Mapal improves machining of axial piston parts

Mapal has carefully examined critical components of the fluid power industry and their potential for complete machining. An example is axial piston pumps and motors, a central component of which is the cylinder block, made either of steel (C45 or 42CrMoS4) or spheroidal cast iron (EN-GJS-500-7 or EN-GJL-400-15. Mapal experts have developed a solution that reduces the machining time for a customer’s cylinder blockby 19%.

“One customer was struggling with high costs for manufacturing cylinder blocks,” says Tobias Stolz, component manager for general machining at Mapal. “A great deal of effort was required to ensure the defined surfaces, which had to be between Rz = 27 and 37 µm, as well as the high quality of liners with tolerances for roundness, straightness and parallel alignment of 3 µm.”

The customer today machines the pressure and suction kidney with the Mapal OptiMill-Uni-Pocket solid-carbide milling cutter as part of a new process. This tool supports the boring operation by way of inclined plunging. The machining of these inlets and outlets therefore does not require any other tools.

A step drill with Tritan-Drill geometry offers similar benefits when pre-machining the piston bores, dispensing with the requirement for a spot face. Furthermore, thanks to sharp cutting edges, the bottom of the bore no longer requires deburring. The multi-stage Mapal fine-boring tool ensures optimal quality before pressing in the brass bush. It is not only very precise during machining but also particularly economical thanks to the HX insert’s six cutting edges. These three tools alone reduce machining time by 19% compared with the previous method.

“We offer our customers economical processing solutions to their machining challenges for all functionally relevant parts in the fluid power industry,” summarisesStolz.

For further information www.mapal.com

Walter PVD grade suits high-load grooving

Walter is launching its patent-pending Tiger·tec Gold WSM33G grade: the company’s first PVD grade to accommodate the high loads that occur during grooving operations. The cutting tool material combines third-generation TiAlN with TiSiN to form a multi-layer coating with exceptional hardness and increased toughness, reports Walter.

A special post-treatment reduces friction and ensures a smooth surface, thereby optimising chip removal and process reliability. Furthermore, the gold top layer makes it easier for users to detect wear. Walter uses the new PVD coating on single-edged SX cutting inserts with positive engagement and a self-clamping system. It is also applicable to indexable inserts from the double-edged DX18 system, where a second prism ensures stability in the insert seat.

For manufacturers, the fact that this grade is usable with both systems delivers maximum versatility as it caters for all insert widths from 1.0 to 10mm. Another advantage of the Tiger·tec Gold WSM33G grade is its adaptability, even under challenging conditions. Walter says the universal grade is suitable for 75% of all applications, including grooving and parting-off, groove and copy turning,and slot milling.

The system can undertake these operations on a range of materials, including steel (ISO P30), stainless steel (ISO M30) and materials with difficult cutting properties (ISO S30). Offering universal application, long tool life and high resistance of the multi-layer coating against plastic deformation and flank face wear, Walter says that its WSM33G grooving inserts are a productive and reliable choice.

For further information www.walter-tools.com

Bandsaw training, commissioning and re-training

The bandsaw has evolved significantly since its invention in the 19th century. But with such a great utility comes complexity; operating a bandsaw machine safely and efficiently requires an intimate understanding of the machine’s workings, its potential hazards and the techniques to leverage its full potential. Saws UK therefore provides a guide to bandsaw training, commissioning and re-training.

Regardless of the specific type of bandsaw, be it horizontal or vertical, metal-cutting or wood-cutting, comprehensive training is crucial. Recognising the need for expert-led, comprehensive bandsaw machine training, the Saws UK University took shape.

Training begins with a deep dive into the machine’s architecture, exploring each part’s function and interaction with the whole system. Participants are guided through the myriad components of the bandsaw, from the blade, guides and wheels, to the motor and the drive system. Operators also learn about safety, daily machine operation and bandsaw maintenance. As participants progress, they delve into more advanced topics, such as fine-tuning machine settings for different materials, troubleshooting common issues and mastering advanced cutting techniques. 

The process of bandsaw commissioning sets the foundation for the successful operation of the machine. It is the initial set-up, where the bandsaw machine is assembled, installed, tested and adjusted to ensure it operates as efficiently and safely as possible. This is why bandsaw commissioning is an essential component of the training programme at Saws UK University. 

Bandsaw machine re-training ensures that operator knowledge and skills remain current, aligning with the latest developments in bandsaw technology and industry practices. Saws UK University tailors re-training sessions to the needs of attendees, covering everything from basic refresher courses to advanced workshops focusing on new technologies and techniques. 

For further information www.sawsuk.com

Unilap steps into new sectors with Vollmer

Darrell Hughes founded South Yorkshire Saw & Tool Co in 1974 as a small saw blade sharpening and ancillary supply company. Wind forward almost 50 years from the inception of a company working out of a two-bay garage and the transformation of the Doncaster-based company is beyond comprehension. Everything has changed. The company name, the facility, the industries served and the manufacturing processes.In fact, the only remaining constants are the long-serving personnel, family ownership and sharpening technology from Vollmer UK.

Changing its name in 1992 to Systco Unilap, the saw blade sharpening company acquired its first Vollmer machine in the late 1970s and has bought a complete suite of German-built machines over the years. To manufacture the countless product lines with thousands of new, re-sharpened and serviced tools delivered every week, the company has 11 Vollmer machines.Three arrived in 2022.

With 25% annual post-Covid expansion in traditional markets and growth in new segments, Unilap needed capacity, hence its investment in a Vollmer CHX840 with HS loading system in April 2022. Quickly following this machine was a Vollmer QXD250 with HC5 loader in July, with a Vgrind 260 with HC4 loading system arriving in October of the same year.

The reasoning behind the CHX840 and the QXD250 was simple. Unilap purchased the automated CHX840 saw blade sharpening machine to add unmanned ‘lights-out’ running and alleviate capacity on the 22-employee company’s other saw blade manufacturing and servicing machines. Likewise, Unilap already had a nine-year-old Vollmer QXD200 machine running around the clock, so upgrading to a brand-new QXD250 would add capacity and support rapid growth in the metalworking industry.

For further information www.vollmer-group.com

New saws give edge to British Steel project  

The arrival of three new Behringer saws at British Steel’s Skinningrove service centre will herald a major new milestone in its development.The £2.2m equipment will be a pivotal part of the operation, bringing increased productivity, greater accuracy and more intuition to the whole process of making special profiles for customers.

The £26m centre will include cut-to-length lines, product milling, machining and warehousing operations, and will enable British Steel to make and process an extended range of value-added profiles for the forklift industry.

The process of making sure special profiles meet requirements involves cutting down 14m bars, where accuracy is critical. The new saws will automate the process, deliveringmore precisionandthree times more speed than the previous saws.The advanced milling and machining capability will mean British Steel can offer profiles with tolerances of just 0.1mm.

Project manager at the Skinningrove service centre, Stuart Webster, says: “The new saws and product transportation systems that Behringer are providing will be integral to our facility.They will allow Skinningrove Special Profiles to move into the next phase ofanticipated market development in forklift mast sales. The saws will also significantly improve our capability to cut all products faster and meet tighter tolerances that satisfy the developing requirements of our customer base.”

British Steel’sspecial profiles business manufactures 250,000 tonnes of specialist products for a range of sectors, including the material handling market, of which the “profitable and growing” market for forklift trucks is a part.

For further information www.britishsteel.co.uk