INTERNATIONAL NEWS

Automated prismatic machining made easy

New from machine tool company DMG Mori is the PH Cell 500, a modular system for handling machine pallets carrying one or more fixtured components into and out of the working area of various models in the manufacturer’s monoBLOCK machining centre range. These models include the DMU 65 and DMU 75 second-generation verticalmachines, as well as the DMU 65 H horizontal model. Maximum transfer weight including the pallet is 500 kg.

The compact storage and retrieval system offers similar advantages to those of the larger PH Cell 800 for handling loads weighing up to 800 kg. Depending on the configuration of the rack modules, the PH Cell 500 has space for up to 32 pallets. Maximum workpiece dimensions are 500 x 500 x 750 mm.

As part of its ‘machining transformation’ drive, DMG Mori for many years has been developing and introducing customisable handling systems for automatically storing, loading and unloading components into the working area of its machine tools, either fixtured on pallets or directly as individual workpieces. Such configurations enable flexible, efficient production, even of small batches and one-offs. In practice, DMG Mori says the PH Cell 500 can increase productivity by up to 300% and reduce unit production costs by as much as 50% by rapidly presenting parts to the spindle.

The new cell is available as standard with a single storage module featuring three shelves with space for twelve 400 x 400 mm or nine 500 x 500 mm pallets. An alternative version with four shelves can accommodate 16 of the smaller or 12 of the larger pallets. A combination of different pallet sizes is possible.

DMG Mori can retrofit the PH Cell if the machine has been prepared at the factory for automation.

For further information www.dmgmori.com

Soraluce launches high-rail gantry machines

Soraluce, a manufacturer of milling, boring, multi-tasking and automated solutions, is launching its Dynamic Line, featuring the company’s new high-rail gantry machines. The Dynamic Line comprises three machine models tailored to applications in sectors such as aerospace, mould and die, and mechanical engineering, with solutions designed for specific materials like composites, light alloys and steel. The machines are available in the UK from TW Ward CNC Machinery (Ward CNC).

Dynamic Line machines can feature either five-axis contouring fork-type or high-torque milling heads. This versatility ensures the handling of intricate and complex shapes. The machines also come with a splash guarding system to uphold cleanliness and safety standards. Moreover, diverse dust extraction systems, both within the enclosure and integrated into the heads, facilitate the removal of dust and debris generated during machining.

A key feature of the high-rail gantry machines is axis speeds up to 60,000 mm/min and acceleration up to 4 m/s². The five-axis contouring heads offers speeds up to 30,000 rpm.

From a precision perspective, thermal stability ensures that performance remains consistent even in the face of fluctuating temperatures and rigorous machining tasks. Highly calibrated kinematics further support accuracy.

Heavy-duty mechanical heads deliver power up to 73 kW for challenging cutting tasks. Moreover, Soraluce’s new offer delivers a diverse range of mechanical five-axis contouring heads with torque up to 2000 Nm.

Integrated intelligent damping solutions such as DAS+ and DWS, complemented by a full cast-iron structure, augment stability and performance. These features work in tandem to minimise vibration under demanding cutting conditions.

Soraluce’s global business development director Oier Elguezabal says: “These machines embody our commitment to innovation and excellence, empowering manufacturers to achieve unparalleled levels of productivity and quality in their operations.”

For further information www.wardcnc.com

Subcontractor takes up five-axis machining

Based in County Cork, Maas Precision Engineering performs its CNC milling on seven Hurco vertical machining centres. The first arrived more than 20 years ago and is still running today. Mass Precision caters for all quantities, with the company manufacturing anything from one-offs and small batches up to 20,000 or more.

Managing director Tadhg Hurley says: “We owe our business success to Hurco and are confident in the machines. I know we can turn parts around quickly, making prototypes in one day or a maximum of two days. Every person here can program every machine. Whether it be a 20-year-old machine or a new five-axis model, we usually program directly at the machines and can process orders quickly because we know they’re going to be right.”

The machines play their part, but Maas Precision sets out to make the right investment at the right time. In 2018 the company purchased its first five-axis VMC, a Hurco VMX42SRTi with swivelling B axis and rotary C axis set in the table. The main benefit was the ability to complete more operations in a single set-up.

The transition to five-axis machining was clearly a success as a second five-axis model is now in place: a Hurco VMX30Ui of more compact design with a swivelling trunnion carrying a rotary table. Mass Precision can easily transfer programs between the Hurco machines, new and old, to balance capacity utilisation. The company must respond quickly to changing customer demands, so being able to swap production runs between machines helps to build confidence in attaining challenging targets.

For further information www.hurco.co.uk

A high-end HMC inside a small footprint

To accommodate the diverse needs of the marketplace, Starrag Heckert has introduced its new H Compact series of horizontal machining centres (HMCs). The benefits of HMCs can sometimes be overshadowed by the sizeable footprint of the machines in comparison to their vertical counterparts. However, with its H Compact Series, Starrag Heckert says it is delivering the benefits of a horizontal with a compact footprint that will appeal to manufacturers.

Looking at the merits of the new machines, Lee Scott from Starrag says: “These horizontal models feature a trunnion table with five-axis capability. We can also incorporate a high-speed table for turning, a configuration that gives us the ‘T’ range. In its basic guise, it’s a twin-pallet HMC with a monobloc mineral cast base that is very vibration-absorbent and stiff.”

The machine column has positive-leveraged ratios that are credit to maximum guideway distances, while weight compensation improves the performance, accuracy and efficiency of the ballscrew-driven Y axis.

Alluding to the pallet system on the new series, Scott says: “It’s a twin-pallet machine where the ground pallet surfaces ensure perfect interfaces for the fixtures, whether it be on a trunnion or a standard B axis. Outside of the machine, we have the set-up station. Thus, while the first pallet is working inside the machining area, the second pallet is either loaded by a robot, an FMS or an operator.”

Taking a closer look at the operator interface on the new H Compact series, the machine incorporates the latest FANUC or Siemens control.

“Operators love our system, it has a touchscreen and multi-screen facility that offers the perfect solution for engineers who want to get the maximum amount of data from the machines,” concludes Scott.

For further information www.starrag.com

ENERGY EFFICIENCY IN FULL FORCE AT HIGHLY AUTOMATED SANDVIK COROMANT PLANT

The Gimo, Sweden production facility of Sandvik Coromant, a specialist in the design and manufacture of premium metal-cutting tools and machining technology, is tapping into the benefits of VERICUT Force from CGTech. The company is using this physics-based software, which analyses and optimises cutting conditions during component machining, to deliver savings in both cycle time and energy consumption.

Sandvik Coromant’s Gimo production plant manufactures tool bodies (holders) for indexable-insert cutters used in milling, drilling and turning operations. The facility produces a catalogue of around 15,000 standard products, as well as customised tools. However, Gimo is no ordinary plant. In 2019, the World Economic Forum recognised the factory as just one of 16 digital ‘lighthouses’ worldwide for the fourth industrial revolution (Industry 4.0). And it is clear to see why.

The Gimo site is up and running 8760 hours per year and features extensive automation. In fact, the whole night shift is unmanned, operated by hundreds of industrial robots and automated guided vehicles (AGVs). Furthermore, a digital ‘thread’ runs throughout the factory that automates everything from customer order to despatch, with data feedback from production to the company’s systems supporting process analysis and continuous improvement.

“When a customer places an order it triggers an automated design process based on parametrics,” explains Sandvik Coromant production engineer Björn Ljunggren. “The next step is preparation for production, namely the automatic generation of programs for robots, measuring systems and machine tools. Machine programming includes comprehensive verification and simulation using VERICUT.”

VERICUT ensures stable processes, which are essential for unmanned operations. The site has been a VERICUT user for over 10 years, recording no machine crashes in that time. Now, the Gimo factory is introducing VERICUT Force for program optimisation to this part of its automated process.

At Gimo, the whole set-up simply runs by itself in the plant’s specially created automated batch mode environment. There are no design engineers or production engineers sitting in front of CADCAM stations. Instead, the system determines everything automatically, including workpiece material and lead-time requirements.

While machining optimisation using VERICUT Force serves to reduce cycle time, the Gimo site wants to leverage the benefits of this software to help with a bigger ambition: becoming carbon-neutral by 2035.

“Our goal is energy-efficient manufacturing: reducing energy consumption and increasing sustainability,” explains Ljunggren. “That’s why we’re moving beyond simulation and verification to optimisation with VERICUT Force. Reduced production time and energy-efficient manufacturing go hand-in-hand.”

The reduction of program time using VERICUT Force relates to less spindle time, fewer motors running, less coolant pumps in use and so on. As a factory, Gimo monitors its energy consumption very closely. This busy site currently consumes 56-58 MWh of electricity every day. To draw a comparison, UK energy regulator Ofgem estimates that a typical household in England, Scotland and Wales uses 2.7 MWh per year.

To assess VERICUT Force, Sandvik Coromant requested a trial involving the machining of a popular drilling product, CoroDrill DS20. The material for this drill is a premium tough steel with a high hardness value. Machining took place on a new STAMA CNC vertical machining centre featuring a number of sensors that help monitor electricity consumption, not just of the machine, but also the compressed air system, high-pressure coolant pumps and so on.

The trial involved the use of VERICUT Force on roughing operations, predominantly adaptive milling and slot milling in the chip space and flutes of the drill, while running the VERICUT Air Cut Optimization module on remaining compatible operations. Advanced data management software at the Gimo site logged all machine data for comparison purposes.

“When running VERICUT Force optimisation we saw a 15% reduction in energy consumption: that was our bottom-line result for the whole machining process,” states Ljunggren. “Of course, it depends on what components we run, our running hours and the price of a kWh.”

To provide transparency, the calculation was based on machining three drill holders per hour, with the machine running 16 hours a day. Comparing data from before and after VERICUT Force optimisation revealed a 0.59 kWh saving per workpiece: a 15.3% reduction. This equates to a saving of 1.77 kWh per day and more than 10,000 per year. At an electricity price of 28 cents per kWh the financial saving would translate to €3,000 per machine, per year.

This outcome shows that a typical machine shop running 10, 20 or 30 machines can achieve savings of up to €30,000 (10 machines), €60,000 (20 machines) or €90,000 (30 machines) per annum based solely on reductions in energy consumption. Further savings will result from faster cycle times, extended tool life and increased capacity.

With the trial based on just one machine, the potential net effect for Sandvik Coromant’s Gimo facility is huge, both in terms of financial savings and sustainability. The factory is home to around 400 machines.

“Of course, some extra savings come from a reduction in cycle time,” explains Ljunggren. “With Force optimisation our trial showed a total cycle time reduction of 12% for the drill bodies.”

The Gimo facility is now in the process of rolling out the use of VERICUT Force optimisation to other drill product families. Two cells housing six machines already run the software; this will rise to 11 machines by the summer of 2024.

“Force doesn’t take long to learn: you basically select the material, specify some optimisation parameters and just run it. We had great support from CGTech throughout the adoption process, both globally and here in Sweden, which really helped ensure the success of this project.”

For further information www.cgtech.com