Flexible twin-spindle machining center
Improved universal cylindrical grinder
New developments in broach grinding
New Makino L2 5-axis vertical machining centres
Process automation: on the way tothe clouds
Measurements trigger an appetite for more
EMO Hannover 2017 will showcase navigational aids for the smart factory of the future
Progressively larger volumes of data smooth the path of machine learning for adoption in production operations
Cloud solutions are on everyone’s lips: digitalised data in app-based strongholds in the clouds are being tasked with automating processes and rendering them more efficient. The EMO Hannover 2017 will be showcasing viable approaches and providing fit-for-purpose navigational aids on the data highway to the smart factory of the future.
Between fascination and a slight uneasiness –that's roughly the sort of subliminal reaction even experts occasionally feel when it comes to the subject of “artificial intelligence”. Autonomous robots, self-driving vehicles or cognitive systems that image the functioning of the human brain and are even able to checkmate a chess grandmaster, may trigger concerns regarding a loss of human control. As a key technology for Industry 4.0, self-learning systems can be expected to find their way into the factories, especially if they are introduced gradually and “in small digestible pieces”, and prove that money can be earned with them.
Less Energy | More Power: Highly efficient turnkey solutions for metalworking
Double-sided fine grinding machine with basic innovations
Complex 3D components with powder nozzle or in a powder bed
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Deep-hole drilling and milling in an Industry 4.0 environment
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CONTENTS
September - October 2017/2 Vol.43
Measurements trigger an appetite for More 4 Process automation: on the way to the clouds 8 The journey towards Industry 4.0 12 Maximizing process efficiency with proportional pumps 14 BIG KAISER to showcase its latest high-performance tooling systems at EMO Hannover 16 State-of-the-art technology maximizes filtration performance and production uptime Baldwin to bring PureFiltration to EMO 2017 17 EMO 2017 Simufact to present process simulation solutions for machine tool makers and mold makers 18 Protected and user-friendly digital business models for Industrie 4.0 20 MachineWorks New Software Release Presented at EMO 2017 21 Free forms, micro-structures, reflective surfaces - new sensor trio from one source offers solutions for challenging measurement tasks 22 Hanging upside down 24 WITTENSTEIN at EMO 2017: Planetary and right-angle gearheads: WITTENSTEIN alpha redefines the premium segment 25 SCHNEEBERGER MONORAIL MR 4S new generation 26 Hydraulic weight balancing saves Energy 27 SKF at EMO: Affordable machine health monitoring with Multilog IMx-8 28 New hydrostatic guide shoes 29 Less Energy | More Power: Highly efficient turnkey solutions for metalworking 30 Infrared camera for the metal industry up to 2000 °C 32 DEFINING PRECISION. ABRASIVE TECHNOLOGY BY TYROLIT 33 Everything from a single source with Skiving3: Machine - Tool – Process 34 Supfina to exhibit cutting-edge technology at EMO Hannover 2017 36 HURCO shows just how powerful CNC machining centers can further improve your performance 37 Kaeser at EMO Ideal foundation for Industrie 4.0 38 Targeted cooling at the blade 40 New Makino L2 5-axis vertical machining centres: Optimum solution for high-volume parts production 41 Maximum performance when milling,the new Ultra Power Collet Chucks (UPC) by FAHRION 42 Intelligent equipment for smart Production 44 KELCH KENOVA set line V9xx-S System concept to meet the most demanding requirements 46 High-precision and cost-effective marking with zeus tools 48 Intelligent, flexible, fast: NCSIMUL rewrites Rules in CNC Manufacturing 50 New Rotating - Tilting Table for Tool Manufacturing Combines Highest Dynamics with Precision 52 DUALIS demonstrates at the EMO 2017: Transparent production processes in the smart factory 54 Status monitoring system for ball screw drives 55 High stock removal capacity thanks to new hybrid bond 56 Flexible micro sandblasting machine 56 Optimized tooling concepts for deep hole boring 57 Double-sided fine grinding machine with basic innovations 57 Complex 3D components with powder nozzle or in a powder bed 58 Reliable and cost-effective cleaning of industrial wastewater 59 New developments in broach grinding 59 High-performing transfer machine 60 Deep-hole drilling and milling in an Industry 4.0 environment 61 Flexible twin-spindle machining center 62 Improved universal cylindrical grinder 62
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Measurements trigger an appetite for more Progressively larger volumes of data smooth the path of machine learning for adoption in production operations Between fascination and a slight uneasiness –that's roughly the sort of subliminal reaction even experts occasionally feel when it comes to the subject of “artificial intelligence”. Autonomous robots, selfdriving vehicles or cognitive systems that image the functioning of the human brain and are even able to checkmate a chess grandmaster, may trigger concerns regarding a loss of human control. As a key technology for Industry 4.0, selflearning systems can be expected to find their way into the factories, especially if they are introduced gradually and “in small digestible pieces”, and prove that money can be earned with them. As a sub-category in the field artificial intelligence (AI), it’s primarily machine learning (ML) that’s relevant for industrial manufacturing operations. ML enables systems to understand their surroundings, to plan actions, to respond to impediments, and to communicate with humans. Machines use production data and intelligent algorithms to learn to recognise recurrent patterns and objects autonomously. The learned knowledge can then be applied to unknown and unsorted data. This enables sources of error be identified, processes to be planned and optimised, and forecasts to be drawn up. Machine learning needs Big Data
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Design Technology (IPK) in Berlin. But the examples from the IT conglomerates cannot be adopted just as they are for industrial applications as well.
Prof. Jörg Krüger Head of the Automation Technology Department at the Fraunhofer Institute for Production Systems and Design Technology (IPK), Berlin Photo: Fraunhofer IPK The hype currently associated with machine learning, although the concept in actuality dates back to the 1980s, is due to the modernday options for data processing. It was only with the advent of Big Data applications, high–performance computers and gigantic cloud memories that the appropriate infrastructure came into being, used primarily at first by the internet giants. But the industrial sector is following suit. “From the perspective of robotics, we are following very closely what players on the global market like Google and Amazon, with their IT competences and infrastructures, are developing and researching in regard to production technology,” confirms Prof. Jörg Krüger, Head of the Automation Technology Department at the Fraunhofer Institute for Production Systems and
It’s true than many companies, especially large ones from the automation and control segment, have been infected by the “ML virus”. But in the view of sectoral pundits the use of machine learning in the industrial segment is in many cases still in its infancy. This appraisal should not be obscured by spectacular demonstrations, e.g. when IBM impresses the public with its Watson system in the Cognitive Factory. Or when Festo, with fascinating exhibits like the very recent “elephant’s trunk”, an intelligent bionic handling assistant, answers the question of how people in the factories of tomorrow can interact with their machines simply, efficiently and above all safely. The technology exists. It’s exciting, and stimulates the imagination, but translating it into real products capable of delivering sales and profits will probably take some years yet. SMEs and start-ups – the ball’s in their court The fundamental question involved here is whether machine learning is only something for global players and their ideas for a comprehensive concept of a digital factory. Or whether, besides a top-
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down development thrust by financially potent large companies with their highly competent research and development departments, a bottom-up breakthrough spearheaded by flexible, innovative small and mid-tier enterprises would also be conceivable. “Artificial intelligence is an important issue for the future,” says Dr. Wilfried Schäfer, Executive Director of the VDW (German Machine Tool Builders’ Association) and an organiser of the EMO Hannover 2017 (18 to 23 September), the world’s premier trade fair for the metalworking sector. “So small and mid-tier enterprises should also address the possibilities of machine learning in their production operations, enabling them to derive options in good time for their own development thrust.”
feedback, networking, moving things forward. Digitalisation there is a boardroom issue.” Innovative start-ups can make their own contribution to progressing development. Sensosurf has adopted the slogan “Sensor integration meets machine learning”. Founded in 2016 as a spin-off of the Institute for Microsensors, -Actuators and –Systems (IMSAS) at Bremen University, the company transfers microsystem technologies to the tough environmental conditions encountered in the mechanical engineering sector. These include flanged and pedestal bearings, linear guides and threaded rods. “We’re exploring fields from which so far there had been as yet scanty information or none at all available,” says Dr. Winkelmann. For data evaluation, machine learning is deployed in order to use information on the machines and processes. Strategy of small steps
Dr. Cord Winkelmann, Managing Director of Sensosurf GmbH, Bremen. Photo: Sensosurf For Dr. Cord Winkelmann, Managing Director of Sensosurf in Bremen, things have already been set in motion here on many fronts. “The big companies tend to develop their own solutions, often very complex and comprehensive ones, sometimes spectacular and very effective in terms of marketing,” he comments. “These include a kind of bee swarm flying to and fro, collecting information, exchanging mutual
Large quantities of data are essential for machine learning; without them it’s simply not possible. For swift market penetration, says Dr. Winkelmann, it’s crucial that the information generated pays off from the very first moment. “It’s always the small steps we begin,” he explains. These include data evaluation at the machine, networking the machines with each other, detecting what’s characteristic about what’s happening. “Once you see what data are obtained, evaluated and visualised, you quickly get used to the new insights and the opportunities they offer,” says Dr. Winkelmann. “Measurements trigger an appetite for more.” What proves most persuasive for machinery manufacturers, he says, is that the machine learns to protect itself a-
Collecting data for machine learning and Industry 4.0: smart flanged bearing with integrated force measurement from Sensosurf. Photo: Sensosurf gainst operator error. The data obtained can also be used as a defence against unjustified warranty claims, for example. “It’s important to map out migration paths for companies showing how they can introduce the technology of machine learning in small, digestible pieces,” concurs Fraunhofer expert Prof. Krüger. He sees the principal focuses of using ML at machine tool manufacturers as currently centred around the field of condition monitoring. This essentially involves interpreting measured data using pattern detection processes. The knowledge required for detecting process or machine conditions is acquired by the processes of machine learning. Potentials in energy management Besides the fields of predictive maintenance, condition monitoring and quality management, however, self-learning systems can also progress energy management. At the EMO Hannover 2017, the Munich-based company Gerotor will be premiering its HPS high-power storage system, which is designed to reduce the energy and connection costs involved with the aid of intelligent algorithms. The idea for the product originated with Formula 1, or to be more precise with the KERS
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The HPS high-power storage system from Gerotor will be premiered at the EMO Hannover 2017 (18 to 23 September). The idea for the modern flywheel accumulator originated with Formula 1. Photo: Gerotor (Kinetic Energy Recovery System) used there. The system was imposed upon racing cars at the time for reasons of environmental protection, since it returns to the drive axle energy produced during violent braking manoeuvres, by means of a rotating flywheel system. Gerotor’s founders saw huge potential in “this efficient and at the same time wear-free technology, not only for cars driving round in circles,” as Gerotor’s director Michael Hein colloquially puts it. In the search for an application that likewise involves many and frequent braking and acceleration functions, sometimes within a matter of seconds, they found what they were looking for with machine tools and tool spindles. The advantages of digitalising and networking the power storage system were obvious: “If you’re inside the energy circuit, you’re in the information centre too.” Coupled directly to the line, without requiring a power connection of its own, the new power storage system upgrades the efficiency of the entire line by means of energy recovery, peak smoothing and digital-
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isation. For this purpose, the system measures all currents and cycles, acquires data and information, improves its own algorithms, and draws conclusions. Whereas with traditional control strategies energy savings of at most 10 to 25 per cent can be achieved, says Michael Hein, users with intelligent strategies ought to achieve about double the savings effect. For Michel Hein, energy management offers a particularly simple and efficient entry route into ML. “Energy systems have to be 100-per-cent predictive,” he emphasises. “We need intelligent control strategies and an infrastructure that re-adjusts itself.” Return on investment is crucial He admits, however, that the concept of machine learning is practically ignored in meetings with customers The crucial consideration is rather the ROI (return on investment): “We sell our products solely by means of the argument that we save more than we cost.” This may in fact be one of the reasons why many companies tend to be rather taciturn when asked about their ML strategies. Machine learning is a means to an end, not a sales argument. There is in any case no blueprint for introducing your own strategies. It’s advisable to call in some expert knowledge, through either one of the various Fraunhofer institutes or outside service providers. As Jörg Krüger explains, each company first has to clarify what form of intelligence is desired for a machine, a system or a robot, such as detection of the machine’s condition, autonomy, automatic adaption to changes like tool wear and tear or component characteristics. Autonomous replanning and self-organisation of
Michael Hein, Director of Gerotor AG, Munich. Photo: Gerotor production sequences, comprehending human commands and gestures for simplified programming das also rank among the capabilities that a machine could learn by itself. But Jörg Krüger also points out that this entails a further question: who checks whether something has been properly learned before the machine starts to operate automatically with the knowledge concerned? There are also questions to be answered regarding IT security and data protection, or who assumes liability for decisions taken by an intelligent system. Could perhaps once again the “uneasiness” in dealing with cognitive systems, and possible loss of control come into play here? Cord Winkelmann doesn’t think so. A much more serious impediment for machine learning, he believes, and indeed for the digital transformation in general, is the inadequate provision of fast internet in many places, particularly for plants located in rural areas.
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Process automation: on the way to the clouds EMO Hannover 2017 will showcase navigational aids for the smart factory of the future Cloud solutions are on everyone’s lips: digitalised data in app-based strongholds in the clouds are being tasked with automating processes and rendering them more efficient. The EMO Hannover 2017 will be showcasing viable approaches and providing fit-for-purpose navigational aids on the data highway to the smart factory of the future. A “smart system optimisation” capability that detects errors in concatenated production processes and automatically indicates their causes and their propagation” will be exhibited at the EMO Hannover 2017 by the Stuttgart-based Fraunhofer Institute for Manufacturing Engineering and Automation (IPA). How does this work in practice? Felix Georg Müller, the institute’s designated specialist on autonomous manufacturing system optimisation, explains: “Smart system optimisation involves a technically detailed and at the same time auto-
mated evaluation of standstill causes and error causality relationships in a production line. As soon as the production operation is up and running, data are synchronously communicated from all steps of the process to an analytical tool.” This tool can now draw conclusions using the algorithms developed at the Fraunhofer IPA and edit the information concerned in the desired form. Data-driven production optimisation The database comprises status and process information from all technical sub-steps of the entire process chain. The analytical tool can use these to continuously identify in near-real-time where errors or standstills are occurring, or will occur as a result of several nonconforming factors interacting in different steps of the process. In contrast to classical OEE, the user receives a cause assignment immediately. (Ed-
“Smart System Optimisation” ensures technically detailed and at the same time automated evaluation of standstill causes and error causality relationships in a production line.
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itor’s note: OEE – Overall Equipment Effectiveness – is a measure for the added value created by a line, and a ratio that helps to determine, monitor and improve the productivity, the profitability and the overall effectiveness of production lines in the context of the manufacturing process.) For example, the user sees which process is blocking the other one, and can identify where the causal trigger is located. It’s also possible to prioritise trouble-shooting, since the real bottleneck of the production line is being computed at any time. This is based on all currently detected error patterns, brief stops and reject rates, thus reflecting a real-time view of the line concerned. The data sources are either additionally installed sensors, like smart cameras, or (if no process information is available) the machine data logger developed at the IPA. This is already capable of supplying to the analytical tool mass data from the Siemens S7-1500, Beckhoff CX1020 and Mitsubishi Q series of industrial control systems. Since this means that all relevant variables are available at millisecond intervals, the operating behaviour can be learned. “Thus we can give commonly used machine control systems a Big-Data capability, and integrate existing machine data into the analytical model,” comments IPA expert Felix Georg Müller. “Our tool has already enabled us to achieve cycle time reductions of between
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As soon as the production operation is up and running, data are synchronously communicated from all steps of the process to an analytical tool. The data are based on status and process information from all technical sub-steps of the entire process chain. six and ten per cent and monitor continuous compliance with the optimum on highly standardised machines at automotive component suppliers.” This data-driven production optimisation is based upon continual, extremely detailed analysis of the line’s behaviour, and of all individual processes involved in a production line. This cannot be done manually; automation is essential, due to the extremely high data processing volume concerned. For instance, the causes of errors are no longer sought solely in the line’s dynamic behaviour, but also, for example, by detecting anomalies in the process data of all individual processes. This means errors can be determined and eliminated even more precisely. With conventional approaches, a process optimiser would be occupied for hours or even days simply by reviewing and analysing a data record, and nonetheless could always only examine one time section – namely the one represented by the data record concerned. At the EMO Hannover 2017, says Felix Georg Müller in conclusion,
other important result is the milling tools, which combine the process operations of smoothing, roughening, and chamfering, thus making for enhanced efficiency. The above processes replace the conventional forming processes, and render superfluous the hard fine machining hitherto required.” Turning/rolling enables hardening distortion to be precompensated, which well-nigh halves the process chain involved. Moreover, flexibility is massively increased since in the event of a variant change only the NC code has to be altered, and no forming machines need to be retooled.
Process chains in automakers’ plants
The “holistic process chain control,” says the IFW scientist, “is a cross-machine concept: this means that the turning/milling centre and the inductive hardening machine are interlinked, and coordinate with each other using process-integrated geometry measurements.” If a component after the hardening process is approaching a tolerance limit, then for the next component precompensation will be directly adjusted during soft machining. This means that the manufacturing quality is autonomously assured on a cross-machinery basis.
Process automation was also a keynote of the “Process Chain in Automakers’ Plants” (PiA) conference held in Bielefeld on 3 and 4 July 2017, where one of the projects presented was HL-Pro-Ket. What precisely is new about the “integrated approach”? Patrick Kuhlemann, a research assistant at the Institute of Production Engineering and Machine Tools (IFW) at Leibniz University in Hanover, explains: “First of all I should mention the innovative turning/rolling process: for this purpose, a hybrid turning/rolling tool has been developed which unites conventional turning and deep-rolling in a single tool. An-
Driven by the rising number of individualised products, says Patrick Kuhlemann, “we are expecting a definite trend at the EMO Hannover 2017 towards optimising manufacturing processes by means of integrated, innovative process control. This is designed to bring the optimisation costs per component variant into line with the costs of efficient mass production.” The IFW will be presenting a “feeling” machine tool. Thanks to skilful integration of process control and rigorous utilisation of the multiplicity of sensor signals available, the machine is able to detect and anticipate deviations in geometry or shape, and thus to
“visitors will be able to experience live how data-driven production optimisation actually works. The guests we welcome to our stand will be able to see for themselves at our mini-factory how dynamic bottlenecks, dependences in production lines, and anomalies are detected and evaluated. This means complete real-time transparency for complex production lines is possible at an time.”
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To quote Patrick Kuhlemann, research assistant at the Institute of Production Engineering and Machine (IFW) of Leibniz University in Hanover: “At the EMO Hannover 2017, we’re anticipating a definite trend towards optimising production processes by means of integrated, innovative process control.” compensate for them automatically: “In the shape of our demonstrator, we are thus presenting an innovative procedure that efficiently meets and masters the challenge of rising variant diversity.” Interaction of processes is crucial for productivity
For Gerald Mies, President Milling & Factory Automation at FFG-Werke GmbH, Eislingen, “line productivity has always been crucial to a properly functioning manufacturing process”. It is here, he says, that in future many decisions will be taken on the ideal interaction between machining, automation and assembly processes. For this purpose, vendors are needed who comprehend the planning and design work involved throughout the entire line, and can supply it from a single source. This, he continues, offers options for flexible modification of components and sequences while the development process is still ongoing, which in its turn assures perfectly harmonised machining and automation cycles, and thus maximised productivity. In future, data interchange between automation, machining equipment and peripherals will be playing an increasingly significant role. “We optimise this,” says Gerald Mies, “by having specialists inhouse for CNC machining and automation, and can thus synergise the interfaces and match them precisely to the specific requirements involved. Besides optimisation of line effectiveness and the operating costs, a significant role is also
Single- and two-spindle machines can additionally be used as fully functional honing machines by means of their own adjuster spindle in conjunction with linear drives.
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played by new automation concepts, which have to be conceived in a symbiosis of machinery and automation. For the EMO Hannover 2017 “we shall be showcasing new ideas and visions.” For example, there will be an “unparalleled, wide-ranging exhibition of modernday production technology with path-breaking digital solutions”. What precisely can visitors expect? Gerald Mies explains: “We offer practically everyone involved with mechanical manufacturing and automation ideas for their own manufacturing operations.“ The bandwidth ranges from standard machines to highly productive series manufacturing in turnkey systems and on rotary transfer machines. Other exhibits will feature large-component machining with integrated additive technologies and non-cutting processes. “On our stand, we’ll be aiming to show visitors that we can provide them with an added value that they haven’t yet been able to expect from any other vendor.” Massively progressing digitalisation How does the Emag Group in Salach intend to massively progress the digitalisation of its production technology for establishing intelligent factories? Oliver Hagenlocher, Head of Marketing, explains: “Digitalisation is already a reality for us. Today’s world is now digital, so we need solutions immediately.” Firstly, he says, the task is to identify how existing applications can be optimised and rendered accessible to the digital world. Secondly, it needs to be clarified what requirements this will entail for the production operation of tomorrow. Besides developing software solutions, Emag also intends to render the relevant hardware (in the shape
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lecting further ideas and opinions, enabling us to tailor our products even more responsively to the requirements obtaining in the industrial sector.” Solutions in the cloud and at the machine
A high-performance work spindle and the twelvefold tool revolver ensure fast metal-cutting processes when machining the blank.
of machine tools and automation solutions) fit for purpose in the smart factory. This thrust is exemplified by the modularised machines and the matching modularised Trackmotion automation concept. This combination enables production lines to be constructed on a modular principle. Machining processes are broken down into easy-to-handle sub-processes, and set up on the appropriate modularised machines – which is already being practised in sprocket manufacture, for example. The Trackmotion automation system here enables the modularised machines to be very simply and efficiently concatenated. With harmonised usability of the software, Emag aims to “simplify control, monitoring and analysis of the production operation”. In practice, says Oliver Hagenlocher, it works like this: “The usability or user experience (UX) constitutes developments within the context of digitalisation, and describes the experiences that an end-user has gained with a particular software package. In the category of mobile apps, particularly, a positive UX is crucial to the success of a software package.” Nowadays, users expect
not only a substantively fit-for-purpose software package, but also an intuitive operator control concept, one that facilitates a fast start-up without any elaborate training being required. “We’re looking forward,” says Oliver, “to presenting our new solutions to existing and prospective customers at the EMO Hannover 2017, and in a direct dialogue col-
To quote Peter Schneck, Managing Director of TDM Systems GmbH, Tübingen: “The presentday spectrum of technical feasibility creates far more options for tool lifecycle management – the future lies in the cloud.”
Another instrument for process optimisation is the Tool Lifecycle Management Strategy (TLM) from TDM Systems GmbH in Tübingen. Managing Director Peter Schneck explains how important this strategy is for the factory of the future: “Two years ago, when we introduced this strategy, we raised classical tool data management to a whole new level. Thus it’s the unique selling point of our software that the system not only manages and makes available any information once inputted, but above all that during production of a workpiece it collects the relevant data at the machine. This data feedback creates a continuous improvement process quasi in the loop.” From the EMO Hannover 2017, Peter Schneck is primarily expecting a focus on the issues of digitalisation and networking: “This has always been our core competence, long before the times of Industry 4.0. With this new era, the options available for tool lifecycle management are multiplied.” Networking – and thus TLM – no longer stops at the doors of the factory hall. Modern-day TLM, he says, means transparency and cooperation that transcend the boundaries of individual plants, locations and nations, with short response times and mobile utilisation. To quote Peter Schneck: “We are, of course, embracing the dominant trend of being able to manage data and make them available through and in the cloud. Thus the future of TLM lies in the cloud as well.
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The journey towards Industry 4.0 Hartmut Pütz, President Factory Automation EMEA at Mitsubishi Electric Europe, talks about the digital transformation of industry. He focuses on the effects on manufacturing businesses, especially at a production level, and how customers will benefit from innovative Mitsubishi Electric solutions.
sation-on-demand process can happen even faster.
Manufacturing industry is currently undergoing a period of rapid change. In concrete terms this can be seen as the move from automated production to fully digitised manufacturing. New goals are continually being set, but the target is to use existing standards to achieve them.
supply chain. They have to react
The way things will develop depends largely on the requirements of end users, which have changed massively in recent years. End users increasingly expect more product variety and customisation, but at a similar price point. An obvious example is the speed at which online configurators have influenced the car market. Vehicle manufacturers have long relied on options lists to make a profit from selling a passenger car. However, competition has increased and more technology has now become standard. That has resulted in the requirement for a larger range of personalisation options to be offered in order to entice buyers into choosing a certain model. For less complex end products, the customi-
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With the rise of online ordering, the link from a sale to a machine tool or a robot altering its work pattern is closer than ever. To satisfy this demand suppliers require the highest levels of flexibility from their manufacturers throughout the
very quickly, changing production numbers for individual items on the fly. This is where the ‘smart factory’ starts to come into being. As an automation solutions provider, Mitsubishi Electric is a partner to industry. We support our customers in the development of their business ventures with consultation on industrial automation and Information technology. All our activities relating to the digital transformation of enterprises - creating the ‘smart factory’ – are part of our ‘eF@ctory’ concept. This encompasses the eF@ctory Alliance, a worldwide active network of cooperating companies. The network brings together manufacturers of industrial components as well as specialist system integrators and software providers. These partner companies collaborate at an individual level to offer flexible, optimised solutions.
A great example of the e-F@ctory Alliance working toward delivering proven solutions to Industry 4.0 challenges Hartmut Pütz, can be found at MitPresident Factory Automation EMEA at Mitsubishi subishi HiTec Paper EuElectric Europe B.V.
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rope GmbH in Bielefeld, Germany. There, a more holistic approach to predictive maintenance has been achieved by implementing a Smart Condition Monitoring solution developed in cooperation with FAG Schaeffler. The technology allows a whole range of parameters from the coating machine and its ancillary parts to be monitored around the clock. That data is then used to analyse the condition of individual components as well as the health of the individual machine and of the wider plant. The information gained from the system includes maintenance recommendations. This enables intelligent decisions to be made in advance, based on real need, not simply routine. The solution has created a new working methodology, drastically reducing unplanned downtime and the risk of subsequent damage. Overall, the result is vastly improved predictive maintenance, optimised asset lifecycle management and production, while reducing total operating costs. When talking about Industry 4.0, the Internet of Things (IoT) is inevitably a key theme as well. They are related concepts with an essential relationship and form the basis for Industry 4.0. Recent estimates already put the number of devices that are connected through the IoT at about 5 billion, and this is likely to soar over the next few years. Combine that prediction with the amount of data that is being generated and processed by a more connected factory, and it is easy to see why companies’ IT infrastructure needs to change.
We can appreciate, then, the attraction of cloud based data storage and processing services. They have the potential to deliver more secure, reliable, scalable and affordable data collection and distribution than on-site IT platforms. Businesses are increasingly using cloud services not simply to store large volumes of data, but also to perform analytics tasks. Processing the data means deriving trend information and presenting users with customised dashboards. The intelligence gained can be used to improve overall plant performance and asset management. Edge Computing is complementary to Cloud Computing, and businesses are increasingly finding that they need the capabilities of both. The cloud delivers the ‘bigger picture’ of the IoT, while Edge Computing brings the IoT to life by supporting applications that demand a real-time response. Mitsubishi Electric has developed solutions that support both of these complementary IoT approaches. Our company offers simple and secure access to a range of different cloud services, like SAP Hana, Microsoft Azure and Amazon. But we also facilitate it for niche cloud applications and dedicated cloudbased analytics services using Edge Computing. The results can be widely distributed intelligence, with remote devices generating lots of information. Those are linked over standard open protocols that can be seen as the key to forming a digital nervous system within business-
processes and systems for better decision making. Within the context of the Internet of Things; we have also been able to realise a project together with Intel®. The company is using an IoT gateway from Mitsubishi Electric to aggregate and securely input data into a big data analytics server. For Intel®, this pilot is forecast to save millions of dollars annually and provide other significantly valuable business benefits. Mitsubishi Electric, is supporting customers worldwide in their goal of developing their individual business models in terms of digitalization. Moreover we are contributing to the developments of innovative international organisations such as the German Government committee “Plattform Industrie 4.0”, the Industrial Internet Consortium (IIC) in the USA and the Robot Revolution Initiative (RRI) in Japan. Our eF@ctory strategy has also been recognised by leading initiatives and organisations, such as the Best Practise Award (category: Industrial Internet of Things in Factory Automation) from Frost & Sullivan and the ‘Strategic Point of Light partners’ award issued by the Taiwanese government. In combination with the trust invested in us by our customers, these milestones show that we are already a good way towards the future of a digitized world.
es. The networked digital data is then combined into bidirectional systems to integrate data, people,
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Maximizing process efficiency with proportional pumps Henkel’s Bonderite duaLCys process is fast establishing itself as a game changer for greater efficiency and safety in machining and cleaning Two years after it was first introduced to the metalworking market, Henkel’s innovative Bonderite duaLCys process has proven its superior cost-efficiency and sustainability over conventional cooling lubrication and cleaning processes. Most recently, the process demonstrated these advantages in a demanding precision tool machining project at German customer Mapal. Henkel will highlight Bonderite duaLCys in its exhibit at EMO 2017 in Hannover, Germany (Hall 6, Booth K01). Bonderite duaLCys is part of Henkel’s comprehensive portfolio of process solutions for the metalworking industry that can be tailored to the precise needs of customers across their entire value chain from casting and machining to assembly. The innovative duaLCys technology offers significant improvements in all competitive criteria, including time, fluid and energy consumption as well as product quality and process safety. Essentially, it leverages the synergies between the process fluids by recycling the cleaner into the lubricant bath rather than discarding it as waste. Inspired by the bactericide-free duaLCys technology, Henkel has developed an entire range of standard and specialized, one-component products: • Bonderite L-MR 20717 is the allrounder, suitable for nearly every machining operation, to include a wide variety of operations and materials.
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• Bonderite L-MR 21164 is designed for the machining of various specialized materials such as brass, copper, zinc-coated, aluminium alloys, and pure magnesium. It also provides stability in very hard water conditions. All the products are free of both boron and formaldehyde, and offer excellent bio -stability, corrosion protection, high lubricity and good cleaning ability. Featuring very fine dispersion, they also function well in a wide range of water hardness and applications, and deliver improved sustainability as well as significant cost savings. Over all systems and customer installations in the past 18 months, Bonderite duaLCys has reduced the cooling lubricant consumption by 60 percent. The process has been widely adopted for almost all metal substrates throughout the automotive in-
dustry and is fast entering other market segments. Winning partnership Mapal Präzisionswerkzeuge Dr. Kress AG, for instance, is using the system in their machining of special tools for a manufacturer of large mining drill bits. With Bonderite duaLCys, the customer was able to speed the process, while eliminating the use of solvents formerly needed to fully remove the cooling lubricant from the machined surfaces. In a further step toward even greater efficiency and sustainability, Henkel has partnered with Hamburgbased LDT Dosiertechnik for combining the duaLCys process with LDT Dosatron proportional pumps for dosing the cooling lubricant. These water-powered pumps require no electric supply or other utilities such as compressed air.
Henkel’s Bonderite duaLCys process is an innovative 2-component process where the cleaner can be recycled into the lubricant bath. The dual system, which features pre-cleaning during machining, offers low foam, low temperature cleaning, cooling and lubricating performance and corrosion protection. Switching to the new system can achieve cost savings of up to 40% due to less product, waste, water and energy consumption. (Photo: Henkel, PR041)
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compressors and other machined parts. “The Bonderite duaLCys process is a unique concept in the area of machining and in-process cleaning for the metalworking market,” adds Desinger. “Recycling the cleaning fluid instead of throwing it away, and making use of its synergies with the water-soluble cutting fluid, results in an excellent combination of high lubricity, superior part cleanliness and excellent corrosion protection.” Enhanced lubrication for longer tool life Using Bonderite duaLCys, MAPAL is able to speed-up machining, while eliminating the use of solvents formerly needed to fully remove the cooling lubricant from the machined surfaces. (Photo: Henkel, PR041)
Martin Desinger, Business Development Manager, Lubricants, Europe, at Henkel Adhesive Technologies, comments: “In close collaboration with LDT Dosatron, we succeeded in developing a tailor-made ‘plug and play’ system available in customized configurations for integration into new or existing Bonderite duaLCys process lines.” Better working conditions and process results Henkel’s duaLCys process utilizes the synergy between a lubricant and a cleaner: Bonderite C-NE 10466 high-performance, water-based neutral cleaner, and Bonderite L-MR 21466 cutting fluid. The cleaner produces no foaming in most common water hardness, provides excellent corrosion protection and can be used at room temperature. The machining fluid is a finely dispersed lubricant. Both are free of boron and bactericides and have very strong bio stability. The system is suitable for most metal substrates, including steel, stainless steel, cast iron and aluminum alloys. The Bonderite duaLCys process requires less water and saves energy by allowing the cleaner bath to operate at a reduced temperature.
In addition to minimizing waste while delivering low reject rates and high surface quality, Bonderite duaLCys also offers improved working conditions resulting from the use of safer, more predictable solutions. In the automotive industry, the process can provide a competitive edge to OEMs, Tier 1 suppliers and machining companies alike by enabling a more costeffective, sustainable way of manufacturing metal parts such as powertrain components, wheels, HVAC
Machining tools last much longer in operations using Bonderite duaLCys, thanks to its much higher lubricity as well as its superior cleaning capability, compared to conventional products. The lubricant also features precleaning properties due to its combined formulation. Operations can save up to 40 percent in process costs and reduce lubricant drag-out by as much as 70 percent. Henkel will showcase its successful Bonderite duaLCys process at EMO Hannover 2017 in Germany from September 18 to 23 (Hall 6, Booth K01). www.henkel-automotive.com/dualcys.
Andreas Rotenberger from MAPAL’s R&D team discusses Bonderite duaLCys’ performance with Jürgen Schöllkopf, Lubricants Project Manager at Henkel Adhesive Technologies during a regular technical support visit. (Photo: Henkel, PR041
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BIG KAISER to showcase its latest high-performance tooling systems at EMO Hannover Ruemlang, Switzerland – August 10, 2017 – BIG KAISER, a global leader in premium high-precision tooling systems and solutions for the metalworking industries, will present its extensive portfolio of high-precision boring tools at EMO 2017 in Hannover, Germany, September 18-23, 2017. The spacious white and blue stand located at B46 in Hall 3, will provide visitors the opportunity to view BIG KAISER’s full range of machining tools, and consultation with experienced technical experts. BIG KAISER will feature four newly-announced products: • EWE - second-generation boring heads with wireless connectivity to BIG KAISER’s user-friendly smartphone and tablet app for easier tool monitoring and configuration. • Torque Fit - collet chuck tightening fixture with an integrated buzzer torque indicator and LED over-tightening error indicator for high-precision tightening and exceptional machining results. • Level Master FM - new version of BIG KAISER’s two-axis level de-
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tector with wireless connectivity that simplifies accurate level setting by transmitting tool information to a remote display device. • C-Centering Cutter - multifunction cutter for both spot drilling and chamfering, with immediate chip evacuation with coolant, anti-chipping negative land formed nose for spot drilling, delivering a significantly extended tool life. • An attractive exhibit will be the world’s fastest two-stroke motorcycle, the Suter 500 from BIG KAISER's official technology partner Suter Racing.
“Our theme for the EMO is ‘higher performance guaranteed’, where some of the finest tools in the industry hold their own with realworld technological excellence of Suter Racing,” explains Taku Ichij, CEO at BIG KAISER. “Suter shows just what can be achieved by aligning intense dedication and sincere enthusiasm with leading-edge engineering know-how – an approach much in line with BIG KAISER's philosophy.” www.bigkaiser.com
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State-of-the-art technology maximizes filtration performance and production uptime
Baldwin to bring PureFiltration to EMO 2017 Baldwin Technology Company Inc. is pleased to announce that it will showcase its state-of-the-art PureFiltration systems for the first time at the EMO 2017 trade show in Hannover, Germany, September 18-23 (hall 6 booth L16). The revolutionary PureFiltration system, developed for a wide range of fluid filtration applications, enables a high-efficiency and cost-saving filtration process. Since the filters are automatically self-cleaning, no additional filter aid is required. Additionally, elimination of downtime due to filter change or filter cleaning leads to maximized production uptime. The system’s ability to significantly extend the lifecycle of industrial fluids will also minimize the waste of production chemicals. These PureFiltration features will save direct production costs and help reduce environmental footprints. Launched in 2012, PureFiltration is installed at leading manufacturing companies worldwide within printing, glass, automotive, machine-tool, aerospace and different types of surface treatment process, etc., where it delivers well proven positive results, such as accurate and consistently high filtration performance, minimized usage of con-
sumables and waste of chemistry, less energy consumption, enhanced tool surface quality and low maintenance costs. “PureFiltration meets the industries’ increasing demands for a high-performance filtration quality combined with environmentally friendly aspects, increased productivity and energy savings. Since PureFiltration is equipped with
of additional filter aid, it will pay off for our customers in a short period of time,” says Bernhard Brandmeier, Product Line Leader Fluid Management, Baldwin Technology. The PureFiltration technology is manufactured at the Baldwin facility in Friedberg, Germany. www.baldwintech.com
long-life filter elements and is free
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EMO 2017 Simufact to present process simulation solutions for machine tool makers and mold makers At this year´s EMO, Simufact - an MSC software company – will be presenting their process simulation solutions aiming at tool and mold makers. Simufact will provide insights into their products for simulating forming and additive manufacturing processes. Optimizes additive manufacturing of complex tools and molds: Simufact Additive Additive Manufacturing provides new capabilities for manufacturing complex injection molding metal tools; not conventionally producible geometries are possible. However, a key is the mounting of contour close tempering channels with minimum wall thicknesses, which allows for shorter cooling times of the produced parts. Since additive manufacturing is
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a micro-welding process, distortions and residual stresses in the additively manufactured parts are typical issues – so Simufact Additive is a highly relevant technology to mold making companies employing additive manufacturing technology: The software predicts the final distortion and residual stresses of metal 3D printed molds. The software helps toolmakers to shorten the optimization process for the manufacturing of such complex tools and molds and to reduce the number of costly real try-outs. Simufact Additive is a powerful and scalable process simulation environment for ‘right first time’ optimization of laser powder bed fusion processes covering the AM process steps starting with ‘printing’ of the part; followed by heat treatment, cutting the
part off the build plate and removal of support structures, plus heat and pressure combined processes (HIP). Simufact Forming for Machine Tool Makers Simufact Forming is a simulation software for hands-on professionals working with forming technology. The software is extremely robust and fast, which is needed to provide timely results and affect the design phase. It is easy to use and allows process design engineers to optimize the manufacturing process on a computer prior to a physical tryout. Simufact Forming covers all major areas of metal forming: forging, cold forming, sheet metal forming, all rolling processes, open die forging and mechanical joining to name the most important fields of application. Simufact Forming sup-
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ports in microstructural simulation, calculation of die load, the material flow and the prediction of material properties during heat treatment. Simufact Forming comes with valuable process chain capabilities, which allow for consideration of forming results from former manufacturing steps leading to highly accurate results in the manufacturing process chain.
Improving die life by simulation Simufact Forming considers all relevant boundary conditions, including stress rings and spring supported dies. The realistic prediction of the forming forces, while taking into account spring back effects and the elastic-plastic material behavior, is necessary for a high precision simulation of e.g. cold forming processes. The analysis of forming processes pro-
vides a higher process understanding of complex die designs (spring supported dies, flashless precision forging) and helps to optimize die life through investigation of die loads. In a joint project, Simufact and Prokos GmbH (Brankamp/Marposs group), specialist for process monitoring systems in forming technology, and MÜhling GmbH & Co. KG, expert in the area of cold forming and cold formed components, have analyzed how linking process simulation and process monitoring can improve die life. The increasing accuracy of simulation models as well as the simulation-based predictions of the press force progression provide users useful practical assistance for adjusting tool settings on the machine. Project results have proven that this approach simplifies the production machine’s set-up and helps prevent a systematic overloading of the dies and machines which results in an increase of die life, fewer die failures and overall a more robust production process. www.simufact.com.
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Protected and user-friendly digital business models for Industrie 4.0 For its premier presence at EMO, the world’s leading trade fair for the metalworking industry hosted in Hanover, 18 to 23 September, Wibu-Systems, a global powerhouse in secure license management, is preparing a comprehensive program that will engage intelligent device manufacturers, industrial operators, and end users alike. At its booth B60, in the Industrie 4.0 area of hall 25, the company will show how connected systems for intelligent production can result in new revenue streams. Since the dawn of Industrie 4.0, WibuSystems has leveraged its core values of uniformity, comprehensiveness, robustness, simplicity, uniqueness, and continuity to bring CodeMeter’s technology to a new level of compatibility with a broader range of platforms, secure elements, and applications. Numerous research projects, partnerships, and collective demonstrations have also scaled up the game and produced new and innovative solutions for the Industrial Internet market. IUNO, the German National Reference Project for Cybersecurity in Industrie 4.0, is a perfect expression of this collaborative spirit. In one of the projects that are being developed in this context, Wibu-Systems is cooperating with TRUMPF, a global leader in machine tools, laser technology, and electronics. Strategically positioned close to AXOOM, TRUMPF’s daughter company and a specialist in combining production and IT expertise for smart manufacturers, Wibu-Systems is ready to show the results of the efforts undertaken so far. AXOOM’s digital business platform is designed for use along the entire production value chain. Wibu-Systems’ CodeMeter protects the intellectual
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CodeMeter enables protected business models for the Industrie 4.0 age property and provides business-enabling opportunities through versatile and secure software licensing. Both technologies have been integrated into a tapping machine that addresses two separate use cases to bring producers and consumers together: Creating new drinks: The producer creates a new drink, whose recipe is encrypted via CodeMeter and transferred to AXOOM's marketplace. The corresponding license is set as an item in CodeMeter License Central, the database-derived license and entitlement application, which automates the process of creating, delivering, and managing software licenses. Selling drinks: The consumer selects a drink. The order travels through the marketplace, and the license for the creation of this specific drink is transferred from CodeMeter License Central to the mixer. Ruediger Kuegler, VP Sales and Security Expert at Wibu-Systems, who will be on site at EMO and give a lecture on
how to monetize machines with modular features at the Forum in booth B60, hall 25, on September 20th, 11.30 am to 12.00 pm, states: “We live in exciting times, as computational power, cloud storage, and security technologies have reached the capability and pricing point to transform our world and can now offer a plethora of automated, digital, and tailored services. Expanding our imagination is our next frontier. Following the same pattern, CodeMeter, our protection, licensing, and security technology, is becoming more sophisticated and convenient every day and providing an optimal effort-performance relationship”. Stephan Fischer, Head of Digital Business Solutions at TRUMPF and CEO of AXOOM, adds: “Together with AXOOM and Wibu-Systems, we are generating new synergies that are creating seamless secure connections between machines, software, and industrial processes to meet the requirements of data-driven business models.” www.wibu.com
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MachineWorks New Software Release Presented at EMO 2017 MachineWorks Ltd, leading supplier of CNC Simulation and Verification Component Software, MachineWorks® and of Solid Modelling Software Toolkit for Processing Polygon Mesh, Polygonica®, will be exhibiting brand new features at the largest International Machine Tool Show, EMO Hanover this September, 18th - 23rd in Hall 27 stand number B73. What’s New in MachineWorks version 8.0? These will be some of the exciting new features on display at EMO Hannover: Surface and Feature Detection MachineWorks New Surface and Feature detection allows users to analyse cut surfaces and detect its features. Users may be interested in finding generic geometrical features like cylinders or spheres (surface detection) or may be looking for machined features such as drilled holes (Feature Detection). Both Surface and feature detection represent vast time savings when creating CAD data from polygonal data or generating a toolpath. Sheet Bending New Functionality MachineWorks has optimised the simulation of sheet metal bending thanks to brand new features that provide optimisation of collision checking results and performance. Collision Detection Optimisation Concaves shapes in machined parts can present a challenge to collision detection and slow down the
client-side of the communications therefore making implementation much easier. Video Feature to Record Simulation
results of the checking, typically for U- and L-shapes. MachineWorks‘ latest release has overcome this problem by adding more automation enabling significant performance improvements on the collision inference. Simulation Restore Feature This new handy MachineWorks feature allows to take ‘snapshots’ of a solid, for example the stock, during the course of a simulation and quickly revert to them at will. When programming or editing a toolpath incrementally, this fast ‘undo’ option becomes an extremely useful function to have to hand. Cloud Simulation MachineWorks new version offers customers APIs to perform a cloudbased simulation more efficiently. MachineWorks functionality supports both client and server-side rendering of simulation in real-time as a standard. An improved compression scheme and tools to handle communication and decompression means that a fast a network connection between client & server is no longer required. There’s also a new client-side library that introduces an API to handle the
MachineWorks new release allows users to generate a 3D recording of a simulation that can be used to create movie files to view later. The recording contains information to allow you to manipulate the view (e.g. change the ‘camera’ position) when producing a movie. Most sales & marketing departments including ours would kill for this feature. About MachineWorks MachineWorks Software sets the standard for CNC Simulation and Verification component software in the industry. More than 60% of CAM developers in the world have integrated MachineWorks technology into their applications and benefited from MachineWorks’ cuttingedge functionality since 1994. MachineWorks’ toolkit has been integrated by software and hardware OEMs looking for a solution in simulation of material removal and clash and gouge detection of any type of CNC machining. MachineWorks’ core technology combines speed, accuracy and stability. It is ideally suited for anti-crash systems, complex machining and full machine simulation. www.polygonica.com
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Free forms, micro-structures, reflective surfaces - new sensor trio from one source offers solutions for challenging measurement tasks A new 3D sensor range now offers versatile and high-precision measurement technology for a wide range of applications. Direct from a single source, users have at their disposal a sensor for the highly precise measurement of reflective surfaces, a white light interferometer for the inspection of surface structures and a universal sensor for capturing free forms. The result is a Wi-Fi-enabled sensor range with a great variety of applications that can be used in the inspection of precision products, electronics and vehicle parts. The innovative sensor portfolio combines 3D shape measurement, white light interferometry and stereo deflectometry to handle challenging measurement tasks. In the automotive industry, the electronics industry or precision mechanics, the combined sensors cover several stages of production. In the production of clocks, for example, the systems are used to inspect the housing, the position of the clock hands, and the cover glass to make sure that all interior parts are present. The ability of the white light interferometry system to precisely capture surfaces in the form of a topological map thus ensures a reliable inspection for completeness and quality with accuracies down to the nanometer range. In the field of information and communication electronics, this new technology combination allows for the inspection of finished products
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and the testing of individual components such as circuit boards. In smartphone manufacturing, the sensors perform a highly precise inspection, checking that the battery has been inserted and that the integrated circuits are lying flat, while also inspecting the cover glass. To ensure these versatile application possibilities, the three powerful sensors are equipped with different technologies. NetGAGE3D: New product line for high-precision white light interferometry With only one scan, the NetGAGE3D white light interferometer reliably delivers high-precision measurement results in the nm range to ensure a reliable measurement of different surface area properties such as flatness or roughness, but also of dimensional accuracy and completeness. The new and extended 3D sensor range follows in the footsteps of the tried-and-
tested KORAD3D series used in numerous applications. Equipped with new features, NetGAGE3D now captures real-color 3D surface images and achieves 4-times faster scanning thanks to a new signal processing method and an integrated processor. The sensor ensures highly precise measurement results, in particular through using high resolution images of height structures. Because the incoming measurement light and the camera lens of the NetGAGE3D are mounted coaxially, depths such as boreholes, channels and etched structures are measured without any shadows. In addition, NetGAGE3D can accurately capture various materials in different processing conditions as well as transparent objects contact-free down to the nanometer range. Thanks to high-quality components, the self-preserving enclosure and low maintenance requirements, NetGAGE3D is very robust. Its opera-
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ods and 3D point cloud technology, the APS3D bridges the gap between 3D robot guidance and 3D in-line measurement technology. APS3D can be adapted optimally to the task at hand thanks to tailored software packages guaranteeing reliable results in both applications with short cycle times. With the combination of stereometry, triangulation and phaseshift strip projection, APS3D can be used wherever object geometries need to be measured accurately at high speed or where fast robot guidance with shortest cycle times is required. Connected 3D Quality Control: Versatile, networked, easy to use tion is very simple thanks to intuitive menu navigation and users can intervene directly in the manufacturing process by means of operator self-inspection. Depending on the object size, the sensor can be used with different measuring fields and is available as NetGAGE3D, NetGAGE3D-S, NetGAGE3D-M, NetGAGE3D-L and NetGAGE3D-XL. SpecGAGE3D: Multi-camera system for highly reflective surfaces SpecGAGE3D is the reliable measurement system for the detection of reflective surfaces, combining phasemeasuring deflectometry in stereo mode with strip pattern lighting. The sensor measures glossy and reflective
surfaces, such as progressive bifocal lenses or deflection mirrors of headup displays, with high-precision height and curvature measurements down to the nanometer or millidiopter. In addition, SpecGAGE3D quickly and reliably detects cosmetic errors during shape measurements, so that the defective parts can be rejected early in the process. In its latest version, it is now equipped with four cameras and measures several parts simultaneously, thus reducing the cycle time. APS3D: Reliable quality inspection through flexible shape measurement Through a pioneering technology mix of different measurement meth-
All three systems of the sensor combination are equipped with Wi-Fi as standard. NetGAGE3D and APS3D already have an embedded PC, while SpecGAGE3D can be equipped with its own processor in the near future. Thanks to the embedded PC and Windows touch operation, the systems are very easy to use and can even be controlled from a tablet using the “Remote Desktop” function. Network capability and embedded technology are general development objectives that ISRA is already pursuing with its SmartCam solution, a camera with integrated computing power and “Touch & Automate” portfolio of network-enabled sensors. At the same time, ISRA is offering new management software with which the systems can share collected data with one other or with a database. The Enterprise PROduction Management Intelligence Software, EPROMI uses the production line’s entire data set to provide users with a fully transparent overview of their manufacturing processes. Combined with networkenabled inspection technology, EPROMI provides the basis for closely networked and INDUSTRY 4.0 compatible production. www.isravision.com
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Hanging upside down
The Institute of Technology in Architecture at the ETH Zürich is committed to researching digital production processes in architecture and the building technology of the future. The area gantry in the laboratory hall was kitted out with numerous features for ETH Zürich. It has two bridges with two telescope axes each. The usual legs on the area gantry were omitted and the two bridges were fitted directly to the s-
teel ceiling of the building. Spectacularly so - the four robots are attached upside down to the Güdel portal in order to provide the greatest possible working area. The design supports the latest research in the interaction between humans and robots. The robots come from above, humans move around below. Students from many countries are using the robotic system to research the future of digital construction and the scaling of process-
es in the construction industry. The area gantry could be used for 3D printing or online concreting. A ramp robot builds mesh molds, which are then filled with concrete. The subject of the research is the combination of two traditionally separate concrete constructions elements, formwork and reinforcement, into one automated fabrication process with robots. With this technology, Güdel is at the cutting edge of digital architecture. Güdel technology • Area gantry AG, 45m long and 16m wide • Two bridges with four Z-axes • Working area of 47m x 15m x 6m with four upside down robots • 36 axes • Component production at Güdel Switzerland www.gudel.com
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WITTENSTEIN at EMO 2017: Planetary and right-angle gearheads: WITTENSTEIN alpha redefines the premium segment At the EMO Hannover from September 18 to 23, 2017, WITTENSTEIN alpha will show) in Hall 25m booth Nr A36) two re-engineered and extended planetary gearhead families together with their respective right-angle equivalents in the premium segment. At the EMO Hannover from September 18 to 23, 2017, WITTENSTEIN alpha will show two re-engineered and extended planetary gearhead families together with their respective right-angle equivalents in the premium segment. The optimized Premium Linear Systems will be a further highlight at the booth in Hall 25 (Stand A36). Machine tools are among the most important application segments for gearheads, servo actuators and linear systems. WITTENSTEIN alpha offers highly economical mechatronic solutions featuring customized technology to meet the dynamics and precision requirements of these machines. At the upcoming EMO Hannover 2017, WITTENSTEIN alpha will focus on the premium segment – with re-engineered and extended gearhead families plus the new, complementary Premium Linear System. Planetary gearheads for more motor output and binary reduction ratios The new Premium XP+ gearhead and its right-angle equivalents (XPK+ and XPC+) are each available in five different sizes. Both the maximum speed and the maximum torque have been significantly improved. These gearhead variants are suitable for much higher input speeds. This positively impacts on the drive train as a whole, enabling even more efficient sizing and creating valu-
able downsizing potential. The traditional standard reduction ratios have simultaneously been extended with three binary ratios: i=8, 32 and 64. Low-backlash planetary gearheads: the benchmark for power density and modularity More speed and more torque – leading to more power density than ever before – is also the maxim for the optimized RP+ low-backlash planetary gearheads. The highly rigid gearhead design, which was specially developed for linear applications with a rack and pinion, provides unprecedented performance. This is crucial to ensure precise and repeatable kinematics in high performance machine tools and is now also integrated in four sizes in the version with a bevel gear input stage. Thanks to the bevel gear input stage of the new RPC+ series, the same reduction ratios can now be achieved with the right-angle versions as with the coaxial RP+. The segment is rounded off by the hypoid right-angle RPK+ variant, which likewise has a modular design Premium Linear System for even more options The re-engineered Premium Linear System, which exploits the added technological benefits of the enhanced
planetary and right-angle gearhead series, will also be making its debut. The preferred linear systems (from 5 to 120 kN) – now redefined – are always comprised of the ideal combination of a gearhead, rack, pinion and lubrication system. INIRA – the quick and easy assembly system for racks – can optionally also be used for all systems that have been optimized in terms of component utilization, moving force, movement speed and rigidity. For even higher requirements, the system can be further optimized by the sales engineers using cymex®, for example by improving the natural frequencies in the drive configuration together with the customer (taking the master slave / gantry into account) or accommodating other specific wishes. Mechatronic drive technology and nanoprecise measurement systems for machine tools The Galaxie® Drive System, servo actuators in several different configurations and the IDS3010 measuring sensor with sub-nanometer resolution from WITTENSTEIN subsidiary attocube systems AG will also be exhibited by the innovation leader for mechatronic drive technology under the motto “WITTENSTEIN in all axes”. www. alpha.wittenstein.de
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SCHNEEBERGER MONORAIL MR 4S new generation SCHNEEBERGER's high precision and stiff MONORAIL MR roller guideways are used worldwide for a broad range of mechanical engineering applications, especially for the high precision machine tool market and other high sophisticated and accurate machine types. The new MR 4S profiled roller series, introduces 4 major improvements relating to the distribution of lubricants, dirt resistance, shock resistance, and serviceability. The new MR 4S series of MONORAIL roller guideways from SCHNEEBERGER features a use - oriented lubrication system supported by a wide range of different interfaces. In addition, the type and method of lubrication can be specifically assigned externally. The lubricators and front plate are seal - welded to form pressure - tight lubrication channels, which considerably improves lubrication when operating in idle. To prevent the ingress of dirt and the loss of lubricant, the carriages are equipped with double - lipped wipers all around. The fixing of the double - lipped cross wiper mounted on the front plate has also been optimized in the new MR 4S series. These plates, in turn, are supported on both sides along the entire cross - section, which ensures reliable functionality even under extreme loads. In addition, the new version is especially easy to service. After first removing the steel front plate, the cross wipers can be exchanged
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by pulling them up and over the rail in an axial direction. Another key feature of the MR 4S MONORAIL guideway are the shock resistant carriages. For example, the front plate is made from stainless steel. It covers a plastic front plate to provide additional protection against damage and contamination. Both plates are fastened to the body of the carriage using the same four screws. This improves stability and ensures continuously good running characteristics. To further improve reliability under heavy loads, even the heavily stressed carriage bodies have been optimized to counteract fatigue stress of notched parts that may occur. Even the heavily stressed carriage bodies have been optimized to counteract fatigue stress of notched parts that may occur. The MONORAIL MR 4 S series is available in the sizes 25, 35, 45, 55 and 65 and the maximum length per single rail is 6000 mm. The sixth size, the MR 100 is especially suit-
able for loads of approx. 150 tons. The body of all the carriages and the rails are made of high - quality hardened steel. Specially shaped rollers are used as rolling elements which contributes to extreme rigidness and the high dynamic and static load carrying capacity. In the standard version, the system can be accelerated by up to 50 m/sec 2 and designed for speeds of up to 3 m/s. Each size is available in a variety of accuracy classes – from G3 down up to G0. A wide range of accessories and options are available. All MONORAIL MR 4S can also be equipped with the SCHNEEBERGER MONORAIL AMS distance measuring system. www.schneeberger.com
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Hydraulic weight balancing saves energy For large machining centers hydraulic weight balancing of spindle heads and/or work piece tables pays off. Because HAWE Hydraulik's cleverly arranged systems cut down the processing center's consumption of electricity and resources. For large machining centers hydraulic weight balancing of spindle heads and/or work piece tables pays off. Because HAWE Hydraulik's cleverly arranged systems cut down the processing center's consumption of electricity and resources. They contribute not only toward energy efficiency in production, but also lower the machines total costs of ownership (TOC). What's more, when hydraulically counterbalanced, the motors for the vertical axes of spindle head and work piece table can be dimensioned significantly smaller, which provides for more dynamic movements of the axes and generates additional savings in electricity. Hydraulic weight balancing is an autonomous system. Once it has been pressurized it requires no further energy intake. A hydraulic cylinder that is connected with the hydraulic accumulator takes up the weight of the spindle head and/or work piece table. The pressure in the system is set so that the cylinder balances out the weight. Merely the force of friction and the inertia of masses must be overcome to move the spindle head along the vertical axis. This in turn requires significantly lower drive power.
The power pack supplying pressurized oil is only needed when filling the system ahead of start-up and in case of maintenance. As these two instances are not timecritical the power pack's capacity can be smaller. One suitable solution could be HAWE’s compact MPN power pack. It meets the criteria of providing high operating pressure with small capacity, has a compact built and a large tank volume for filling and emptying the system.
pressure range. The machine operator will then undertake the corresponding actions, i.e. check the system for leakages or control the accumulator’s preload pressure. A pressure valve secures the hydraulic accumulator, while a drain valve is used to empty the storage for maintenance work. The compact valve bank, BA type, contains all these standard components, so that pipe works and assembly of a separate block construction is omitted.
It requires a pressure reducing valve for the supply of the pressurized oil, so that the required operating pressure is set while filling the system. During operations a pressure switch monitors the system's pressure, signaling any under- or overshooting of the predefined
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SKF at EMO: Affordable machine health monitoring with Multilog IMx-8 In hall 7 on booth B31 at EMO in Hannover (18 - 23 September) SKF showcases a compact, easy-to-use model in its IMx range - offering sophisticated yet highly cost-effective, fit-for-purpose condition monitoring for a multitude of industrial applications.
most users can set up the system with little or no previous experience. Of particular benefit for remote applications, where routine site maintenance visits are few and far between, the greatly enhanced internal memory of the IMx-8 (4GB as opposed to the 8MB of previous models) enables stand-alone monitoring and logging of large amounts of data, which are easily accessed for analysis following a critical event.
SKF presents a compact 8-channel version of its highly popular IMx machine health monitoring platform. Initially targeted at the Offshore Wind and Marine sectors, this versatile system brings affordable machine health monitoring to a much wider industrial user base. The Multilog IMx-8 eight-channel unit provides an attractive option for users of mechanical and fluid power train applications, while the combination of an 'Event Capture' feature will appeal to Machine Tool users requiring a cost-effective crash detection capability.
Unlike its 16 and 32 channel variants, the compact DIN-rail mounting 8-channel IMx-8 takes up very little cabinet space, so it can be installed into instrument cabinet enclosures, often alongside existing instruments. Suitably housed, it also serves space-restricted applications such as small size marine thruster pods or direct drive wind turbines, where instruments often need to be located as close as possible to the monitored machinery. Having power and communications over Ethernet makes installations much easier for the customer, and the app-based configuration interface means
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Freddy Hernandez, SKF Product Line Manager, Surveillance Systems, comments: "Customer feedback confirms many applications require less than the 16 channels offered by our existing Multilog IMx solutions. The IMx-8 now offers a more compact, versatile means of monitoring rotating machinery and this cost effective, reduced channel online system fills a large gap in the market, offering new features, functionality and flexibility not available anywhere else." SKF showcases additional efficiency-raising solutions for the „world of metalworking“ until 23 September at EMO in Hannover. Visitors to the fair will find SKF in hall 7 on booth B31. www.skf.com
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New hydrostatic guide shoes Highest precision and best surface quality on work piece require hydrostatic linear guide in machine tool. With new developed guide shoes, standard elements can be used, which reduce effort for development and assembly much. Highest precision and best surface quality on work piece require hydrostatic linear guide in machine tool. With new developed guide shoes, standard elements can be used, which reduce effort for development and assembly much. Slide and guide are simpler to produce, because hydrostatic pockets, flow control and pressure sensors are in guide shoe. Machine tools get in vibration by process forces, drive and vibration by unbalanced spindles. Hydrostatic guide damps vibration excellent and enable by this much better surface quality than using ball guides or roller guides. By 10 to 1000 times less friction of hydrostatic guides, work piece are positioned and machined multiple more precise. Also thermal position change and necessary drive power is reduce by less friction. Hydrostatic pockets lifts slide at start of machine and make sure slide has never contact to guide. So the axis is free of wear and keeps its excellent features many years unchanged, even at high load with high speed or during short stroke oscillation. At no move, hydrostatic system is insensible to overload or had beats by large surface contact. By use of the progressive volume flow controllers (PM-flow controller) from company Hyprostatik Schönfeld GmbH (Göppingen, Germany) hydrostatic guides get known as very stiff, carries high forces and very reliable. New hydrostatic guide shoes New developed hydrostatic guide shoes are modular designed assembly ready elements for simple economic in-
tegration in new machines. Available are drawings, 3D-step files and recommendation design for parts around. Guide shoes are available in size 50x100mm or 70x140mm each in 2 lengths useful for slide starting with length and width 400mm. At ends of guide shoes are PM-flow controller for active pocket flow control. There is only one oil enter at the attachment surface with constant pressure from pump. For check at assembly or supervision of loads during use of machine tool sensors measure pocket pressure. CNC control can use this to detect too heavy work piece or cutting force. Pressure sensors are not necessary for proper function of guide shoes. Many large screws fix guide shoe rigid to slide. By keeper pockets and rails, hydrostatic guides shoes can be used in vertical moving axis same than cross axis of portal machines. The oil coming out of the pockets is collected in U-type guide and leaded back in tank of hydraulic unit. Useful seal covers for sufficient protection of oil return to dirt, chips and machining liquid is available. Slide, guide and keeper rails can be unhardened, fine milled to high precision or by Granite, depending on application.
Guide shoes are selected by size, length and pump pressure to max. forces acting in the machine. Pump pressure can be 32, 50 or 80 bar for forces 5 to 115 kN. The higher the max. speed, the thinner is the oil, selected out of viscosity class VG68, VG46 or VG32. The oil is filtered 10µm and cooled to room temperature in hydraulic unit. When guide shoes have large distance or base is granite, side pockets are on one guide shoe for less thermal gap change. Short rigid slides need only 4 guide shoes at slide edges. Longer slides have additional guide shoes in the middle for higher rigidity. Compared to INA guide shoes HLE-45A-XL at same load capacity and rigidity, new hydrostatic guide shoes from Hyprostatik Schönfeld GmbH have 10 time less flow and 30 time less energy enter. By this, cost, size and cooling power for hydraulic unit is much less. New guide shoes already used successful at cylindrical grinder, surface grinder, thread grinder, gear grinder and high precision hard turning machines. www.hyprostatik.de
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Less Energy | More Power: Highly efficient turnkey solutions for metalworking With new syncromill machining centers, Fill is supplying customeroriented solutions for the future of the automotive industry. The highly efficient syncromill machining centers from Fill Machine Engineering accelerate the production processes in metal machining and increase productivity. As a process and full-range supplier with decades of experience, Fill solves even the most complex of production system challenges reliably and economically. At EMO 2017, the world's leading trade fair for metalworking, from 18 to 23 September 2017 in Hannover, the Austrian metalworking experts will be presenting one part of a fully integrated production facility for engine blocks. From machining on the syncromill C21-80/800 to parts handling and the fully automatic inspection system. As another highlight at the trade fair, Fill will be showing the syncromill c21-63/600 dual-spindle machining center, featuring a revolutionary tool replacement system and a footprint of only 11 square meters, live in action on the exhibition stand (Hall 12, Stand C71). Hannover/Gurten, 18 September 2017 – �With the extension of thesyncromill product line, we are further consolidating our position as a full-range supplier in the metalworking sector. Our Development
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department works intensively with the latest technologies to provide our customers with a real competitive advantage,� explains Friedrich Dallinger, Head of the Metal Machining Technology Competence Center at Fill Machine Engineering. Revolutionary tool replacement system The syncromill C21-63/600 machining center being presented for the first time at the EMO scores highly with significantly shorter outage times and increased flexibility. The ingenious tool changing concept enables efficient, economical production of complex workpieces. With extremely short chip-to-chip times of 1.8 seconds and possible tool dimensions of up to 15 kg and
350 mm diameter, Fill is setting new standards in this size of machining center. Less Energy | More Power The syncromill machining centers stand for maximum productivity, flexibility, precision, and energy efficiency. Whether it be aluminum, steel, or other materials, the widest variety of machining operations can be performed on workpieces in single or multiple clamping operations. Perfect looks outside, hightech inside! Use of more efficient, intelligent components, such as cooling, hydraulic, and high-pressure preparation systems, has enabled a reduction in energy consumption of 45 percent compared to the predecessor model, and the
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mized and specific component data processed in production. The MWF (Machine Workflow) system from Fill allows customers to maintain a constant overview of the current performance of their production processes. Corporate data
cycle time for machining tasks has been reduced by an average of 13 percent. Turnkey solutions made by Fill A thorough understanding of complex production processes and use of the very latest technologies, such as simulation, visualization, and virtual commissioning, are the basis for high-tech total solutions. Thanks to its extensive product range, Fill supplies individual solutions for the widest variety of customer requirements with regard to machining, inspection, and integration processes – all from a single source. The clamping fixtures designed, developed, and produced by Fill for this purpose represent another customer benefit. Optimum coordina-
tion with machine and workpiece is a significant factor in ensuring the highest levels of quality and precision in component machining. As a special machine builder and systems integrator, the Austrian company develops system concepts for the widest variety of component sizes and application areas. Performance always under control Thanks to the continuous development and refinement of machining concepts, Fill Machine Engineering ensures long-term success for its customers. In conjunction with intelligent networking systems developed in-house in compliance with Industry 4.0, procedures are already being continuously opti-
Fill is a leading international machine and plant manufacturing company serving diverse branches of industry. The family-owned business excels in the use of the latest technology and methods in management, communication, and production. Business operations encompass the fields of metal, plastics and wood for the automotive, aircraft, wind energy, sport and building industries. The company is the global market and innovation leader in aluminum core removal technology, casting technology, wood bandsaw technology, as well as in ski and snowboard production machines. Andreas Fill and Wolfgang Rathner are joint CEOs of the company founded in 1966 that is still completely family-owned and now has more than 740 employees. In 2016, the company recorded sales of 145 million euros. www.fill.co.at
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Infrared camera for the metal industry up to 2000 °C
The infrared camera optris PI 05M features a continuous measurement range from 900 to 2000 °C. It has an optical resolution of 764 x 480 pixels and measures at a wavelength of 500 to 540 nm. Thus, the PI 05M supplements the optris PI 1M (0.85 to 1.1 µm). The new infrared camera optris PI 05M features a continuous measurement range from 900 to 2000 °C. It has an optical resolution of 764 x 480 pixels and measures at a wavelength of 500 to 540 nm. Thus, the PI 05M supplements the optris PI 1M (0.85 to 1.1 µm). Thanks to its special spectral range, measurement errors resulting from unknown or changing emissivities are reduced. “The PI 05M is another compact thermal imager, developed for the worldwide metal in-
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dustry. It is especially suitable for temperature measurement of molten metals”, explains Dr.-Ing. Ulrich Kienitz, CEO of Optris. Measuring high temperatures at frame rates of up to 1 kHz The optris PI 05M measures surfaces continuously from 900 to 2000 °C. At a frame rate of 1 kHz, measurements can be conducted with an optical resolution of 72 x 56 pixels. This region of more than 4000 pixels can be freely positioned. Additionally, there is a direct real-time analog output, again featuring a freely positionable 8 x 8 pixel region. These possibilities offer an optimal adaptation to the respective application. Special wavelength ideal for high temperature measurements and laser processing applications
The camera detects IR radiation in the spectral range between 500 and 540 nm and is therefore ideally suited for laser processing applications as radiation above 540 nm is blocked excellently. The, for the metal sector commonly used diode lasers in the range of 900-1030 nm and Nd:YAG laser at 1064 nm have thus no disturbing influence on the measurement. The camera works here without the need for additional filters. A general advantage of measuring metals at this short wavelength is a significant reduction of measurement errors resulting from changing or unknown emissivities. www.optris.com
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DEFINING PRECISION. ABRASIVE TECHNOLOGY BY TYROLIT EMO Hannover, is the leading metal machining trade fair in the world and includes production areas from machine tools through to precision tooling up to linking equipment and industrial electronics. More than 2,130 exhibitors came to EMO Hannover in 2013 and some 143,000 trade visitors from more than 100 countries. From 18 - 23 September 2017, the leading international trade fair will once more offer a large number of recent innovations and official market launches. On its 120 square metre stand, TYROLIT will present a large number of innovative products for the Automotive and Precision Engineering Industries. This year there will be a focus on medical technology. Both super abrasives and conventional grinding and polishing tools for finishing orthopaedic components, particularly for hip and knee joints as well as for medical instruments, injection needles and for dentistry. In addition, two new product highlights will be presented for the first time on the TYROLIT stand (Hall 11, Stand C06) - the COOL CUT 2 (for the knife industry) and the STARTEC PG-2 (for the tooling industry). The new products in detail Grinding tools for machining orthopaedic components. A large number of medical technology products which will produce measureable customer benefits will be showcased at the EMO in Hanover. TYROLIT will present special high performance tools for machining cobalt chrome and ceramic materials for hip and knee joints that can be tailored to customer requirements. With knee joint machining, ceramic CBN grind-
ing tools, for example, lead to lower
layer disc can be used for grinding and polishing in one process step, which considerably increases productivity. The COOL CUT 2 is available for all knife grinding machines and applications and will be customised for the relevant process by the experienced TYROLIT application engineers. STARTEC PG-2: Innovative grinding tools for high-speed external cylindrical and longitudinal grinding.
process times and thus reduce costs per component. TYROLIT also offers grinding tools that can be replated with a grinding layer height of up to 20 mm for fewer tool changes. When manufacturing hip joints and cups, TYROLIT polishing tools provide a particularly high surface quality. Using this innovative grinding tool set, comprising pre-grinding, fine-grinding and polishing honing sleeves, TYROLIT reduces the number of process steps from 5 to 3 steps and thus the machining time by up to 50%. COOL CUT 2: High performance grinding tools for knife grinding With the new COOL CUT 2, TYROLIT has once more established a milestone in knife grinding. The newly designed bond is impressive because temperatures are kept significantly lower in the grinding zone. As a result, burning can be prevented particularly on difficult to machine cutlery. For the first time with an epoxy resin bonded grinding tool, they have managed to adapt the porosity individually to the respective application. This guarantees the best possible, particularly cool finish. Another advantage of the COOL CUT 2 is its tried and tested 2 in 1 application. This means the two
With the new STARTEC PG-2 product line, TYROLIT will be presenting a new, innovative rough grinding wheel especially for peel grinding hard metal tool blanks. The special combination of process-optimised diamond quality and high-strength metallic bond results in this roughing wheel that delivers a feed increase of up to 20%. The special core design prevents vibration during grinding and thus guarantees a particularly high surface quality of up to Rz 1.5 Âľm and up to 10% reduction in disc wear. The finishing wheel is available with either long-life ceramic or metal bonds, which smooths out large allowance fluctuations after roughing and produces a particularly high quality surface finish up to Rz 0.9 Âľm. The STARTEC PG-2 is available from stock another essential advantage for customers. The multilingual TYROLIT team of marketing managers and application engineers look forward to greeting many familiar and new customers at the exhibition stand. www.tyrolit.com
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Everything from a single source with Skiving3: Machine - Tool - Process
Gear skiving according to the Liebherr concept has proved itself. Specialists from Kempten, Ettlingen and Collegno offer competences from a single source in a full-service package. Gear skiving according to the Liebherr concept has proved itself. Specialists from Kempten, Ettlingen and Collegno offer competences from a single source in a full-service package. “For successful gear skiving, users need more than just a good machine”, summarizes Dr.-Ing. Oliver Winkel, Head of Application Technology. “With skiving3 , we not only sell the LK 300 or 500 but a whole process. The customer presents a gear and we supply a machine, tools and technology for its production.” The holistic approach from Liebherr has already been tried and tested in practice. For many customers, the process of skiving is new, and there-
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fore the operators of the machines need comprehensive training and assistance. On top of that, the tool design is a very complex issue. “We have organized our division of labor very well”, reports Oliver Winkel. “In Kempten, we calculate the tools which are then designed and manufactured in Ettlingen or in Collegno, in
Italy. We have the entire process under control for both cylindrical and conical tools.” Skiving machines have to endure a lot The gear skiving machines LK 300 and 500 are based on the tried-andtested components of the correspon-
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ding large hobbing machines. However, process-related modifications were essential. For instance, the entire machine had to be more rigid and equipped with extremely powerful spindles. A gear skiving machine requires a table with a direct drive owing to the high workpiece speeds required. This drive works with an automatic control that constantly has the optimal parameters. The clamping fixture, which links the workpiece and the machine, is extremely complex and is designed by Liebherr. As skiving is a highly dynamic process, the machine is practically supplied on a “turnkey” basis with individual clamping fixtures for each workpiece, precise rigidity and contour accuracy. “This overall view is an important part for the production success”, explains Siegfried Schmidt, Team Leader in Development and Design of Skiving. “A complex process
such as skiving has many specific obstacles, which we overcome with very specific mathematical solutions.” The newly developed LHGe@rTec control system also contains the mathematical formulas for pressure angle corrections. This way, quality improvements can be easily achieved via the kinematics of the machine. Simple integration in production The optional tool changer, which can be used to change between roughing and finishing tools, for example, is new. Liebherr offers a ringloader as a standard option for the workpiece changing device; other automation solutions, such as belts and robots, can also be realized upon request. Skiving3 is popular especially for internal gearing with medium size and quantity as it is much faster than shaping and more economical than
broaching. In situations where gear skiving is not possible or appropriate, owing to interfering contours or quantities that are too low, Liebherr still offers technological alternatives with gear shaping and gear hobbing. Machines overview LK 300/500 •Maximum module: 5 •Maximum gearing diameter: 300 / 500 mm •Maximum workpiece outside diameter: 500 / 600 •Maximum table speed: 3000 / 1500 1 / min •Maximum tool diameter: 250 mm •Maximum tool speed: 2700 rpm •Maximum spindle output: 32 kW www.liebherr.com
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Supfina to exhibit cutting-edge technology at EMO Hannover 2017
The best technologies for your surfaces: Under this motto, Supfina presents the latest developments in superfinishing and fine grinding at EMO Hannover 2017 (Stand B37, Hall 11), which takes place September 18-23. In-house preparations for EMO Hannover 2017 are moving ahead at full speed, and much has already been written about the world’s premier trade fair for metalworking. Internationally renowned Supfina Grieshaber, however, has decided to wait until the show to unveil three new product innovations in the fields of superfinishing and fine grinding. In the 160 sqm exhibition booth, Supfina is excited to display its latest superfinishing and fine grinding innovations — three of which will make their debut at EMO. With
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these presentations, Supfina will once again demonstrate its commitment to responding to its customers’ needs with the best technology solutions. “We will show our visitors, customers, and other interested parties the latest innovations in surface finishing, as well as provide a comprehensive presentation of our core applications,” says Oliver Hildebrandt, Managing Director of Supfina. Please visit us at Stand B37 in Hall 11 to see what all of the excitement is about! With locations in Germany, the United States, and China, Supfina Grieshaber GmbH & Co. KG is one of the world’s leading manufacturers of surface-finishing equipment. Our product lineup includes machinery and devices for superfinishing as well as flat-surface machin-
ing, double-disk grinding, and fine grinding. Decades of experience— along with a steadfast commitment to researching and developing the latest technology—means that our machines can more than handle the demands and rigors of your everyday production. Combine this expertise with excellent customer service and you’ll understand why Supfina Grieshaber continues to be so successful. www.supfina.com
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HURCO shows just how powerful CNC machining centers can further improve your performance where HURCO will demonstrate how the powerful 3-axis CNC machining centers in its VMXi series can further improve your milling performance: The addition of a Kitagawa GT 200 rotary table as a fourth axis has further expanded Pliening near Munich, Germany. where HURCO will demonstrate how the powerful 3-axis CNC machining centers in its VMXi series can further improve your milling performance: The addition of a Kitagawa GT 200 rotary table as a fourth axis has further expanded Pliening near Munich, Germany, September 2017: The EMO trade fair (Hall 12, Stand D84) is its range of applications. HURCO is sure that the highly efficient machining centers in its VMXi series will help increase profitability, especially when it comes to one-off part or small series production. A major advantage of the VMXi machines is their compact construction: “For example, you don’t need much space to set up a VMX 30i, but it has a comparatively generous working area and cutting performance that is something to be proud of,“ declared Michael Auer, Michael Auer, Managing Director of HURCO GmbH. The addition of a Kitagawa GT 200 rotary table as a fourth axis significantly increases the range of applications these CNC 3-axis machining centers are capable of. When you start the program, up to four sides of a component can be machined at once, without reclamping, and if surface machining is needed on circular components, it can do that too. The additional axis can be installed or uninstalled with ease, to suit current needs.
HURCO machining centers in action You can see more HURCO machines at the EMO trade fair at the stands for Air Turbine Tools, (Halle 12 Stand E 06), Robert Stock (Halle 5 Stand C 44), manufacturers of precision metal cutting tools, and YG-1 GmbH (Halle 3 Stand E03). Air Turbine Tools uses a HURCO VM 10i, YG-1 GmbH a HURCO VMX 24i, while Robert Stock AG is running a VMX30i. The compact design of the CNC 3-axis machining centers makes them ideally suited both to metal cutting tasks in series production and to tool-making and mold-making applications. Conversational control system: fast, accurate and easy to use HURCO's machining centers are equipped with the "WinMax” conversational control system, with optional DXF. The powerful control system software simplifies programming and sets the machine up for producing precision parts in just three steps. “Using our WinMax DXF software, the programming time for a workpiece can be as lit-
tle as half that of other dialog programming systems,” stated Michael Auer. About HURCO HURCO Companies Inc. was founded in 1968. The company specializes in industrial technology, developing and manufacturing interactive computer control systems, software and computer-aided machine tools and components. The end market is primarily customer-focused single piece and small series production within larger companies in industries such as aerospace, defense, medical devices, energy, transport and computer engineering. The company is headquartered in Indianapolis, Indiana, in the United States, with production facilities in Taiwan, Italy and China, and sells its products in Europe, Asia and North America. Subsidiaries in Germany, Italy, France, England, Poland, China, India, Singapore, South Africa and the United States handle sales, application support and customer service. www.hurco.com
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Kaeser at EMO Ideal foundation for Industrie 4.0
Compressed air and Industrie 4.0 - Kaeser Kompressoren has precisely the right solutions for deriving maximum benefit from this powerful combination. At EMO, Kaeser Kompressoren presents a comprehensive showcase of innovative products. and services. Compressed air and Industrie 4.0 – Kaeser Kompressoren has precisely the right solutions for deriving maximum benefit from this powerful combination. At EMO, the compressed air systems specialist presents a comprehensive showcase of innovative products and services with powerful advantages. All users – no matter the scale of their operation or industry – are sure to find the right solution for a compressed air supply that’s reliable, efficient and most importantly, completely ready for integration into the Industrie 4.0 environments of the future.
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Kaeser offers single units as well as complete system solutions that cover the entire compressed air system life-cycle. Kaeser’s extensive product portfolio ranges from highly efficient rotary screw compressors for compressed air production, together with compatible treatment options, intelligent controllers and management systems – to innovative and individually tailored service solutions, including predictive maintenance and cost-effective contracting solutions. Efficiency first An efficient compressed air supply begins with efficient components, which is why Kaeser now equips all of its rotary screw compressors from 30 kW and up with Super Premium Efficiency IE4 motors as standard. With the best efficiency values currently available, they serve to further cut compressor power consumption. Moreover, further re-
finement and optimisation of Kaeser’s renowned Kaeser Sigma Profile airends – the key components actually responsible for producing the compressed air – has helped boost specific power in rotary screw compressors from 75 kW and up, for example, by as much as 12 percent. The new DSD and FSDseries rotary screw compressors therefore offer significantly enhanced efficiency and higher flow rates – which translate into tangible energy cost savings. The frequency-controlled ASD compressor series has set yet another milestone: the synchronous reluctance motor now installed as standard for the first time features markedly lower rotor power losses – precisely in the crucial partialload range – compared to asynchronous motors. Industrie 4.0 compatibility It‘s a given that the central aspects
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any complete system. With the innovative Sigma Smart Air service, Kaeser makes customer-tailored maintenance services available to every user. In addition to enabling predictive maintenance in combination with the Sigma Air Manager 4.0, Sigma Smart Air ensures optimum energy efficiency and compressed air availability. Simply buy the compressed air you use – contracting with Sigma Air Utility
of Industrie 4.0 – machine networking and communication capabilities – are highly beneficial no matter what size of compressor is used. Accordingly Kaeser is now also extending Industrie 4.0 capabilities to its smaller rotary screw compressor models (2.2 to 22 kW) so that users of these units can also benefit from seamless integration into Industrie 4.0 environments. Specifically in the future, SX - ASK series rotary screw compressors will feature the Sigma Control 2 compressor controller as standard equipment – the component necessary to unlock the powerful benefits of machine networking. Sigma Air Manager 4.0
Kaeser’s signature compressed air management system, now featuring improved 3D Advanced Control, perfectly harmonises the operation of all components in a compressed air system to ensure maximum availability and energy efficiency at all times. As such it acts as the central node and basic requirement for taking advantage of powerful Industrie 4.0 services such as permanent energy management and predictive maintenance. Individualised service Modern, innovative service solutions are a crucial part of a compressed air supply’s life-cycle; in fact, they’re a vital component of
Operator models, such as Sigma Air Utility, perfectly complement Kaeser’s extensive range of futureoriented compressed air products and solutions. Not everyone whose business relies on compressed air necessarily wishes to take on the effort and responsibility of maintaining their own on-site compressed air supply. So for some, paying for compressed air as a service can be highly worthwhile: the amount paid is directly linked to actual consumption. And since fixed costs are transformed into variable costs, the financial impact of production fluctuations is also reduced. Kaeser Kompressoren is a worldleading manufacturer and provider of quality compressed air products and services. All products are made in Germany at the company’s Coburg and Gera plants. Kaeser is represented in over 100 countries by a comprehensive network of branch offices and authorised partners. Kaeser currently employs approximately 5500 people worldwide. www.kaeser.com
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Targeted cooling at the blade
Boehlerit is adding yet another element to its already extensive product portfolio for turning operations: tool holders with connections for an integrated cooling agent supply. The integrated cooling agent supply directly to the indexable insert via the tool holder significantly improves the cooling of the blade. At the same time, the temperature development in the workpiece is reduced, allowing for more accurate tolerances and reducing the wear of the cutting edge, thereby increasing tool life and productivity. In many cases, cutting speeds or feed rates as well as surface qualities can also be improved. Additional benefits of
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an integrated cooling agent supply via the tool holder are improved chip control and more efficient chip removal. The precisely positioned stream of cooling agent helps optimise efficiency and process reliability of your turning operations. The new Boehlerit tool holders with connections for integrated cooling agent supply are available with toggle clamp (P) and screw clamp systems (S). The P tool holders are suitable for all ISO-certified indexable inserts. There are no loose parts and only a small number of spare parts is required, making handling noticeably easier. The indexable inserts may be clamped safely and speedily and are easy to
remove thanks to a forced release mechanism. As there is no troublesome build-up, chip removal is unimpeded. With the S tool holders, clamping of the insert is also quick and safe – in this case, using a tapered positioning screw. Again, chip removal is obstacle-free and a maximum of three spare parts is required. In both cases, the cooling agent is supplied either from the rear, i.e. the end of the shank, or from the bottom up on the cutter. www.boehlerit.com
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New Makino L2 5-axis vertical machining centres: Optimum solution for high-volume parts production The new Makino L2 5-axis vertical machining centre delivers high accuracy and rigidity from a ultra-compact footprint. Two models dedicated for indexing applications and impeller machining, respectively, will be launched at EMO in Hannover this year. Both versions of the L2-5Ax have been custom-designed for high-volume, small-part manufacturing processes, ready for automation. Combining a rigid construction and flexible spindle design with an ultracompact footprint, the L2 offers a highly stable and reliable machine platform for fully unattended, roundthe-clock processing of small components. The small size of this machine means it can be effectively employed in virtually any kind of work-piece flow arrangement, ranging from manual transfer of parts to automated part movement in robot-based systems. Equipped with a high-power spindle, the machine can easily tackle the rigorous milling, drilling and tapping tasks required for various production parts—and has the speed and acceleration to reduce part cycle times manifold. The L2 features dual direct-drive (DD) motor and brake on the A-axis and a single DD motor and brake on the C-axis to achieve high-speed, highaccuracy 5-axis machining. L2 5-Axis Index The L2 5-Axis Index specification comes with a high-speed 5-axis index table and machining capabilities for a variety of materials and work-pieces,
targeted at the high-volume parts production segment in various industries such as automotive and medical equipment. It can handle work-pieces up to Ø400 mm and 80 kg in weight. The table is fitted with eight hydraulic and pneumatic ports for easy integration of automated fixtures. The machine comes with a 16,000 rpm HSKA50 spindle. The automatic tool changer (ATC) has a capacity of up to 15 tools or 30 tools as an optional specification with a maximum diameter, length and weight of 80 mm, 250 mm and 8 kg respectively. L2 5-Axis Impeller Designed for high-speed impeller machining, the L2 5-Axis Impeller specification machine has two outstanding features – a high-speed si-
multaneous 5-axis table and a 25,000rpm spindle. The cartridge exchangetype, 25,000 rpm spindle (HSK-A50) comes with oil-air lubrication and delivers power of up to 18.5 kW and torque of up to 21.5 Nm. The X, Y and Z axes have 1 G, 0.9 G and 1.4 G acceleration/deceleration respectively. Both L2 machines are designed for simple integration into a variety of automated part transfer and loading configurations, including exterior loading arms and fixed or movable robot loaders. These automated configurations can contribute to higher production rates, shorter lead-times, reduced labour costs and significant savings in floor space. www.makino.eu
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Maximum performance when milling,the new Ultra Power Collet Chucks (UPC) by FAHRION The new Ultra Power Collet Chucks (UPC) by FAHRION were specifically developed and optimised for rough applications. The UPC holders are therefor a consistent development of the CENTRO|P holders. Today, the decisive factor for high-performance milling is the material removal rate. Increasingly powerful machines and controls as well as better substrates, coatings and geometries of the cutting tools aim at continuing to increase the material removal rate to be achieved. How is it possible to transfer these performance increases from the cutting edge to the machine? Here, the solutions of today such as power chucks, shrink-fit or hydraulic expansion clamping technology up to Weldon holders are insufficient solutions. The new Ultra Power Collet Chucks (UPC) by FAHRION were specifically developed and optimised for such applications. The UPC holders are a consistent development of the CENTRO|P holders, which have already been used and accepted on a broad basis and provide a wide range of advantages. In combination with the patent-pending UPC clamping nut completely newly developed as well as the WD collet already presented and also patented, the engineers at FAHRI-
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ON have succeeded in developing a truly innovative and unique system solution. As usual for the CENTRO|P family, which has proven its worth many times, the collet is completely seated in the cone with the UPC holders as well. In combination with the patented double guidance between holder and clamping nut as well as the trapezoidal thread for the ideal force transmission, this arrangement ensures a high concentricity and optimum stiffness of the overall system with the UPC holders as well. In this system, either the known
high-precision (HP) collets with a concentricity of 0.002 mm or the WD collet with integrated extraction protection recently introduced are used. Regarding this WD collet, a patented wedge clamping technology, which engages with the Weldon surface available as standard, prevents an extraction of the milling cutter absolutely reliably even under highest tensile load. The inner cone of the holder and the outer taper of the collet are from a single source and optimally adjusted to one another in the production. Thus, they achieve the best concentricity results in the system as well.
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The patent-pending Ultra Power clamping nut (UPC), which was completely redesigned, achieves highest clamping forces with maximum damping in the system at the same time. Due to the special, multi-part structure of the clamping nut, the friction between collet and clamping nut during the clamping process is minimised to the same extent as with the anti-friction coating of the HPC clamping nuts known from FAHRION. Thus, higher clamping forces can be achieved in the clamping system. At the same time, the torsion of the collet in the chuck is considerably minimised. This leads to high concentricity. Furthermore, the multipart design ensures additional damping, which is a great advantage when using the robust WD collet. This optimum interaction of the perfectly matched components results in a complete solution that is significantly superior to all solutions known in the market so far. The clamping forces reach the level of shrink-fit holders, but without the problem of the lack of damping known for shrinking. The damping values, in turn, can compete with the values of the hydraulic expansion clamping technology, but with the advantage of a considerably stiffer overall construction. Compared to power chucks, the FAHRION UPC is substantially less sensitive to radial load since the cross section of the holder has no weakening constriction, which is usual for power chucks. Compared to the Weldon holder used as stopgap in many cases, the FAHRION UPC is clearly superior - especially regarding the concentricity and thus the service life, the surface quality and, in particular, the spindle load. These properties make the new Ultra Power Collet Chucks the preferred solution for high material removal rates - whether with full slot or trochoidal circular paths and regardless of whether in heat-treatable steel, titanium or other special alloys. The UPC holders from the CENTRO|P premium programme are extremely robust, have an excellent concentricity and dampen the vibrations in the best possible way. www.fahrion.de
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Intelligent equipment for smart production
"Industrial production is on the verge of a fundamental change," underlined Dr. Markus Klaiber, Chief Technology Officer/CTO of SCHUNK GmbH & Co. KG in Lauffen, Germany with a view to EMO 2017. "In the years ahead, the digitalization, use of mechatronic products, and automation of production processes, collaboration between humans and robots as well as intelligent networking of all process-relevant components will promote a new concept of industrial production." The primary focus will be on three aspects: communication between all the components involved, maximum transparency within the system, component, con-
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trol technology and corporate levels, and flexible responses to external and internal events. "The used types of clamping devices and gripping systems are of significant importance in all three of these areas," the production specialist emphasized while maintaining SCHUNK’s position as the world’s leading supplier in both segments: "Our aim is to utilize the exposed position of our modules "closest-tothe-part" in the future, in order to enable detailed monitoring of every individual process step as well as to permanently supply the higher-level ERP system control and cloud solutions with process data and to be able to react flexibly to any respec-
tive events." Autonomous handling scenarios SCHUNK already provides a large number of clamping force blocks that are capable of communication, fully automated palletizing systems and quick-change solutions for flexible production. The family-owned company will continue to expand its Industry 4.0 portfolio at the EMO. The highlight will be a functional manufacturing cell in which an intelligent SCHUNK EGL PROFINET gripper with variable power and positioning enables autonomous handling scenarios, and ensures fully automated quality assurance. Without the need for additional external
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sensors, the gripper autonomously detects defective components and decides for itself whether the part should be removed from the process. The recorded information can be continuously transferred to the machine control system, to higher-level internal and external systems as well as to cloud solutions for statistical process analyses. All the process steps are moni-
tored in real time and superordinate levels such as ERP systems or cloud-based monitoring platforms are provided. In addition, SCHUNK is pushing the trend toward fluidfree, highly interconnected machine tools with the VERO-S NSE-E mini - the first global electrically controlled 24V quick-change pallet module.
System program for workpiece direct clamping SCHUNK is even setting the stage for exciting new products for mechanical clamping systems that reduce idle times, increase productivity of machine tools and enable flexible processes. Therefore SCHUNK is going to further expand its modular system for workpiece direct clamping modules, to expand its portfolio of lightweight chucks and, after numerous successful customer tests, to get the ball rolling with the slim, vibration damping TENDO Slim 4ax hydraulic expansion toolholder. The underlying message: "Easy to use, easy to integrate, easy to maintain," says Dr. Markus Klaiber. "Because modern gripping systems and clamping devices are the key to efficient and flexible production processes." www.schunk.com
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KELCH KENOVA set line V9xx-S System concept to meet the most demanding requirements Kelch GmbH, which specialises in peripherals and services for manufacturers and users of machine tools for cutting processes, is launching a new system concept for a tool presetter from the KELCH KENOVA set line V9xx-S range. The focus here is on the redesign of the shrink fit equipment and side unit. The redesign also incorporates a redesigned control panel and innovative components, including an operating monitor with touchscreen with an ergonomically designed holder for optimum operating convenience. “Once again Kelch is setting new benchmarks in the design of tool presetters. Handling is made significantly easier, thanks to the new shrink fit cooling concept. The benefits for users include the convenient operation of the unit coupled with maximum precision. After all, KELCH has over 75 years of experience in this field,” explains Viktor Grauer (B. Eng), member of the Executive Board and Head of Innovation Management at Kelch. Measurement, shrinking
presetting
and
A combined tool presetter and shrink fit device for the precise and repeatable presetting of tools in shrink fit holders to a target dimension represents the pinnacle of tool presetting. Kelch has rigorously redesigned its KaliTec system, which has proved itself over many years and resulted in the KENOVA set line V9-S system.
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New tower concept – measuring tower and shrink fit equipment fully redesigned About the measuring tower Kelch has fully redesigned the tower design for all Premium Line series units (V6, V9 und V9-S) . The basic design of the tower is made of highly rigid grey cast iron and the design has been systematically simplified. Additional component options, including cutting edge monitor, turning centre and grinding camera, can be very easily attached to the new tower. A laser pointer (laser class 1) integrated in the camera holder is also new and is used for improved visual locating of the cutting edge. About the shrink fit equipment New fixed shrink fit equipment has
been designed for the V9 basic machine. The position of the tower on the V9 basic body has been chosen to enable convenient and accessible handling. The shrink fit equipment is fixed on the right front side of the V9 basic body using a stable bracket adapter, which enables tools with a max. Ø of 420 mm to be measured. A smoke extraction unit is also optionally available for the shrink fit equipment. The stop ring can be swapped easily and quickly, as with the previous unit. EASY operating software has been adapted for ease of access: in the event of a service, the software moves the coil body into a conveniently accessible replacement position. Multifunctional side unit
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motorised adjustment of the X, Z and C axes is done using a joystick instead of using cursor keys. The X and Z linear axes are controlled by steering the joystick in the direction indicated by the arrows on the cover panel. A push-button is incorporated in the top of the joystick to move the C axis. All 3 axes can be moved simultaneously. A toggle button incorporated in the top of the joystick switches between fast mode and creep speed for each movement of the axis. Operating monitor with touchscreen Kelch has fully redesigned the side unit: all the key components for the “shrink fitting” and “cooling” workflows are accommodated in the side unit. The induction coil control and cooling unit are integrated in the lower part of the side unit.
A data printer can be held on the side of the side unit with a separate holder. Users also have the opportunity to attach additional brackets at the side, which provide space for storing additional spindle inserts and tool holders in the KELCH Tul system.
The close positioning of the side unit to the V9 presetter helps to ensure that there are no long distances between the work processes shrinkingwith measurement and cooling.
The side unit is equipped, as standard, with a wireless keyboard and wireless mouse, which further simplifies operation of the unit.
There is space on the worktop of the side unit for a label printer alongside the adapters, cooling bushings, cooling stations etc. needed for shrinking.
New redesigned control panel for all Premium Line series units (V6, V9 and V9-S) The innovative control panel stands out on account of the fact that the
A further unique feature is the fixture of an optionally available operating monitor with touch function. While the standard monitor is fixed on the side unit on the side facing the user, the touch version is supplied with a swivel arm for ease of operation and can be positioned by the user according to their body position. Kelch GmbH, based in Weinstadt near Stuttgart, offers peripherals and services for manufacturers and users of machine tools for cutting processes. With over 100 employees, the company generates annual revenue of approx. €13 million. As a fully owned subsidiary of Harbin Measuring & Cutting Tool Group Co., Ltd. (HMCT), Harbin/China, Kelch is part of the China General Technology (Group) Holding Co., Ltd. (Genertec), Beijing. Genertec is represented in 100 countries worldwide, with 45,000 employees in 51 companies. Kelch GmbH acts as the technology centre for the international business group in Europe. KELCH develops, manufactures and markets tool holders, cleaning devices, shrinking devices, presetters as well as measuring machines and also offers tool management services. www.kelch.de
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High-precision and cost-effective marking with zeus tools One manufacturer was looking for a cost-effective, high-precision solution for lettering a cork ring as a way of lending the bottle an attractive and unique piece of detail. The zeus marking tool 131 with a customized marking roll exactely met his needs. Impressive detail on a cork ring The perfect sensory experience all-round High-precision, cost-effective marking with zeus tools To set themselves apart from the competition and highlight the premium nature of their product, few industries attach as much importance to packaging as the luxury food and drink industry. One manufacturer was looking for a cost-effective, high-precision solution for lettering a cork ring as a way of lending the bottle an attractive piece of detail that could prove decisive in a customer’s decision to buy the product. The manufacturer found the solution in the form of zeus marking tool 131 and a customized marking roll, perfectly designed by Hommel+Keller Präzisionswerkzeuge GmbH for this application. When it comes to food and drink, a full-bodied taste and attractive aroma are key purchasing criteria for customers. But first impressions are important, too. Demanding consumers look at the whole pic-
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This unique lettering significantly enhances the quality of the cork ring and transforms an ordinary metal band into an unmistakeable, distinguishing feature – all thanks to the marking technology from Hommel+Keller Präzisionswerkzeuge GmbH. ture, which of course includes the look and feel of the packaging. After all, a high-quality exterior is associated with a unique taste sensation. Even the tiniest of details can make that all-important difference. The quality of a cork ring – a simple device that stops the cork from slipping too far down into the bottle – is instantly enhanced through the addition of unique lettering, transforming an ordinary metal band into an unmistakeable, distinguishing feature and “trademark”. Highquality workmanship, precise and clear lettering and a consistent typeface are prerequisites for this attractive effect. With its revolving marking technology, Hommel+Keller Präzisionswerkzeuge GmbH had the perfect solution.
“The task was to emboss lettering, completely uniform in appearance, onto the 22-mm-diameter metal ring. The focus was as much on consistently high quality and precision as on the economical and simple machining of these mass-produced parts. In combination with marking roll 40, zeus marking tool 131 is perfect for this task,” says Reinhold Dreher, application engineer at Hommel+Keller Präzisionswerkzeuge GmbH. A marriage of precision and economy The tool really shows off its strengths when lettering large and medium production volumes with identical text. The marking roll is rolled evenly over the part being
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process, exact concentricity and minimal tolerances (+/- 0.025 mm) in the component diameter are essential for consistent high-precision machining and the clarity of the lettering,” says Reinhold Dreher. Summary
The zeus marking tool 131 in combination with a custom-prepared marking roll was the perfect solution for this impressive piece of detail on the cork ring. produced, which ensures high process reliability, uniform lettering with a high degree of dimensional accuracy and 100% reproducibility. And what’s more, all different kinds of lettering types are possible. The zeus tool performs its task not just cost-effectively, but also with precision. Carbide running pins ensure high speeds and, in turn, short machining times. And unlike with, for example, needle embossing, the marking tools from Hommel+Keller Präzisionswerkzeuge GmbH can be seamlessly integrated in the production process. The zeus marking tool 131 can be used on all standard machine types, in particular on short and universal turning lathes, turning/milling centres and multispindle turning machines. Reinhold Dreher: “This means an end to manual retooling on separate machines; the part can be marked in a complementary step of the machining process in one machine.” In addition, the tool is extremely easy to handle: the marking roll can
be exchanged in just a few quick and easy moves, which means that the tool can be used universally for different lettering tasks. Customized marking roll The marking roll containing the custom text must be precisely matched to the application, which means that it is specifically prepared. For the cork ring, the 17 characters – each with a height of 1.5 mm – had to be embossed with uniform spacing. To make it highly resistant to wear and thus suitable for the demands of high-volume production, the marking roll was made from cold-work steel and specially surface-hardened. As is normally the case in revolving marking procedures, the tool achieves the required embossing depth of 0.3 mm through multiple continuous rotations of the marking roll.
The results are impressive and perfectly unite the look and feel. Not only does the marking tool from Hommel+Keller Präzisionswerkzeuge GmbH lend the cork ring an impressive piece of detail, but shorter machining and set-up times and the absence of transit and idle times help to lower unit costs and increase cost-effectiveness. The perfect solution for lettering large and medium production volumes quickly, precisely and costeffectively. This unique lettering significantly enhances the quality of the cork ring and transforms an ordinary metal band into an unmistakeable, distinguishing feature – all thanks to the marking technology from Hommel+Keller Präzisionswerkzeuge GmbH. www.hommel-keller.de
“Since the size of the marking roll depends on the diameter of the component and the marking roll is constantly engaged with the component during the entire embossing
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Intelligent, flexible, fast: NCSIMUL rewrites Rules in CNC Manufacturing
SPRING Technologies presents a game changer technology at EMO 2017: With NCSIMUL SOLUTIONS NC programs can be converted automatically to other machines with different kinematics and controls - nc code verification and optimization included. SPRING Technologies presents a game changer technology at EMO 2017 SPRING Technologies, a leading software provider for enhancing the efficiency of CNC machines, is gearing up for one of the most important trade fairs of the year: the EMO in Hanover, Germany from 18 to 23 September 2017. This year, digitalization and Industry 4.0 are the focus of the world’s leading metalworking trade fair. Under the motto “Connecting systems for intelligent production”, the trade fair will provide an overview of business models arising from Big Data and connecting the value chain. The EMO theme of this year will be strongly represented at the NCSIMUL trade fair booth as efficiency, innovation and flexibility will lead the way in CNC manufacturing in the future.
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Fast, flexible machine switches with simulated and optimized NC codes
ics and control. This is a true game changer in today’s CNC manufacturing process.”
“A big challenge in manufacturing is to be able to react quickly and flexibly to customer orders and changes in shop floor resources while always making optimum use of the machines reducing overall production costs: machines, raw material, tools, programming time. Manual re-programming in the traditional process can take several days. With NCSIMUL NC programs can be converted automatically . This way, switching the machine can be done in only a few hours. As a result, considerable time is saved, not only in programming. In addition, the quicker new CNC machines can be put into operation, the sooner they will contribute to the production results”, explains Gilles Battier, CEO of SPRING Technologies, and continues: “The uniqueness of our technology is that NCSIMUL 4CAM not only reads, simulates and optimizes CAM files and NC programs, but is also able to write a new program which will run error-free on the desired target machine, kinemat-
The machine simulation checks the NC code after the post processor operation, generating absolutely collision-free programs at maximum speed which also considers the set-up situation, as well as swivel and entry movements in the machining area. Furthermore, the tool paths will be optimized; unnecessary tool motions, as well as the dreaded tool crashes, will be avoided. According to the manufacturer, NCSIMUL users can reduce the processing time of their NC programs by 20% on average simply by optimizing processes. The digital shop floor - in an automated and intelligent process A digital tool management using its own 3D kernel and a quality graphic presentation completes this innovative software solution. “In this way, the entire process from the CAM system to the first chip removed can be digitally mapped and controlled. It is this integrated process with its outstanding 3D technology and fast cal-
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culation which makes the difference with our NCSIMUL SOLUTIONS,” highlights Herbert Schönle, General Manager DACH of SPRING Technologies. Digitalized CNC manufacturing, however, does not end at the plant gate: 3D NC videos of simulations can, for example, be used within supplier management, allowing a linked production process reaching beyond company borders. And in reverse,
users can download tool data directly from the tool clouds; existing CAD/CAM data can be imported via interfaces to be used in all leading CAM programs. Paper set-up sheets should become a thing of the past. The digital technical document management provides real-time access to current modifications and interactive co-operation.
awarded the Trophée de l’Innovation 2016, and in Germany the MM Award at AMB 2016 and the INTEC Preis 2017.
In France, NCSIMUL 4CAM was
www.ncsimul.com
All features of the latest NCSIMUL 2017 version are available for EMO visitors to experience via live demos. NCSIMUL trade booth: Hall 25, stand no. B27
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New Rotating - Tilting Table for Tool Manufacturing Combines Highest Dynamics with Precision HIRSCHMANN GMBH developed 2-axial rotary indexing table for serial laser machining at maximum speed New developed 2-axial rotary indexing table by HIRSCHMANN GMBH for laser applications in tool manufacturing for the first time combines maximum speed and highest precision. Designed on behalf of customer’s order this solution can be seen on trade fair EMO from 18th till 23rd of September, 2017 in Hannover (hall 13, stand C101). The innovation is setting new standards in efficient laser machining of parts with tight curve radius or complex shapes. The presented changes of motion require acceleration profiles, lying at the limits of technical possibilities. “In this motion combination of rotating and tilting extremely high acceleration values on the T-axis and the R-axis are reached“ says Rainer Harter, CTO of HIRSCHMANN GMBH. In cooperation with engine manufacturer Etel the company succeeded to reach the speeds requested by customer on a 2-axial rotary indexing table. For machining of parts a simultaneous motion between tilting and rotating axis is necessary, controlled by overall control system of production line. Permanent High Speed
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With this application in serial production extremely robust tools for milling and turning processes are made. The contour is cutted out of basic material by an water guided and thus cooled laser beam, that is responsible also for finishing. The task of the rotary indexing table is to pass the work pieces – PCD (polycrystalline diamonds) or MCD (monocrystalline diamonds), hard metals or ceramics – directly along the laser beam. And this in an exactly defined angle, in appropriate radius and with constant speed. Rainer Harter: „Even this was the special challenge. Because the laser has a defined energy content, a constant traverse speed is requested for precise material removal.“ The new development of HIRSCHMANN GMBH meets all parameters, requested by Synova, a manufacturer from Switzerland specialized on manufacturing of laser machining equipment. “Hereby we reach acceleration values, that will enter new dimensions” says Rainer Harter. To reach this level intensive coordination with engine manufacturer Etel was necessary. The rotating-tilting table has a direct drive in both T-axial modules (tilting) and also integrated is a high-precise measuring system and the break function. The R-axis (rota-
tion) is designed as rocker, equipped with own drive and an additional measuring system. Integrated in R-axis is the high-precise chuck HSK - A 63, developed by HIRSCHMANN, for clamping of work pieces to be machined. This compact clamper is especially designed for applications in tool machining. “The great advantage for our customers is, that we can deliver all out of one sorce. As a result of a complex manufacturing process and sophisticated assembling methods the component parts are adjusted to each other precisely and harmonize at its best”, so Rainer Harter. The 2-axial rotating-tilting table is delivered by HIRSCHMANN as completely assembled unit, putting into service is made at works on a special test bench. “This allows us to guarantee functioning, to measure accuracy and to check performance data”, argues HIRSCHMANN CTO. The New Development also Optimizes Cutting Actions At the first step the 2-axial rotary indexing table made by HIRSCHMANN is used for laser applications. But it is planned, that the innovation is applied also for milling operation and other cutting actions, where higher accuracies are required. Thus precision of parts and machining processes can be im-
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2-axial Rotary Indexing Table for seriell laser machining with maximum speed. Foto:HIRSCHMANN GMBH proved and operating efficiency can be increased significantly. About HIRSCHMANN For more than 60 years HIRSCHMANN develops and manufactures trendsetting products amongst others for vehicle construction, motor sport, aerospace, railed vehicles, mechanical engineering,
naval architecture and wind power plants. Core competences lie in the three product lines Rod Ends and Spherical Bearings, Rotary Indexing Tables and Reference Systems. In these sectors HIRSCHMANN has extensive expert knowledge as well as experience for decades and can offer beside a varied standard assortment also customer-specific solu-
tions. The medium-sized enterprise from Baden-WĂźrttemberg with sales companies in US and China actually has about 200 employees. www.hirschmanngmbh.de
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DUALIS demonstrates at the EMO 2017: Transparent production processes in the smart factory Smaller batch sizes, more complex components, a higher variety of products and the digital conversion are fundamentally changing the industrial production. The DUALIS GmbH IT Solution supports these processes with smart solutions. Smaller batch sizes, more complex components, a higher variety of products and the digital conversion are fundamentally changing the industrial production. The DUALIS GmbH IT Solution ( www.dualis-it.de ) supports these processes with smart solutions for the planning and visualization of manufacturing processes . The company will demonstrate these solutions at the EMO – fair for the metalworking industry – in Hanover from 18 to 23 September. In hall 25, stand C25 DUALIS will present the 3D simulation platform Visual Components, the advanced planning tool GANTTPLAN 5.5 and more. „Connecting systems for intelligent production“ – at the EMO everything is focussed on innovations relating to modern production technology in the metallworking industry. Numerous exhibitors from all over the world are presenting their products and services at the fair, all in terms of digitalization and industry 4.0. Thereby, the focus is on connected products and processes. “Today, the production flows are increasingly digitally processed. We make them plannable and optimizable and render process knowledge
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faster replicable.“, explains Heike Wilson, managing director at DUALIS. The APS (Advanced Planning and Scheduling) system GANTTPLAN by DUALIS represents a central component of the smart factory. The modular-based advanced planning tool takes over the detailed order scheduling as well as the result visualization in the graphical user interface. This facilitates the planning and control of production-relevant parameters, such as employees, material and scheduling, which leads to more efficient processes and planning security. GANTTPLAN is the key link between the management and production level and it can be seamlessly integrated into existing MES and ERP systems. Thus, it complements for example the iTAC.MES.Suite, the Manufacturing Execution System of the DUALIS holding company Itac Software AG. DUALIS does not only intervene in ongoing operations, but also in pre-
liminary stages. This is where the 3D simulation platform Visual Components is deployed. This software facilitates the simulation and planning of factory processes before being implemented in practice. „By displaying and analyzing the processes, the plants and production lines can be tested in detail before the construction or commissioning. This leads to cost and time savings and at the same time the new application szenarios of the production 4.0 become more transparent and calculable.“, explains Heike Wilson, managing director at DUALIS. Together with iTAC Software AG DUALIS will present this and other industry 4.0 solutions and platforms supporting the digital conversion in the factories at the „EMO 2017“. www.dualis-it.de
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Status monitoring system for ball screw drives August Steinmeyer will be unveiling a newly developed status monitoring system. The evaluation electronics converts and analyzes the measuring signal from the ball screw drive and communicates with the machine control, which recommends any upcoming replacement of the ball screw. Together with ifm Electronic, August Steinmeyer has developed a technology concept in which sensors in the ball screw drive measure the preload and temperature directly at the rolling contact zone. As the company explains the principle, the evaluation electronics converts and analyzes the measuring signal and communicates with the ma-
measurement is reportedly even possible with superimposed or extraordinary operating forces. High cost savings are said to be possible through service orders that are foreseeable. Moreover, a history record enables conclusions to be drawn about any machine overloading. The ball screw status monitoring developed by The system also helps August Steinmeyer continuously monitors the preto optimize the lubricaload of the nut on the spindle shaft. tion to special requirements by applicationchine control that has a light indicaspecific load balancing. tor and recommends an upcoming replacement of the ball screw. The
www.steinmeyer.com
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High stock removal capacity thanks to new hybrid bond Cafro, a manufacturer of diamond bond is now part of and CBN wheels and tools, will be the Cafro 2017 stock presenting the new M404 hybrid list, which has been bond at EMO Hannover 2017. expanded and imThe company, which has recently proved thanks to new joined the Mirka Group, reports that technical developin its manufacture of carbide mills ments. These include and drills, the main requirement is The new M404 hybrid bond is now part of the Cafro the new Standard Line 2017 stock list. working time reduction. This is said CBN products (quality to particularly apply during the flutWD) and the new bond cording to the Italian exhibitors, the ing operation. Tests on CNC grinders family Top, which is described as a wheel is silent during grinding, have apparently shown that the resin bond with the best profile rethere are no vibrations, both the new M404 hybrid bond allows for tention. wheel and workpiece remain cold, higher stock removal with lower www.cafro.com power absorption at the spindle repower absorption, a longer dressing mains constant, and there are no interval and a better surface finish absorption peaks. The new hybrid than the market benchmarks. Ac-
Flexible micro sandblasting machine The Seckler Robomation product range has been extended by a new solution. The Sandero micro sandblasting machine has been designed to increase the economic efficiency of sandblasting processes while meeting strict modern quality requirements. As the exhibitors explain, the Seckler Sandero has been developed to carry out the automatic and uniWith the Seckler Sandero, up to four programmable form micro sandblasting of cylindrimicro sandblasting nozzles are available at each table cal components. The machine can position. reportedly accommodate parts up to a maximum diameter of 80 mm workpiece stations. According to and a maximum length of 150 mm. the Swiss manufacturers, it is possiIt comprises a stand-alone blasting ble to have a maximum of four indisystem with rotary table and eight
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vidually programmable blasting nozzles at each table position. After the blasting process, the workpieces are carefully blown off so that they can be removed dust-free from the parts fixture. www.seckler.ch
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Optimized tooling concepts for deep hole boring In order to produce long bores with tight tolerance requirements and good surface quality, BTA-Tiefbohrsysteme have enhanced their tool range for solid boring and skiving. The German exhibitors, who manufacture tools covering the complete range of internal contours that can be produced by the deep hole drilling technology, are deploying new inserts to optimize the chip geometry during solid boring. Moreover, instead of being mounted directly on the tool body, all inserts are now mounted into cartridges to markedly increase the life expectancy of the tools. As the company further reports, new skiving tools activated by coolant pressure have also been developed to reduce the machine set-up time when changing from solid boring to skiving. These new tools are claimed to effectively meet the highest requirements made on tolerances and surface quality.
New solid boring and skiving tools from BTA-Tiefbohrsysteme
www.bta-tiefbohrsysteme.de
Double-sided fine grinding machine with basic innovations The Peter Wolters AC Microline 1000-F has been equipped with a new twin loader and robot cell. Lapmaster Wolters, a company formed by the acquisition of the surface processing specialist Peter Wolters by Lapmaster Group Holdings in 2014, will be particularly highlighting the AC Microline 1000-F fine grinding machine at their booth at EMO Hannover 2017. The grinder has been fitted with a new twin loader and robot cell. In addition to a number of smaller enhancements, the exhibitors point to the solid welded construction of the machine. Further key improvements singled out by the manufacturers include a center-fed height adjustment driven by a servo motor and a linear electrical unit to load and unload the carriers.
The Peter Wolters AC Microline 1000-F
www.lapmaster-wolters.de
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Complex 3D components with powder nozzle or in a powder bed
With the Lasertec 3D and Lasertec SLM series, DMG Mori is setting itself up as a full-line provider in the additive manufacturing DMG Mori will be highlighting key generative production processes. The company sees itself as a complete supplier both for the additive manufacturing of metal components and in post-processing. DMG Mori points out that it is successful on the market in additive manufacturing with laser deposition welding using a powder nozzle. Selective laser melting in a powder bed is now expanding the product portfolio. As the company explains, it is demonstrating its integral competence by bringing together the
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key generative manufacturing processes under one roof and sees itself as a full-line provider in both the additive manufacturing of metallic components and in postprocessing. The Lasertec 3D and SLM series are considered the cornerstones of the strategic orientation in this future technology. Whereas the Lasertec 3D hybrid successfully combines laser deposition welding by means of powder nozzle and five-axis milling, the Lasertec SLM series stands for selective laser melting in a powder
bed. Both technologies are said to complement each other ideally in the product range. According to the manufacturers, they attach particular importance to the powder bed process, which has a market share of 80 percent where the additive manufacturing of metallic components is concerned. The latest innovation stages of the two processes will be presented at EMO Hannover 2017, integrated in continuous process chains. www.dmgmori.com
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Reliable and cost-effective cleaning of industrial wastewater In the metalworking industry emulsions and wash waters are disposed of externally at high costs or are treated using technologies such as evaporators or ultra-filtration. The new Akvo-Float technology has been designed as a reliable and cost-effective alternative. Akvola Technologies is a water technology specialist that provides cost-effective and environmentallyfriendly solutions based on AkvoFloat. As the German company explains, this is a proprietary flotation-filtration process used to clean hard-to-treat industrial wastewater containing high concentrations of oil (free, dispersed and emulsified) and suspended solids. The interna-
The patented hybrid Akvo-Float method combines micro-flotation and filtration techniques, both in a single tank.
tionally patented hybrid process combines micro-flotation and filtration and is based on innovative ceramic flat sheet membranes. Both processes are arranged in a single tank and are said to completely eliminate oils, greases, lubricants and suspended solids from the water. As the developers point out, technologies such as evaporators or ultra-filtration often have cost-intensive operating problems due to the fluctuating quality of metalworking industry wastewater. The new separation technology is seen as a reliable and cost-efficient alternative to evaporators, ultra-filtration (UF) and external disposal. www.akvola.com
New developments in broach grinding According to the company Lapmaster Wolters, the BG1000H-T broach grinding machine is part of a series of high-precision profile grinding machines developed for the tool and mold industry.
industry, is reportedly able to handle workpieces with center distances of 2,000 mm and diameters of 200 mm. The advantages of the
The BG1000H-T machine on exhibition has been developed to grind flat and round broaches. The BG range, which comprises high-precision pro- The BG1000H-T broach grinding machine is used file grinding machines for the profile grinding of round and flat broaching for the tool and mold tools.
line singled out by the manufacturers include the fast retooling from flat to round tooling and the variety of grinding applications for rotationsymmetric components. The use of an optional measuring probe enables the tooth thickness and pitch for the profile grinding and the tooth pitch for the back taper to be measured. www.lapmaster-wolters.de
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High-performing transfer machine
The TFL 400 rotary transfer machine has been designed for a large production volume. With the TFL 400, Riello Sistemi is offering a rotary transfer machine that combines large production volumes and maximum reconfiguration capability. It is available with six to twelve work stations, of which one or two can be designed as a loading and unloading station. The TFL 400 features a three-position revolving tool change system, is equipped with a HSK 63 taper and can also be equipped to house facing heads as well. It is described as highly reliable and capable of
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changing the tool without chip or coolant contamination from adjacent machining units. Available with six to twelve work stations, whereby one or two of them can be used to load and unload workpieces, the transfer machine features a rotary table that ranges from 2,000 to 2,400 mm in diameter according to the number of stations. It is fitted with a rotating clamping fixture for each station, with an innovative rotation system that ensures faster rotation times than the direct-drive solution. In addition, as the Italian
exhibitors point out, maximum positioning accuracy and stiffness during machining is effectively ensured through a triple Hirth coupling. Its excellent reliability and performance is said to make the TFL 400 a technologically more advanced machine in comparison to the competition available during recent years. www.riellosistemi.it
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Deep-hole drilling and milling in an Industry 4.0 environment
The new machines from Cheto have been prepared for the requirements of Industry 4.0. The Portuguese company Cheto has developed a machine for deephole drilling and milling that is also ready for Industry 4.0 requirements. Toolmakers and service providers are seen as the main target group. Cheto maintains that its machines have always had a very good costbenefit ratio thanks to their versatility, and now the machines have also been adapted to the require-
ments of Industry 4.0. The new concept on show is said to enhance the products with features pioneering the introduction of new methods and work analyses in line with Industry 4.0. The current models have been adapted with a new optional automatic gun drill, allowing storage of gun drills up to 1.8 meters long. With this new option, the machines will reportedly be able to operate around the clock without the
need for human interaction. The new SiC machine model can apparently machine five sides without angular limitation. According to the manufacturers, it has a maximum angle of -25째/+25째 and four sides work limitation. The kinematics allow the machining of five sides with only one setup and a working angle of -90째/+45째. www.cheto.eu
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Flexible twin-spindle machining center The new Metéor on show from PCI is a CNC machining center that offers high flexibility with configurations between four and five axes. The machine has been designed with a double spindle. PCI announces that the company has brought together years of experience working in the automotive industry and high-level technologies into the production of the new twin-spindle Méteor. Reportedly designed in accordance with the latest high-efficiency standards for automotive applications, the new machine is claimed to satisfy the most challenging project require-
been on reliability and high dynamics, according to the French manufacturers, and it comes alongside a complete new range of machines. Whether gantry loaded or equipped with an automated pallet changer, the new Méteor TS630V is said to fit a broad range of applications and offer the flexibilThe Méteor twin-spindle machining center from ity of between four- and PCI five-axis configurations. ments of OEMs (Original Equipment www.pci.fr Manufacturers). The development focus for the machining center has
Improved universal cylindrical grinder productive times and With larger heights of and distances enhances productivity. between centers, the new Varia uniThe machine is available versal cylindrical grinding machine with distances between from Kellenberger is said to be faster centers of either 1,000 and more precise, offering consisor 1,600 mm and with tently better performance. heights of centers of eiThe Varia universal cylindrical grindther 200/250 or 300 ing machine from Kellenberger has almm. There are over 30 ways featured hydrostatic guideways wheelhead variations for optimal shape accuracy in all with external and intergrinding tasks involving interpolating axes. In addition, the direct drives on The Varia's generously dimensioned doors with a large nal grinding spindles. the rotary axes ensure high position- field of view allow an optimal control of the processing The grinder is equipped with the latest Heidening speeds and accuracy. With larger and facilitate access to the workroom. hain Grindplus 640 or heights of and distances between static B-axis is also equipped with a diwith the Fanuc 31i as before. The new centers, the new model is said to be rect drive, which allows the revolving remote maintenance concept ensures faster and more precise, offering conwheelhead to pivot roughly three higher security when connecting to sistently better performance. Drives times as fast as without a direct drive the customer network via VPN tunnel optimized for performance move the and positions with a precision of less or mobile communication. longitudinal and cross slides at speeds than one arc second. As the manufacof up to 20 m/min and at an axis resturers point out, this reduces nonwww.kellenberger.com olution of ten nanometers. The hydro-
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