Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Figure 1. First Core Blowing Test. The bottom of the core collapsed due to a lack of strength.
Brazilian steel giant Usiminas recently introduced the new foundry core making simulation software MAGMASOFT® as part of their strategy to establish robust designs and processes for their core production line. The first project on which this software was utilized was already in progress at that time.
The main goal was to optimize the process conditions for the existing tooling layout. This core, called the thin waist core, represents some of the biggest challenges for Usiminas core production: its length (920 mm), substantial changes in the sand flow direction during blowing, the need to fill certain parts of the core through counter-flow and big variations in the cross section within the core.
First trials showed problems with the process, which led to a complete collapse of the lower part of the core. The core blowing and curing steps for the PU coldbox process were analyzed, making it possible to draw preliminary conclusions regarding the existing defects.
Figure 2. Curing Gas Concentration. The curing gas does not penetrate into the core to the same extent everywhere.
The lack of core strength was related to a poor curing process. The first simulation (Figure 2) already showed that the problematic regions experienced only very low curing gas concentrations during gassing, which was the root cause for the failure.
On the production line, various process conditions such as the curing and purging times and gassing pressure were changed. These attempts provided better results (Figure 3). However, a perfect core could still not be produced. The further analysis with MAGMASOFT® focused on the evaluation of the local concentration of adsorbed curing gas, as it shows the regions where the catalyzing gassing agent cannot activate the chemical reaction. This result clearly demonstrated that only a very small quantity of catalyst was available for accelerating curing in the defect regions (Figure 3).
Figure 3. Core Blown with new parameters in comparison with the local concentration of adsorbed curing gas. The problematic area corresponds exactly with low concentrations in the simulation.
Evaluating simulated curves for the gas mass flow through the vents made it clear that the catalyzing gas was not reaching the critical area. The open venting cross section of the top and central vents was allowing the gas to escape before it reached the bottom of the core.
Instead of making costly modifications to the core box, Usiminas determined that a possible – and simple – solution was to close some vents in the top and center regions, in order to increase the gas concentration in the bottom. However, it was clear that these changes obviously would also influence the core blowing step.
The optimization led to a considerable increase of the curing gas concentration in the lower regions of the core (~36%) (Figure 4). Also, the amount of adsorbed curing gas increased in comparison to the original project. Applying these modifications, Usiminas produced another core, which did not show any gassing defects. Since the venting area was reduced, some filling defects were present, as expected.
Figure 4. Total gas mass flow through the lower vents. The change in mass flow becomes clear. Removing some of the upper and middle vents resulted in a 36% increase in the gas escaping through the lower vents.
Having solved the curing related defects, a further core blowing analysis was carried out. The simulation results showed a very good match between the real defects and areas of low packing density. The flow animation also showed that the problems occurred because these areas had to be filled by a counter flow of the sand (Figure 5).
Another characteristic of the defects was that they all occurred next to the parting line of the core box. Some of the defects showed a smooth surface, indicating that the sand had been removed by a strong air flow. The core blowing simulation results supported the Usiminas conclusion that an improper sealing of the tool was the root cause for these defects. Air could escape with high speed through the parting lines, resulting in the defect formation.
This hypothesis was tested using a silicone rubber band to obtain an improved sealing of the relevant areas of the tool. With this modification, a new core was produced which was absolutely free of any defects.
About software for casting process simulation
Casting process simulation software considers the complete casting process including mold filling, solidification and cooling, and also provides the quantitative prediction of mechanical properties, thermally induced casting stresses and the distortion of cast components. Simulation accurately describes a cast component’s quality upfront before production starts, thus the casting layout can be designed with respect to the required component properties. This results in a reduction in pre-production sampling, but also the precise layout of the complete casting system leads to energy, material and tooling savings for the foundry.
The range of application of MAGMA solutions comprises all cast alloys, from cast iron to aluminum sand casting, permanent mold and die casting up to large steel castings. The software supports the user in component design, the determination of melting practice and casting methodology through to mold making, heat treatment and finishing. This saves costs consequently along the entire casting manufacturing line.
During the last 10 years, the use of casting process simulation has become a valuable business asset for many foundries worldwide. MAGMA5 constantly expands the capabilities of casting process simulation and will further accelerate the acceptance of this technology, in the future.
About Usiminas
With 50 years of operation, Usiminas is the leader in the Brazilian flat steel market and one of the largest steel companies in Latin America. It has a nominal capacity of 9.5 million tons of steel per year. Usiminas Mecânica is a leading provider of capital goods and services to the steel, railway, mining, automotive, energy, petrochemical, marine and infrastructure industries in Brazil. With recent substantial investments, the foundry of Usiminas Mecânica has become one of the largest manufacturers of both small and large steel castings in the country. The yearly production capacity is 30,000 tons, representing about 10% of the projected production in Brazil.
About MAGMA
MAGMA offers comprehensive solutions to the metal casting industry, casting buyers and casting designers worldwide. The MAGMA product and service portfolio includes the powerful modular simulation software MAGMASOFT®,with the newest release MAGMA5, as well as engineering services for casting design and optimization.
Today, MAGMASOFT® is used throughout the metal casting industry, especially for the optimization of cast components in automotive and heavy industry applications.
MAGMA Giessereitechnologie GmbH was founded in 1988 and is headquartered in Aachen, Germany. A global presence and support are guaranteed by offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, India and China. Additionally, more than 30 qualified partners represent MAGMA around the world.
For more information on this release, please contact:
Christof Heisser
President
MAGMA Foundry Technologies, Inc.
10 N. Martingale Road, Suite 425
Schaumburg, IL 60173
Phone: 847-969-1001 ext. 225
Email: cheisser@magmasoft.com
Web: www.magmasoft.com
No. 1030 is a 550ºF floor-level electric cabinet oven from Grieve, currently used for heating large gears at the customer’s facility. Workspace dimensions of this oven measure 48” W x 48” D x 60” H. 40 KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 2000 CFM, 2-HP recirculating blower provides horizontal airflow across the workload.
This Grieve cabinet oven features 6” insulated walls, aluminized steel exterior and interior, plus five levels of dual-lane roller conveyor rated at 300 lbs. per level.
Controls onboard No. 1030 include a digital indicating temperature controller, manual reset excess temperature controller with separate control contactors and a recirculating blower airflow safety switch.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, IL 60073-2898
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese, VP
CAROL STREAM, ILLINOIS – The demand has never been greater for specialized supply chains that deliver medical materials to meet the production demands of OEM’s. These businesses are acutely aware of the need to use quality metals and materials in their products to assure performance, durability and long-term reliability. Due to the recent revisions to ASTM standards F136 and F138, Banner Medical has installed a multi-axis, computer controlled Ultrasonic Inspection System designed and built by Matec Inspection Companies, Inc., for precision ground bars.
ASTM F136 and ASTM F138 are commonly specified standards in the design of titanium and stainless steel surgical implants; and recent revisions to each standard call for ultrasonic testing at final diameter for all centerless ground, or peeled and polished bars, which are greater than or equal to .375” in diameter.
“The decision to purchase this highly versatile inspection system was driven by the current and future needs of our customers. We are experiencing greater demand for ultrasonic testing of medical grade raw materials and the recent changes to ASTM standards F136 and F138 will increase demand even further in the very near term,” said Bob Khin, Vice President of Quality Assurance, Banner Medical.
“We recognize the impact these revisions will have on our customers. Ultrasonic testing at final diameter has the potential to add significant delays and cost to the supply chain. Our new ultrasonic inspection unit allows us to ensure the precision of centerless grinding and testing under one roof. We are providing our customers with a cost effective, time saving solution to the problems which could arise as manufacturers begin to comply with these changes. We will maintain the inventory, production capability, and testing equipment in a medical focused factory,” said Dan Stoettner, Executive Vice President and Chief Operating Officer.
To fully comply with industry testing standards, Banner Medical has hired additional qualified personnel to operate the equipment and implement the proper management systems including Rick Wallen, Director of Technical Services. He will assume full responsibility for the ultrasonic testing program. Rick was employed at Zimmer Inc. for 34 years in various roles and most recently served as Principal Engineer, Quality. He was responsible for all nondestructive testing requirements company-wide.
“We feel very fortunate to have Rick join our team. He is an industry recognized expert in ultrasonic testing and Quality Management Systems, and we are certain he will make an immediate impact within our organization. Rick is an ASTM certified Level III Engineer and an ASQ certified Quality Auditor. He is going to help us provide the very best service to our customers,” said Bob Khin.
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Banner Medical serves the medical device, implant, and instrument industry with medical-grade metal materials; Banner Medical is ISO 13485 and ISO 9001 certified, and FDA CFR part 820 compliant.
For more information:
BILL NORLANDER
Medical Products Specialist
494 East Lies Road
Carol Stream, IL 60188-9425
P:630.868.1230
F:630.653.7555
E: bnorlander@banner-medical.com
www.banner-medical.com
MIKE HADLEY
Supply Chain Manager
494 East Lies Road
Carol Stream, IL 60188-9425
P:630.868.1229
F:630.653.7555
E: mhadley@banner-medical.com
www.banner-medical.com
North American users can now make full use of the benefits of a modular product, built to NEC (NFPA 70) standards, to configure common DC bus lineups and high horsepower drives, with optional UL/cUL listing
Siemens announces a new version of its popular Sinamics S120 Cabinet Module (CM) drive packages, compliant with North American standards and offered with optional UL/cUL listing. This unique product enables easy configuration of complex common DC bus lineups for multi-motor coordinated drive systems, as well as high horsepower (hp) stand-alone drives for a wide variety of industrial applications.
Key to the global growth of the Sinamics S120 CM range is its modularity and flexibility. Pre-designed, fully type-tested modules, including line side components, line infeeds (bus supplies) and motor inverters, all with a broad range of standard options, are selected and configured by the customer. Compared to the traditional approach of custom-engineered systems, this approach offers significant reduction in engineering and manufacturing lead times, which translates into reduced project costs and a compressed delivery schedule, while minimizing technical and commercial risk on even the most complex drive systems.
Individual cabinet modules from Siemens have a standardized power and control interface, which allows them to be freely positioned in a lineup that best suits the particular application and makes them easy to install and connect. The broad range of standard options including the DC bus current rating and enclosure type, for example, is available to tailor selections to best meet jobsite and environmental conditions. Despite standardization, this design offers a high degree of flexibility for both power and control circuits. For line side converters, there is a choice of non-regenerative Basic Line Module (diode rectifier) or fully regenerative Smart and Active Line Modules. Both of these are IGBT inverters, the Smart Line Module being a more basic six-pulse unit, while the Active Line Module offers low harmonics exceeding the demands of IEEE 519. Unity or controllable power factor and DC bus voltage control allows stable operation of motors even on irregular power supply systems. Basic and Smart Line Modules can also be configured in 12-, 18- or 24-pulse systems for low harmonic operation. All these configurations are now compliant with the National Electrical Code (NFPA 70) and Short Circuit Current Ratings per UL508A supplement SB, up to 100 kA.
The SINAMICS S120 firmware, combined with Drive-CLiQ (the flexible backplane bus), allows users to assign control units multiple Line and Motor Modules, plus mount the control units and associated I/O and sensor modules anywhere within the line-up or even remotely in a centralized control cabinet or control room. Drive-CLiQ provides automatic electronic nameplate, real-time control data transfer, diagnostic and parameter value gathering and fault tolerant transfer protocols. For external control systems, high-speed industrial Ethernet communications can be parameterized for EtherNet/IP, PROFINET or Sinamics Link (peer-to-peer), while programming can be done via a dedicated port or Ethernet TCP on the Ethernet network simultaneously with Profinet or EtherNet /IP.
Sinamics S120 Cabinet Modules were designed to address the need for a complete, ready-to-connect-and-run drive system that enables customers to configure an enclosed drive lineup with a central line infeed (rectifier) and common DC bus, supplying power to multiple motor modules (inverters). Typical uses for such systems requiring multi-motor coordinated drive systems include paper machines, steel rolling mills, test stands, cranes, mixers and oil/gas field equipment. Very high horsepower single drive applications also benefit from this Siemens system.
The use of a common DC bus configuration with these new drive packages allows energy exchange between motors that are simply powering and others regenerating power back to the AC system, which can save up to 80% of the energy consumed when using standard installations.
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com
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Field-replaceable 24-bit encoders in 10 styles and reduced lead times highlight new line of servomotors; three inertia versions, seven shaft heights on highly-configurable line
Siemens Industry, Inc. announces reduced lead times for its Generation II Simotics 1FK7 servomotors. Highly-configurable to suit a wide variety of applications, this new line features seven shaft heights, Quick-Connect power connector and high-accuracy 20- and 24-bit field replaceable encoders in 10 styles, all combined with a four-week lead time beginning July 1, 2013 — and ultimately reduced to three-weeks beginning January 1, 2014 on all models.
The Generation II servomotor offers three inertia versions — standard, high-dynamic for rapid acceleration jobs, and high-inertia for maximum smooth running. These motors are designed for operation without external cooling and the heat is dissipated through the motor surface. With 10 styles of field-replaceable encoders, the 1FK7 Generation II servomotors provide easy maintenance in the field, with reduced downtime and operating cost savings. Further, a 10 percent improvement in continuous (S-1) power is achieved since the encoders are mechanically and thermally decoupled from the motor. The mechanical decoupling also means the encoder is more resistant to vibration conditions on the machine. In addition, there is no need for battery back-up on the absolute encoders.
Generation II Simotics 1FK7 servomotors provide users with 3x overload, 2.5 percent torque ripple, cross profiling for easier mounting, Siemens Drive-Cliq interface for easier field commissioning and unit recognition with the Siemens Sinamics S120 drive family, plain shaft or keyway design, three IP ratings and are supplied with or without holding brake.
The full application of engineering assistance and service of the global Siemens network supports this new line of servomotors.
For more information on these new Siemens servomotors, please visit www.usa.siemens.com/simotics.
For product information and inquiries, call +1 800 879 8079 ext. Marketing Communications or e-mail SiemensMTBUMarCom.industry@siemens.com.
Continue readingStandard and custom styles available for all popular machine tools; offered for all tapers, including HSK and BT30; fixed and adjustable models
Adjustable Angle Heads
Heimatec, a world leader in live tools and multi-spindle drill heads, today announces immediate availability of its newest development, a line of standard and custom angle heads, available in all popular sizes and styles to accommodate today’s machine tools and CNC machining center builders.
Designed for heavy milling, deep drilling and tapping operations often found in the off-highway, energy, rail and other heavy-duty industries, this new Heimatec line of angle heads features twin or double twin sets of matched angular contact bearings plus a rear radial support bearing, ensuring maximum stability in use.
All the gears on these angle heads have inclined teeth made from high-resistance gear steel and have been specially hardened, ground and lapped in sets to provide the smoothest transmission output possible.
Heimatec angle heads are made from high-tensile strength aluminum. High-precision spindle bearings maintain the highest possible spindle concentricity.
Heimatec Angle Heads offered in various sizes and styles for all popular machining centers
Full 360º body rotation with positive compression locking, 90º incremental repositioning without indicating, maximum torque to 150 Nm, gear ratio 1:1 standard with others available, spindle speeds to 18,000 rpm and interchangeable torque arms are other standard features of this line from Heimatec.
CAT 40, BT 40, BT 30, HSK 63A, CAT 50, BT 50 and HSK 100A taper styles are available, as well as custom modifications such at 18” extension shafts. Heimatec offers a full one-year warranty on all parts and labor.
Click HERE to view a short video on the product.
For further information and literature, or to arrange a demo on this new line, please contact:
Preben Hansen, President
HEIMATEC INC.
16 E. Piper Lane Suite 129
Prospect Heights, IL 60070
Phone: 847-749-0633
Fax: 847-749-2445
Email: info@heimatecinc.com
Website: www.heimatecinc.com
Connect with Heimatec Inc: 
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Heimatec is an international tooling manufacturer, based in Renchen, Germany. Its experienced staff is dedicated to providing customers the most innovative tooling technology possible. In 2010, the company opened Heimatec Inc. in Prospect Heights, IL, near Chicago, to serve its growing North American customer base with sales and service, plus an extensive inventory of products. Heimatec serves the auto, aero, medical, off-highway, rail, energy, woodworking, composites and other industries, as well as an ever-increasing number of machine tool OEM’s worldwide.
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No. 1014 is a 350ºF electric shelf oven from Grieve, currently used for curing composites at the customer’s facility. Workspace dimensions on this oven measure 84” W x 30” D x 54” H. 25 KW are installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 1000 CFM, 1-HP recirculating blower provides horizontal airflow across the workload.
This Grieve shelf oven features 4” insulated walls, aluminized steel exterior, Type 304, 2B finish stainless steel interior and six 200 lb. capacity (each) shelves supported by ball slides with shelves extending 30” in front of oven for easy loading/unloading.
Controls onboard No. 1014 include all safety equipment needed for handling flammable solvents, including explosion-venting door hardware, plus a 12-port vacuum manifold with pressure gauge and hand valve at each port, solenoid valve to relieve vacuum and 2-HP rotary vane vacuum pump with pre-filter.
For more information, please contact:
THE GRIEVE CORPORATION
500 Hart Road
Round Lake, IL 60073-2898
Phone: (847) 546-8225
Fax: (847) 546-9210
Web: www.grievecorp.com
Email: sales@grievecorp.com
Attention: Frank Calabrese, VP
Advanced Machine & Engineering (AME) provides solutions to run 56 different block sizes at Rockford-area machine shop
In its production of various cylinder and related products for hundreds of customers, TRD Manufacturing, Inc. of Machesney Park, Illinois (near Rockford), a division of Bimba, one of the leaders in actuation devices, was challenged by an ever-increasing variety of sizes, styles and materials in their workpiece blocks. As VP of Operations Kerry Reinhardt explains, “TRD is a fast-paced manufacturer but very dedicated to high quality and fast turnaround on deliveries. We have an established reputation as a solution provider to the fluid power industry.” The company sells through distribution with its end users found in the general manufacturing, automation integration, mining, forestry, medical, food and various mill industries. TRD products are regularly specified as OEM components, plus the company serves the huge MRO marketplace.
To meet the demand for products in an ever-expanding line, complicated by the just-in-time delivery schedules often encountered, as Manufacturing Manager Tom Jensen notes, “TRD was seeking a partner who could develop fixturing to fit our manufacturing business model of quick set-up and the flexibility to run small or large batches of product from a multitude of block sizes.”
TRD turned to a local supplier of various machine tool components, Advanced Machine & Engineering (AME) in Rockford, Illinois. The head of the AME workholding group, Alvin Goellner, observes, “After a few discussions and visits to each other’s plants, we knew TRD would benefit most from our Triag line of modular workholding devices.”
Tom Jensen concurs. “We knew AME had a reputation for building top quality fixturing. Their in-house manufacturing capabilities were very impressive and we knew they could handle a project of this size, based on the other customers they serve and the fact that they are just across town from us, which made it easier to work through the preliminary discussions, quoting and final product delivery.” The horizontal machining center (HMC) used for this particular application at TRD is an Enshu GE480H, with 30” x 30” x 30” travel and a 180-position toolchanger, expandable to 240-position. Workpieces are mounted and handled on a Fastems 10-station pallet changer. Currently, the block sizes run at TRD are 56 in number and run in sizes from 1” x 2” x 2” to 3” x 9-1/2” x 14”. Weights range up to 114 lbs. Final part varieties produced on the machine number over 450, made from 1018 steel and 303 stainless. Lot sizes vary from one-offs to 500, but generally run between 25-50 on average. This machining center set-up runs two shifts per day, with the expectation of running 24/7 during peak demand periods.
The challenge for Alvin Goellner and his team at AME was to design a series of fixtures that was flexible enough to hold 56 different block sizes, offer quick changeover and offer the ability to run different parts on each side or run multiple pallet loads of the same part in high production, when needed. As Goellner notes with a smile, “It was a real one-size-really-can-fit-all situation. We knew the HMC with pallet changer was very costly to run, so keeping downtime to a minimum was essential.”
The solution came in the form of ten Triag custom modular tombstone-style fixtures from AME, who partners with Triag, a major European workholding component supplier, as their exclusive North American distributor. As Jensen notes, “The fixturing in our existing machining cell was fixed, based on block size. AME fixtures use a vise system that quickly adjusts to any size with repeatability, a really key factor in the equation, as it allows all our work shifts to be pre-taught the process. We normally have the fixtures set for specific part sizes but this AME solution now allows us to run any size part on any pallet very quickly for high-volume jobs.” He also observed there was a very short start-up time in the TRD shop, as the flexibility of the tombstone design and the fixturing mechanisms were relatively easy to learn for the operators.
Jensen continues, “We met with Alvin Goellner and brainstormed the improvements needed on our current fixturing system. AME laid out a concept and provided drawings for each fixture, which we then reviewed and approved, based on our current production schedules and anticipated workloads, going forward. All the fixtures ordered arrived on-time or ahead of schedule, a very refreshing experience.” Goellner was the lead man for AME on the project, bringing his 20+ years of fixture design and build experience to the task. Because all aspects of this project’s customized manufacturing, assembly and test of the Triag tombstone fixures were done in-house at AME, there was little delay in the processing of the project and all design changes were quickly accommodated, according to Jensen.
Reinhardt further commented, “The overall experience was excellent and the results have been outstanding for TRD. The project went well and all our expectations were met.” He estimates the improvement percentage in production on the Enshu HMC to be over 40%, after several months in operation.
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TRD combines 27 years of precision machining and engineering with an unmatched selection of options and modifications to deliver the highest quality customizable NFPA (National Fluid Power Association) cylinders on the market today. At TRD, the customer’s specials are their specialty.
Advanced Machine & Engineering Co., is a manufacturer located in Rockford, IL, serving the Machine Tool Industry with precision components and accessories, including spindle interface components, workholding devices, and, through our sister company, Hennig, machine enclosures, chip removal and filtration systems. The Fluid Power – Safety markets are served with cylinder rod locks and safety catcher devices; and the Production Saw market with our AMSAW® carbide saw machines and Speedcut blade products. AME has manufacturing partners and customers around the world and across the U.S. To learn more, visit www.ame.com.
Hennig, Inc. designs and produces custom machine protection and chip/coolant management products for state-of-the-art machine tools, production lines, power generators and other equipment. Hennig products are designed to protect against corrosion, debris and common workplace contaminants. Manufacturing facilities are located in the U.S., Germany, Brazil, India, Japan, France and South Korea. Repair centers are located in Machesney Park, IL; Chandler, OK; Livonia, MI; Blue Ash, OH; Mexico City, Mexico and Saltillo, Mexico. To learn more, visit www.hennigworldwide.com.
For more information on this story, please contact:
Kerry Reinhart
TRD MANUFACTURING, INC.
A Bimba Company
10914 North Second Street
Machesney Park, IL 61115
Phone: 815-654-7775
Fax: 815-654-7783
Email: reinhartk@trdmfg.com
Web: www.trdmfg.com
OR
Alvin Goellner
ADVANCED MACHINE & ENGINEERING CO.
2500 Latham Street
Rockford, IL 61103
Phone: 815-962-6076
Fax: 815-963-4703
Email: info@ame.com
Website: www.ame.com
Connect with AME online: 
The International Monetary Fund (IMF) estimates that the world economy will grow by 3.5 percent this year, with the impetus coming less from Europe and more from dynamic, newly industrialized countries. One example is the automotive industry. According to the association for the German automotive industry (VDA), China’s share of the market in passenger cars increased by 59% and that of Brazil by 18% during the first few months of 2013. The same market is also growing in India and Russia. For a long time, new production facilities have been planned and are under construction, providing great opportunities for the machine tool industry – as the example of EMAG proves. Specialists are developing turnkey manufacturing systems that are tailor-made to suit specific market conditions, with the new production facilities in particular gaining substantially from this increased market activity.
Whether in the automotive or energy supply industry, the development of industrial key sectors within the BRIC countries (Brazil, Russia, India, China) has a direct influence on the machine tool industry, as it is this branch that, in the end, must supply most of the necessary manufacturing solutions. There are numerous indicators for this fact. For instance, according to Germany Trade and Invest (GTAI), the Russian enclave of Kaliningrad will – over the next 3 years – will see an investment of 3 billion Euro in six assembly facilities and fifteen sub-supply companies for the national automotive industry, with more international sub-suppliers also establishing outlets in the market. Similar activities are reported from Brazil. According to Anfavea, the country’s automobile association, approximately 22 billion USD are to be invested in production between now and 2015. In India, economic growth is generally attracting “an abundance of investment projects in the country’s infrastructure, as well as in new industrial complexes,” states GTAI.
The German machine tool industry is prepared for such a dynamic development and the opportunities it provides can be seen in the textbook case of EMAG. Their specialists see themselves as “partners in solutions” for the metalworking industry. Such an approach is of great importance, especially in the emerging markets. “As it happens, we don’t just deliver a machine tool. We deliver closely pinpointed manufacturing solutions that are, in every respect, tailor-made to customer requirements”, explains Dieter Kollmar, Managing Director of EMAG Holding GmbH. “This applies, of course, to typical factors such as batch sizes, component variants or, more generally, the flexibility of the processes applied. At the same time, we determine locally the technologies, automation equipment, interfaces and control systems required.“ The advantages for the customer are obvious, especially where an existing production line is extended or where a greenfield manufacturing facility must be created in a new market place. Our manufacturing systems are always “from a single source.” Even complex processes with peripheral machines and equipment are presented as turnkey projects by EMAG, thus considerably reducing the efforts of local production planners.
VL 2: Highly effective, truly outstanding space saver
The VL 2 is a pick-up turning machine with which the EMAG engineers are fulfilling a combination of two extreme demands: highest possible output rates on the smallest possible footprint. “This is a truly all-important aspect,” confirms Dieter Kollmar. “Although the floor space requirement for this vertical turning machine is just about 5 square meters, it is a machine of substantial capability, including a fully comprehensive automation concept with conveyor belt, workpiece storage and pick-up spindle. In combination with vertical turning, this results in very fast machining processes. “In other words, short loading travel guarantees the lowest possible component cost. Compared to horizontal turning machines, productivity rates increase quite noticeably. And maintaining the VL 2 is simple. All service units are freely and quickly accessible. The user can set up the machine in one step. “That too is important, when productivity levels enter the equation. Operators without prior experience, working at a new and unfamiliar location, will be able to quickly familiarize themselves with the machine. All in all, this is an optimal solution for those who want to extend production with as little investment as possible,” notes Kollmar.
VT 2-4: For demanding shaft production
A similar approach is shown with the VT 2-4 Vertical Turning Machine, with which the EMAG specialists have created an equally fast manufacturing system for shaft production. Even demanding machining processes can be realized on it. When machining shafts up to 400 mm length and 63 mm diameter, component costs reduce considerably, with extremely short chip-to-chip times (as with the VL 2) being the reason. Workpiece grippers transport the workpieces into the machine and remove them again, once they have been machined. Depending on the workpiece, the changeover can be accomplished in just 6 seconds. And the actual turning process is fast, too. 4-axis machining allows the component to be machined from two sides simultaneously. Vertical alignment of the workpieces provides consistent process integrity, as the unrestricted chip flow prevents the formation of clusters in the machining area.
Central project management
“We are convinced that these EMAG solutions are optimally designed to cover not only the specific requirements of an emerging market, but also those of Europe and the USA,” as Dieter Kollmar his company’s philosophy. Everything is greatly simplified, starting with production planning, as there is no need for separate workpiece and finished component storage, with the added advantage of a reduced floor space requirement. At the same time, the EMAG Group engineers act as central project developers, having access to machines with optimal interfaces. This guarantees a fast run-in and makes the machines maintenance-friendly. “When it is a question of arriving quickly at a wholly integrated, highly effective manufacturing solution, this approach must – from our point of view – be the first choice,“ Kollmar concludes.
For more information, please contact:
Kristal Kilgore
EMAG LLC
38800 Grand River Avenue
Farmington Hills, MI 48335
Tel: (248) 875-0313
Fax: (248) 477-7784
E-mail: kkilgore@emag.com
Web: www.emag.com
CAROL STREAM, ILLINOIS — Firth Rixson Metals, a global leader in specialty metals manufacturing and distribution based in the United Kingdom, and Banner Medical, a leading provider of supply chain solutions for medical-grade materials to the device, implant, and instrument industry, announce their exclusivity agreement for sales and marketing for Cobalt Chrome in the United States, effective January 1st, 2014.
“The medical-grade metal materials that Firth Rixson Metals produces are of the highest standards. By combining this offering with Banner Medical’s expertise in quality assurance, we will meet the stringent demands of the medical industry,” stated Elinor Oldroyd, GM of Firth Rixson Metals.
“Banner Medical specializes in medical-grade materials and offers deep expertise in the quality management that is necessary to fully comply with FDA 21 CFR 820. The depth, breadth and detail of Banner’s approach to quality management and supply chain management is unique and that distinction justifies the patent-pending status of Banner’s Essential Quality Systems,” says Banner Medical Executive Vice President / Chief Operating Officer Dan Stoettner. “Firth Rixson shares our commitment to vigilance and quality in both products and service.”
The Firth Rixson-Banner Medical agreement focuses on the Device industry’s need for precision-ground cobalt chrome materials. Stoettner went on to say, “Given the importance of cobalt chrome to today’s device, implant and instrument industry, we strongly believe that the Firth Rixson-Banner Medical alliance can help our customers realize true supply chain control on Cobalt Chrome materials, making them able to effectively address the unprecedented FDA scrutiny which exists today in the United States.”
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Firth Rixson’s technological and operational excellence, combined with the firm’s economies of scale, has made the company the metals provider of choice for demanding customers in diverse specialized industries in more than 40 countries.
Banner Medical serves the medical device, implant, and instrument industry with medical-grade metal materials; Banner Medical is ISO 13485 and ISO 9001 certified, and FDA CFR part 820 compliant.
For more information:
BILL NORLANDER
Medical Products Specialist
BANNER MEDICAL
494 East Lies Road
Carol Stream, IL 60188-9425
P: 630.868.1230
F: 630.653.7555
E: bnorlander@banner-medical.com
MIKE HADLEY
Supply Chain Manager
BANNER MEDICAL
494 East Lies Road
Carol Stream, IL 60188-9425
P: 630.868.1229
F: 630.653.7555
E: mhadley@banner-medical.com