Full direct drive technology on every axis

Willemin-Macodel, has just presented two new machines at EMO. Full direct drive technology on a 5-axes machine – a world premiere – makes the 508MTLinear the most advanced machining solution on the market. The other world premiere is the latest upgrade to the 408MT, which becomes the first compact 5-axes machining center equipped with a turning turret, pushing the boundary between machining involving milling and turning.

The 508MTLinear multi-process machining center, which allows bar milling and turning, is the first machine on the market to feature Full Direct Drive technology on all its working axes.

Advanced features
This full direct drive technology combines three linear motors and two torque motors on the rotary axes. This design offers highly dynamic control and guarantees equal performance on all axes – thereby avoiding the presence of weak elements in the drive chain.
Thermal stabilisation (control of all heat sources) ensures the processes are extremely robust, in particular for machining of parts in small production runs, or even of individual parts. The vertical axis is completely controlled by compensating for its own weight and by a combined electrical/mechanical braking system in the case of emergency shutdown.

A solution like no other
These decisive innovations complete the features already available on Willemin-Macodel machines: high-performance spindle with integrated motor at 42,000 rpm, large capacity tool magazine, tool changeover time 0.8 seconds, plus flexible and modular automation functions. The full range of technology presented at EMO makes the 508MTLinear the most advanced machining solution on the market.

Fore more information, please contact Anne Hirtzlin
Tel: +41 79 745 16 70
[email protected]

Willemin-Macodel SA
Route de la Communance 59
CH-2800 Delémont
Tel.: +41 32 427 03 03
Fax: +41 32 426 55 30

We will come back on the second new machine presented at EMO in another post soon.

Powerful programming of bar-fed mills

Time will tell, but increasingly, there is evidence that points to the fact that bar-fed mills could well represent the future of complex, small parts manufacturing. To see this coming paradigm shift, one need only walk the halls of the latest EMO, where a number of major machine tool manufacturers displayed their own, unique offerings of bar-fed milling machines.

Much as the rise in popularity of multitasking, turn-mill centers and Swiss-type lathes made thousands of manufacturers re-evaluate their programming methodologies, a move to bar-fed milling should cause a similar sort of second look at a company’s approach to CNC programming and CAM software selection and usage. Much like a traditional multitasking turn-mill center, programming a bar-fed mill involves more than simply programming milling in one place and turning in another.

The Function of Bar-Fed Mills
As the name implies, a bar-fed mill is a machine tool that, at its heart, is a vertical machining center, with the important exception that a bar-feeder, similar to that found on a production lathe, is used to introduce raw stock into the working environment. The machining table found on a traditional VMC is essentially a second spindle on a bar-fed mill where work can be handed off after being completed on the primary spindle. As a result of this important change in architecture, these machines can achieve the continuous production of a bar-fed turn-mill or Swiss-type lathe, while offering all the machining benefits of a VMC—for example, large tooling carousels and milling horse power.

Turn + Mill ≠ Bar-Fed Milling
As bar-fed mills can accommodate both turning and milling operations in a single setup, one shouldn’t make the mistake to assume combining a seat of milling CAM software and two-axis turning software will be sufficient to program these machines efficiently. In reality, bar-fed mills will generally perform turning interspersed with a variety of milling possibilities, from indexing on the face and diameter of the part to polar and cylindrical interpolation. In many cases, even though a part generally starts from round stock on these machines, it may never even see a turning operation, except for perhaps a cut-off operation to transfer the part to the subspindle.

A powerful tool
PartMaker CAM software deals with the challenges presented by this range of turning and milling possibilities in two ways. From a toolpath processing perspective, PartMaker employs a “divide and conquer” programming approach, which lets the user break down a part into a series of simpler operations. The programmer can then consider each operation in relation to the coordinate system in which it will occur and the tool motions it will require automatically.

Five-Axis Simultaneous Machining
Adding another degree of difficulty for programming bar-fed mills is the ability to perform five-axis positioning and five-axis simultaneous machining. Taking advantage of this capability requires an equally powerful CAM system that supports the virtually limitless programming capabilities five-axis milling introduces.

Simulation
To achieve their machining capabilities, bar-fed mills offer some unusual kinematic machine architectures. For example, one common feature of popular offerings of such machines is an “inverted” second spindle, where the work is held vertically, horizontally and degrees in between with respect to the machining spindle, rather than only horizontally as is usual for the second spindle of a traditional turn-mill center or Swiss-type lathe.  A CAM system for these machines needs to be able to simulate their unique architectures to allow the user to prove-out the process visually before sending a program to the machine to ensure the setup goes as quickly and efficiently as possible.

For further information on Delcam’s PartMaker software, please contact
Peter Dickin, Marketing Manager
Direct phone: 0121 683 1081
[email protected]

.
Delcam plc
Small Heath Business Park,
Birmingham, B10 0HJ, UK
www.partmaker.com

Cryogenic machining: it works!

MAG highlighted cryogenic machining at EMO last week! The revolutionary cryogenic, through-the-tool machining system was actually presented on four high performance machine tools and a robotic system using the new, eco-friendly liquid nitrogen coolant.

MAG’s newly developed liquid nitrogen cooling system was introduced to the public last fall, finally succeeding in implementing this radically new way to work. Within a short time span, the MAG experts were able to develop a practical, through-the-tool system effectively, applying it to different materials and machining technologies.

Wide spectrum of application
Four cryo equipped machines were displayed at EMO, demonstrating breakthrough applications in difficult to machine materials:

  • an aerospace titanium blisk on a vertical machining center NBV 700 5X
  • an Inconel part on a vertical turning center VDM 1000
  • a hardened shaft on a turn/mill center VDF 450 TM
  • a CGI crankcase on the hydraulic-free SPECHT 600 E

Also, a robotic root end drilling system equipped with cryogenic technology was able to demonstrate how easy composites material machining can be, if it’s done at the right temperature. Wind turbine manufacturers will benefit greatly from this new development.

Main benefits of cryogenic machining
According to MAG’s numerous tests, the following results can be highlighted (compared to classical machining):
Aerospace titanium bliskfor aircraft turbine

  • Increase tool contact angle during trochoid five axis milling (Up to 30% higher feed rate)
  • Tool life doubled

Inconel ring

  • Tool life doubled for ceramic rough and carbide finish turning
  • 30% productivity gains

Drive shaft (see picture)

  • Up to double tool life
  • Up to 50 % increased cutting speed

GCF root end of wind Turbine blade

  • 30% higher cutting rate
  • Significantly higher productivity, machine 150 more blades per year capital investment

GCI Cylinder block

  • Approximately 25 % higher output reduces capital investment (4 instead of 5 machines)

These results are quite impressive and this also stunned the jury of the EMO innovation award as MAG won this trophy for its cryogenics technology.

“This is one of the greatest breakthroughs in the history of metalworking and it promises to rewrite the book on machining speeds and costs for difficult to machine materials, which are critical in aerospace, and coming into common use in automotive and general industry applications as well,” said Michael Judge, Vice President of Cryogenic Business Development.

Want to know more?

MAG Europe GmbH
Stuttgarter Straße 50
73033 Göppingen
Tel.:  + 49 7161 201 4083
Fax: + 49 7161 201 4120
www.mag-ias.com

In Switzerland
MAG Switzerland AG
Amsler-Laffon-Strasse 1
8201 Schaffhausen, Switzerland
Tel: +41 52 63 11 119
Fax: +41 52 62 50 154

The most flat pneumatic quick-change pallet module in the world

Schunk, the competence leader for clamping technology and gripping systems continues to enlarge its program of VERO-S Quick-Change Pallet System (discovered at EMO 2011). With a height of 20 mm, the VERO-S NSE mini module from Schunk is the most flat pneumatic quick-change pallet module in the world. This provides ideal conditions for retrofitting existing machines, making full use of the engine room, and allows direct clamping of small workpieces.

Since the VERO-S NSE mini has small gauges for bore holes, small workpieces can now be directly clamped.

The patented drive concept consists of a fast stroke and a clamping stroke, and ensures that the compact module of the innovative family-owned company has a highly compact performance. At a module diameter of 90 mm, and a clamping pin diameter of only 20 mm, the NSE mini also has integrated turbo function and enormous pull-in forces of up to 1500 N. The clamping pin is positioned via a short taper and is fixed with three clamping slides. Locking is done mechanically via spring force. It is self-locking and form-fitted. The large contact surfaces between clamping slide and pin minimize the surface pressure in unclamped condition, and also the wear of the module.

Fast and precise
Since the minimum clearance between two clamping pins amounts to 100 mm, the NSE mini has particularly small and variable gauges for bore holes for workpiece and pallet clamping. It provides flexibility in the field of zero point clamping which has never been seen before. Even small workpieces can be directly clamped, and are completely machined from five sides without restricting accessibility of the lathe chuck or chuck jaw. For this purpose, the clamping pins of the Quick-Change Pallet Systems are directly screwed in the workpiece. The components are quickly exchanged in the machine, and are positioned, fixed, and clamped in the the Quick-Change Clamping Modules at a repeat accuracy of less than 0.005 mm. In order to optimize accessibility, the clamping height of the workpieces can be adjusted with module height extensions, and therefore the machine spindle can reach all five sides of the workpiece without needing special tools.

SCHUNK GmbH & Co. KG
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. +49-7133-103-0
Fax +49-7133-103-2399
[email protected]
www.schunk.com

PS: We will come back on Schunk innovation later (we’ve seen a prototype of light-weight gripper made of … wood!)

Index MSC-8 NC: more efficient with eight spindles

Index, the multispindle specialist headquartered in Esslingen, Germany, unveiled its new eight-spindle NC automatic production lathe, the Index MSC-8, from its Multiline series, at the EMO Hannover 2011. The modular eight-spindle machine built on the multispindle modular system can also efficiently machine highly complex workpieces that would have driven the previous multispindle machines normally equipped with six spindles to their limits.

The new Index MSC-8 NC multi-spindle automatic lathe opens up additional opportunities for already unbeatably fast multi-spindle parts machining: Highly complex parts that even six-spindle machines have previously had to decline are no problem for the new eight-spindle machine.

Two swiveling synchronous spindles for optimal rear end machining
Each of the eight symmetrically arranged spindles are assigned two cross-slides which can travel both on the X as well as on the Z-axis. Each cross-slide can be additionally equipped with a Y-axis. Added to that are up to two swiveling synchronous spindles for simultaneous rear end machining. Combined with a total of up to 16 cross-slides, the new eight-spindle machine is therefore a true multi-talent even for highly complex machining.
The speed of each of the eight spindles can be controlled separately.
The fluid-cooled spindle drum keeps the thermal growth in the spindle carrier to a minimum.

High stiffness
The cross slides with integrated drive have a low-mass design with hydrostatic bearing support to mitigate vibration and rattling while workpieces are being machined.
Another of the machine’s highlights is its double workpiece rear end machining capability, which is achieved using swiveling synchronous spindles that are locked into the end positions by three-part Hirth couplings. The high level of stiffness that this achieves also guarantees that even with bar diameters up to 24 mm, rear end machining operations with very high cutting volumes and simultaneously high machining precision can be performed.

Front-opening machine – diverse and various uses
Also the new eight-spindle Index MSC-8 can be operated both as a bar lathe as well as a handling machine. The advantage of the front-opening design for the operator is the excellent accessibility during setup and tooling.
The standard version of the machine, the Index MSC-8, already offers diverse and numerous applications: it can be operated as an eight-spindle machine, as a double four-spindle machine or as a machine with double rear end machining. When operated as an eight-spindle machine, the drum indexing angle from spindle to spindle is 45°; if the machine operates with two times four spindles, the drum indexing angle is 90°. Results from double four-spindle machining: two finished parts are produced by the machine per work cycle.

Many operations
When it comes to the machining sequence, the Index engineers have exhausted all options for further improving efficiency: After front machining, for which six spindle positions are available, the workpieces are picked up by two rear machining units and machined simultaneously on the rear end. Because rear end machining is done during two drum indexing cycles, up to six tools can be used for this simultaneously with the other spindles.

There are already a total of 27 machining tools available in the standard model, of which 16 can be used simultaneously. As usual with Index multispindle machines, the new eight-spindle MSC-8 can handle all technologies for turning centers, such as turning, drilling, milling, multi-edge turning, hobbing, tooth milling, deep-hole drilling or slotting.

INDEX-Werke GmbH & Co. KG
Michael Czudaj
Sales Manager Germany and Austria
Phone +49 711 3191-570
[email protected]
www.index-werke.de

In Switzerland
SPRINGMANN SA
Machines-Outils
Route des Falaises 110
CH-2008 Neuchâtel
Tel 032 729 11 22
Fax 032 725 01 01
[email protected]
www.springmann.ch

New range of products launched

At EMO, Tornos is launching a new line of products. The MultiSwiss 6×14 machine provides a link between multispindle turning machines and sliding headstock machines. Based on the “fully integrated” concept and featuring innovative front access, this new machine is designed with three types of customer in mind: users of numerical multispindle turning machines, users of cam-operated machines, and users of single-spindle turning machines.

The MultiSwiss benefits from completely open front access, allowing the operator unrivalled working conditions since he can virtually “get inside” the machining area to work on it, and since all the peripherals are fully integrated. Swarf evacuation is also exemplary: as all the slides are “vertical”, the swarf naturally “falls” directly onto the evacuator. To complete the ergonomics of the working area, the Moutier group’s engineers ensured perfect integration of all of the required peripherals right from the design stage. The MultiSwiss includes, as standard, a paper filter system combined with a superfine filter located in the oil tray. In addition to the filter and the bar feeder, the machine’s casing is designed to house the cooling device, the chip conveyor and the oil mist extraction device.

As small as a single spindle
The fact that all the peripherals are fully integrated means that its footprint is reduced and the MultiSwiss can
quickly find its place in the heart of any workshop. The machine takes up no more space than a single-spindle
machine of equivalent capacity, equipped with a bar feeder.

Outstanding performance
With a capacity of 14 mm, the machine can house up to 15 tools in main operation and 3 in secondary operation, on an independent station which can be interpolated. Each module of the machine was tested before being fitted on the machine. The new barrel locking system designed to replace the conventional Hirth gear was tested over 40 million cycles before it was awarded its validation certificate and a number of machines were sent to customers to test over several months. The machine has a thermo-regulated core allowing production to be started up quickly. The use of hydrostatic bearings ensures exceptional damping and allows excellent surface finishes to be achieved. The separation of the guides lends the machine unprecedented rigidity. Results are excellent; once the operating temperature is reached, the precision is in the region of 4-5 microns. To shorten the heating times as much as possible, the MultiSwiss features an oil circulation pump start-up option which means that all the components can be harmonised even before starting work.

The machine is on display at the Tornos Stand at EMO Hanover, Hall 17 Stand B04, and the first deliveries are
scheduled to start in October of this year. You can still go and discover the machine there.

There is also an online presentation here.

www.tornos.com
[email protected]

Cheers and have a safe trip back from EMO.

Pierre-Yves Kohler

PS: Sorry for those we were unable to see at EMO…the show is so big and exciting that we were unable to visit every company we wanted to.

PS2: We discovered a lot of news at this year’s EMO and the results for companies seem quite good… stay tuned!

The VM 130 – unprecedented precision in high volume internal diameter grinding

The Peter Wolters GmbH from Rendsburg, Germany, presents the Voumard VM 130 internal diameter grinding machine for high volume production during the EMO Show at Hannover, from September 19 to 24.

The machine is perfectly suited for high precision mass production of small and mid-sized work pieces, e. g. components for fuel injectors in the automotive industry. With up to 6 grinding spindles and several different types of dressing units being available, the machine is very flexible and can be configured for a wide range of products and applications, such as grinding internal diameters, tapers and faces. The automated work piece loader with double gripper can be easily connected to external automation concepts, resulting in high throughput and low costs per piece.

Highest precision
Like all Voumard machines, the VM 130 is designed for highest precision and tightest tolerances. Hydrostatic bearings and linear drives combine highest acceleration and positioning accuracy when moving the axis. The renowned Voumard concept of the X- and Z-axis being separated from each other results in outstanding rigidity of the VM 130 machine structure, which is mandatory for high precision grinding applications. Additional components, such as gauges for pre-, in- and post-process measurement provide data for automatic process optimization and statistical process control. The VM 130 is ready to load work pieces with a diameter of up 70mm and 70mm in length, while the smallest internal diameter that can be ground is 0.8mm. The Voumard specific CNC user interface, based on a Fanuc control, is made from grinding specialists for grinding specialists and allows for easy and convenient setup even of complex grinding recipes.

You can still discover this new machine at EMO, hall 11 booth No. D58. Do not miss it.

Peter Wolters GmbH
Büsumer Strasse 96
D – 24768 Rendsburg
Phone: +49 (0)4331 458 160
Fax: +49 (0)4331 458 290

Frank Runkel –Director Voumard Product Line
[email protected]