FEATURE ON CNC MILLS & MACHINING CENTRES

Window plant sees clearly with Filtermist

Steel window manufacturer Crittall has adopted the FX series of compact oil mist collection systems from Filtermist within the busy machining department of its production plant in Witham, Essex.

When making the transition to CNC machining from older punching and stamping technology, the company encountered the problem of coolant mist and fumes from the machine tools.

“We rapidly found that the factory was starting to mist up, making for an unpleasant workplace environment,” explains production director Darren Joyce. “Additionally, there was far too much coolant on our parts, which was creating even more fumes during downstream welding operations.”

He continues: “We wanted to revise the way we work with coolant and cutting fluid. One of the biggest challenges was moving away from the paper-type filters used on our type of machine tools. We needed to find something that would take the oil out of the air and deliver a cleaner working environment.”

Alluding to how the company started working with Filtermist, Joyce recalls: “We did a lot of investigation and spoke to several machine tool manufacturers, which brought us to Filtermist. Filtermist manufactures what is effectively a drum that centrifugally spins and removes oil from the air. We’ve now installed them in all of our CNC machining centres. Although the Filtermist FX5002 unit is successful in spinning oil out of the air, we’ve taken it a step further. With modification, we’re now recycling the oil and using it on our flood-based coolant machines, extending the service life of the oil.”

Crittall has gone from not knowing Filtermist to having 12 of its FX5002 units installed on its machining centres in less than a year.

More information www.filtermist.co.uk

Danfoss UK invests in three-machine FMS

A flexible manufacturing system (FMS) comprising three Makino A61nx horizontal four-axis machining centres is now in place at the Warwickshire factory of Danfoss UK. The machines are served by an AGV (automated guided vehicle) running on a linear track along a storage and retrieval system housing 32 machine pallets that are loaded and unloaded at two workstations. The company is a subsidiary of the global, Danish-owned manufacturer of mobile hydraulic and electro-hydraulic products, compressors and speed controls for electric motors.

Following its turnkey installation by NCMT, sole UK and Ireland agent for Makino, the FMS replaces stand-alone production centres used in the manufacture of prismatic components from steel and aluminium. The components are part of integrated manifolds for the mobile hydraulic industry.

The Makino machines offer a rigid, robust spindle capable of delivering both high speed and torque. Each HMC features a 313-tool magazine, minimising the need to replenish cutters between batch runs, despite the throughput of both high-mix and high-volume production. Danfoss can route any pallet with a fixtured component to any machine, limiting the amount of movement necessary and providing considerable flexibility and productivity. Machine utilisation is close to 100%, as there is always a part waiting for immediate presentation to one of the spindles.

The automated system allows the manufacturer to run the facility 24/5 and at weekends when necessary. Two operators manage the cell during each of two day shifts, followed by unattended operation from midnight until 06:00.

NCMT supplied applications engineering support throughout the project, ensuring the efficient transfer of programs from the previous machines to the new Makino models.

More information www.ncmt.co.uk

Heller shows pure passion at AMB 2024

Under the motto ‘Passion for Production’, Heller presented its latest 360° solutions for
tomorrow’s production at the recent AMB 2024 exhibition in Stuttgart. Among the exhibits
was the latest generation of the F 5000 five-axis machining centre, equipped with a newly
developed rack-type tool magazine offering a particularly compact footprint.
The F 5000 is available with a work envelope of 800 x 850 x 1100 mm (X/Y/Z), a pallet size of
630 x 630 mm and a maximum clamping load of 2000 kg. Due to its modular design, it is
possible to configure the machine for a wide range of applications, ensuring maximum
precision and performance in the production of small to medium batch sizes.
Highlights include the completely redesigned swivel heads and integrated motor spindles,
developed and manufactured by Heller, with an HSK-A 100 tool interface as standard and an
HSK-A 63 interface available as an option. The dynamic swivel head with fifth axis ensures
maximum machining performance. Its drive is based on a backlash-free drive concept.
Tilt kinematics are now available as an alternative to swivel kinematics. Compared with
swivel heads, tilt heads offer a significant increase in flexibility for five-axis machining. Tilt
kinematics can also support the machining of recesses and undercuts, for example.
Heller’s head of development Dr Manuel Gerst explains: “Especially for the production of
integral components, which are often required in the aerospace industry, it’s very important
that the machines used can also operate at a negative angle. Mechanically, this is not

possible with swivel heads. We’ve designed the new tilt heads specifically with these
applications in mind. With an HSK-A 63 tool interface and a high-speed spindle, they are
predestined for these applications.”
More information www.heller.biz

Starrag machines make turbine gearboxes

With over 100,000 gearboxes already produced for wind turbines, the NGC Group from
China has eight machines supplied by Starrag at its main factory. This historical success was
reason enough for the Chinese specialist in wind turbine powertrains to increase the
number of Berthiez, Dörries and Heckert machines to 20.
 
China wants to be carbon neutral by 2060 and wind power plays an important role in this
plan. Huai’an, NGC’s third factory in China (in addition to production facilities in Nanjing and
Baotou), will set the course for a carbon-free future. Units for the large offshore wind
turbines with 15, 18 and 20 MW capacity have also recently been built there. This is where
Starrag comes in, with its ‘Renewables’ market segment, which has made a name for itself
with machines for manufacturing wind turbine drivetrains. Since 2006, 100 machines have
been delivered to China, of which about one in five went to NGC.
 
“In 2007, we won NGC as our first Chinese customer in the wind power industry there,”
recalls Jörg Heinrich, director of the Application & Technology Department at Starrag
Shanghai Co Ltd. “After successfully handing over the first machine, a Heckert horizontal
machining centre in 2009, NGC immediately ordered three more Heckert machines.”
According to NGC, the machining centres can process workpieces 25% faster than
competitor models. The production technology and the special on-site service were well
received in China and, since 2022, NGC has increased the number of Starrag machines in its
factories to 20.
 
A Dörries vertical turning machine has gone to Baotou and nine machines from Starrag’s
Berthiez, Dörries and Heckert product ranges have been shipped to the new factory in
Huai’an.
More information www.starrag.com

Strategic realignment at Fair Friend Group

The Fair Friend Group (FFG) has initiated a comprehensive strategic realignment to address the current global challenges in the industry and strengthen its competitive position. As part of this transformation, FFG has appointed Dr Sebastian Schöning as its new CEO.

Schöning, who holds a PhD in mechanical engineering, brings over 20 years of professional and management experience. Since 2021, he has served as the group’s COO and as CEO of MAG IAS GmbH. In his new role, Schöning will spearhead global strategy development and lead the group’s operations.

As a global turnkey supplier, Fair Friend Group (FFG) delivers machine tools and machining centres for the manufacturing of internal combustion engines, electric motors, crankcases, axles and wheels. A key element of the realignment is the increased leveraging of synergies among Fair Friend Group’s globally operating companies. This enables FFG to provide customers with even more integrated and custom solutions.

Additionally, FFG plans to expand its range of standard machines and develop new technologies in emerging industries such as humanoid robotics and energy. By integrating AI, smart manufacturing, energy efficiency and decarbonisation, FFG aims to ensure future-oriented and environmentally friendly production. Customers will benefit from a wide range of highly specialist machines and production systems, allowing manufacturing companies to respond flexibly to both regional and global market demands.

“Our clear vision, strong management team and relentless drive to help customers succeed are the keys to future growth,” says Schöning. “With the measures we are now implementing, we’re ideally positioned to expand FFG’s market presence in the global machine tool industry.”

More information www.ffg-ea.com/en