FEATURE ON MACHINING CENTRES

Huge time savings achieved with Sylvac solution

Excel Precision, a prominent player in the UK’s EDM sector, recently worked with Bowers Group to address a complex machining challenge faced by a machine tool company. The solution cut the client’s component setting time from around a week to less than an hour, also resulting in a 12-week reduction in production time.

Steve Batt, technical director at Excel Precision, says: “Our innovative solution transformed a complex and time-consuming process into a highly efficient one. By incorporating innovative technology from Bowers Group and smart engineering from our team here at Excel, we not only met the client’s precision requirements but also significantly increased their annual production capacity by reducing production time.”

The client had a precision issue with a deep-seated bore. The initial approach involved using a conventional DTI but proved inefficient, taking 5-8 days to achieve the required runout. This lengthy timespan was primarily because of the inability to observe the part’s movement during adjustments in the confined bore, which extended to a depth of 350 mm.

Available from Bowers Group, the Sylvac D62S digital display and PS12D digital probe were the solutions identified. The D62S sits on a carbon-fibre tube with a wire passing through, connecting it to the two digital probes. A specially developed mechanism allows one probe to take measurements in the X direction and the other in the Y direction, ensuring precision despite the tight confines of the bore.

Immediate feedback shows a dramatic reduction in set-up time, enabling the client to set the component within an hour, a significant improvement from the initial 5-8 days. Additionally, when combined with a custom fixture, it improved the client’s production capacity by reducing production time by at least 12 weeks.

For further information www.bowersgroup.co.uk

Geometry measurements guarantee accuracy




For more than 43 years, IASA Instandhaltungstechnik AG has been a reliable partner in the field of maintenance, mechanical engineering and machining technology. Based in Switzerland, the core expertise of IASA AG lies in the production of precision components and the servicing and overhauling of pumps, fittings and safety valves.

Since 2011, IASA AG has been using a Unisign CNC – a compact, high-performance machining centre for the rapid, precise and cost-effective production of aluminium structural components. Its 100 kW spindle drive with a speed of 25,000 rpm removes aluminium at a rate of more than 10,000 cm3/min.

Thanks to the rigidity specified in its design, the machine remains extremely stable throughout. However, after so many years of operation there is an understandable need to verify machine precision, which is why the production manager at IASA AG, Yannic Zünti, recently contacted Unisign and asked for a geometry measurement.

When checking the TRAORI point (the pivot point of the turntable and swivel table), Unisign identified a small dimensional inaccuracy in the Z axis. The company corrected this discrepancy before carrying out further measurements on the spindle in two temperature scenarios – hot and cold. The result: both measurements were once again comfortably within the machine’s specifications.

The Unisign machine at IASA AG is now back in operation, in a way that is cost-effective and prevents wear; it is once again ready to continue production at an extremely high degree of accuracy for many years to come.

Says Zünti: “Unisign enables us to achieve an ideal balance between high reliability, speed, performance and accuracy. Those values are not only of importance to us, but are also crucially important to our customers.”
For further information www.unisign.com

Conference delegates discover future of NDT




More than 60 sales partners visited VisiConsult last month for a conference to discover new topics around the NDT division brand VCxray. Delegates from new business partner Diondo also participated and shared valuable insights into its portfolio that will make new opportunities possible for customers in the field of non-destructive testing (NDT).

VisiConsults’ guests participated from almost 30 different countries, and were curious to learn more about how VCxray’s solutions help their NDT customers to reach the next level of quality.

Lennart Schulenburg, managing director at VisiConsult, expressed his delight: “Finally we can meet again with a large number of our valuable channel partners and present all of our latest developments. Since the last conference a few years ago, VisiConsult has tripled in size, launched three brands, founded its own service company for materials testing and, last but not least, developed many great systems.”

One of the exciting parts was the presentation of x.OS (X-ray Operation Suite) for professional and comprehensive quality inspection. X.OS covers the complete processes that are important for different roles within part inspection and quality management.
There were also numerous presentations on other X-ray solutions and technologies, with the sharing of application reports and success stories.

Another highlight was getting acquainted with new business partner Diondo and a corresponding presentation on the portfolio that will significantly complement VCxray’s existing solutions with high-end CT systems.

Nikita Fedorov, global sales channel manager of VCxray, says: “With so much news and changes, it’s important that our channel partners get together, are updated by us, and exchange information with each other. Even more important for us is the opportunity to listen to our partners.”
For further information www.visiconsult.de

Boost for accuracy and control at toolmaker




Dartford-based toolmaking specialist Synergy (Kent) Ltd has invested in the latest Sodick AD35L from Sodi-Tech EDM, a move that has seen both precision and ease-of-control improve in comparison with the company’s existing die-sink machine. The new AD35L has been set to work producing punches with intricate and precise forms for the compaction industry.

“Such has been our growing order book that it was clear we needed to increase our EDM capacity,” explains one of the company’s owners Ian Chambers. “For this reason, we decided to assess the market for an additional die-sink EDM.”

Despite having never used a Sodick machine before, the company’s research identified the AD35L as the solution. Following a full demonstration by Sodi-Tech EDM and the manufacture of sample parts, Synergy placed the order. Since installation, the machine has been dedicated to a single repetitive job; special compaction punches made from Vanadis 30 tool steel and carbide with the requirement for a tight form sparked in the top face. The AD35L completes three punches every day.

“The tight form includes a maximum corner radius of 0.1 mm,” explains Chambers. “We have to hold a tolerance on concentricity of 5 µm, and 10 µm on size, depth and profile shape, as well as a high level of surface finish. However, our new AD35L meets the specification day-in, day-out.”

Ease-of-use and high levels of control are additional features of the AD35L to have impressed Chambers: “Considering I have been a user of another EDM brand for the past 30 years, the learning curve on the Sodick machine was really short,” he says. “In fact, we were running-capable in just 2-3 days.”
For further information www.sodi-techedm.co.uk