Latest Press

• 1AC 230V, 50–750W and 3AC 200-480V, 0.4–7kW versions
• Digitally native drive system from planning to operations
• Security Chip Integration and UMAC program protection
• PROFIsafe integrated SIL3 / PLe safety functionality
• Combines with PLC via technology object for advanced motion control
• 3C3 and ANSI/ISA G3 compliant coating for harsh environments
• Motor options available for numerous manufacturing industries 

With the SINAMICS S210 next generation servo-drive system, comprising a digitally native drive with wide range of corresponding motors and gearboxes, Siemens brings a new level of high-dynamic, motion control in mid-range operation to stand-alone and multi-axis machines, recently introduced to the North American manufacturing industry.

This next generation servo-drive system introduces a new level of safety and security to discontinuous motion control in the mid-range segment, as well as moving, processing and positioning functions on a wide assortment of packaging, printing, labeling, pick-and-place, stacking, assembly, chip sorting and filling machines, with a special emphasis on food-and-beverage and pharmaceutical applications, owing to the availability of stainless-steel motor and planetary gearbox options.

SINAMICS S210 offers DC link coupling on 3-phase units for increased power efficiency on multi-axis applications. Corresponding SIMOTICS highly efficient synchronous motors feature high-resolution 22- or 26-bit absolute encoders, single or multi-turn. One-cable connectivity is standard and all motors and feature IP64, IP65, IP67 or IP69X protection. Easier setup and selection are assured with the integrated EMC filter and braking resistor.

For the engineering of SINAMICS S210, machine builders and machine users can utilize
the embedded web-server or Startdrive integrated with the Siemens TIA Portal. Easy implementation of the SINAMICS S210 servo-drive system for global use is provided by universal standards and certification compliance.

SINAMICS DriveSim model integrates into simulation software to allow machine builders to create a digital twin of the drive and motor in a project’s planning phase to ensure highest efficiency and performance of the equipment in use. In the field, the S210 is capable of communicating status through Edge or cloud-based data capturing for continuous monitoring and data analytics. Using the Siemens Analyze MyDrives application, machine users can monitor key conditions for advanced anomaly detection. Seamless transfer of data from the drive to the machine controller, Edge device and the cloud are maintained for truly digital native operation from planning through operations.

In the area of cybersecurity, SINAMICS S210 comes standard with integrated security for network connectivity, providing enhanced communication, integrity and authenticity checks
to protect against tampering, plus the drives offer User Management and Access Control (UMAC) within TIA Portal.

These new servo-drives are paired with the popular Siemens SIMATIC S7-1500 PLC or ET200 SP open controller and various SIMOTICS servomotor and planetary gearbox designs.  Increased engineering efficiencies are gained with integration into the TIA Portal and TIA Selection Tool for optimized system selection and programming.

With Safety Integrated onboard, the SINAMICS S210 servo-drive system offers machine users up to SIL3 level of protection across an extended range of safety integrated functions including safe stopping and safe limited speed or direction. Integrated into the Startdrive advanced software, the menu-guided safety acceptance testing assures proper operation and safety validation.

The new SINAMICS S210 next generation servo-drive system is ready for digitalization and brings an enhanced level of safety and security to stand-alone or multi-axis machines for use in various manufacturing industries. 

 Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 75,000 employees internationally.

Siemens Corporation is a U.S. subsidiary of Siemens AG, a technology company focused on industry, infrastructure, transport, and healthcare. From more resource-efficient factories, resilient supply chains, and smarter buildings and grids, to cleaner and more comfortable transportation as well as advanced healthcare, the company creates technology with purpose adding real value for customers. By combining the real and the digital worlds, Siemens empowers its customers to transform their industries and markets, helping them to transform the everyday for billions of people. Siemens also owns a majority stake in the publicly listed company Siemens Healthineers, a globally leading medical technology provider shaping the future of healthcare. In addition, Siemens holds a minority stake in Siemens Energy, a global leader in the transmission and generation of electrical power. In fiscal 2022, which ended on September 30, 2022, Siemens Group USA generated revenue of $18.6 billion and employs approximately 45,000 people serving customers in all 50 states and Puerto Rico.

ANCA, a leading global manufacturer of CNC grinding machines, proudly announces the launch of its first Female Machinist Award. This prestigious accolade aims to recognize and honor the outstanding achievements of female machinists in the tool and cutter grinding industry. By promoting gender diversity and equality, ANCA is dedicated to fostering an industry that excels in every aspect.

Johanna Boland, ANCA Group Strategy & Communications Manager and member of the judging panel, says: “Recognizing and celebrating the contributions of women in the tool and cutter grinding industry is a vital step towards unlocking the industry’s true potential. By embracing and empowering women, we discover a wealth of diverse perspectives, fresh ideas, and extraordinary talent. ANCA is committed to shining a spotlight on these remarkable individuals, because we believe that their success fuels the success of our industry as a whole.”

The Female Machinist Award is open to women of all skill levels who are actively working with ANCA technology in the tool and cutter grinding industry. We are searching for individuals who exhibit unwavering passion for their craft, demonstrate a commitment to excellence, and contribute to the advancement of the industry.

A panel of experienced professionals from the tool and cutter grinding industry will serve as judges for this award. Submissions will be evaluated based on the following criteria:

• Exceptional problem-solving skills to overcome challenges or obstacles during projects
• Innovative and effective tool design
• Demonstrated ability to think critically and find innovative solutions

The winner of the Female Machinist Award will be rewarded with a fully funded ticket to attend a prominent trade show where ANCA is exhibiting. This invaluable opportunity will enable the winner to connect with industry professionals, gain insights into the latest technological advancements, and build valuable relationships.

The winner will have exclusive access to the ANCA team, including top-tier leadership, skilled engineers, and renowned product experts. The prize also comes with opportunities to network with like-minded professionals and participate in educational seminars and workshops.

If you or someone you know embodies the qualities of a talented female machinist deserving of recognition, we strongly encourage you to apply for the Female Machinist Award today!

To learn more and apply, visit www.anca.com. The application deadline is August 31, 2023.

For further information, please contact:

Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com

About ANCA CNC Machines

ANCA CNC Machines is a global leader in the design, manufacture, and service of advanced CNC grinding machines. With an illustrious history spanning over 50 years, ANCA is renowned for its cutting-edge technology, innovative solutions, and exceptional customer support. ANCA’s comprehensive range of products includes tool grinders, CNC grinding machines, software, and automation solutions, catering to diverse industries such as aerospace, automotive, medical, and general manufacturing.

Platinum Tooling, the exclusive importer of Heimatec live tools and angle heads plus other global brands of precision machine tool accessories, is pleased to announce the appointment of Frank Twomey as the company’s Regional Sales Manager. In his new role, he will oversee all activities in eighteen states located in the Northeast, Mid-Atlantic and Southeast Regions of the United States. Company President, Preben Hansen, made the announcement at the company’s headquarters in Prospect Heights, Illinois.

Twomey graduated from Piedmont Technical Institute in 1991. His first job was as a machinist at Ross Industries. He then took on the role of Applications/Service/Quality Engineer at Walter Grinders and SCM Group as an Applications and Service Engineer. Between working as an Applications and Service Engineer, he became the CNC Manager of Euro-Composites Corporation and later Plant Manager at MTEQ. In 2015, Twomey took on the role of District Sales Manager for OSG USA.

Frank brings a vast amount of experience in aerospace, medical, machine tool, cutting tool, metal and composite industries. His technical expertise includes programming CNC machines using Mastercam and Alphacam CAD/CAM software and is well versed in PLC programming. During his career, Frank studied and trained in lean manufacturing, value stream mapping, ISO processes/audits, OSHA compliance, cost reduction, facility/line set-up and operator training. Continuing his education in 2020, Twomey obtained his CPSP (Certified Professional Salesperson) certification and in 2021 obtained his CPSL (Certified Professional Sales Leader) certification through NASP (National Association of Sales Professionals).

Commenting on this new hire Hansen said, “It is great to have Frank on the team as his expertise will benefit clients across industries. I am excited to see all that he will achieve.”

For more information, please contact:

Preben Hansen, President
PLATINUM TOOLING TECHNOLOGIES, INC.
16 E. Piper Lane
Suite 128
Prospect Heights, IL 60070
Phone:  847-749-0633
Fax:  847-749-2445
Email:  phansen@platinumtooling.com

New MTC technique offers dramatic improvement in CNC machine tool stability 

By Pat Boland, ANCA, Co-Founder & Managing Director

Introduction

Melbourne Australia based machine tool builder ANCA has been granted a U.S. patent for Motor Temperature Control (MTC), a technique that dramatically improves the stability of precision machine tools.

Problem to be solved

A key element of machine tools is the spindle which holds and drives the cutting tool which machines the workpiece. Any dimensional errors in the spindle will be reflected as dimensional errors in the workpiece. A common technique in modern machine tools is to use motorized spindles where the driving motor is an integral part of the spindle. ANCA’s patent is a way of maintaining the motorized spindle at a constant temperature. A significant problem in the use of precision machine tools is the impact of changes of temperature particularly in the temperature of the spindle. Changes in temperature of the machine tool can be caused by changes in ambient temperature, coolant temperature, run time, spindle rpm and spindle load.

Solution

ANCA’s solution is to actively control spindle temperature by varying the electrical losses in the motor element while simultaneously maintaining spindle motor speed and load. This is accomplished by using special firmware in the spindle drive amplifier. Although simple in concept, this in practice is a major step forward in manufacturing technology.

Examples of the application of MTC

Faster Warm Up time

A near universal approach to precision machining is to run the machine in a warmup cycle to bring all the elements of the machine to some level of thermal stability. Typically, this warmup cycle will take approximately half an hour. Using MTC, this time can be reduced to around 5 minutes. Figure 1 shows the impact of MTC on actively heating the spindle to reach working temperature quickly.

Stability in batch grinding of endmills

Figure 2 shows the results in grinding two batches of 6mm diameter endmills, with and without MTC.

Grinding a Skiving Cutter.

Electric vehicles incorporate a high-speed gear box in their drivetrain. The accuracy of the components of this gear box will impact on lifetime, efficiency, and noise of the electric vehicles.  Figure 3 shows a typical skiving cutter which is used to manufacture internal and external gears and will determine their accuracy. ANCA manufactures a special machine, the GCX, for grinding this class of tools. MTC is a key enabling technology for this machine to produce cutters to AAA class. Firstly, it is used to control the temperature of a dressing spindle which is used to create a high accuracy profile on the grinding wheel. MTC is also being used to control the main grinding spindle temperature during up to 12 hours of continuous grinding. Figure 4 shows the measurement results for contour accuracy of a tooth and index accuracy for all the teeth.

Summary

Motor Temperature Control (MTC) is a major innovation in machine tool technology. It improves the accuracy and stability by controlling the temperature of motorized elements of the machine by special software in the spindle drive amplifier. It drastically reduces the time required for a machine to reach working temperature.

For further information, please contact:

Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

Beginning with the full 330mm bar stock material loading into the collet; the blank and tool geometry is ground, including any features (such as rear chamfer, for example), before the finished tool is cut off. The tool is then removed by the robot and loaded into the finished pallet. This program continues along the remaining bar stock until all useful raw material is consumed. To complete the automation process, waste is handled by the cell, before new bar stock is loaded into the collet.

ANCA’s TX machine platform is the solution for blanket grinding

ANCA’s machine platforms with the addition of a robot cell, can be utilized to implement the blanket grinding process. Tool size and application will determine which machine is right for you.

The two main features offered by the TX, beneficial in performing the blanket grinding function are the large working envelope and the high torque spindle. These attributes not only allow work on longer bar lengths, but also enable production of a larger range of tool sizes and geometries without limitation, including tools which require a high material removal.

The TX platform also fits any of ANCA’s robot cell solutions, including RoboMate, and the dedicated TXcell offering, which offers large format cell automation, many standard options and the flexibility for automated custom solution.

The nimble RoboMate cell is offered on both TX and MX platforms and offers customers a low barrier to entry for blanket grinding and production automation.

How blanket grinding can help you

Customers are increasingly demanding products that are more unique and with higher complexity – but more importantly, with immediate response and shorter delivery time; when meeting these expectations, costs take a back seat, while focus is on delivery.

Using ANCA’s robot automation solutions in blanket grinding enables you to realize these demands with minimal disruption to existing production lines, less planning, reduced manual handling and increased utilization and efficiencies. These benefits can compound to deliver an overall value proposition and increased return per tool.

Blanket grinding may also offer a reduction in floor space by removing separate machines and consolidating processes into a single footprint to produce the same tool. The process consolidation allows changes in parts and features to be easily handled. For example, grinding of shank features (Weldon flats or coolant slots) and the handling of very small parts can be made simpler by adding many features in a single setup.

Benefit from blanket grinding

Become more agile

You can provide a quick response to customer requests without the need for re-tooling or disruption to high volume production lines, while also guaranteeing highest quality across the batch.

• Eliminates need for re-tooling
• Reduced setup times
• Quick response without disruption, allowing further utilization of more specialized machinery
• Improved quality
• Ability to easily add special shank features in single setup, e.g. coolant slots, Weldon flats, and more

Reduce costs

Applying blanket grinding will go a long way to improving cost recovery, through increased utilization and efficiencies as well as removal of manual labor and setup times. There is also a benefit in reduced footprint through process consolidation into a single machine.

Blanket grinding can reduce costs through:

• Machine utilization
• Reduced stock waiting in process
• Minimal manual handling
• Reduced tooling and setup; single machine setup, not multiple stations
• No process interruption

Reduce lead times

• Eliminate setup times
• Eliminate tooling across multiple machines
• Variations of the similar profile/geometry can be produced uninterrupted
• Enables automation and “lights out” production

For further information, please contact:

Amanda Bakun
Marketing & Communications Manager – Americas
248-497-1168
amanda.bakun@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

Global distributor Wesco and Siemens team up with local integrator to enable major Tennessee tire manufacturer achieve consistent tension, save money

As Chad Garner, a Nashville-based application engineer with distributor Wesco, relates, “We were presented with a significant challenge by one of our great customers, a tire manufacturer in the area.  They needed to upgrade their multiple wire drawing machines for tire cord production in the plant.”

Garner goes on to explain in detail.  “They were faced with very specific challenges.  The machines needed to hold a very tight and consistent tension to meet the wire specifications.  The company was using a ‘black box’ solution that had been custom-developed for them by a small local company that was no longer in business.  The black box, in this case, originally allowed the user to dial in the tension on the wire without making any adjustments to the drive parameters.  However, the system was now only able to hold +/- 500 grams of tension on the line, even after the customer had tested nine different control schemes to find a solution.  Ideally, their goal was to replace the black boxes with off-the-shelf products, but their current drive and control supplier was not able to help satisfactorily.  Wesco, in tandem with a local integrator and Siemens, was able to devise a solution, using standard Siemens components for the first line.”

The full solution to this challenge comprised a SIMATIC S7-1500 PLC plus remote I/O racks, SCALANCE wireless switches, SIMATIC HMI panels and, the heart of the solution, the SINAMICS S120 drive system, running 30 axes of motion control, plus various servo motors and other control products.   All these components were supplied as a total solution to the integrator and the tire cord manufacturer by Wesco.

Thanks to the success on the first machine, three more wire drawing lines at the facility were upgraded with the Siemens solution, with more planned for future installation.  A total of 120 axes of motion run by the SINAMICS S120 drives are currently in operation.  The key to success here was the tight tension control programmed into the S120 drive control unit.

Chad Garner of Wesco further observes, “A major financial aspect of this project was the amount of money invested in the controls cabinet on each machine.  The legacy PLC and Ethernet cards, if purchased from the previous supplier, would have cost approximately $30,000 and we were able to supply our better solution for about one-third that amount.  This was not only a significant reduction in cost from the previous solution, but it also resulted in component reduction, as we were able to combine functions in fewer parts.  The Siemens solution offered the customer integrated Ethernet on the PLC, so there was a reduction in expensive hardware, also achieving a smaller footprint in the plant.”

Matt Wagner, a Drives and Motion Consultant on the Siemens team, comments, “By replacing the old black box solution for tension control on these wire drawing machines at the tire manufacturer, our team, working in tandem with Wesco and the local integrator, was able to achieve all the required wire draw specs and do it with off-the-shelf solutions from the Siemens product lines.  It’s exciting when we can exceed the goals of the customer, retrofit a substantial part of the manufacturing operation and save them a lot of money in the process.  Can’t do much better,” he mused.

Using ANCA technology, SJ Tools can manufacture complicated tools for their clients with a reduction in cost and delivery time

Founded in 2015, SJ Tools is a Mexican company in Saltillo, Coahuila state that designs and manufactures cutting tools, tooling, special and standard inserts. SJ Tools offers solutions for milling, reaming, interpolations, drilling, endmills (spherical, toric, flat, double radius and barrel), drill bits (standard, step and shape) and reamer. A wide range of products are manufactured for the automotive, aerospace, medical, dental and agricultural industries. They offer services in Mexico and in the United States.

Recently, the company won the ANCA Tool of the Year competition with a cutting tool that combined multiple features into a single tool, all with very precise surface finishes.

Speaking about how SJ Tools developed their capabilities, CEO Edwin Juarez said they didn’t have the experience they now have at first and thanks to the customer with which they started with, they were able to create their first two-step combo drill tool carrier. Two inserts in the first diameter and four more in the second. Since they started supplying tools, the company wanted to demonstrate to its customers that tools are not always to blame for issues during production and that is why they have state-of-the-art quality machines to guarantee repeatability. In 2017, SJ Tools started sharpening and manufacturing carbide tools and purchased an ANCA FX5 Linear. Impressed by the results from the machine, SJ Tools decided to expand the number of ANCA Machines.  Currently, they have four ANCA machines to manufacture and sharpen carbide tools. Two of them are MX7’s with robot, one is an FX5 with the AR300 Robot and one without.  They use RoboMate for high volume tool production or FastLoad-MX for low-volume. Very soon, they will buy an ANCA machine for the sharpening of PCD.  He added that “the great team around us makes SJ Tools grow day by day.”

The ANCA MX7 Linear is a powerful, versatile CNC tool grinder designed for production grinding. It is built to meet the demands of high output, high precision manufacturing. The 38 kW (51 HP) permanent magnet spindle provides high torque at lower RPM which is ideal for carbide grinding and a wide range of other applications. The MX7 Linear is a hard-working, high productivity system with unique features that enable it to handle varied batch sizes with minimum set-up time. The new cylindrical linear motor design increases reliability further and ensures a superior surface finish.

The FX5 Linear features increased spindle power provided by the new 12kW standard spindle and an additional option of 19kW, adding more flexibility in the tool room. Furthermore,  the high-powered spindle reduces the production cost and increases net output across a wider range of tools.

Thirteen years ago, the director of SJ Tools heard about ANCA and five years ago, he requested a meeting with Mr. Russell Riddiford, the president of ANCA for North America, to present him with an ambitious project. Riddiford believed in the project and helped the company buy their first machine. Juarez explained that they decided to use ANCA because “SJ Tools is an innovative company that likes to have the best technology and ANCA is always innovating. We like that because we are walking the same path.”

Russel Riddiford said, “Since I first met Edwin and spoke with him about the initial project with SJ Tools, I’ve been thrilled about the partnership! SJ Tools is an exciting company, with a team full of innovators that are pushing the boundaries and the art of toolmaking in Mexico. Under Edwin’s leadership, SJ Tools continues to invest in new Tool and Cutter Grinding technology, allowing them to expand into new industries and to continue to push the limit of toolmaking.” He added that as expertise grows and word of mouth gets out, SJ Tools’ demand for products continues to grow and that ANCA is honored to be one of their partners.

The company uses a wide variety of ANCA products and software but the ones they like the most are ANCA Tool Compensation and ANCA Wheel Compensation. This helps a lot to reduce adjustment times. In addition, automation allows machines to continue working on weekends without an operator.

Thanks to ANCA, “We have manufactured complicated tools with customers who themselves are surprised that they are manufactured in Mexico since large companies have not wanted to manufacture or sharpen since very tight tolerances are required.  We are very happy with our machines and our customers are as well as we have helped them reduce costs and delivery times.”

Juarez praises ANCA for several reasons, including its software, service, and staff. He commented that “The simple form of their software, the attention of their technical service in the United States and Mexico has been captivating us more and more.” He also highlighted the help of Russell Riddiford, stating that he is grateful for his support from the first moment.

Benefits of tools that have multiple functions in a single tool include reduction in cycle times, as well as reducing and optimizing the use of inventory space. Referring to the increase in the number of tools with multiple functions, he concluded, “In such a competitive market each and every one of the companies that manufactures seeks savings. This is why we need to innovate, develop, design tools and look for processes that give better performance to our clients’ tools.”

For further information, please contact:

Amanda Bakun
Marketing and Communications Manager, Americas
M: +1 248 497 1168
Amanda.bakun@anca.com

ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

Edwin Juarez
CEO, SJ Tools
T: +52 8441226437
E.juarez@sjtools.mx

By Rich Guillemette, CEO, Guill Tool & Engineering

Guill is analyzing the latest market demands, combined with its extrusion die design expertise, to deliver solutions to its customers. Guill’s new Spiderless Pipe Die is an alternative solution, utilizing precision tooling to provide material savings vs conventional Basket Dies.

The global market for pipes used in irrigation systems, sewage systems and industrial applications is expected to grow in the coming years. According to a report by MarketsandMarkets™, the global market for pipes is projected to reach USD 23.5 billion by 2025, growing at a CAGR of 6.1% from 2020 to 2025.

The demand for pipes is driven by the increasing need for water and wastewater infrastructure, as well as the growth in industrialization and urbanization. These factors are expected to drive demand for pipes in emerging economies such as China, India and Brazil, as well as in developed markets such as the United States and Europe. The U.S. government has announced several infrastructure improvement plans aimed at revitalizing the country’s aging infrastructure, including its water and wastewater systems.

In March 2021, President Biden proposed the American Jobs Plan, a $2 trillion infrastructure plan that includes funding for a wide range of infrastructure projects, including the modernization of water infrastructure. The plan proposes to invest $111 billion in drinking water infrastructure, $45 billion in reducing lead exposure in drinking water and $56 billion in modernizing water infrastructure, including wastewater treatment plants and stormwater management systems.

What differentiates Guill’s Spiderless Pipe Die design over a basket die is Guill’s focus on precision tooling, developed from decades of experience in medical tubing, flow analysis and Guill’s ISO 9001 and AS9100 (Aerospace) quality systems. The significance of Guill’s Spiderless Pipe Die becomes clear when one considers material savings.

In general, the cost of the polymer raw material can range from 50% to 70% of the total cost of producing polymer pipes. The cost of other materials such as additives, fillers and reinforcements, “as well as the cost of energy, labor, equipment and overhead also contribute to the total production cost.

In some cases, the cost of energy, particularly electricity and natural gas, can be a significant part of the total cost of production, especially for large-scale production facilities. In other cases, labor costs in regions with high labor costs, can significantly impact the cost of production. Also a factor is that the cost of the raw polymer can be affected by market fluctuations in the price of oil, impacting the cost of petrochemicals used in the production of polymers. Additionally, the cost can also be influenced by supply and demand factors and global trade dynamics.”

Guill’s Spiderless Pipe Die is now available to meet the needs of its customers, as they consider all these factors required to be competitive in the production of pipes from 2” to 15” OD.  This product was entirely conceived, designed, engineered, manufactured and CFD tested at the Guill factory in West Warwick, Rhode Island.

The Guill Spiderless Pipe Die incorporates unique design features to produce pipe more efficiently, according to company CEO Rich Guillemette.

For more information, please contact:

Tom Baldock
GUILL TOOL & ENGINEERING
West Warwick, Rhode Island
www.guill.com
+1 401 828 7600

This industrial, true 6-axis continuous fiber-reinforced 3D printer enables tool-less rapid fabrication of aerospace-grade integrated composite structures.

Pushing the envelope in additive manufacturing

Aerospace and defense design engineers and the complex components they develop require true manufacturing agility. Shepherding ideas from seeming impossibilities to sparks of inspiration to groundbreaking products that enable innovation can be both exhilarating and maddening. To iterate quickly and enable true collaboration, the fastest teams in engineering employ the Electroimpact SCRAM system powered by the Siemens SINUMERIK ONE CNC.

Helping to make the impossible possible, Electroimpact has integrated an in-situ out-of-autoclave thermoplastic Automated Fiber Placement (AFP) process, an advanced Fused Filament Fabrication (FFF) 3D printing process, a Fused Granulate Fabrication (FGF) 3D printing process, and subtractive machining into a unified Scalable Composite Robotic Additive Manufacturing (SCRAM) system. SCRAM is an industrial, true 6-axis continuous fiber-reinforced 3D printer that enables the tool-less rapid fabrication of aerospace-grade integrated composite structures.

High-performance thermoplastics combined with a high percentage of continuous fiber reinforcement are used to produce parts with exceptional material properties previously unheard of in the world of additive manufacturing. The enhanced performance of the 6-axis system offers unmatched dexterity and flexibility, enabling shapes, accuracies and intricacies not possible otherwise.

This technology has no equal in the industry and is a unique offering available only from Electroimpact. The capabilities and processing speed of the SINUMERIK ONE control empower Electroimpact engineers to achieve these breakthroughs in additive manufacturing.

True 3D printing

Most 3D printing processes are more accurately described as 2.5D printing. The material is deposited successively in
flat slices, which when stacked together form a 3D object. In contrast, the SCRAM process renders true 3D printing.

Layers of continuous fiber-reinforced thermoplastic capably take the shape of complex contours, including aerodynamic surfaces and ducts for fluid flow. As a 6-axis process, fiber orientation within each layer can be tailored to the specific application, providing optimal strength and appropriate stiffness distribution throughout the part, much like a conventional AFP system.

In addition to the continuous fiber-reinforced thermoplastic printing process and the FGF support tool printing process, SCRAM cells are also fitted with two FFF nozzles optimized for deposition of thermoplastic material reinforced with short or “chopped” fiber.

A proprietary laser heating system is incorporated, producing exceptionally strong bonds between layers. This process is ideal for situations in which layering continuous fiber is geometrically impossible or otherwise does not make sense. “It allows us to deposit the material exactly where it needs to be and only where it needs to be, achieving the highest possible strength and lowest weight,” says Ryan Bischoff, senior composite engineer at Electroimpact.

This is a true 3D printing process where the layers are not simply a stack of planes. Complex geometries such as variable density core and other internal structures can be printed directly onto continuous fiber-reinforced layers with widely varying curvature. If desired, additional continuous fiber-reinforced layers can then be deposited on top of the chopped fiber-reinforced core structure, forming an upper skin.

The system is an integration of several additive and subtractive processes, combined with Electroimpact’s patented accurate robot, a rotating build platform and a climate-controlled build chamber.

Electroimpact then supercharges everything with the SINUMERIK ONE control from Siemens. “SINUMERIK ONE allows us to run more complicated code much faster,” says Kylie Martineau, Electroimpact controls engineer.

“Electroimpact expanded from doing mostly drilling and fastening to additive manufacturing about 15 years ago,” Bischoff says.  “That move and the advancements over the years led to the development of a system that we call a ‘factory in a cell.’ Instead of needing a whole assembly line, with each dedicated machine only performing a single function, it is one system, which can be printing ducts for jet engines one day and a wing component the next. It can be quickly changed and adapted according to needs.”

The SCRAM enables the tool-less rapid fabrication of aerospace-grade integrated composite structures. This factory in a cell gives builders the option to produce low-run parts that make all the difference in their designs.

This might be a carbon fiber element for Formula One racing or a part made from a revolutionary alloy that is destined for space. For short runs or small runs, nothing can compete with this technology. “Here is where the factory in a cell helps teams develop parts much more quickly than a traditional facility. You complete the whole process within the SCRAM system. It makes sense because these are not the kind of parts that are produced in the thousands,” Bischoff says.

“Our customers are doing extraordinary work, and we are right there alongside them,” he adds. “Your Electroimpact engineer is with you though the lifespan of the system for all questions and requests. We are here to help builders push boundaries. We service our equipment till the day it dies. Support is one of the things that Electroimpact does better than anyone else in the industry.”

With the SCRAM system, 3D printing replaces the need for the traditional complex tooling development typically used for automated carbon-fiber layup. This eliminates the inflated cost and time investments needed in traditional tooling and development; therefore, the SCRAM system allows for faster corrections and modifications.

Once the complex tooling is printed, the SINUMERIK ONE control facilitates rapid changes throughout the process. First, the SCRAM system changes to a multi-axis milling head that finishes the form to exacting specifications. Then the SCRAM system changes once again to the 6-axis carbon-fiber placement head and applies the intricate pattern of carbon fiber tape to the support material.

Bischoff explains that the tape is deposited quickly, establishing the form. Next, the support material additive is then completely dissolved away, leaving behind a component in the exact shape the manufacturer needs.

“The knowledge that we’re able to dissolve the tooling without creating graywater brings us great peace of mind,” Bischoff says.

The SCRAM system, with the power of SINUMERIK ONE, also enables iteration. “We are working to make an open system that will support the material choices and make the parts each customer needs. We are driven by customer demand,” Bischoff explains.

The processing speed of the Siemens SINUMERIK ONE CNC

Electroimpact engineers appreciate the advanced features of this next-generation control platform.

“The faster processor times for both motion control and PLC, combined with new functionalities of the SINUMERIK ONE, further enable the incredible work Electroimpact is doing with the SCRAM system,” says Steve Czajkowski, engineering manager at Siemens.

Brian Cubie, account manager for Siemens, agrees. “Our system is the foundation on which they are building, and it is just incredible to experience,” he says. “I have been in robotics for many years, and to see what the engineers at Electroimpact are doing in terms of digitalizing the factory floor is exciting. They are always at the forefront. Electroimpact does a phenomenal job of taking our new SINUMERIK ONE control and adding encoders for feedback and run it though their own kinematics.”

SINUMERIK ONE is built for high-speed processing that enables the accuracy needed for specialized parts. It is ideally suited to the SCRAM’s groundbreaking ability to shift from 3D printing to finishing and continuous carbon-fiber placement, all from one control.

SINUMERIK ONE makes product development faster, more flexible, and more efficient.

Digital twin technology

Looking towards the future, the SINUMERIK ONE control platform will take the SCRAM into advanced digital twin technology. This will help teams engineer a fully functioning machine even before a real-life prototype exists and for teams to transfer tasks from the real world to the virtual environment. It will keep projects moving consistently to the work preparation phase. Having SINUMERIK ONE as a built-in tool will help reduce overhead costs for projects and support.

“There‘s a huge industry push to having a digital twin,” Martineau says. “I am extremely excited about supporting SCRAM in our customers’ endeavors moving forward. Each customer is pushing what is possible. They are reaching for ideas that are slightly out of the ordinary. With this true digital twin, instead of needing to travel for an on-site visit or asking for photos or video footage of their challenges, the PLC will allow simulation right inside the control.”

Just as customers can run the digital twin from their computer, Martineau will be able to operate the digital control of a customer’s SCRAM right from hers.

“We hear from customers when they’re striving for the next level, pushing the system to the max. Being able to jump in and see what’s happening is so valuable,” she says. “The digital twin capabilities of SINUMERIK ONE will enable us to work extremely close to our customers in the future, supporting their desires to push the envelope of product development. With digital twin technology this accurate, customers will benefit from knowing we can jump in anytime to seamlessly help troubleshoot.”

Strong partnership

Siemens and Electroimpact have been partners for more than 10 years. The SCRAM previously included the SINUMERIK 840D sl, a precision CNC control highly favored by the aerospace industry. SINUMERIK ONE is faster and excels at more complex code. With the advancements of the SINUMERIK ONE control, the possibilities are endless.

“Electroimpact is always pushing the envelope,” says Brian McMinn, head of the Siemens Machine Tool Systems business. “Their approach is to always be at the very leading edge of manufacturing technology. We are glad to be a part of their team as SINUMERIK ONE has the power and speed to make it all possible.”

Expect to see further advancements from Electroimpact in the next few years that raise the bar even higher for complex aerospace design and development.

The SINUMERIK ONE control will continue to evolve and support the next wave of design and development in machine building.

For more information and to watch the video, visit:  usa.siemens.com/ei-scram