Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
New technology provides safer, cleaner work environment, as well as cost savings, for foundries by capturing and recycling unused pattern spray.
SCHAUMBURG, IL — Hunter, the first name in automated matchplate molding machines and mold handling equipment, announced today the introduction of its new CESAR™ vacuum pattern spray recovery system. The CESAR system will be made available to the world market at the company’s Cast Expo 2013 Booth #473, where it will be mounted on Hunter’s new HLM-10 linear motion molding machine. CESAR will run throughout Cast Expo 2013, one of the foundry industry’s leading events, being held April 6-9th at America’s Center in St. Louis, MO.
According to Hunter Foundry Machinery Corporation president and CEO Bill Hunter, who invented the system, “CESAR” stands for Contain, Evacuate, Separate And Recover. “This relates to the proper disposition of pattern spray typically used in sand molding operations, to act as a release agent between the mold and the pattern plate,” Hunter said. “We invented it in response to our customer’s needs, in recognition both of modern foundry and global environmental standards and to help improve their return-on-investment (ROI).
In operation, the closed-loop CESAR System from Hunter executes the following:
Most typical molding machines include a spray head positioned in the sand filling station and a spray evacuation device positioned near the rotary cradle or the spray head. The spray is then dispersed onto the pattern plate as it enters the rotary cradle. But uncontained, excess spray can go onto other parts, as well as into the foundry atmosphere. This is why Hunter created its new CESAR System.
“In our new CESAR System the evacuation device – a slotted tube on the circumference of the rotary cradle – connects to an inline vacuum pump. Then, a cyclonic separator and water separator capture release agent vapor from the air collected in the tube,” Hunter stated, adding that CESAR provides a cleaner, safer working environment in the sand foundry while providing not only substantial savings to a foundry’s operation but also a positive environmental benefit to that foundry’s “green” initiative.
ABOUT THE COMPANY
Hunter Foundry Machinery Corporation was founded in 1964 as Hunter Automated Machinery Corporation with the invention of the first gravity-filled automated matchplate molding machine. This established the company’s history of innovation and launched the foundry industry into a new industrial revolution. Pioneered by William “Al” Hunter in his garage, the original HMP-10 machine streamlined the laborious metal casting process by offering foundries unimagined new production capabilities, producing as many molds in one hour as most had been able to produce in an entire day. As industry demands grew Hunter responded with advanced solutions such as automated mold handling equipment and coresetters.
Now in its 50th year, Hunter Foundry Machine Corporation’s inventions have earned nearly 150 patents around the world. With more than 1,800 molding machines and mold handling systems installed around the world, Hunter’s sales and service reach extends from its manufacturing sites in North America, South America and China through its offices in the U.S., Europe, Brazil, India and Shanghai to every corner of the globe. Sales and technical support, as well as the company’s $12 million parts inventory, serve to maintain each machine’s original production capability, as well as Hunter’s preeminence in the world market.
FOR MORE INFORMATION PLEASE CONTACT:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Attention: Bill Hunter, CEO
Web: www.hunterfoundry.com
Connect with Hunter Foundry online: 
Expanding its pioneering position as the industry’s preeminent innovator, this new corporate name reflects the company’s single focus and dedication.
SCHAUMBURG, IL — Hunter, the first name in automated matchplate molding machines and mold handling equipment for the foundry industry, is celebrating its 50th year in a very special way. President and CEO Bill Hunter is announcing the company’s new name: Hunter Foundry Machinery Corporation. The company will be at Booth #473 throughout Cast Expo 2013, April 6-9th at America’s Center in St. Louis, MO. The company is also introducing its new HLM Series automated matchplate molding machines, which are based on Bill Hunter’s newly patented linear motion technology.
Founded in 1964 as Hunter Automated Machinery Corporation, the company’s reputation as a global foundry equipment leader has built steadily, beginning with its creation of the first truly automated matchplate molding machine developed by the company founder, the late William Allan “Al” Hunter. Since that time it has expanded into linear and rotary mold handling lines, sand handling, preparation and testing equipment, and more.
“Ever since my father founded our company nearly 50 years ago, our reputation has been built on the successful development of new products and technologies for the global foundry industry. It has been our privilege to serve this industry with the latest innovations, as was my father’s vision, ever since,” said Hunter.
“As an inventor, his primary focus was pioneering the automation of matchplate molding and mold handling processes to facilitate our industry’s most backbreaking tasks,” Hunter observed, adding, “As an entrepreneur, he named our company Hunter Automated Machinery Corporation to reflect a potential for creating forward-thinking solutions for other industries, as well.”
“Today we’re looking both at our history and ahead, to our legacy of innovation within the foundry industry,” Hunter stated. “Accordingly, we are announcing at Cast Expo 2013 the renaming of our company to Hunter Foundry Machinery Corporation, as a reflection of our single-focus past, present, and future exclusively within this industry,” he noted.
According to Hunter, the company has always been 100% dedicated to the foundry market. “It’s not only our business focus, it’s our inspiration,” he said. “The great people in this industry motivate our company to constantly and tirelessly pursue better ideas, technologies and production solutions for foundries worldwide. Our new name is a clear reflection of our business now, more than ever.”
The company’s introduction of the first gravity-filled automated matchplate molding machine established its history of innovation, and launched the foundry industry into a new industrial revolution. Its original HMP-10 machine streamlined the laborious metal casting process by offering foundries unimagined new production capabilities, producing as many molds in one hour as most had been able to produce in an entire day. As industry demands grew Hunter responded with advanced solutions such as automated mold handling equipment and coresetters.
Hunter’s inventions have earned the company nearly 150 patents around the world. With more than 1,800 molding machines and mold handling systems installed around the world, Hunter’s sales and service reach extends from its manufacturing sites in North America, South America and China through its offices in the U.S., Europe, Brazil, India and Shanghai to every corner of the globe. Sales and technical support, as well as the company’s $12 million parts inventory, serve to maintain each machine’s original production capability, as well as Hunter’s preeminence in the world market.
FOR MORE INFORMATION PLEASE CONTACT:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Attention: Bill Hunter, CEO
Web: www.hunterfoundry.com
Connect with Hunter Foundry online:
New HLM-10 Linear Motion Machine, First of Hunter’s New Product Line, Unveiled at Cast Expo 2013
Minimizing maintenance while promoting stability, HLM Series combines and integrates magnetically coupled rodless cylinders and linear bearings for movements of squeeze platen, cope flask, sand measuring hopper, and other components on machine. Separation of hydraulic power system facilitates maintenance, while linear motion-operated, programmable access doors maximize operator protection. Linear motion machine also features CESAR™ vacuum pattern spray recovery system.
See the HLM in action HERE!
Hunter Demos JetSlinger™ Air-Amplification Product At Cast Expo 2013
JetSlinger™, the newest add-on to industry innovator Hunter Foundry Machinery Corporation’s latest products, helps ensure improved pattern definition, as well as uniformity of mold hardness and surface integrity.
JetSlinger™ is an available option for the new Hunter HLM linear-motion machine, as well as a retrofit option for the company’s XL automated matchplate molding machines. It is an air amplification apparatus based on the Venturi principle that accelerates sand into the cope and drag flasks on these Hunter machines.
See the JetSlinger™ in action HERE!
FOR MORE INFORMATION PLEASE CONTACT:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive Schaumburg, IL 60196
Phone: (847) 397-5110
Fax: (847) 397-8254
Email: info@hunterfoundry.com
Attention: Bill Hunter, CEO
Web: www.hunterfoundry.com
Connect with Hunter Foundry online:
TCT Stainless Steel, Inc., a Lebanon, Tennessee metal service center, is proud to announce the commissioning of a new 64” wide heavy gauge EMAG slitter. This line is capable of slitting .035 to .3125 gauges. Maximum coil weight is 40,000 lbs. with a maximum 72” outside diameter uncoiler/recoiler. The line is complemented with an Alcos (8) position carousel packing line.
This new line is in addition to the existing 20” Stanat light gauge slitter commissioned by TCT in late 2012, which slits .005 gauge.
The addition of this line complements the other (4) slitters, rolling mill, edger and cut-to-length capabilities that TCT currently offers to customers. With these additions, TCT now offers more in-house capabilities and services than any service center in the Southern United States, according to a company spokesperson.
TCT invites all interested parties to visit the company at 711 Maddox Simpson Parkway, Lebanon, TN for a personal tour or visit www.tctstainless.com for a virtual tour. Let TCT show you what these new lines can do to benefit your operation.
For more information, please contact:
TCT STAINLESS STEEL, INC.
711 Maddox Simpson Parkway
Lebanon, TN 37090
1-800-877-8366
Phone: 615-443-4657
Fax: 615-449-6079
Web: www.tctstainless.com
Email: tcttn@tctstainless.com
Attention: Sherry Shaub, General Manager
TCT Stainless Steel, Inc. is one of the steel industry’s leading service centers. Our vast, in-house capabilities include virtually every facet of coil processing. Our capabilities include slitting, tempering, gauge reduction, cut-to-length, edging, buffing and tension leveling. TCT currently serves the aerospace, medical, electronic, telecommunication, automotive, lift equipment, building trade and other markets.
The combined inventory of our Michigan and Tennessee service centers include annealed and tempered stainless, aluminum, carbon and coated steels. Our dedication to providing high-quality products, short lead times and reliable delivery has always been the key to our success. We are constantly improving our facilities to include state-of-the-art technology, SPC and quality control standards.
Customer satisfaction is our specialty. Whether it be heavy or light gauges, narrow or wide widths, small or large quantities – TCT guarantees satisfaction and dependability at competitive prices. Our outstanding reputation for product quality is backed by our dedicated, customer-oriented team. Our sales staff welcomes all orders and inquiries and will respond quickly with reliable service and industry leading lead times.
During EASTEC 2013, Siemens will present its newest solution for the job shopfloor, the Sinumerik 808D, an attractively-priced CNC for entry-level milling and turning machines.
Over 50 years of Siemens CNC experience have been brought to the development of this control, which is specially designed for the highly competitive, high-volume 230V, three-phase and economy machine tool market. With up to three-axis plus spindle control capability in milling or turning applications, the 808D is offered as a package with Siemens Sinamics drives and Simotics motor solutions. The Sinumerik 808D will be immediately available for OEM machine tool builders and in-the-field retrofit installation by Siemens business partners worldwide.
FOR MACHINE TOOL BUILDERS
Start with an IP 65 enclosure, easy-to-load USB port, mechanical, hot and soft keys for easy, intuitive operation, clamp-mounted front panel and a modular design that allows customizing by machine model or with out-of-the-box operation. Plus, the machine control panel is connected using plug-and-play technology using a simple USB interface. On a turning machine, the Sinumerik 808D provides high contour accuracy and maximum machine productivity on high-volume production runs. On a milling machine, likewise, the Sinumerik 808D offers machine builders of vertical machining centers all the benefits of the Siemens MDynamics velocity control for mold and die section work.
A 7.5-inch LCD color display with 640 x 480 resolution for easy reading, selectable function keyboard, rotary dials for speed and spindle override, LED tool number display, durable buffer battery and rear connection ports for USB, RS232 C, distributed and onboard I/O, setpoint to feed axes and spindle, spindle encoder, fast I/O, e.g., for probes and handwheel operation are all standard on the Sinumerik 808D.
With 80-bit nano floating point accuracy and intelligent jerk limitation for smoother path cutting and less mechanical stress on the machine structures, workpiece accuracy and repeatability are improved. Whether turning with a C-axis changeover or milling mold sections where path control is paramount, the Sinumerik 808D has been designed to significant heighten the performance level of basic machine tools.
With programGuide Basic, a wide range of pre-determined technology cycles are available, in addition to the standard G-code and coordinate transformation language. Standard ISO codes can also be intermixed with high-level Sinumerik CNC commands on the 808D. The onboard contour computer further allows complex programs to be created and modified at the CNC without the need for a CAD/CAM system.
For routine or even online help with maintenance or troubleshooting issues, a simple push of a button is the only requirement, as the complete library of system parameters is accessible onscreen.
Commissioning is made easier with a ready-to-run PLC program. Customizing the PLC is simpler, as well, with function and data blocks for program testing and debugging built-in. The Sinumerik 808D further allows easy connection to the PLC I/O of other machine devices, whether proximate or remote. The open architecture of Siemens CNC has not been sacrificed on the 808D, so customized HMI screens and menu trees are easily defined and created.
Finally, with Manual Machine Plus (MM+) function on this new CNC enables transition from conventional machining to CNC programming. A machine equipped with MM+ can be operated using handwheels but with all the benefits of CNC-assisted technology cycles.
The Sinumerik 808D is offered with full THREE-YEAR WARRANTY on parts and labor.
FOR END-USERS
In addition to the above features and benefits for the machine builder, shop operators and programmers alike will appreciate the Sinumerik 808D for its many end-user advantages, including simplified keyboard entry of all program values, named part programs in subfolders just like a PC, convenient shortcut keys to access tool offset lists or the Program Manager, intelligent jog features easily identified and graphically-supported, precise tool handling and tool wear data readily available onscreen and a powerful simulation routine. An operator can access all system information and obtain online help, whenever needed.
The multimedia training materials include on-screen tutorial video and full step-by-step procedures to go from the blueprint to the finished part. For offline training, a fully operable software machine control panel on a PC is available to end users.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
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At this year’s EASTEC Show in West Springfield, MA, Siemens will demonstrate new versions of its popular, compact CNC for the job shop, the Sinumerik 828D.
SINUMERIK 828D BASIC T
The Sinumerik 828D BASIC T is designed to address the needs of shopfloor turning machines.
It combines CNC, PLC, operator panel and axis control for five axes/spindles, including live tooling. Milling and drilling operations on a turning machine, both for face and peripheral surfacing, are therefore possible. In tandem with the new Sinamics S120 Combi drives package, the 828D BASIC T represents a new level of efficiency and virtually maintenance-free operation, as the fans, hard disks and batteries of past CNC generations have been eliminated.
With rugged diecast magnesium front panel on an IP65 enclosure, the BASIC T enables an Ethernet connection, USB or Compact Flash (CF) card program loading. An 8.4-inch color display for easy readability and simple QWERTY keyboard provide fast ramp-up for the operator. Various communication ports in USB, Ethernet, Drive-CLiQ, PLC I/O interface, RS232 C and NC inputs/outputs are standard.
In operation, reliable 80-bit nano accuracy means contour control precision and a better workpiece, every time, while Siemens intelligent kinematic transformations provide the proper orientation of machining plane to work surface.
Though simple command language is provided for operator ease, the BASIC T functions with the highest level of ISO programming language. Established cutting cycles can be utilized with fully Animated Elements for the faster visualization of part production on various levels with combinations of Sinumerik CNC and ISO programming languages possible, as well.
SINUMERIK 828D BASIC M
Similarly, the new Sinumerik 828D BASIC M class features the same quality performance as the T class, but for use on milling machines. Even in complex moldmaking operations, mirror-smooth surfacing and reduced machining times are enabled. Again, in tandem with the Sinamics S120 Combi drives package and Simotics feed and spindle motors, the 828D BASIC T will operate a milling machine at the highest level of performance possible. Superior axis and spindle dynamics within a broad speed bandwith yield quality workpieces, every time.
All the other benefits of the Siemens CNC family, including the Sinumerik Operate graphical user interface platform as well as ShopMill and ShopTurn easy programming are offered in these new 828D CNCs.
SINUMERIK 828D
The Sinumerik 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. This control family is ideal for single-part and small-batch production. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical workstep programming systems, while high-level language programming can be used in conjunction with programGuide to significantly reduce programming times for large-scale serial production.
Also included with this expansion of the Sinumerik 828D family of CNC, modern PC and mobile phone technology are also available for the mid-range machine tool. Extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate data networks.
Through the use of its Easy Message functionality, the Sinumerik 828D family offers production status monitoring by text messaging (SMS). Depending on the recipient’s profile settings, the machine tool can transmit information about workpiece machining status, report on the tool condition currently
in use and send machine maintenance bulletins to a mobile phone, anytime and anywhere. These combined functions are designed to help keep machine downtime to a minimum.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on this story, please contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
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Turning-milling centers with coordinated drive and CNC engineering achieve superior accuracy and repeatability
Hamuel CEO Dr. Markus Stanik (right) and his sales manager Jochen Schaede agree: “The Sinumerik 840D sl CNC complements perfectly the capabilities of our five-axis turning-milling centers in the HSTM Series. Because of this fact, we can usually convince leading turbine manufacturers from the aerospace and automotive industries about the dynamics, high-performance and precision of these machines.”
The complete machining of turbine blades requires striking a balance between powerful roughing and ultra-precise finishing, a task for which the modern five-axis turning-milling centers are ideal, when robust machine construction is combined with high-quality drive and control engineering. Experience is the solid basis on which the Hamuel Maschinenbau GmbH & Co. KG, Meeder, Germany, can offer a great deal: with 85 years of machine tool manufacturing, 35 years of CNC machining, 25 years of five-axis simultaneous machining and over 10 years in the construction of five-axis turning-milling centers. CEO Dr. Markus Stanik knows that experience by itself cannot be any yardstick for the quality of machine tools, noting, “It certainly helps us, together with the right partner companies, to design and build the machines so that our customers can be successful in the marketplace.” This machine builder and its many customers have developed correspondingly positive accomplishments together. Today, Hamuel stands on three standards:
The latter, as evidenced by Hamuel’s HSTM (high-speed turning-milling) series, has been marketed since 1999 and makes a decisive contribution to the sales and success of the company. Leading turbine manufacturers from the aerospace and power-generating industries have been particularly impressed by the dynamic response, capability and precision of these machines. Even the smallest faults are unacceptable on turbine blades
Form deviations are unacceptable for products such as turbine blades and blisks because even the smallest error would significantly reduce the efficiency of the power plant or aircraft turbine.
The HSTM that runs on the Sinumerik 840D sl CNC controllers is used mainly to manufacture turbine blades and blisks (turbine disks) deployed in stationary steam and gas turbines as well as in mobile turbines for aircraft jet engines and large turbochargers. These products always consist of high-strength materials, such as titanium or high-alloyed steels. Form deviations are taboo in such applications, because even the smallest error would significantly reduce the efficiency of the turbines. Correspondingly high and comprehensive are the requirements placed on the machine tools. Hamuel sales manager, Dipl.-Ing. Jochen Schaede, explains: “Our customers normally manufacture large turbine blades longer than approximately 1000 mm from forging blanks. In contrast, shorter workpieces are milled from a solid piece of material with a stock-removal ratio of approximately 80 percent. This makes it obvious that our machines must not only rough-cut very productively but also finish with high precision.” Whereas productivity takes precedence for rough-cutting, accuracy is more important for the subsequent finishing of the spatial free-form surfaces. “With regard to accuracy, our high-performance machining centers achieve a precision in the micrometer range coupled with excellent surface quality,” added Schaede.
Form deviations are unacceptable for products such as turbine blades and blisks because even the smallest error would significantly reduce the efficiency of the power plant or aircraft turbine.
Key to this capability is the combination of compact machine construction together with perfectly matched drive and control engineering. The basis is the robust machine design with a one-piece machine base – either as welded construction cast with special concrete or latterly directly as polymer-concrete made from a single piece of material. The careful distribution of the masses ensures the best dynamic rigidity. The experience of the developers at Hamuel paired with the knowledge of the Siemens mechatronic experts make such results possible, as Jochen Schaede confirmed: “Thanks to various simulation tools, the Siemens engineers could provide us with very exact data to which we could add or remove masses. It was certainly advantageous that we could procure all components required for the dynamics from Siemens starting with the spindle, including the axis drives, and ending with the CNC. This means we needed only a few iteration loops in order to obtain a perfect dynamic rigidity in the machines.” It is also important that all components are arranged so that the horizontally clamped turbine blades and blisks can be machined optimally. This is also facilitated by the 45°-inclined orientation of the axes that ensures a favorable swarf removal further augmented by the permanent rinsing of the machine internal area. The accessibility has also been enhanced by this inclined axis orientation. Such designed and built HSTM machines equipped with precise direct drives from Siemens achieve a maximum positioning accuracy of 5 µm with traversal speeds exceeding 40 m/min in all linear axes. Indeed, the extremely fast rotary axes have a positioning accuracy of 3 µm. This allows the user to achieve maximum productivity, accuracy and surface finishes in the range of Ra = 0.8 µm, and so fully meet the industry requirements placed on the blade machining. CNC ensures optimized surface transitions at the inlet and outlet edges One of the biggest challenges for the turbine-blade manufacturing industry concerns the critical surface transitions (leading and trailing edges) of the turbine blades. To achieve a high quality, the milling paths described with curve interpolation points must have a constant machining speed. As a consequence, the leading and trailing edges demand extreme angular accelerations. The number of curve interpolation points to be described is correspondingly quite high.
The manufacturing of precise free-form surfaces for turbine blades demands the highest performance from the CNC. The excellent block-cycle times of the Sinumerik 840D sl and its look-ahead function improved as part of the new “Advanced Surface” motion control, which play a significant role here.
The controller now faces the challenge to reliably process the generated NC steps that are supported by the fast block cycle times and the look-ahead function of the CNC. “Hardly any other controller can supply the drive information for all five axes in the required short time as reliably as the Sinumerik 840D sl controller,” confirmed Jochen Schaede, who added, “The new Advanced Surface motion control that includes among other things an optimized look-ahead function is also excellent. And I would also like to mention the five-axis high-speed turning-milling of free-form surfaces requires a continuous spatial reorientation of the geometry vectors.” This leads to the use of the Traori (transformation orientation) principle in the Sinumerik 840D sl. Hamuel’s customers can therefore achieve reproducible results with the best-possible surface finish, exact contour accuracy and with the maximum possible machining speed.
Despite being a high-end controller that offers many modern features, the Sinumerik 840D sl CNC is easy-to-use.
In addition to the primary properties of precision, productivity and reliability, Hamuel also appreciates other properties of the Siemens drive and control engineering – an example: the DRIVE-CLiQ interface. When this digital connection is used, all appropriately equipped drive components are detected automatically. Only a cable for the connection is required to achieve this result. Equivalent circuit diagram data for the motors and the characteristic values of the installed encoder systems are all stored. This avoids the need for manual data input during the commissioning and so makes this task more reliable and much faster, according to Hamuel engineers. Sales manager Schaede is also impressed with the “know-how” protection onboard the control. With the help of innovative software, his customers can protect all their programs and their application know-how, using individual passwords and so largely prevent unauthorized access. According to Hamuel, the Teleservice offered by Siemens has proven to be an important advantage for its machine users who often operate globally. It allows not only software problems to be rectified but also updates to be installed fast and reliably without needing to be present onsite. Manufacturing operations save time and money and they always remain up-to-date with the latest software releases, via this service. Powerful motor spindle with Hirth gearing
Leading turbine manufacturers are particularly impressed by the dynamics and high-performance of the HSTM machines. The perfect interaction of the robust Hamuel machine construction and the high-quality Siemens drive and control engineering provide the basis for this satisfaction.
The capability of the turning-milling center also depends greatly on the 54-kW motor spindle made by Weiss Spindeltechnologie GmbH (a Siemens subsidiary). Equipped with a HSK A63 tool holder, it is able to provide the high torque required for roughing plus speeds as high as 16,000 rpm for finishing. This means an optimum cutting speed is always guaranteed. As a practical detail, the Hamuel engineers also emphasize the integrated Hirth gearing that makes it possible to clamp the spindle and relieve load on the bearings during the turning process. The machine sizes in the HSTM Series are oriented to the length of the workpieces to be produced in standard ranges from ≤ 500 mm (HSTM 300) to 1750 mm (HSTM 1500). On special request, Hamuel also builds larger machines. A project for machining blades as large as 2500 mm in length is currently running in the field. CEO Markus Stanik explains, “Thanks to our modular machine construction, we are able to satisfy special requests and build turning-milling centers in these dimensions.”
The manufacturing of precise free-form surfaces for turbine blades demands the highest performance from the CNC. The excellent block-cycle times of the Sinumerik 840D sl and its look-ahead function improved as part of the new “Advanced Surface” motion control, which play a significant role here.
New developments already in the introductory phase are also evolving at Hamuel. For example, in the near future, a special gas will be able to be used to cool the tool in the HSTM machines. A machine base made of mineral casting is also now offered. One of the first machines of this type has already been presented at EMO. “This material not only exhibits excellent properties with regard to vibration suppression but we have also been able to reduce somewhat our dependency on steel suppliers,” noted Markus Stanik. For the machine user, this makes itself apparent directly in improved surface quality and a significantly longer tool service life. CNC gantry milling machines of the HSM (high-speed milling) series In addition to the component production and the construction of the HSTM series, the company’s HMS Series machines are another mainstay for Hamuel. These simultaneous five-axis machining centers are designed for high-speed cutting (HSC). They feature not only the modern Siemens drive and CNC control engineering, but also the optimized milling-head systems and the high-performance high-speed spindles, providing this capability. HSM machines allow high-performance roughing and ultra-precise finishing. With regard to the size of the HSM machines, the manufacturer adapts the designs specifically based on the customer requirements. As a component producer, Hamuel also has its own machines in constant use at its factory.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
About Hamuel Maschinenbau GmbH & Co. KG, Meeder, Germany
Hamuel was founded in 1927 and is now part of the Hamuel Reichenbacher company group. More than 2000 CNC machines from this enterprise group are currently in use globally for the machining of a wide range of materials. The focus of Hamuel Maschinenbau comprises three areas: the production of machine-tool components, CNC gantry milling machines (HSM) and five-axis CNC turning-milling centers (HSTM).
Continue readingAn announcement from Bill Hunter, CEO of Hunter Automated Machinery Corporation, the world leader in automated matchplate molding machines, mold and sand handling equipment for the foundry market, Jim Fitzgerald will assume the newly created position of Chief Operating Officer, effective Friday – February 1, 2013.
Jim Fitzgerald will assume the position of Chief Operating Officer
Jim began his career as a machine assembler for Hunter in 1977, shortly after his graduation from Central College in Pella, Iowa. For the past 35 years, he has been dedicated to shop operations and manufacturing management at Hunter. He was promoted to his current position as Vice President at the company, following Art Hisel’s retirement in 1992.
Jim’s responsibilities as COO will include all Schaumburg, IL-based activities, with the exception of Sales and Marketing. His goals will include maintaining and building upon the company’s reputation for producing the world’s highest-quality foundry machinery and for providing superior after-sale support.
“Jim brings the education, proven ability and determination to help Hunter achieve these goals. His leadership and commitment to our company is unquestionable and exemplary,” said Bill Hunter in making this announcement.
For more information on this news, please contact:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive
Schaumburg, Illinois 60196-1094
USA
Phone: 847-397-5136
Email: sales@hunterauto.com
Highlights include two-sided machining and servo drive technology
Recently, Northern Italian machine tool manufacturer Biglia introduced its multi-functional turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC. The mechanical concept, together with the scalable control, provides users with the most diverse standard turning and milling operations. The result is increased flexibility and higher speeds for end users. That quality machine tools are built in Northern Italy is nothing new. And this fact is confirmed again by the “Quattro” series from the machine tool manufacturer Biglia. These machines are multifunctional turning centers that are valued throughout Europe for their high reliability and performance power. The machines are available in different versions from 11 to 15 CNC axes. They are also intended for different turning diameters (45, 52, 65, 71 and 80 mm).
Biglia has equipped its turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC control. The individual machines have 11 to 15 NC axes.
The two opposing spindles form a special feature of the “Quattro” series. This allows the workpiece to be machined from two sides, which reduces the machining time. The second spindle can also be moved linearly in two directions (lengthwise and crosswise). This provides some leeway in the case of additional milling operations, but it can also be used for automatic workpiece unloading. Two turrets, mounted on the y-axis, ensure proper positioning of the necessary tools.
The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.
This innovative machining technology allows the creation of not only rotary but also prismatic workpieces – including polygons. Dealing with everything in one setup not only reduces cycle times, it also enhances accuracy. The machines are developed on the basis of a modular concept that ensures flexible application options – from the universal CNC lathe, to complete machining of complex workpieces with powered tools (c- and y-axis).
Getting it right, from the start
By offering the Siemens Sinumerik 840D sl CNC control, Biglia now wants to expand its previous options and its own market by combining its technologies with that of the Siemens control. “In this project, which is of personal significance to all of us who worked on it and of strategic significance for Biglia, we wanted to do everything perfect right from the start and to get the most out of it,” says Giovanni Delmondo, Business Development Manager for machine tools with Siemens Italy. The result is an all-round successful machine series with a highly modern control that already includes the innovative system expansions of recent months – including increased energy efficiency options offered by the control and drive systems from Siemens.
To illustrate this, Giovanni Delmondo points out that “the fans on the spindles are shut down automatically when they are not required, or certain services such as hydraulics, lubricant supply, or compressed air are deactivated during machine standstill times. This is handled via special screen forms on the control and is extremely simple, using the Run MyScreens function.”
Also notable is the standard energy efficiency solution from Siemens in the Sinamics S120 drives onboard this machine series. This includes automatic power factor correction or regenerative feedback of the energy generated in braking operations, a substantial factor in energy savings.
Performance and scalability
The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.
The centerpiece of the automation concept of these Biglia turning centers is the Sinumerik 840D sl control. This is a universal and flexible CNC system, implemented in the Sinamics S120 design (see Fig. 3). It is suitable for up to 31 NC axes. Whether you are turning, drilling, milling, grinding, laser-machining, nibbling or punching, the Sinumerik 840D sl is suitable for use in the most diverse machining technologies. The CNC control also has PLC (programmable logic controller) functionalities, so that a special PLC can be eliminated, if applicable.
This high-end control from Siemens is ideally suited to medium and complex tasks and production and can be adapted to the task, thanks to scalable hardware. The CNC is also characterized by openness, so the operator interface and also the software present few limits to specific job adaptability. This applies all the way to supplementing the NC core of the control; however, a special license is required for this adaptation.
On the Biglia turning centers, the control was equipped with the Sinumerik Operate user interface, making operation simple and intuitive. Three different methods of parts programming are possible: Classic ISO code programming, programming with the help of the integrated ProgramGuide with graphical support of the selected cycles, and the new two-channel ShopTurn with graphical 3D simulation. The user is led step-by-step through the cycles, whether for simple metal removal, drilling, thread cutting, pocket milling, groove milling or engraving. Complex programming cycles for complex contours are also possible. The “ProgramSync” function for automatic synchronization of the machining programs via two channels ensures a significant increase in machine productivity. The control is equipped with a 15″ monitor and integral keyboard.
Siemens CNC in metalcutting applications.
The Quattro series from Biglia also uses the highly effective personnel and machine protection system provided by the Sinumerik control concept with the Sinumerik Safety Integrated package.
Biglia is also breaking new ground with servo drives. Thus, the new servo motor generation 1PH8 from Siemens is used for the main spindle motors in this series. The linear axes are further equipped with the new 1FK 7 G2 series of permanent-magnet synchronous motors. These motor types from Siemens enable onsite replacement of the encoders without having to dismantle the complete motor. This combination of machine and CNC control in the Quattro turning centers from Biglia provides users with greater flexibility.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensSiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
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Custom configured solution from Hunter allows major Pennsylvania foundry to integrate mold handling line with other brands of automatic molding machines
See the video HERE.
Schaumburg, Illinois (USA) – The Buck Company is an ISO 9001: 2008 Certified foundry in Quarryville, Pennsylvania, near Lancaster and nestled in the Susquehanna Valley near the Maryland border. Here, ferrous and non-ferrous castings of ductile, gray and malleable iron, as well as aluminum and brass are poured in medium and long runs to produce a wide variety of end products for the agricultural, metalworking, materials handling, marine, military and other market segments.
A challenge was presented to Buck’s longtime molding machine supplier, Hunter Automated. Another brand of molding machine had been acquired at Buck for a particular use in the non-ferrous foundry. Hunter was asked to provide a mold handling line for the particular conditions and footprint available at Buck and to devise a “handshake” mechanism to interface with this new machine.
It was determined that the best solution for the floor space and pouring equipment logistics was a Hunter HLH linear mold handling line. However, the pouring height of the Hunter line did not match the mold discharge height of the other machine brand, so an elevation change mechanism was needed to accommodate the difference between the mold’s exit height from the machine and its placement onto the pouring line section of the Hunter line.
The solution was found in a walking beam (boardless) conveyor line devised and patented by Hunter, combined with an articulating arm and elevator mechanism that could raise the mold onto the pouring line for loading of the weight and jacket, all without risking mold shift.
As the mold exits the machine, in this case at Buck, a series of walking beams gently sequence the molds forward to the elevator station. The “traffic cop” on this conveyor is a plurality of proximity sensors, used to monitor each location along the conveyor section and coordinate with the pouring operation, so mold collision and back-up are avoided. As pattern changes are made, work breaks occur or melts are prepped, these sensors remain in operation to protect the integrity of the process.
Once the mold reaches the end of this standard boardless walking beam conveyor section, an articulating arm and elevator mechanism gently raise the mold to the standard height of the Hunter handling system. Achieving this result saved Buck considerable manpower in materials handling, plus floorspace and capital investment, while allowing this Hunter customer to maintain high productivity in this section of its non-ferrous foundry operation.
As Dean Martin, sales manager for Hunter, explains, “We had a meeting of the minds with the automatic molding machine builder and we worked out a feasible plan to solve the handshaking issues presented by this production scenario. There were really no serious setbacks or conflicts, as we had the common goal of satisfying Buck’s requirements with the optimum production results plus an on-target budget.” He further described how the machine builder and Hunter’s seamless working relationship helped develop this transitional walking beam (boardless) conveyor system.
Buck used the expertise of its projects manager Art Tout and non-ferrous foundry superintendent Steve Ward to work with the molding machine builder and Hunter to achieve the best solution. As Steve noted, “The Hunter linear line was more practical than the rotary turntable design, which we also have in another section of the foundry. With a smaller footprint and relatively low maintenance, it was a good solution.” He joked, in describing the way Hunter worked with the machine builder, “They played well in the sandbox together.”
The typical mold being handled on this line weighs 400-500 lbs. (181-227 kg), having been produced on the molding machine with a 20” x 24” plate dimension.
Matt Sullivan, president at Buck, discusses the unique solution devised for the mold handling with Dean Martin, sales manager for Hunter. View the video from this sit-down HERE
Buck President Matt Sullivan observed, “We were very impressed by the way everyone responded. The machine builder and Hunter actually needed very little input from us. We’d presented Hunter with some very tight floorspace restrictions and they worked hard to overcome the challenges for us. We had good experiences with the HLH lines in other parts of the foundry in the past and we were confident it would do the job here, even being modified. We knew the HLH would work from morning to night with few, if any, problems. The option of going vertical with the mold cooling was vital, given the floorspace.” He also noted the installation and the modification of the overall system was seamless.
Martin concluded by noting, “…the boardless conveyor system used here at Buck, while a special modification to our standard board conveyor design, was completely designed, engineered and built by Hunter personnel. We’ve used this solution and others at several companies since the Buck install, with very satisfactory results.”
Hunter holds several patents on the unique features of its mold handling systems, which can be utilized with any boardless molding machine.
For further information on this announcement, interested parties may contact:
HUNTER AUTOMATED MACHINERY CORPORATION
2222 Hammond Drive
Schaumburg, Illinois 60196-1094
USA
Phone: +1 847 397 5136
Email: sales@hunterfoundry.com
Web: www.hunterfoundry.com
Attention: Bill Hunter or Dean Martin