Sandvik Coromant extends indexable insert drill capabilities to deliver improved hole quality and longer tool life

Sandvik Coromant has launched a reinforced variant of its CoroDrill® 880 indexable drill that will substantially improve production economy in large diameter hole-making applications. The latest CoroDrill 880 tool body is compatible with a range of insert grades, including a grade based on the company’s new Zertivo™ technology, which delivers optimized cutting edge integrity.

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Representing the latest breakthrough in U-drill evolution, the reinforced CoroDrill 880 features a new enhanced drill body that is up to 30% stiffer than its predecessor for applications of four to five times the drill diameter. This gives a more reliable drilling experience and a much better hole quality. In addition, the combination of enhanced drill body and the new Sandvik Coromant grade chain for steel and cast iron results in a considerable improved insert tool life.

In tests, a customer manufacturing slewing rings for the wind power industry tried the new and improved tool body for CoroDrill 880 in application requiring holes of five times the drill diameter. When using the old tool body in 42CrMo4, the hole size decreased over time providing an undersized hole after a period of use. With the new, stronger tool body, CoroDrill 880 produced correctly sized holes for a much longer period of use. In addition, the customer saw a tool life increase of 975%.

Two of the insert grades, GC4324 and GC4334, are designed with Inveio™ coating for better wear resistance. The third, GC4344, produced with Zertivo™ technology, provides great edge-line security as a result of optimal coating and substrate adhesion properties.

These three grades complete the full grade chain with solutions for all ISO P and ISO K materials and a large variety of applications:

• GC4324: Productivity booster for stable conditions
• GC4334: First choice for good to average conditions
• GC4344: Excellent performance in difficult conditions

The new grade positioning is designed to make it easier to select the right grade from the start.

The CoroDrill 880 product range covers hole diameters from 12 to 84 mm (0.472-3.307 inch) off the shelf, as well as engineered solutions up to 129 mm (5.078 inch). The drills produce holes with tolerances of H12–13 and are suitable for holes up to five times the drill diameter.

www.sandvik.coromant.com/en-gb/products/news/Pages/default.aspx#new-drilling-tools.

LASYS meets France: Messe Stuttgart gains cooperative venture partner

Messe Stuttgart, organiser of the international trade fair for laser material processing LASYS, has entered into an extensive cooperative venture with IREPA Laser, the organiser and supporter of the French congress with accompanying exhibition ESPACE LASER. For the first time, a joint stand with up to 20 French companies from the laser industry is planned for LASYS 2016 under the title “ESPACE LASER s’invite sur LASYS”. In 2017 it will be called “LASYS meets … France”, when LASYS will be represented with interested companies from Germany, Austria and Switzerland at the trade fair in Strasbourg.

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With its campaign “LASYS meets …”, Messe Stuttgart has already expanded its presence in the target countries China and Turkey. For instance, the trade fair is a guest at AMB China in October 2015. Another event is planned for February 2016 in Istanbul. Thanks to the cooperative venture with IREPA Laser, another strategic market has been added with France.

ESPACE LASER was launched in 2001 by IREPA LASER, a recognised technology centre in France for industrial laser processes and materials. Around 40 leading companies from the French laser industry, as well as international suppliers, were acquired as exhibitors for this year’s event, which took place in September in Lyon. The exhibitors included BeAM, Gravotech, Laser Cheval and Optoprim, among others.

For Monique Caboche, the organiser of ESPACE LASER, this cooperative venture with LASYS represents an exciting new challenge, which also coincides with the 20th ESPACE LASER. “We couldn’t pass up on this opportunity to execute ESPACE LASER in our partner city Stuttgart and give our manufacturers access to the German, Swiss and Austria economies. We are looking forward to welcoming LASYS at ESPACE LASER in Strasbourg in 2017.”

Another partner in the ESPACE LASER network is the European Material Research Society E-MRS (www.european-mrs.com). As a professional supporter, E-MRS is participating in a planned German-French conference programme during LASYS 2016, in particular on the topic of materials.

Gunnar Mey, Department Director of Industrial Solutions at Messe Stuttgart, adds: “Within the framework of the German-French partnership, we are sowing the seeds for cross-border cooperative ventures and business dealings for French manufacturers and experts at LASYS 2016. In return, we are making it possible for our exhibitors to be represented with the “LASYS meets … France” offer in Strasbourg at “ESPACE LASER 2017″ and to successfully operate on the French market through our partner network.”

About LASYS

As the only international trade fair, LASYS clearly focuses on system solutions in laser material processing. Since the start of the trade fair in 2008, it has successfully established itself as a user platform for the latest laser systems, machines and processes. LASYS addresses all industries and materials, in particular decision-makers from the international industry. The focus is on all tried-and-tested, but also innovative, manufacturing processes, applications and potential uses of laser in industrial manufacturing.

The VDMA is a professional and conceptual supporter of LASYS.

LASYS takes place at the Stuttgart trade fair centre from 31 May to 2 June 2016.

www.lasys-messe.de

Intelligent clamping technology makes a huge contribution to effective production processes

Under the title of “Production optimisation with intelligent, flexible clamping concepts”, the High-Precision Tools Association in the German Engineering Federation (VDMA) will on 24 February 2016 be hosting the Clamping Technology Forum at the METAV in Düsseldorf (23 to 27 February 2016).

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Four manufacturers of clamping devices, one user, and Hanover University will each be spotlighting their own clamping concepts for enabling production processes to be optimised to best effect. Subjects addressed will include RFID in tool clamping systems or the “feeling machine” in the context of Industry 4.0, plus quick-change systems for workpiece clamping.

To quote Hans-Joachim Molka, Chairman of the Clamping Tools Special Section in the association: “In the interaction between the machine and the tool, innovative clamping technology assures stability in the production process and high levels of machining accuracy. Nonetheless, clamping technology is frequently underestimated.” The approximately 60 members of the Clamping Tools Special Section in the German Engineering Federation (VDMA) can offer tool clamping options for metal-cutting tools and forming tools, workpiece clamping options both rotational and stationary, mechanical, pneumatic, hydraulic, electrical … plus innumerable clamping components and systems. Dependably automated solutions and machine concatenations are no longer conceivable without query mechanisms at the clamping element, is Hans-Joachim Molka’s firm conviction. An innovative clamping element can adapt to any specific machining situation.

The sector is, however, facing multifaceted challenges. Falling batch sizes with a large number of variants, high levels of workpiece complexity, complete machining in a single set-up, cost downsizing, unmanned manufacturing, networked production, lengthy useful lifetimes describe the multifarious priorities involved. With Industry 4.0, too, clamping devices are much in demand. They have to be communication-capable if effective production processes are to be assured. With increasing frequency, customers’ requirements can be met only by providing sophisticated, technically advanced special solutions. The Clamping Technology Forum at the METAV aims to raise awareness of what precisely manufacturers of clamping tools can contribute towards their customers’ corporate success.

“In actual fact, when firms are investing in production equipment, they often think about the tool clamping technology much too late,” reports Hans-Joachim Molka from daily business experience. Then, he adds, either the budget has been used up, or machinery, space or workpiece constraints now permit only a compromise solution. In order to map out for users how they can achieve optimum results with early advance planning, the Clamping Technology Forum is being held at the METAV for what’s already the second time. “At the last METAV, our Clamping Tool Forum was extremely well received, with more than 50 people attending. We aim to build on that,” says Hans-Joachim Molka in conclusion. “We want to see a closer dialogue with the users from the machine tool industry, and offer expertise and corporate competence in terms of clamping tools.”

www.metav.de

Renishaw announces a new version of the REVO® multi-sensor 5-axis measurement system

Renishaw is pleased to announce the launch of REVO-2, a new improved version of the revolutionary multi-sensor 5-axis measuring head for use on co-ordinate measuring machines (CMMs). REVO-2 and its new CMM controller UCC S5, build upon the successful REVO multi-sensor system with enhanced power and communications capability to carry the latest REVO sensors such as the RVP vision measurement probe. The head also has an increased range of movement in the negative A-axis which can improve part access and reduce the complexity of stylus set-ups.

Blade scan with REVO-2
Blade scan with REVO-2

REVO-2 incorporates Renishaw’s own ATOM™ optical incremental encoder system that uniquely combines miniaturisation with ruggedness and exceptional metrology performance. ATOM is the world’s smallest readhead using filtering optics. It offers speeds up to 20 m/s (29,000 RPM on a 17 mm disc) and resolutions to 1 nm (0.004 arc second on a 108 mm disc) with a range of linear and rotary (angle) scales available in stainless steel and glass.

REVO-2 is the only scanning system for CMMs that simultaneously controls the motion of three machine and two head axes whilst collecting workpiece data using its range of 2D and 3D tactile probes, surface roughness measurement probe and now non-contact vision probe too. The head’s novel design incorporates sophisticated laser measurement and electrical signal transmission technology for precise workpiece measurement at extremely high rates of data capture. The five-axis control system removes most of the unwanted dynamic errors associated with machine movement because the measuring head performs most of the work. As the head is much lighter and more dynamic than the CMM, it is able to quickly follow changes in the part geometry without introducing harmful dynamic errors. The REVO-2 multi-sensor system is managed by the same I++ DME compliant interface as the original REVO product.

In recognition of the revolutionary 5-axis measuring technology that has brought dramatic benefits to part inspection on CMMs, the REVO system has received multiple prestigious awards.

www.renishaw.com/cmm

Milling, Turning and Wire EDM Updates In Edgecam 2016 R1

The latest release of Edgecam’s game-changing manufacturing software contains over 30 important new and enhanced items of CAD and CAM functionality for milling, turning, and wire EDM.

Head Table support for MTM Machines
Head Table support for MTM Machines

Turners now benefit from a new time-saving Pre-Finish Plunge option found in the Finishing Grooving cycle in Edgecam 2016 R1. A single plunge cut is generated at the centre of a groove feature, and the cycle then continues to finish the feature in the usual way. As this removes most of the material it does away with the need for a Rough Grooving cycle.

Following on from Waveform turning, the existing Rough Turn Cycle now features a new Ramp Cut strategy. This method is typically used for turning deep recesses with double-sided turning inserts…and extends tool life as the contact point on the insert is constantly changing, avoiding notching. The new strategy can be used with decreasing cut increments.

Five more milling CAM cycles have been upgraded to use images and help tooltips. Edgecam’s Product Manager, Simon Mee says: “This helps users to quickly understand the command function and also presents a consistent user interface.” The cycles are Parallel Lace, Pencil Mill, Face Mill, Flat Land Finishing, and Constant Cusp Finishing.
Enhancements have been made to Edgecam’s 3D modelling software, EWS. A new 2D Offset Tool makes design creation easier. Common shapes and profiles are quickly duplicated and copies by an offset amount, reducing sketching time. More time is saved while creating constraints, as it is no longer necessary to exit the command – the dimension value is now immediately editable. And entities dynamically snap during the sketching phase. Also, an enhanced Arc command now includes a Set Diameter/Radius option, allowing multiple identical circles to be added to a sketch.

Edgecam 2016 R1 sees the completion of memory-handling developments for working with multiple solid models. “Similar to Parasolid, Inventor and Granite files, users will now see noticeable performance improvements when working with ACIS models. This is achieved by only storing a single solid model – when duplicates are required Edgecam creates references to the original geometry. Customers working with tombstone parts or sub-spindle lathes will reap significant benefits from this new functionality.”

A number of significant upgrades have been made to the Operations function, which is used in particular by new or infrequent Edgecam programmers as a quick and easy way to develop complex toolpaths. Roughing, profiling, turning, and 4- and 5-axis commands have been enhanced, as well as the addition of a new chamfering operation.
The roughing operation is now stock-aware, and adopts the Waveform toolpath strategy. In addition, the rough turn operation now supports the B-axis…and the 4- and 5- axis operations can now directly pick on the solid model.

A function used for both milling and turning operations now saves additional time on the Update Stock command. “Through intelligent coding, the command no longer needs to process the graphical aspects of the machine set-up,” says Simon Mee. “This means the Machine Simulator can focus on pure toolpath. Further performance improvements have been made to the simulator when dealing with large toolpaths such as roughing and 5-axis cycles. The simulator now groups multiple cuts intelligently, to provide an optimum performance benefit.”

A further enhancement to the Automatic Feature Finding command means users can set a Partial Hole Angle when creating features. The value will control which hole features can be detected, and eventually machined.

Building on enhancements from previous releases, Edgecam 2016 R1 now offers extended collision detection and improved NC output for machining holes. Simon Mee says this feature is especially beneficial when non-uniform clamps are used. The cycle’s ‘link’ moves are minimised. As they’re calculated from the local fixture height, this reduces cycle time considerably. As a result of this, the program output has been improved, as the specific retract value can be used in canned cycles.

Wire EDM users benefit from a new Smart Cycle machining command. This combines 2-axis and 4-axis wire machining into one function, by analysing the input geometry shape. It guarantees that the output code always matches the feature shape, without the user needing to do anything else.

Edgecam 2016 R1 also introduces a ‘Test For Separation / Slug Removal’ function into the wire EDM simulator. Users can examine if slugs of material can become detached from the main stock body. The simulation test displays all separations, and shows which direction they’ll take. By knowing of any problems at this stage, users can decide whether to change the machining process. This is especially valuable on complex 3D shapes, where it’s not always obvious if separation is possible.

www.edgecam.com

Mastering the Challenges in LSR Molding

Products made of LSR (Liquid Silicon Rubber) confront the molder with special challenges. Due to its rheological properties and curing kinetics, the desired quality outcome can only be achieved through a narrow process window.

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However, LSR has good physiological properties and a high thermal stability and has therefore a growing demand, particularly in the medical, baby care and design sectors.
To face the challenging production with sufficient preparation, the narrow processing window can be set up upfront with SIGMASOFT® Virtual Molding. This way the processor increases his know-how for future projects, and also the process stability. The risks associated with costs and delivery dates are also reduced.

The advantages of a virtual injection molding process are shown by SIGMA Engineering GmbH at Fakuma 2015 in a joint project with Momentive Performance Materials Inc. and CVA Sillicone. For this purpose, the design article “Ursula”, a carry-mesh for bottles, is evaluated with SIGMASOFT® Virtual Molding. The interlaced geometry of “Ursula” with a maximum flow-length of 619 mm requires stable flow and curing properties, to guarantee a robust process and the required part quality.

To reach this goal, the manufacturing feasibility was evaluated with SIGMASOFT® Virtual Molding. Not only the part, but the complete mold was taken into account, including cold runner, over several molding cycles. Besides the filling of the mold (Figure) and the part curing behavior, also the complete thermal mold behavior was considered. The thermal response of the mold has a decisive impact on the part properties. The comprehensive rheological and thermal analysis shows that the Silopren LSR 2670 meets the production requirements of Ursula. The results of the virtual production are shown at Fakuma at the SIGMA Booth, A5-5105. A Live-Demo is presented at the booth of Momentive (A4-4307), where Ursula will be produced in a CVA mold.

To achieve an accurate prediction with SIGMASOFT®, besides the complete mold and process data, it is important to have precise material data, to calculate exactly the material behavior. To make those easier accessible for SIGMASOFT® users, Momentive delivers the material data of a large number of its materials to SIGMA. The new material data for several standard and special LSR grades are available for the user in the SIGMASOFT® v5.1 database.

www.sigmasoft.de

CECIMO forecasts growth to continue in 2015

CECIMO, the European Association of the Machine Tool Industries presents the state of the European machine tool industry at EMO Milano 2015:

• The European machine tool production will grow to 23.6 billion euros in 2015;
• Machine tool sales in Europe will reach 14.2 billion euro in 2015 thanks to the improving business confidence.

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Together with the European economy, the European machine tool (MT) production also intensified in 2014: it grew by1.3% to reach 23.0 billion euro. Since the European MT industry exports worldwide, it is affected by two opposing trends. First, a slowdown in emerging markets makes these reduce their investment in industrial machinery. Secondly, growth is relatively stable in developed markets like Europe and North America, which implies more investment in industrial machinery. Both trends considered, the European machine tool production is estimated to increase to 23.6 billion euro in 2015 (+3%).
Despite the slowdown of global economic growth, the European MTs’ exports still perform well. Machine tools with a total value of 18.2 billion euro were shipped abroad in 2014. CECIMO expects the exports to grow by 3% to 18.7 billion euro in 2015, which would be the second best result of all times. “Rising wages in the emerging economies put pressure on production costs. The European machine tool industry focuses on productivity and high efficiency that gives us our competitive edge. Our highly innovative, state-of-the-art machines are in demand all over the world because they offer intelligent and cost efficient manufacturing solutions. These are promoted on a large scale during EMO Milano 2015,” explained Dr Frank Brinken, the Chairman of CECIMO Economic Committee and a member of the Board of Directors of several machine tool companies.

CECIMO imports rose to 8.8 billion euro in 2014. The weak euro will slow imports’ growth down but we estimate that the European industry’s needs will push the MT imports to 9.2 billion euro this year (+3%). After two years of stagnation, the European businesses’ investments picked up in 2014. The European MT consumption expanded by 10% in 2014 to 13.7 billion euro. The consumption is expected to go on increasing and record 14.2 billion euro in 2015. The improving demand in European markets is confirmed by the strong order intake. In the second quarter of 2015, the CECIMO domestic orders’ index increased by 6% and 14% in comparison with the previous quarter and the same quarter last year respectively. We expect the European MT consumption to grow for the next four years.

The industry in need for political action at EU level
Europe generates 39% of the global machine tool output and European exports (including intra-EU trade) account for 50% of the world machine tool exports. As much as 50% of all patents filed globally for machine tool technologies are European. Europe’s strength lies, in fact, specifically in its capacity to supply advanced machine tool technologies.
The European MT sector goes towards the adoption of disruptive manufacturing technologies like intelligent production and additive manufacturing. It wants to participate in public-private partnerships and focuses on cross-disciplinary cooperation. The sector is accelerating the integration of new technologies like big data and industrial internet into its equipment and services, laying the foundations of the future’s intelligent and connected factories. They are also heavily involved in helping our manufacturing workforce to adapt to new technologies and the new business environment.
It is clear that innovation is and will be the motor of growth for the MT industry, and the lack of investment in manufacturing is its most important obstacle. Filip Geerts, director-general of CECIMO says: “The EU decision makers must use the European Fund for Strategic Investments to finance support programmes helping to accelerate “technology transfer” whilst tackling the underinvestment problem.”

www.cecimo.com