INTERNATIONAL NEWS

3D-printed body panels for wind tunnel tests

Stewart-Haas Racing partnered with 3D Systems to determine the best-performing aerodynamic shape for the new 2024 NASCAR Ford Mustang Dark Horse through an innovative approach to testing hundreds of different body panel shapes in a highly efficient way.

3D Systems’ SLA machines and 3D Sprint software in combination with the development process used by the two companies, yielded a race car body for the Ford Mustang Dark Horse race car that combines the aesthetics of a 2024 production car with aerodynamic performance for the Ford team’s race cars to win races and a NASCAR Cup series championship.

To submit a new race car body shape, the Ford race teams needed to meet specific aerodynamic coefficient specifications as determined by NASCAR. This is ideally achieved during a full-scale wind tunnel test of the submitted car body, which can be extremely costly and time-consuming. Stewart-Haas Racing found a more efficient solution that allows it to test dozens of different body panel shapes during each test session by partnering with additive manufacturing firm 3D Systems. 

The 3D Systems’ 3D Sprint software is intuitive to use and enables the technician to set up CAD models of parts that require printing. It is then possible to send the resulting files to 3D Systems’ ProX 800for fast, accurate printing of the parts in the desired material. By fastening the 3D-printed parts to the sub-structure of the full-scale car, Stewart-Haas Racing could define the entire car body shape using these 3D-printed tiles.As the car wasundergoing tests in the wind tunnel, additional 3D-printed tiles could be added or removed from the car to test various concepts.

More information www.3dsystems.com

First infinitely reusable manufacturing mould

Fyous is launching the world’s first infinitely reusable moulding technology, known as PolyMorphic moulding, at this week’s RAPID + TCT event in Los Angeles. Fyous’ technology can shapeshift in under 20 minutes, producing zero tooling waste and making usable parts 14 times faster than 3D printing.

The technology, devised and engineered by Fyous’ co-founders Joshua Shires and Thomas Bloomfield, features more than 28,000 densely packed pins that create the mould. Once the pins are in position, the mould can withstand 6 tonne of distributed pressure. Metamorphic by nature, Fyous says that patent-pending PolyMorphic moulding has the potential to transform the manufacturing industry, reducing waste generated through tooling amends, coupled with faster production times in comparison to 3D printing and traditional mould-making.

By inputting a 3D CAD model, Fyous software generates the PolyMorphic mould shape. The PolyMorphic machine then shapeshifts the mould to create the intended product. On completion of production, the PolyMorphic mould returns to the machine ready for the next shapeshift.

“Our mission is to deliver a revolutionary moulding technology that will disrupt prototyping and manufacturing sectors worldwide,” says Shires. “Using PolyMorphic moulding to create fast, accurate moulds for tooling will reduce time to market for a huge array of products and unlock commercial viability for desirable products which currently have no cost-effective manufacture method.”

He adds: “PolyMorphic moulding is a zero-waste technology where raw materials are conserved and the moulds can be used repeatedly. We will remove not only physical waste in the form of materials and tooling, but also remove wasted time by accelerating product development, prototyping and manufacture efficiencies.” 

More information www.fyous.com  

Rapid grinding in the smallest of spaces

In many applications it is uneconomical to use oversize universal cylindrical grinding machines for the external machining of smaller components. With the new WPG 7 CNC external grinder, Emag Weiss demonstrates another way of grinding workpieces with a maximum length of 250 mm. This very small machine requires only a minimal footprint, but at the same time features a whole range of high-tech components for flexibility and productivity.

The WPG 7 fits on two Euro pallets for easy transportation by crane as an easy to set-up machine. It is then possible to start grinding immediately without compromising on quality or process reliability as the WPG 7 has negligible heat build-up thanks to its rigid design. In addition, in-process measurement with Marposs technology, which works independently of the cycle time during the machining process, is available as an option.

The machine uses straight or angled external grinding wheels (with or without profile) featuring a maximum diameter of 500 mm. It is not possible to integrate an internal grinding wheel and there is no B-axis for swivelling the headstock.

Included in the WPG 7 are features such as highly dynamic axes, a powerful and controllable grinding wheel drive, and a work-head with stationary or live centre (MK4/MK5 or W20/W25). The graphical dialogue interface of the control panel is also important for productivity. It is based on a FANUC control system and considerably simplifies the input of technology parameters for certain cycles. The basic version of the control already includes all common grinding cycles.

Last but not least, Emag Weiss offers the WPG 7 CNC solution with automatic or manual loading.

More information www.emag.com

Nissei showcases indexable insert grinder

Nissei Industry from Japan has been developing vertical and horizontal double-disc grinding machines for more than 40 years. Among other things, these machine concepts are for grinding hard materials, one of the company’s core applications in the Asian market. One specific application is the surface grinding of indexable inserts made of carbide, cermet or ceramic. Nissei presented a machine optimised for this purpose, the VP3-400RW, at the recent GrindingHub exhibition in Stuttgart, Germany.

When grinding indexable inserts, the demands on the mechanical and thermal stability of the processing machine are particularly high. The unit from Nissei has the corresponding rigidity, and this with a comparatively compact design. Thickness variations of the ground indexable inserts with capability values of Cp/Cpk of well over 4 are achievable with dimensions of 6.33 ±0.13 mm, for example.

As the main drives for the two 400 mm diameter diamond grinding wheels, the VP3-400RW contains two AC spindle motors delivering 15 kW each. The internal workpiece feeder, which has a 180° swivel function and linear oscillation, features AC servomotors for high dynamics and fast set-up.

The control of the VP3-400RW is by FANUC, allowing various machining modes such as simultaneous grinding of both sides of the workpiece or grinding of the sides one after the other, as well as grinding of only one side. It is possible to store and automatically call-up the respective machining parameters for different types of indexable inserts. Another important feature is the fully automatic dressing device, which can correct the shape on both grinding wheel surfaces simultaneously if necessary.

Nissei presented the VP3-400RW at GrindingHub as a co-operation partner of Nagel.

More information www.nagel.com

Telsonic generator boost ultrasonic cleaning

As a company with a heritage of ongoing product development and innovation, Telsonic has recently launched its new DCG cleaning generator, which the company says delivers powerful ultrasonic energy for industrial cleaning applications.

The new DCG is a high-power cleaning generator that is compact in design and suited to use in harsh operating environments. Telsonic designed the generator’s inputs and outputs especially for system integration, offering all possible external control options. A further important feature of the DCG generator is high compatibility with its ECO predecessor. The new DCG does, however, benefit from new functions, such as analogue inputs and outputs. These I/O are compatible with popular industry standards, which allow the cleaning process to provide important feedback.

A number of generator variants are available with options for 25 or 40 kHz frequency, and maximum power levels between 800 and 2400 W, together with a supporting range of tube resonators from 340 to 1180 mm depending upon the variant selected.

Application areas for the DCG ultrasonic generator include cleaning production level or finished components, and as part of maintenance procedures. The range of industries that can tap into the advantages of the technology includes automotive, aerospace, medical, electroplating, precision engineering, power stations, metal and aviation, to name but a few.

Telsonic UK offers a comprehensive range of ultrasonic modules and systems for a variety of plastic and metal welding, cutting, sealing, cut and seal, sieving and cleaning applications.

More information www.telsonic.com