Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
See the MJC video HERE.
Custom machine tool builder in California contracts with research center at university in Glasgow, Scotland to design specialized equipment for forming new jet engine structures; machine completely controlled by Siemens CNC
AFRC facility performs fundamental and applied research on the forming and forging of metals, primarily for aerospace applications. A full battery of materials and performance testing is conducted at AFRC by a team of materials and process experts
MJC Engineering is a custom machine tool builder, specializing in metalforming machines for such applications as spinning, flow forming, wheel spinning and rotary forging. The company was recently contracted by the Advanced Forming Research Centre (AFRC) at the University of Strathclyde in Glasgow, Scotland for a very unique application, namely, a cold-forming rotary forge press that works the material between two synchronized rotary dies. The dies operate in angle from the parallel. Typically, the angle is fixed but, on this custom designed machine from MJC, the angle is fully programmable. This configuration allows compression in a concentrated area and provides a more efficient method for metal deformation, while producing superior mechanical properties in the finished section. Up to 90 percent material savings can be achieved by the use of this revolutionary metalforming technology, in comparison to conventional machining from a solid blank.
Operator loads workpiece during test run-up on machine; very hard aerospace materials such as Hastelloy and Inconel are typically processed
The aim of this new CNC technology, according to MJC company president Carl Lorentzen, is to make the aerospace engineers rethink how they design their products, so that a maximum material savings on exotic and costly metals can be realized.
Rotary forging can be defined as a two-die forging process that deforms only a small portion of the workpiece at a time, in a continuous manner. The reduced instantaneous area of tool and workpiece contact means lower forging forces are required to cause deformation in the material. Typical components for rotary forge operations are round or cylindrical hollow parts that deploy expensive or exotic alloys, require extreme material property targets or involve very complex geometries. At AFRC, the rotary forging machine provided by MJC is processing AerMet® 100, Inconel 718 and Allvac® 718Plus®, Ti-6Al-4V as well as the creep-resistant Ti6242 and some beta alloys.
New rotary forge press from MJC, built specially for the Advanced Forming Research Centre (AFRC) at the University of Strathclyde in Scotland. Two independent and synchronized rotary dies are fully programmable on the Siemens CNC to affect 0-45º pitch angles
Onboard the machine, the bottom and top spindles pivot from 0-45º, operated by AC vector motors and drives, plus an overall motion control CNC, all provided by longtime supplier to the builder, Siemens. The CNC is a Sinumerik 840D, which controls all the axis and spindle motion, hydro and servo positioning valves, plus the synchronization of up to four cylinders for the integrated motion of the rotary dies. In the processing of the workpiece, the control is monitoring all machine conditions, while maintaining the synchronized angles of the twin rotary dies.
Siemens CNC controls the entire machine process
Programmed motion sequences on the machine must be maintained with high precision to avoid improper deformation of the materials during the cold-forming process. In a manufacturing environment, where the high production output of parts is critical, this process must remain extremely well-regulated, documented and monitored. The CNC has the capability to upload all data in real time.
The unique operation of this MJC rotary forging press involves the application of pressure on a small portion of material at a time, reducing stress and saving up to 90% in material, compared to subtractive machining from a solid blank
Carl Lorentzen comments further on this MJC development, “Though the concept of the rotary die forge is certainly not new, the computer-controlled synchronized dual rotary dies on this machine offer a number of unique advantages in the cold-forming process of metals. The idea originated in a somewhat different form in the automotive market with the development of a front wheel hub hollow shaft. The cold-forming of metal around a bearing was combined with robot loading in production. The concept, combined with the Siemens CNC and its ability to control all the motion so precisely, made the development of this machine more practical for us.”
MJC is a custom machine tool builder, with equipment currently serving in the military, aerospace, general metalforming and automotive after-market segments of industry. The company is a member of PMA, NFTC and AMT.
The AFRC is jointly sponsored by the Scottish government, Scottish Enterprise and a variety of international aerospace manufacturers and engineering firms, including Boeing, Rolls Royce, TIMET, Aubert & Duval and Barnes Aerospace. It has operated as a world-class facility, supporting fundamental and applied research into the forming and forging of metals, since 2009. Having doubled in size recently, AFRC is expanding its market applications into the automotive, energy and marine markets. The center can currently heat, shape, finish, measure, test and analyze all types of metal materials and components in-house. The research done here comprises investigations into residual stress, die life, process characterization, materials characterization, heating and thermal processes, super-plastic forming, sheet forming and related technologies in automation, metallurgy and metrology.
The key challenge for AFRC, according to its website, is to take low maturity technology developed in a university environment and successfully deploy it into a manufacturing facility.
See the video of MJC @FabTech HERE.
For more information on this story, please contact:
MJC ENGINEERING & TECHNOLOGY, INC.
15701 Container Lane
Huntington Beach, CA 92649
Phone: 714-890-0618
Fax: 714-895-3561
Web: www.mjcengineering.com
Email: clorentzen@mjcengineering.com or carlson@mjcengineering.com
Attention: Carl Lorentzen, President or Per Carlson, VP
or
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarcom.industry@siemens.com
Attention: John Meyer, Manager of Marketing Communications
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.
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.
Causes, effects and control
This whitepaper covers definitions, harmonic generation, effects of harmonics and control of harmonics. It also addresses general awareness of power system harmonics, their causes, effects and methods to control them especially when these harmonics are related to variable frequency (or adjustable speed) drives.
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For more information, please visit www.usa.siemens.com/motioncontrol
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.
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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.
Continue readingNew CU250S-2 control unit now in stock; supplements existing Siemens G120 drive with universal vector control and encoder feedback
Siemens Industry, Inc. announced today the availability of the new Sinamics CU250S-2 control unit for use with its popular Sinamics G120 variable speed drives. The unit provides vector control with encoder feedback. Additionally, the operation of single-axis applications with exact speed and torque control on induction motors, as well as positioning tasks with high demand on I/O, are supported, with different encoder interfaces provided on the module. These new units complete the G120 product portfolio and replace the CU240S with encoder interface.
Typical applications for these new control units include single drives with a large number of I/O or those with high speed control requirements, including extruders, centrifuges, wire-drawing machines, basic fabric webs, conveyors, lifters and others in markets ranging from automotive assembly, textiles, printing and chemical processing to nearly all conveyors and material handling.
The new Sinamics CU250S-2 control units can be combined with existing power modules to support all G120 drive applications, with or without encoder evaluation, for demanding applications requiring speed feedback. Additionally, STO (Safe Torque Off), SBC (Safe Brake Control) and SS1 (Safe Stop 1) features are all integrated, enabling their application on basic safety requirements. With the purchase of an optional software license, extended safety functions can be obtained, along with software for a single positioning function (EPos).
Comprehensive communications interfaces for general machine building are provided on this new Sinamics control from Siemens, including Profibus DP, Profinet (Ethernet I/P), RS485 (USS protocol, Modbus RTU) and CANopen, allowing convenient connection to other Siemens systems as well as external automation systems. No external gateway is needed.
Other features include an integrated USB port, so users can simply go online to facilitate engineering set-up and maintenance, plus an integrated slot for an SD card to allow simple cloning and firmware updates or upgrades.
For more information about this line of Sinamics control units, please visit: www.usa.siemens.com/sinamics
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.
Continue readingThe art of organ building at the highest level with modern CNC techniques…
Laukhuff relies on five-axis milling center from Spinner with Sinumerik 840D sl for small-series production
Walter Rhein, Manager of Cutting Applications at Laukhuff
At Laukhuff in Weikersheim, Germany, tradition and modernity merge together in a way that can not merely be seen, but also heard. The family-run company, with almost 200 years of history, is the international leader in organ building – as a supplier to the best-known organ builders and a provider of its own complete instrument developments. The company operates on a global level with 150 employees, considering itself an artistic crafting enterprise rather than an industrial company. Company CEO Hans-Erich Laukhuff emphasizes, “In our carpenter’s workshop and when manufacturing organ pipes, we are hardly able to use any machines because 90 percent of the work must be done by hand. When it comes to cutting, however, this is a different matter. Here, we can use modern milling and turning machines with innovative CNC equipment, so that we can keep productivity levels as high as possible.”
Walter Rhein is very satisfied with the five-axis Spinner U5-620 with Sinumerik 840D sl
If required, these masters of organ building will supply everything from a single source. Laukhff further explains, “If requested, we will take on all the tasks involved in the design, the manufacture of individual parts and the installation onsite. We even make the bench seat and the key lights ourselves, as there are no usable, satisfying solutions in the market today.”
The high level of perfection shown by this organ builder is reflected in the optics, in the haptics (touch and feel) and naturally in the sound of the instruments. It also has a positive effect on their reliability. After all – quite unusual in these fast-moving times – it is typically not necessary to plan the replacement of a Laukhuff organ for more than 100 years. However, a few spare parts will still be required.
Despite the fact their high quality is globally recognized, this family-run company is still facing constant cost pressure. To achieve a high throughput in cutting applications, the company uses five CNC turning machines and three CNC milling machines – together with their latest acquisition, a five-axis CNC center (3+2) from Spinner’s U-series, with a state-of-the-industry Siemens Sinumerik 840D sl CNC onboard.
Impressive price-performance ratio
With the Sinumerik-controlled Spinner U5-620, Laukhuff uses new options for the more productive manufacturing of organ components, such as chimes
Company owner and CEO Hans-Erich Laukhuff and Production Manager Walter Rhein already had positive experiences with the CNC. However, since mid-2009, they have been relying on the Spinner machine tool factory in Sauerlach, Germany for the first time and using the U5. According to the production manager, this decision was based on the price-performance ratio and the small space required by the machine in contrast to comparable machines from other manufacturers. The U5-620 only needs 2000 x 2400 millimeters of surface area, but achieves travel distances of 620/520/460 millimeters in the X/Y/Z-axis direction.
The new Spinner machining center has high-quality individual components, including 32 tools as standard, a double arm for rapid tool changes and linear axes on roller bearing guides. Michael Schulz, Spinner sales representative at Hollenbach GmbH, confirmed, “This enables us to achieve rapid feed speeds of 48 meters per minute in all directions. Even in terms of accuracy and surface quality, our U-series sets a very high standard.”
In terms of the productivity and quality increases that can be achieved, as well, the organ builder expects the acquisition of the Spinner machine to be amortized within a relatively short period of time. Ultimately, an organ builder will often manage without time-consuming retooling, as Rhein noted, “In the cutting applications for our organ pipe tuners, we previously had to retool three times and needed around 13 minutes just for clamping – which doesn’t even take into account the downtime while retooling. The five axes mean that production is now possible in a single clamping, within about eight minutes per piece. All in all, we are at least twice as fast as a result.”
Graphically-animated user interface
Like many medium-sized contract manufacturers, this organ builder’s employees also program directly at the machine. CNC specialist Kurt Stüdlein is totally convinced about the Sinumerik 840D sl because, “…it is powerful, safe to operate, user-friendly and reliable. But the CNC user interface, tailored to shopfloor programming, also scores highly, being graphically-animated and logically-structured. ShopMill, the resident software suite, is great, particularly for beginners. Production Manager Rhein further explains, “Even a fitter who has only just finished his training, without any extensive programming experience, can work with it, after some brief instructions.”
CNC professional Stüdlein adds, “Even on complex components using the 3+2 axis machining, I can create lots of programming steps with ShopMill. If I reach the limits when entering certain contours, or if I am quicker with DIN, then I can switch from the graphic to the text-oriented DIN interface at the touch of a button.” For additional employee safety, the Safety Integrated software solution is also built into the control. This means that it is possible for the user to safely track his program’s production process in setup mode with the machine doors open.
Laukhuff is certain, based on the experience gained, that he has made the right decision with the Spinner-Siemens CNC combination. The technology and the continuously fast service from both companies have convinced him, “If there is a problem, we are helped very quickly – which is not always a given with other manufacturers in this particular industry.”
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.
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.
Continue readingPress Conference for the Americas — EMO Hannover / Hall 25, booth D33
Broad-based CNC competence: Siemens will be demonstrating how productivity, flexibility and safety can be increased in CNC production with an array of smart additions to its Sinumerik portfolio.
Industrial corporations are facing deep-rooted changes in the world of manufacturing. These changes are taking place alongside increasing integration of product development and production processes with the benefit of innovative software systems and high-performance software — a decisive step on the road toward a new industrial age in manufacturing. “Siemens has invested a lot of work in the integration of automation technology along the entire value chain over a period of many years, and is playing a cutting-edge role in shaping the future of production,” stated Bernd Heuchemer, Vice-President, Global Marketing and Communications, Siemens AG, Drive Technologies Division, Motion Control Systems Business, at a press conference held in the run-up to the EMO 2013 recently. “In the Sinumerik environment in particular, and consequently in the field of CNC production in general, Siemens has been heavily involved for many years already in the area of simulation and the virtual machine, as well as the integration into factory IT systems. Our aim is to drive this process of integration forward to ensure that the field of machine tool construction is also prepared to embrace the next step in the industrial revolution,” continued Heuchemer.
With its Sinumerik family, Siemens offers an integral portfolio of CNC for everything from simple machine tools through standardized machine concepts to modular premium solutions, complete with “smart machine” solutions for the economical manufacture of high-end workpieces. It is working towards the consistent expansion of this CNC technology expertise. “In the future, production models will demand ever greater productivity, flexibility and efficiency, while at the same time expecting simplified machine operation and production sequences. As it continues to develop the Sinumerik CNC portfolio, Siemens is working to satisfy all these expectations,” said Rajas Sukthankar, General Manager, Siemens Industry, Inc., Machine Tool Systems Business. The innovations presented by Siemens at the EMO 2013 will consequently focus on smart function improvements, which will make for greater CNC operating convenience, increase precision at the workpiece and allow greater machining safety across every category of machine, from the compact to the high-end solution. A new function to protect against unwanted component collisions will be showcased by Siemens, for example, alongside improvements to its cohesive Sinumerik Operate user interface, including upgraded simulation options.
The Sinumerik CNC portfolio is additionally playing an increasingly important role in preparing the ground for the next step in the evolution of CNC production, also within the framework of the Siemens Integrated Drive System (IDS). With a view to optimizing the addition of value across the entire process chain through consistent integration, IDS is used to integrate all the components of the drive train consistently into the complete production process environment. This also applies to Sinumerik CNC system solutions.
For every Sinumerik application, ideally coordinated system components such as high-powered Sinamics drives and Simotics motors have always been used as the ideal complements. Alongside horizontal integration of the entire drive train, with Sinumerik Integrate for Production, Siemens is also allowing vertical integration within the control architecture of industrial manufacturing automation. As the example of a leading passenger car manufacturer illustrates, this type of vertical and horizontal integration within the production process can speed up the series start for a new vehicle by up to 50 percent.
The integration across the entire product life cycle can in turn be implemented using suitable Product Lifecyle Management (PLM) software solutions from Siemens. This concept is already being implemented by leading metals processing industries such as the automotive, aerospace and medical technology sectors. This entails the increasing execution of product development and production planning onscreen, before a single machine tool has even been installed. If a modular machine is developed on a virtual basis right from the outset so that it can be fully simulated, time savings up to 40 percent can be achieved. In running operation, productivity increases of 10 percent or more are also made possible by continued simulation and optimization. At this year’s EMO, Siemens will be showcasing the further development of its PLM software, which encompasses scalable solutions for component production and further improved IT integration from the workpiece model through to the machine tool. Siemens will also be revealing the next stage in productivity for NC programming with the further development of its already popular PLM software, NX CAM. Going forward, this software will include special industry-specific machining functions as well as access to a new Manufacturing Resource Library.
Siemens is extending its preparations for the next step in manufacturing to offer the machine tool building industry an emerging series of integrated solutions. An integrated workpiece measurement system, with a measurement accuracy of 30 nanometers deployed in the world’s biggest precision optics machine, allows the production of telescopes capable of seeing up to 13 billion light years into space.
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.
During EASTEC 2013, Siemens will present its newest solution for the job shopfloor, the Sinumerik 808D, an attractively-priced CNC for entry-level milling and turning machines.
Over 50 years of Siemens CNC experience have been brought to the development of this control, which is specially designed for the highly competitive, high-volume 230V, three-phase and economy machine tool market. With up to three-axis plus spindle control capability in milling or turning applications, the 808D is offered as a package with Siemens Sinamics drives and Simotics motor solutions. The Sinumerik 808D will be immediately available for OEM machine tool builders and in-the-field retrofit installation by Siemens business partners worldwide.
FOR MACHINE TOOL BUILDERS
Start with an IP 65 enclosure, easy-to-load USB port, mechanical, hot and soft keys for easy, intuitive operation, clamp-mounted front panel and a modular design that allows customizing by machine model or with out-of-the-box operation. Plus, the machine control panel is connected using plug-and-play technology using a simple USB interface. On a turning machine, the Sinumerik 808D provides high contour accuracy and maximum machine productivity on high-volume production runs. On a milling machine, likewise, the Sinumerik 808D offers machine builders of vertical machining centers all the benefits of the Siemens MDynamics velocity control for mold and die section work.
A 7.5-inch LCD color display with 640 x 480 resolution for easy reading, selectable function keyboard, rotary dials for speed and spindle override, LED tool number display, durable buffer battery and rear connection ports for USB, RS232 C, distributed and onboard I/O, setpoint to feed axes and spindle, spindle encoder, fast I/O, e.g., for probes and handwheel operation are all standard on the Sinumerik 808D.
With 80-bit nano floating point accuracy and intelligent jerk limitation for smoother path cutting and less mechanical stress on the machine structures, workpiece accuracy and repeatability are improved. Whether turning with a C-axis changeover or milling mold sections where path control is paramount, the Sinumerik 808D has been designed to significant heighten the performance level of basic machine tools.
With programGuide Basic, a wide range of pre-determined technology cycles are available, in addition to the standard G-code and coordinate transformation language. Standard ISO codes can also be intermixed with high-level Sinumerik CNC commands on the 808D. The onboard contour computer further allows complex programs to be created and modified at the CNC without the need for a CAD/CAM system.
For routine or even online help with maintenance or troubleshooting issues, a simple push of a button is the only requirement, as the complete library of system parameters is accessible onscreen.
Commissioning is made easier with a ready-to-run PLC program. Customizing the PLC is simpler, as well, with function and data blocks for program testing and debugging built-in. The Sinumerik 808D further allows easy connection to the PLC I/O of other machine devices, whether proximate or remote. The open architecture of Siemens CNC has not been sacrificed on the 808D, so customized HMI screens and menu trees are easily defined and created.
Finally, with Manual Machine Plus (MM+) function on this new CNC enables transition from conventional machining to CNC programming. A machine equipped with MM+ can be operated using handwheels but with all the benefits of CNC-assisted technology cycles.
The Sinumerik 808D is offered with full THREE-YEAR WARRANTY on parts and labor.
FOR END-USERS
In addition to the above features and benefits for the machine builder, shop operators and programmers alike will appreciate the Sinumerik 808D for its many end-user advantages, including simplified keyboard entry of all program values, named part programs in subfolders just like a PC, convenient shortcut keys to access tool offset lists or the Program Manager, intelligent jog features easily identified and graphically-supported, precise tool handling and tool wear data readily available onscreen and a powerful simulation routine. An operator can access all system information and obtain online help, whenever needed.
The multimedia training materials include on-screen tutorial video and full step-by-step procedures to go from the blueprint to the finished part. For offline training, a fully operable software machine control panel on a PC is available to end users.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
Continue reading
At this year’s EASTEC Show in West Springfield, MA, Siemens will demonstrate new versions of its popular, compact CNC for the job shop, the Sinumerik 828D.
SINUMERIK 828D BASIC T
The Sinumerik 828D BASIC T is designed to address the needs of shopfloor turning machines.
It combines CNC, PLC, operator panel and axis control for five axes/spindles, including live tooling. Milling and drilling operations on a turning machine, both for face and peripheral surfacing, are therefore possible. In tandem with the new Sinamics S120 Combi drives package, the 828D BASIC T represents a new level of efficiency and virtually maintenance-free operation, as the fans, hard disks and batteries of past CNC generations have been eliminated.
With rugged diecast magnesium front panel on an IP65 enclosure, the BASIC T enables an Ethernet connection, USB or Compact Flash (CF) card program loading. An 8.4-inch color display for easy readability and simple QWERTY keyboard provide fast ramp-up for the operator. Various communication ports in USB, Ethernet, Drive-CLiQ, PLC I/O interface, RS232 C and NC inputs/outputs are standard.
In operation, reliable 80-bit nano accuracy means contour control precision and a better workpiece, every time, while Siemens intelligent kinematic transformations provide the proper orientation of machining plane to work surface.
Though simple command language is provided for operator ease, the BASIC T functions with the highest level of ISO programming language. Established cutting cycles can be utilized with fully Animated Elements for the faster visualization of part production on various levels with combinations of Sinumerik CNC and ISO programming languages possible, as well.
SINUMERIK 828D BASIC M
Similarly, the new Sinumerik 828D BASIC M class features the same quality performance as the T class, but for use on milling machines. Even in complex moldmaking operations, mirror-smooth surfacing and reduced machining times are enabled. Again, in tandem with the Sinamics S120 Combi drives package and Simotics feed and spindle motors, the 828D BASIC T will operate a milling machine at the highest level of performance possible. Superior axis and spindle dynamics within a broad speed bandwith yield quality workpieces, every time.
All the other benefits of the Siemens CNC family, including the Sinumerik Operate graphical user interface platform as well as ShopMill and ShopTurn easy programming are offered in these new 828D CNCs.
SINUMERIK 828D
The Sinumerik 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. This control family is ideal for single-part and small-batch production. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical workstep programming systems, while high-level language programming can be used in conjunction with programGuide to significantly reduce programming times for large-scale serial production.
Also included with this expansion of the Sinumerik 828D family of CNC, modern PC and mobile phone technology are also available for the mid-range machine tool. Extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate data networks.
Through the use of its Easy Message functionality, the Sinumerik 828D family offers production status monitoring by text messaging (SMS). Depending on the recipient’s profile settings, the machine tool can transmit information about workpiece machining status, report on the tool condition currently
in use and send machine maintenance bulletins to a mobile phone, anytime and anywhere. These combined functions are designed to help keep machine downtime to a minimum.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on this story, please contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
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Turning-milling centers with coordinated drive and CNC engineering achieve superior accuracy and repeatability
Hamuel CEO Dr. Markus Stanik (right) and his sales manager Jochen Schaede agree: “The Sinumerik 840D sl CNC complements perfectly the capabilities of our five-axis turning-milling centers in the HSTM Series. Because of this fact, we can usually convince leading turbine manufacturers from the aerospace and automotive industries about the dynamics, high-performance and precision of these machines.”
The complete machining of turbine blades requires striking a balance between powerful roughing and ultra-precise finishing, a task for which the modern five-axis turning-milling centers are ideal, when robust machine construction is combined with high-quality drive and control engineering. Experience is the solid basis on which the Hamuel Maschinenbau GmbH & Co. KG, Meeder, Germany, can offer a great deal: with 85 years of machine tool manufacturing, 35 years of CNC machining, 25 years of five-axis simultaneous machining and over 10 years in the construction of five-axis turning-milling centers. CEO Dr. Markus Stanik knows that experience by itself cannot be any yardstick for the quality of machine tools, noting, “It certainly helps us, together with the right partner companies, to design and build the machines so that our customers can be successful in the marketplace.” This machine builder and its many customers have developed correspondingly positive accomplishments together. Today, Hamuel stands on three standards:
The latter, as evidenced by Hamuel’s HSTM (high-speed turning-milling) series, has been marketed since 1999 and makes a decisive contribution to the sales and success of the company. Leading turbine manufacturers from the aerospace and power-generating industries have been particularly impressed by the dynamic response, capability and precision of these machines. Even the smallest faults are unacceptable on turbine blades
Form deviations are unacceptable for products such as turbine blades and blisks because even the smallest error would significantly reduce the efficiency of the power plant or aircraft turbine.
The HSTM that runs on the Sinumerik 840D sl CNC controllers is used mainly to manufacture turbine blades and blisks (turbine disks) deployed in stationary steam and gas turbines as well as in mobile turbines for aircraft jet engines and large turbochargers. These products always consist of high-strength materials, such as titanium or high-alloyed steels. Form deviations are taboo in such applications, because even the smallest error would significantly reduce the efficiency of the turbines. Correspondingly high and comprehensive are the requirements placed on the machine tools. Hamuel sales manager, Dipl.-Ing. Jochen Schaede, explains: “Our customers normally manufacture large turbine blades longer than approximately 1000 mm from forging blanks. In contrast, shorter workpieces are milled from a solid piece of material with a stock-removal ratio of approximately 80 percent. This makes it obvious that our machines must not only rough-cut very productively but also finish with high precision.” Whereas productivity takes precedence for rough-cutting, accuracy is more important for the subsequent finishing of the spatial free-form surfaces. “With regard to accuracy, our high-performance machining centers achieve a precision in the micrometer range coupled with excellent surface quality,” added Schaede.
Form deviations are unacceptable for products such as turbine blades and blisks because even the smallest error would significantly reduce the efficiency of the power plant or aircraft turbine.
Key to this capability is the combination of compact machine construction together with perfectly matched drive and control engineering. The basis is the robust machine design with a one-piece machine base – either as welded construction cast with special concrete or latterly directly as polymer-concrete made from a single piece of material. The careful distribution of the masses ensures the best dynamic rigidity. The experience of the developers at Hamuel paired with the knowledge of the Siemens mechatronic experts make such results possible, as Jochen Schaede confirmed: “Thanks to various simulation tools, the Siemens engineers could provide us with very exact data to which we could add or remove masses. It was certainly advantageous that we could procure all components required for the dynamics from Siemens starting with the spindle, including the axis drives, and ending with the CNC. This means we needed only a few iteration loops in order to obtain a perfect dynamic rigidity in the machines.” It is also important that all components are arranged so that the horizontally clamped turbine blades and blisks can be machined optimally. This is also facilitated by the 45°-inclined orientation of the axes that ensures a favorable swarf removal further augmented by the permanent rinsing of the machine internal area. The accessibility has also been enhanced by this inclined axis orientation. Such designed and built HSTM machines equipped with precise direct drives from Siemens achieve a maximum positioning accuracy of 5 µm with traversal speeds exceeding 40 m/min in all linear axes. Indeed, the extremely fast rotary axes have a positioning accuracy of 3 µm. This allows the user to achieve maximum productivity, accuracy and surface finishes in the range of Ra = 0.8 µm, and so fully meet the industry requirements placed on the blade machining. CNC ensures optimized surface transitions at the inlet and outlet edges One of the biggest challenges for the turbine-blade manufacturing industry concerns the critical surface transitions (leading and trailing edges) of the turbine blades. To achieve a high quality, the milling paths described with curve interpolation points must have a constant machining speed. As a consequence, the leading and trailing edges demand extreme angular accelerations. The number of curve interpolation points to be described is correspondingly quite high.
The manufacturing of precise free-form surfaces for turbine blades demands the highest performance from the CNC. The excellent block-cycle times of the Sinumerik 840D sl and its look-ahead function improved as part of the new “Advanced Surface” motion control, which play a significant role here.
The controller now faces the challenge to reliably process the generated NC steps that are supported by the fast block cycle times and the look-ahead function of the CNC. “Hardly any other controller can supply the drive information for all five axes in the required short time as reliably as the Sinumerik 840D sl controller,” confirmed Jochen Schaede, who added, “The new Advanced Surface motion control that includes among other things an optimized look-ahead function is also excellent. And I would also like to mention the five-axis high-speed turning-milling of free-form surfaces requires a continuous spatial reorientation of the geometry vectors.” This leads to the use of the Traori (transformation orientation) principle in the Sinumerik 840D sl. Hamuel’s customers can therefore achieve reproducible results with the best-possible surface finish, exact contour accuracy and with the maximum possible machining speed.
Despite being a high-end controller that offers many modern features, the Sinumerik 840D sl CNC is easy-to-use.
In addition to the primary properties of precision, productivity and reliability, Hamuel also appreciates other properties of the Siemens drive and control engineering – an example: the DRIVE-CLiQ interface. When this digital connection is used, all appropriately equipped drive components are detected automatically. Only a cable for the connection is required to achieve this result. Equivalent circuit diagram data for the motors and the characteristic values of the installed encoder systems are all stored. This avoids the need for manual data input during the commissioning and so makes this task more reliable and much faster, according to Hamuel engineers. Sales manager Schaede is also impressed with the “know-how” protection onboard the control. With the help of innovative software, his customers can protect all their programs and their application know-how, using individual passwords and so largely prevent unauthorized access. According to Hamuel, the Teleservice offered by Siemens has proven to be an important advantage for its machine users who often operate globally. It allows not only software problems to be rectified but also updates to be installed fast and reliably without needing to be present onsite. Manufacturing operations save time and money and they always remain up-to-date with the latest software releases, via this service. Powerful motor spindle with Hirth gearing
Leading turbine manufacturers are particularly impressed by the dynamics and high-performance of the HSTM machines. The perfect interaction of the robust Hamuel machine construction and the high-quality Siemens drive and control engineering provide the basis for this satisfaction.
The capability of the turning-milling center also depends greatly on the 54-kW motor spindle made by Weiss Spindeltechnologie GmbH (a Siemens subsidiary). Equipped with a HSK A63 tool holder, it is able to provide the high torque required for roughing plus speeds as high as 16,000 rpm for finishing. This means an optimum cutting speed is always guaranteed. As a practical detail, the Hamuel engineers also emphasize the integrated Hirth gearing that makes it possible to clamp the spindle and relieve load on the bearings during the turning process. The machine sizes in the HSTM Series are oriented to the length of the workpieces to be produced in standard ranges from ≤ 500 mm (HSTM 300) to 1750 mm (HSTM 1500). On special request, Hamuel also builds larger machines. A project for machining blades as large as 2500 mm in length is currently running in the field. CEO Markus Stanik explains, “Thanks to our modular machine construction, we are able to satisfy special requests and build turning-milling centers in these dimensions.”
The manufacturing of precise free-form surfaces for turbine blades demands the highest performance from the CNC. The excellent block-cycle times of the Sinumerik 840D sl and its look-ahead function improved as part of the new “Advanced Surface” motion control, which play a significant role here.
New developments already in the introductory phase are also evolving at Hamuel. For example, in the near future, a special gas will be able to be used to cool the tool in the HSTM machines. A machine base made of mineral casting is also now offered. One of the first machines of this type has already been presented at EMO. “This material not only exhibits excellent properties with regard to vibration suppression but we have also been able to reduce somewhat our dependency on steel suppliers,” noted Markus Stanik. For the machine user, this makes itself apparent directly in improved surface quality and a significantly longer tool service life. CNC gantry milling machines of the HSM (high-speed milling) series In addition to the component production and the construction of the HSTM series, the company’s HMS Series machines are another mainstay for Hamuel. These simultaneous five-axis machining centers are designed for high-speed cutting (HSC). They feature not only the modern Siemens drive and CNC control engineering, but also the optimized milling-head systems and the high-performance high-speed spindles, providing this capability. HSM machines allow high-performance roughing and ultra-precise finishing. With regard to the size of the HSM machines, the manufacturer adapts the designs specifically based on the customer requirements. As a component producer, Hamuel also has its own machines in constant use at its factory.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
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Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
About Hamuel Maschinenbau GmbH & Co. KG, Meeder, Germany
Hamuel was founded in 1927 and is now part of the Hamuel Reichenbacher company group. More than 2000 CNC machines from this enterprise group are currently in use globally for the machining of a wide range of materials. The focus of Hamuel Maschinenbau comprises three areas: the production of machine-tool components, CNC gantry milling machines (HSM) and five-axis CNC turning-milling centers (HSTM).
Continue readingHighlights include two-sided machining and servo drive technology
Recently, Northern Italian machine tool manufacturer Biglia introduced its multi-functional turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC. The mechanical concept, together with the scalable control, provides users with the most diverse standard turning and milling operations. The result is increased flexibility and higher speeds for end users. That quality machine tools are built in Northern Italy is nothing new. And this fact is confirmed again by the “Quattro” series from the machine tool manufacturer Biglia. These machines are multifunctional turning centers that are valued throughout Europe for their high reliability and performance power. The machines are available in different versions from 11 to 15 CNC axes. They are also intended for different turning diameters (45, 52, 65, 71 and 80 mm).
Biglia has equipped its turning centers of the ‘Quattro’ series with the Sinumerik 840D sl CNC control. The individual machines have 11 to 15 NC axes.
The two opposing spindles form a special feature of the “Quattro” series. This allows the workpiece to be machined from two sides, which reduces the machining time. The second spindle can also be moved linearly in two directions (lengthwise and crosswise). This provides some leeway in the case of additional milling operations, but it can also be used for automatic workpiece unloading. Two turrets, mounted on the y-axis, ensure proper positioning of the necessary tools.
The turning centers from Biglia have two spindles and two independent tool turrets for simultaneous machining.
This innovative machining technology allows the creation of not only rotary but also prismatic workpieces – including polygons. Dealing with everything in one setup not only reduces cycle times, it also enhances accuracy. The machines are developed on the basis of a modular concept that ensures flexible application options – from the universal CNC lathe, to complete machining of complex workpieces with powered tools (c- and y-axis).
Getting it right, from the start
By offering the Siemens Sinumerik 840D sl CNC control, Biglia now wants to expand its previous options and its own market by combining its technologies with that of the Siemens control. “In this project, which is of personal significance to all of us who worked on it and of strategic significance for Biglia, we wanted to do everything perfect right from the start and to get the most out of it,” says Giovanni Delmondo, Business Development Manager for machine tools with Siemens Italy. The result is an all-round successful machine series with a highly modern control that already includes the innovative system expansions of recent months – including increased energy efficiency options offered by the control and drive systems from Siemens.
To illustrate this, Giovanni Delmondo points out that “the fans on the spindles are shut down automatically when they are not required, or certain services such as hydraulics, lubricant supply, or compressed air are deactivated during machine standstill times. This is handled via special screen forms on the control and is extremely simple, using the Run MyScreens function.”
Also notable is the standard energy efficiency solution from Siemens in the Sinamics S120 drives onboard this machine series. This includes automatic power factor correction or regenerative feedback of the energy generated in braking operations, a substantial factor in energy savings.
Performance and scalability
The Sinumerik 840D sl control is based upon the Sinamics S120 drives platform.
The centerpiece of the automation concept of these Biglia turning centers is the Sinumerik 840D sl control. This is a universal and flexible CNC system, implemented in the Sinamics S120 design (see Fig. 3). It is suitable for up to 31 NC axes. Whether you are turning, drilling, milling, grinding, laser-machining, nibbling or punching, the Sinumerik 840D sl is suitable for use in the most diverse machining technologies. The CNC control also has PLC (programmable logic controller) functionalities, so that a special PLC can be eliminated, if applicable.
This high-end control from Siemens is ideally suited to medium and complex tasks and production and can be adapted to the task, thanks to scalable hardware. The CNC is also characterized by openness, so the operator interface and also the software present few limits to specific job adaptability. This applies all the way to supplementing the NC core of the control; however, a special license is required for this adaptation.
On the Biglia turning centers, the control was equipped with the Sinumerik Operate user interface, making operation simple and intuitive. Three different methods of parts programming are possible: Classic ISO code programming, programming with the help of the integrated ProgramGuide with graphical support of the selected cycles, and the new two-channel ShopTurn with graphical 3D simulation. The user is led step-by-step through the cycles, whether for simple metal removal, drilling, thread cutting, pocket milling, groove milling or engraving. Complex programming cycles for complex contours are also possible. The “ProgramSync” function for automatic synchronization of the machining programs via two channels ensures a significant increase in machine productivity. The control is equipped with a 15″ monitor and integral keyboard.
Siemens CNC in metalcutting applications.
The Quattro series from Biglia also uses the highly effective personnel and machine protection system provided by the Sinumerik control concept with the Sinumerik Safety Integrated package.
Biglia is also breaking new ground with servo drives. Thus, the new servo motor generation 1PH8 from Siemens is used for the main spindle motors in this series. The linear axes are further equipped with the new 1FK 7 G2 series of permanent-magnet synchronous motors. These motor types from Siemens enable onsite replacement of the encoders without having to dismantle the complete motor. This combination of machine and CNC control in the Quattro turning centers from Biglia provides users with greater flexibility.
For more information about Siemens CNC solutions for the machine tool industry, visit our website: www.usa.siemens.com/cnc.
For more information on the this story, contact:
SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES
MOTION CONTROL
MACHINE TOOL BUSINESS
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/cnc
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communication
Follow us on Facebook: www.facebook.com/SiemensSiemensCNC or Twitter: www.twitter.com/siemens_cnc_us.
—
Siemens Industry Sector is the world’s leading supplier of innovative and environmentally friendly products, solutions and services for industrial customers. With end-to-end automation technology and industrial software, solid vertical-market expertise, and technology-based services, the sector enhances its customers’ productivity, efficiency and flexibility. With a global workforce of more than 100,000 employees, the Industry Sector comprises the Industry Automation, Drive Technologies and Customer Services Divisions as well as the Metals Technologies Business Unit.
The Siemens Drive Technologies Division is the world’s leading supplier of products, systems, applications, solutions and services for the entire drive train, with electrical and mechanical components. Drive Technologies serves all vertical markets in the production and process industries as well as the infrastructure/energy segment. With its products and solutions, the division enables its customers to achieve productivity, energy efficiency and reliability.
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The ideal and efficient solution for closed-loop temperature control
The improved TCP3000 temperature controller from Siemens is a scalable, pre-engineered solution to make plastics extruder machines more simple and economic
ATLANTA — Siemens Industry, Inc. unveiled today its improved TCP3000 temperature controller for plastics machines making extruders more simple and economic.
This pre-configured solution allows OEMs to save time and expense when equipping their machines; provides users with the highest degree of flexibility, scalability and performance; and offers simple and clear operator screens for temperature zone monitoring and control.
The TCP3000 can be operated using the new Simatic Multi-Panels including the 10-inch MP 277 and the 12-, 15- or 19-inch MP 377. It is supported by standard Simatic PLC software from Siemens, which requires no special high-level programming expertise.
Machine operators, technicians and maintenance engineers have a wide range of screens
at their disposal for easy and convenient operation and service. These include:
For more information about our solutions for extrusion, visit our website: www.usa.siemens.com/plastics.
For specific product information and inquiries, call (800) 879-8079 ext. Marketing Communications or send an e-mail to: SiemensMTBUMarCom.industry@siemens.com.
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