Tag Archives: Bernard and Company

Ann Arbor, Michigan – GMTA (German Machine Tools of America) represents various top-quality German metalworking machine builders, including Wera Profilator, K + G, Pittler, Praewema and WMZ, as well as Arnold lasers. These machines are sold to the North American market exclusively by GMTA, primarily for gear and spline production, as well as other power transmission and various metalworking applications. The company’s target markets include automotive, off-highway, energy and other heavy equipment manufacturing. Machines are provided for gear honing, gear grinding, the patented Scudding® process for gearmaking, polygon milling, turning, gear tooth pointing and multi-task machining operations, as well as various laser operations or laser line integration and parts washing. This newsletter is provided to our friends in the media to keep you and your readers updated on News of Note at GMTA.

In the news…

-GMTA continues their relationship with Eastern Michigan University (EMU), recently accepting Shannon Lynch, from the Masters in German and International Trade program, as an intern. Shannon’s mentor at GMTA and herself an MBA holder from EMU, the corporate treasurer Claudia Hambleton, remarked, “It’s the first time we’ve ever done anything like this. I feel really strongly about corporate responsibility for young people coming up into the industry…everybody needs experience, but how do you get it? I think this is a really good opportunity for Shannon.” The two shared several German classes at EMU, so the partnership was a natural fit. Shannon is responsible for assisting Claudia with daily office duties including receiving, invoices and translations, in communications with the company’s German partner firms. During her internship, Shannon has also had the opportunity to engage in industry-related educational and technical sessions such as the Economic Forum of the German American Chamber of Commerce, an Advanced Excel Workshop for data analysis and the recent North American International Auto Show Charity Preview, a very prestigious event and a great networking opportunity for the leaders in automotive manufacturing.

-GMTA participated in the annual Auto Show Charity Preview in Detroit and a good time was had by all.

-GMTA is running at “light speed” with their new Arnold laser work cells. Available as single or double work cells, the Arnold systems are offered as CO2 or fiber lasers, with full integration into a machining line, either by means of robotic part articulation or other automated transfer mechanisms, most of which are being supplied to customers by GMTA engineering. Leads from IMTS and the company’s aggressive ad program are already being developed into serious opportunities for the company, often in tandem with other machine tool lines and the Rosink parts washers now offered by GMTA.

-Recently, a Diskus vertical double-disc grinder was sold to Hoergiger Fine Stamping in Canada. The DDS 600 machine feature two vertically arranged motor spindles, each equipped with 600mm grinding wheels used for simultaneous two-sided grinding of shims. The machine has a rotary through-feed system and an integral post-process measuring system, all developed by Diskus engineering and provided to the customer by the GMTA teams from Ann Arbor.

Präwema SynchroFine gear honing machines from GMTA

-The Mexico office of GMTA is reporting brisk activity, owing to the substantial procurement authority in-country now. According to VP Scott Knoy, “This contrasts with bygone days, when the decision-making and purchasing were largely centered in America and specifically in Detroit. It’s a whole new ballgame with the Mexican market today and we believe our new location (Queretaro) there is well positioned to serve this dynamic manufacturing environment.” GMTA already has a substantial installed base of machines in Mexico from all their partner companies.

-GMTA management will be attending EMO in Milan with its partners, then exhibiting at Gear Expo, being held this year in Detroit, October 20-22.

-The alliance with Star, through which GMTA is sourcing tooling locally, continues to prosper and mutually benefit both companies.

-GMTA was featured prominently in a recent article in Manufacturing Engineering magazine, covering the subject of gear making for the energy sector.

-Now available from GMTA, the Präwema SynchroFine 205 HS gear honing machine features direct-driven, digitally controlled spindles for the tool and the workpiece, enabling precise, rigid synchronization. The Präwema Honing gear finishing process produces quality comparable to grinding results for spur and helical gears, as well as shafts. The machine’s software checks the stock allowance and workpiece runout and then optimizes the X-axis approach distance. Measuring the workpiece does not affect the cycle time and the process can reduce overall cycle times by 3 to 5 sec.

For more information on this announcement, please contact:

GMTA (German Machine Tools of America)
4630 Freedom Drive
Ann Arbor, MI 48108
Phone: 734-973-7800
Fax: 734-973-3053
Web: www.gmtamerica.com
Email: scott@gmtamerica.com
Attention: Scott Knoy, VP
Connect with GMTA online:

Guill Tool, a West Warwick, RI designer and builder of extrusion tooling, offers an assortment of literature for machine builders and extruders at its website, www.guill.com.

Individual brochures are offered, depicting the wide array of tooling possibilities…straight inline heads, rotary heads and crosshead dies…available to suit any extrusion machine built anywhere in the world, running all types of compounds.

Guill provides tooling for plastic, rubber, TPE and other material extrusions, with end products ranging from extremely thin-walled, multi-lumen medical tubing and catheter balloon tubings up to multi-layer wire & cable jacketing and 20” diameter pipe for industrial applications and agricultural drip lines. Guill also provides tooling for film, sheet and profile extrusions.

The company designs, engineers, machines, assembles, tests and delivers all tooling to its worldwide customer base in all the consuming industries for extrusions. The company also offers tooling carts and disassembly/cleaning stations for easier line integration.

According to company sources, the utilization of properly designed and engineered tooling can result in substantial material savings for extruders of all types.

NOTE: Guill will attend MD&M West in February, NPE in March and Interwire in April, 2015.

Please visit www.guill.com to request a quotation or obtain company literature.

For further information, please contact:

GUILL TOOL & ENGINEERING CO., INC.
10 Pike Street
West Warwick, RI 02893
Phone: 401-828-7600
Web: www.guill.com
Email: sales@guill.com
Attention: Bill Conley
Connect with Guill Tool online:

Longtime market leader in all-electric injection presses NIIGATA will introduce two new machines to the market at the upcoming NPE in Orlando, March 23-27.

Visit NIIGATA at NPE Orlando, Booth W-1363, March 23^rd-27^th with a free guest pass.

NEW: NIIGATA all-electric MDVR110S7000 (Vertical IMM with 2-station rotary table)

NIIGATA introduced the world’s first all-electric vertical IMM in 1996 and its latest model, the S7000, capitalizes on NIIGATA’s long history and 100% focus on making all-electric machines.

Highlights of the new MDVR110S7000 include:

~While many vertical machines have high table heights, forcing the customer to build a work platform around the machine, the NIIGATA patented vertical toggle system allows lowering the table height on this 110-ton model to just 3.4 feet from the ground, including leveling pads.

~The machine has a wider table than standard verticals, allowing larger molds to be placed on the platen. The MDVR110S7000 boasts a mold size capacity of 500mm x 500mm (33.64” x 33.64”).

~Fast table rotation of under 1 second.

~Ultra low-speed injection can be beneficial in molding thicker walled insert jobs. NIIGATA boasts an ultra low-speed capability of just .01 mm/sec injection speed.

~With a 2-station machine running separate “A” and “B” mold halves, a molder can often encounter problems with differences in mold halves causing part variations. With the NIIGATA Vertical, two completely independent injection profiles can be set for the “A” and “B” halves, allowing the molder to finish the job without making expensive and time consuming mold repairs or adjustments.

Niigata MD110S7000 horizontal all-electric injection press, NPE Booth W-1363

NEW: NIIGATA MD110S7000 horizontal all-electric IMM

Having introduced our first fully-electric machine at the Japan Plastics Fair in 1984, NIIGATA has devoted 100% of its R&D resources toward improving all-electric molding machine technology. Using the Japanese Kaizen system, we are now introducing our 7th generation of the all-electric machine, built entirely in Japan to tough quality standards.

A few NEW features of the MD110S7000 all-electric IMM include:

~Elimination of moving platen’s lower side tie bar bushings to improve the cleanliness of the part drop area.

~Addition of an FDA-approved grease supply system that allows medical cleanroom and food grade applications with fewer worries about part contamination.

~NIIGATA’s standard high nozzle touch force, similar to that of the hydraulic machines, can now be dialed down when the application allows, to promote longer sprue bushing life.

~Fully automatic and adjustable mold clamping force is continuously monitored by tie bar sensors.

~NIIGATA’s horizontal machines boast the industry’s shortest footprint, but heaviest overall weight to provide superior machine durability.

Also in the Niigata booth…

NIIGATA MD385W6000 all-electric IMM:

NIIGATA’s “workhorse machine”, the MD385 is being exhibited running a drink cup mold provided by a customer, together with an impressive IN-MOLD LABELING SYSTEM manufactured by Campetella of Italy. See and learn more about the MD385 HERE and at the show!

Also running during the show…

NIIGATA MD55S6000 all-electric IMM:

NIIGATA’s small size all-electric press will be exhibited at the booth of LUBE Corp. USA ( #W-2389). This machine will have clear covers, highlighting the automatic lube system of the machine. ( http://lube-global.com/english/)

Don’t forget! NPE, Booth W-1363

For more information on all these developments, please contact:

Peter Gardner
Vice President Sales and General Manager
NIIGATA Operations North America
DJA Global Group
939 AEC Drive
Wood Dale, IL 60191
Phone: 630.875.0202
Fax: 630.361.6060
E-mail: peter.gardner@niigata-us.com
Website: niigata-us.com
Connect with NIIGATA online:

Major Tool & Machine, Inc. retrofitted two of their machining centers in 2010 changing to a CNC technology platform that was completely new to the company. Ten more such large-scale retrofits have followed, bringing increased enthusiasm, momentum and productivity.

Major Tool & Machine has been on track to retrofit over a dozen of its giant milling and turning machines within just two years, all supported by a new Siemens CNC platform. MTM’s management says the process has been an empowering experience for the company.

CNC upgrade enhances performance and precision

Major Tool & Machine (MTM) is a large job shop, producing precision milled and turned hardware throughout the company’s 500,000 square foot Indiana facility. Performance is essential, because MTM contracts with aerospace, energy, nuclear and defense companies on many mission-critical, one-off projects. Owner and CEO Steve Weyreter will tell you openly, MTM is more competitive by way of a significant CNC technology change, starting with an aggressive retrofit strategy.

Günther Zimmermann, CNC Controls Engineer at MTM, says the company’s retrofit program and the decision to change to the Siemens SINUMERIK CNC platform have brought a new enthusiasm and momentum to the company. Over the last two years the change has also brought significant time and cost reductions, especially in the areas of programming, maintenance engineering, and machine operations.

“The initial goal in early 2010 was to retrofit two Cincinnati U5 Gantry machines,” Zimmermann recounts. “We evaluated two CNC technology platforms and after considerable analysis our CEO Steve Weyreter announced that Siemens would best support the company’s future.”

The decision to reduce costs by moving to a single CNC platform was the least difficult decision for the company to make, Zimmermann explains. The larger challenge for MTM was the integration of a new CNC technology platform that was new to the company.

Bill Henderson, MTM’s manager of large machining and maintenance, agrees that the decision to change to a Siemens CNC platform integrated with advanced part and tool probing was critical, because the shop manages constant changeovers from one complex job to the next, making setup times a critical time/cost constraint for the company. Another big advantage is the increased flexibility by only having to train machinists and maintenance personnel on one type of control.

Henderson went on to say “the decision to change to a new control has signaled higher expectations for the company, along with new challenges for those who program, operate and maintain the company’s big machines.

Naturally, there’s a resistance to change,” Henderson says. “People are comfortable with what they normally run, but after our discussions with the people on the plant floor, they understood the overall objective. Our retrofit program is not finished, yet it’s already showing tremendous benefits.”

An advantage MTM gained by its retrofit strategy has been the ability to interchange heads and rotary tables from machine to machine. Easy-to- use head storage and tool management programming provided by the Siemens CNC platform support the new interchange capability.

Retrofitter Doug Huber says having Siemens as a new CNC technology partner has made a difference for Major Tool & Machine, but it’s also been an evolutionary uplift for his own retrofitting company, Indiana Automation.

“Indiana Automation has increasingly retrofit using Siemens controls in recent years, Huber explains. “On a retrofit, we always try to exceed what the original machine could do, and that’s just kind of inherent when you put on a Siemens 840D. Major Tool’s first retrofits were the Cincinnati U5 machines, a bridge model and two gantry models. These are five-axis machines and five-axis is the 840D’s forte. The processing power of the control is so much better, that it just whips through the blocks faster. So right off, cycle time is a major performance enhancement.”

Huber says something else happened this time. As his firm finished retrofitting the first three giant machines with Siemens five-axis controls, drives and motors, the reaction within the company was not just that the machines were now predictably more efficient, but that they performed as very different machines. A new advantage is the ability to interchange machining heads from machine-to-machine, and all driven by the Siemens CNC platform.

Central to MTM’s retrofit program has been the Siemens SINUMERIK 840D sl control, which features the SINUMERIK Operate interface. The highly intuitive interface enables both programmers and operators to easily capitalize on the broad capabilities of the control.

“On many of the U5 machines, the axes come off with the heads,” Huber explains, “and we rebuilt these machines to accept any one of three different heads. That’s one of Major Tool’s key strategies. They insist on having flexible machine capabilities, so that they can run all kinds of different parts. They have straight heads for serious metal cutting, contour heads for five-axis work and finesse work. They have 90-degree heads for more flexibility than a straight head, but it’s also not as fragile as the contour head. And they wanted to interchange all of these heads to automatically go pick up a head out of the shuttle and, on the fly, reconfigure the axes and the zero positions. To do this, the compensation tables all had to be updated. Everything needed to be done with the macro program so that each head came on ready to run.”

The interchangeable head strategy was a challenge, Huber says, because the machines were not originally capable of sharing heads. But with support from Siemens, the strategy has worked, including the ability to interchange rotary tables as well as heads. “Each head or rotary table has a configuration file that has all the settings and compensations and travels with it from machine to machine. So now when you mount that head the control just runs the configuration file that goes with it and its all set up for you. We also incorporated Siemens Tool Management for each machine’s 60-pocket tool chain. We used the feature on these machines to manage all the different tooling MTM uses, both in the automatic tool changer as well as the ones manually loaded.”

Huber says, “MTM’s ability to smoothly transition to more advanced CNC is largely due to the HMI’s ease of use. The Operate interface is a huge help to us and to Major Tool. The HMI helps make better parts. And it didn’t take very long for the operators to fall in love with it.”

Programming as easy as 1-2-3: Using the SINUMERIK Operate interface, a machinist can turn on coolant flow by 1) pressing Cycle Stop to stop the machine, 2) Coolant On, and 3) Restart.

“I had never used a Siemens control before,” admits MTM machinist Mike Burthay. “I have extensive knowledge of G-code and CNC controls and I would say the Siemens 840D sl with the Operate interface is the easiest one I’ve ever run. It’s user friendly, that’s exactly the words for it.”

Burthay reports several ways in which the Siemens SINUMERIK Operate interface has made his life easier. “There’s not as much G-code,” he says. “The control does it all for you as long as you put in the parameters as to size, length, width. Then once you’re in Job Mode, there’s a screen where you can tool change or jog the machine around to certain positions, or turn the spindle on, turn the coolant on, anything that traditionally required G-code. So now you can push a cycle stop button to pause the machine, enter a change such as turning coolant on, then restart the program.

“Another function I love is Block Search, which allows me to start or restart right in the middle of a program. Say you’re finishing a pocket and you have to run the tool two or three times to get a tight tolerance, I can enter in a line number and hit Block Search, the control picks up every line before that, restarts the spindle and everything for you.”

Burthay says the Siemens control also enables him to program parts right on the machine whenever necessary, using a simple yet robust program called ShopMill. “I can go into ShopMill, type in some parameters and it will kick out that G-code program for me automatically. Say I want to drill a hole two inches deep. I open ShopMill, pick my tool, tell it the depth and these steps are all interactive on the screen. It even shows me 3D motion images of the tool path, confirms the drill going down as expected into the part. So I hit go and it puts a drill cycle into the program for me.”

Programmed for collaborative growth

Lead Programmer, Tim Hayden, has from the beginning conducted all processor setups for the newly retrofitted machines. Hayden says integrating the Siemens CNC platform has been an empowering experience he had not expected, given the fact that he had never before set up a post processor to run a Siemens control, nor had he ever before operated a Siemens control.

“Now, when I look at the Siemens control, I think man, it would have been so much better to have had it all along,” Hayden says, “because the other control I’ve been using is just a lot more cryptic. The Siemens control with the SINUMERIK Operate interface is more powerful for writing macros and the language seems modern, whereas the other control seems like it is still based on an old FORTRAN type language.”

Work offsets for compound angles can be scaled and rotated using the Frames function of the Siemens SINUMERIK Operate interface. Many advanced machining operations can be managed simply, without the use of time-intensive manual G-code programming.

Hayden points to the Frames coordinate and offset programming function of the Siemens interface as an example of improved programming convenience.

“We do a lot of work on compound angles,” Hayden explains, “and with the Siemens Frames function, you can scale and rotate your coordinate system on the control, just plug it in with your work offsets. Whereas, on the other control you will see a G54 request, you’ve got to enter G-code. You can’t just plug it into your work offsets like you can with the Siemens control.”

Hayden says the SINUMERIK Operate interface brings greater programming flexibility. The HMI enables him to enter G-code using a comparatively more advanced manual data entry (MDI) function; however the HMI has all but eliminated the need for G-code entry by way of its intuitive design and evolved capabilities.

Another example of such HMI evolution is in the area of data management.

“When we post a program, we no longer have to use a G-code based MDI,” Hayden explains. “We no longer need to type in T= and enter a nine digit number and then enter M6 to make a tool change. With the Operate HMI, you pick your tool off a screen and hit cycle start. It’s just as easy to program going to a position. Instead of doing things the old way by typing G0X0Y0Z0 into the MDI, you open the Operate interface, click position, then click how you want to wrap it and then you just type the numbers into those fields. So it’s a lot more user friendly.”

Hayden says the Siemens CNC platform has supported greater collaboration at MTM between him and the machinists, and this is helping the company find ways to increase performance and efficiency. He agrees with his coworkers’ assessments that shorter setup times and greater operator freedom are making a significant difference.

“One of our production bottlenecks has been programming,” Hayden says. “The machinists that run our machines are professionals, they’re not button pushers, and with the SINUMERIK Operate interface, we can now rely on them to control and program certain parts right on their machines, while we programmers work on the more complex projects.”

“Siemens was the best fit for all of us,” Hayden concludes. “Siemens CNC is set up as an open control, and with that kind of flexibility, it seems anything is possible.”

For more information on Siemens SINUMERIK CNC, visit www.usa.siemens.com/cnc.

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

Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.

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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit. For more information, visit http://www.usa.siemens.com/industry.

The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability. For more information, visit http://www.usa.siemens.com/drivetechnologies.