Category Archives: Hard turning

Fritz Studer Award 2014 – Innovative Grinding Technologies

As market and technology leader in cylindrical grinding, STUDER decided to endow the fourth research prize, the «Fritz Studer Award». In the fall of 2014 applications were submitted from many European countries.

Handing over of the Fritz Studer Award 2014 through Dr. Gereon Heinemann (Managing Director Fritz Studer AG, right) to the winner Dr. Eduardo Weingärtner.
Handing over of the Fritz Studer Award 2014 through Dr. Gereon Heinemann (Managing Director Fritz Studer AG, right) to the winner Dr. Eduardo Weingärtner.

The research award targeted graduates from European universities and higher education technical colleges. All graduates, who have dealt with scientific topics or have had an applied research focus during their studies or as a subject in a dissertation and who are able to proffer substantiated results or partial results from their work can participate in the competition. The aim of the work is to strengthen the innovative power of the machine industry with technically feasible approaches.
The submitted topics were to be dedicated to one of the following fields:
− Innovative machine concepts or components for machine tools in precision machining
− Alternative materials in mechanical engineering
− Simulation models of dynamic and thermal behavior of machine tools
− Control and sensor concepts for machine tools
− New or further developed manufacturing technologies, especially in hard-fine machining, such as grinding, hard turning, etc.
The submitted projects were assessed by an expert jury. The jury was composed of Prof. Dr. Konrad Wegener, Institute of Machine Tools and Manufacturing at the Swiss Federal Institute of Technology Zurich, Dr. Heinrich Mushardt, United Grinding Group AG and Dr. Frank Fiebelkorn, Head of Product Development, Research and Technology at Fritz Studer AG. The decision criteria for assessment included, for example, the ease of implementing the findings in the machine industry, novelty and idea of the research work, scientific content, form and correctness of statements and results.
With the topic of «On-Machine Wire Electrical Discharge Dressing of Metal Bonded Grinding Wheels», Dr. Eduardo Weingärtner from the Swiss Federal Institute of Technology Zurich, Institute of Machine Tools and Manufacturing (Switzerland) had the honor to receive the Fritz Studer Award 2014.
The focal points of Dr. Weingärtner’s research are the examination of wire erosion as an alternative process for dressing metal bonded diamond grinding wheels. Dr. Weingärtner is involved not only in the development of a wire erosion dressing unit and its integration into a grinding machine but also in the modeling, simulation and optimization of the wire erosion dressing process. In his dissertation he developed a special wire guide, which is key to the feasibility of a reliable dressing process, as the precision and efficiency of the process were thus able to be increased considerably. With the thermo-electric model developed by Dr. Weingärtner, the performance of material removal by erosion can be predicted; the influence of relative speed on the erosion process is more easily comprehended and graphitization of the diamonds can be analyzed.

Sandvik Coromant support for automotive sector embraces extensive machining solutions for transmission shafts

Range of tools and high-performance grades address challenges to deliver improved productivity, security and tool life in transmission shaft machining

Transmission shaft machining solutions include soft stage turning with GC4325 and GC4315 high-performance turning grades
Transmission shaft machining solutions include soft stage turning with GC4325 and GC4315 high-performance turning grades

The Sandvik Coromant portfolio of automotive component manufacturing solutions offers a selection of tools and insert grades designed to optimize the machining of transmission shafts.

Beginning with soft stage steel turning, high-performance GC4325 and GC4315 insert grades for internal and external operations offer superior levels of wear resistance, the ability to withstand high cutting temperatures and cutting edges that stay in shape for long times in cut.

Moving to hard part turning, CBN inserts are the first choice for turning high quality steel surfaces in the hardness range 58-65 HRc. CBN inserts from Sandvik Coromant have wiper options optimized for specific applications: WH (wiper HPT) generates low cutting forces for best surface integrity, while WG (wiper general) permits higher feed capacity.

The CoroCut® 1-2 grooving programme offers a number of benefits to those machining transmission shafts. For instance, patented spring clamping delivers high rigidity and clamping force accuracy, while both over- and under high precision coolant is available and easily connected via plug and play adaptors. What’s more, CoroCut 1-2 is now available in GC4325 high performance grade for steel.

Clearly, as a transmission shaft, these complex components demand numerous gear and spline milling operations. Among the tools ideal for addressing this challenge is CoroMill 176, an innovative indexable insert cutter for productive gear wheel machining that is designed for gears in the module range 4 to 10. Also, deployed widely for transmission shaft applications are the CoroMill 172 disc cutter for milling high-quality gear profiles and, similarly, CoroMill 171 for small gear modules. The latter features inserts with two cutting edges, while the same cutter body can hold inserts for different gear profiles.

Other gear and spline profiles on transmission shafts can be tackled using InvoMilling™, the unique Sandvik Coromant approach to milling spur and helical gears using indexable insert cutters, along with CoroMill 161 and 162. Using this single tool set on multi-task machines or five-axis machining centres it is possible to create many different profiles by simply changing the CNC program instead of changing the tool.

www.sandvik.coromant.com/en-gb/industrysolutions/automotive/transmission/pages/shafts.aspx.

When the machining process makes the difference

For many specialists working with machining companies in France and Europe, the name of Huron is a little part of the past. It is the brand of the machine on which they learned. It is always there and one may think about it with nostalgia, but seldom with a clear vision of what it is today: a dynamic manufacturer who offers extraordinary machines and machining processes. Meeting near Strasbourg with Ms. Labeauvie, Marketing Manager and MM. Echevard, CEO and Lutz, commercial Director.

The new premises of Huron in Eschau (Strasbourg, France) is fully air-conditioned and currently hosts three lines of products made according to the principles of Lean manufacturing. The company covers nowadays 12'000 m2 in Illkirch and 8'000 m2 in Eschau. Additional 12,000 m2 are planned in Eschau (2016-2017).
The new premises of Huron in Eschau (Strasbourg, France) is fully air-conditioned and currently hosts three lines of products made according to the principles of Lean manufacturing. The company covers nowadays 12,000 m2 in Illkirch and 8,000 m2 in Eschau. Additional 12,000 m2 are planned in Eschau (2016-2017).

During the visit of the assembly workshops, what immediately grasps attention is the dimensioning of elements of machines. Ball screws, linear guides and castings seem to be largely oversized when compared to the usual standards of the market. Mr. Lutz confirms: “The stiffness is the first asset of our machines, everything is very widely dimensioned. They are very sturdy, reliable and accurate”. This strategic choice obviously directly affects all design, engines, hydraulic systems, everything is “large”. Is this not of luxury? The CEO say: “Absolutely not, this is what makes us different and has allowed the continuous growth of our turnover for several years”.

Two examples of extraordinary results
The company is full of examples which seem invented from scratch because of extraordinary results. M. Echevard says: “I was visiting a car manufacturer and seeing a machined camshaft, I assumed they were machined in about twenty hours. After discussions with the client, he told us they needed a little bit more than 90 hours to finish it. We analyzed the part and optimized the process on a Huron machine and offered the solution. We were able to produce the part in 17 hours” thus a gain of more than 80%. Another example, a microtechnology complex assembly requiring 100 hours of machining and the assembly of 7 components is carried out today at the customer’s on a Huron center in one piece, it requires approximately 8 hours of machining, and is totally finished on the machining center.

Much more to discover in Eurotec’s next issue

  • Gains at all levels
  • Innovation at the service of customers
  • Processes on demand
  • Results: hard to believe
  • Rebuild brand-awareness and value
  • The Amerindian of the future
  • Huron in a few facts
The vertical milling gantry centers of the KK family are the largest of the range of the manufacturer, a car’s engine can be fully placed into its machining area.
The vertical milling gantry centers of the KK family are the largest of the range of the manufacturer, a car’s engine can be fully placed into its machining area.
The DX100 turning Center is aimed at the realization of small parts for the medical fields, automotive or hydraulic, for example. It is the smallest machine proposed by Huron.
The DX100 turning Center is aimed at the realization of small parts for the medical fields, automotive or hydraulic, for example. It is the smallest machine proposed by Huron.

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Huron Graffenstaden
156 route de Lyon
BP 30030
67401 Illkirch Cedex
France
Tel. + 33 (0) 3 88 67 52 82
Fax + 33 (0) 3 88 67 69 00
www.Huron.eu
[email protected]
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In Switzerland:
Joseph Binkert
Machine tools
Grabenstraße 1
8304 Walliselen
Tel. + 41 44 832 55 55
Fax + 41 44 832 55 66
www.binkertag.ch
[email protected]
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…brought to you by Eurotec-Online.com

To optimize machining processes

It has happened to everyone to stumble on a machining process. We change a few parameters in the hope the results will be better… but sometimes it is not enough and the number of tests quickly grows too large without any appreciable visible improvement.

Based on different algorithms, Caravelcut reduces the number of necessary tests to find the optimum and removes result based on chance. It is very rare that machining processes are fully optimized, CaravelCut permits  it very simply.
Based on different algorithms, Caravelcut reduces the number of necessary tests to find the optimum and removes result based on chance. It is very rare that machining processes are fully optimized, CaravelCut permits it very simply.

In this case, one possibility is to use the method of design of experiments (D.O.E.) that allows finding the optimum in carrying out a minimum amount of tests. But the method must be known and requires also the mastery of mathematical instruments. Today CaravelCut offers a simple and effective alternative. Meeting at the tools manufacturer’s Louis Bélet with MM. Pierre Falbriard, responsible for R&D using CaravelCut for many years and Leonello Zaquini, Honorary Professor HE-Arc – engineering and founder of CaravelCut.

Mathematical and statistics methods
Start-up founded in 2010, Caravelcut offers a decision support system based on mathematical statistics methods, passion of the founder. He says: “I had hundreds of pages of documents and equations and I found it a pity not to make my researches available to the industrial world. I thought to write a book that would present all the formulas and models… but it would not have simplified the life of users, this is why I finally opted for a website that allows everyone to use these algorithms”. The site accompanies users step by step through the optimization of the cutting parameters and machining solutions.

Amazing results of precision
Is this solution reliable? Mr. Falbriard says: “I give you an example. In a project of a new tool, we chose 9 parameters varied on two levels. Automatically a batch of 12 tests has been generated with different parameters to change. […], we measured them and powered the system. Immediately CaravelCut posted the results in graphic form and we were able to choose the most relevant parameters for designing our tool. According to the forecast provided by Caravelcut, the new tool created should be capable of machining 3932 holes before being worn. Of course as soon as built we tested it and we could achieve a little less than 3900 holes. In my opinion the system is totally reliable and very robust”.

Different optimization services

  • Economic optimization
  • Production optimization
  • D.O.E. to improve machining
  • Statistical analyses
  • Reduction of torsion
  • Improvement of the surface roughness
  • Tool life
  • Accuracy and vibration
  • Reduction of burr
  • Kriging interpolation

In Eurotec you will be able to see how a watchmaker was able to save nearly 100’000 CHF a year using CaravelCut and much more, stay tuned.

CaravelCut
Leonello Zaquini
He-Arc – engineering
University of Applied Sciences
Western Switzerland
Eplatures-Grise 17
2300 La Chaux-de-Fonds
Tel. + 41 32 930 29 52
Fax + 41 32 930 29 30
[email protected]
www.caravelcut.com

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Midest 2013.

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…brought to you by Eurotec-online.com

Micro-assembly in high-tech materials

The Rubis Precis/Micropierre/High Tech Ceram group specializes in high-precision machining of hard materials such as technical ceramics, ruby, sapphire and tungsten carbide. The company announces now new capabilities in assemblies in high-tech materials.
Rubis_precis_Eurotec
New assemblies in high-tech materials like titanium and ceramics used in new leading markets like aerospace, aeronautic, medical and analysis are now offered by the high precision specialist.

Advanced skills
These micro-assemblies are assembled using a variety of techniques, for instance metallising, brazing, laser welding and crimping. The Group is one of the world leaders for the supply of such high-tech assemblies to solve many difficult problems like wear or corrosion resistance in harsh environment, insulation at ultra-high temperature or voltage, resistance in ultra-vacuum or high pressure. The skills in assembly are perfect complement to the company’s well-known skills for machining the same hard materials.

From manual to automatic…
The company relies on 25 automatic, semi-automatic and manual machines for all types of assembly/micro-assembly, these are chosen depending on the complexity of the parts and the size of the production runs.

Black and white zirconia ceramic watches
To show its skills in machining and assembly in high precision ceramics and microtechnology the company also unveiled a pair of zirconia watches.
These can be bought directly at the factory; you can find more information here.

Rubis_precis_2_Eurotec
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The Rubis Precis group will be exhibiting its skills at Midest in Paris from November 19 to 22, 2013.

www.rubis-precis.com
[email protected]

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Midest 2013.

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…brought to you by eurotec-online.com

Incredible novelties just unveiled

On this EMO’s eve the companies active in our field are busy preparing their product launches in Hannover and indeed we have some news for our readers.

emonews copie

Innovation is more than ever bringing distinctive assets to companies active in microtechnology. In Eurotec’s latest issue you will be able to discover many of those in premiere:

Machines

  • Almac – Complete new product range
  • Hermle – Combining MIM and machining
  • Humard Automation – High precision turning machine designed by users
  • Kern – Hard materials high speed machining
  • Mikron – Transfer machine to another level
  • Rollomatic – For the first time a laser machine with Rollomatic’s features
  • Schaublin Machines  – To turn and grind with the same machine
  • Tornos – EvoDeco for large diameters
  • Willemin-Macodel  – 701s a stunning new concept for high precision

Tooling

  • Mikron Tool – Quantum leap in milling technology
  • Gühring – Universal taps

This issue also includes many other articles helping our readers being better informed.
Components

  • Eichenberger Gewinde – A ball screw for every situation

Lubrication

  • Motorex – International training

Cleaning

  • NGL Cleaning Technology – To manage industrial wastewater

Subcontracting

  • Pierhor – Microns hunters for more than 100 years
  • Obal – To outsoure  and have more time for important activities

Trade shows

  • EMO, Hanover
  • WMTF, Lucerne
  • Motek, Bondexpo, Blechexpo, Stuttgart
  • EMTE-EASTPO 2014, Shanghai

You can read Eurotec 389 online here and you can download it here.
For Tornos and Almac you can read the embedded decomagazine here.

But having a paper magazine in hands is nice don’t you think? Indeed you can also subscribe to receive Eurotec directly on your desk by surface mail or by air-mail here.

I wish you an interesting reading. Stay tuned for more news here.

Pierre-Yves Kohler
Publisher and editor
Eurotec

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…brought to you by Eurotec-online.com

To turn and grind on the same machine

We already presented this new Schaublin machine on these pages (and you will be able to discover more in Eurotec’s next issue). Nevertheless I was able to take a few pictures yesterday… Enjoy.

With its large machining area and the pivoting NC, set-ups and production are very easy.
With its large machining area and the pivoting NC, set-ups and production are very easy.

The new 202TG was presented at the Schaublin inauguration of its new building on June 21 and Rolf Muster, CEO tells us: “We are very confident for the future with this new machine, the first was sold on June 20 to a Malaysian company and a few more are being negotiated. It’s very positive for a machine that has not been officially launched”. This customer is active in the automotive industry but the machine is dedicated to all fields of activity..

Basically the kinematics of the machine is simple, it includes a synchronous motorspindle (up to 7’000 rpm, 30 Nm) with a W25 nose and possible use of a bar loader (19 mm max.). Two cross-slides receive the different tooling on both sides and the tailstock as well as the part catcher are mounted on a gantry.
Basically the kinematics of the machine is simple, it includes a synchronous motorspindle (up to 7’000 rpm, 30 Nm) with a W25 nose and possible use of a bar loader (diam. 19 mm max.). Two cross-slides receive the different tooling on both sides (here a turret on the back and two grinding spindles on the front) and the tailstock as well as the part catcher are mounted on a gantry.

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Another picture to see the tailstock supporting the part for better machining.
Another picture to see the tailstock supporting the part for better machining.

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The new 202TG is programmed classically in ISO.
The new 202TG is programmed classically in ISO.

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Schaublin Machines SA
Rue Nomlieutant 1
2735 Bévilard
Suisse
Tél. +41 32 491 67 00
Fax +41 32 491 67 08
[email protected]
www.smsa.ch

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