IRISH MANUFACTURERS IMPRESSED WITH BUMOTEC S191NEO FROM STARRAG

The primary aim of the IMR(Irish Manufacturing Research) is to demystify, de-risk and deliver emerging technologies and new knowledge that enables industry to succeed at the cutting edge of advanced manufacturing. It is this mission statement that emphasises why the organisation has a Bumotec S191neo multi-tasking production machine at its facility in Mullingar.

Explaining the relationship between the two organisations, Chris Judge, head of machining technologies at the IMR says: “The IMR is a not-for-profit, state-funded organisation that helps Irish manufacturing companies to explore and adopt new and emerging technologies. Starrag approached us about having a Bumotec S191neo installed at our facility, and we are delighted with the machine as it enables IMR to bring very advanced technology to precision engineering companies.

He continues:“It allows engineering companies to access a high level of technology and, since its installation we’ve had multiple companies and agencies engaging with us to perform test cuts. A kind of‘test before you invest’ situation. The installation gives companies a risk-free scenario to see the potential of the technology.”

Following hugely successful pilots in ICMR and i2e2 industry-led initiatives, the IMR was established in 2014. Initial funding of €15m was approved and the first employees were hired. A collaborative R&D programme ramped up, launching projects in IoT, data analytics, chilled water optimisation, knowledge management and schedule optimisation.

To support the expansion of the research roadmap into areas such as additive manufacturing, machining and robotics, with their much larger equipment footprint, IMR successfully developed a new industrial R&D lab in the old tobacco factory in Mullingar. In partnership with a cluster of Irish SMEs, a unique national facility supporting high-TRL industry-focused research in a ‘factory’ environment was launched.

Today, IMR has more than 60 experienced employees continually developing a portfolio of highly impactful research for industry. The organisation has developed strong links with mainland Europe and won multiple EU-funded programmes. The IMR says it is delighted to be making a difference for Irish-based manufacturers and aims to assist many more on their Industry 4.0 journey. 

Discussing a recent event hosted by the IMR at its facility in Mullingar, County Westmeath,Starrag UK director of sales and applications Lee Scott says: “Instead of having a seminar where lots of people come together, we a prepared a timed event where people could come and have one-to-one meetings and talk in private about problems and challenges with their parts. It enabled manufacturers to see two very different components undergo machining on the Bumotec S191neo with a changeover in between. This ability to change from one part to another, as well as the machine’s incredible capability, is a huge selling point of this technology.”

Looking closer at the machine, Starrag UK applications engineer Martin Richardson comments: “The Bumotec S191neo is an advancement from our old S191. It’s a seven-axis mill-turn machining centre, which makes it a very flexible machine with multi-axis, multi-position and multi-pick-up stations.”

He adds:“What we’re trying to do with events at the IMR is demonstrate quick changeover from one part – an anterior bone or spinal plate – to central jaws that are part of a robotic arm set-up. The robotic arm can change vice jaws, spindle collets and spindle liners from one to another in the region of 5 to 10 minutes. From there, a probing program initially sets the tooling lengths for each tool that has been changed.The machine is then back up and running in 15 to 20 minutes.”

Equipped with peripherals such as temperature-controlled high pressure, chip conveyor and bar loader makes for a modular proposition. Coupled with the Bumotec palletiser or a robotic, modular or custom-made automation cell, provides users with access to ‘24/7’ type production, which is only interrupted by preventive maintenance when required. In addition to milling and turning, the machine is also suitable for grinding, polishing, skiving, gear hobbing and diamond cutting, thereby allowing the completion of complex, demanding parts in a single cycle.


The man-machine interface, developed on a Windows-based PC application, with support for field technicians, switches from one screen to another with a simple swipe. It is therefore possible to monitor machining operations in progress, view programming parameters track production in real time. Intuitive and easy to use, Starrag reports that the Bumotec S191neo requires less training, thereby allowing its use by operators with a lower skills base.

Looking at a selection of components manufactured on the Bumotec S191neo at the IMR, Starrag UK sales manager Paul Zajac says: “The machine is capable of manufacturing a very wide range of complex parts for a various industries. Components vary from aerospace sectorparts like fuel injection systems for turbines, to implants for the medical technology industry. There’s also a wide range of parts for the watchmaking industry, the micro-mechanical sector and, in particular, very accurate parts for satellites. Components of this naturerequire machining from a wide range of materials: from plastic through to PEEK, stainless steel, carbide, ceramics [both green and white hardened ceramics that you can only grind] and titanium.”

Confirming this diversity of application range is Ethan Croke from Starrag UK: “It’s great to show the diversity of the machine and how quickly it can be changed over. Engineers need to know about the rapid changeovers and how it’s not just a machine built for a single application. The Starrag applications team are particularly strong and the machines are extremely well built.”

More information www.starrag.com

Future-proof machining solutions from Index

The world of metalworking is undergoing significant changes. Industries such as automotive, medical technology and mechanical engineering are presenting new challenges that many manufacturers need to address. At the recent AMB 2024 exhibition in Stuttgart, Index showcased manufacturing solutions tailored to meet these evolving demands. Visitors to the company’s booth discovered how the latest turn-mill centres, multi-spindle machines and production lathes are able to enhance competitiveness.

At the show, two new models demonstrated how Index has further adapted its offerings to meet customer needs. On the Index G200.3, the previously rigid upper turret now features a pivoting Y/B axisfor angled drilling and milling operations. Another new highlightat AMB was the Index G320 compact. Equipped with a 102 mm main spindle, this turn-mill centre has the footprint of a G220.3 but is nearly as powerful as the regular G320 – and saves a great deal of space, resources and costs. Both machines were shown in their long versions (1200 mm turning lengths).

Another Index turn-mill centre also featured at AMB: a G220, seen at the stand of cutting tool manufacturer Horn. The two companies are linked by a technology partnership aimed at improving processes for high-speed whirling, hobbing, bevel gear cutting, groove turning and polygon turning.

Another ambition for Index atAMB 2024was toshowcase its newly developed MS24-8 to a wide audience for the first time. This multi-spindle machine offers a 24 mm bar clearance and features eight main spindles. Further machines on the stand included Index C200 and ABC automatic lathes.The C200 wasdisplayed in the FANUC variant, while visitors could view the ABC with Siemens 840D sl control.

More information www.index-group.com

MR Components relies on intelligent automation

MR Components, a medium-sized company from Grigno, has significantly increased its production capacity and simultaneously improved quality by introducing intelligent automation with Emagvertical turning lathes (VTLs). The company, which specialises in the production of parts for differential and planetary gears, now produces around 80,000 components per month.

Alessandro Reguzzo, the founder and managing director of MR Components, says that the key to success lie in the consistent automation of manufacturing: “The use of automated machines was the key to accelerating our production. The machines run unmanned, allowing us to produce in the evening without having to introduce a night shift.”

MR Components relies on Emag machines equipped with integrated measuring probes, allowing 100% component inspection. In fact, the company uses various manufacturing systems from Emag to meet the different production requirements of its customers.

“On one of our production lines we work with Emag VL 7 machines, where the operator manually places the workpieces on the automation belt,” explains Reguzzo. “On other production lines we work with VL 4 machines that feature TrackMotion automation. Here, automation is very fast and we have greater autonomy, so we can also run the machines in unmanned mode.”

There are also other Emag manufacturing systems on site, such as VL 4 and VL 6 machines automated with robots. The decision was made to use a system with robots here, as many components have to undergo other operations in addition to turning, such as marking, which can take place very easily and flexibly with the robot.

MR Components is now planning further investments involving the use of two VL 8 machines in combination with robots to produceparts with diameters up to 450 mm.More information www.emag.com

Okuma America launches LB2000 EX III lathe

Okuma America Corporation is introducing a new addition to the company’s horizontal lathe line-up: the Okuma LB2000 EX III. The new machine joins the company’s flagship line of LB-EX series lathes. Okuma debuted the LB2000 EX III at the recent IMTS 2024 exhibition in Chicago.

The LB2000 EX III can create finely-tuned small parts or complex components when paired with optional MYW (milling, Y axis and sub-spindle) facilities. Hallmarks of the LB-EX lathe family include high-accuracy machining, partly attributable to the machine’s rigid construction. Additionally, the LB2000 EX III features a high-power, high-torque PREX motor built to facilitate heavy and high-speed cutting. This, in combination with Okuma’s ‘Thermal-Friendly Concept’, which minimises thermal growth during the machining process, ensures machining accuracy and thermal stability.

The model at IMTS featured the additional MYW features. Okuma America’s team of experts showcased the machine’s capabilities by conducting a special machining demonstration of electric guitar tuning knobs. The demonstration featured peripheral technologies from various technologypartners, including Hainbuch, Iscar, Mastercam, Mitsubishi Materials, QualiChem and Sandvik Coromant. Additionally, the demonstration was part of a special collaboration with guitar manufacturer, Dean Zelinksy, to create an electric guitar completely from metal. One of these special metal Dean electric guitars was on display at the Okuma stand.

Okuma’s LB4000 EX III also features the company’s new OSP-P500 control, an open-architecture CNC designed exclusively for Okuma machines. This next-generation control enables numerous intelligent machining technologies, including a Windows-based, open-architecture platform for easy integration to applications on the Okuma App Store and beyond.

More information www.okuma.com

Mazak debutsthree-turret turning centre

Yamazaki Mazak unveiled the latest addition to its range of high-volume turning centres at the AMB 2024 exhibition in Stuttgart recently. The new HQR-200/3 NEO promises increased levels of productivity alongside high accuracy and efficiency.

Mazak’s HQR-200/3 NEO features three turrets and two spindles. With manufacturers striving for productivity and profitability, the additional third turret achieves a faster return on investment by reducing cycle time by approximately 25%, based on an example component produced using a two-turret configuration. The added tool stations enhance processing capabilities to complete complex parts in a single set-up.

Suitable for medium-to-high batch sizes across the aerospace, automotive and general subcontract industries, the new machine design – which is only 120mm deeper than the two-turret version –increases the maximum workpiece size for lower-turret chuck work from 212 to 320mm diameter. 

The HQR-200/3 NEO on show at AMB was part of a model series comprising two spindle sizes and three turrets. Complementing the standard 65 and 80mm diameter bar-working capability, the HQR-200/3 NEO is available with an optional enlarged 112mm spindle bore for bar work up to 102mm diameter. Unique to Mazak, this enlarged spindle bore option facilitates the machining of prismatic components from bar material using only a turning centre – work that otherwise would require a machining centre to complete. 

Enhanced automation features include a redesigned unloading hand that contributes to a 20% reduction in unloading time compared with previous models, while the Smooth Oscillating Cutting function automatically breaks up chips and swarf to prevent unwanted build-up. 

More information www.mazakeu.co.uk