Manufacturers gear up for Iran exhibition

The 18th edition of IInEX (International Industry Exhibition – formerly TIIE) is set to take place at the Tehran Permanent International Fair Ground in Iran on 13-16 October.

This showpiece annual exhibition will this year cover some 26,000 sq m of show space, as organised by Idro International Trading Co.
With a host of international exhibitors expected from across the world, visitors from Iranian industry will be able to enjoy the latest innovations offered up by sectors such as machine tools, workshop equipment, industrial automation, cutting and forming tools, and technical services. As always, MTI will have a strong presence at the show, where the team will be busy engaging with visitors by helping them use MTI’s combination of magazine and website ( to find the optimum machine for their application.
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Reaping the rewards with latest cutting tools

Vetech Product Design & Development Ltd is a subcontract manufacturer that was conceived by engineers with an expertise in the garden equipment sector. When the Buxton-based company opened its doors for business in 1994, the founders applied their industry knowledge to win business from the globally recognised Bosch brand. Since its inception, the company has always invested in the latest technology to drive its business forward, and central to this strategy is support from its cutting tool partner Industrial Tooling Corporation (ITC).

More than just another subcontract manufacturer, Vetech offers design and consultancy services to a customer base that now incorporates high-profile names in the military, electronic sensor, motorsport and plastic moulding sectors, as well as the ever-expanding network of garden equipment manufacturers. Upwards of 60% of business at Vetech is aluminium mould tools for the garden and leisure industry; and it is here that cutting tool specialist ITC has made all the difference.
Over 10 years ago, Vetech realised that its CNC machine tools could not achieve the high spindle speeds required for machining mould tool ribs with small diameter cutting tools. Vetech visited the TCT trade show and found the solution on the ITC stand in the guise of high-speed spindles. Delivering immediate success, Vetech then approached ITC regarding its line of standard and special cutting tools.
Commenting upon the founding of the relationship that spans over a decade, Vetech senior design engineer Andy Smith says: “We found a solution for running our tools at high speed through ITC. At that time, we were also witnessing problems with our previous cutting tool vendor. The issues included limited stock and tool range availability, excessive lead times on special tools and poor technical support. ITC came to see us and we trialled some solid carbide tools. The tools were successful and 10 years later, ITC supplies over 90% of our cutting tools.”

Many of the aluminium mould tools manufactured at Vetech are for rapid prototyping projects, making turaround times critical. With the availability of high spindle speeds of 60,000 rpm, Vetech could apply ITC’s 1 mm diameter solid-carbide end mills to mould tool ribs that were previously processed using EDM.
Referring to this, Smith recalls: “We process a lot of mould tools that often incorporate cross-rib designs. On one of our early tools for a lawnmower motor end frame, we had to spend 3 hours programming two different electrode designs that would then require an additional 4-5 hours of machining. After this, the erosion time would be upwards of 8 hours and finally there would be an additional 3-4 hours of hand finishing. With ITC tools and the high-speed machining, we immediately eliminated this 16-20 hour process and replaced it by CAM programming the mould tool and machining it in 4-5 hours with impeccible surface finishes. This cut our complex mould tool production times by 75%. Essentially, we were producing a challenging mould every two weeks; ITC reduced our mould tool production costs by over 25% almost overnight.“
Since this early success, Vetech has invested in Hurco VMX42M and a VMX30Ti machining centres. These VMCs offer a spindle speed of 12,000 rpm and both the EDM process and speed increaser have since become virtually redundant.
During this early point of the relationship, Vetech was using both the 2112 and 2001 series end mills to increase tool life by over 30% and reduce cycle times by an average of 35%.
“The 2001 series has been an exceptional performer,“ says Smith. “We use the 16 and 20 mm diameter tools with a 2 mm radius and the smaller 6, 8 and 12 mm tool with a 1 mm radius. The tools are extremely rigid and offer high material removal rates with outstanding surface finishes. Furthermore, the tools are particularly long, so we can pull them further out of the holder for different applications.“
Despite primarily machining aluminium, the ITC 2112 series is a steel geometry end mill.
“The 2112 series has performed extremely well down the years and we‘ve now replaced it with the new 2172 ball-nose cutter,“ says Smith. “Our new 2172 has a 0.5° angle above the ball and this gives added rigidity. More pertinent to us is the clearance that this 0.5° angle provides. The clearance angle naturally creates a draft angle that is essential on mould tools. Draft angles eliminate friction and ensure the mould tool performs at an optimal level. With regard to rigidity, we can run a 2 mm diameter 2172 series at machining depths of 35 mm. This limit was previously 20 mm with other tools and we are looking at pushing this depth to 42 mm; more than double what was previously possible. When it comes to mould tools, the tool reach is a key aspect, so the 2172 series is creating benefits in both machining depth and the creation of a draft angle.“

Over the past couple of years, Vetech has redesigned and developed the Hayabusa 1300cc motorcycle engine to generate huge power and reliability benefits to small vehicles such as the Mini and Fiat 500. ITC has also been integral in reducing cycle times with the engine development programme.
“We machine motorsport components such as oil hoses and pipe fittings that require undercut machining,” explains Smith. “For this, ITC has tweaked its 2001 series for us, grinding a radius on the flute for undercut machining. This is supported by an undercut feature in our HyperMill CAM software. We can now reduce the time for machining an undercut from 10 minutes to just one minute. This dedicated 16 mm diameter tool with a 2 mm radius allows us to use the side of the tool for machining undercuts. The flexibility also enables us to conduct rough and finish machining with one tool, completing the job in fewer set-ups.”
ITC has recently invested heavily in new grinding centres for the production of ‘micro’ cutting tools, and this investment has seen the company add new product lines and extend existing ranges. Vetech has already proven to be a beneficiary of this ITC investment.
“We use a complete range of ITC tools, but the addition of micro end mills and the extension of existing lines are ideal for our mould tool engraving. We are using the extended 2112 series tool in diameters from 0.4 to 1 mm with a flute length of 8 mm to engrave at high speed. As
well as having high-quality tools for intricate engraving applications, we can also use these small diameter tools in conjunction with our high-speed spindle to reduce machining times on mould tools.
“With the arrival of a complete line of micro tools, we can undertake very high-speed machining for long periods of unmanned machining,” he adds. “Our small mould tools require 4-6 hours of machining, while larger tools can run for over 24 hours and sometimes upwards of 50 hours. Intricate mould tools require micro tools, and by applying the 2112 series of micro tools, we can now run unmanned for long periods with exceptional surface finishes and achieve cycle time reductions beyond 30%. However, the most critical aspect of unmanned machining is tool life and consistent performance. The ITC range certainly operates with reliability, efficiency, cost effectiveness and performance.”
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Mazak charity campaign raises £1400

Yamazaki Mazak UK has raised £1441 for Cancer Research UK following a series of dedicated charity events that took place throughout August.

The machine tool manufacturer, which is located in Worcester and employs over 900 people, held the company’s biggest ever cake sale at its European headquarters at the start of the month. Over 600 cakes were sold over two days, all of which were donated by two of Mazak’s corporate catering partners, Brookes Catering and Elior.
The company also ran a wide-reaching raffle for employees and their families, with prizes ranging from £100 Amazon vouchers and a mountain bike to an ‘Afternoon Tea for Two’ and an overnight stay at the Worcester Whitehouse Hotel. However, the charity initiatives were not limited to Mazak’s Worcester site. On Saturday 11 August, Mazak’s senior marketing executive Milko Hadzhigenov climbed Mount Snowdon in just 4.5 hours, to support the fund raising efforts. Mazak’s charity page will remain live for a further three months; to make a donation, please visit the web address below.
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Baileigh unveils latest press brake

Baileigh Industrial is launching its BP-3305CNC press brake that is said to be sufficiently compact to fit in a garage, but powerful enough for use on the shop floor.

A factory-installed, two-axis, programmable CNC controller makes it both versatile and simple to use, providing the ability to hold up to 40 programs.
The BP-3305CNC press brake is reportedly quiet and extremely safe, with an automated light curtain that instantly stops and reverses direction when fingers get too close to the bending operation.
The frame of this CNC hydraulic press brake is made from fully welded steel plate, designed to give minimum amounts of deflection, as well as offering maximum rigidity when using all 33 tons over its full length of 1.6 m. Baileigh’s BP-3305CNC also features a heavy-duty torque tube that connects a pair of hydraulic cylinders, ensuring accuracy to 0.04 mm. The machine runs on 220 V three-phase power and uses only quality components from manufacturers such as NOK, Siemens and Omron. All bending functions are controlled by a foot pedal.
Baileigh Industrial is a manufacturer of a complete line of metalworking equipment. For over 16 years, the company’s machines have been designed to increase productivity in the workshop and handle maximum capacity with ease. Customers range from large-scale commercial fabrication shops, to passionate hobbyists. Baileigh’s machines have been used by teams such as Gas Monkey Garage and Diesel Sellerz of the ‘Fast N’ Loud’ and ‘Diesel Brothers’ shows on the Discovery Channel.
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Productivity leap for cam lobe manufacturers

Hatebur has developed and tailored its HOTmatic AMP 20N, a machine that is specifically designed for the manufacturing of forged cam lobes.

With this machine, the company aims to improve the efficiency and productivity of suppliers in the automotive industry.
“Almost all of the world’s forged cam lobes are produced on Hatebur machines,” states Thomas Christoffel, CEO of Hatebur. “With the development of the HOTmatic AMP 20N, we are reacting to new trends in the industry. We want to make our customers even more productive and strengthen our market leadership.
“The trend is heading towards thinner cam lobes in order to support the lightweight construction of engines,” he continues. “That is why the R&D division of Hatebur has started early with fundamental research on cam lobes featuring a thickness of 8 mm instead of 12 mm. The thinner cam lobes impose higher demands on the forming machine – in particular with regard to the shearing quality, pressing force and part transfer.
The HOTmatic AMP 20N offers a total press load of 1500 kN; the machine body has been reinforced to guarantee the necessary stability.
In three forming stations – and with a maximum of 200 strokes per minute – the AMP 20N produces cam lobes with an outer diameter of up to 48 mm out of raw parts with 24 to 217 g.
The up to 6 m long, almost 1200°C hot bars are brought exactly into position via four feeder rollers, powered by servo drives.
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