INTERNATIONAL NEWS

Maximum precision and fast machining

Maintaining maximum precision while working more efficiently is something the Hirschvogel Automotive Group has been able to achieve using the HyperMill CAM program from Open Mind.

The amount of programming required has dropped dramatically and there has been a double-digit percentage reduction in machining times. Furthermore, one important side effect is that there is much less stress on tools and machines.
Hirschvogel manufactures powertrain parts, chassis frames, engines, gears, and diesel and fuel injection components which are increasing at such a rate that the company will shortly achieve a turnover of €1bn. The Denklingen plant manufactures parts using hot, warm and cold forming processes, and rotary swaging operations. Without a high degree of technical expertise in the area of toolmaking, it would not be possible to ensure the required quality of the products. The latest manufacturing technology has an important role, too; plans were first put in place during 2013 to switch from the previous CAM system to a more powerful solution.
Although 13 CAM suites were initially considered, the company opted for HyperMill as it reduced programming times significantly. This factor was important as toolmaking typically involves small batch sizes; around 200,000 tools are produced each year by Hirschvogel, with batch sizes fluctuating between one and 24. The tools weigh between 100 g and 12 tonnes, and are manufactured on 32 machining centres, 17 of which are of five-axis configuration.
“In the past, when I developed a five-axis NC program for a toothing stamp, I had to wait for about one and a half hours for the paths to be calculated, but with HyperMill the paths are calculated in around five minutes,” says NC programmer Günter Fasching, providing an example of the savings achieved.
For further information www.openmind-tech.com

Fast and simple tooling data solution

CNC Software Inc, developer of Mastercam, has collaborated with carbide tooling specialist Widia, to provide a solution that enables CAM users to quickly import tool assemblies from Widia Novo directly into Mastercam 2018.

Mastercam developers worked closely with Widia to let users import 3D tool assemblies directly into Mastercam, validate them, and save them in their Mastercam file and/or tool library. Features such as automated filtering ensure that the holders and tools which are selected can work together for the particular job. Users of Mastercam benefit from having the correct tooling for the material and type of machining operation, plus an accurate 3D model that can be used for visualisation and collision checking, in addition to the time savings.
“We found that in the past, our customers complained of having to search through big complicated catalogues to find related parts, then having to request or build the assemblies from scratch for use in systems such as Mastercam,” says Rich Taft, product owner at CNC Software. “With the integration of Widia Novo and Mastercam, customers save significant time searching for desired tools and building 3D tool assemblies that can be brought directly into Mastercam for easy use by most shops.
“Accurate tool definitions are a critical factor in modern CAM applications. Tool-path algorithms take advantage of these definitions to provide safe and efficient motion. In addition, the models that we import from Widia Novo help us to generate accurate in-process stock models that can be leveraged in subsequent operations. Customers can also make use of these models in verification and machine simulation to catch programming errors before the program ever gets to the machine tool.”
For further information www.widia.com/novo

Travelling-column machine with Siemens CNC

The latest machine from Yamazaki Mazak to feature a Siemens CNC is its VTC-760C vertical travelling-column machining centre, which is controlled by the 828D.

Based on a dual-load configuration, the machine benefits from a compact footprint, as well as a long X-axis stroke and 2300 mm fixed table. Also featured is a 12,000 rpm spindle and rapid traverse rates of 42 m/min in the X, Y and Z axes.
The inclusion of the Siemens control represents an entry into the commodity market, as the 828D is viewed as a mid-range CNC for turning and milling machines. A 15.6” touch-screen display runs on Sinumerk Operate 4.7 and features a built-in keyboard with USB and ethernet interfaces.
A number of intelligent operations underpin the CNC, including ShopMill, which automatically compiles machining step programs to enable multiple clamping operations with fewer tool changes. A built-in maintenance planner is also included.
The control communicates in over 20 languages and can be programmed to send SMS messages to operators, machine setters, or service and maintenance technicians, providing alerts for tool life, availability of blanks and upcoming maintenance schedules. Importantly, the control is also able to provide automatic feedback on a range of machine diagnostics.
Similarly, the VTC-800/20SR, on which Mazak has offered the Siemens 840D sl control since 2013, is now the first company machine to feature the new style of control panel. Comprising a 19” touch screen, the latest control panel can be tilted and rotated to offer improved operator ergonomics. As with the 828D, the 840D sl runs on Sinumerik Operate 4.7 and is able to provide users with a number of connectivity and diagnostic functions.
For further information www.mazakeu.co.uk

Mazak’s Inabe plant goes into operation

Yamazaki Mazak has announced the completion of the first construction phase and start of assembly operations at its new Inabe plant in Mie prefecture, Japan.

The new plant has been opened to meet the increasing demand for large five-axis machine tools, specifically in the aerospace, construction and energy industries. Inabe is the sixth Mazak production facility in Japan.
Construction of the Inabe facility began in 2016, with the first phase completed in February 2018. The production of large machine tools has already been transferred to Inabe from the Minokamo plant in Gifu prefecture. In addition, by starting operations at Inabe, overall production capacity in Japan has been increased by 20%. The plant represents an investment of ¥16bn (first construction phase) and presently spans a floor space of 33,000 sq m.
For further information www.mazakeu.co.uk

The all-round solution in machining

MS40C-8 is the name given to an eight-spindle machine tool from Index for the fully automated production of complex components.

Indeed, there are a number of good reasons why the CNC multi-spindle machine, made near Esslingen, Germany and driven by Kollmorgen servo technology, is seen as a true all-around solution in machining technology.
For instance, the optimum speed and feed rate can be programmed for each spindle location and each cutting edge, and these can even be modified during the cutting process. Moreover, the eight fluid-cooled motor spindles integrated in the spindle drum are infinitely variable, require no maintenance, and are driven with synchronous motors. Kollmorgen AKM permanent magnet servomotors are installed in the cross slides.
Index uses the Kollmorgen motors, in part, as positioning axes for the tools. High-power density enables compact designs that take up less space when installed in the work area. Furthermore, the good torque density of the AKM synchronous servomotors allows Index to convert the rotational movement of the motors into a linear motion without gears. The ball bearing spindles are connected directly to the motor shaft for this purpose.
A lack of gears means there are fewer moving parts, and improves the zero backlash and overall stiffness of the drive. Index needs zero backlash and stiffness, especially with multi-stage thread cutting, so that the tool always completes the next machining step precisely using the threading attachment.
Fitting with Drive-CLiQ is an example of how the synchronous servomotors from Kollmorgen can adapt to the diversity of CNC and automation technology, particularly for machining. This design configuration lets machine builders use drives outside of closed systems, without losing any of the convenience or performance benefits.
For further information www.kollmorgen.com