THIS WEEK’S HIGHLIGHTS

Transforming five-axis machine tool calibration

Renishaw has incorporated its new off-axis rotary measurement mode into the CARTO software suite, providing a single source for testing off-axis measurement using the XR20 rotary axis calibrator and XL-80 laser system. The latest release of CARTO, version 4.7, streamlines the measurement of rotary positioning accuracy for five-axis machine tools, where the XR20 rotary axis calibrator cannot always mount on the centre of rotation.

CARTO is a single software solution for Renishaw’s range of calibration products. Data collection takes place using the CARTO Capture application, while the CARTO Explore application is for data analysis. The new off-axis rotary measurement mode in CARTO Capture is a licensed option and allows the XR20 rotary axis calibrator, combined with the XL-80 laser system, to capture off-axis measurements in one session.

Dan Throup, product owner – calibration software, says: “A single test record is created in the CARTO database, significantly reducing the number of steps in the measurement process. This improved method gives greater data integrity and traceability from the Explore application to analyse the results. In addition, the Capture application now uses a new automatic sign detection move when capturing the angular errors associated with an off-axis test. This simplifies the process and reduces the chance of user error.”

First launched in 2012, the Renishaw XR20 rotary axis calibrator aids the direct measurement of rotary errors for stages, jigs and machine tools. The off-axis rotary measurement mode in the CARTO software suite provides a simple, accurate check for the alignment and positioning performance of rotary axes of any configuration.
For further information www.renishaw.com/carto-add-ons

Okuma announces green credentials

Since October 2022, production at Okuma’s three main machine tool factories in Japan has used only carbon-neutrally generated electricity, a goal achieved earlier than expected. The firm’s machining centres, CNC lathes and grinders are available in the UK and Ireland through sole agent NCMT.

Okuma also says that, from April this year, it will be labelling certain of its products ‘Green-Smart Machines’ if they are able to cut energy consumption considerably. These machines reducepower usage thanks to a trio of advanced technologies: the Thermo-Friendly Concept, whichnegates the need for a warm-up period; ECO Suite plus, which provides autonomous energy saving by monitoring spindle temperature and the pump; and systems for spindle cooling, which Okuma says reduce energy consumption by as much as 68% due to optimised control.
For further information www.ncmt.co.uk

CADCAM suite adds new tool-making function

In the mould and die industry, Open Mind says that its hyperMILL CADCAM suite is regarded as a completeend-to-end solution as it can cover aspects such as electrode manufacturing and wire EDM. Now, it is the introduction of the five-axis radial machining function that takes centre stage.

The new function is suitable for the process-optimised production of round moulds, where surfaces cannot undergo hand finishing or polishing operations. For components such as blow moulds that are applied in vehicle bumper production or consumer goods bottles, high-quality machined surfaces are critical as secondary hand finishing can introduce optical facets and surface inconsistencies that may appear in downstream processing.

According to Open Mind, improvements to the current version of hyperMILL – combined with five-axis radial machining – are setting standards in blow-mould machining. Thanks to a new radial projection method, it is possible to calculate toolpaths extremely quickly, and the user can apply various machining strategies to respond flexibly to the component conditions.

The new ‘Flow Equidistant’ infeed strategy is the first of its kind that supports the generation of toolpaths with a constant infeed for vertical and challenging surfaces. This capability means that surfaces can integrate into the overall machining sequence, with processing taking place in a single step. Seamless machining with a very high surface quality is guaranteed, reports the company. Every machining sequence needs to produce sharp corners at the junction of the upper and lower halves of the mould to avoid problems during the moulding process. An automatic tangent extension feature eliminates the manual CAD steps needed to extend the numerous surface elements found in complex designs.
For further information www.openmind-tech.com

Sheffield Forgemasters partners WaldrichSiegen

Sheffield Forgemasters has signed a long-term partnership with machine tool supplier WaldrichSiegen for lifetime support of its proposed new machining facility.WaldrichSiegen will deliver a 10-year, through-life and production-support contract, plus the design, manufacture, installation and commissioning of 17 new machine tools to create highly accurate, complex machinedshapes from ultra-large steel castings and forgings. McDowell Machine Tools represents WaldrichSiegen in the UK.

The machining line will sit in a proposed new building at the company’s Brightside Lane site, and includes a series of large-scale, five-axis vertical turning lathesthat form part of a recapitalisation investment of up to £400mover 10 years. Scheduled for delivery between 2025 and 2028, the machine line-up comprises: seven heavy-duty VTLs with 5-8m tables; three gantry mills with 6-16m turning capability; three RAM hydrostatic boring mills; three heavy-duty horizontal lathes with 24-27 m beds; and one gantry bandsaw.
For further information www.sheffieldforgemasters.com

Advanced tube simulation software from Unison

New Opt2Sim Tube bending simulation software is now available from Unison Ltd, the inventor of all-electric tube manipulation.

“In developing Opt2Sim Tube, our goal was to offer a tube simulation product that would make it simpler and more straightforward than ever before to create virtual parts ready for uploading bending data to the machine,” says Unison’s joint managing director, Alan Pickering. “In Opt2Sim Tube, we give users the ability to drag and drop STEP files into the software program and extract tube data instantly. In addition, users can draw parts by simply entering XYZ or YBC co-ordinates, viewing them in 3D. Bend data is quickly converted into printable reports and users can also extractindividual tube data.”

Unison’s Opt2Sim Tube software sits within the company’s wider Opt2Sim suite of 3D simulation software programs. Developed for ‘design to manufacture’ production strategies, Opt2Sim tube-bending simulation software uses machine and component data to provide a precise, virtual insight into the tube-bending process before commencing production.

Products within the Opt2Sim software suite include a version where both CAD modelling capability and the control engine combine toprovide accurate simulation and enhanced collision detection. Believed to provide unique capabilities for enhanced batch processing, simulated bending takes place on an exact CAD representation of the Unison Breeze or Synergy machine.

Additional options include advanced AI that will always aim to find a solution to even the most complex tube geometry, or whenever detecting a potential collision between tube and machine. The AI feature is particularly useful with right/left machines and when assisting in the development of highly complex parts, such as those used in the oil and gas industry.
For further information www.unisonltd.com