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Category Archives: News About Our Clients

Longtime Chemcoaters Director, Bill Krippes, Retires

Chemcoaters, Gary, Indiana, Bill Krippes, Director of New Product Development, is officially retiring from Chemcoaters on July 28, 2018, after 16 years of dedicated service.

Bill has been in the coil and mill-applied coating industry for over 46 years, serving in R&D, Technical Service, and Sales roles. He started his career developing products for JM Eltzroth before moving on to spend more than a decade at PPG specializing in mill-applied coatings, with a specialty in dry film lubricants (Chemform) and mill-applied zinc phosphates. In 2001, Bill brought his experience and knowledge to Chemcoaters in Gary, Indiana. While here, Bill has been a staple of the organization.  His expertise in dry-film lubes for stamping and his product development skills have helped advance Chemcoaters’ core business and aided in educating a future generation of employees.

In August, Bill will officially retire but will continue to serve as a New Business Development Consultant. In that role, he will continue to help Chemcoaters’ customers find coating solutions to overcome issues with stamping and corrosion.

As Bill moves into his new consulting role, Brit Capizzano will move into the role of R&D manager.  Brit has spent the last 6 years under the guidance and mentorship of Bill. Moving into the future, Chemcoaters will continue to provide customers with unique coating solutions and unparalleled expertise.

Based in Gary, Indiana, Chemcoaters, Inc. is a leading supplier of green coil coatings, as well as traditional prepaint and protective coil coatings such as dry film lubes and other RoHS-compliant coatings.  Virtually no VOCs or HAPs are present in the process. The company’s patented InterCoat® ChemGuard 300 coating is formulated with trivalent chrome vs. hexavalent chrome, making it environmentally friendly in all building, architectural, transportation and consumer appliance applications.   InterCoat® ChemGuard 300 coating has superior corrosion resistance, as well.  Chemcoaters offers a presentation on their unique and proprietary patented coating that evidences this fact to all interested parties.

 

For more information, please contact:

Bill Capizzano, President
Chemcoaters, Inc.
700 Chase Street
Gary, IN 46404
Phone:  877-411-2905
Email:  billc@chemcoaters.com

or

Mike Tieri, Vice President, Sales & Marketing
Phone: 708-715-7759
Email: MikeT@chemcoaters.com

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Schütte Offers PC Multi-Spindle Automatics

PC Multi-Spindle AutomaticsSchütte (Jackson, Michigan) now sells its PC, their new multi-spindle automatics.

Often, manufacturers need automatics that have greater capabilities. These include the machining of non-ferrous metal or steel, a combination of heavy roughing and accuracy, simple programming combined with versatility and a single machine that performs several production processes. The answer to these challenges is Schütte’s PC series.

Automatics in the PC series are machining centers. They are used whenever classic cam-controlled automatics reach their limit. Besides turning, PC multi-spindle automatics perform tapping, mill cutting, polygon cutting and eccentric drilling operations. Six or eight work spindles, endworking and cross slides can be controlled independently of each other. Rear-side machining can have up to three tools. Over 56 CNC axes can be easily programmed with Schütte’s SICS 2000 system.

PC multi-spindle automatics are designed for material removal of geometrically sophisticated parts made of hard solid materials. The machines are designed to be robust, durable and technically flexible for complex drilling operations. Furthermore, they provide ready-to-install precision parts in large and small batch sizes. Machines in the PC series feature short setup, non-production and part production times.

These machines are used by automobile manufacturers and suppliers, the fittings, pneumatics and hydraulics sector, as well as in the production of precision parts.

 


For further information, please contact:

Brittany Oulch
SCHUTTE USA, LLC
4055 Morrill Road
Jackson, MI 49201
Phone: 517-782-3600 ex.10
www.schutteusa.com
boulch@schutteusa.com

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Major Automotive Supplier Expands Its Market with Schuler Presses

Huissel utilizes MSP servo presses for high production of complex stampings 

Canton, Michigan – Huissel, well-known as a reliable die and sheet metal part supplier for the European automotive and supplier industry, looked to Schuler presses to help expand their market.

Thanks to a digital twin, the commissioning of the new press is also considerably faster.Huissel wanted to complete the die manufacturing process chain in Frankenthal, Germany, and the related delivery of sheet metal parts at the Enkenbach-Alsenborn site for its product line. According to the two managing directors, Peter Busalt and Gerald Schug, these market potentials could not be achieved with the existing machinery. A system was needed that would permit economical manufacturing of medium and high lot sizes while enabling easy operation. Huissel chose the Schuler MSP 800; the latest expansion of the newly developed servo press series of Schuler.

“We examined suppliers from Spain and Italy to Germany,” says Peter Busalt. “But only the MSP series from Schuler currently has the functions we need.” Gerald Schug adds, “The ease of operability of the machine was important for us, for example, because this aspect helps even inexperienced employees quickly achieve good results in regard to taking advantage of the full potential of the servo press.”

With the MSP 800, Schuler has now sold the strongest machine in the series.Operators can select from predefined movement curves or program them freely. A fixed component of the control system is the Smart Assist software from Schuler, which performs the setup procedure for the dies step by step – another advantage for Gerald Schug: “In this way, we can shorten the usual launch of production to a fraction of the previous time.”

The commissioning of the new press is also considerably faster thanks to a digital twin. Here, the virtual system model is connected to the real control system with the machine and system visualization system. All functions of the MSP 800 can be simulated on the computer in this manner. The functionality and operation of the system can therefore be tested and trained on the real machine.

Huissel will set up a new building in its Enkenbach-Alsenborn factory for the MSP 800. As a whole, this project is the largest single investment in the company’s 100-year history. Huissel also intends to attach dies that it has manufactured in its Frankenthal factory 25 miles away to the new servo press. The tie rod structure of the MSP 800, which offers particularly high rigidity, also guarantees the quality of the parts production.

Schuler presented the MSP 400, a smaller version of the MSP 800, to the general public at the EuroBLECH trade fair in Hanover for the first time. The smallest members of the group, the single-rod automatic blanking press CSP 100 and the double-rod automatic blanking press MSP 200, are already in use at stamping companies. What all these presses have in common is the innovative knuckle-joint drive with highly dynamic servo motors and additional smart functions, such as condition monitoring.

Schuler is currently in development and will soon offer a press force of 1,250 tons.


For more information, please visit:

www.schulergroup.com/servopresses

For further information on Schuler Inc., North America, please contact:
Jeferson Valerio, Director of Sales
Schuler Incorporated
7145 Commerce Blvd.
Canton, MI 48187 USA
734-207-7200
info@schulerinc.com
www.schulergroup.com

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The Water Research Foundation Launches Tailored Collaborative Research Demonstration of CalPrex™ High Efficiency Phosphorus Recovery

Centrisys/CNP, located in Kenosha, Wisconsin, is collaboratively working with the Milwaukee Metropolitan Sewerage District (Milwaukee, Wisconsin), the Metro Wastewater Reclamation District of Denver (Denver, Colorado), the Madison Metropolitan Sewerage District (Madison, Wisconsin) and the Massachusetts Water Reclamation Authority (Boston, Massachusetts).

Together, they will perform Tailored Collaborative Research (TCR), a program of The Water Research Foundation (WRF), to demonstrate phosphorus removal and recovery potential of the CalPrex™ process at the Madison Metropolitan Sewerage District from September to November.

The TCR will collect high-quality data from the CalPrex™ process and allow the participating utilities to evaluate high-rate phosphorus recovery prior to anaerobic digestion and its positive effects on operations and maintenance. This will help the utilities better meet stringent biosolids regulations and simultaneously mitigate operations and maintenance issues related to phosphorus levels in sludge. A peer review of the findings will be conducted and the results will be disseminated to industry professionals through the WRF LIFT Link platform.

Phosphorus (P) removal and recovery is one of the hottest topics in the wastewater biosolids industry today. Tightening regulations for both land applications and the sale of biosolids have water reclamation professionals eager to evaluate technologies that remove nuisance phosphorus from biosolids in a cost-effective and sustainable manner.


CNP – Technology Water and Biosolids designs and supplies nutrient recovery and biosolids treatment optimization systems. CNP’s key technologies are: AirPrex® and CalPrex™, phosphorus recovery technologies, and PONDUS™, a Thermo-Chemical Hydrolysis Process (TCHP). CNP is a division of Centrisys Corporation. Centrisys Corporation is a U.S.A. manufacturer of dewatering centrifuges, sludge thickeners and complete dewatering systems for municipal and industrial wastewater. The company’s focus is centrifuge equipment, including the award-winning THK sludge thickener. Centrisys provides global service, repair and parts for all brands of centrifuges. 

For more information, please contact:

Centrisys/CNP
9586 58th Place
Kenosha, WI 53144
262-654-6006
Jessie Jones, Marketing Associate
Email: Jessie.jones@centrisys.us
Website: www.cnp-tec.com

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The Centrisys/CNP THK Sludge Thickener Improves Municipal and Industrial Wastewater Applications

With eight purchase orders in the last 3 months, the company’s sludge thickener has been used in several wastewater treatment facilities and wineries.

THK 600In the last few years, the U.S. has undergone a series of innovations and technology advancements. These changes have impacted several industries, leading them to save energy and resources. One such industry is wastewater treatment. Seven wastewater treatment plants in San Antonio, TX; Lincoln, NE; Belvidere, IL; Grandville, MI; Fargo, ND; University of Florida, Beijing airport and an East coast winery have benefited from the Centrisys/CNP THK sludge thickener. It offers proven performance with lower life cycle costs, less or zero polymer, higher G-volume for higher capacity and less redundancy, as well as up to 50% less power consumption compared to standard dewatering centrifuges.

THK 200“I’m surprised it’s taken this long for other treatment plants to see the value of this piece of equipment. The Kenosha WWTP (Wastewater Treatment Plant) installed our first THK200 in 2011. This one machine replaced four DAFT units, operated 24/7 using no polymer and achieved 5% TS cake and 95% capture. In 2015, we upgraded our plant process and now have an additional THK200 for primary sludge. With this THK, we doubled our solids concentration and cut in half the amount of water sent to the digesters,” said Melissa Arnot, P.E. Director of Operations at Kenosha Water Utility.

The basis of the THK design highlights what Centrisys is best known for – centrifuges. This sludge thickener is not a modified dewatering centrifuge, which is typically what happens when a conventional dewatering centrifuge is used for thickening sludge. The THK sludge thickener is designed and built specifically to thicken both primary and waste activated sludge using the fundamental principles of a centrifuge, DAFT and Rotary Drum Thickener.

According to Centrisys/ CNP’s CEO, Michael Kopper, “Equipment in this industry should last for decades. Those decision makers who understand the increasing importance of lower lifecycle costs and higher process efficiencies are clearly making the right choices for their plants and ultimately rate payers and our environment.”

THK 200


Centrisys Corporation is a U.S.A. manufacturer of dewatering centrifuges, sludge thickeners and complete dewatering systems for municipal and industrial wastewater. The company’s focus is centrifuge equipment, including the award winning THK sludge thickener. Centrisys provides global service, repair and parts for all brands of centrifuges. CNP – Technology Water and Biosolids designs and supplies nutrient recovery and biosolids treatment optimization systems. CNP’s key technologies are: AirPrex® and CalPrex™, phosphorus recovery technologies, and PONDUS™, a Thermo-Chemical Hydrolysis Process (TCHP). CNP is a division of Centrisys Corporation.

For more information, please contact:
Centrisys Corporation
9586 58th Place
Kenosha, WI 53144
262-654-6006
Jessie Jones, Marketing Associate
Email: Jessie.jones@centrisys.us
Website: www.centrisys.com

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Centrisys/CNP Announces Exclusive U.S. Distributorship for the Passavant® hydrograv® adapt System

Passavant hydrograv adapt SystemCentrisys/CNP (Kenosha, WI), a leader in decanter centrifuge technology and systems for nutrient recovery and sludge optimization, has announced their exclusive distributorship for the Passavant hydrograv adapt System in North America (U.S. patent pending).

Unlike fixed inlet structures for secondary clarifiers, the Passavant hydrograv adapt System consistently and continuously adjusts to current loading in a clarifier. If the loads are low, the hydrograv adapt automatically shifts the inlet elevation and opening height to a low position, introducing the mixed liquor below the sludge blanket. As the loads increase, the hydrograv adapt system shifts itself to a higher elevation and opening height, ensuring ideal hydraulic conditions for the operation of the secondary clarifiers and avoiding sludge overflow.

Benefits of the Passavant hydrograv adapt System include improved process stability of secondary clarification, a reduction of effluent suspended solids to usually less than 3 mg/L, improved particulate phosphorus removal, improved clarification capacity from hydraulic optimization and overall low maintenance requirements.

At WEFTEC 2018, Dr. Martin Armbruster, the Managing Director and founder of hydrograv GmbH and the inventor of the hydrograv adapt system, will co-present on the topic of “Stress Testing of a Secondary Clarifier with an Adaptive Inlet Structure.” His expertise in the field of clarifier CFD simulation includes optimization and practical engineering for more than 1,000 clarifiers in 200+ treatment plants worldwide. His experience in improving hydraulic efficiency of water management systems is based on 500+ hydrograv® with CFD simulations installations. The seminar will take place on Wednesday, October 3 at 1:50 p.m. in room 239.


Centrisys Corporation is a U.S.A. manufacturer of dewatering centrifuges, sludge thickeners and complete dewatering systems for municipal and industrial wastewater. The company’s focus is centrifuge equipment, including the award winning THK sludge thickener. Centrisys provides global service, repair and parts for all brands of centrifuges. CNP – Technology Water and Biosolids designs and supplies nutrient recovery and biosolids treatment optimization systems. CNP’s key technologies are: AirPrex® and CalPrex™, phosphorus recovery technologies, and PONDUS™, a Thermo-Chemical Hydrolysis Process (TCHP). CNP is a division of Centrisys Corporation.

For more information, please contact:

Centrisys Corporation
9586 58th Place
Kenosha, WI 53144
262-654-6006
Jessie Jones, Marketing Associate
Email: Jessie.jones@centrisys.us
Website: www.centrisys.com

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Centrisys/CNP Announces New Technologies at WEFTEC 2018

CS6-4 dewatering centrifugeCentrisys/CNP (booth #4921) will showcase their “More with Less” approach to innovation in the areas of sludge and biosolids management – including thickening, dewatering, resource intensification and nutrient recovery at WEFTEC 2018, October 1-3 in New Orleans.

Centrisys will introduce their new CS6-4 dewatering centrifuge, their smallest centrifuge to date. The CS6-4 bridges the gap between benchtop studies and full-scale installations. The CS6-4 continuously treats flows from 4 to 10 gpm, making this centrifuge a better alternative to a conventional laboratory centrifuge, which processes samples in batches. The CS6-4 provides scalable solid-liquid separation data to move R&D projects forward.

“We introduced the CS-6 into our equipment portfolio because so many of our customers requested it; there was a need and we simply provided a solution” Michael Kopper, CEO Centrisys/CNP.

Additionally, Centrisys will discuss their latest exclusive distributorship for the Passavant® hydrograv® adapt System in North America (U.S. patent pending). Unlike traditional inlet structures for secondary clarifiers, with the hydrograv adapt System, mixed liquor is introduced near the bottom of the clarifier, below the sludge blanket. The inlet elevation and opening height adjusts to flow conditions so it is always operating in ideal hydraulic conditions.

Centrisys will hold an in-booth discussion with Dr. Armbruster, the Managing Director and founder of hydrograv GmbH and the inventor of the hydrograv adapt system, on Tuesday, October 2 at 2 p.m. Additionally, Centrisys/CNP equipment and processes will be highlighted in the following seminars at WEFTEC 2018:

  • Digestion: Let Me Upgrade You / Tuesday, Oct. 2 at 4:00 p.m. / Room 244
  • Advances in Solid Clarification / Wednesday, Oct. 3 at 1:50 p.m. / Room 239
  • Sidestream Impacts from Startup to Implementation / Wednesday, Oct. 3 at 3:30 p.m. / Room 354
  • Expectations Exceeded? Promises Met? / Wednesday, Oct. 3 at 4:00 p.m. / Room 344

Visit Centrisys/CNP at WEFTEC 2018, booth #4921.


Centrisys Corporation is a U.S.A. manufacturer of dewatering centrifuges, sludge thickeners and complete dewatering systems for municipal and industrial wastewater. The company’s focus is centrifuge equipment, including the award winning THK sludge thickener. Centrisys provides global service, repair and parts for all brands of centrifuges. CNP – Technology Water and Biosolids designs and supplies nutrient recovery and biosolids treatment optimization systems. CNP’s key technologies are: AirPrex® and CalPrex™, phosphorus recovery technologies, and PONDUS™, a Thermo-Chemical Hydrolysis Process (TCHP). CNP is a division of Centrisys Corporation.

For more information, please contact:
Centrisys Corporation
9586 58th Place
Kenosha, WI 53144
262-654-6006
Jessie Jones, Marketing Associate
Email: Jessie.jones@centrisys.us
Website: www.centrisys.com

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Schuler and Porsche Form Joint Venture for Car Body Parts

Joint venture for “press shop of the future”

Canton, Michigan, September 5, 2018 – Porsche and Schuler announce plans to build an innovative press shop together for the car factory of the future. Representatives of both companies signed the contract on Tuesday, September 4, 2018 for the foundation of a corresponding joint venture. The European Commission has already green-lighted the joint undertaking. Approval from further anti-trust authorities is still pending. The objective of this Schuler and Porsche joint venture is to create what is termed the “Smart Press Shop” as part of a networked Industry 4.0 approach. The new press shop’s pioneering technologies will enable the highly flexible production of complex car body parts, where the focus will be on aluminum body panels and small batch production.

“Porsche wants to use the joint venture to lay the foundations for the future of sports car manufacturing,” says Albrecht Reimold, Member of the Executive Board for Production and Logistics at Porsche AG. “We plan to exploit future technologies and innovations in order to make our processes even more efficient. By dovetailing design, development, car body planning, toolmaking and production within the Porsche Group, we can significantly influence the quality of our sports cars.”

Schuler CEO Domenico Iacovelli stated, “Porsche and Schuler will be using a press shop that sets new standards in two respects – in terms of manufacturing performance, as well as the digital networking and readability of data streams along the entire production process. Not only Porsche will benefit from this major step forward, but ultimately other manufacturers as well.”

The systematic further development of process know-how in the field of metalforming will be achieved in part by the end-to-end networking of production data and the use of machine learning. Porsche and Schuler aim to set new standards in the field of predictive maintenance and intelligent production control.

The joint venture will utilize Schuler’s new Servo 20 Technology. It raises maximum output from 18 to 20 strokes per minute while reducing energy consumption per stroke and per part. A newly developed die-changing concept makes it possible to produce small batch sizes with a high degree of economic efficiency. Further features of the new line include an optimized servo drive in the downstream presses plus a reduced footprint.

The joint venture will operate as an independent company (GmbH & Co. KG) held in equal proportions by Schuler AG and Porsche. Each of the two companies will invest a double-digit million Euro amount in the joint venture. Over 100 highly skilled jobs are to be created. The location of the new company has not been finally decided yet. However, its location is expected to minimize logistics distances for car body parts  – thus significantly reducing CO2 emissions.

 

For further information on Schuler Inc., North America, please contact:
Jeferson Valerio, Director of Sales
Schuler Incorporated
7145 Commerce Blvd.
Canton, MI 48187 USA
734-207-7200
info@schulerinc.com
www.schulergroup.com

About the Schuler Group – www.schulergroup.com

Schuler is the world market leader in metal forming technology. The company supplies presses, automation solutions, dies, process know-how, and services for the entire metalworking industry and lightweight automotive design. Customers include automobile manufacturers and suppliers as well as companies from the forging, household appliances, packaging, energy, and electronics industries. Schuler is the leading supplier of minting presses and supplies system solutions for aerospace, rail transport, and large pipe manufacturing. In 2017, Schuler posted sales of € 1,233 million. Following the acquisition of toolmaker AWEBA and a majority stake in Chinese press manufacturing company Yadon, Schuler employs around 6,600 members of staff in 40 countries. The Austrian ANDRITZ Group holds a majority share in Schuler.

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Centrisys/CNP’s R&D Director Receives Young Professionals Award from Water & Wastes Digest

yoshiCentrisys/CNP, Kenosha, Wisconsin, is proud to announce that Hiroko Yoshida, R&D Director, was recently selected as one of Water & Wastes Digest (WWD) top young professionals in the water and wastewater industry.

The impressive WWD award is given to up-and-coming professionals in the water and wastewater industry who are talented and passionate professionals under 40 years old. These individuals must not only excel in their professional lives, but also give back to their community and hold worldly attitudes and views about the industry’s importance and necessity around the globe.

“I’m very excited to have won this award and love being part of such an innovative company,” Yoshida says. “It’s satisfying to start a project at the lab scale and see it progress into a full installation with great results.”

Yoshida previously accepted an invitation to the White House to attend the U.S. EPA Nutrient Recycling Challenge conference and was named one of the top four winners at the event. She notes one of her professional accomplishments as being part of the team was to bring the first full scale AirPrex® installation to the U.S.

She holds a B.S. in environmental studies from the University of Nebraska-Lincoln, Master of Science in water resource management and civil and environmental engineering, University of Wisconsin-Madison and a PhD in environmental engineering, Technical University of Denmark.

Yoshida specializes in solids handling and hopes to contribute to the advancement of the industry as it relates to that specialty. She has worked at Centrisys/CNP for over three years and is currently leading a pilot test program for CalPrex™, Centrisys/CNPs newest phosphorus recovery technology. Yoshida is involved with data analysis and process optimization. She says that the technology may be used in both municipal and industrial applications. “CalPrex is a lot more involved than normal,” Yoshida says. “Everyone is working night and day on this pilot — we’re excited to show what it can do.”

Yoshida stresses the importance of Centrisys/CNP as a whole. “Everyone in the company works so hard to bring these great innovations,” she says. “It’s not a win for just me; it’s a win for the team. I’m just looking forward to learning more!”


Centrisys Corporation is a U.S.A. manufacturer of dewatering centrifuges and sludge thickeners, as well as complete dewatering systems for municipal and industrial wastewater. The company’s focus is centrifuge equipment, including the award winning sludge thickener THK series. Centrisys provides global service, repair and parts for all brands of centrifuges. CNP – Technology Water and Biosolids Corporation designs and supplies nutrient recovery and biosolids treatment optimization systems. CNP’s key technologies are: AirPrex® and CalPrex™, phosphorus recovery technologies recovery technology, and PONDUS, a Thermo-Chemical Hydrolysis Process (TCHP). CNP is a division of Centrisys Corporation.

For more information, please contact:

Centrisys/CNP
9586 58th Place
Kenosha, WI 53144
262-654-6006
Jessie Jones, Marketing Associate
Email: Jessie.jones@centrisys.us
Website: www.centrisys.com

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DMG MORI Machine Produces Oil Field Rock Bit Using Full CAD-CAM-CNC Process Chain on 5-Axis Machining Center

Major machine tool builder offers their customer an entry-level, compact machine that works a 440-pound steel workpiece into a rock bit with better tool life, higher degree of accuracy and overall production efficiencies through partnership with Siemens

A DMG employee showcasing the DMU 50 with Siemens’ 840D sl CNC. The features of the 840D allow a streamlined simulation of the actual cutting path.

DMG MORI manufactures a wide variety of conventional chip-cutting machining centers for OEMs and production job shops serving the demanding oil-and-gas industry.  Inherent in this market are several factors that lobby for great care and planning in the machining process. Typically, components produced for the oil-and-gas field are very large, very heavy and often have complex contours, making the machining time long and the tool life short. The DMU 50, although an entry-level 5-axis machining center from DMG MORI, is a compact unit that features considerable strength, as the following example will detail.  “It is a David handles Goliath type of story,” says Matthias Leinberger, the business development director for Siemens PLM (Product Lifecycle Management).

On one recent application, DMG MORI was challenged with a 440-pound, 8” diameter x 8” high workpiece made from 1045 grade steel and being machined into a rock bit for oil field exploration. The customer further presented the builder with the need for fast changeover to produce the part from various metal materials, with all the attendant tool changes and workpiece setup variances present. The customer, a major upstream oil industry supplier, was trying to decide if the better path for this product was a single block of steel or a near net casting being machined.  Both high-speed roughing and then very precise 5-axis machining were required in this small footprint machine, which had been selected by the customer due to specific plant capacity utilization concerns, plus their desire for a flexible, reasonably priced and highly cost-effective machine tool.

Close up of the DMU 50 with Siemens’ 840D sl CNC.

The machine builder turned to its longtime business partner, Siemens, for assistance.  By offering a total package of CAD-CAM-CNC hardware, software and engineering services, Siemens was able to help the machine builder substantially improve every aspect of part production, including reduction of design-to-part protocols, machining time, tool life, surface finish, dimensional accuracies and overall production efficiencies.  This scenario was particularly applicable in this case, as the production runs were anticipated to be low with short lead times.

Starting from the CAD file, the Siemens PLM team ran the program through its NX CAM process, eliminating the set-ups through full 5-axis operation. The User Defined Events (UDEs) feature inside the NX program allows simple check boxes for triggering post-processors references for coolant pressure, spindle speed settings and more.  This avoids manual programming and, as a result, reduced the program transition time from as long as two days to approximately 30 minutes.

An oil field rock bit being machined on a DMU 50 with Siemens 840D sl CNC. Both high-speed roughing and precise 5-axis machining are possible on this small footprint, entry-level machine.

Once the program was ready for the CNC, the features of that control allowed a more streamlined simulation of the actual cutting path. The 3D quick set compressor feature provides a parametric itemized data file for all path motions, thereby eliminating collision and ensuring the optimum tool path, in conjunction with the NC kernel and PLC on the machine tool.  As Siemens technical applications center manager Randy Pearson observes, “This feature is a huge time saver for our customer, as the test ball and probe in the spindle mechanism can be run at any point in the cycle, testing the actual machine kinematics at any time. The procedure can also be automated to run on the table at prescribed time intervals.”

The high-speed machining feature is highlighted here by Cycle 800, which is a static plane transformation that allows a 5-axis machine to define a rotated working plane in space. It is commonly known in the trade as 3+2 programming.  The cycle converts the actual workpiece zero and tool offsets to refer to the rotated surface.  Of note here, the cycle accommodates particular machine kinematics and positions the physical axes normal to the working plane.  This is referenced as TRAORI or transformation orientation.

Meanwhile, Sinumerik Operate, the CNC’s easy-to-use, graphical user interface on the machine allows the operator to perform a variety of integrated tool management and information management functions, all transportable on a USB or network connection.

In the simulation, the loading and fixturing of the workpiece is performed virtually in the NX CAM program, which also calculates a consistent chip load, critical in these large material removal applications. The simulation further verifies the tool length at all cutting sections and the program is finalized for the machine to begin.

In production, this process also yielded a substantial improvement in tool life on this very heavy part over the 3-¾hour cycle time, according to DMG National Product Manager, Luke Ivaska.  “With the combination of the NX CAM software, plus the CNC on the machine and all it could do, we had some initial challenges, as most software programs are purpose-built CAM packages that allow quick and easy use by anyone.  They have significant limitations; however, as the software drives the tool path and the operator has very little control.  With NX and Sinumerik CNC, we have a lot more input on the creation of the tool path.  I have yet to find a problem I could not solve with NX.”

In the CNC, the Sinumerik Operate affords the end user’s operator and manufacturing engineering personnel full access to a variety of conditions in production, including all roughing and finishing data in plain text, plus all 5-axis transformation orientation data logged for restart after any interruption and manual restart.

An 8×8″ rock bit machined from 1045 grade steel on the DMU 50. Speedy setup and machining was made possible with Siemens’ total package of CAD-CAM-CNC hardware.

Easy-to-use probing for work offsets is another advantage the builder and their customer enjoy with the CNC used on this machine.  The operator is guided graphically for setting the workpiece zero, for example, while the tool length is automatically included in the calculation.  With the Operate system, the difference between the position value in the machine coordinate system and workpiece coordinate system is saved in the active zero offset.

The variable streamline operation of the machine tool combines here with an interpolated vector to produce a smoother finish in the machining of the intricate rock bit surfaces in a single tool path. The machine seamlessly transitions from square-to-round machining and then the extreme angle paths needed to accurately machine the internal surfaces.  A single bit portion of the program is automatically captured, so a step-and-repeat program can be built-up. The simulation of each bit cutting path was done on both the NX CAM and the CNC programs. It is literally like working with a “Digital Twin” of the machine.

This vectored program, it should be noted, is transportable to any machine with comparable results, according to Randy Pearson and PLM director of business development Matthias Leinberger, who comments, “Precisely because the machine kinematics are knowable, this program, once created, can be transferred onto multiple machines within the same facility or run by shops around the world, all tied together by the control, so there is total continuity between the operations, the data capture protocol and feedback received for production analysis.”  Randy Pearson further noted that, in this application, the customer’s desire to change the materials used on successive runs could be easily accommodated by the control, owing to its ability for on-the-fly adjustments, based on the orientation of the tool tip to the workpiece.

This project was accomplished, using CELOS® onboard the DMG MORI machine.  CELOS facilitates the total interaction between operator and machine, in this application, as it has numerous apps to enable instant call-up of actual conditions, full data comparison through a link to CAD and CAM products, plus full interface to the customer company’s ERP system for logging and analysis, with in-process remote adjustments achievable.  In the case of this oil-and-gas customer, interactive communication to a global production network is also provided, which allow the customer to run parallel production of different rock bits at locations around the world, with seamless data tracking and full production analysis.


For more information on this story, please contact:

Siemens Industry, Inc.
John Meyer
(847) 640-1595
john.meyer@siemens.com

For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to:  cnc.us@siemens.com

To watch a video of this line in operation, please visit https://youtu.be/xA1hyv6A7Hs

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