Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Closed loop between WENZEL gear inspection system and Nidec gear grinder
♦ Utilizing VDI/VDE Gear Data Exchange format
♦ Automatic process corrections
Wixom, MI – IMTS 2022 will host a variety of gear technologies that will set the tone for manufacturing innovation in the years to come. At the forefront is the integration of data for process control, providing outstanding solutions to manufacturers. WENZEL America and Nidec’s collaboration started with the mutual drive for serving their customer with excellence through data management.
“Showing how easily WENZEL’s metrology systems integrate into any production process is what we would like to display at this year’s show. We are excited to have Nidec as a partner to demonstrate how we apply this to the gear industry,” said Drew Shemenski, President of WENZEL America. “Collaborations like this are a way we bring innovation to our customers.”
The successes achieved in the field of measurement technology solutions based on closed-loop processes are pushing the boundaries on throughput and delivery. Because of this, launching the technical collaboration between Nidec and WENZEL at IMTS 2022 was an easy decision.
According to Scott Knoy, VP Sales at Nidec Machine Tool America, “Both Nidec and WENZEL are able to utilize the international VDI/VDE gear data exchange format. Our joint effort with WENZEL offers gear manufacturers the ability to automatically make corrections to the process based on inspection data. This will be shown at IMTS connected to Nidec’s internal gear generating grinder, the ZI20A-G.”
Speaking on integrated metrology at IMTS, WENZEL’s Chief Digital Officer, Prof. Dr. Heiko Wenzel will emphasize the solutions that WENZEL develops and works towards productivity success for their customers through integration.
Interested parties can contact:
Scott Knoy, VP Sales
248-756-5017
Scott.Knoy@nidec.com
NIDEC MACHINE TOOL AMERICA LLC
46992 Liberty Drive
Wixom, MI 49393
www.nidec-machinetoolamerica.com
By Amie Burke
Participating in a trade show can be a little overwhelming to think about social media when you’re busy with your trade show or expo responsibilities. You know that it is important to let your social media followers know that you are at a show, but what do you do when you are there? Sticking to a couple of these posting ideas can help make it less of a task and help highlight how important your company is to the industry.
Highlight your booth setup.
The first post to make while you are on location with your booth is to actually highlight your whole setup. If it is possible, a behind the scenes shot of the actual set up the day before a trade show would be a great way to remind your followers that you will be at a particular event along with directions to get to your booth. Posting the finished set up, in all of its glory, on the first morning of the trade show will remind your followers what booth they are looking for. Posting a couple of eye catching photos or time-lapse videos of the set up process, then finishing the story next morning with a nice photo of the whole setup or a less than a minute video walk through tour, is an effective way to kick off your first day.
Focus on the unique and important.
What makes your booth area unique? Do you have important clients or guests coming to visit? Are you doing a special giveaway that’s only at the trade show? These are great things to highlight when you are in full swing of the trade show. Posting a quick video tour of something unique about your setup or a photo of a meet up with a client will help in showing how inclusive and friendly your booth is to not only your followers on social media, but potential clients at the show as well. Make sure to use trade show specific hashtags in order to maximize this idea especially if you are doing a trade show specific giveaway or have a sponsorship of an event.
Take it to the next level.
While you are at a trade show, you will see all kinds of new technology or enjoy groundbreaking speeches and presentations. If you are able to share some of the next level information that you are learning, do it! Your followers will find it very interesting and it shows that you are the kind of company that is always looking forward to the next progression in your industry.
Trade shows and expos can be a great way to not only show off what your company can do for your clients and potential partners, it can highlight that your company is ready to make meaningful connections through your industry. While posting about trade shows on your company social media pages, always remember that those channels are an outreach to the rest of the world outside of the expo hall. Not only will the posts help with information inside the show, posts will help show others who could not be there, that you understand the importance of connection and keeping up with what’s new in your industry.
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Exact Metrology: A Division of In-Place Machining Company and a comprehensive 3D metrology service provider and hardware sales company, recently used CT (Computed Tomography) to assist a former Ohio State University student with a special project.
Caroline Karbowski a Biology major as well as an undergraduate student researcher in Molecular Biology, started her own company called See3D. A nonprofit organization, See3D helps the blind and visually impaired to see through touch using 3D printing to create models. They then distribute them to those in need.
Since 2017, See3D has distributed over 1,400 models to people in 23 states, 9 countries and 23
organizations. Ms. Karbowski taught herself Braille in 6th grade because she wanted to “read books in the car without getting dizzy.” From there, her interest grew and she discovered that she could add Braille labels to 3D printed models. Blind students could make their own scientific observations instead of only relying on someone else’s observations.
See3D contacted Exact Metrology wanting to take a particular physical part and convert it into a digital model, a service the company can provide rapidly with multiple methods of data capture and full-time staff for modeling and reverse engineering. The nonprofit had access to a scale model of the Ohio State House. The model is presumably a one-off model made by an artist. The challenge consisted in modeling the minute details and features of the state house into a printable format. An accurate point cloud was required. The geometry of the part and small features made industrial CT scanning the ideal choice for data capture.
The scan was completed by an Exact Metrology applications engineer, with a ZEISS METROTOM 6 scout (GOM CT). Using an x-ray generating source and a digital detector, an image showing the difference in density was created. Thousands of images were taken automatically. When a sufficient number of images were captured, they were stitched together to create a 3D x-ray image or volume. The volume can then be surfaced into a model by the gray value difference between materials in the volume. In this case, an outer shell featuring a core and a base. The applications engineer noted that when a point cloud was generated of the Ohio State House, it had too many points to be feasibly processed into a printable format. Exact Metrology’s in-house reverse engineering team removed the unnecessary data points while maintaining accuracy to provide a printable digital model of the state house. The engineer commented on his experience by saying, “I enjoyed this job because it was an interesting, unique part with the added bonus of helping See3D provide a valuable service.”
Last year, Caroline was selected as the Next Generation Innovator of the Year by her university. To hear her talk more about See3D and the inspiration behind it, view below:
In-Place Machining Company: On-Site Machining Solutions In-Place, Any Place in the World.
In-Place Machining Company, with facilities in Wisconsin, Washington, Virginia, Ohio, and Ontario, Canada, is the premier provider of high-precision engineered on-site machining, metrology, and large scale cutting & drilling services for a wide range of renewable energy, aerospace, industrial, and military customers throughout the world.
Exact Metrology: A Division of In-Place Machining Company, is ISO9001, AS9100 Certified as well as ITAR Registered.
Exact Metrology: A Division of In-Place Machining Company, with facilities in Cincinnati, Ohio, Moline, Illinois and Milwaukee, Wisconsin, plus affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.
For more information, please contact:
Exact Metrology: A Division of In-Place Machining Company
Steve Young
11575 Goldcoast Drive
Cincinnati, OH 45249
Local: 513-831-6620
Toll Free: 866-722-2600
www.exactmetrology.com
stevey@exactmetrology.com
Introducing one nanometer axis resolution, the new MX7 ULTRA machine’s performance can maintain less than +/- 0.002mm line form accuracy of any profile which includes ballnose and corner radius endmills. See the ultra-performance machine at IMTS – Booth #237406.
The new MX7 ULTRA can manufacture large volumes of endmills and other cutting tools of the highest accuracy and quality. The minute size of a micron is beyond the human eye, but in becoming even more precise and moving from micrometers to nanometers, ANCA will offer the highest accuracy and quality in a cutting tool in the market. New software, hardware and design features are combined to make significant advances in surface finish, accuracy, and controlled runout, to deliver batch consistency from the first ground tool to the thousandth.
The MX7 ULTRA includes:
Pat Boland, ANCA co-founder says: “The MX7 ULTRA is a significant development in precision machine design and will change the industry expectations for accuracy and tool life. Achieving these outstanding results has only been possible because of our extensive experience working with customers to manufacture the highest quality cutting tools over many years. At ANCA we are always designing and innovating to find better customer solutions and I am very proud of the ANCA team that has developed the MX7 ULTRA.”
“The ULTRA machine is truly market changing. It is the culmination of ANCA’s elite technology, deep industry knowledge, and customer experience in grinding,” says Thomson Mathew, ANCA product manager for the MX series and software products.
Unlike its competitors, ANCA is vertically integrated. This provides a significant advantage as it means ANCA teams can develop and manufacture their own machines from base to canopy – including controls and drive systems, design and simulation software and even machine monitoring software. Owning all the technology means engineers and designers can consider the entire machine as a single system when developing new solutions.
“We wanted to create technology that could produce premium cutting tools that are above the current market standard in both accuracy and tool life. We introduced nanometer resolution into our axis, which is new to the cutting tool market. The result is a perfect example of ANCA’s vertical integration capabilities as we have the in-house ability to fine tune or develop the new algorithms for our drives to make this happen.”
“Cutting tools like ballnose, corner radius, barrel shape ballnose and double corner radius endmills are used widely across industries including diemold, aerospace, and power generation. The surface finish quality, accuracy and runout are critical for the performance and cutting life in all applications – so our customers want a guarantee that their first tool will be exactly the same as the hundredth, or thousandth. The MX7 ULTRA can produce high quality cutting tools to suit all customer needs to satisfy all industry types.”
“With almost 50 years of expertise, we are experts in the field of cutting tools and we want to impart our knowledge through best grinding practices. As part of the ULTRA experience, skilled application engineers will be available to train and educate our customers to ensure the machine will produce high quality tools from the first day of production.”
“It has taken years of research and development, and engineering excellence for us to develop this premium solution to grind high quality tools. In my 25 years in the industry, I believe this is one of the most outstanding innovations we have accomplished that will really change the cutting tool market. We are confident that our customers will be very satisfied with the life and performance of cutting tools produced on this premium machine,” Thomson concluded.
The MX7 ULTRA superior performance highlights
Greater control for the velocity and acceleration or deceleration along with machine jerk limits: To increase the stiffness of the C-axis, the MX7 ULTRA combines developments to the nanometer or micro degree resolution in the linear and rotary axis, tuning parameters, several system enhancements, and major mechanical changes.
ULTRA-fast response to internal or external disturbances: ANCA’s newly designed servo control algorithm allows silky smooth motion of an axis with the use of a unique algorithm and nanometer measurement in the control system. This will create finer cutting edges and eliminating micro-chips making it more efficient while used in actual machining of materials.
Better cycle time and higher productivity of high-quality cutting tools: The unique algorithm is key to the performance of the machine and ensures outstanding tracking performance. It also allows ULTRA-performance of the servo system without using a complex, complicated, or expensive mechanical system.
Reduces setup times and scrap: Cutting-edge software has been developed by ANCA to ensure batch consistency in large volumes. LaserUltra is part of the MX7 ULTRA package to maintain consistency and accuracy of the grinding process which includes in-process measurement and compensation to accommodate wheel wear and other external variations during large batch grinding. Its analog capability can maintain less than +/- 0.002mm line form accuracy of any profile which includes ballnose and corner radius tools.
Increased wheel life and better-quality tools: Tool and wheel performance can be further optimized by the iBalance software, which guides a user to the optimal grinding position and RPM for vibration monitoring and balancing the wheelpack inside the machine. Correctly balanced wheelpacks result in superior surface finish and reduced wheel wear due to the elimination of wheel vibration.
Consistency in finished tool quality: A major inclusion in the MX7 ULTRA package is the total tool runout measurement and compensation operation in iGrind. When an endmill is in rotation it is important that each tooth hits at the exact same spot along the workpiece for longer tool life and efficient cutting. Every tool in the batch can be measured and compensated for runout to make sure the entire batch is within a tolerance of 0.002mm. It is another piece of assurance that the first endmill will be as good as the last.
Consistent spindle thermal stability: Motor Temperature Control (MTC) is a patented (US PAT. 11,394,331) innovation built into the motor spindle drive firmware. Smart control algorithm actively manages and maintains the temperature of motorized spindles in the MX7 ULTRA. Dramatically reduced machine warmup time means production can start sooner, once the machine has reached thermal stability. This improves productivity and machine use. Consistent thermal stability of the spindle over time regardless of changes in load or speed, or coolant temperature, greatly improves the dimensional stability of grinding results.
Post grinding processes: The smoother, finer cutting edge and surface finish as a result of the combination of all the above including the nanometer control will assist in all post grinding applications like edge preparation and coating. A finer edge that has been properly prepared has greater stability, which reduces the likelihood of it chipping, while also decreasing surface roughness which can cause increased friction between the tool and the workpiece.
For further information, please contact:
Johanna Boland
Group Corporate Communications Manager
M: +61 407799779
Johanna.Boland@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.
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Global EDM supplier also moves to new location to enhance production and service capabilities
Batavia, Ohio- Beaumont Machine is a world-class builder of Electrical Discharge Machines (EDM) for the aerospace, power gen and electronics production industries. Founded by Ed and Tanya Beaumont over 30 years ago, the company was recently repurchased, after the owners had sold the business in early 2013. As Ed Beaumont explains, “We had a great relationship with the new owner but we believed the company needed a revitalization to benefit our customers, employees and the evolving EDM industry. In addition to repurchasing Beaumont Machine, we have reassumed the day-to-day operation of the company. In addition, we have moved the operation into a larger location to increase production and expand our service capabilities.” That new location is 2010 Glenn Parkway in Batavia, Ohio, just outside Cincinnati.
Beaumont Machine’s contributions to the aerospace and power generation industries are many and, with this buyback, the company is ready to meet the needs of the changing EDM industry. “We pride ourselves on not only understanding the applications in the various industries we serve but also on building the best machines for the applications we encounter, from small hole to large workpieces,” adds Tanya Beaumont.
From the standard mill style EDM to machining cells with complete robotic operation for large aircraft engine and launch vehicle sections, Beaumont has built machines with an 8’ part rotation, a robotic arm with 10’ reach, and machines as small as 36” in width. A new 7-axis EDM drill has just been developed. All Beaumont machines feature the most advanced CNC technology and user interface.
With customers worldwide, as Ed Beaumont observes, “We are committed to innovation and customer partnerships in various industries, in countries around the globe. It’s a testimony to the fact that the world is still hungry for American technology and ingenuity. We’re very proud of that.”
Ed and Tanya Beaumont founded the company, Beaumont Machine, 30 years ago. Beaumont Machine focuses on building a line of standard EDM’s as well as custom machines plus repairing and retrofitting machine tools of all types. The company started building Fast Hole EDM in 1997 and has been specializing in EDM technology since that time. In 2013, they turned over the ownership of the company to a new owner. With this reacquisition of the company, Ed and Tanya Beaumont are again actively involved in day-to-day operations.
Among its recent successes is a custom robotic EDM work cell for SpaceX, as shown in the below photo.
For more information on these developments, please contact:
Ed Beaumont, President
BEAUMONT MACHINE
2010 Glenn Parkway
Batavia, OH 45103
Phone: 513-701-0421
Exact Metrology: A Division of In-Place Machining Company and a comprehensive 3D metrology service provider and hardware sales company, recently announced they have become the North American distributor of HandsOnMetrology. The new digital platform HandsOnMetrology.com was set up to share the benefits of 3D metrology with a global community. As a representative of this new 3D scanning network, Exact Metrology will be an official contact for companies in the US who want to optimize their quality control processes with new, state of the art 3D scanning and automation solutions.
Available at both the Brookfield (Milwaukee), Wisconsin and the Cincinnati, Ohio location, the #HandsOnMetrology portfolio offers measuring systems including GOM Scan 1, ATOS Q, T-SCAN 10/20 and the hand-held T SCAN hawk. Exact Metrology also offers the GOM ScanCobot automation solution.
GOM Scan 1 delivers the foundation for detailed and accurate 3D meshes with industrial standards such as GOM fringe projection technology and Blue Light Technology. The sensor is built to deliver 3D data with high precision. Easy to operate, the scanner is ideal for simple and fast measurements of small to medium-sized parts, even in confined spaces. With pre-installed GOM Inspect software, users can generate precise meshes and obtain 3D data easily and quickly.
ATOS Q is a flexible 3D scanner for complex measurement and inspection tasks in different industries. The scanner delivers fully traceable measurement results, especially in harsh conditions. Optical and electronic systems of the robust, optical 3D sensor are dustproof and splashproof. ATOS Q captures quality information quickly and with a high degree of detail, providing a reliable basis to easily interpret the information. Its Triple Scan Principle offers advantages for measuring reflective surfaces and objects with indentations. The Blue Light Equalizer enables high-speed fringe projection and is so powerful that, on dimensionally challenging surfaces, short measuring times can be achieved.
The compact hand-held 3D scanner T-SCAN hawk is designed to capture data whenever needed. It includes technical features such as: photogrammetry of large objects, multiple laser sources and three scanning models. This makes it the perfect solution for fine detail. Thanks to the GOM Inspect onboard, the T-SCAN hawk offers a complete solution to simplify your entire workflow from scanning to evaluation and reporting.
The GOM ScanCobot, a mobile automated 3D scanning system, easily integrates with ATOS Q. With the high-precision quality of ATOS combined with an automated robotic arm, the GOM ScanCobot is cost-effective and easy to use. It improves efficiency in quality control of small to medium-sized parts, including plastics, fabricated metals and castings. The combination of the GOM ScanCobot and the proven ATOS performance results in fast fringe projection, data processing, high throughput and a design ideal for industrial use.
In-Place Machining Company: On-Site Machining Solutions In-Place, Any Place in the World.
In-Place Machining Company, with facilities in Wisconsin, Washington, Virginia, Ohio, and Ontario, Canada, is the premier provider of high-precision engineered on-site machining, metrology, and large scale cutting & drilling services for a wide range of renewable energy, aerospace, industrial, and military customers throughout the world.
Exact Metrology: A Division of In-Place Machining Company, is ISO9001, AS9100 Certified as well as ITAR Registered.
Exact Metrology: A Division of In-Place Machining Company, with facilities in Cincinnati, Ohio, Moline, Illinois and Milwaukee, Wisconsin, plus affiliated offices throughout the country, is a comprehensive metrology services provider, offering customers 3D and CT scanning, reverse engineering, quality inspection, product development and 2D drawings. The company also provides turnkey metrology solutions, including equipment sales and lease/rental arrangements.
#HandsOnMetrology
#HandsOnMetrology is a new global 3D scanning network and provides a digital go-to for everything you always wanted to know about 3D scanning on the platform HandsOnMetrology.com. The platform is operated by GOM Metrology that sets new standards in optical 3D metrology. From step-by-step setup instructions to more advanced tutorials and expert hacks: the platform is made for learning and for getting inspired. It gives users all the information they need to deliver 3D scanning excellence. HandsOnMetrology.com supports the community of designers, technicians, engineers, scientists and specialists with valuable knowledge to increase product quality, optimize processes and expand possibilities.
For more information, please contact:
Exact Metrology: A Division of In-Place Machining Company
Dean Solberg
20515 Industry Avenue
Brookfield, WI 53045
Local: 262-533-0800
www.exactmetrology.com
deans@exactmetrology.com
See ANCA’s specialized grinding solution for greater flexibility and capability for unattended production of wood tools at IWF – Booth B8285
FAMEG is one of the biggest chair manufacturers in the world. Established in 1881, FAMEG has dominated the market with a wide variety of product and commitment to quality. The company now has customers in 50 countries worldwide, an 800 strong production team and is headquartered in Radomsko, Poland.
Andre Bronowski, Sales Director at FAMEG said: “The chair design is similar to a fashion business. The product needs to be attractive, but it also needs to be strong enough for use. We work with many designers, from Poland and abroad from Germany, Sweden, Spain and Switzerland.”
“The process to manufacture a chair is not so simple. First, you have to source round wood, cut and bend the wood or make as plywood. For these processes we need cutting tools, a lot of cutting tools. After cutting, we assemble the complete chair – staining and lacquering to produce a final product.”
“Two to three years ago, we decided that we would make all our own woodworking tools in house and that’s why we contacted ANCA. Nowadays, production requires a lot of flexibility and short lead times. We calculated that it would be best to control this process ourselves.”
“Furthermore, to ensure our quality standards we try to control all steps during production. Having the ANCA FX7 in-house means that we can now supply all the tooling for ourselves, save money and are even looking at manufacturing cutting tools for other companies,” Andrea stated.
Ireneusz Idzikowski, FAMEG Product Manager said, “We decided to purchase an ANCA machine because of how long it was taking to source cutting tools. We need our cutting tools fast. Our manufacturing deadlines are very short, so if we couldn’t get the tools we needed quickly, it was a big problem.”
“A second reason was diversity of cutting tools. Our production requires using specialized tools that have unusual dimensions. Obviously, we also use standard cutting tools, but the majority were specials. Tools made for special request and of special construction are not always perfect. Often you have to make a correction, which doesn’t have to be related to the tool itself but the production process of the used machine, which we can now do in real time – rather than shipping it back to a supplier.”
“We use the ANCA FX7 for both production and resharpening. For production we have equipped the machine with a robot to produce tools in an automatic cycle, replacing the operator’s work.”
“The machine has solved a lot of production problems. Now we can access cutting tools when we need them. It means we have stock or can manufacture the required cutting tool pretty much immediately, which wasn’t possible until now. It completely changed our work quality production wise.”
“We are also very happy about the service, ANCA service technicians help us in solving various technical questions and we know who to call and that they won’t leave us alone with our problem,” Ireneusz concluded.
Duncan Thompson, ANCA Special Projects Manager said: “FAMEG approached ANCA to see if we could find a custom solution for our FX grinding machine to have greater flexibility and capability for unattended production of wood tools. In partnering with FAMEG, we now have developed a machine package ideally suited to companies operating in the wood cutting tool industry.”
“The solution has a special tooling system that can be used on our highly affordable and versatile FX7 machine. With its inbuilt robot and dedicated tooling, the FX7 can easily change automated production between woodworking profile blades, used to form skirting boards and architraves, and solid round shank tools such as routers and drills used in production of furniture and nested flat panel applications.”
FX7 includes an inbuilt robot for tool and wheel pack changing, making it the ideal foundation for FAMEG’s application. Two systems of work holding are offered: one for flat profile blades and another for round shank routers. Changeover between the two is designed to take less than 15 minutes. To support unattended production, a new robot head changes not only wheel packs (up to six for ultimate grinding flexibility), but also loads profile blades, or round shank routers without the need to make any changes to the robot tooling. Changeover of the machine from profile blade grinding setup to routers takes less than 30 minutes.
Production of different tool types is supported by dedicated tool software packages for programming profile blades, compression routers, standard and profile routers and drills. All these grinding programs can be verified offline on the ANCA CIM3D package, ensuring the first tool produced is exactly as expected.
ANCA’S SOLUTIONS TO INCREASE YOUR WOODWORKING TOOL PRODUCTIVTY AT IWF
ANCA offers a variety of CNC grinding application solutions to suit the woodworking tool industry. Through collaboration with different companies, such as FAMEG, ANCA offers a range of CNC Tool and Cutter Grinders, along with dedicated woodworking software and automation solutions, to suit a range of tool types.
With ANCA, manufacturers can diversify wood tool applications on FX machines. ANCA’s woodworking solution for the FX7 offers outstanding flexibility for unattended production. At IWF, visitors can see ANCA’s FX7 grinding compression routers.
Diversify your wood tool applications on ANCA FX machines:
Visit ANCA at IWF at Booth B8285.
For further information, please contact:
Johanna Boland
Group PR and Communications Manager, ANCA
M: +61 407799779
Johanna.Boland@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.
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The technology offers maximum flexibility, efficiency and part quality, as well as material savings of up to one million USD per year
Canton, Michigan, July 27, 2022 – A blanking line is usually made up of a coil line, an uncoiler, a threading unit, leveler, roll feed, the cutting area and the stacking unit. This holds true with laser blanking lines, but the material is cut by a laser cell instead of a shear or press. Justine Fonteyne, Schuler’s Area Sales Manager of the Americas, has recently explained the technology’s multiple advantages in an online seminar.
There has been a rising interest for laser blanking lines, given the die-free blanking capabilities. Schuler has sold 15 worldwide, including five in North America. With the frequent changeover of new car models, vehicle manufactures are happy to avoid investing in expensive dies – especially new players within the EV market, for which ramp-up production may be slower. “And die change time costs production time,” Fonteyne underlined. Additionally, no dies equate to no die storage or maintenance, and less initial infrastructure investment as no heavy press foundation or loop pit is required. Apart from that, no noise or vibration is emitted.
Overall equipment efficiency of up to 80 percent
Because of Schuler’s Dynamic Flow Technology (DFT), Schuler’s laser blanking lines are also much faster than conventional stop and go laser cutting systems like flatbed lasers. The material runs continuously without the need to stop-and-start before cutting. The output can reach 45 parts per minute, depending on the geometry of the blank. Due to no die changes, the overall equipment efficiency (OEE) is up to 80 percent.
“Depending on the part mix, Laser Blanking can be the cheapest way of blanking,” Fonteyne stated. “Due to digital nesting solutions, the technology has much greater material utilization.” In contrast to conventional lines, the parts can be designed independently from die restrictions. Also separation strips can be avoided with edge-to-edge nesting. Improvements in material utilization of an outer body part mix of approximately 1 percent quickly add up to material savings of up to one million USD per year.
No wear of dies and presses
Schuler’s laser blanking lines produce homogenous cutting edges with hardly any burr. “This is relevant for aluminum because the flitter in the die is reduced to almost zero,” Fonteyne explained. The rising number of high-strength steel pose further challenges to conventional lines regarding the wear of dies and presses, but the lasers are not affected by this at all. Schuler offers workshops for part simulation and optimization as well as business calculation.
Fonteyne provided insight into Schuler’s Track & Trace solution that has already been implemented at the Smart Press Shop in Germany, a joint venture between Schuler and Porsche. “Being the first station for the material in the press shop, we start the tracking of the production data here,” said Fonteyne. “The production data is connected to every part and can be tracked easily and continuously. For example, data pertaining to the thickness of a blank or the amount of oil distributed can be transmitted to the press line in order to achieve a perfect forming process.
Watch the complete video of the online seminar here: https://youtu.be/oC59OzaCW0c
Listen to Carla Bailo, President & CEO of the Center for Automotive Research (CAR), and Justine Fonteyne discuss laser blanking via CAR’s podcast: https://anchor.fm/the-car-podcast/episodes/Laser-blanking—featuring-Justine-Fonteyne-of-Schuler-Group-GmbH-e1krdmp/a-a8799jm
Internet
laserblanking.schulergroup.com
About the Schuler Group – www.schulergroup.com
Schuler offers customized cutting-edge technology in all areas of forming—from the networked press to press shop planning. In addition to presses, our products include automation, dies, process know-how and service for the entire metalworking industry. Schuler’s Digital Suite brings together solutions for networking forming technology and is continuously being developed to further improve line productivity and availability. Our customers include automotive manufacturers and suppliers, as well as companies in the forging, household appliance and electrical industries. Presses from the Schuler Group mint coins for more than 180 countries. Founded in 1839 at our headquarters in Göppingen, Germany, Schuler has approx. 5 000 employees at production sites in Europe, China and the Americas, as well as service companies in more than 40 countries. The company is part of the international technology group ANDRITZ.
For further information on Schuler Inc., North America, please contact:
Jaime Bartholomai, Marketing & Communications Manager
Schuler Incorporated
7145 Commerce Blvd.
Canton, MI 48187 USA
Jaime.Bartholomai@schulergroup.com
Zimmermann Milling Solutions, a leading global high-tech supplier of portal milling machines, will virtually show three new gantry machines at their booth. IMTS will be held September 12-17, 2022, in Chicago.
When discussing rigidity, nothing beats mass. Our biggest double bridged gantry sets new standards for dynamic roughing while maintaining high precision. The FZ42 CNC gantry milling machine represents power at its best, combining work areas of different sizes, travels, milling heads and CNC controls. Regardless of weight and size, the milling process is exact. Furthermore, the gantry design is particularly suitable for the entire range of component machining. The structurally rigid center-guiding gantry, cross and Z-Ram, and dynamic milling head enable a consistent, efficient milling process. This combination of high thermal stability and rigidity meets industry-specific requirements in tool and die making, aerospace and automotive industries.
Just as strength and agility make an athlete perform at his/her best, the same is true for the newest high-performance gantry FZ37. Due to its modular system concept, the FZ37 is available in various sizes, custom configuration and CNC controls. The newly designed gantry with center guided Z-Ram in combination with Zimmermann’s dynamic milling heads ensure an efficient and consistent milling process. The high thermal stability and rigidity meet industry-specific requirements in model, tool and die making as well as in the aerospace and automotive industries.
The FZ32 is the high-performance athlete for dynamic machining of aluminum, fiber composites, plastics and tooling board. Its thermosymmetrical design results in high surface quality and accuracy. The rigid center-guiding gantry allows the company to meet the increasing demands in model and mold making as well as aerospace. Additionally, the flexible design of the FZP machine line offers various sizes and configurations through its modular system as well as extensive equipment options and a fully enclosed work area, including effective dust extraction systems and more.
Visit Zimmermann at IMTS 2022 in the South building, Level 3, booth 339336.
For more information, please contact:
ZIMMERMANN INC.
30587 Century Drive
Wixom, MI 48393
Phone: 248-956-8511
www.zimmermann-inc.com
Mr. Cornelius Kiesel, President
cornelius@zimmermann-inc.com
Los problemas de las cadenas de suministro están impulsando a más empresas a fabricar internamente. Paralelamente a esta tendencia en la fabricación de automóviles se encuentra el aumento de los vehículos eléctricos y el aumento de la automatización. Respondiendo a las necesidades de la industria, Nidec Machine Tool (Wixom, Michigan) está presentando la nueva máquina de talladura de engranajes en IMTS 2022 en el Stand 237036. Haciendo hincapié en la alta velocidad, la precisión y la eficiencia, la nueva máquina produce engranajes para automóviles eléctricos e híbridos, así como para aplicaciones robóticas y de automatización.
El modelo GE15HS está diseñado para engranajes con un diámetro máximo de 150mm, ampliamente utilizado en automóviles y motocicletas. El motor de accionamiento directo de alta velocidad y alto par de torsión*1 para el husillo principal proporciona una velocidad máxima del husillo de 6,000 min-1*2 – tres veces mas rápida que modelos anteriores. El husillo de alta eficiencia que sujeta la pieza de trabajo utiliza una mesa especial que proporciona alta rigidez y rotación de alta velocidad para manejar la carga de empuje necesaria*3 para un mecanizado de alta eficiencia. Los engranajes de corte con herramientas de corte super duras Nidec producen una rugosidad superficial de menos de Ra0.4*4; a la par con el rectificado de engranajes. Scott Knoy, Nidec Machine Tool America VP de Ventas dice, “El GE15HS proporciona eficiencia de proceso, eliminando el proceso de acabado del afeitado antes del tratamiento térmico, mejorando así la productividad y reduciendo el costo de procesamiento.” Una máquina más grande, la GE25HS, también está disponible.
Utilizado en combinación con los nuevos materiales y recubrimientos de Nidec Machine Tool para herramientas de corte, el modelo GE15HS proporciona una producción en masa estable con una velocidad de corte máxima de 1,500m/min.
Desde el lanzamiento del producto en 2004, se han entregado e instalado más de 2,800 máquinas de talladura Nidec GE Series.
El stand Nidec también contará con ZI20A-Generación de Rectificadora de Engranajes Interna. El acabado duro de engranajes de anillo interno en masa es la frontera final para aplicaciones de transmisión automotriz y de camiones. Para engranajes de anillo interno silenciosos y de malla suave, el ZI20A-G utiliza tecnología patentada para el rectificado de ruedas roscadas. Este proceso innovador ofrece una producción rápida y muy rentable de engranajes de anillo interno para engranajes planetarios.
Notas
*1: Los motores de mecanismo de accionamiento directo utilizan el par de torsión proveniente de un motor sin pasar a través de una caja de cambios u otro mecanismo para controlar la pérdida de conducción debido a la fricción y reducir el desgaste de las piezas.
*2: La notación “min-1” es una unidad que expresa el número de vueltas en un minuto, sinónimo con “revoluciones/rotaciones por minuto” (rpm).
*3: La carga de empuje es la fuerza aplicada al eje en una dirección horizontal (paralela) (direccion axial del
*4: Resultado del mecanizado interno con GE15S (Datos de la pieza de trabajo: Módulo 1.6mm; Nu. de dientes 19; ángulo de hélice: 24°; ancho de la cara: 24mm)
| GE15HS | GE25HS | |
| Diámetro max. de la pieza | 150㎜ | 250㎜ |
| Módulo de corte max. | 4㎜ | 6㎜ |
| Diámetro max. de herramienta de corte | 90㎜ | 130㎜ |
| Longitud max. de la herramienta de corte | 190㎜ | 230㎜ |
| Montaje del eje de la herramienta de corte | 150㎜ | 180㎜ |
| Velocidad max. de rotación del husillo | 6,000 min-1 Mecanismo de accionamiento directo | 2,300 min-1 |
| Salida nominal del motor principal | 24 kW | 25 kW |
Para más información, por favor póngase en contacto con:
Scott Knoy
Nidec Machine Tool America LLC
46992 Liberty Drive
Wixom, MI 49393
248-669-6136
www.nidec-machinetoolamerica.com
La demanda de producción en masa de engranajes de alta precisión continúa aumentando con el cambio a la electrificación de los vehículos. Con la necesidad de mejoras en NVH y eficiencia de combustible, además del movimiento hacia la fabricación de bajo costo, Nidec Machine Tool, con su experiencia tanto en máquinas herramienta de engranajes como en herramientas de corte, ofrece una línea completa de máquinas de producción de engranajes. Al ofrecer herramientas de corte de precisión y soluciones de procesamiento para lograr un procesamiento de alta precisión y alta eficiencia, Nidec Machine Tool proporciona un soporte integral para la fabricación en una amplia variedad de industrias.
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