FEATURE ON CNC MILLS & MACHINING CENTRES

Danobat buys Delta Wheel Truing Solutions

Vertical turning lathe (VTL) manufacturer Danobat is strengthening its position in the North American rail market with the acquisition of US-based company Delta Wheel Truing Solutions. Signing the agreement at Delta’s headquarters in Escanaba, Michigan, Danobat continues to make its way in the United States. Danobat entered the US market in 1982. The company has a technical centre in Chicago focused on the development of solutions for processes such as hard turning.

“This acquisition is an important boost that will position us as one of the benchmark players in the North American rail sector, bringing competition for in-situ wheel profiling maintenance that has been lacking in North America,” says Oskar Uria, director of the Railway Business Unit at Danobat. “Delta’s expertise and know-how will be a strategic support for Danobat to grow in such a demanding market.”

The main objective of this approach is to get closer to the US market, offering products tailored to the specific needs of customers in the North American railway sector. In addition, the Escanaba plant will provide direct services, ensuring a close and agile service to customers. 

Delta has a team of people with extensive experience in the design and manufacture of rail wheel re-profiling equipment. In addition, it holds several patents on different systems, offering unique solutions to the market. The manufacturing capacity in the US, its products and customer base are key elements for future joint development with Danobat.

Danobat has recently inaugurated a new 130,000 sq ft plant with increased manufacturing capacity at its Elgoibar manufacturing complex in northern Spain. The acquisition of Delta adds to its strategic investments for the coming years.

More information www.danobatgroup.com

Smaller F-series HMC released by Heller

Following the launch by Heller of the F 6000 travelling-column five-axis horizontal machining
centre (HMC) at the EMO trade show in Hanover last September, the German manufacturer
is introducing another new model. The F 5000, with its smaller working volume of 800 x 850
x 1100 mm, has 1000 x 1000 x 1400 mm axis travels and comes with many different types of
in-house developed, integrated motor spindles.
A speed cutting unit in combination with the HSK-A 100 tool shank (HSK-A 63 optional)

reaches speeds of 15,000 rpm. As an alternative, a dynamic cutting unit is suitable for
universal use at up to 400 Nm and 12,000 rpm. For heavy-duty machining, a power cutting
unit with a gear spindle and 1146 Nm of torque output is available.
The redesigned spindle head is of compact design and high rigidity thanks to the robust 45°,
backlash-free kinematics and short distance between the bearing and tool shank. Swivel
range is 350° for flexible five-sided machining. Customers can specify either a chain-type
magazine for up to 150 cutters or a rack-type magazine with 425 positions for HSK-A 100
tools (489 for HSK-A 63).
Featuring a cast-iron structure, modular design and narrow width at 3.7 m, the machining
centre is configurable to various small-to-medium batch production applications, ranging
from general mechanical engineering through powertrain component machining to
aerospace. The production platform is just as efficient for the manufacture of single parts as
it is for series runs, reports Heller.
As with the F 6000, the F 5000’s capabilities are expandable to include turning at up to 700
rpm, interpolation turning, gear cutting, grinding, power skiving and even friction stir
welding.
For further information www.heller.biz

Big Investment Proves Ideal for KeraJet

KeraJet, an international digital printing machinery manufacturer has recently invested in a
new large-capacity gantry-type mill from Zayer. The machine, an Altea 8000, with its large X-
, Y- and Z-axis travels of 8000mm x 4350 x 1500 mm and 8000 x 3000 mm fixed table, is
producing machine frames, engine bridges and other performance-critical parts that go into
its digital printing machines. Zayer machines are available in the UK exclusively from Mills
CNC.
Says Jose Luis Granell, head of the machining workshop at KeraJet: “Our digital printing
machines are accurate, but such precision is only possible as long as the components that go
into them are machined to tight tolerances and exacting surface finishes. It’s worth bearing
in mind that when it comes to our print-head technology, our machines are working day-in,
day-out for customers achieving accuracies in the micrometre and even nanometre range.”
The Altea 8000 works an eight-hour shift but, if there is call for repeat components and the
process is secure and repeatable, it runs unattended through the night to improve KeraJet’s
productivity significantly. Flexibility is another major benefit of the Zayer machine.
“We can use the machine in pendulum mode machining workpieces up to 4000 mm in
length in both work zones, as well as machining longer parts using the full stroke of the
machine,” explains Granell. “In addition, the Altea 8000 features 30° and 45° heads. When
machining aluminium, for example, we use the 30° head with electro-spindle at 18,000 rpm.
We use the 45° head when machining steel and select the electro-spindle if and when
superior surface finishes are necessary.”
The Altea 8000 also has several onboard software apps that help improve the machine’s
performance and process reliability.
For further information www.millscnc.co.uk

Innovative front axle machining made easy

Bharat Forge Kilsta is one of the world’s largest forging companies, specialising in heavy crankshafts, front axle beams, steering arms and other chassis components. The company is based in Karlskoga, a Swedish city renowned for its centuries-old forging tradition. Here, Bharat Forge Kilsta mainly produces front axles for trucks and buses. It first forges beams from steel and machines them to make full front axles. To do this, the company previously used CNC machines of the older Unisign Univers model. However, the company invested in a trio of Unitwin6000 machines in 2022/2023.

Prior to expanding with the new models, Bharat Forge Kilsta needed to outsource part of its manufacturing process. “We didn’t have the capacity to machine all the front axles that our customers requested,” explains production development engineer Thomas Forsling. “To be less reliant on subcontractors we wanted to do more of our machining in-house. That’s why we started to explore options for extra machines.”

According to Forsling, the Unitwin6000 provides even greater speed, reliability and precision, although two of the older machines are also still in use. The Unitwin6000 enables Bharat Forge Kilsta to manufacture almost all of its front axles in-house. Another major benefit is speed.

“The old machines have one spindle that does the machining, which means we can do one side of the beam at a time,” explains Forsling. “In contrast, the Unitwin6000 machines both sides simultaneously. The handling is also quicker, because we don’t have to change the beams manually in the machine. As a result, our production speed is now a little over double what it was previously.”

For further information www.unisign.com

FANUC RoboDrill offers mill-turn capability

FANUC UK now offers what it describes as an affordable muti-axis turning and machining solution aimed at helping manufacturers in aerospace, automotive, utilities and energy supply chains reduce cycle times, cut costs, save space and boost production efficiency.

The FANUC RoboDrill D21LiB5ADV Plus vertical machining centre has a 24,000 rpm spindle and a Nikken two-axis high speed rotary table featuring a built-in direct drive motor that achieves 1500 rpm. Visitors to the MACH exhibition in Birmingham earlier this year could see the machine in action producing scroll compressor aluminium housings. The demonstration showcased the cost-saving and performance benefits available from combining milling and turning processes.

“FANUC and Nikken worked together to create a combined machining/turning cell with an extended range of functionality, offered at a fraction of the cost of machines with similar capabilities,” says Oliver Selby, head of UK sales at FANUC UK.

He continues: “At the heart of the solution is our D21LiB5ADV Plus RoboDrill, which is a three-axis machine in its core configuration. The Nikken table adds a further two axes, allowing users to turn and machine components on the same unit. This is a real breakthrough, bringing the functionality of million-pound machines within reach of SMEs at a significantly lower cost. It helps them become more competitive and to consider undertaking work that was previously beyond reach.”

Less than 3 m long and a little over 2 m wide, the RoboDrill/Nikken solution is a lean machine with a compact footprint. The Nikken 5AX-201 tilting-rotary table features pneumatic clamping to allow the rapid mounting and changing of difficult-to-hold components.

For further information www.fanuc.eu