Two machines: one control

At EMO 2021 (4-9 October, Milan), Siemens will show two machines controlled with a single Sinumerik One control system: a five-axis milling centre and a robot-based additive manufacturing machine. With these two machines, it is possible to repair large gears, such as those used in wind turbines. At the show, Siemens will demonstrate how to mill the gear wheels flat, before using the robot to rebuild the teeth in an additive manufacturing process. Final precision grinding will take place on the five-axis milling centre. The repair – instead of new production – not only saves material resources, but reduces energy consumption by about 60%.

Sinumerik One is said to represent the core element for the digital transformation of the machine tool world. Thanks to the digital twin via ‘Create MyVirtual Machine’, both machines could be developed, tested and functionally approved in parallel long before the real machines were put into operation. Machine builders thus get to a better machine faster, while machine users arrive faster at the right workpiece.

With its Digital Enterprise portfolio, Siemens supports companies exactly where the current challenges lie. With the help of digital twins, such as Sinumerik One, and the use of future technologies like AI or edge computing, machine builders and users can collect, analyse and understand the data generated in a meaningful way. This capability allows them to react quickly and flexibly to challenges, and adapt their products and manufacturing processes to new requirements and save resources.

Siemens thus supports the machine tool industry in utilising the full potential of data for flexible and sustainable action.

For further information
www.siemens.com

Meet the hyperMILL team

EMO will provide a great opportunity for manufacturers to meet the Open Mind Technologies team and discuss their challenges with machining specialists in person. Version 2021.2, the most recent release of the hyperMILL CADCAM suite, will also be on show at Stand G12 in Hall 7. In addition, the Open Mind team will be providing an early look at what is to come in Version 2022.1, as well as demonstrating the hyperMILL Virtual Machining Center, which generates simulations based on real NC data and creates a virtual rendering of reality in the machine.

For further information
www.openmind-tech.com

Micro-machining the smart way

Chiron (Stand B05, Hall 4) will use the EMO exhibition to present its Micro5 compact machining centre. This small five-axis machine (the size of a fridge), which is now available in the UK from the Engineering Technology Group (ETG), guarantees maximum precision for small workpieces required by industries such as medical, watchmaking and jewellery. Micro5 offers a 5:1 ratio of machine to workpiece, and a five times lower weight, not to mention 50 times less energy consumption than conventional systems. The maximum workpiece size for the Micro5 is 50 x 50 x 50 mm.

For further information www.engtechgroup.com

20% faster cycle times with new control

German machining centre manufacturer Röders has introduced to its range an upgraded CNC system capable of programming and controlling a full range of metal-cutting operations more efficiently, from roughing and high-speed milling, to micron-accuracy jig grinding.

Available on its three- and five-axis machining centres, the Racecut control enables demanding precision requirements to be met, while at the same time delivering high cutting performance, including when machining hard materials. Availability of the machines in the UK and Ireland is through sole sales and service agent Hurco Europe.

Underpinning the high performance in terms of accuracy and speed are frictionless linear drives and 5 nm resolution glass scales. These combine with the benefits of the new CNC system, which has a high clock rate of 32 kHz. The smallest deviations in cutter paths can be detected and corrected, even during high-speed cutting, raising processing speed and optimising surface quality. Tests carried out by the manufacturer indicate that it is possible to reduce machining times by as much as 20% while maintaining the same surface finish.

Additionally, extensive compensation in the control for deviations in the angular position of the rotary table and swivelling trunnion of five-axis machines, plays a central role. Particular attention has also been paid to the control’s ability to compensate precisely for spindle growth, while a further notable feature is the patented, frictionless weight compensation system in the Z axis.

For thermal stability to ensure positioning accuracy of less than 1 µm, the machine has sophisticated temperature management. The temperature of the medium that flows through all key elements is controlled to an accuracy of ±0.1°C, which may be extended down to ±0.02°C for certain applications.

For further information
www.hurco.co.uk

Automated heavy part production in six axes

New CAM technology introduced by Hexagon’s Manufacturing Intelligence division makes it possible to use complex six-axis milling machine tools for the production of large parts. The specialist programming tools provide accurate simulation and generate efficient six-axis tool paths to ensure that these advanced machines offer increased productivity.

Hexagon’s Edgecam software features new tools that focus on six-axis machines equipped with two rotary axes on the head and one rotary table, where this sixth axis enables milling tools to machine all sides of a large part, including areas that are otherwise impossible to reach without repositioning workpieces. The new dedicated six-axis tools provide greater tool-path control and more accurate simulation of processes, reducing the need for expert intervention on the shop floor, improving the utilisation of advanced machinery and avoiding the risk of costly damage.

Edgecam improvements additionally provide greater flexibility for five-axis milling by offering tools that allow CNC programmers to select the level of automation they prefer when creating tool paths. Using these tools, programmers can choose to automate tool-path generation, manually create all tool paths, or generate tool paths using a combination of automated and manual tools. The ability to customise programming preferences increases control over exactly how parts are machined, helping users reduce programming time on tasks that are simple to automate and making it easier to work more closely with complex tool paths when needed.

Productivity is also improved with rough grooving operation optimisation that eliminates unnecessary machine movement, resulting in a cycle time reduction of up to 60%.

For further information
www.edgecam.com