premiere in Milan as a partner at the WITTENSTEIN S.P.A. booth comprises bevel and spur gears, internal gearings and special gearheads. The proper-

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ties of these gearing solutions are tailored to individual needs: the torque, motor speed, running noise, displacement sensitivity and rotary transmission are all designed according to customer specifications and manufactured efficiently in an ultra-modern production environment - both as standard products and as prototypes. Crucial processes such as heat treatment and fine grinding of the gearing components take place in-house at WITTENSTEIN bastian. The result: consistently high-end quality up to DIN 1 from a single source.

Engineering, development and production at WITTENSTEIN bastian are optimally meshed for maximum precision and performance. This is a

vital precondition in many areas from automotive gearboxes, crankshaft and camshaft sprockets or oil pump drives to racing car gears and electromobile drive technology. The motion and positioning axes of machine tools, CNC machining centers, direct drive tools, robots and automated handling systems likewise profit from high-performance gearing technology made by WITTENSTEIN bastian.

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Automation 4.0 toolcraft and PCam reinvent the automation era

C 0 toolcraft is collaborating with the Swiss company PCam to develop a novel automation solution over a workspace of 80 m² a system supplier specialising in metal turning, milling and additive manufacturing, toolcraft delivers end-to-end solutions from a single source. The company’s machinery is based on the latest technology to ensure superb quality, from initial contact to the completed order. toolcraft is now once again investing in the future and will take its first step towards Industry 4.0 in early 2016.

No standard solution toolcraft is collaborating with the

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Swiss company PCam to develop a novel automation solution over a workspace of 80 m². Focussing once again on the competitive advantage to be gained from innovation, toolcraft is also investing to expand its machine park and is planning to use the automation project as a showcase for future customers. The custom solution will combine two Hermle C32 machining centres.

“Our aim is to machine 24 hours a day, 7 days a week,” says Christoph Hauck, Managing Director of toolcraft. “With this in mind, we were

looking for an automation solution that would match our specific requirements. PCam is the perfect partner to help implement the innovative production method.”

A new dawn for automation In contrast to typical automation solutions, the robot in this solution travels on a portal above the machines and loads them from above through a hatch. It also inserts the necessary milling tools automatically into the integrated milling tool changer. The benefits are clear, as

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al and the necessary milling tools are available to ensure smooth, flexible and consistently reliable production.

Automation 4.0

C 1 The robot travels on a portal above the machines and loads them through a hatch the design not only saves space, but guarantees flexible machining as well. This is because the operator can still access the Hermle machining centres directly to operate them manually, independently of the automated processes. This flexibility is particularly important when it comes to machining small and medium-sized series. Storing the milling tools externally also has a significant cost benefit, as large milling tool magazines are not needed in the machining centres.

ed and workpieces are removed via the loading and unloading stations, allowing the operator to plan production for when the machinery is unattended. This enables jobs to be processed at the weekend, for example, and the finished parts to be transferred out of the automation system at the start of the following week. The PCamCell software is the system control centre. It plans and controls the process predictively, checking whether adequate materi-

The automation solution can also be used with existing machines. In fact, the guiding principle of Alex Magnetti, owner of PCam, is “Use what you have”. “Our concept is completely independent of machine manufacturers and machine technologies. We provide chains of all kinds, connecting extremely different machines to one another – with or without robots.” The system at toolcraft is also modular and extensible, with plans to expand it already in the pipeline. “It can also be linked to our ERP system, which would enable the software to determine the machining sequence fully automatically in line with our delivery deadlines,” says Christoph Hauck. That would represent yet another step towards Industry 4.0.

Fully automated production Components are still programmed in the same way as before, while the automation system’s cell controller accesses the approved machining programs directly and the machining jobs are prioritised at the automation system terminal.

The robot automatically fetches the workpiece pallets for machining and the required milling tools from the shelf, loads the machines and starts the machining runs, before returning the finished parts to the shelf. Tools and material are provid-

C 2 The machining jobs are prioritised at the automation system terminal

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SHW Werkzeugmaschinen shows a spectacular array of novelties at the EMO SHW Werkzeugmaschinen shows a truly spectacular array of novelties at the EMO. The technological highlight is the new SHW fork milling head with continuously variable A- and C-axis and high frequency spindle. Furthermore, the company presents a precision granite machine bed for the highest possible dimensional accuracy in difficult climate conditions and the new SHW TightBlock for a level machine installation without a foundation. The sensation for bargain hunters is the 650 years anniversary edition "eysenwerck" offered at a special rate.

According to SHW Werkzeugmaschinen, the new fork milling head, newly developed in cooperation with the Kessler company, is particularly interesting for 5-axis simultaneous machining in classical mechanical engineering as well as for smoothing in module-making.

With up to 26,000 rpm, the integrated high frequency spindle is ideal for light metal machining. For steel machining, the user can choose between High-Feed-Cutting (HFC) or High-Speed-Cutting (HSC).

The continuously variable A- and Caxis enables machining around the work piece. Traverse distan-ces of x = 2,000-30,000 mm, y = 1,300-2,600 mm and z = 1,300-1,500 mm offer the user tremendous freedom even for bulky pieces. Weights of work pieces of up to six tons are possible, because the milling head moves

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around the work piece. The new SHW-fork milling head is available in the two editions UniSpeed and PowerSpeed.

Granite bed for highest possible precision The new precision granite bed by SHW promises highest precision and dimensional accuracy when working under unstable climate conditions. Due to the very low expansion coefficient and high abrasion resistance and rigidity, the highest possible precision is to be expected. The new machine bed made of massive granite is made as a block from one piece. Due to the thermal characteristics, the factory hall does not have to be air-conditioned. And still the user will achieve the most precise results.

The SHW-TightBlock is also new. A welded steel construction filled with polymer concrete in front of

the machine enables level assembling of the PowerSpeed series without a foundation. Despite traversing distances of x > 3,000 mm and y > 1,600 mm and workspace which is completely freely configurable, SHW offers total enclosure of the machine and provides a high displacement circle when working with bulky work pieces.

Anniversary machine for bargain hunters The big hit at the EMO will surely be the SHW-650-years anniversary machine "eysenwerck". SHW has extended its special offer from the in-house trade fair until 31 October 2015. For as long as stocks last, price-conscious bargain hunters will receive an unbeatable 134,000 Euro price advantage on the UniSpeed 5 standard machine. SHW at the EMO, Hall 1, stand C13.

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Starrett shows its cut and thrust at EMO At this year’s EMO exhibition in Milan, Starrett (Pavilion 18, Stand B13) will show a number of recently launched sawing machines and new blades developed specifically to increase customer productivity.

The company’s 63 m2 stand in the ‘band saws, blades and sawing’ hall will feature live cutting demonstrations.

Ideally suited to a wide range of industry sectors the Starrett S4230 and S4240 semi-automatic machines will be demonstrated. Featuring state-of-the-art technology that has been specifically adapted to increase the capabilities of the band sawing machines, both feature cast iron bows for vibration damping and longevity, a minimal footprint and controlled hydraulic blade feed.

The S4230 supports productive cutting and is able to cut mitred corners on both the negative (-45o) and positive sides (60o). Fitted with a 1.5 kW motor it can cut material up to 300 mm diameter or 270 mm square. The 2.25 kW motor on the S4240 combined with a rigid structure creates a semi-automatic band saw that is ideal for intensive use and for cutting harder materials up to 300 mm diameter or square. It can also cut mitred corners at an-

gles of between -45o and 75o, making it ideal for intricate work.

A fully-automatic CNC machine, the S6330 has a blade speed between 20 and 100 m/min controlled by a variable frequency drive. Featuring a dual column design to balance the cutting forces generated it ensures precision and stability. The S6330 will be used to demonstrate the exceptional cutting capability of Starrett’s carbide band saw blades for hard and abrasive metal cutting applications. New carbide tipped blades at the show will include the Advanz MC5 and Advanz MC7, both feature positive rake angles and ground teeth geometry that has been specifically developed for a group of materials.

Advanz MC5 trapezoidal cutting tooth geometry has been designed to create five chips as the blade passes through the raw material. It is ideal for highly productive cutting of ferrous metals at a reduced cutting time while achieving an excellent finish. Applications include automotive aluminium cast blocks, cast iron, bronze and copper on machines with hydraulic feed control.

As the name suggests, the trapezoidal cutting tooth geometry on the Advanz MC7 generates seven chips. This allows the blade to cut difficult materials such as mechanical construction steels, tool steels, stainless steels, Inconel and titanium, using a similar chip loading principle to that applied during high speed machining. Slow, heavy cuts are replaced by faster, lighter cuts resulting in quicker cutting action that is less detrimental to the machine’s components.

As well as carbide tipped blades, Starrett will also highlight its Versatix MP blades with a special tooth geometry developed for cutting structural materials with increased tooth strength, and Primalloy that features a high cobalt and vanadium content on teeth to guarantee longer blade life with high quality surface finish, increased wear and heat resistance, easy penetration in hard and difficult to machine materials, increasing the blade performance and resulting in cost-effective cuts compared to conventional bimetal blades.

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World's first: Additively manufactured hydraulic chuck With the HighTorque Chuck (HTC) with narrow contour, MAPAL has succeeded in combining the benefits of the hydraulic expansion technology with the 3° back taper known from the shrink chuck. This is made possible by the additive manufacturing process employed at MAPAL in the form of selective laser melting (SLM). SLM is a powder bed-based process. Loose metal powder is melted layer by layer onto the areas where material is required by means of a laser beam.

The part is built up from bottom to top.

During the production of the hybrid HTC with narrow contour, the functional area is applied to the conventionally manufactured tool body by SLM. Thanks to the additive manufacturing, the clamping range can be positioned very close to the chuck tip which would not have been possible with conventional manufacturing. This provides an optimum radial run-out of < 3 µm at the location bore and < 5 µm at 2.5 x diameter, as well as high shape accuracy with good vibration damping. The damping in the system reduces microstructure cracking at the cutting edge. That in turn ensures longer tool life and less strain on the machine spindle. Furthermore, the additive manufacturing eliminates the need for the soldered joint that has always been a limiting factor until now.

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The HTC with narrow contour has all the benefits of the proven MAPAL HTC (HighTorque Chuck) technology, whereby the "T" stands not only for high torque transmission, but also for thermal stability. The wide operating temperature range up to 170 °C ensures additional process reliability. The balancing quality is G=2.5 at 25,000 revolutions per minute.

The new chuck offers significant benefits not only for mould making, but also for applications in the automotive and aerospace sector.

Why? The HTC with narrow contour is suitable for all machining operations in contour-critical areas. It allows quick and simple clamping of the tool. That means: Neither training courses nor high retooling costs or expensive peripherals are re-

In the hybrid process, the functional area is applied to the conventionally manufactured tool body by SLM.

The HTC with narrow contour is the first additively manufactured chuck from MAPAL. quired for implementation.

The HTC with narrow contour is available in the clamping diameters of 6, 8, 10 and 12 millimetres for HSK-A63 and SK-40. Intermediate sleeves enable additional diameter ranges to be covered. In addition, the chuck is optionally available with dynamically balanced HSK. That again is something new: For the first time is has become possible to dynamically balance components with HSK connection, because the mass imbalance that has been caused by the different depths of the key block slots until now has been eliminated in the optimised HSK.

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BIG KAISER announces fastest air turbine spindle at 120,000rpm The air turbine ensures that Z-axis thermal expansion is minimized.

Frequently, cutters can get extended slightly due to thermal expansion when the machine spindle runs at high rotation speed – the RBX12 solves this problem due to its air turbine drive, ensuring high accuracy for micro-machining.

Improves finish quality, extends tool life and reduces wear on OEM spindles BIG KAISER, a leader in premium high-precision tooling systems and solutions for the aerospace, automotive, energy, medical and watchmaking industries, introduces the RBX12, a high-speed air turbine spindle that achieves a market-leading rotational speed of 120,000 rpm.

The new air turbine spindle enables existing machines to be costeffectively upgraded and highspeed micro-machining to be done in a normal machining centre, without the need to purchase an expensive new high-speed machine.

Operating at such high speeds helps to improve machining accuracy, enhance surface finish and significantly lengthen tool life, as well as reducing wear on the cutting tool., High-speed operation also means

Headshot of Peter Elmer, CEO of BIG KAISER Precision Tooling AG that processing time can be reduced. In various trials, BIG KAISER was able to reduce the machining time by more than 300% because of higher rotation speed.

Due to its ceramic ball bearing type, the runout accuracy of the RBX12 is excellent, which enables ultra-thin wall cutting. This is ensured by a runout measuring system that can detect spindle movement during high-speed rotation.

“For micro-machining applications, the new RBX12 means that companies can get the most out of their existing equipment, achieving high levels of precision and speed,” says Peter Elmer, CEO of BIG KAISER.

The RBX12 fits into a standard machine with centre spindle with BBT30/40 or HSK-E32 and HSK-A63.

It has a body diameter of 32 mm, and therefore is ideal for industries requiring high precision, such as medical and other microtechnology applications. For ease of use, automatic tool change is possible.

The RBX12 is available now.

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Ionbond at EMO 2015 Ionbond, the specialist in PVD, PACVD, and CVD coating technology, will once again demonstrate its superior coating solutions for cutting tools at EMO in Milan. Between 5 and 10 October, Ionbond is pleased to welcome its guests at booth D17 in Hall 10 and will present multiple innovations and new developments for the worldwide market.

Ionbond has developed a new series of three premium PVD cutting tool coatings which make use of proprietary advanced arc technology. The new process deposits the coatings at energy levels far higher than conventional arc sources. The coatings significantly increase in density while reducing growth defects, resulting in a much smoother surface. Comparison tests with leading competitor coatings conducted by various customers and at Ionbond’s internal cutting tool laboratory show substantially improved service lifetimes of the tools in all major types of machining operations. The three coatings will be placed on the market with the name extension “Plus” as Hardcut Plus TiSiN, Crosscut Plus AlCrN, and Maximizer Plus TiAlN. Ionbond is proud to be able to present the new coatings as an absolute novelty to the tool market.

Over the last decades, AlTiN has become a mainstream standard coating for cutting tools. Until today, these coatings have been produced by means of PVD technology.

Ionbond has developed new indus-

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trial scale CVD technologies for the deposition of high aluminium containing TiAlN coatings, including a dedicated low-pressure CVD process module. Initial tests with cemented carbide inserts for milling and turning tools have shown superior performance compared with both conventional CVD as well as PVD coatings. The low-pressure process module can be retrofitted on any existing Bernex™ BPXpro system or integrated into new Bernex™ BPXpro CVD coating systems.

In addition, Ionbond will present the newly developed Bernex™ MOCVD Evaporator. This self-contained module is designed for the sublimation of solid metalorganic

precursors and for the direct transportation of the evaporated materials into the CVD coating process chamber. Thus, the MOCVD Evaporator makes available a multitude of additional elements not attainable in gaseous or liquid form and opens up many new possibilities for coating compositions in CVD processes.

Ionbond will be joined at Booth D17 by its sister company Hauzer Technocoating from the Netherlands, showcasing its latest addition to their advanced PVD tool coating equipment, the Flexicoat 850 CARC+. In addition, IHI Machinery and Furnace Co., Ltd. from Japan will present its heat treatment and carburizing equipment.

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CLOOS at SCHWEISSTEC 2015 The perfect solution for every requirement From 3rd to 6th November 2015 the trade fair duo of Blechexpo and Schweisstec will place Stuttgart under the banner of industrial sheet metal processing and cutting and joining technologies. In hall 6, booth 6407 Carl Cloos Schweisstechnik GmbH will present a wide range of manual and automated welding. The exhibition visitors can expect a wide range of welding processes for different materials and components.

The focus of the CLOOS exhibition booth is on an automated robot system which is equipped with an automated torch changing system.

No matter if thick or thin, steel or aluminium â&#x20AC;&#x201C; here you find the right welding process for every product requirement. The welding specialists will present the new Tandem Weld generation for process-safe and very quick and comfortable welding. With the Cold Weld process an alternating current produces a very special pulse form, which brings about an extremely low heat input. The Laser Hybrid Weld process is the combination of

The high-quality QINEO welding power sources have been developed specifically for commercial and industrial welding purposes. a laser beam with a MIG/MAG welding process in one common process zone. thus using the advantages of both processes. The Narrow Gap Weld technology offers a particular economic efficiency for welding thick-walled component parts.

Avoid production downtime by an automated change of consumables Another highlight is the new fully automated current tip and gas nozzle changer SpareMatic which allows non-stop welding with operative components. When the welding robot needs new nozzles, the automatic current tip and gas noz-

zle changer comes into play. The changer takes the torch consumables and replaces them for new ones. Due to its compact, modular design, the SpareMatic can be integrated into both new and existing systems.

High-quality power sources for manual and automated applications Besides, CLOOS will present the wide QINEO model range of highquality welding machines for manual and automated welding. The new QinTron inverter welding machine is characterised by a robust design, optimum ignition and welding characteristics and an excellent price/performance ratio. During live-demonstrations of manual welding trade visitors can experience the welding machines.

QIROX comprises all solutions for automated welding and cutting.

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RPS Endurance inverters with new parallel operation feature – available in 20 ft “ICON ND” stations up to 2.25 MWac Bonfiglioli’s RPS Endurance inverters are now ready to tango: With the introduction of the new tandem feature, two units operate seamlessly in parallel on a single medium-voltage transformer winding. This makes the performance and ease of handling of RPS Endurance inverters now fully available for megawatt-scale PV stations.

Thanks to the further extended power range of single RPS Endurance units of up to 563 kWac at 50°C ambient temperature, the new features allows the effortless realization of 1MW+ tandem configurations with a common ac connection, paired with the best-inclass 15 % permanent overload capacity (up to 648 kWac) at reduced ambient temperatures. Constructed with a record footprint and designed for maximum productivity even in the toughest conditions, these ratings make the RPS Endurance a truly compact powerhouse.

A unique feature for indoor-rated PV inverters, the innovative twozone ambient protection system distinguishes the RPS Endurance from other solutions and makes it a preferred choice wherever harsh

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agement options, the RPS Endurance is built to satisfy your power control requirements in the fast developing global PV market.

RPS Endurance is a robust, compact powerhouse with a rated power of up to 563 kWac for each inverter unit. conditions for plant installation and operation are present, such as in the “sun-belt” regions of the world. The intelligent encapsulation design maximizes uptime through a full IP54 ambient protection degree of active components.

Thanks to advanced air cooling technology, the inverter design ensures outstanding reliability and serviceability. With numerous selfprotection functions and grid man-

The new RPS Station ICON ND series integrate 2 x 2 units of RPS Endurance inverters into a compact 20 ft container design, achieving an excellent power rating of up to 2.25 MWac per station. This great compactness is paired with a proven and easy-to-maintain forced-air cooling system. ICON ND stations are delivered ready to connect to an external three-winding mediumvoltage transformer, helping customers to significantly reduce project execution times.

Electrical Schematic of RPS Station ICON ND with 2 x 2 units of RPS Endurance

RPS Station ICON ND – The perfect home for RPS Endurance inverters

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NSK products make debut at Agritechnica 2015 Visitors to Agritechnica 2015 (Hanover, 10-14 November) will witness the debut appearance of NSK rolling bearings designed purposely for the agriculture industry.

Central to the NSK exhibit will be ‘Agri Disc Hubs’ – ready-to-install units deployed in soil tillage machinery such as compact disc harrows, seed drills and strip-till equipment.

Agri Disc Hubs comprise doublerow angular contact ball bearings that are able to absorb very high radial and axial loads. Via a flange, the units can be fitted directly and easily to disc harrows, for example.

The robust design of Agri Disc Hubs is among the principal features of these innovative units, which are expected to operate in harsh environments. Sudden shock loads caused by rocks in the soil for instance create high axial loads as a result of the angle at which tillage equipment is positioned in relation to the direction of travel. What’s more, abrasive material like dust, and corrosion due to the presence of water and fertiliser, are known to cause problems for conventional bearing solutions. Agri Disc Hubs, however, offer extremely long service life without the requirement for maintenance, even when subjected to the severe mechanical stress encountered in agricultural applications.

Among the design innovations aiding the performance of Agri Disc Hubs is a highly effective cassette seal system that prevents the infil-

tration of abrasive dust and moisture into the bearing interior (see image), even if the machinery or equipment is in contact with substances such as manure, and cleaned using high pressure jets.

Furthermore, no grease can leak or spill on to the soil as the bearings do not require re-lubrication.

Agri Disk Hubs are produced at NSK’s Neuweg site in Munderkingen near Ulm. The plant has origins dating back to 1954 when it was established and operated by a class-leading manufacturer of agricultural machinery. The site was taken over

by NSK in 1990. Able to call on more than 60 years’ experience in the production of roller bearings for agricultural equipment, this modern, highly flexible facility can also manufacture small batches of bespoke or modified units in line with customer requirements.

A selection of Agri Disk Hubs for 400 to 800 mm disc diameters are set to take centre stage at Agritechnica 2015, where NSK will be found on Stand C 44 in Hall 17. Also on the stand will be other bearing types developed with and for reputed manufacturers of agricultural machinery. These will include, for example: ready-to-fit pulley bearings for field choppers; four-point bearings for seed drills; and ‘Gage Wheel Bearings’, which are doublerow angular contact ball bearings featuring extra width that are ideal for use in the various rolls of soil tillage machinery.

NSK at Agritechnica 2015: Hall 17, Stand C 44

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Athlonix 22DCP Brush DC Motors deliver speed-to-torque performance in a cost-efficient package Portescap introduces the next generation of Athlonix™ high power density brush DC motors.

Athlonix DCP motors offer an optimized price-to-performance solution ideal for a broad spectrum of applications. Available in a 22mm diameter, the new 22DCP motor will feature an energy efficient coreless design with an optimized self-supporting coil and magnetic circuit, which delivers maximized power density and sustained endurance over the life of the motor.

Athlonix 22DCP motors are available in 2 variations, precious metal commutation and graphite commutation with Alnico magnet inside.

The unique constant force spring design for carbon brush ensures consistent performance. An REE (Restriction of Electro Erosion) coil is an available option, which ensures extended life of the motor.

With maximum continuous torque up to 6.5 mNm and higher stall torque than similar comparative motors. Athlonix 22DCP motors are

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ideally suited for use in applications such as medical & industrial pumps, gas analyzers and security & access and power tools.

“Athlonix motors are powered by a proprietary self-supporting coil resulting into maximized magnetic flux and ampere-turns for a given diameter” says Sunil Kumar, Brush DC Product Line Manager at Portescap. “In contrast, typical selfsupporting coils have inherent ampere-turns limitations that affect the magnetic flux density in the magnetic circuit, which further limits power output and endurance of the motor,” he says.

Component standardization and design modularity ensures quick customization capability for samples across various applications.

Standard configurations can be delivered with maximum one week lead-time Athlonix motors are compatible with encoders and gearheads of various sizes and ratios and are also available on our online motor configurator MotionCompass™. They are manufactured in an ISO certified facility, and are RoHS compliant.

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Emerson Presents Elevator Drive&Motor Solution at Interlift 2015 Control Techniques and LeroySomer, both part of Emerson Industrial Automation, an Emerson (NYSE:EMR) business, are displaying their range of variable speed drives and a new permanent magnet motor specifically for the elevator market at October’s Interlift 2015.

The Control Techniques E200 and E300 drives and the LeroySomer E27 motor make installing and commissioning elevator systems quick and simple.

E200 & E300 have an intuitive user interface which allows easy adjustment via a back-lit LCD keypad and rapid set-up in familiar elevator language and units. Meanwhile, the compact and silent E27 motor offers a completely new design to ease mechanical and electrical installation. A central sheave allows a simplification of the chassis, while also offering full access to the sheave and traction ropes. Equipped with fast connectors for the power, the brakes, the thermal sensor and the encoder, the E27 motor guarantees a quick and reliable electrical connection.

Optimum ride comfort is provided by the new drive and motor solution: both E200 and E300 integrate a high resolution multi-step S-ramp for start, run, slowdown and stopping, as well as an ultra-fast current loop for vibration free motor control. Additionally, E300 offers extra

levels of ride comfort with direct to floor positioning, an advanced communications interface supporting DCP3/4 and Modbus RTU protocols, short floor operations and on-board data logging capabilities. In association with the E27 motor equipped with optional load cell, ride comfort is improved as the starting torque is adapted depending on the load.

Combined with the E200 or E300 drives ( STO according to EN618005-2:2007) and the E27 motor, the Brake Control Unit (BCU) is a contactorless solution offering two mains functions; the management of the brakes supply during normal operation and the management of the rescue (according to EN81-20 / 50). The two independent contactors cutting the line between the drive and the motor along with the two cutting the line of the brakes supply can be removed. The benefit is the removal of the noise from the elevator shaft, along with the direct savings in components and wiring.

John Orrells, elevator market strategic manager for Emerson Industrial Automation, said: “The E200 and E300 drives, combined with the E27 motor and Brake Control Unit (BCU), offer a complete solution for our elevator customers.

“These products have been developed after extensive market research and feedback from our customers. Our research has directly influenced our engineering and design program, resulting in drives and motors designed specifically to operate together.

“This provides an additional guarantee of high performance for the customer, with simplified maintenance and after-sales service, while meeting the requirements of the elevator market.”

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New generation Leroy-Somer LSA 46.3 & LSA 49.3 alternators launch Leroy-Somer Electric Power Generation in Emerson today announced the launch of two new Leroy-Somer products that will renew the brand offering in the 1801000 kVA power range.

The Leroy-Somer LSA 46.3 180 365 kVA (400V - 50Hz) generator features an improved power density over its predecessor, the LSA 46.2. The bulk of the body has been significantly reduced thanks to an innovative and improved air cooling system, and an integration of the excitation system in the main body of the machine. The new design of the connection box allows for a quicker wiring of the machine and easier access to key electronics for maintenance.

The Leroy-Somer LSA 49.3 660 – 1000 kVA (400V - 50Hz) alternator also benefits from a reduced footprint, with enhanced electromechanical performances. The electrical performances of the LSA 49.3 have also been increased, with an efficiency now up to 95% and a high motor starting capability. The LSA 49.3 terminal box has been optimized for faster deployment and to provide a better support to the latest generation of digital regulators.

“The launch of these new products demonstrates our continuous commitment to innovation and growth.” said Xavier Trenchant, President of the Electric Power Generation division “In a challenging economic environment, we

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continue to invest to better anticipate our customers’ expectations.

This means that our products are continuously improving to deliver top-of-the-range performances, offering reliable, cost-efficient solutions for demanding applications. We have also recently extended our offering to provide a

competitive solution on less demanding applications. Consequently, we do provide the best value proposition to our customers across all power ranges and types of applications, keeping our historical focus on quality and services.”

The LSA 46.3 and LSA 49.3 are optimized for continuous and demanding applications, including marine, power plants, cogeneration, rental or critical standby in commercial and industrial premises.The Leroy-Somer LSA 46.3 and LSA 49.3 will be available to order starting Q3 2015.

For more information, please visit www.emersonindustrial.com/elect ricpowergeneration

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Robotmaster at EMO 2015!

Robotmaster will be exhibiting at EMO 2015 which will be held October 5-10 at Fiera Milano in Milan, Italy.

Visit Robotmaster in Hall 4, stand A36 and discover the revolutionary software that has enabled the economic implementation of manufacturing robots to companies of all sizes, from small local shops to large global manufacturing conglomerates.

On the Robotmaster stand, a Staubli robot will be used to produce a complex composite part demonstrating how Robotmaster can program a more versatile and less expensive robot as easily as one would a CNC machine tool!

We invite you to stop by our booth

Robotmaster is true CAD/CAM for robots! Robotmaster easily programs processes such as; trimming, de-burring, polishing, welding, dispensing, grinding, painting, 3D machining and machining molds.

and preview Robotmaster 6.3. The work flow and the manner in which features interact have been radically improved since the previous versions.

By optimizing the user work flow and a major core technology enhancement, Robotmaster is 3 and up to 10 times faster than the previous version, depending on the part being programed.

Robotmaster速 is a product of Hypertherm Robotic Software, specialized in dedicated software solutions for industrial automation, manufacturing and robotics since 1996.

Robotmaster is distributed in Europe

by Intercam SA. For more information please visit our http://www.robotmaster.com or email us at info@robotmaster.com

Plastron Hot Runner Systems Co LTD Plastron Hot Runner Systems Co LTD was establihed in 1998 to serve the plastics industry,The all of HRS were our own designed and developed by our experiences and our own R&D inventions. In addition to standart lines,custom designed accordance with customers or requirements.Plastron is among leading companies in HRS market and all employs who all experts in their respective fields.

Plastron allways shared the knowledge and experiemnets with customers.Plastron is produce good molding solutions for customers.Plastron leading Hot Runner Systems Design and Implementation, as well as Coiled heaters, Nozzles. Flex Heaters also Manifolds with such systems remains part of the products in the market place. www.plastron.com.tr

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