Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Contact us today:
(847) 934-4500
tdaro@bernardandcompany.com
Zimmermann FZ42 portal milling machine with five-axis, five-sided cutting capability
By using a Zimmermann FZ42 portal milling center, Volvo gets the power and torque needed to cut engine fan cases plus the accuracy to turn the machine tool into a coordinate measuring machine for inspection of finished parts
Located near Hartford, Conn., Volvo Aero Connecticut specializes in the machining of large components: fan cases for aircraft engines and gas turbines, fan and compressor structures, compressor rotors, low-pressure turbine cases (LPT) and military parts, usually from aluminum and titanium, as well as Inconel and Waspaloy. It currently manufactures the largest fan casing in the world, at 3.5 meters (11.5 feet) in diameter, for the massive GE90, the only aircraft engine in existence providing 127,900 pounds of thrust, to power the Boeing 777 line. Volvo Aerospace also produces numerous titanium fan cases for Rolls Royce engines.
With the large workpieces, high material removal rates and challenging geometries inherent in aerospace metals manufacturing, coupled with substrates that are often difficult to machine, such as titanium, there is always a need for powerful machining with superior accuracy. Such conditions present substantial hurdles at aerospace supply companies, as they seek to maintain that delicate balance between these seemingly opposing concepts.
As part of its program for the GEnx engine, to be used on the Boeing 787 Dreamliner, Volvo Aero Connecticut recently added a Zimmermann FZ42 machine tool, a five-axis, five-side portal milling center, to its already impressive manufacturing cells at the Hartford facility. The new machine joins other five-axis mills, vertical turning machines, four-axis machining centers and a deburring robot.
Key features on the FZ42 that led Volvo Aero Connecticut to make this acquisition included:
GE90 engine; Volvo Aero Connecticut made the fan casing, currently the largest of its kind at 3.5m (11.5 foot) diameter
In addition, this FZ42 carries a high accuracy package that provides optimum temperature control of the structural machine parts through the use of a special fiber-reinforced compound in the massive side columns. Also facilitating this process are built-in cooling ducts in the portal and Z-axis slide, independent cooling circuits for the A-axis, C-axis and spindle, ground surfaces on the guideways for the Z-axis and side columns, plus a double-pitch measuring system on the A-axis and C-axis.
During the course of manufacturing, thermal expansion of both machine components and workpieces can substantially impact the positioning accuracy of the machine, the stability of the workpiece and the resulting effect on the finished part dimensions. This unique combination of temperature control and mechanical accuracy in the machine construction were an important deciding factor for Volvo Aerospace in acquiring the FZ42.
According to Martin Thorden, engineering manager at Volvo Aero Connecticut, “These features, combined with the onsite machine set-up provided by Zimmermann, were very important to us, especially on this new GEnx project.” Thorden further noted the importance of the control on the machine, a Sinumerik 840D CNC from Siemens. “We see a very big benefit in how well we are able to control the tool with the CNC. We have been able to use the control to take on additional tasks that were previously handled by our CAD/CAM system.” Specifically, he cited the unconventional approach Volvo Aerospace took in machining the big fan cases. They installed the machine without a rotary table, thus realizing over $500,000 in direct cost savings plus material handling time. As a result of that decision, they believed they needed a top-of-the-line control to probe and accurately machine all the features on the part.
Volvo Aero Connecticut, located near Hartford, comprises three buildings, the largest being 40,000 square feet, where various aerospace and military aircraft components are typically produced from aluminum, titanium, Inconel and Waspaloy.
After machining, Volvo Aero Connecticut can actually transition the machine tool into a coordinate measuring machine for inspection, according to Thorden, owing to the superior accuracy provided by the CNC, as well as the special 90 degree angle heads supplied with the machine, part of the MuST® spindle technology from Zimmermann.
Onboard the machine tool, a massive 120-position tool carriage holds various HSK63 and HSK100 tools that are used to machine the substrates worked here. Inside a series of four side stations, within the machine workspace, four additional specialty tools are stored and used for various operations in the machining and measuring process.
All motors and the drive package onboard the Zimmermann FZ42 at this Volvo Aero Connecticut facility are also made by Siemens.
In a typical machining sequence, the milling head on this machine, equipped with the Zimmermann MuST® spindle system, provides Volvo Aerospace numerous other advantages, according to Martin Thorden. All roughing and subsequent finish passes on any material can be achieved in one set-up, which reduces the preparation time and overall production costs by as much as 10%. There is also no need for additional machines and the corresponding materials handling time. The head design further enables Volvo Aero Connecticut to perform tasks other than milling, using the specialty heads stored on the side stations. Changing the spindle, instead of the milling head, enhances repeatability and further reduces the company’s spindle interface costs, according to Thorden.
The combination of increased accuracies, reduced equipment needs and faster throughput has highlighted this Zimmermann machine installation at Volvo Aero Connecticut.
For additional product information and inquiries:
Zimmermann Inc.
Phone: 248-305-9707
Web: www.zimmermann-inc.com
Email: Matthias@zimmermann-inc.com
Attention: Matthias Tockook
Volvo Aero Connecticut
Phone: 860-667-8502
Web: www.volvoaero.com
Email: Martin.Thorden@volvo.com
Attention: Martin Thorden
Siemens Machine Tool Business
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
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.
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Practical Operation
The SCHÖMA machine factory opted for a cycle turning machine with Sinumerik 840D solution line CNC for the manufacturing of individual parts and small batches of locomotive wheels; this machine also features Siemens ShopTurn with Manual Machine function. This hardware and software solution combines the flexibility and benefits of conventional machining with the productivity and efficiency of a CNC and this is what tipped the balance in its favor for one customer.
Christoph Schöttler Maschinenfabrik GmbH (SCHÖMA) is based in Diepholz, Germany. The company specializes in the development and production of diesel-engine locomotives. The model range includes tunnel and shunting locomotives; service, field and narrow-gauge locomotives; handcars, passenger carriages and gang cars. Around 90 percent of the locomotives produced each year at SCHÖMA are destined for use in tunnel construction.
Each construction project brings its own specific requirements and each country through which the locomotives travel has different environmental and safety legislation. SCHÖMA uses a modular system to meet a diverse range of customer requirements and the resulting need for a variety of equipment and product versions. One of the tasks facing the company is working out how to equip the locomotives for transportation by rail on differing track widths. Another requirement is locomotives with driving wheels featuring diameters between 600 mm and 900 mm, depending on local track usage.
The right decision
Faced with even more demanding requirements in terms of production capacity and flexibility, SCHÖMA’s Managing Director, Christoph Schöttler, last year decided to add a cycle-control Seiger Record LC 1400 lathe to his inventory of machines. “We opted for a head turning machine, as we do not need a tailstock to produce driving wheels, axle bearing housings and gear wheels. It is working just as we envisioned, so we obviously made the right decision,” says Schöttler.
SCHÖMA constructs around 120 locomotives each year, which equates to 480 wheels. In addition, there are also repair orders, which increase the workload to between 560 and 600 driving wheels per year. These wheels are produced in two mountings from forged blanks on the cycle turning machine. The first mounting is used to machine the wheel flange on the reverse side and the wheel hub. The shaft locating bore is pre-turned. In the second mounting, the first task is to pre-turn the driving wheel profile, then the rolling circle level and the wheel shaft locating bore are finished.
Careful approach
The cycle turning machine is controlled by a Siemens Sinumerik 840D sl CNC, equipped with the ShopTurn software package with Manual Machine feature. If required, ShopTurn programming can be performed on a separate PC as part of an operator’s work planning, without interrupting the work sequences on the machine. The programs are routed to the machine via the network, where they are called up as required, depending on the workpieces to be produced. The Sinumerik CNC is used for both numerically controlled machining and manual operation with the ShopTurn’s Manual Machine functions. In manual mode with electronic handwheels, the machine behaves just like a conventional lathe with an actual value display.
During face and longitudinal turning, the process operates with the entered feed and spindle speed. The real highlight of the system is that every cycle can be used straightaway, without having to create a custom program. At SCHÖMA, the option for manual intervention is used for setting the zero point or for simple contours. Diameters are determined manually, if driving wheels have been newly profiled or if driving wheel profiles require resurfacing. The wheel profiles abrade as a result of the high loads experienced in heavy-duty operation or on poor-quality tracks or as a result of the driven wheels skidding.
“With a machine that uses only CNC, it is difficult to rework the driving wheels, as it is not possible to determine how much material needs to be removed. With this optional manual mode, however, users can adopt a careful approach. This sums up the ease of control,” explains Walter Horstmann, head of mechanical production and wheel set construction at SCHÖMA.
Siemens ShopTurn with Manual Machine for the job shop
After machine start-up, the basic MANUAL screen is immediately displayed and offers direct access to choosing machining options without having to create a parts program.
Machining procedures such as “taper turning” and “straight line face and longitudinal turning” can be executed immediately. The operator simply selects tool, feed speed, spindle speed and orientation, plus, if required, machining angle, then presses “Start”. The active direction is graphically displayed in the basic screen, using a compass rose symbol. All machining steps such as entry, thread grinding and drilling can also be started in manual mode.
For additional product information and inquirie, contact:
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
SiemensMTBUMarCom.industry@siemens.com
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. 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 readingHAN-KWANG INTRODUCES THREE NEW LASERS
Korean giant enters U.S. market with big splash at recent FABTECH show
PL Machine
At the recent FABTECH show in Chicago, the largest builder of laser machines in Korea introduced three new CO2 lasers for metal fabrication, including two plate/sheetmetal machines and one tube/pipe cutter. Reaction from the attendees was very positive and interest quite high, as all three machines ran continuously throughout the show.
Details on the machines follow here:
Han-Kwang takes the next step in its technology development with the introduction of the Series PL laser system. Incorporating our unique Beam Radius Control (BRC) and Constant Beam Delivery System (CBDS), Series PL also features the newest Han-Kwang laser technology, our S5 High-Speed Cutting Head, which significantly increases the cutting speeds on all sheet metals, up to 1120 IPM for 20ga mild steel and 790 IPM for 16ga stainless. In addition, the practical machine design and highly functional, ergonomic controls make the Series PL the new benchmark in long gantry laser systems.
Features
• BRC-Beam Radius Control
Through optimizing the beam diameter for each different material and thickness, cut quality is greatly increased.
• CBDS-Constant Beam Delivery System
By keeping the entire length of the beam delivery constant over the work area, beam quality at the cutting focal point is enhanced.
• S5 High Speed Cutting Head
Adopting the new generation of the sensing board and the cutting head means cutting speeds for sheet metals such as mild steel, stainless and aluminum are dramatically increased.
• PMU-Plasma Monitoring Unit
Constantly monitors cut error such as plasma and restart with faster piercing and more stable cutting quality.
• LCS-Lens Crack Sensor
Built-in LCS monitors the status of lens contamination to give maintenance personnel instant alerts for replacement.
• Rotary axis for tube cutting
Cuts tubes up to 12” OD to give your operation substantial flexibility in work strategies
• Siemens SINUMERIK 840D with 15” touch screen
Use of the highest powered CNC, with open architecture and simplified set-up with plain language commands, plus full interface to your shop programming/monitoring network, means greater productivity at the machine and overall in your operation
• Onboard high-efficiency air filter & dehumidifier with monitoring window
Utilizing its own power supply, this unique Han-Kwang system guarantees contamination-free cutting and unmatched consistency.
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PS Machine
Han-Kwang takes the next step in its technology development with the introduction of the Series PS laser system. Incorporating our unique Beam Radius Control (BRC) and Constant Beam Delivery System (CBDS), Series PS also features the newest Han-Kwang laser technology, our S5 High-Speed Cutting Head, which significantly increases the cutting speeds on all sheet metals, up to 1120 IPM for 20ga mild steel and 790 IPM for 16ga stainless. In addition, the practical machine design and highly functional, ergonomic controls make the Series PS the new benchmark in short gantry laser systems.
Features
• BRC-Beam Radius Control
Through optimizing the beam diameter for each different material and thickness, cut quality is greatly increased.
• CBDS-Constant Beam Delivery System
By keeping the entire length of the beam delivery constant over the work area, beam quality at the cutting focal point is enhanced.
• S5 High Speed Cutting Head
Adopting the new generation of the sensing board and the cutting head means cutting speeds for sheet metals such as mild steel, stainless and aluminum are dramatically increased.
• PMU-Plasma Monitoring Unit
Constantly monitors cut error such as plasma and restart with faster piercing and more stable cutting quality.
• LCS-Lens Crack Sensor
Built-in LCS monitors the status of lens contamination to give maintenance personnel instant alerts for replacement.
•Siemens SINUMERIK 840D with 15” touch screen
Use of the highest powered CNC, with open architecture and simplified set-up with plain language commands, plus full interface to your shop programming/monitoring network, means greater productivity at the machine and overall in your operation
• Onboard high-efficiency air filter & dehumidifier with monitoring window
Utilizing its own power supply, this unique Han-Kwang system guarantees contamination-free cutting and unmatched consistency.
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Han-Kwang takes the next step forward in fully automated tube cutting systems with the introduction of the new Series TL. All our experience in tube cutting technology has joined with our expertise in the design and engineering of materials handling systems to offer users a very affordable yet superior quality and highly flexible system for virtually non-stop production of tubes and shapes. Coupled with our exclusive Han-Kwang ProDesign 3D CAM/CAM software and fully controlled by a single CNC workstation, Series PL will provide unmatched productivity to your operation.
Highlight of the Series TL is our highly advanced S5 cutting head, which combines superior measurement and sensing mechanisms to change from signal size to pulse monitoring, resulting in optimum cutting conditions. This new cutting head design is further enhanced by Han-Kwang’s quick piercing nitrogen-injection technology. Smaller holes, quicker ambient area cooling and a substantial reduction in hole-to-hole cutting time will all benefit your production and your bottom line.
Features
• BRC-Beam Radius Control
• CBDS-Constant Beam Delivery System
• Magazine-fed bundle tube loading system
• Tube V-support system
• Rotary chucking system
• Completely enclosed safety workstation with automatic doors and light barrier system
• Panasonic 2500W resonator
• Cutting capability to 21’ long x 6” diameter
• Material thicknesses to 0.25” mild steel and 0.2” stainless
• Siemens SINUMERIK 840D, the highest-powered CNC on the market for maintaining complete processing cycle control by a single operator, using touchscreen and simple language commands
• ProDesign 3D CAD/CAM enabling fast adjustments to the production scheduling to yield maximum productivity from the system
• Unique Han-Kwang air filtration and dehumidifying system for cleaner cuts and more operator-friendly environment
For more information on this emerging new player in the laser machine market, please contact:
Robert Won, Director/North American Sales
HANKWANG USA, INC. Web: www.hankwang.com
Agency contact: Tim Daro Bernard & Company www.bernardandcompany.com
Fryer Easy Turn Combination Lathe with Siemens SINUMERIK 840D sl CNC lets operators at Continental Machine program, set-up and run faster; critical for one-off operations
By definition, says Josh Johnson, vice-president, Continental Machine, Rockford, Illinois, his prototype and short-run production shop must constantly run lean. There can be no tolerating excessive programming, set-up or machining time of any kind, otherwise the shop loses and, in this economy, Johnson notes, that is simply unacceptable.
Continental Machine is a seven-person, 13,000 square-foot facility that houses a variety of CNC milling, turning, wire EDM, hole popping and grinding machines, as well as various sheetmetal and plastic injection molding machinery. Therefore, the shop is well positioned to produce a wide variety of metal and plastic prototypes used by its diverse customer base, which spans markets such as window hardware, bicycle components, automotive parts, chemical processing, medical devices and foodservice equipment. Materials processed here are just as wide-ranging, including aluminum, CRS, tool steels such as A2 and D2, zinc, brass, copper, bronze, titanium and a variety of engineered plastics such as glass-filled Delrin.
Recently, this job shop purchased a Fryer Easy Turn-21 CNC Combination Lathe, controlled by a Siemens SINUMERIK 840D sl numerical control. The two operators responsible for this machine upgrade at Continental had limited experience with CNC and none whatsoever with the Siemens protocol, as this was the first of its kind at the shop.
The Easy Turn-21 was particularly appealing to Josh Johnson, who comments, “The set-up is extremely easy. Teaching the tools, altering the lengths and diameters is kept very simple. After the initial learning curve, which took only a few days, the operators picked up on the conversational programming, right away. Also, one of the best features on the machine was that you could still turn the parts by using the electronic handwheel and just one function, such as hogging off material automatically or putting on a tapered thread.” He noted this feature was not only more comfortable for the operators, but it also allowed them to quickly and efficiently prove out part programs. Johnson commented that this would not have been possible on previous machines, owing to the flexibility of the control onboard the Fryer. The result has been a minimum 20% improvement in the overall cycle time on most part programs run at Continental. For this primarily prototype job shop, that fact translates into a substantial increase in the work product possible here.
Echoing this sentiment, Sue Ostrander, sales manager, Fryer Machine Systems, explained the process that led her company to select the SINUMERIK 840D sl numerical control for all its milling and turning machines, a move that was recently formalized by the company and announced to the trade.
“Since its inception 26 years ago, family-owned Fryer Machine Systems has based its operation on three core principles: build a quality product, price it fairly and provide quality service. This philosophy has allowed Fryer’s business to grow even in challenging times,” she said.
Fryer manufactures a diverse line of over 50 models of high-quality CNC machine tools in its 50,000 square-foot facility in Patterson, New York. Over the years, Fryer has become well-respected for its quality and innovation, throughout the job shop and production machining market segments.
“Moving to the Siemens 840D sl platform was the next step in Fryer’s ongoing commitment to provide our customers with the most innovative machine tools available in the market today,” Ostrander continued. “The Siemens solution allows machine tool end-users to achieve higher productivity through easy and intuitive features and step-by-step, on-screen programming. This enables them to dramatically reduce set-up, programming, and tooling times, while significantly increasing output.”
“The SINUMERIK 840D sl modular design allows us to take full advantage of the superior mechanical features in our machines,” continued Larry Fryer, president and CEO, Fryer Machine Systems. “Fryer has always been known for our easy conversational controls and the move to Siemens has allowed us to greatly enhance this feature,” Fryer noted. “The 840D sl menu-driven system combines an advanced geometry calculator that displays the part while the operator is programming it. Sophisticated solid model graphics allow the operator to verify the part program with more clarity than ever before,” he said.
Larry Fryer has also been impressed with the automatic tool set-up and easy part set-up, made possible by the Siemens CNC. Fryer explained that auto-run mode is where many operators experience difficulty. Siemens and Fryer Machine Systems worked together to create an electronic handwheel run mode that gives the operator a safer way to prove out program execution, both forward and backward, using a standard electronic handwheel.
Fryer further stated, “Siemens provides us with a highly flexible solution that is critical to our ability to meet the specific needs of each customer. Our enhanced capability to offer the same control for both turning and milling gives Fryer machines a unified platform that is very important to customers both in the short-term and for long range expansion. Coupled with Siemens quality and reliability, they are invaluable to us in competing in today’s aggressive marketplace.”
Johnson added this comment on the service and training received by his operators at Continental. “Siemens has been helpful and very thorough in their training and after-sale service. The ShopTurn program, being integral to the control, now enables us to accurately determine tool path, potential collisions, tool changes and real world run time. This makes our operators’ jobs much easier, with the added benefit of allowing us to estimate much more accurately than ever.” Johnson further noted the CNC has substantial hard drive space, thus allowing most programs to be stored directly on the machine, though the company does maintain a back-up system.
For more information on this story, please contact:
CONTINENTAL MACHINE CO.
Email: conmach@onecommail.com
FRYER MACHINE SYSTEMS, INC.
Web: www.fryermachine.com
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
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.
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Kimray, Inc., an Oklahoma City-based manufacturer of control valves and related equipment for oil and gas producing companies, reports an 83% increase in their machining efficiency, achieved largely as the result of recently acquired CNC production equipment.
Founded in 1948 by Garman Kimmell, Kimray operates a 274,000 sq. ft. facility and employs over 400 people to serve its expanding customer base of oil and gas producing companies. Kimray machines iron, steel and aluminum, as well as thermoplastic materials, to build its comprehensive line of control valves, thermostats, energy-exchange glycol pumps, gas-operated pilots and other process control devices. Their products are used to control vessel and lead line temperatures, liquid level inside pressurized vessels, pressure drops and liquid/gas flow.
The company maintains a turnkey manufacturing facility, including dozens of lathes, grinders, turning, milling, sawing and bore finishing/honing machine tools, nearly all with CNC systems onboard. Originally, two machines were purchased, an Emco Maier EMCOTURN 420 MC PLUS and HYPERTURN 665 MC PLUS Lathes, each equipped with Siemens SINUMERIK 840D CNCs and SIMODRIVE 611D drive packages. As their productivity greatly increased, Kimray decided to purchase two more Emco Maier machines to keep up with increased demand for their products.
The company operates a host system for file storage and back-up on all part production data. As one operator of these lathes observed, “I liked the Fanuc 18i-T CNC we used on other machines in the shop, but, with the SINUMERIK 840D, you can do so much more, such as instant programming and cut and paste operations, while the machine is running or stopped. Each screen allows you to be very detailed about what you’re doing, such as separating your mains from your subs with your part and workpiece programs. I use the Siemens CNC for axis and spindle movements on both machines (Emco Maier 420 Dual Main and Counter spindle Machine and the 665 Main and Counter Spindle Machine). My programs and data can be recessed easily and transferred back to the machines (from the company’s main host system), as needed. I can run my programs out of workpieces and sub-spindles, including milling and stenciling out of the sub-programs. I use the parts program as my way to transfer files and folders to the main system and back again.”
He further commented on the controls, “On a typical set-up, I like the sensitivity of the CNC. Being able to move the axis only a ten thousandth at a time to a hundred thousandth at a time comes in very handy for me. I also like the program test feature, especially on new programs. Each tool has its own geometry page and up to four offsets, making things much less complicated.”
Lastly, regarding the machine builder, this operator noted, “I received lots of good advice and training from the folks at Emco Maier, especially Doug Poling. He’s also assisted me a few times by phone, when needed.”
In the manufacture of its oil and gas production controls, Kimray typically machines bar stock of 303, 304, 310, 316 and 17-4 stainless, as well as D-2 tool steel, 6061-T6 aluminum, brass, Delrin and Teflon. Cast iron, ductile, steel, stainless and aluminum are also machined here. The 83% increase in machining efficiency has been achieved, due to these four Emco Maier machines with Siemens CNCs, according to Kimray sources and company production data.
In determining the increase in overall machining efficiency at Kimray, VP of Operations David Hill commented, “Our commitment to run CNC machine tools has long been in place and the addition of the Emco Maier lathes with Siemens controls onboard are the latest steps in this process. We’ve literally had no problems with these machines, the CNC’s or the drives. When Kimray operators can keep running and producing parts in such a way, the impact on our overall efficiency is immediate and substantial.”
Mike Morris, Kimray’s Plant Engineer, added that “the control is strong and easy for the operators to use”. Over the years, the CNCs have been virtually bulletproof.”
From the builder’s perspective, Emco Maier shares Kimray’s appreciation for the performance of its CNC/drive package supplier.
“Our 420 machine enables simultaneous production of two parts without interruption or collision. The digital drives (Siemens SIMODRIVE 611D) produce dynamic performance in both the main spindle and X/Z axes,” commented the company’s Director of Sales Support Operations for Emco Maier USA. “Plus, programming is just the same as on any CNC lathe. Only one program is generated. The program for the second workpiece is simply transferred to the bottom system by means of a selector switch. No additional programming is necessary. As we like to say, twice as nice.”
The 665 Hyperturn machine enables true 4-axis machining plus full c-axis capability on both the main and counter spindles. The 665 uses some of the same programming features, plus the same digital drive system as the 420, but in a larger package.
For more information on this story, please contact any of the following individuals:
KIMRAY, INC.
Web: www.kimray.com Email: info@kimray.com
EMCO MAIER CORP.
Web: www.emcomaier-usa.com
SIEMENS MACHINE TOOL BUSINESS
John Meyer
Manager, Marketing Communications
Siemens Industry, Inc.
(847) 640-1595
www.usa.siemens.com/cnc
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.
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New Siemens 1FT7 servo motors, shown (l to r) in forced ventilation, water-cooled and air-cooled styles
Siemens introduces the 1FT7, a line of high-performance servo motors for such demanding motion control applications as machine tool CNC interpolation, production machine indexing control and more. Their use results in higher dynamic response, due to a 30% shorter design and 4x overload capacity versus 3x on the predecessor family of servos. Less downtime also results from the rigid vibration-insulated encoder mounting, which also enables the OEM or end user to exchange the encoder in the field in less than five minutes, without encoder alignment.
Design engineers have a choice in selecting this servo, as it is available in air-cooled, forced ventilation and water-cooled designs. The water-cooled design of the 1FT7 is provided with stainless steel piping in the stator.
Start-up and commissioning personnel will appreciate the Siemens electronic nameplate and digital encoder interface on this new servo, DRIVE CLiQ, as it simplifies start-up or replacement by not requiring all electronic data to be entered, as the DRIVE CLiQ cable recognizes all drive system components. With this feature, these motors become essentially plug-n-play devices. The drive recognizes the motor automatically and optimizes the parameterization accordingly. This digital encoder interface further allows users to route all their different encoder types along one signal cable.
High-resolution encoders, currently 22 bit, enable these servos to become highly precise motion control system components and these new high-dynamic 1FT7 motors also feature very low rotor inertia, thereby making them practical in applications where it was previously impossible to drive a servo. Such applications include sorters in the printing industry, which previously required mechanical cams but can now utilize electronic cams for better energy efficiency and less wear.
For a catalog or more information on these new servo motors, please contact:
SIEMENS INDUSTRY, INC.
GENERAL MOTION CONTROL
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web: www.usa.siemens.com/motioncontrol
Email: SiemensMTBUMarCom.sea@siemens.com
Attention: John Meyer, Manager, Marketing Communications