INTERNATIONAL NEWS

Aluminium machining in new dimensions

Machine tool manufacturer Bavius Technologie GmbH was able to achieve impressive material removal rates of over 20 l/min on its new high-end HBZ AeroCell 160 model with a new generation of high-volume milling cutters from Mapal. The result of this successful collaboration comes at the right time for the aerospace industry, which is taking off again following the downturn caused by Covid-19.

In order to test new machines and at the same time provide customers with references, Bavius carries out milling tests that push them to their limits and beyond. Here, the OptiMill-Alu-Wave, new and improved version of the solid-carbide roughing cutter from Mapal, was selected to showcase the HBZ AeroCell 160. For the tests on aluminium workpiece, the milling cutter with the largest available diameter of 25 mm ran with a spindle power of up to 175 kW, a torque of 66 Nm and a material removal rate of 30 mm.

At a spindle speed of 25,465 rpm and a cutting speed of 2000 m/min, the spindle power was gradually increased. Slot number 6 delivered the best material removal rate with a record-breaking 20 l/min.

“With the 25 mm OptiMill-Alu-Wave, we have achieved a new dimension in aluminium machining,” states Stefan Diem, application engineer at Bavius. “The milling cutter is definitely better than anything we have used previously.”

Bavius used the Safe-Lock system as pull-out protection.

“In this speed range, symmetrical pull-out protection is very important in order not to create imbalance,” explains Tim Rohmer, product manager – solid-carbide milling tools at Mapal. “A Weldon flat, which is often attached to such tools as pull-out protection, is the wrong solution here. To guarantee the smooth running of the machine, there’s no way around careful balancing, even with symmetrical tools.”
For further information www.mapal.com

Half a century of Wohlhaupter’s MultiBore

Allied Machine and Engineering, a manufacturer of hole-making and finishing cutting tools for the metal-cutting industry, is celebrating 50 years of Wohlhaupter’s MultiBore, the world’s first modular boring system. Making headlines in 1973, Allied Machine says that Wohlhaupter’s MultiBore was the first of its kind that allowed users to change boring tools directly at the spindle. While still a best-seller 50 years later, MultiBore now has applications in a much wider range of machining operations.

Until the early 1970s, machine shops used universal facing and boring heads for rough and fine boring. These boring heads had an integrated shank designed specifically for the machine spindle of the corresponding machine manufacturer. However, every machine manufacturer had its own facing and boring heads, even if some of these came from the same manufacturer, in many cases Wohlhaupter. There were no standardised spindle connection points, so users required their own tools for each machine type.

This situation ultimately created demand for universally applicable modular tools. Instead of a one-piece boring head, it made sense to design tools modularly to fit on all machine tools (with different basic holders), while also offering the capability for individual assembly into complete tools adapted to the workpiece. Wohlhaupter implemented this idea with MultiBore and presented the new product for the first time at the Hannover Trade Fair in 1973. Renowned machine manufacturers quickly decided to supply their machining centres with these new tools, marking the beginning of Wohlhaupter’s success story.

Today, MultiBore comes in a complete diameter range of 0.4 to 3255 mm. MultiBore boring tools fit directly into the master shanks, or users can take advantage of intermediate modules to create full assemblies adaptable to the workpiece and fixtures.
For further information www.alliedmachine.com

New technology cleans parts with dry CO2 granules

For in-line dry component cleaning applications, ACP systems is releasing itsPowerSnow QuattroClean technology. The process compresses recycled liquid CO2 into cleaning granules using an integral unit. Compressed air then accelerates the granules, fed through a purpose-designed nozzle, for blasting on to surface that requires cleaning. Thanks to the elimination of the customary external pellet production and logistical effort associated with conventional dry ice cleaning, it is possible to realise a fully-automated and uninterrupted cleaning or deburring process.

The new cleaning process efficiently removes stubborn particulate and filmic contamination from virtually all materials and material combinations. Using cleaning granules made from recycled liquid CO2, the process can clean entire surfaces or selected areas in a reproducible manner. Applications range from surface finishing in body-in-white automotive processes and the removal of welding beads, to the fine deburring of medical instruments and fine-tolerance watch components.

Cylinders or tanks feed the mediato the QuattroClean PowerSnow system, thus offering unlimited shelf life.The jet of compressed air containing the granules has a temperature of around -78°C.

On impacting on the surface, four effects occur. A thermal effect leads to sudden local cooling, where the different expansion coefficients between the substrate and the contaminants cause cracks to form in the latter. A mechanical effect also takes place, where the transfer of momentum detaches impurities. When the snow granules impact on the surface, they undergo a transition from the solid to the gaseous phase, with an abrupt increase in volume of around 600 times. This so-called sublimation effect creates micro-pressure waves that also detach contaminants. In addition, during the transition phase, a solvent effect removes filmic/organic contamination.
For further information www.acp-systems.com

MEETING CURRENT AND FUTURE COMPONENT CLEANING REQUIREMENTS THROUGH DIVERSIFICATION INTO HYDROGEN TECHNOLOGY

The economy is undergoing a transformation that poses challenges for many areas of industry. New products and various megatrends require adjustments to manufacturing technologies, as well as to the range of products and services available. Ecoclean GmbH is proactively addressing this change through greater diversification of its solution portfolio for industrial component cleaning and by introducing the new business area of hydrogen technology.

Energy transition, sustainability, demographic change, mobility, automation and digitalisation, and security: these megatrends are resulting in technological and social changes. And at an increasingly rapid pace. This development demands increasingly higher flexibility and agility from companies, particularly in the field of industrial parts cleaning. Whereas yesterday it felt like the automotive industry was setting the standards in terms of cleanliness requirements, today it is completely different industrial sectors, each with its own specific requirements.

Ecoclean, a global specialist in the supply of equipment and systems for industrial component cleaning, surface treatment and automation, is responding to these changes with a future- and market-oriented diversification strategy. The course for this approach was set several years ago with corresponding financial and personnel investments. As a result, new solutions for high-tech industries are now available, in addition toequipment and systems for tasks in the previous sectors, such as automotive and its associated supply chain, mechanical engineering, joining technology, the jewellery and watchmaking industry, and the aerospace arena.

Also included in this ensemble is the semiconductor industry and its suppliers.To be able to manufacture ever smaller and more powerful microchips by means of EUV lithography, means placing extremely high demands on the components required for the production equipment in terms of purity. In addition to ultra-fine particulate residual impurities in the nanometre range and extremely strict specifications regarding filmic contamination, outgassing rates for organic substances and residual moisture as well as ‘prohibited’ substances/elements play a quality-critical role. Likewise, it is necessary to meet stringent cleanliness requirements for vacuum technology components in the UHV, XHV and UCV range –such as those required in high-power laser systems, high-tech measuring instruments and analysis equipment, for example.

Precision optics, micro-optical parts and sensor systems, among others for semi-automated and autonomous driving as well as industrial digitalisation applications, also require avery high degree of cleanliness for lasting fault-free function. For these challenging tasks, Ecoclean offers industry and application-specific solutions from pre-cleaning to intermediate and final cleaning connected to or integrated in a cleanroom. For the design of process and plant technology, the company has its own High Purity Test Centre with a validated clean room and corresponding measurement technology.

High cleanliness requirements have always been commonplace in medical technology. With the introduction of the European Medical Device Regulation (MDR), the requirements for cleaning medical devices such as implants, instruments and equipment, as well as for qualification, documentation and traceability of the processes, have become even stricter. In the meantime, the US Food & Drug Administration (FDA) is planning to harmonise its quality system regulation with the MDR, so that uniform regulations will apply regardless of market access.

To solve the very different tasks in medical technology in a requirement-oriented, efficient and sustainable manner, Ecoclean offers a complete and globally available portfolio of qualified cleaning systems. Co-operation with renowned partners also enables the realisation of turnkey projects with corresponding packaging and cleanroom solutions.

Software specially developed for medical technology, RFID technology and audit trails ensure the complete fulfilment of all specifications regarding component identification, documentation and traceability. In addition, the company’s experts provide support with qualification (IQ, QQ and PQ) on request. Thanks to the Ecoclean’s comprehensive medical technology and regulatory know-how, combined with extensively equipped technology centres (including a cleanliness laboratory and validated cleanroom), it becomes possible to devise the technically and economically optimal solution for every cleaning task. The potential duplication of this solution for further production sites is straightforward, a process that subsequently accelerates qualification and commissioning.

By entering into the development, manufacture and sale of electrolysers for the production of green hydrogen and solutions for its use, the company is opening up a new business area. To this end, Ecoclean and the Zentrum für Sonnenenergie und Wassersoff-Forschung Baden-Württemberg (ZSW) are pooling their expertise in the joint ‘EcoLyzer BW’ project. Based on robust and well-tested system technology for alkaline pressure electrolysis developed by the ZSW and Ecoclean’s expertise and decades of qualification in process engineering and industrial production technology, electrolysers are designed as modular systems with compact standard modules.

With power classes initially ranging from 1-10 MW, they enable the simple and cost-efficient construction of electrolysers adaptable to a wide range of applications. Typical uses include those for industry, mobility, energy supply for neighbourhoods and storage of re-generatively produced surplus energy from wind power and photovoltaic plants.

A first solution in this area came to fruition in September 2023 with a test rig for alkaline pressure electrolysis. It will make it possible to test and validate electrolysis stacks with an output of up to 500 kW and a diameter of 1200 mm.Through this diversification strategy, Ecoclean is helping to meet the challenges associated with disruptive developments, as well as various megatrends.
For further information www.www.ecoclean-group.net

First-rate contacts, new projects and concrete deals

Technical discussions, a strongly attended expert forum and a positive overall mood on all three days of the trade fair testified to the fact that the recently concluded 20th parts2clean exhibition fulfilled all expectations. More than 3000 trade visitors came to the event, the majority of them armed with tasks and projects, as well as a thirst for new information. This resulted in numerous high-quality contacts, new projects and even direct business deals for the more than 150 exhibitors (from 14 countries) at the event.

“We placed a stronger focus on the range of solutions offered at parts2clean for tasks where the highest cleanliness requirements need to be met,” reportedChristoph Nowak, project director at Deutsche Messe, “We thus succeeded in attracting more visitors from this segment of the industry to parts2clean.”

This was confirmed by Dr Günther Schmauz, board member at ACP systems: “With our high-purity snow-blast cleaning solutions, we were previously more of a niche supplier at parts2clean. At this year’s event, however, we were able to welcome a large number of trade fair guests from the fields of EUV lithography, including system partners and suppliers, as well as e-mobility.”

Rainer Straub, board of management and VPsales andcustomer service at
Ecoclean, expressed similar sentiments: “Parts2clean was significantly more successful for us this year than in 2022, certainly due to the ‘high-purity’ theme, which is a focal point in our programme.”

According to Manfred Holzleg, general manager of Safechem Europe “parts2clean always provides the opportunity to meet a diverse audience. This year, we were able to hold numerous discussions, especially with visitors from industries that are new to us. As a result, we can open up new fields of business.”
For further information www.parts2clean.de/en