INDEX
02. INDEX
THE SATISFACTION OF A DREAM COME TRUE
.03
MESSAGE OF THE MANAGEMENT
.04
INNOVATION TOUR
.06
NEW ADVANCED HEAD MANUFACTURING CENTRE
.08
A SHORT REVIEW OF THE HEAD AND QUILL RANGE
.10
A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE
.12
MILLING & BORING: FINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL
.16
IMPROVED PRECISION IN LARGE WORKING VOLUMES FOR ANY HEAD
.17
MORE ACCURACY IN THE WORKING AREA
.18
FV MODEL: 5 AXES CONTINUOUS HIGH SPEED MILLING
.19
OPTIMUM PERFORMANCE UNDER CONTROL
.20
CYCLES DEVELOPED FOR SPECIFIC NEEDS
.21
PHOTOGRAMMETRY: FAST PART FITTING
.22
ACTIVE/PASSIVE DAMPING SYSTEM: INCREASING PRODUCTIVITY
.23
APPLICATIONS CORNER
.24
INNOVATION CORNER
.25
SORA-NEWS
.26
THE SATISFACTION
OF A DREAM COME TRUE
Half a century on, SORALUCE not only continues to grow against the physical backdrop of the banks of the Deba River, but also continues to transcend its geographical limits through the joint effort of the founders and those who continue their work, turning this local reality into a globalised success. The SORALUCE brand name, through a wide network of alliances and subsidiaries, is today present in all five
continents and is a world reference point in the design and production of milling-boring machines, basing its prestige on constant technology innovation and a philosophy of excellence. These assets have provided the heirs of this great undertaking with a vocation for leadership, without forgetting the original aspiration to create a company model that would be solidarity-minded and fairer for all.
THE SATISFACTION OF A DREAM COME TRUE .03
MESSAGE
OF THE MANAGEMENT SORALUCE is celebrating its first halfcentury this year, but it is also embarking on the start of a new stage in its existence. The future is complex and there are major challenges on the horizon, but there are also many opportunities for a company whose trademark has been to overcome all the obstacles in its path with courage, innovation and commitment. These are complex times, and rapid transformation means a company must mobilise all its skills. SORALUCE S.Coop is therefore conducting profound strategic reflection to decide on the most efficient way of using its resources and alliances to take on the challenge of growing, changing and assuming more risks. It is doing this through an important process called SORALUCE’s Third Cycle of Change, which involves a series of projects and initiatives with the aim of consolidating the company’s leadership on a world level. This far-reaching Strategic Plan aims to encourage product and market development and to empower SORALUCE’s teams of
04. MESSAGE OF THE MANAGEMENT
people so that we can keep on growing while at the same time accomplishing our basic tasks with excellence and improving the company’s day-to-day work. The aim of this is to be able to compete globally, meeting the needs of a wide, diversified base of geographical markets and customer sectors through technology, product range, quality, service and competitive prices. But this action must also be invested with great dynamism. Today’s business world is highly globalised, fast-moving and complex. If a company stands still, it will be out of the action. And advancement involves constant heavy investment, which is only possible if sufficient financial profit is generated each year.
Rafael Idígoras, Managing Director of SORALUCE
People
High-performance systems and processes
Placing all this in a working context and taking into account the increasingly open, demanding, changing, collaborative, selfmanaged and international environments, what matters is the experience acquired by SORALUCE’s people and teams through each project they are involved in.
It is necessary to implement highperformance systems and processes. High-performance systems require simple processes, and simple processes have complex work behind them, which means people must produce more through the work they carry out. This increased work means a need for more highly qualified people, with a global vision and a strategic and operational framework of action backed by new systems, processes and forms of interaction within and outside SORALUCE.
It is therefore vital to develop a global vision throughout the organisation, to trust in our people and our management capabilities and the company’s own management capacity, and to promote and facilitate empowerment and commitment of all the people making up the organisation. Associations SORALUCE’s aim is also to enhance its capacity for creating important associations, both within the company and outside it, encouraging people to help each other to develop new possibilities for action, as companies are more and more competitive as regards skills and qualification.
MESSAGE OF THE MANAGEMENT .05
Bird´s eye view of the Headquarters in Osintxu
Start
P1
P3 P4
INNOVATION TOUR
The visit consists of a guided tour around the company to see how SORALUCE applies technologies it has developed itself and adapted to the actual production range in order to improve customer competitiveness. The visit will be developed at the OSINTXU PLANTS (P1 – P3 – P4). Detailed discussions customised to the requirements / interest of each customer will be able to be discussed afterwards.
We kindly request that you follow the General Safety Rules, do not trespass the marked lines. The drawing shows the path to follow as well as what can be seen in each place. Taking pictures / videos is strictly prohibited without the permission of SORALUCE personnel.
06. INNOVATION TOUR
P1
Plant # 1 New Advanced Head Manufacturing Centre and Module Assembly Workshop.
New advanced head manufacturing centre dedicated to the design, machining, assembly, checking and service for HEADS and QUILLS.
Refer to Page. 8-9
Area dedicated to the assembly of X-axis subassemblies as well as Y/Z modules for the machines.
P3
Plant # 3 Assembly plant for SP-FP-FS-FR models.
P4 P3
Plant # 4 Assembly plant for FR-FX-FXR models.
P4
Refer to Page. 20 Refer to Page. 16 Life machining trial
Active damping system
Refer to Page. 23 Refer to Page. 17
Refer to Page. 18
Photogrammetry demonstration. Machining simulation
Refer to Page. 22 Volumetric calibration CUSTOMER AREA Innovation Corner
Refer to Page. 25 Applications Corner
Refer to Page. 24 5 axis continuous high speed milling machine FV. Life machining trial
Refer to Page. 19 Milling and Vertical Turning in one machine. New F-MT concept. Machining simulation Showed machine
Refer to Page. 15
In production
INNOVATION TOUR .07
NEW ADVANCED
HEAD MANUFACTURING CENTRE
08. NEW ADVANCED HEAD MANUFACTURING CENTRE
“SORALUCE HAS A CLEAR TECHNOLOGICAL VOCATION THAT LOOKS AFTER THE PRECISION AND THE RELIABILITY AT ANY TIME. FOLLOWING THESE PREMISES SORALUCE PRESENTS THE NEW ADVANCED HEAD MANUFACTURING CENTRE.”
Design
Manufacturing
Verification
Assembly
Running-in NEW ADVANCED HEAD MANUFACTURING CENTRE .09
HIGHLY RELIABLE AND ACCURATE HEADS SORALUCE milling-boring heads are acknowledged as being in a class of their own thanks to their high reliability. The broad range of SORALUCE heads (Universal, Orthogonal, Horizontal, Modular Quill, Angular, Special, etc) are distinguished by their precision and high performance, enabling complex milling, boring, drilling, reaming and taping operations to be performed with great accuracy. Complete design, manufacturing, assembly and verification processes are conducted in-house, under the same roof, by an experienced team of highly skilled designers and assembly engineers.
10. HIGHLY RELIABLE AND ACCURATE HEADS
To ensure high quality heads, the workshop is equipped with state-of-the-art, temperature and humidity controlled, high precision manufacturing machinery and assembly equipment. With strict in-process quality controls and exhaustive run-off on specific test benches, SORALUCE certifies the highest quality for the most critical elements on this kind of machines.
A SHORT REVIEW
OF THE HEAD AND QUILL RANGE
A WIDE RANGE OF GENERAL PURPOSE HEADS AND QUILLS Automatic indexing head
Orthogonal head
32 / 46 kW 2.5º x 2.5º / 1º x 2.5º / 0.001º x 0.001º 3000 / 4000 / 5000 / 6000 rpm
32 / 46 kW 2.5º x 2.5º / 1º x 1º / 1º x 0.001º 4000 / 6000 rpm
Fixed horizontal boring head
NC facing and boring head
Up to 60 kW 3000 / 4000 / 5000 rpm
Automatic angular rotary head with manual tool change
Modular quill spindle · Ø 130 mm, W=700 mm, 46 kW, 2500 (3000) rpm · Ø 150 mm, W=1000 mm, 71 kW, 3000 rpm · Ø 180 mm, W=1000 mm, 71 kW, 2500 rpm
AND SPECIFIC SECTOR / APPLICATION HEADS
THAT CAN BE INTERCHANGED AUTOMATICALLY
Angular head for Railway bogie machining
Angular head for motor block machining
5 Axis continuous head for Mould and Die and Aeronautics
A SHORT REVIEW OF THE HEAD AND QUILL RANGE .11
A SHORT REVIEW OF OUR CURRENT PRODUCTION RANGE
T RANGE HIGH PERFORMANCE IN A COMPACT MACHINE MACHINE VERSIONS MACHINE MODELS
Moving table TA-A / TR
Moving-rotary table TA-D
LONGITUDINAL TRAVEL - “X” AXIS
2000 – 2500 – 3500 – 4500 – 5500
mm
VERTICAL TRAVEL - “Y” AXIS
1000 – 1250 – 1400 – 1600 – 1800
mm
1000 – 1200 – 1300
mm
(TA-A / TR) 2200 x 850 mm to 5860 x 1200 mm (TA-D) 1000 x 1000 mm to Diam 1400 mm
mm
Up to 16.500 kg
Kg
24 - 28 - 43
kW
4000 – 5000 – 6000
rpm
CROSS TRAVEL - “Z” AXIS TABLE SURFACE LOAD ON THE TABLE SPINDLE POWER HEAD SPEED
_ Long-lasting precision, resulting from a strict design and assembly process. _ Optimum stiffness and mechanical stability. _ High stock removal capacity and precision machining in one single machine. _ Customizable machine thanks to a huge variety of heads and options available. _ Complete splash guarding. _ Designed to be compact and ergonomic. 12. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE
S RANGE ERGONOMIC AND LARGE CAPACITY MACHINE MODELS
SL / SP 2500 – 3500 – 4500 – 6500 – +2000·n
mm
VERTICAL TRAVEL - “Y” AXIS
1600 – 2000 – 2600
mm
CROSS TRAVEL - “Z” AXIS
1000 – 1300– 1500
mm
43 (Direct Spindle motor)
kW
4000 – 5000 – 6000
rpm
LONGITUDINAL TRAVEL - “X” AXIS
SPINDLE POWER HEAD SPEED
_ High flexibility and high precision finishing machining results. _ High performance and efficiency provided by a high torque direct drive spindle motor. _ A wide range of accessories can be installed in the work area to improve production capacities. _ Pendulum machining, minimizing non-productive times. _ First class ergonomy and stability with very low foundation cost.
A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE .13
F RANGE PRECISION FOR LARGE DIMENSIONS MACHINE MODELS
FL / FP / FS / FR / FX / FX-R 3000 – 4000 +2000·n
mm
VERTICAL TRAVEL - “Y” AXIS
1400 – 8000
mm
CROSS TRAVEL - “Z” AXIS
1000 – 1900
mm
QUILL TRAVEL - “W” AXIS
Up to 1000
mm
28 – 71
kW
4000 – 5000 – 6000
rpm
LONGITUDINAL TRAVEL - “X” AXIS
SPINDLE POWER HEAD SPEED
_ Accurate and efficient machining results. _ Remarkably versatile - efficiently and precisely customised for any specific customer need thanks to the wide range of options available. _ Large range of Automatic Heads, Boring heads, Quills and special heads. _ Low gravity centre design in all the range: improved stability and reduced foundation costs.
14. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE
F-MT RANGE
MULTITASKING MACHINING
MACHINE MODEL LONGITUDINAL TRAVEL - “X” AXIS VERTICAL TRAVEL - “Y” AXIS CROSS TRAVEL - “Z” AXIS SPINDLE POWER HEAD SPEED
F-MT RANGE 3000 – 4000 – 5000
mm
1600
mm
1000 – 1300
mm
43
kW
4000 – 5000 – 6000
rpm
_ Integration of several processes in one machine: traditional milling machine operations + turning capabilities for heavy duty components, providing the possibility of manufacturing complex components in one machine and in one single setup. _ Flexible working area that can be configured to the customers’ needs with one or multiple working stations with fixed tables and rotary tables usable for both milling and turning operations. _ High dynamics: 45 m/min for the X axes and 35 m/min for the Y and Z axes, with acceleration of 2 m/s2 in each individual axis.
MILLING & BORING MACHINE .15
MILLING & BORING FINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL
SORALUCE has redefined the concept of Milling & Boring thanks to its new patent, unique on the market, for a Quill changing system that helps combine the benefits of the traditional boring machines with the advantages of modern milling machines, all in one single machine.
TRADITIONAL SOLUTION
SORALUCE SOLUTION
Long distance from the column to the spindle nose in automatic heads.
Short distance between the automatic head and the column.
That means:
That means:
Less than 32 kW for the indexing heads.
Need to move the component to machine one component on 5 faces.
Machine stopped during quill repairs and revisions.
Most stable solution: up to 46 kW @ S1 with Automatic / Orthogonal heads; up to 60 kW @ S1 with angular heads. Compact solution: the spindle axis of the indexing head is at the same distance as the spindle nose of the boring bar. Non-stop machining. The machine keeps on running all the time, even when checking the quill. Different quill diameters / lengths can be combined in the same machine. Full interchangeability with standard heads. Maximum flexibility thanks to the full Automatic Head & Quill Changing System.
The system interchanges the modular quill spindle with the rest of the heads totally automatically, thus allowing different quill spindles with different diameters and lengths (Ă˜ 130 - 180 mm / W: 700 - 1000 mm), to be available together with all the necessary heads to machine any component.
16. MODULAR QUILL
IMPROVED
PRECISION
IN LARGE WORKING VOLUMES FOR ANY HEAD
The Dynamic CNC Ram Balance System, patented by SORALUCE, basically takes care of the geometrical accuracy –straightness and parallelism- of the ram traverse over the Y and Z axis travels, and is specially suitable for machines equipped with extensive traverses and a head changing system. · CNC controlled The system is driven by a numerically controlled servomotor. Drive action is measured using a direct-measuring scale that checks actual system response. The system is 100% controlled at any time and in any position and with any head.
· Balance system The system works in both positive and negative directions. This means that optimum compensation can be achieved for a wide variety of head weights. The figures that can achieve are below 0.04 mm for the ram drop in the spindle nose and 0.04 mm/m on the level over the ram with any head and for a cross traverse of 1900 mm. These values are typically improved with figures below 0.025 mm and 0.025 mm/m respectively.
· Dynamic Configurable compensation values. Tables can be positioned anywhere in the work area. Works for any position. Different tables created for different heads. Real time customised compensation.
PATENTED
WO 2010/072856
Vertical Axis Saddle Servomotor
Damping System
Planetary reductor Planetary roller screw Measuring system
Fixed roller bearings
Figure of the DBS3 system
Loose roller bearings (one DOF)
RAM BALANCE .17
MORE ACCURACY IN THE WORKING AREA Thanks to the specific SORALUCE developments, head articulation positioning deviations have been reduced to a minimum. These allow for the compensation of head kinematic values and orthogonal position offsets (M10 functions), for any position in the work area. Some advantages of the system developed by SORALUCE: · Calibration for any type of head. · Calibration for any position in the work area. · Calibration for any angle, not just orthogonal. · Offset error compensation due to thermal expansion. · Distance between different head spindle noses is measured (machines with automatic head changing system). · Easy-to-use interface, 100% integrated with HEIDENHAIN iTNC530 HSCI and SIEMENS 840D SL.
18. ACCURA HEADS
Equip the machine with this pack and recalibrate the head yourself in a few minutes whenever and wherever you want!
FV MODEL
5 AXES CONTINUOUS
HIGH SPEED MILLING
MACHINE MODEL
FV
LONGITUDINAL TRAVEL - “X” AXIS
6000
mm
VERTICAL TRAVEL - “Y” AXIS
2500
mm
CROSS TRAVEL - “Z” AXIS
1200
mm
40
kW
8000
rpm
SPINDLE POWER HEAD SPEED
Specially designed for high precision moulds and dies machining, the FV high speed milling centre stands out for the following characteristics: _ Linear motors in “X “ and “Y “ axes with acceleration of 4.5 m/s2. _ “X “ and “Y“ axes at 60,000 mm/min speed and “Z“ axis at 50,000 mm/min. _ High dynamics. _ Centered cross slide. _ Giroscopic head at 5 axes.
5 AXES CONTINUOUS HIGH SPEED MILLING .19
OPTIMUM
PERFORMANCE
UNDER CONTROL
The current production scenario, unattended machining is becoming more and more important to continue with the tendency of increasingly cost efficient processes. SORALUCE Adaptive Control consists of an automatic adjustment of the defined cutting parameters depending on the real machining situation that is permanently monitored by the Adaptive Control Algorithm integrated into the CNC of the machine. This way, when the real working load on the spindle is less than programmed (less material than expected), the machine can speed up the feed, shortening the machining time. By contrast, when the working load is higher than programmed (more material than expected), the machine automatically slows down the feed to protect the machine and the workpiece.
路 Optimum Cycle Time 路 Unattended machining 路 Increased Machine life
The technology that supports this development is based on processing the signals transmitted from the monitoring process system to the machine control unit. This technology is indicated for roughing and semi-finishing process.
HMI
Adaptative control parameter CNC
Gain Adaptative Control algorithm
driver motor spindle
Power consumption WATTIMETRO
M
20. ADAPTIVE CONTROL
CYCLES
DEVELOPED Thanks to its accumulated knowledge of the customer’s real needs, SORALUCE develops and provides specific Custom Made User Cycles to facilitate programming of repetitive machining operations be performed in on complex components.
FOR SPECIFIC NEEDS
Additionally, SORALUCE incorporates cycles to guarantee the precision of rotary travelling tables: · Compensation of the rotary axis of the table. · Compensation of the tilting axis of the table.
This Custom Cycles pack includes cycles such as: · Pecking cycles drilling. · Tapmatic tapping. · Spiral milling by interpolation. · Conical milling by interpolation. · Radius milling by interpolation. · Chamfer milling by interpolation.
CYCLES DEVELOPED FOR SPECIFIC NEEDS .21
FAST PART FITTING RAW PART SET-UP SYSTEM BY
PHOTOGRAMMETRY Large raw parts require time consuming alignment processes, even more than the machining process itself for high added-value parts. Before machining starts, precise overstock distribution is mandatory. Alignment processes require two main steps: first, characterisation of raw part geometry, and second, alignment to machine axes. A new raw par set-up system is presented, based on 3D vision technology, with the aim of minimising the raw part alignment process time. The new solution consits of two main modules: Fitting and Alignment. Fitting module (stand-alone) enables the fast and accurate raw part geometry characterisation by photogrammetry. CAM programs are decoded for automatically determine the ideal part geometry to obtain by the machining process. Optimal raw part set-up in automatically determined, ensuring an adequate overstock distribution. As a result, optimal 3D coordinates of specific optical references fixed to the part are determined prior to its set-up in the machine. Alignment module (CNC integrated or stand-alone) enables the non-contact measurement of the optical references during the alignment process in the machine, by means of a machine integrated 3D vision based wireless system, automatically calculating the requerired fixturing corrections for the precise raw part set-up.
22. PHOTOGRAMMETRY
As a result, fast raw part fitting and alignment is possible with 1 mm precision. Main benefits of the system are: · Time savings: 70% on Fitting & 60% on Alignment processes. · Reduction of non-quality costs and Increase of work safety. · Floor space flexibility and availability: photogrammetric raw part measurement for fitting calculatiion, and a portable machin-integrated visión based system for alignment. · Independence from operator skills: automatic fitting and alignment criteria and algorithms.
Machine integrated 3D vision system
INCREASING PRODUCTIVITY
ACTIVE / PASSIVE
DAMPING SYSTEM
Nowadays, chatter is one of the main limitations of milling processes. Machine tool chatter vibrations cause an unacceptable surface finish on the workpiece reducing the life of the tool and the mechanical components of the machine. SORALUCE offers the solutions to overcome this problem through the ACTIVE / PASSIVE DAMPING System which consisting of an inertial actuator and a sensor placed close to the cutting point. The sensor measures the vibration and then the inertial actuator produces a force on the host structure according to a designed control law.
The control law is selected to introduce damping in the process. The main advantage of this technique is that the controller can deal with any change in the dynamics of the system. The performed tests shows that the appearance of chatter can be avoided in most of the cases with the ACTIVE / PASSIVE DAMPING System and the productivity of the milling machines are increased considerably: the material removal rate is doubled.
250 always unstable
depth of cut (%)
200 stable with the actuator
150 100 50
stable without the actuator
0 750
800
850
900
950
1000
1050
1100
1150
ram output (mm)
ACTIVE/PASSIVE DAMPING SYSTEM .23
APPLICATIONS CORNER
路 Technological and production services:
路 Training services:
- Turnkey projects: machining processes, tools, equipment and machining.
- Generic machine handling training.
- Individualized study of each production phase.
- Advanced training in machining processes:
- Specific CNC training.
- Analysis of cycle times with 3D simulations.
路 Tools, equipment, etc. 路 Measuring
- Analysis and optimization of production processes. - Advice on machining processes. - Integral solution and investment return study. - Customized software development depending on the application. - CAD/CAM programming and post-processor generation.
TURN KEY PROYECTS
Process
Machining Training
Tools
Vericut
Fixtures
CNC 24. APPLICATION CORNER
INNOVATION
CORNER
Conscious of the need to develop and innovate its products if it is to remain a market leader for Boring-Milling Machines, SORALUCE is backed by IK4-Ideko, the only Spanish Research and Development Centre dedicated exclusively to Machine Tools, which belongs to DANOBATGROUP. SORALUCE subjects all its components and machines to constant development at the IK4-Ideko Technology Centre. This ensures that the design of its products and productivity can be continually improved and adapted to the latest technological innovations.
DRIVEN BY IDEAS, DRIVEN BY INNOVATION
A number of research lines are continuously open in order to develop new solutions suitable for current and future needs of the manufacturing processes of different industrial sectors. During the present Innovation Days 2012, some innovations jointly developed and in pre-industrialization status will be shown in live as: 路 The Volumetric calibration, to improve the precision of the machine in the whole working area. 路 The use of the Photogrammetry, for setting up parts quickly and accurately. 路 The Dardo system, to eliminate tool vibrations by measuring and modifying the cutting conditions. 路 The Active damping system, to eliminate the chatter effect by the increase of the damping coefficient of the machine.
I N N O V A TION CORNER .25
SORANEWS
PRESS RELEASE
SORALUCE invests 6 million Euros extending its German delegation. SORALUCE, which specialises in the design and manufacture of milling-boring machines and milling centres, is to invest 6 million Euros strengthening its BIMATEC-SORALUCE delegation, in Limburg, Germany, with the aim of reinforcing its presence in the country, extending its installations and projecting an image to the world of its success in that country. Soraluce is part of the DANOBATGROUP, the machine tool division of MONDRAGON Corporation. Its German headquarters’ showroom is currently 1,300 m2 in size, and this is to be extended by 2,500 m2 in June 2012. In addition to the showroom extension, its current offices are also to be extended by 1,900 m2, which house administrative and customer support services (turnkey projects, after sales service, training etc.) in order to promote its activities. But the most noteworthy aspect of the changes will be its new showroom capacity, a 10 m crane height will allow the Guipuzcoa firm to present its 8 m high machines in this market.
At the end of 2008 it started extending its delegation in order to maintain and increase its lead in this market, and consequently in the rest of its export markets. The Managing Director of the Guipuzcoa firm, Rafael Idigoras, indicates that “Germany is of fundamental importance right now in economic, political, technological and industrial terms”. It is the leading consumer and producer of high technology machine-tools. The start of works coincided with the recent EMO 2011 machine-tool fair in Hannover, and are expected to be inaugurated in 2012, SORALUCE’s 50th anniversary, for which different events are being organised.
SORALUCE has been present in Germany for 20 years, where it manages its customer relations, accounts, installation and after sales services, etc. Fruit of its work over the years is its install base of 800 machines with leading customers.
Soraluce Italia started 2012 on the right foot in the big dimensions milling and boring machines sector. The Cimolai group, world leader in large-scale metal constructions has, for the second time, put its trust in Soraluce Italia by acquiring a Soraluce FXR-64000 milling-boring machine with record dimensions: 64000 mm longitudinal travel, 8000 mm vertical travel and a cross travel (including quill travel) of 2900 mm. The FXR-64000 is special not only because of its size, but also because its technological innovations and advanced level of automation. These include: Modular Quill, stepless universal head, horizontal head, special measuring probes unit, angular head, pick-up for heads, tool magazine and preparation for rotary travelling unit.
26. SORA-NEWS
It should also be mentioned that the FXR-64000 is ready for integration with a second column during phase two to optimise plant productivity. The Cimolai group investment means yet another record: execution and machining of parts 65 metres long, 6.5 metres high and 4.5 metres wide, forming part of a manipulation system to be installed in a single industrial bay of special dimensions and characteristics.
SORALUCE installs a new SP milling machine in the mining sector W orcester-based Joy Mining has taken delivery of a 5-axis SORALUCE SP 8000 travelling column universal milling/machining centre from T W Ward CNC Machinery. The machine has replaced an ageing Butler Elgamill CNC universal bed mill, which was used to machine castings, as well as flame-cut large plates.
Based on a 50-acre site, the 250-employee company produces components for armoured face conveyors, large gear cases, sprocket ring gears, framed components for powered roof assemblies and hydraulic rams, as well as performs assembly tasks on a range of large valves.
A key feature of the company’s work, of which 80% is exported, is small batch manufacture parts, requiring complex machining cycles – batches rarely exceed four-off. The expertise of its production engineers is key in delivering such parts competitively.
As part of the justification, Ward CNC had to ensure the machine met the specific requirements of Joy Mining’s management team against five other competitor machine suppliers.
As Robert Wilks, production engineering manager, explains: “Because much of our work is small batch and very diversified, the extensive skills of our setters and operators are key to not only running the machines, but also for tooling up, programming and for taking complete responsibility for the manufacturing tasks.” And in searching for a new replacement machine tool, Joy Mining was adamant it had to allow the company to gain maximum advantage from the strength of its skill base. Installed in September, the SORALUCE SP 8000 has halved cycle times and reduced tool costs on the castings and plates, while its ability to produce other components, such as large gearbox housings, has also been exploited. The machine’s Heidenhain iTNC530 with conversational interface provides the two setter/operators that man the SORALUCE around the clock with an ideal solution to prepare and program the next scheduled component while the machine works through the existing product cycle. Says day shift operator Ean Stamp: “As cycle times vary between one hour to two days (four shifts), we have ample time to work together and incorporate our machining experience in planning the next task, while overseeing the cycle that’s being run. This may not achieve the fastest cycle time, but ensures the part fully conforms to requirements.”
In addition, other key elements in the selection, justification and purchase of the machine included its ability to operate in a selfcontained, cell-type environment, as well as the pedigree of the builder and the supplier’s proven service record. With all other areas satisfied, the final hurdle was machining trials, carried out at SORALUCE’s HQ in Spain. As part of the buying process, SORALUCE had to satisfy the machining demands of samples of Hardox high strength and impact abrasion conveyor machinery. DEMONSTRATED SAVINGS Since installation, the machine has demonstrated overall savings of some 50% on milling and, in particular, drilling cycles, plus provided a significant reduction in tool costs, as a result of its inherent rigidity. Says Mr Wilks: “We very rarely have to change inserts, which is helping our tool inventory and costs.” A key feature of the machine is its use of the BT50 Big Plus patented spindle system. This has enabled Seco’s latest Performax indexable insert drills to be used for the first time as a test bed for the tooling supplier. Holes in brackets between 10 and 70 mm diameter, and bores up to 90 mm diameter have been produced from solid, employing the 20-bar through-the-tool coolant pressure. The SP 8000 also features adaptive feed control, DXF download and dynamic collision monitoring, plus Renishaw non-contact laser probing. Overall, the SORALUCE has achieved uptime of 80% - 75% was the target.
SMS orders large SORALUCE automated production line After 15 months of engineering, cutting tests and negotiations, SORALUCE has achieved one of the biggest orders of its history from SMS Meer, consisting of a large automated production line. SMS is a German company with a total annual turnover of EUR 1.2 billion and 2,400 employees. SMS Meer is a division of the SMS group, world market leader in plant and machine engineering for the industrial processing of steel, aluminium and non-ferrous (NF) metals. Through organic growth and acquisitions of other leading companies, SMS Meer has developed into the leading full-line provider in the field of metal forming. The contract consists of an automatic production line composed of 4 SORALUCE milling-boring centres which will be located in the plant at Mönchengladbach. Additionally two milling-boring machines will be installed in this plant, one of them for operator training.
Another two SORALUCE machines will be installed in the Aachen plant, a bed type milling centre and a multitasking F-MT machine for milling/turning large size components in the same machine in the same setup. The challenge of the project is based on integrating the SORALUCE milling-boring machines into a flexible machining cell integrating both an automatic parts feeder and a centralized tool management system. The keys to the success of the project have been the high dynamics of the machines, a changeable head configuration that allows more than 96% availability and local service and technical support from Bimatec-Soraluce.
SORA-NEWS .27
AT YOUR DISPOSAL WORLDWIDE WITH OUR SUBSIDIARIES AND PARTNERS. SORALUCE, S.Coop. Osintxu auzoa E-20570 BERGARA (Spain) Tel.: +34 943 769 076 Fax: +34 943 765 128 e-mail: soraluce@soraluce.com www.danobatgroup.com
LOCAL SALES AND SERVICE SOLUTIONS ADAPTED TO YOUR NEEDS.
In den Fritzenstücker 13-15 65549 LIMBURG (Germany) Tel.: +49 6431 97820 Fax: +49 6431 71102 e-mail: info@bimatec.de www.bimatec.de
Room 826, Golden Land Building, 32 LiangMaQiao Road. Chaoyang District. 100016 BEIJING (China) Tel.: +86 10 6467 3639 Fax: +86 10 6467 2119 e-mail: info@danobat.cn www.danobat.cn
SORALUCE ITALIA S.R.L. Via Rovigo, 89 35042 ESTE - PADOVA (Italy) Tel.: +39 0429 603 001 Fax: +39 0429 615 497 e-mail: soraluce@libero.it
SORALUCE FRANCE, S.A.R.L. 3, Allée Jean Image 77200 TORCY - MARNE LA VALLEE (France) Tel.: +33 1 60 05 02 06 Fax: +33 1 60 06 56 47 e-mail: soraluce@club-internet.fr
Row House No.21, Aditya Breeze Park, Survey No.1, Hissa No. 2,3,4 Mauze Balewadi 411045 PUNE (India) Tel.: +91 20 66 094531 e-mail: danobatgroupindia@danobatgroup.com
SORALUCE AMERICA, INC. 5301 E. State Street, Suite 203 61108 ROCKFORD, IL (USA) Tel.: +1-815-315-9261 Fax: +1-312-205-0358 e-mail: sales@soraluce-america.com
Ul. Argunovskaya, 3/1 129075 MOSCOW (Russia) Tel.: +7 495 7877445 dgmarketing@mondragon.ru
B-dul Muncil Nr. 14 400020 CLUJ NAPOCA (Romania) Tel.: +4(0) 264 415 485 Fax. +4(0) 264 415 487
SORALUCE Osintxu auzoa P.O. Box 90 E-20570 BERGARA (Gipuzkoa) Spain
Tel.: +34 943 76 90 76 Fax: +34 943 76 51 28 soraluce@soraluce.com www.danobatgroup.com
This document is not contractual. SORALUCE reserves the right to make changes to all models without prior notice. The illustrations in this catalogue remain the property of SORALUCE. 04/2012
BIMATEC SORALUCE Zerspanungstechnologie GmbH