Drill machining of forged steel

High forces must be applied to machine parts from forged steel. This material also tends to form longer pieces of swarf that are difficult to remove. For these reasons, Höhnhart, Austria-based Ferdinand Bernhofer GmbH machines forged steel workpieces on a two-spindle machine from Schwäbische Werkzeugmaschinen GmbH (SW).

Bernhofer began ambitiously expanding its range of services several years ago, with the expansion of installation-ready machining to a standard service being a top priority. Bernhofer therefore set out to find a manufacturer of suitable machine tools. Above all, the machine tools had to be sturdy and powerful enough to handle the three-shift machining of forged parts. The components being machined are combined in groups so the systems can be changed over or re-tooled as quickly and smoothly as possible. Another criterion was the most extensive automation possible, in order to conserve resources through 24/7 operation.

The first project was a family of parts with six variants made of quenched and tempered steel for motorcycle frames. Project goals included fully automatic machining and product swaps with no change-over. The BA 322 (a horizontal machining centre from SW with two synchronous spindles), was chosen to accomplish these ambitions.

“The mutual trust we have built on this foundation led us to choose SW again for the next project,” says managing director Ferdinand Bernhofer.

To explain, the new project involved machining particularly large drawbar eyes made from different variants of 42CrMo4. The task was made more difficult by the relatively large number of holes and fits that had to be machined, and was further complicated by the need for cooling lubricant to drill the holes. SW’s milling machine type BA 722 was purchased for this purpose. The larger machining centre, also with two spindles, was needed mainly because considerably greater quantities were to be removed through machining than for the motorcycle parts. Machining must remove up to 3 kg of material from each drawbar eye, which may weigh up to 18 kg, depending on the variant.

For further information
www.sw-machines.de

ONA’s QX Neo improves control

The latest range of ONA’s die-sink EDM has a graphical interface with more intuitive and visually friendly menus.

In short, the QX Neo enables a 3D view of the entire machining process. As well as showing the part and letting the user manipulate it easily thanks to its tactile technology, the equipment includes a control that ONA says has never been seen before in die-sink EDM. This control makes it possible to view the part to be eroded on the screen, as well as the electrodes and their travels. As a result, it is possible to view the complete EDM process, select electrodes and even modify machining sequences quickly and easily with a simple touch before running the program.
The new range improves the control of the equipment and its usability through the optimisation of the HMI, drastically reducing the possibility of programming errors. Features include: a high-quality 24-inch screen; intuitive programming supported by graphics help; improved environment for programming and simulation; and graphic interaction throughout the process – digital programming from the solid to the part. Further functions include the verification of electrode position, travels, machining order and job list.

QX Neo also makes it possible to import the files directly from CADCAM, as well as to access and run the programs located in another computer.
The ONA Security Pack guarantees protection of the customer’s sensitive information. This system enables the creation of a machine administrator, the set-up of different access profiles, the limitation of file deletion or modification, the blocking of external accesses, and a log of power-on and working hours.

For further information
www.onaedm.com

Houghton relocates

Houghton International has officially moved premises and is now fully operational at the Ronnie Mitten Works site on Shields Road in Newcastle-upon-Tyne. The company has consolidated its existing sites into 120,000 sq ft of engineering space at the CA Parsons Works in Heaton, the birthplace of the steam turbine (alongside Houghton’s existing pump repair facility). The new site will enable the company to be more efficient and flexible, while simultaneously creating significant space for future growth. Houghton has retained its existing large machine facility on Shields Road, which is adjacent to its new workshop.

For further information
www.houghton-international.com

EDMs boost tool-making capability

The Teisnach facility of Rohde & Schwarz, a specialist in electromechanical assemblies, has installed two Mitsubishi Electric EDM machines from the MP Connect series to help boost the precision production activities of the plant’s tool-making department. Covering more than 74,000 sq m, the Teisnach plant is home to 1850 skilled workers and is considered the tool-making centre for the group.

Says Andreas Bauer, head of toolmaking: “To maintain a high degree of flexibility, we’re constantly reorganising our operations. This is also a reason why we keep tool making here a little separate and autonomous.”

Five wire EDM machines are in operation in the tool shop at Teisnach, mainly in the production of punching, bending and extrusion tools. The two new Mitsubishi Electric MP1200 Connect and MP2400 Connect machines are used mainly for stamping and bending tools.

“Using these two precision machines we can operate with high process security, while they also give us the required flexibility,” says Bauer. “Last year we decided to make a change in our wire EDM machines. We took a close look at the main suppliers and drew up a requirements profile with our entire team.”

All the pros and cons – as well as the sustainability issues – were examined. The price-performance ratio was also a crucial factor. Rohde & Schwarz paid visits to users and compared the technical data until the company was convinced that Mitsubishi would be able to supply the market’s best machines.

“We drafted our 2027 tool-making strategy back in 2017,” Bauer reports. “Last year we took the first big step and invested around €2m, among other things in the two Mitsubishi systems. In doing so, we gave new impetus to micro-erosion, micro-milling and micro-drilling.”

For further information
www.mitsubishi-edm.de

Small cost, big improvement

Following a free R&D intervention by the University of Sheffield’s AMRC, a precision engineering SME has been shown how an investment of just £20 could bring about a huge improvement in its manufacturing process and unlock significant savings. The AMRC was able to show management at Chesterfield-based subcontractor CBE+ that with a new tool holder, which would cost £60 rather than the £40 one currently in use, it could attain a 10-15% improvement in tool life. Funds from the HVM Catapult paid for the project as part of a commitment to working with SME manufacturers.

For further information
www.amrc.co.uk