The Siemens Sinumerik CNC controllers have been getting the maximum productivity out of each machine for over 50 years. Now they have another partner on their side: the Hainbuch Testit software. It is available on a data carrier for installation on Siemens CNC controllers [Sinumerik 840 D sl plus PCU50]. This means that a separate laptop is not needed anymore and manufacturing with “theoretical clamping forces” is also a thing of the past.
Thanks to Testit, the operator always knows which clamping forces exist and where, and the actual maintenance status of the clamping device. And given the safety standard DIN EN 1550, it is a “must have”. This means: The Testit clamping force gauge together with the Siemens CNC controller executes a target-actual comparison of the maintenance status of a clamping device. If the limit values are underranged, a warning message is output. Perfect, don’t you think?
Safe results – even with mandrels
The globalization of markets requires an optimum of the machining process. Those who face stiff competition can no longer afford to manufacture just by “feeling”. Measurement data is demanded! It not only functions perfectly for outer diameters and during rotation, it also precisely measures the holding force of mandrels for inner diameters.
Clamping force measurement for O.D. and I.D. clamping
Can be used rotating and for stationary applications
Direct input onto the Siemens CNC controller
The AMB Stuttgart started yesterday with the halls full of visitors. At the DMG MORI booth (quite crowded too), many novelties. Among them, the new Lasertec 65D hybrid machine. Let’s have a look at it.
For the first time additive manufacturing is integrated into a high-tech 5-axis milling machine. This innovative hybrid-solution combines the flexibility of the laser metal deposition process with the precision of the cutting process and therewith allows additive manufacturing in milling quality.
10 times faster
The process uses the metal deposition by powder nozzle, which is up to 10-times faster than the generation in the powder bed. Up to now additive technologies have been used to generate prototypes and small parts. By combining both, additive manufacturing via powder nozzle and the traditional cutting method in one machine, totally new applications and geometries are possible. Especially large workpieces with high stock removal volumes are now possible to be machined in an economical way.
Opening new possibilities to designers
The flexible change between laser and milling operation allows the direct milling machining of sections which are not reachable anymore once the part finished.
Highlights Lasertec 65 3D
Complete machining in milling quality with fully automated change between milling and laser operation
Laser deposition welding with powder nozzle: 10-times faster vs. powder-bed-process
Wall thickness from 0,1 mm to 5 mm possible (depending on laser and nozzle geometry)
Feasibility of 3D-contours without backing geometry: e.g. machining of a flange, machining of a cone
To be seen in Stuttgart on the Entrance West, Hall 7, Booth A01
In 2013, Heller placed a strong emphasis on the further development and refinement of its products. The 2013 investment volume stabilised at a high level being significantly in excess of 16 million EUR.
Investments focused on the assembly plant in China, machines and other equipment and modernisation of operating and business facilities. In response to the growing market in Eastern Europe the company is investing to increase customer proximity, e.g. with the expansion of its sales and service activities at the Heller location in Yekaterinburg/Russia.
14.1 million EUR in development
Another priority was development expenditure. Last year, the company spent at total of 14.1 million EUR in this area – 10% up on 2012. The focus was on the diversification of the product range, enabling the company to better serve its existing customers and expand business into new target groups, attracted by the traditional strengths of Heller, including customers from outside the company’s traditional clientele from the automotive industry. At the same time, Heller continued working on the expansion and intensification of its regional business.
Tailored to the needs
Three new developments and numerous product enhancements result in a completely revamped and expanded product portfolio for 4-axis and 5-axis machining and combined milling/turning, especially in terms of large-part machining. Another addition is a completely new developed external milling machine for the machining of small light-duty crankshafts to round off the lower end of the product range in terms of external and internal milling processes. In terms of its turnkey competence for crankcase manufacturing systems, Heller is offering systems for the coating of cylinder bores on the basis of twin-wire arc spraying technology already successfully introduced in the market. Under the name Heller CBC (CylinderBoreCoating), Heller it expands the process chain in crankcase manufacturing. First systems are already in operation for high-volume production in Germany and Japan. At the production location in Nürtingen, the Heller CBC TechnologyCenter is operating a flexible system showing the current status of development that can also be used directly for customer projects.
Future perspective: high-quality machines and state-of-the-art solution competence supporting the success of customers.
The investment in a new machining centre has to pay off. To make production future-proof, Hellers’ customers need reliability, precision and high productivity. In response the company provides a combination of high-quality mechanical engineering and state-of-the-art solution competence.
GF Machining Solutions, a division of GF, is to acquire Liechti Engineering AG, Langnau/BE (Switzerland). The company is a leading specialist of 5-axis milling machines designed to produce blades and blisks for aircraft engines and power generating turbines.
With more than 10 000 planes in the order books, aircraft production is planned to stay strong for the foreseeable future and so is the demand for engine parts. The acquisition of Liechti Engineering AG will allow GF Machining Solutions to significantly strengthen its presence in this promising market sector.
Both companies can look back to a successful cooperation over the last ten years, with GF Machining Solutions acting as a supplier for Liechti. Their competences and product ranges are also highly complementary. The current management under Ralph Liechti will remain in place and the company continues to operate out of its present premises in Langnau/BE. The two parties agreed not to disclose the purchase price and further details of the transaction.
Since its foundation, Almac has always been committed to providing tailor-made solutions, mainly targeting the Swiss watch market. Although its integration into the Tornos group has enabled it to develop internationally, its potential has remained largely untapped. The company is now turning a new corner by implementing a real strategy to enable German customers to benefit from the same advantages as Swiss watchmakers.
Mr. Devanthéry, the Director of Almac, explains, by way of introduction: “Almac is a fairly new brand on the German market. The brand is not yet very widely known and customers do not immediately think of Almac when it comes to precision milling and micro milling.” We have yet to build our reputation there.
Tried and tested machines
And this is the paradox currently faced by Almac outside the Swiss market: the company finds itself positioned like a newcomer to the market, even though the solutions it is offering have been validated by one of the most demanding and most dynamic business sectors in the world. With over 1000 machines installed, the company is a renowned player in the “micro precision” sectors; these not only include watchmaking, of course, but also jewellery, medical and micromechanics in general.
Pleasantly surprised customers
Customers who have seen the new Almac machines, and their eye-catching design, have been pleasantly surprised. […] Mr. Devanthéry adds: “We must not forget that our expertise lies in our unique experience in the Swiss watchmaking market with its highly sophisticated constraints.”
What upcoming customer events will Almac be attending in Germany?
Upcoming events which Almac will be attending include the AMB in Stuttgart (September), Prodex in Basel (November) and the Turning Days in Villingen-Schwenningen (April 2015).
Current discussions about 5-axis machining centres are ongoing. Whilst some sceptics claim that more challenging programming or higher demands on the machine and the control speak against the technology, insiders emphasise the benefits of faster machining resulting in savings potentials plus higher precision and reduced tool wear due to shorter milling paths. That is also why Heller placed the focus on this particular technology during WerkTage 2014, being already the 7th edition of this event. With seven machining centres live in action, guided plant tours and moderated panel discussions, the event was again fully geared towards the tasks of the users.
Already ahead of the event, organisers were aware of the expected number of visitors and an international response to WerkTage 2014. However, none of them had anticipated that they would be welcoming more than 800 guests from 20 different countries. With a share of more than 60%, the majority of visitors still came from Germany, followed by guests from Switzerland, Portugal, Spain and the US. Just as diverse as the nationalities of visitors to Nürtingen were the branches of industries interested in economically viable manufacturing solutions, including representatives from the automotive industry and its suppliers, machine builders, mould and die manufactures through to aerospace companies.
Understanding of tomorrow’s trends
The 7th edition of Heller WerkTage provided visitors with an opportunity to gain an understanding of tomorrow’s trends. Aspects presented included solutions offering precision and 5-axis competence and a comprehensive approach to the process chain. Heller demonstrated its full spectrum of productivity with seven machining centres on display, machining a diverse range of components and meeting a wide variety of requirements. An out-facing head solution and trochoidal milling, universal application using oversized tools and boring in all its facets were presented on three 4-axis machining centres from the H series. Three 5-axis machining centres from the F series were the focal points in terms of 5-axis machining. Model FP 4000 demonstrated high precision with in-process gauging and 5-axis machining from 6 sides, whilst model FT 4000 showcased strategic 5-axis simultaneous machining. Additionally, Heller cycles and combined mill/turning operations were demonstrated on 5-axis machining centre model CP 8000. Live machining demonstrations were complemented by a total of three new developments and numerous product enhancements, including the expansion of the process chain in crankcase manufacturing with Heller CBC (CylinderBoreCoating).
GF Machining Solutions’ System 3R Transformer Automation is engineered to grow in line with the business needs and — ultimately — ensure a greater return on the capital equipment investment of customers.
Extreme flexibility is the heart and soul of the Transformer, a scalable Automation system based on standardized modules. The Transformer allows users to begin with one or two machines and later add machines and magazine capacity, to finally extend the Automation to include up to 12 machines in a single cell.
The machines in a Transformer cell can be of the same make and type, or the cell can just as easily incorporate different machining technologies and come from different manufacturers. Open architecture is one of the system’s clear advantages. The customer can select the machine or machines that best meet their specific manufacturing requirements and the Transformer — custom configured— complements that choice. Flexibility and productivity remain in constant focus.
Mounted on pallets
The Automation system handles workpieces and/or electrodes that are mounted on pallets (i.e., based on a reference system, more commonly known as tooling). System 3R offers a wide range of tooling systems that provide solutions to palletize workpieces from small to large or in combination of different systems in the same Automation cell by using chuck adapters. In addition, the Transformer can handle different tooling systems, so it can be configured even if customers already have a tooling system in place in their workshop. Customer-specific solutions are a key ingredient of this system.
Additional in-process accessories
Multiple loading station that can be used without stopping production,
A draining station for emptying workpiece cavities after machining,
A washing machine for cleaning your workpieces,
Coordinate measuring machine (CMM) integration for pre-setting and/or parts inspection.
The Transformer also offers user-friendly cell management software to guarantee consistency. All production data is entered in a structured manner or imported through a data exchange interface for major enterprise resource planning (ERP) systems, and the System 3R CellManager handles everything in the cell, from automatically loading the jobs into the machines to recording the machining time of each job.
GF Machining Solutions
1217 Meyrin 1
T +41 22 783 31 11
F +41 22 783 06 12 www.gfms.com