INTERNATIONAL NEWS

A successful large-scale mill-turn project

Soraluce customer, Krones, from Neutraubling, Germany, required a mill-turn machine with a fixed portal and two movable milling and turning rotary tables, each with a diameter of 6 m, in double-table design and a high degree of automation. To complicated matters, the project commenced in the middle of the Covid-19 pandemic.

All arrangements could only take place by telephone and video call – a visit to the manufacturer´s plant or to the customer during the decision-making phase of the investment was ruled out for safety reasons. The customer´s concept was supported by figures, data and 3D simulations, but finally seeing the finished machine, a PR 6000 2T, after the months of planning and discussion – 32 m long, 14 m wide and weighing just under 300 tonnes – is a whole different story. It is not just a large portal milling and turning machine, but one of the largest machines with a double-table design in Germany.

While machining on one milling and turning rotary table, set-up can take place on the other. At Krones, the company uses the machine to produce roundels for bottling in the food industry. With a tool-change system featuring 500 tools and an ABB robot for the changeover, the degree of automation is optimal. Process control comes courtesy of a Siemens Sinumerik One CNC. Soraluce created a digital twin for the plant that simplified and shortened commissioning on site considerably.

A follow-up order for a fully automated production line with three portal milling and turning machines connected to a large pallet station and central tool magazine, confirms the confidence in Soraluce. Machine tools from Soraluce are available in the UK from TW Ward CNC Machinery.
For further information www.soraluce.com

Supersizing Wind Power Production

Denmark-based HACO A/S has invested in two large-capacity Droop+Rein portal-type machining centres from Starrag to meet the rising demand for components for larger offshore wind power turbines having outputs of up to 16 MW. The new machines will perform the complete machining of components such as rotor housings (with diameters up to 10,000 mm; though sizes up to 11,500 mm are also now under consideration), as well as front and stator sheets, brake discs, and other components. HACO’s ‘supersizing’ of its production enhances its established (60 years) contract manufacturing success.

When it comes to wind power, Denmark is leading the way: electricity generated by wind power fulfils 40% of the country’s energy requirements, and HACO’s prime customer, Valmont SM A/S, is a leader in the supply of steel components to the wind-power sector.

HACO currently processes around 10,000 tonnes of high-strength steel each year, but the wind-power sector is now also looking increasingly at the use of aluminium alloys, castings and composites, so the company’s investment in the two new machines was taken with these materials in mind.

The choice of Droop+Rein machines for this significant investment was based on HACO’s long-standing experience with Starrag on machine reliability/longevity, customer service, machine price and the delivery schedule of the new duo. Until now, Valmont has been transporting the welded blanks to HACO’s site 100 km away but, with this multi-year contract now embracing larger components, the two companies have decided on a more sustainable form of collaboration which sees HACO establishing a subsidiary plant for the two new machines close to Valmont’s HQ, which is near the sea to allow convenient shipping.
For further information www.starrag.com

Renishaw opens technology centre in India

To support its rapidly growing customer base in India, Renishaw opened a new technology centre in Bangalore last month. The new facility provides customers with access to demonstrations of the company’s solutions for metrology and material analysis. Spanning 12,000 sq m, the site houses Renishaw’s technical, operations, and sales and marketing teams, as well as the warehouse and technology centre.

The centre allows companies to work with engineers to understand how their processes can become more efficient and productive using Renishaw technologies. Visitors will be able to view demonstrations of the company’s product portfolio, including its metrology equipment for process control applications. The investment is seen as crucial in enabling Renishaw to keep up with India’s rapid industrial growth.
For further information www.renishaw.com

High performance at low cost per edge

So that customers can meet customer demand for lower part prices, the new Seco Helical SN8-13 milling system features double-sided helix inserts with eight cutting edges that significantly reduce cost per edge to boost slotting, side milling and circular rough milling efficiency.

Built for difficult applications involving ISO P, M, K and S materials, the cutters offer application-specific sub-family designs featuring left or right-hand helixes, half- or full-effective teeth options, two front insert and many radii choices for long tool life and maximum chip evacuation. Reliable and user friendly, the Helical SN8-13 also eliminates incorrect indexing of front and helix inserts, reducing operator error.

“The demand for price reductions is ongoing and forces shops to economise production operations wherever possible, while still maintaining part quality and profit margins,” explains Benoît Patriarca, global product manager – helical milling at Seco Tools. “With the Helical SN8-13 system’s design combined with high-performance insert geometries and grades, they can achieve all these goals with one tool.”

Incorrectly indexed inserts can lead to machine downtime, quality issues and scrap. To eliminate the risk of mistakes, the SN8-13 milling system cutters make the mounting of front and helix inserts easy and fool-proof, even for inexperienced operators.

As an economical alternative to milling products for depths-of-cut from 50 up to 100 mm, Seco offers the Helical SN8-13 in a range of sub-families built with its SN13 helix inserts, including: R217/220.82 (XO16 lead insert for standard use); R217/220.82-H (AC15 lead insert for heavy-duty applications); R217/220.81 (AC15 lead insert for low power situations); and R217/220.81-K (AC15 lead insert for weak fixture situations).
For further information www.secotools.com

Reliable and stable machining of steel parts

With the new MP6 geometry, Walter is rounding off its range for the medium machining of steel (secondary application: ISO M, K, S). The MP6 combines features for medium machining, such as a positive rake angle, with those of roughing inserts, such as a tough cutting edge. This makes the geometry a suitable link between the existing MP4 geometry for medium machining (with good chip-breaking on soft steels) and the RP4 geometry for roughing operations (with a tough cutting edge for high feeds).

Walter offers the MP6 geometry in CCMT, DCMT, TCMT and VBMT basic ISO shapes. A short primary chamfer on the cutting edge, which is characteristic of roughing inserts, ensures a high degree of stability, even in challenging conditions like when machining forged parts with interrupted cuts. The 18° rake angle, tough cutting edge and special chip-breaking geometry ensure chip control during medium machining.

Walter specifies feeds from 0.1 to 0.4 mm/rev and depths of cut from 0.4 to 4 mm as the range for the machining parameters. To prevent vibration on thin-walled components, Walter has given the MP6 geometry an open chip-breaker groove, which reduces cutting pressure even when machining at a higher depth of cut. This feature also makes the MP6 suited to unstable components and components with long overhangs, such as during internal turning. Its straight cutting edge makes it suitable for use as a chamfer insert, regardless of the application.

In addition, the new Tiger·tec Gold grades have a positive impact on tool life. WPP10G, WPP20G and WPP30G are adapted to different operating conditions, leading to increased tool life and performance across a broad range of applications.
For further information www.walter-tools.com