Audi will gradually initiate the restart of production at its plants in Europe during the coming weeks, following its temporary suspension in mid-March.

The upcoming regulated restart in the worldwide Audi production network, together with suppliers and service providers, will be co-ordinated with the Volkswagen Group, and will focus on a comprehensive package of measures for employee safety. In this respect, Audi is following the guidelines of the Robert Koch Institute and the regulations of health authorities in the respective country.
“Audi teams of experts have adapted processes with a view to health protection in consultation with specialist departments and works councils,” says board member for production Peter Kössler. Vehicle production at the Audi sites will be gradually ramped up from the end of April onwards, according to a fixed plan. Engine production in Győr, Hungary, has already started.
For further information www.audi.com

The Cut DX18 double-edged grooving and parting-off system has been launched by Walter GB. With novel lateral clamping, the system is said to elevate performance standards, especially on Swiss-type automatic lathes and multi-spindle machines.

This newly developed tool is the latest addition to Walter’s ever-expanding grooving and parting-off range that offers users increased tool life and high process reliability in quick cycle times, says the company. Suitable for parting diameters of up to 35 mm, DX18 features a positive engagement system – the insert geometry lends itself to being locked securely – as opposed to conventional screw clamping where the characteristics of the cutting forces mean that existing clamping forces are insufficient, with negative effects on machining quality and process reliability.
A further innovation with the Walter Cut DX18 is the use of the SmartLock system in the G4014 tool holders, which simplifies insert changeover. Rather than having to remove the entire tool (often in cramped and ‘oily’ machine conditions), SmartLock’s insert clamping screw is changeable to either side of the tool for easy and quick insert change, with a blanking plug provided to protect the unused side. Thanks to the positive engagement, a new insert – even those of very narrow width – will always locate correctly.
The potential of the system has been successfully proven in tests on a Swiss-type automatic lathe, where the customer particularly liked not having to remove the tool for insert changing. An outer diameter of 12 mm was parted off from 1.4057 high-tensile martensitic stainless steel – the cutting-edge width was 2 mm. DX18 more than doubled tool life compared with the single-edged alternative, and with maximum process reliability and productivity.
For further information www.walter-tools.com

Modern truck engines are produced at the Mercedes-Benz plant in Mannheim, where the requirements for ideal manufacturing include extremely tight tolerances for the decisive dimensions of engine blocks. Thanks to close co-operation between specialists from Mercedes-Benz, the machine manufacturer and Mapal, significant progress was made when a new production line for machining engine blocks was designed and implemented.

The engine blocks have a complex geometry and numerous key characteristics for which the highest tolerance classes must be reliably observed. Depending on the engine type, these include multiple H7 fits, various areas with accuracy specifications less than 15 µm, and chamfers with tight tolerances, including a 20° chamfer with an outlet for which an angle tolerance of just ± 0.025° must be observed.
A first line for machining these engine blocks was commissioned in 2011. When planning a second line, the persons responsible drew on their experience with the first line. The team identified the machining of the bores for the cylinder liner adapters as particularly challenging. Machining was divided into two stations: one for pre-machining and one for fine machining.
To this end, Mapal has developed complex actuating tools that are equipped with up to 20 indexable inserts, including ISO inserts and custom inserts. The actuating tools feature a tool body in monoblock design, and the HSK-160 connection shows an enlarged face surface with a diameter of 200 mm. One tool weighs a total of up to 60 kg.
Despite the connection and a tool length of 380 mm, it must be ensured that the tool has a radial run-out accuracy of 3 µm. The slides are actuated by a drawbar via an additional NC axis in the machine controller that had to be integrated in the HSK connection and suitable for the automatic tool change. This challenge was solved with a high-precision bayonet coupling that is used to couple the drawbar automatically during a tool change.
For further information www.mapal.com

A specialist in tooling systems and solutions for the metalworking industries, Big Kaiser, has introduced the latest version of its EWA fine-boring tool.

Available in the UK from Industrial Tooling Corporation (ITC), the intelligent and automatic tool received its global premiere at the EMO 2019 exhibition in Hanover last September. EWA achieves fast, accurate boring because the process does not need to be stopped to make measurements or manual adjustments. As well as saving time, this instils confidence in the operator and minimises costly scrap that can result from manual adjustment errors.
Notable, the EWA’s motor is sealed against dirt and water to IP69 rating. The clamping system provides additional stability and repeatability to deliver consistently high levels of reliability and precision at cutting speeds above 200 m/min.
To maximise flexibility, the tool offers an adjustment range of 22 mm, which ITC says is substantially larger than similar solutions available in the market. Furthermore, the system has an integrated accelerometer that measures vibration during the cutting process and, in the event of excessive vibration, alerts the machine to automatically adjust its cutting parameters.
“The EWA is far ahead of the rest in its level of automation and sophistication, and this gives our customers real benefits in terms of time and money saved,” says Jose Fenollosa, head of R&D at Big Kaiser. “It also makes it ideal for Industry 4.0 applications.
We are talking to potential customers now, including some leading machine-tool manufacturers.”
EWA is initially available in two versions. The EWA Peripheric covers diameters from 68 to 90 mm, while the EWA Centric incorporates a central boring bar with internal coolant for smaller diameters. Further models for different adjustment ranges are currently in the design phase.
For further information www.itc-ltd.co.uk

Universal Robots is strengthening its commitment to customers during these unpredictable times by introducing free online meetings with expert consultants.

Businesses can now request consultations with local experts from anywhere in the world. Universal Robots believes that even in the most difficult times, businesses should have access to the tools needed to secure improved output and maximised productivity. The company is also launching a series of on-demand webinars, encompassing topics such as machine tending and welding.
For further information www.universal-robots.com