Cloud-based app for CNC machining optimisation

Productive Machines, a spin out from the University of Sheffield Advanced Manufacturing Research Centre (AMRC) is unveiling‘Essential Optimization’, a web application that prevents chatter vibrations and provides engineers with a simple-to-use solution to select optimum, stable spindle speeds and feed rates.

The Essential Optimization app, powered by Productive Machines’ machining dynamics algorithms, promises to turbocharge machining operations by mitigating chatter vibrations and cutting force related problems. This new capability enables manufacturers to increase productivity, reduce waste and improve surface finish. It provides a new approach to stable milling by taking into account both the machine tool dynamics and the cutting forces involved prior to manufacture. This user-friendly software-as-a-service (SaaS), assists manufacturers in making their processes hyper-efficient without the need for installed software or machining physics expertise.

“Productive Machines is committed to providing cutting-edge solutions that assist engineers in reaching the best part, faster, first time,” says Dr Erdem Ozturk, CEO of Productive Machines. “Our Essential Optimization app represents a significant step forward in the quest for chatter-free machining. We are replacing trial-and-error processes with data. By combining tap testing data and innovative algorithms, we’re providing a vital easy-to-use tool for the machining industry. This capability will be a direct input to our digital twin, enabling five-axis tool-path simulation and optimisation in 2024.”

Richard Nevill, commercial director at Productive Machines, adds:“We are running a special promotion to get engineers/operators tap testing called TapStarter. Tap testing, enhanced by Productive Machines’ easy-to-use technology, brings precision and efficiency to manufacturing, enabling operators to optimise machine tool performance, reduce waste and enhance product quality.”

For further information www.productivemachines.co.uk

Innovation meets tradition: CNC milled nutcracker

In keeping with the Christmas season and its traditions, Open Mind made an exact replica of a famous nutcracker from Erzgebirge, a region in East Germany. Milled from aluminium, the example demonstrated an end-to-end digital process chain and efficient five-axis machining with hyperMILL.

Production took place at Emuge-Franken’s Rückersdorf application centre on a Hermle C32 machining centre in a single clamping operation using five-axis simultaneous machining, thus allowing continuous machining without segmentation. Five-axis helical drilling providedthe opening cut for the large central pocket of the upper body. Strategies from the hyperMILL MAXX Machining high-performance package optimised roughing operations, while thefive-axis rest machining function ensured that the roughing took place safely and efficiently.

Finishing leveraged the benefits of ‘high-precision surface’ mode, whereby hyperMILL generates tool paths on the actual CAD surfaces and not on a calculation model. The large surfaces of the nutcracker that curve in two directions, lent themselves to the use of FRANKEN’s circle segment end mill in various shapes. Open Mind’s hyperMILL offers optimum control of the cutting edge area of circle segment cutters.

“In the nutcracker machining example, we had the problem that the dimensions of the part were actually too large for the work area of the machine – a challenge that many manufacturers face,” explains Michael Förster, senior product marketing manager at Open Mind. “What would normally require many manual adjustments and individual simulations in order to avoid travel limitations and find safe tilt positions can now be implemented quickly and reliably thanks to the virtual machine and NC code-based simulation.” 

The hyperMILL Virtual Machining package includes an optimiser that adapts the connecting movements between the individual milling operations to the kinematics of the machine and solve limit switch problems.

For further information www.openmind-tech.com

£140,000 for iAero Centre

The Heart of the South West LEP has announced £144,500 to support ‘factory of the future’ digitisation for SMEs. This new funding will allow the iAero Centre at Yeovil to install an Advanced Manufacturing Research Centre (AMRC) Factory+ demonstrator and equipment, thus creating a dedicated digital data demonstration space. TheiFACTORe project will focus on harnessing the power of data to drive innovation and collaboration in the aerospace and advanced manufacturing sectors. By collecting and analysing vast amounts of data, companies can enhance efficiency and productivity.

For further information https://iaerocentre.co.uk

Mapal Group in mourning

Tooling specialist Mapal reports that Dr Dieter Kress passed away on 27 December 2023 at the age of 81 after a long illness. At the helm of the Mapal Group for almost five decades,he was a passionate entrepreneur and an impressive personality. Dr Kress shaped the once small company into an international group. Although he retired from active management in 2018, Dr Kress continued to take a keen interest in the company’s developments. “Mapal is my baby and that’s why I’ll never let it out of my sight completely,” he once said. The entire workforce joins the Kress family in mourning his passing.

For further information www.mapal.com

Record-breaking revenue for Mills CNC

Mills CNC, the exclusive distributor of machine tools by DN Solutions and Zayer in the UK and Ireland, and a supplier of advanced automation systems, has had a great 2023. The company, celebrating its 50th anniversary this year, announced that combined sales revenue from all of its operations over the past 12 months, surpassed £78m for the first time in its history.

“2023 was a real watershed for the company,” statesTony Dale, Mills CNC’s CEO. “We introduced new models, began selling Zayer machines,and our automation and turnkey solutions business went from strength-to-strength.These factors, combined with higher demand for our more established DN Solutions machine tools, resulted in our best-ever sales performance and I would like to thank all our customers for their continued support.A big ‘shout out’ also goes to our incredible team because, without them, we simply couldn’t have achieved such ground-breaking results.”

For further information www.millscnc.co.uk