FANUC unveils latest-generation ROBOCUT

Thanks to a number of breakthroughs, FANUC says that its new ROBOCUT α-CiC series of wire EDM machines offers even higher levels of reliability, cutting speed, surface finish and dimensional precision. The many customer-centric enhancements include an entirely new mechanical structure, pitch error compensation across the complete work surface, a simplification in taper cutting adjustment and a hardened table as standard.

FANUC’s new ROBOCUT α-CiC provides users with a major accuracy boost thanks to the introduction of a high-precision pitch error compensation function. A special factory-calibrated compensation grid ensures pitch error correction over the entire X-Y table area – rather than a single central point – delivering a significant advantage in workpiece accuracy. It no longer matters where the workpiece is located on the work surface, the same level of optimum precision will result.

Improvements in taper cutting performance and ease of adjustment represent another notable advance. The traditionally complex operation of setting and adjusting the wire taper is now straightforward thanks to the use of a basic jig guided by on-screen instructions.

FANUC appreciates that process control is paramount to success in wire EDM operations. ROBOCUT control enhancements via the latest feature-rich FANUC iH Pro user interface focus on leveraging the advantages of the new mechanical structure to cut more efficiently. The new and improved user interface with its 15’’ widescreen, multi-touch LCD means that more intuitive operation is a further advancement, even for those relatively new to wire EDM.

Two model sizes are available: the ROBOCUT α-C400iC and ROBOCUT α-C600iC. Users can load workpieces with dimensions up to 1050 x 775 x 400 mm in the X, Y and Z axis respectively, with a maximum weight of 1000 kg.

For further information
www.fanuc.eu

CAMWorks adds wire EDM module

HCL Technologies has launched a wire EDM module for its CAMWorks suite of CADCAM software. The wire EDM module includes new functionality that takes the design model to G-code in one click. Once the user clicks the ‘Solid to G-code’ button, the system automatically searches the part for machineable features, identifies them, generates all the operations with the user’s preferences and settings (including tool offsets, cutting conditions and start holes), creates the toolpaths, and posts the G-code. Using the new wire EDM module, even complex two-axis parts, two-axis parts with tapers, and full four-axis wire EDM parts are now programmable in a single click.

The new CAMWorks wire EDM module also includes enhanced feature recognition for non-planar geometry. Instead of the user needing to project the geometry for the top and bottom of the part and create 2D sketches, the new wire EDM software uses geometry directly from the solid model to construct and create the correct top and bottom profiles automatically.

Additional highlights include automatic angular wire threading, support for SOLIDWORKS patterns, and automation based on face colours.

Automatic angular wire threading analyses the part and automatically recognises when angular threading would be required. It then creates the tool paths necessary to allow for angular threading of the wire and to machine the part.

Support for SOLIDWORKS patterns simplifies the NC code and streamlines the programming process by automatically identifying the patterns and utilising them to simplify the CNC program.

The technology based on face colours allows the user to easily identify and manage features that require programming, as well as the machining required.

For further information
www.camworks.com

Largest electric bus order

BYD UK and Alexander Dennis Ltd (ADL) have jointly confirmed that their electric vehicle partnership will deliver the UK’s largest ever electric bus order. The order has been placed by RATP Dev London, one of Transport for London (TfL)’s principal bus operators, for a total of 195 single and double deck vehicles. With this order, RATP Dev London confirms its commitment to supporting TfL’s electrification plan for London’s bus network, a key objective of the Mayor’s Transport Strategy for 2018, under which all TfL buses will be zero emissions by 2037.

For further information
www.alexander-dennis.com

Asiamold to return in March 2022

Key players from a variety of industries will attend Asiamold 2022, promising to provide global business opportunities for buyers and suppliers alike. Guangzhou International Mould & Die Exhibition (Asiamold) will take place on 3-5 March 2022 at the China Import and Export Fair Complex. Three months after the conclusion of the 2021 fair, many exhibitors from the previous edition have already confirmed their participation for 2022. Notably, despite the impact of the pandemic on many industries worldwide, Asiamold 2021 saw a 27% increase in visitors from the previous year.

For further information
www.asiamold-china.com

Rocol creates savings for A&M EDM

As an engineering solutions company, A&M EDM is always striving to enhance its operations and capabilities to maximise its service to clients in the aerospace, motorsport, automotive, marine, medical, rail, defence and general subcontract sectors. To achieve this, the company has invested in technology that extends from three, four and five-axis machining centres, EDM wire and spark erosion, and laser welding, through to a temperature-controlled metrology department. When A&M EDM was not getting the best from its machines and cutting tools, the company worked with MSC Industrial Supply to instigate a change of cutting fluid supply. The result was a relationship with the cutting fluid experts at Rocol.

Playing a proud role in the Ventilator Challenge and having more than 57 CNC machines on the shop floor, as well as a host of accreditations and accolades, the Smethwick-based manufacturer utilises MSC to deliver best practice engineering support. Frequent onsite visits proactively identify ways to help A&M EDM optimise its processes. When it came to improving the performance of its metalworking fluids while maintaining high-quality machining, MSC identified Rocol as the perfect partner to collaborate with A&M EDM.

Like many subcontract manufacturers, A&M EDM machines a variety of materials that include stainless steel, mild steel, aluminium, Inconel, titanium and exotics with a variety of production demands from bespoke one-offs and short runs through to longer run batches.

This variety of materials poses a challenge for any cutting fluid supplier, but Rocol recommended its Ultracut Evo 255 metalworking coolant, an extreme pressure (EP) soluble oil-water mix cutting fluid. Rocol and MSC suggested this product as it is not only versatile and suitable for a wide variety of machining applications and materials, but would deliver a significant saving in the volume of coolant required.

When asked why the company changed cutting fluid supplier to Rocol, Gary Surman from A&M EDM says: “We had three fundamental issues. Firstly, we had operators who were complaining about irritated skin. There was also a smell in the workshop, while thirdly our tool life seemed to be diminishing relatively quickly.”

Adds Surman: “We are delighted that MSC and Rocol have come in and analysed our coolant consumption and recommended a solution that will reduce this to half the amount we were using previously. They invested time in understanding our objectives, and demonstrated a commitment and determination to help us achieve them. We look forward to an ongoing relationship where MSC and Rocol will continue to assess and benchmark our machines regularly, helping us to achieve further efficiency and productivity gains.”

Rocol analysed A&M EDM’s coolant consumption, accounting for the materials and applications while taking samples from active machining operations. The tests at Rocol’s laboratory delivered a comprehensive report on the current fluid product, with details such as the wear ratio, dilution and consumption. From the analysis it was possible to conclude that coolant usage was much higher than it should be, and that A&M EDM needed a versatile, high-performance cutting fluid that would deliver consistent usage and quality results on a range of different materials.

Commenting on the Ultracut Evo 255 Surman says: “Once we got the product into the machines, we had no further concerns about skin irritation, the smell had dissipated and tool life improved.”

Machine operator Callum Bowen re-iterates the point on odour, stating: “The Rocol coolant has made a difference. When I get home from work, I no longer smell; it doesn’t stick to my clothes, unlike the previous product we were using. Additionally, the fluid is very good when cutting different types of material, and it does not fog-up the glass screen on the machine doors, so we can see what’s going on.”

The Rocol Ultracut Evo range of operator-friendly, water-soluble cutting fluids is inherently resistant to degradation and contains no biocides or skin sensitisers. These attributes demonstrate low foaming qualities and reject tramp oil to provide excellent cutting performance and residual corrosion protection.

“Our operators have had no noticeable effect on their hands, whereas before they were getting skin irritation,” says Surman. “Even looking inside the machines, they are much cleaner than they were previously, and we can only put that down to the old coolant congealing and sticking to the walls and surfaces of the machine.”

The analysis showed that with Rocol Ultracut Evo 255, dilution levels improved from 19:1 to 40:1, reducing A&M EDM’s consumption from 41,000 litres to just 20,048 litres per annum. The reduced consumption rate outweighed the increased cost per unit, resulting in a cost saving of £16,900 per year.

“We used to buy around 10 IBCs every year and we are now down to five,” says Surman. “However, it’s not just the cost of coolant we are measuring here. There has also been a significant drop in the costs of our cutters, which we can only put down to the cutting fluid and EP additives that are allowing the tools to last longer. We’ve had a 40% reduction in our tooling spend where roughing operations were being carried out.”

Referring to the waste management of cutting fluid, Surman says: “When the suds kept going-off, we had to dispose of it under our ISO14001 environmental standard. Now, we are no longer disposing of 10 to 15,000 litres a year due to coolant that has perished.”
Naturally, Surman is pleased with the service provided by MSC and Rocol: “Initially, when we were doing the changeover, Rocol engineers were here every day. They were monitoring and checking vigorously. Now, with the coolant fully implemented, they visit once a month. They come round and do all the checks, the reports and the laboratory testing. If we have a problem, Rocol is only a phone call away and they will pop-in on the same afternoon or the following day.”

With a vast machine shop, Surman comments on the implementation throughout the facility: “We had our maintenance engineer fit an IBC and pipe it into every machine, so we have one source with hoses connected to every machining resource. We now have no spillages on the shop floor and we’re no longer trying to carry tanks around.

“The ease of changeover from the previous cutting fluid to Rocol was simple,” he continues. “Rocol did all of the laboratory work in the background. They came in, investigated our work and found a product that was compatible with the materials and jobs we were machining, so we were able to mix. We didn’t need to empty the sumps, we just added it to what was already there, and over time we are now fully Evo 255 compliant.”

For further information
www.rocol.com