Two German firms, five-axis vertical machining centre manufacturer Wenzler (Heller group) and work-holding equipment specialist Roemheld, have developed a process that allows a casting or other component to be secured, while at the same time checking it for accuracy of form and position before machining starts. The solutions avoids adding value to defective workpieces that will later be scrapped, increasing process reliability, raising productivity and lowering manufacturing costs.

Wenzler conceived the idea as it wanted to offer customers, particularly those in the automotive industry, turnkey production centres for the reliable machining of aluminium chassis and suspension components, 24/7. The company’s technical manager Sebastian Knaus says: “We wondered how work-holding technology could contribute to making our customers’ production even more stable and efficient.”

Already familiar with Roemheld’s work-holding equipment, which he describes as “sophisticated, reliable, and sturdy”, he contacted the supplier’s key account manager Benjamin Nagel.

Development of the innovative clamping technology was based on a cast aluminium rear axle frame secured in a test fixture at Wenzler’s technical centre. The pilot phase ended in 2020 and this year it will find use assisting the series production of aluminium structural components at a German automotive supplier.

In more detail, the concept features swing clamps from Roemheld with integrated pressure sensors able to detect cost-effectively and easily the accuracy of the workpiece about to be machined. Intelligent clamping technology checks the parts for defects and contour variations, detects fixturing errors and provides information on the position of the component and the applied clamping forces during machining. Part quality is subject to continuous monitoring with seamless documentation.

For further information
www.roemheld.co.uk

A recently installed CNC rotary table from PL Lehmann is enabling a Bostomatic high-speed milling machine belonging to Billingshurst-based Thomas Keating Toolmaking, a specialist in scientific ground and satellite-based THZ instruments, to perform highly efficient five-axis machining.

“When judged against the alternatives that we considered, the Lehmann TF 507510 rotary table best met our exacting technical criteria and represented excellent value for money,” says managing director Dr Richard Wylde. “Now installed on our rebuilt Bostomatic machine, it is in daily use.

“In addition to the advantages that the rotary table provides to our tool-making activities, it proves extremely useful when we manufacture high-precision scientific instruments,” continues Wylde. “For example, we’re currently involved in the production of next-generation, satellite-based weather prediction instruments. The precision 3+2 axis capabilities provided by our Lehmann rotary table are invaluable when undertaking this challenging work.”

He adds: “Equally, when recently manufacturing thin, metal film coated dielectric mirrors for use in dynamic nuclear polarisation instruments, the rotary table enabled our complex five-axis machining tasks to be performed with ease. In addition to delivering five-axis capabilities, our new Lehmann rotary table has considerably increased our manufacturing speeds. So successful has it been that we are currently in the process of purchasing another Bostomatic that will be fitted with a second Lehmann rotary table.”

Estimates suggest that 90% of machining procedures carried out by five-axis machining centres are basic five-sided processes. Therefore, the fitting of a CNC rotary table (which costs a fraction of the price of a five-axis machining centre) to an existing three-axis VMC, represents an cost-effective way of achieving five-axis capabilities.

For further information
www.lehmann-rotary-tables.com

The Stark division of the Roemheld group has developed a robotic gripper with zero-point clamping for automated pallet exchange on machining centre tables without their own media supply. The new clamping solution is available in the UK and Ireland through subsidiary company Roemheld UK.

Using Roemheld’s latest zero-point solution, the services needed for clamping and releasing the workpiece, whether hydraulic, pneumatic or electrical, are all transferred to the clamping plate via a multiple coupling integrated into the robot’s pallet gripper. The company can supply the system to suit a user’s specific requirements, representing a cost-effective, entry-level solution to automated production that is suitable for retrofit at any time.

Implementation is short owing to the system’s standardised coupling and flexible modularity.

Furthermore, the air-blow removal of swarf and automatic checking of correct component seating, clamping and release, means that customers can rest-assured of safety at all times.

For further information
www.roemheld.co.uk

As a work-holding specialist and precision machining subcontractor, Brown & Holmes relies on coolant solutions from Rocol to keep its machine shop running at optimum levels.

Brown & Holmes CNC programmer Michael Gulliver says: “We are a global precision work-holding company, but we also work closely with prestige companies like Rolls-Royce. We’ve been using Rocol fluids for almost 10 years now and their products are excellent. We have a great relationship with Rocol and, if we have any concerns regarding the fluids, they are immediately on-site to solve any problems.”

The company deploys the UltraCut Evo 250 long-life soluble cutting fluid throughout its Tamworth site.
Gulliver says: “UltraCut Evo has made a significant improvement to our tool life. We’ve used various other products in the past, but the performance and longevity of UltraCut Evo 250 are significant. The cutting fluid also demonstrates a noticeable difference with evaporation. Previous coolants would easily evaporate within the machine envelope and wider work area, but this is not the case with the Rocol fluid. In addition, our operators have noticed that there is no longer an odour in the machine shop.”

Suitable for use with a diverse range of ferrous and non-ferrous materials, UltraCut Evo 250’s prolonged sump life and low odour is down to several factors. Firstly, the cutting fluid rejects tramp oil which, when removed/skimmed-off, eliminates the main food source for bacteria. Furthermore, the fluid itself is inherently resistant to degradation thanks to its bio-stable constitution, while the absence of biocides or skin sensitizers makes it very operator friendly.

For further information
www.rocol.com

The WNT X5G-Z from Ceratizit is a new clamping system for machining centres. Notably, the system offers optimised access from all sides, which allows the machining of components on five or even six faces. Furthermore, Ceratizit says the vice is very easy to operate and significantly reduces set-up times.

In terms of design, the lean, tapered contour of the two (mobile) fixed jaws provides the spindle head/tool with optimum access to the workpiece. The jaws also contain elastomer elements which damp vibrations, thereby playing a role in better surface quality and increasing the service life of the tool and spindle.

Another distinctive feature resides in the system’s jaws and their adapter: a special dovetail guide means the user manually clicks them into position in just a matter of seconds, with no screws or tools required. The structural design incorporates a pull-down action, where following the clamping process it is possible to secure the workpiece with precision. Moreover, the component tends to pull downwards in the clamping device through the redirection of forces, which considerably minimises any lifting during machining.

Ceratizit offers 14 jaw styles with widths of 40, 65, 80 and 125 mm, of which two 125 mm jaws are already included within the supply of a X5G-Z as part of the basic equipment. Designed to be indexable, the quick-change jaws have a classic L-shape. The open angle means they can be used inwards or outwards, a feature which opens up additional options, without extra cost.

The WNT X5G-Z clamping system comes in five models and two heights, which differ in the length of their base bodies. The shortest measures 330 mm, while the others are 430, 500, 630 and 800 mm long.

For further information
https://is.gd/pekoye