FEATURE ON CNC MILLS & MACHINING CENTRES

Heavyweight champs of the (tooling) world

Renowned within the industry for its plastic mould tool and pressure die expertise, Midlands-based Superite Tools has invested in a trio of large capacity CNC milling machines to further extend its capacity. The three Hurco machines modify, repair and enhance customers’ tooling.  

General manager Craig Dingle says: “Being one of the few companies in the country that can handle tools weighing up to 15 tonnes means we have very little direct competition, whichmeans we’ve established a sustainable customer base. Our latest investment in the three Hurco milling machines enhances this foundation even further because we now have the ability to load tools up to 2200 x 1700 x 750 mm on the bed at weights up to 8 tonnes.”

This impressive capacity is provided by a large double-column Hurco DCX 22 vertical machining centre that features a 12,000 rpm 18 kW spindle, supplied by a 40-tool automatic tool changer. With rapid traverse rates of 24 m/min and cutting feed rates of up to 7 m/min, it can certainly chew through some metal.

Alongside the twin-column machine are two Hurco VMX 60T three-axis vertical machining centres designed to deliver high-precision, high-productivity capabilities for batch production, one-offs or mould and die work. Offering a machining envelope of 1524 x 660 x 610 mm in X, Y and Z, these machines can accept workpieces up to 2000 kg on the 1676 x 660 mm worktable.

As well as tooling modification and repairs, these machines also provide an increase in the capacity of the precision-machined parts that the company produces as a subcontract service. Although Superite machines a high variety of parts, batch sizes are intentionally low.

More information www.superite.co.uk

SW presents world firsts at AMB 2024

Schwäbische Werkzeugmaschinen (SW) will present two innovations at the AMB 2024 exhibition in Stuttgart on 10-14 September. For the first time, the company will provide insights into the efficient production of large parts for the aerospace industry and giga-castings with the BA space3-22 on stand 10B51 in hall 10. In addition, this specialist in multi-spindle machining centres will present the world’s first machining centre for multi-spindle power skiving, the BA W06-21.

With the introduction of the multi-spindle BA space3-22, SW says it is setting standards in the efficient production of large and complex components. “The BA space3-22 combines precision with short machining times for demanding components, such as those involved in the giga-casting of large components in the field of e-mobility,” explains André Harter, head of marketing and business development at SW. “We have thus further advanced the paradigm shift towards e-mobility and established ourselves as a pioneer in the machining of complex components such as battery housings.”

The BA space3-22 is for the precise machining of large light metal workpieces and offers maximum flexibility thanks to two independent three-axis units in box-in-box design, optionally with five-axis machining. For large parts, both spindles can work simultaneously on a workpiece and change tools independently. At AMB, SW will demonstrate the versatility of the BA space3-22 with an underbody for an automotive supplier and wing ribs for an aircraft body.

With the BA W06-21, SW is presenting another world first at the booth. “The BA W06-21 with power skiving technology reduces production time by up to 50% compared to conventional processes,” explains Patrick Schneider, product manager at SW. “Thanks to multi-spindle machining in a single set-up, we achieve maximum production output with maximum flexibility.”

More informationwww.sw-machines.com/en

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