Industry EMEA | 18 - January 2019

18 | J A N UA R Y 2 0 1 9

EMEA

industry THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA

SWITCHING TO NSK BOOSTS LINEAR GUIDE LIFE

BY A FACTOR OF NINE

6 120KW ULTRA-FAST CHARGER SET A NEW BENCHMARK IN ELECTRIC VEHICLE (EV) CHARGING

10 EMERSON’S NEW ULTRASONIC WELDING PLATFORM MEETS CHALLENGES OF CRITICAL SMALL PLASTIC PART ASSEMBLY

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KENNAMETAL’S NEW VIBRATION-FREE BORING SYSTEM BOASTS A NUMBER OF TECHNOLOGICAL IMPROVEMENTS

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18 | Industry EMEA | January 2019

THE INDUSTRY MAGAZINE FOR EUROPE • MIDDLE EAST • AFRICA

DELTA ELECTRONICS

NSK

PACKT

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7

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ADVANTECH EUROPE

SIC MARKING

8 ASCO EMERSON

12

10

9 BAUMER

COVAL

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KENNAMETAL

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ADVERTISERS: NSK 5 • IDS 17 • MEPAX 20

www.industryemea.com

ALFA POWER

Contributing Editors: • Emmanuel AHOSSI • Nessren BAZERBACHI • Romain CLASS • Maria DE PABLOS • Anna HARDALOUPAS • Sofiane JEDIDI • Marie RESPINGUE • Christophe VERGUET

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Send your press releases to: editor@industryemea.com To receive Industry EMEA magazine free of charge, please subscribe online at www.industryemea.com

Industry EMEA is the English-language magazine for engineers, published by INDUPORTALS MEDIA PUBLISHING. It contains the latest product and company news for industrial markets.

Industry EMEA edits its articles with the greatest of care, however we cannot guarantee the accuracy of the information presented in them. Our teams disclaim all responsibility concerning the content of this media or how it might be used.

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NEWS

DELTA SHARES ITS EXPERIENCE IN ENABLING LOW-CARBON TRANSPORTATION AT THE SUSTAINABLE INNOVATION FORUM 2018 – AFFILIATED EVENT OF COP24 Delta, a global provider of power and thermal management solutions, participated in the Sustainable Innovation Forum 2018, represented by its senior vice-president and general manager of its Information and Communication Technology Business Group (ICTBG), Mr. Victor Cheng, in the “Overcoming Infrastructure and Charging Challenge” panel discussion.

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he panelists, who also included reputable institutions in the field of e-mobility, such as the City of Milan, the City of Paris, and the Deutsche Post DHL proposed ideas to ramp up the development of electric vehicle (EV) charging infrastructure. Moreover, Mr. Cheng underlined Delta’s unique capabilities in supporting low-carbon transportation through its cutting-edge smart green solutions, which include EV charging, energy storage technology and automotive electronics.

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During the panel discussion, Mr. Victor Cheng, mentioned, “Buildings and transportation are the key industries for mankind’s goal to contain further global warming by 1.5°C. Over the past twelve years, Delta has enabled 27 green buildings across the world by integrating its building automation solutions. In the transportation sector, we are supporting the world’s leading EV makers with our automotive electronics technology, such as, on-board chargers, DC/DC converters, traction motors, etc.. We have shipped more than 300,000 AC EV Supply Equipment (EVSE) units and over 3,500 DC EV chargers, and also have provided our energy storage technology to electric buses currently operating in Poland, the U.S.A., Spain and Turkey.”

The aforementioned panel took special interest on the technologies and mechanisms that shall mitigate the impact of mass EV charging to the electricity grid. In this regard, Delta is advancing microgrid-supported EV charging infrastructure capable of enhancing demand response flexibility by integrating its own renewable energy, 18 | Industry EMEA | January 2019

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power conditioning, energy storage and smart energy management systems. Furthermore, Delta is developing vehicle-to-home/vehicle-to-grid (V2H/V2G) EV chargers that shall allow users to use their EV batteries as mini power plants to support the grid. Delta’s R&D-fueled innovation drive is nurturing distributed energy resources to support low-carbon transportation for sustainable cities.

Delta, with a growing global presence in five continents, has business development as well as R&D capabilities in Poland, home country of the 2018 UN Climate Change Conference (COP24). Our Polish R&D talents are focused on the development of power systems, renewable power and energy storage. In collaboration with partners, Delta’s battery technology supports electric buses currently servicing commuters in Warsaw and other Polish cities. In addition, Delta’s power systems feature industry-leading energy efficiency to enable improved energy savings and productivity in a wide range of mission-critical applications in Poland, such as airports, telecom operators and financial institutions. Lastly, Delta has integrated its EV charging solutions and energy storage to support its local partners’ EV charging infrastructure in major cities in Poland and Slovakia, including Katowice, the host city of COP24, providing EV charging services during the conference.

The Sustainable Innovation Forum 2018 is the 9th edition of one of the most relevant affiliated events of the COP conferences. The event delivers high-level policy discussion and debate, structured and informal networking and inspirational keynote speeches by leading ministers, cities, multilateral organizations, investors and private sector vendors and solution providers. www.deltaww.com

THREE LETTERS. TOTAL QUALITY. NSK sets many things in motion – for example in the steel & non-ferrous industries. As a leading global manufacturer of rolling bearings, NSK combines 100 years of success and a total quality approach.

www.nskeurope.com

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SWITCHING TO NSK BOOSTS LINEAR GUIDE LIFE

BY A FACTOR OF NINE

A UK-based manufacturer of hygienic wipes (wet wipes) is enjoying the benefits of replacing standard linear guides with those manufactured by NSK.

NSK linear guides feature stainless steel sliders and a specially coated rail. The ‘stacker feet’ section uses one slider held stationary, while the rail with a foot mounting is driven up and down in quick succession to compress the wet wipes

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fter experiencing persistent and expensive breakdown situations, the company opted to upgrade by fitting NSK linear guides, which thanks to their stainless steel sliders and specially coated rails, have delivered a nearly nine-fold increase in working life. Installed within the framework of an NSK Added Value Programme AIP, the move has resulted in improved machine performance, as well as reduced maintenance and downtime costs.

The company makes wet wipes for domestic and cosmetic use. However, the plant was having an issue with its converting, cutting and stacking line, which sections and compresses the wet wipes ready for packaging. Here, frequent failures were occurring of the linear guide found on the ‘stacker feet’ section.

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The ‘stacker feet’ section uses a linear guide with the slider held stationary, while the rail with a foot mounting is driven up and down in quick succession to compress the wet wipes.

It could be observed that the material used to manufacture both the rail and slider elements of the linear guide was high-carbon bearing steel, with standard seals attached to the slider.

Unfortunately, the impact of linear guide failure was proving costly for the plant, with increased maintenance and unplanned downtime. Each failure, which on average occurred every two weeks (26 times a year), would result in downtime costs of around €410 per hour. For every failure event, an engineer would require 30 minutes to replace the guide.

Understandably, the company wanted to find a solution to improve machine performance and extend linear guide life. NSK’s engineering team was duly invited to visit the site and review the application. This process revealed that the existing linear guides were frequently failing due to corrosion and the ingress of chemical fluid, causing seizure from grease washout.

Following the review, the engineers recommended replacing the standard linear guides with NSK linear guides featuring stainless steel sliders and specially coated rails.

Since implementation, breakdown events have been reduced significantly. Whereas the plant was previously experiencing 26 breakdowns a year, the company has witnessed just three in 12 months using the NSK linear guides – an impressive 88% decrease. In turn, the company has achieved significant savings in linear guide, downtime and repair costs. www.nskeurope.com

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NEWS

PAY IT FORWARD THIS NEW YEAR – REWRITING THE CODE ON CAREER DEVELOPMENT This Festive and New Year period Packt Publishing Ltd are commissioning their newest group of authors – you, the everyday expert – in order to help the next generation of developers, coders and architects.

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ackt, a global leader in publishing technology and coding eBooks and videos, are asking the technology community to ‘pay it forward’ by looking back at their career and paying their advice forward to support the next generation of technology leaders via a survey. The aim is to rewrite the code on career development and find out what everyday life looks like for those in our community.

The Pay it Forward eBook that will be created, will provide tips and insights from the tech profession. Rather than giving off the shelf advice on how to better your career, Packt are asking everyday experts – the professionals across the globe who make the industry tick – for the insights and advice they would give from the good and the bad that they have seen.

The most insightful and useful responses to the survey will be published by Packt in a new eBook, which will be available for free in early 2019.

As a thank you, survey respondents will automatically be entered into a prize draw to win one of 10 annual Packt subscriptions worth $300.

Commenting on Pay it Forward, Packt Publishing Ltd CEO and founder Dave Maclean, said, “Over time we all gain knowledge through our experiences. We’ve all failed and learned and found better ways to do things. As we come into the New Year, we’re reflecting on what we have learnt and we’re calling on our community of everyday experts to share their knowledge with people who are new to the industry, to the next generation of changemakers.”

“For our part, Packt will produce a book that pulls together this advice and make it available for free to help those wishing to pursue a career within technology.”

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Some of the questions Pay it Forward will seek answers to, include: • What is the biggest myth about working in tech?

• If you could give one career hack, what would it be?

• How do you keep on top of new developments and news?

• What are the common challenges you have seen or experienced in your profession?

• Who do you most admire and why?

• What is the best piece of advice you have received that has helped you in your career?

• What advice would you give to a student wishing to enter your profession?

• Have you actually broken the internet? We all make mistakes, how do you handle them?

• What do you love about what you do?

People can offer their responses here: http://payitforward. packtpub.com/

The survey should take no more than 10 minutes to complete and is in complete confidence, with no disclosure of names or details, unless agreed. www.packtpub.com 18 | Industry EMEA | January 2019

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NEWS

SIC MARKING AT THE CUTTING EDGE OF INNOVATION

An important event was organized in Lyon on the 20th of November by CARA (the European Cluster for Mobility solutions): the 4th edition of Automotive Techdays.

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IC Marking has been selected as one of the most innovative players in the Automotive sector. They presented an All-in-one compact laser marking solution with a micro safety enclosure. This flexible solution is compliant with automotive standards. Options include an embedded 3D measuring system answering to the new Industry 4.0 trend.

This innovative system has been developed by the R&D team thanks to the Operational Excellence program and offers many advantages for their customers :

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• Enhance productivity thanks to quicktool changeover, shorter marking time, • less production waste • Cost savings: compact footprint, low maintenance, fewer consumables, • 100% real-time quality control and increased reliability • Permanent marking on lightweight materials: steel/ composite/aluminum/additive manufacturing/plastics

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SIC Marking is an international company developing innovative permanent marking solutions and automated identification for the complete traceability of industrial components. For over 30 years, SIC Marking has engineered a full range of technically superior marking machines in dot peen, scribing and laser technologies. www.sic-marking.co.uk

NEWS

ADVANTECH'S GLOBAL GAMING HQ, IN NEWCASTLE, UK CENTRE GEARS UP TO MEET HIGHER DEMAND

Advantech, a leader in global intelligent systems, announced the expansion of its Advantech-Innocore facility in Newcastle-Upon-Tyne (United Kingdom). The gaming division, Advantech-Innocore, who are a leader in embedded computer products, design and manufacture some of the market’s most advanced PC products tailored specifically for their industry.

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he expanded Advantech-Innocore facility, located in the Silverlink Business Park, where the company established itself some ten years ago, has nearly doubled in size. The team, currently celebrating 20 years in the industry, has grown year on year and is set to grow further as a result of current market demands.

www.advantech-innocore.com Video available here: https://www.youtube.com/ watch?v=UynhODEINKw&feature=youtu.be

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“This expansion is excellent news for both AdvantechInnocore and the local community. It’s a direct result of the hard work and commitment by all of the gaming team, along with the loyal support of our customers, enabling us to post a 6-year CAGR of more than 30%” said Edward Price, Managing Director, Global Gaming and EU Displays Division at Advantech. “Some of our flagship products were created right here in the UK – including the best-selling DPX range of embedded boards which are approved in all major gaming jurisdictions, and running hundreds of thousands of slot machines and lottery terminals worldwide. Expanding our current facility was a logical choice for us as it helped minimise disruption.”

For its part, parent company Advantech is accelerating the deployment of branch locations globally, to better leverage its 25 years of local industry experience.

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NEWS

LOCAL MP ANDREA JENKYNS SWITCHED ON MULTISITE CHARGERS INCLUDING A 120KW ULTRA-FAST CHARGER THAT HAS SET A NEW BENCHMARK IN ELECTRIC VEHICLE (EV) CHARGING

Attendance at Morley HQ by local MP Andrea Jenkyns .

On the 15th of November 2018, Alfa Power installed and tested its latest charger, and the specifications have been calibrated to achieve 120kW. For now, Alfa Power has decided to cap the supply at 100kW. The ultra-fast charger will be unlocked to achieve its full potential when the market requires. The ultra-fast charger underwent a successful live test at the public launch event and will be available for public use via the My Alfa Power network in the very near future.

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ocal MP Andrea Jenkyns pushed the button that launched a new cluster of sites that went live on the growing network of electric vehicle chargers on the Alfa Power network.

Alfa Power’s newest installation is strategically positioned within the new clean air zone in Leeds, which allows the business to contribute clean fuel options for motorists in the area (CleanairLeeds, 2018).

Charge points With the launch of a 120kW charger, Alfa Power have broken their own UK record of 60kW, effectively doubling the capacity available to EV drivers in the UK. Alfa Power officially launched the 120kW charger at their special event in Morley. The newly installed charging point is located in Leeds, on Bristol Street by Sheepscar junction off the A61, making it an ideal location for motorists who need to charge their vehicle without having to enter the busy route to Leeds city centre.

In September, Alfa Power broke the long standing industry Rapid charging benchmark of 50kW with its 60kW upgradable rapid charger at Crown Service Station Brighouse.

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Since the launch of their first 60kW charger the business has launched many more sites at this new benchmark, and this time the aim was to exceed that record at their multi-site launch.

Like the 60kW rapid charger, the 120kW ultra-fast charger offers simultaneous AC and DC charging options. Both these Alfa Power chargers are capable not only of quick charging but also simultaneously charging up to 4 vehicles together.

Unlike any other charger in the UK market this unit offers

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Six cars from our fleet charging simultaneously including four from the same ultra-fast charger.

both DC delivery options (CCS and CHAdeMO) to be used simultaneously as well as Rapid AC type 2 delivery at 43kW and an open type 2 socket that is capable of up to 22kW charging.

All the new chargers launched at the event will be available for public use, with many more of Alfa Power charging points set to open in the near future across the UK and beyond.

Alfa Power’s first birthday Alfa Power also hosted an exclusive event for its first year birthday celebration, where the business launched a cluster of new sites, and showcased the latest and greatest electric vehicles and offered charging demonstrations using this range of EV’s.

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Alfa Power’s support to the governments initiative Alfa Power support the current Government’s strategy in reducing hazardous emissions and providing clean air zones, which can only be achieved by providing alternative sources of energy, which includes a ubiquitous network of EV charge points across a nationwide footprint.

Alfa Power’s move to make the fastest charging options available to all EV drivers heralds their arrival as a substantial player in the UK’s EV industry. www.alfapower.co.uk

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NEWS

EMERSON’S NEW ULTRASONIC WELDING PLATFORM MEETS CHALLENGES OF CRITICAL SMALL PLASTIC PART ASSEMBLY

IIoT-enabled Branson GSX Platform provides precise control for faster, repeatable, high quality welding of intricate components.

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merson has launched a new generation of ultrasonic welders that support the growing demand for the assembly of smaller and more intricate plastic components. The Branson GSX Ultrasonic Welding Platform is an advanced and intuitive flexible joining solution, designed to optimize and ensure quality welds, while helping manufacturers meet project timelines and deliver expected return on investments.

Plastic components across the medical, electronics, and automotive industries are becoming increasingly miniaturized, with embedded electronics, intricate designs and thinner plastic walls. Conventional welders with high or crushing trigger forces inhibit customers to safely weld small and fragile parts. To meet this challenge, Emerson has developed an Electro-Mechanical Advanced Actuation System that provides unprecedented control and position accuracy. This leverages Branson’s 70+ years of ultrasonic application experience and combines servo-mechanism, software optimization and Branson proprietary dynamic follow-through to enable a broad range of trigger forces to be applied, including the industry’s lowest, ensuring weld precision and control. The Advanced Actuation System also enables the GSX to improve position accuracy, leading to faster, high performance welding of very fragile and intricate components.

The highly configurable GSX welding platform enables customers to accommodate many different parts and application types by using an array of welding parameters and actuation modes during a single weld. This ensures better, consistent, quality welds leading to fewer rejects.

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Using a multicore processor and a linear encoder drive, the multi-tier advanced actuation system can be instantaneously adjusted based on real-time feedback. This ensures the same level of precision and repeatability across multiple welders.

tooling can be replaced in less than five minutes compared to conventional ultrasonic welders which can take over 1 hour. The ability to execute faster changeovers enables a variety of components to be welded with limited disruption to production schedules.

The modular GSX Platform forms the basis for a wide range of models to be launched over the next two years, each designed to suit the needs of specific customer applications. The platform can be configured for all customer environments, ranging from standalone benchtop systems to semi- and fully-automated manufacturing lines. By offering easy integration into a digital environment and standardized transfer of relevant data, the GSX Platform is Industry 4.0/IIoT-enabled, providing access to actionable performance and diagnostic data, supporting production efficiency, traceability and maintenance improvements.

“To remain competitive, manufacturers must bring products to market faster to maximize profitability,” said William Vaughan, Vice President Global Marketing, Assembly Technologies, Emerson. “The Branson GSX provides six sigma levels of quality, repeatability, traceability and increased production throughput to ensure successful delivery of a product line’s expected return on investment.” www.emerson.com/en-us/automation/branson

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Increasingly challenging production timelines, that must be met to ensure a project’s expected return on investment, are inhibited by a loss of operator experience and expertise. Helping to bridge any potential skills gaps, the GSX features simple and intuitive software, supported by 4” and 12” touchscreen HMIs, which enable operators to perform faster, correct set-ups and reduce application testing time. This leads to faster start-up, by up to 60% in most application cases, with an assurance of weld quality and increased production efficiency. By retaining alignment information and set-up within the assembly, a GSX stack and 18 | Industry EMEA | January 2019

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CAST IN CONCRETE - INNOVATIVE VIBRATION DAMPING ON TRUCKMOUNTED CONCRETE PUMPS WITH STRAIN SENSORS

The trend on truck-mounted concrete pumps is for greater reach with less weight. Technical advances at Schwing are currently making it one of the market leaders in this field. In order to raise operator comfort levels on truck-mounted concrete pumps with large booms, the company has launched an innovative vibration damping system.

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chwing, in partnership with Baumer Electric AG, has developed a new strain sensor with an IP69K protection rating and an exceptionally broad measuring range to provide precise signaling of deflections as they occur in the boom.

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Since its formation in the 1930s, the German group of companies has been designing, constructing and selling pumps, machines and plant equipment for the production, transport and reprocessing of concrete: batching plants, truck-mixers, stationary and truck-mounted concrete pumps as well as recycling plants. Whether concreting a swimming pool in the front garden of a family home or realizing prestigious public projects such as the One World Trade Center in New York, USA, or the third Bosporus bridge in Turkey, the machines and plant are deployed wherever concrete is used to provide permanent stability. With six manufacturing sites and subsidiaries or representatives in more than 100 countries, the company provides efficient, reliable and long-term solutions throughout the world. Extensive in-house production capacity for core 18 | Industry EMEA | January 2019

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components guarantees strict inspection processes and high product quality.

Truck-mounted concrete pumps of various sizes and types are manufactured at sites in Herne (Germany), Chennai (India), and Sao Paulo (Brazil). The models with the longest placing booms are manufactured at the SCHWING Group’s German headquarters. With a new boom drive concept, high-strength steel, less weight, and more operator comfort, they are Schwing’s answer to the market's increasing demands in terms of economics, ecology and ergonomics.

Tough construction site conditions Modern placing booms have a reach of almost 65 meters.

With highly efficient twin cylinder piston pumps and a pressure of up to 85 bar, they pump concrete at up to 164 m3 per hour. This obviously causes vibrations in the boom. In order to be able to offer end users improved operator comfort at the end hose, Schwing has developed an innovative vibration damping concept which has included a complete revision of the hydraulic elements. A precision transducer was required which could pick up the

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elongations from the signal boom caused by movement of the whole placing boom, and which would then transmit the command variables for the vibration damping. A force sensor would have to be mechanically built into the direct flow of forces from the arm and then exactly matched to the machine geometry. It was possible to significantly reduce the development effort by absorbing the movement over the elongation. The effect of a force always produces elongations in a mechanical structure. These elongations depend on the geometry of the structure to be measured and the modulus of elasticity.

“We are very pleased with our collaboration,” confirms Vierkotten. “The innovative damping system is also available for the latest S 65 SXF truck-mounted concrete pump from SCHWING which was launched at the beginning of 2018 at the World of Concrete trade fair in Las Vegas. Following comprehensive prototype testing and optimization during the development phases, the new DST55R strain sensor was successfully put into volume production by Baumer. We can imagine using Baumer sensors for future projects on our truck-mounted concrete pumps.”

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Customer-specific solution “We developed a customer-specific, innovative strain sensor in close collaboration with Baumer Electric AG which comfortably overcomes all the challenges,” explains Reiner Vierkotten, Senior Engineer Control Systems at SCHWING GmbH. “The new high-strength steels we have used allow the mechanical stresses and elongations to take place in higher areas than in previously used materials. Conventional strain sensors cannot operate in these areas.”

A completely new set of sensor mechanics was developed using FEM simulations with a measuring range of ±2000 µm/m. The easy-to-mount sensor with long-term seal functions perfectly in multi-shift operation in spite of the tough conditions on building sites. It is calibrated at the factory which speeds up installation and any possible replacement work. The new sensor, with its on-board electronics, supplies a high-resolution digital CANopen

signal directly to the truck-mounted concrete pump’s control system.

Compared to force sensors, which have to be precisely adjusted to the machine geometry, the strain sensor can be easily mounted at the optimum position with just two bolts. This does not affect the structure of the machine, save times in development and makes mounting easy. The robust design of the sensor makes it impervious to shocks, impacts, and other mechanical influences and is therefore ideal for use in the construction environment. At the same time, it is very gentle, reacts quickly, and can accurately detect even the slightest elongation or compression. It is resistant to wind and weather due to its a corrosion-resistant housing. With a certificated protection class of IP69K, its seal is absolutely guaranteed and can be cleaned with highpressure or steam cleaning systems.

www.baumer.com/DST55R 18 | Industry EMEA | January 2019

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COVAL’S NEW CVGL: A LIGHTWEIGHT VACUUM GRIPPER THAT CARRIES THE LOAD

The size and weight of the new CVGL vacuum grippers from COVAL make them the lightest and most compact range in the market. The strict regime meets the expectations of manufacturers who rely on vacuum handling technology for their products and packaging.

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Weight is the enemy” is a well-known motto in the world of racing cars. This same is true in robotics. By reducing the weight and bulk of its vacuum chambers, COVAL enables integrators and manufacturers to incorporate them into robots with lower payloads. This translates into significant savings in terms of investment and operating costs.

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The evolution has also occurred at the design level, resulting in a range of vacuum chambers with simplified lines. All connections are now carried out on top, completely freeing the sidewalls and guaranteeing greater ease of use, for example in boxing/unboxing applications.

Modularity Above All Despite the reduced size and weight, the CVGL is not a “light” version of the predecessor CVG range. They retain all the advantages of a modular range of vacuum grippers: 3 standard lengths (424, 624 and 824 mm, or custom-made to suit the application), 3 gripping interface technologies (foam, suction cups and COVAL-flex), 3 suction flow rates, integrated or external generator. They offer a “tailor-made” solution for vacuum handling of parts of various sizes, weights and materials.

An Example of the Benefits of FrenchFab The CVGL design is based on the expertise gained by COVAL, as a partner to integrators and manufacturers for nearly 35 years, and also the innovative capabilities of its in-house design team.

They fully complement the COVAL range of vacuum pumps, suction cups and accessories for vacuum handling in the packaging industry. The CVGL vacuum grippers are manufactured in Montélier, France, underlining COVAL’s commitment to the French Fab initiative.

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CVGL, What Makes the Difference: • Compact and lightweight • Standardization and modularity to ensure short delivery times • High adaptability

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PLUG AND PLAY

Kennametal’s new vibration-free boring system boasts a number of technological improvements that allows a plug and play operation.

An array of interchangeable heads that includes screw-on and lever-style clamping mechanisms in positive and negative rake configurations.

Kennametal makes deep boring easy.

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alk into most any machine shop and there’s a good chance you’ll hear it: the high pitch whine of a deep boring operation, the chatter loud enough to have even the most hard of hearing among us scrambling for a pair of ear plugs. It’s a problem that has plagued machinists since the day lathe inventor Henry Maudslay first chucked up a piece of steel and tried to bore a hole through it, and has only gotten worse as metals have grown tougher and more challenging to machine.

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Not anymore. Kennametal’s latest weapon in the war on chatter is one that will have machinists everywhere saying, “I need that.” The new boring system boasts the most effective anti-chatter mechanism ever developed by Kennametal, and also offers an extensive range of indexable heads and shank sizes.

Enter the Vibration-Free Zone Someone who knows all about it is Sam Eichelberger, product engineer for lathe systems engineering and part of the team that developed the internal dampening mechanism. “Perhaps the most important thing to know about the new bar is that it’s plug and play,” he says. “There's 18 | Industry EMEA | January 2019

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no need whatsoever for tuning or adjustments—you simply pull it out of the package, mount it in the turret, and get boring.”

There’s more to the story than making the shop a quieter place to work, however. Eliminating vibration and therefore chatter greatly extends tool life, never mind its positive effect on part surface finish. And when tools last longer, they can be pushed harder, with feed rates, cutting speeds, and depths of cut many industry experts once thought unachievable.

Eichelberger is one of them. He lists a number of features that not only make the vibration-free boring system the most easy-to-apply bar you’ll ever bore with, but also the most productive. These include a serrated, bolt-on connection at the bar’s business end that securely clamps a variety of styles and sizes of indexable heads.

Better yet, the heads themselves have been put on a diet, with a shorter length and lighter weight that provides greater stability, contributing to the bar’s improved performance. They’re also coolant-fed,

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Setting the head exactly on centerline is as easy as bringing the angle finder display to zero and locking the bar in place.

to precisely direct a stream of high-pressure coolant where it’s needed most. The result is hassle-free chip control together with maximum cooling in the cutting zone.

Most important of all is the internal dampener. Said Eichelberger, “The bars are both vibration and maintenance free. Within the bar there sits a mass that's supported by a pair of elastic supports, inside of which sits a dampening fluid. This mass vibrates at a predetermined frequency during machining, attenuating the natural frequency of the bar around it to suppress vibration. There are no wear components to worry about, nor tuning—as Sam mentioned, you just set it and forget it.”

The vibration-free system offers superior performance in boring applications up to 10X diameter deep, Eichelberger explained, much deeper than solid carbide or heavy metal boring bars are capable of. Internal and customer test results show surface finishes as good or in most cases better than competitive “quiet bars,” with significantly more aggressive cutting parameters possible across the board.

Anyone who’s ever struggled to get a boring bar exactly on center will appreciate the fact that setup is extremely easy. “There’s a reference flat on the top of the head that accommodates a visual angle finder,” Eichelberger pointed out. “You just rotate the bar until the indicator reads zero, then clamp it in place.”

Considering the higher cost of a such a boring system, they’ll also appreciate the fact that the heads are replaceable in the event of a crash, avoiding damage to the bar itself. And users of Kennametal’s older boring system will find that their new heads fit perfectly with the use of an adaptor.

“The portfolio for our Imperial bars ranges from one-inch in diameter up to four inches, while the metric version starts at 25 mm and goes to 100 mm,” Gable said. “There are a variety of interchangeable head styles available as well, everything from screw-on positive rake inserts for fine-finishing needs to negative rake, clamp-style geometries for heavy roughing.

The bar’s designed to excel in demanding applications, and that’s exactly what it does.”

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Of course, boring bars are only as good as the method by which they’re clamped in the machine. Kennametal has addressed this critical consideration by supplying machinespecific turret adapters, along with a special split sleeve bushing for maximum rigidity. “That’s the goal of this product,” says Kennametal global product manager John

Gable. “The greatest stability possible and the most effective dampening solution available, period.”

www.kennametal.com

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35,000 published articles in 2017: EMEA: 48% - Asia: 31% - Americas: 21%. Most of the articles are published in the top 1000 media worldwide.

With a proven process set for more than 120 active customers, we can adapt to all specific client needs with the highest reliability.

We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.

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