Combined deburring and handling

At ZSO Zerspanungs und Systemtechnik GmbH in Oberstaufen, Kadia has implemented three ‘Deburr-Automation-Cells’. The function of these systems includes not only deburring workpieces, but complete automated handling of parts. European Precision Machines Ltd is the UK agent for Kadia solutions.

For ZSO managing director Carsten Binder, the project was particularly important as it involved the handling and deburring of grey cast iron housings for mobile hydraulic pumps weighing up to 26 kg – heavier than parts usually processed by the company.
“Our plan was to have a robot carry out all the recurring processes,” he says. “Deburring would also be possible on the machine tool, but a robot is a far more cost-effective solution.”

The Kadia proposal was based on a six-axis robot with a payload of 120 kg and a reach of 2.5 m, supplied completely from a single source. Kadia’s scope of supply included process development, the robot, cell, gripper, deburring stations and tools. Not to forget, of course, the sequence programming with all safety-relevant designs. Kadia delivered the first automation cell in April 2019, a second in September 2019 and a third in January 2020.

Notably, the automation cells had to be connected to three identical Heller H5000 machining centres. ZSO had gradually purchased several of these four-axis machines (already equipped with robot interfaces) especially for the pump housings. The robots had to carry out loading and unloading of the machine tools, as well as the deburring, within the machining cycle time (around 20 minutes).

“It’s important for our customers that we were able to increase process reliability and thus produce quality deburring results,” says Binder. “All edges are now deburred absolutely evenly and according to customer requirements; there are no variations in the execution. In addition, the robot never forgets an edge or thread, so reworking is a thing of the past.”

For further information www.kadia.com

DMC orders RenAM 500Q systems

Ahead of its opening in Q1 2021, the Digital Manufacturing Centre (DMC) has purchased two Renishaw RenAM 500Q additive-manufacturing machines.

The machines were chosen to increase efficiencies and quality, while reducing each part’s weight, waste and costs. Silverstone-based DMC has also entered a joint development collaboration with Renishaw’s additive-manufacturing team.

“The process of machine and material selection for the Digital Manufacturing Centre is crucial to our success and was not therefore a decision we took lightly,” states Kieron Salter, CEO. “Offering the service of being a technology partner to our clients means that we have to be armed with state-of-the-art, innovative additive-manufacturing methods and machinery.”

For further information
www.digitalmanufacturingcentre.com

CNC investment at Axium

Swansea-based Axium Process has invested in two new Doosan CNC machines to meet increased demand. This capital investment means the company, which is a manufacturer of bespoke pharmaceutical processing equipment, can support the sector with higher volumes of precision-engineered components that are designed in-house.

The two new additions to the factory floor are a Doosan 220 Lynx twin-spindle CNC lathe and a Doosan DNM 5700S CNC vertical machining centre. Both machines will be used to produce an array of components, including parts for Axium Process’s filtration systems. Among the materials machined at the company are stainless steel (including duplex variants), Hastelloy, titanium and aluminium.

For further information www.axiumprocess.com

Multi-purpose cutting fluid

Industrial lubrication expert Rocol has launched UltraCut 370EP, a semi-synthetic fluid that can be utilised as a coolant for both cutting and grinding operations.

Developed in the UK, the new coolant contains Rocol’s proprietary EP (Extreme Pressure) additive package, ensuring it enhances medium to heavy-duty machining performance, while simultaneously offering surface finish and component quality enhancements, and extending tool life. Furthermore, the semi-synthetic, water-miscible metalworking fluid has been formulated for application on ferrous and non-ferrous materials, meeting stringent industry requirements and minimising the corrosion and staining of components with its residual corrosion protection. Featuring a special blend of additives, UltraCut 370EP is tolerant to tramp oil, retains a low level of foaming and is durable for use in both hard and soft water environments.

When mixed with water, UltraCut 370EP forms a translucent blue micro-emulsion that provides a clear view of both the component and work envelope during machining and grinding applications. The fluid can be applied in dilution ratios from 30:1 to 75:1, with ratios adjusted depending on the machine tool, workpiece material, water hardness, application and severity of operation.
With high dilution ratios possible, Rocol says that UltraCut 370EP will provide significant cost savings, with a single barrel capable of providing up to 15,200 litres of fluid. For grinding processes, the advised dilution with water should be 50:1 to 75:1, depending on operation severity.

UltraCut 370EP is free from components such as bactericides, chlorine, formaldehyde, nitrites, silicone and any animal-derived materials.

For further information
www.rocol.com

New CNC internal grinding machine

Recently made available by Hardinge is the new Voumard 1000 Universal CNC internal grinding machine. A primary design feature is the use of hydrostatic guideways, which are standard on all axes to offer high performance across all ID grinding applications. The hydrostatic guideways are said to provide excellent damping, as well as stick and slip-free operation, resulting in high surface quality and more reliability without any friction loss or wear.

Hardinge believes the machine’s characteristics set a new standard in ID grinding, providing customers with the ultimate combination of precision and performance in an affordable machine. The design optimises production costs when manufacturing high-precision parts for industries ranging from aerospace to medical, with typical applications including grinding operations on hydraulic components, spindles, bearings and gears.

For over 80 years, Voumard has specialised in ID/OD grinding with almost 10,000 installed machines around the world, a large number of which are designed for machining workpieces with large diameters and/or lengths. Acquired by Hardinge in 2014, Voumard is now an integrated part of Hardinge Inc’s grinding group alongside Jones & Shipman Hardinge, Kellenberger, Hauser, Tschudin and Usach. Voumard’s production and support facility is now back to its roots in Switzerland, where it is located within the Kellenberger operations.

Commenting on the new Voumard machine, Mike Duignan, managing director of Jones & Shipman Hardinge, states: “We’ve introduced a new grinding system that incorporates features resulting from customer feedback. These range from the rigid base to the hydrostatic guides, to the new user interface on our controls. The result is a CNC machine that exceeds the most demanding of today’s grinding requirements.”

For further information www.hardinge.com