TORNOS provides productivity solutions to car industries
Automobile industry is tending to reduce the number of suppliers. Customer’s objective to reach cost performance target has never been so important.
Tornos enable customers to reduce costs by maximizing productivity. Tornos customers benefits from the latest know-how. As a supplier to the car industry, customer’s challenge includes the following in particular :
1. Shorter and shorter times to execute parts
2. Versatility of orders and part upgrades
3. Ever growing pressure on prices
4. Very demanding requirements at quality, tolerance and statistical inspection levels.
Reactivity : large batches are broken down in small lots according to the demand, with very short deliveries. Customer’s ability to guarantee compliance with these parameters is one of your best means of success.
Tornos is focused on meeting customer requirements. The experience Tornos has gained in the automotible sector is a benefit Tornos customer base as a whole.
Tornos has been developing products marketed throughout the world for more than 120 years and the company’s reputation speaks for itself.
The experience Tornos has gained in the car industry over the last 45 years means that Tornos can offer high-performance machining solutions for customer’s parts.
Tornos currently offers a full range of MultiSwiss solutions for producing parts measuring 4 to 32 mm in diameter
Introducing Huron, a French machining center manufacturer with a long tradition and success.
Founded in 1857, Huron is a manufacturer of machining centers in France with a long tradition and success. Huron’s production plants and headquarters are located in the Alsace region, the hub of precision industries in France such as aviation, energy, locomotives and automobiles. It is just 10 minutes from Strasbourg International Airport.
Huron is famous for its revolutionary double rotary milling head design in 1890.
Huron is famous for the company that developed the revolutionary double rotary milling head in 1890.
Huron was named after founder Pierre Philippe Huré. Early Huron products include both conventional and unusual designs of vertical and horizontal milling machines, backgeared and screwcutting lathes, horizontal borers and gear-cutting machines.
The Huron symbol, the revolutionary double rotary milling head, was first exhibited at the 18th industrial fair, Grandes Usines.
Huron continues to play an important role in the field of machine tools in Europe today. Huron’s production plant and headquarters are only 10 minutes from the Strasbourg International Airport in the Alsace region, the heart of the electrical and mechanical engineering industry.
Mobilgrease XHP
Product Description
Mobilgrease XHP Series products are extra high performance lithium complex greases intended for a wide variety of applications and severe operating conditions. These greases were designed to outperform conventional products by applying leading edge, proprietary, lithium complex manufacturing technology. They are based on high quality paraffinic mineral oils and are manufactured and formulated to provide excellent high temperature performance with superb adhesion, structural stability and resistance to water contamination. These greases have a high level of chemical stability and offer excellent protection against rust and corrosion. The greases feature high dropping points and maximum recommended operating temperature for the Series is 175º C. Mobilgrease XHP Series greases are available in NLGI grades 3, 2 and 1 and with base oil viscosities ranging from ISO VG 100 to ISO VG 460. Mobilgrease XHP greases are designed for a wide range of applications including the industrial, automotive, construction and marine sectors. Their performance features make them ideal choices for severe operating conditions including high temperature, water contamination, high loads and shock loading and extended re-lubrication operations. Mobilgrease XHP 222 Special is an extreme pressure grease containing molybdenum disulphide that provides protection from wear under shock loads and fretting conditions.
Features & Benefits
Mobilgrease XHP greases are leading members of the Mobilgrease brand of products, which has gained a reputation world-wide for innovation and performance excellence. Mobilgrease XHP greases are state-of-the-art products designed by our formulation technologists and backed by our world-wide technical support staff.
A key factor in the excellent adhesion and cohesion properties and high drop point of Mobilgrease XHP is the proprietary manufacturing technology developed at our research facilities and adopted by our modern manufacturing facilities. These products use specially selected additives to provide excellent oxidation stability, rust & corrosion control, resistance to water contamination as well as antiwear and EP protection.
Applications
Mobilgrease XHP 222 is recommended for industrial and automotive antifriction bearings, chassis components, universal joints and disc brake wheel bearings. It finds particular application in passenger cars, light trucks, taxi fleets and farm equipment. It is also recommended for marine, paper mill, sugar mill and mining applications.
Mobilgrease XHP 222 Special and is used in chassis components, clutch bearings, ball joints of suspension and steering systems in all kinds of passenger cars, trucks, farm tractors, contractor, construction, earth-moving and mobile equipment. It also finds application in king pins, U-joints, fifth wheels and bucket pins.
Introducing Akayama Seiko, manufacturer of special shape steel products with high machining performance
Akiyama Seiko manufactures secondary processed products from special steel (free-cutting stainless steel, free-cutting steel, medium-carbon steel, high-carbon steel, etc.) which are used as component parts for precision machinery and electronic equipment.
Stepping up to an excellent performance
In ASK, we are working together to pursue high precision on a company-wide basis to improve on manufacturing processes and establishing new technologies.
Narrow tolerance at Outer diameter of the CG Bar
ASK’s long-standing processing technology and creative ingenuity will provide narrow tolerance products.
Case Example: Dimensional tolerance of + 0 / 0.004 mm against outer diameter 19.00 mm
High straightness shaft Bar
Straightness of the shaft greatly affects product characteristics. ASK is focused on developing technology to ensure high straightness through continuous research and development.
Case Example: Runout 0.01 mm or less against span 300 mm
Internal Stress Release
After the cold drawn process, the internal stress remains in the steel. Quality of the finished parts after the turning or heat-treatment is negatively affected by this internal stress.
ASK has established a cold working technology to reduce internal stresses, and has received a high reputation from customers.
High precision grinding of nonferrous metals and resins
The grinding processing technology cultivated with ASK has made it possible not only for metal products but also high-precision processing of nonferrous metals such as brass and aluminum and various resins.
Introducing Haefeli sintered diamond and CBN grinding tools
Founded in 1920, Haefeli manufactured sintered diamond and CBN grinding tools in Zurich since 1949.
Haefeli tools is well known for their focus on precision. In particular the original Haefeli grinding pencils, with sintered versions as small as 0.18 mm in diameter is unmatched in the industry.
Haefeli’s product range
Diamond and CBN grinding wheels
Product range available from ∅ 6 mm up to ∅ 400 mm.
CBN and diamond grinding pins
Product range start from as small as ∅ 0,18 mm
Dressing Tools
Polishing Tools
Polishing pastes in syringes with 5 gr. (20gr. availabe on demand) and hand files for treating the edge of cutting tools (burrs and radiuses).
Regenerators
Restore the bite of your resin-ceramic and metal bonded cBN and diamond grinding tools with the HACO-FLEX grinding layer regenerator. The flexible HACO-FLEX is pressed either by hand or by machine without a coolant into the bonding material, ideally with a reduced cutting rate. It penetrates deeply and, like an erasing rubber, it cleans out the gaps until the abrasive grains protrude by about 1/3 from the bonding material.
Special Applications
Some grinding problems seem unsolvable at first glance in particular when developing new products or rearranging the production. We have quickly and flexibly created custom-made grinding tools for such tasks in small as well as large quantities. Simply ask us if you need a custom grinding wheel.
Mikron tools, cutting solutions for professionals
Mikron is manufacturer of high performance tools for technology leading customers looking for high productivity, high precision solutions.
One of Mikron Tool’s well known product is solid carbide deep hole drills highly suitable for machining titanium and stainless steels.
Mikron Tools are suitable for typical applications
- Cross hole drilling
- Deep holes with through coolant
- Solid carbide Slitting cutters for automotive application as well as aerospace etc .
- Deburring ,Chamfering (front and back) endmills for difficult to reach edges /spaces.
- Micro-Endmills
- Carbide Slitting cutters
Amazing performance Mikron Tool’s drill can be seen in the following video.
Mikron Tools offers standardized tools of tungsten carbide for centering, chamfering and drilling, for milling and deburring in the diameter range from 0.1 to 6 mm (.004” to .236”).
In the area of customer-specific tools, the offer comprises the centering and chamfering, milling, turning, grinding or deburring and up to complex combination tools in the diameter range between 0.1 mm and 32 mm (.004” and 1.260”).
DMC, Korea’s first CNC turning machine maker, is looking for new era with partnership with FFG
FFG DMC is the first manufacturer of CNC turning machine in Korea in 1978. Since than FFG DMC has been pioneering the turning machine market in Korea. Joining forces with FFG in 2015, FFG DMC is looking for new engine for innovative growth by globalization.
Source: KOMMA MTM
Start of FFG DMC
FFG DMC started in 1944 by the name of Daewoo Heavy Industry. Since than FFG DMC has demonstrated technology leadership demonstrated by developing the first CNC turning machine in Korea. In the year of 2015, DMC has joined the FFG group to tap into technological know how and production capability of the FFG group as a whole.
Source: KOMMA MTM
FFG is a global machine tool maker consists for global technology leaders such including MAG(Cross Hüller, Excello, LAMB), Honsberg, Hüller Hille, Hessapp, VDF Boehringer, Ikegai, Pfiffner, JOBS, Rambaudi, Sachman and Taiwan’s machine tool maker Feeler and Leadewell.
OTRA is exclusive dealer for FFG-DMC in Seoul and Choonchung area and serving customer in the region with capable service engineer close by.
Source: KOMMA MTM
Magnet Finish gives you the best reproducible honing and polishing results in shortest time.
The Magnetfinish(MF) technology is a new mechanical process for technical surfaces. The magnetic powder works during the process as an elastic tool. Surfaces will be smoothed till a roughness of Ra = 0,02 micrometers.
– Workpiece is positioned in a magnetic field created by magnetic disc
– The gap between workpiece and disc is filled with an processing powder
– The processing powder is both abrasiv and magnetizable
– Bonding the processing powder in magnetic field allows high speed movement
– The direction the powder hits the surface is controlled by programs
: Highest productiv treatment of surfaces, universally usable.
Application
Honing of cutting edges on steel, carbide, CBN, PCD, etc.
Polishing the flute of cutting tools (drills, deephole drills, endmills, taps, etc.)
Polishing after coating, removing of droplets.
Deburring on steel, tap, HSS drills, medical tools, components, etc.
Combined applications for tools and components, e.g. honing of cutting edges and polishing of flutes, e.g. deburring of edges and polishing sealfaces.
Extending lifetime, improved adhasion of following coating layer.
Better chipflow, increased productivity of tools, decreasing of roughness till Ra 0.02 micron.
Reducing friction, increased productivity of tools.
Avoiding of the running phase, extending lifetime, better work results.
All results in only one run, highest productivity.
Mori Fine Blanking Press is OTRA’s recommendation for precision, productivity and cost efficiency.
OTRA has been in supplying fine blanking press for last forty years. In fact most of the fine blanking press that has been installed in Korea has been supplied by OTRA.
Mori Fine Blanking Press is OTRA’s recommendation in terms of precision, productivity and cost efficiency.
Mori’s Fine Blanking Press Products
Customer can select a suitable press based on thickness, material, shape of the product.
Tool for the FB, there are two different types of fixed punch and movable punch. Takes many pieces, progressive, large parts of the tool for fixed punch is used.
Hydraulic FB press that produced has 10 models, from the smallest 160 tons type, to up to 1,500tons.
More recently, developed a Mechanical FB200ton 100SPM and Hydraulic FB500ton 50SPM. It also supports high-speed production.
| Production Table（kN） | ||||||||||
| MFB | 1600 | 2000 | 2500 | |||||||
| FB | 1600 | 2000 | 2500 | 3200 | 4000 | 6500 | 8000 | 10000 | 12000 | 15000 |
Structure and Features of body
- The frame is welded integral structure, careful annealing has been applied.
- Cylinder, Bolster and Ram are using a special steel.
- Ram slide has long and widely eight guides. Can withstand the load eccentricity in composite tool.
- Top stop device, high-precision fine thread called Mechanical stopper has been used. Mechanical stopper. During production, mechanical stopper is fixed at four hydraulic cylinders. And, the accuracy will remain in a repeat stop within 0.01mm. Therefore, you can maintain a stable high-quality composite molding, also prevent damage to the mold.
- Lamb, it takes pressure from below by hydraulic and is controlled so as not to vibrate at the lower stop.
- Main cylinder, V-ring cylinder, Counter cylinder, Auxiliary cylinder of their pressure and timing can be adjusted individually.
- Main cylinder
- Main piston
- Mechanical stopper
- Bottom Bolster
- Counter Piston
- Slide
- Center support
- Eight surface guide
- Bottom guide
- V-ring piston
- Top bolster
- Fast approach cylinder
- Tool safety cylinder
Specification
| FB (Hydraulic) | MFB (Mechanical) | ||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 160 | 250 | 320 | 400 | 500 | 650 | 800 | 1000 | 1200 | 1500 | 100 | 160 | 200 | 250 | ||
| Forces | |||||||||||||||
| Total force | kN | 1600 | 2500 | 3200 | 4000 | 5000 | 6500 | 8000 | 10000 | 12000 | 15000 | 1000 | 1600 | 2000 | 2500 |
| V-ring Force | kN | 800 | 1200 | 1600 | 2000 | 2500 | 3200 | 4000 | 5000 | 6000 | 300 | 600 | 800 | 1400 | |
| Counter Force | kN | 400 | 600 | 800 | 1000 | 1250 | 1300 | 2000 | 2500 | 3000 | 240 | 400 | 500 | 800 | |
| Cutter Cutter Force |
kN | 300 | 400 | 600 | 700 | 70 | 120 | 150 | 100 | ||||||
| Stroke Length | mm | 20〜100 | 20〜140 | 20〜200 | 50 | 58 | 60 | 67.5 | |||||||
| Max Stroke | SPM | 60 | 55 | 50 | 40 | 35 | 30 | 100 | |||||||
| Cutting speed | mm/s | 3〜70 | 3〜60 | 3〜50 | 3〜45 | 3〜40 | |||||||||
| Max Approch Speed | mm/s | 220 | 200 | 180 | 160 | ||||||||||
| Max Decent Speed | mm/s | 220 | 200 | 180 | 160 | ||||||||||
| material | |||||||||||||||
| Min Sheet Length | mm | 2440 | 3000 | 3400 | 3600 | 3750 | 4000 | 1600 | 1700 | 1800 | 2400 | ||||
| Width | mm | 20〜200 | 40〜250 | 40〜320 | 40〜450 | 60〜550 | 20〜160 | 20〜200 | 20〜150 | 20〜150 | |||||
| Thickness | mm | 10 | 15 | 16 | 20 | 6 | 8 | 6 | 6 | ||||||
| Electric Power | |||||||||||||||
| Total Power | KW | 56 | 69 | 82 | 102 | 136 | 160 | 180 | 192 | 230 | 15 | 35 | 35 | 52 | |
| Main Drive | KW | 30 | 37 | 55 | 75 | 90 | 110 | 132 | 160 | 5.5 | 22 | 22 | 30 | ||
| Hydrauric | |||||||||||||||
| Oil Cooler | KW/h | 30 | 38 | 45 | 60 | 70 | 90 | 100 | 110 | 130 | 2.5 | 4 | 5 | 7.5 | |
| Oil Tank Capacity | L | 850 | 1400 | 1600 | 2000 | 150 | 250 | 150 | |||||||
| Press | |||||||||||||||
| A | mm | 1445 | 1625 | 1725 | 1750 | 1825 | 1900 | 2040 | 2310 | 2310 | 2375 | 1160 | 1300 | 1100 | 2100 |
| B | mm | 1510 | 1840 | 1845 | 2030 | 2080 | 2130 | 2310 | 2790 | 2850 | 2950 | 1110 | 1190 | 1200 | 1900 |
| C | mm | 1435 | 1625 | 1815 | 1830 | 1850 | 1980 | 2200 | 2250 | 2250 | 2410 | 1150 | 1280 | 1350 | 1290 |
| D | mm | 2900 | 3400 | 3000 | 3300 | 3300 | 3400 | 3800 | 3900 | 4050 | 4400 | 2650 | 3100 | 3160 | 3680 |
| E | mm | 1465 | 1715 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1450 | 1470 | 1710 | 1714 | 1257 |
| F | mm | 1265 | 1415 | 1150 | 1150 | 1140 | 1080 | 1060 | 1060 | 1040 | 1010 | 1390 | 1620 | 1624 | 894 |
| G | mm | 0 | 0 | 480 | 530 | 665 | 870 | 1175 | 1520 | 1660 | 2050 | 0 | 0 | 0 | 785 |
| H | mm | 2460 | 2600 | 2660 | 2700 | 2840 | 3200 | 3500 | 3800 | 3800 | 4050 | 1620 | 3030 | 3250 | 2120 |
| I | mm | 7010 | 7440 | 7550 | 7780 | 7830 | 8430 | 8765 | 9000 | 9100 | 9775 | 3810 | 2760 | 3550 | 7400 |
| FB (Hydraulic) | MFB (Mechanical) | ||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 160 | 250 | 320 | 400 | 500 | 650 | 800 | 1000 | 1200 | 1500 | 100 | 160 | 200 | 240 | ||
| Tool Space | |||||||||||||||
| Upper Bolster a |
mm | 500 | 650 | 800 | 850 | 900 | 1000 | 1100 | 1150 | 1200 | 430 | 550 | 560 | 650 | |
| b | mm | 500 | 600 | 700 | 750 | 850 | 900 | 1000 | 1100 | 430 | 550 | 560 | 650 | ||
| c | mm | 75 | 75 | ||||||||||||
| Lower Bolster e |
mm | 500 | 650 | 800 | 850 | 900 | 1000 | 1100 | 1150 | 1150 | 1400 | 430 | 560 | 650 | |
| f | mm | 750 | 900 | 950 | 1000 | 1050 | 1200 | 1300 | 1300 | 1500 | 480 | 620 | 560 | 650 | |
| g | mm | 75 | 75 | 110 | 75 | ||||||||||
| Adapter Plate |
|||||||||||||||
| X | mm | 420 | 550 | 650 | 750 | 800 | 950 | 1000 | 1200 | ||||||
| Y | mm | 500 | 650 | 750 | 800 | 950 | 1000 | 1200 | |||||||
| Z | mm | 80 | 100 | 140 | 160 | 200 | |||||||||
| Upper Insert Ring Du |
mm | 320 | 400 | 500 | 720 | 160 | 260 | 320 | |||||||
| du | mm | 180 | 300 | 380 | 580 | 70 | 120 | 250 | |||||||
| Tu | mm | 72 | 80 | 120 | 140 | 175 | 30 | 45 | 80 | ||||||
| Lower Insert Ring Dl |
mm | 250 | 400 | 500 | 720 | 250 | 300 | 320 | |||||||
| dl | mm | 250 | 400 | 500 | 720 | 140 | 180 | 250 | |||||||
| Tl | mm | 72 | 80 | 120 | 140 | 175 | 50 | 60 | 90 | ||||||
| Shut Height | mm | 230〜320 | 300〜380 | 320〜400 | 360〜460 | 400〜520 | 190〜280 | 210〜340 | 305〜355 | 360〜410 | |||||
| Max Open Height |
mm | 370 | 520 | 540 | 600 | 640 | 660 | 700 | 330 | 398 | 477 | 477.5 | |||
REP International: the Most Genuine Name in Rubber Injection Molding!
REP international (http://www.repinjection.com) is a World leader in rubber machinery with 100-year-old success story. The REP company has been selling injection molding machines since 1948. Very early on, REP understood the importance of polymers and elastomers to industry and decided to specialize in the rubber injection technology.
REP’s distinguish itself from the competitions based of superior technologies
Closing Unit:
Injection Unit:
The Y-structure: is a proven principle. The separation of the plasticization and injection functions, associated with the regulation system, gives the entire injection unit unrivalled accuracy and regularity in the elastomer injection process.
For the same volume, the REP injection technique, with separation of the plasticizing and injection functions, means an injection plunger diameter 25% smaller than with the FIFO technique. For the same injected volume, the REP injection unit is twice as accurate as a FIFO injection unit. Metering accuracy is further improved by programming the extruder to slow down before the set point is reached.
Cure Time Reduction Technologies:
http://www.repinjection.com/images/pdf/Turbocuretechnicalarticle_gb.pdf
TurboCure is a patented solution for improving quality and productivity while saving energy. TurboCure reduces cure time up to 50% without compromising compound integrity. TurboCure consists of TempInverter and FillBalancer modules, that can be applied together or individually depending on the application. Turbocure can increase the average temperature of the material without the laminar effect.
By reversing the thermal distribution in the rubber flow, TempInverter reduces cure times up to 30%, providing 15 % energy-savings. In the mould, by rebalancing filling between the cavities, FillBalancer modifies the distribution of temperature in the flow as far as the cavities and makes it possible to reduce the cure time by up to 40%.
The TurboCure solution was awarded several prizes: REP got the AFICEP”s innovation award in 2008 for TempInverter and Beaumont Technologies got the Best of Erie Award 2009 for Fill Balancer.
Energy Savings
Between 1997 and 2010, energy consumption on REP rubber injection molding presses was reduced by 70%. Servo Dive & Drive is an electro-hydraulic solution associated to heat eco management. It allows reducing significantly global energy consumption in the continuity of the efforts made by REP over the past 15 years.
[Figure: Reductions in energy use on REP presses over the past 15 years]
Advantage of Servo Dive & Drive Technologies
- Low-energy consumption
- Near zero water or powered fan requirement thanks to natural cooling of the pump
- Reduced cycle time through better system responsiveness
- Improved Reliability
- Optimal lubrication of mechanical parts
- Very few parts in motion
- Better aspiration
- Easy maintenance
- No need to empty the tank
- Oil-immersed servomotor-driven pump
- Simple mechanism
- Very few hydraulic hose
Electric Valve Gate Cold Runner Block
ServoBloc is an electric valve-gated cold runner block for rubber and LSR. ServoBloc is suited to a large range of rubber compounds, soft to hard, from silicone to FKM, ServoBloc is fully integrated in your rubber injection press (retrofit is possible).
- Sequential diagnostic
- Closed loop control of the speed and position of the valves
- Gate size is a settable parameter
- No risk of oil contamination
KERN GMBH Spindle full service
Thoroughly tested – application-optimized – reliable
The spindle is repair to mint condition
– Inspection of appearance
– Incoming test, force test, sensor test, encoder test, seals test
– Dismantling
– Execute stator check-up, insulation test
– Clean parts and refurbish
– Clean cooling system
– Calibrate bearing seat of shaft and case, measurement of bearing seats under add carry :
constant temperature conditions in regard to dimension, circularity and cylindrical shape
– Renew set of bearing, Hybrid – Ceramic DLS
– Shaft cone HSK-63 laser welding and grinding with measurement protocol
– Stator new winding (Pos.2), if necessary
– Revision clamping system
– New clamping set
– New lock screw
– New sealing sleeve
– New rotary encoder Lenord + Bauer
– New encoder receptacle Siemens 17-pol.
– Renew all connection fittings, if necessary
– Complete balancing of shaft with clamping system
– Adjust bearing pretension
– Level run out
– Check clamping force HSK
– Check and adjust sensors
– Dynamic function check on Siemens test station
– Permanent screening of bearing temperature during the test run
– Bearing condition measurement
– Vibration measurement
– Clamping force measurement
– Execute leakage test for inner cooling system 60 bar
– Complete balancing of spindle
– Compile new inspection protocol.
SCHAUBLIN’s Runout Adjustement System (SRS) is very precise and can be applied to wide range for machines.
SCHAUBLIN’s Runout Adjustement System (SRS) can be applied to all major grining machines including Hawemat, Walter, Anca, Makino, Saacke, Schaublin, DMG, Stausak.
It is possible ot use keep runout to less than 0.002mm using this clamping system.
- Accuracy (less than ±0.002mm) and easy to use.
- Easy maintenance and repair
- Able to protect against contamination and rust
- Able to apply to all major collets and can be used with wide range of machines.
MIKRON Customer case SFS Intec.
The municipality of Heerbrugg is located where the Rhine flows into Lake Constance and Switzerland shares a border with Austria and Germany. Industrial history was written here: In the 19th century, a local brickworks developed a pioneering new production process. At the beginning of the 20th century, Heerbrugg became known as home to companies in the precision mechanics and optics sectors. Heerbrugg is still well-known today. Largely thanks to one of the biggest employers in the region: SFS intec.
Steady growth
SFS intec is big. This is confirmed not only by the headcount – more than 8,000 employees worldwide, including 1,400 in Heerbrugg – but also by taking an aerial view of the Heerbrugg site, the company headquarters. Standing on an area as large as eight soccer fields kare various buildings of different ages and appearance, bearing witness to the steady growth enjoyed by the company since it was founded in 1928.
Under very high pressure
Meticulously arranged in rows and marked off by yellow lines on the floor, close on 100 machines in the pressing plant hall produce 80 to 400 components per minute and machine, while creating an impressive volume of sound. In two to six stages, the machines form wires of 0.5 to 30 mm thickness into components – under very high pressure (up to 350 tonnes) and with no loss of material. The wire raw material is fed in at room temperature. This process is called cold forming. The formed components produced in this manner are then conveyed on for secondary machining.
Metal-cutting with Mikron
Things are much quieter here, and it smells of machine oil. The machines in the secondary machining operations hall are much more compact than the ones used for cold forming. The arrangement of machines is no different: Everything is calculated down to the millimeter, and all small parts and tools have their own fixed place. “Here at SFS intec, when we talk of secondary machining operations, we mean all types of precision metal-cutting, such as milling, drilling and turning,” explains Harald Aspek. The 52-year-old operator is setting up a Mikron Multistar for the finishing of pressed blanks for the automotive industry. “We’ve had this Multistar for 13 years – I know it inside out,” adds Harald Aspek. SFS intec has been using Mikron machines (among others) for precision metal-cutting for over 30 years. Worldwide, there are currently a total of more than 30 machines in operation. Mechanical transfer machines – i.e. older Multifactor and Multistar models – account for the biggest share. The newest additions are CNC-controlled Mikron VX-10s.
Precise and fast
A journey by heavy load lift to the warehouse, where driverless forklifts are doing their rounds, and a short walk across the site road to the neighboring building take Roger Vauthier to his workplace. This is in another of the total of three secondary machining operations halls. There are Mikron machines in this huge hall as far as the eye can see. On each machine, SFS intec produces up to five million components a year, mainly for the automotive industry. “Versatility, very high cycle times and extreme reliability whatever material is being fed in: For me these are the advantages that Mikron machines offer,” says the 44-year-old operator. “And with the new VX-10s we can work with even greater precision and have shorter changeover times than with the Multifactor,” adds team leader Harald Niederer (50). He has been working with Mikron machines since he joined SFS intec 17 years ago. “Mikron machines have enjoyed an excellent reputation at our company for many years,” Harald Niederer points out. “For instance, we also use them to train apprentices.”
Gray not green
There are more Mikron machines in the third secondary machining operations hall. In addition to machines from other manufacturers, this hall also contains the latest Mikron VX-10s. It is striking that the new machines are no longer green, but painted in their standard colors of gray and white. This makes the hall appear much brighter and friendlier. “We introduced a new color concept two years ago,” clarifies Mile Veljaca. The 60-year-old team leader has been with SFS intec for 14 years. “The new Mikron machines remove the cuttings very effectively. They also run very stably once you have set them up correctly,” stresses Mile Veljaca. “There’s always room for improvement, but the people from Mikron fundamentally do a good job.”
Maegerle’s single grinding cycle results in the highest precision for cyloid and reducer gear
Profile precision and surface quality are two essential quality features when manufacturing cycloid gear and cycloide groove for the automotive industry. Only the grinding process is capable of fulfilling these requirements. Grinding the entire profile width in a single work cycle results in the highest precision. Where large quantities are also required at low costs, MÄGERLE’s surface and profile grinding machines provide unrivalled results.
Mägerle embodies the coexistence of tradition and progress
Foundation stone for Swiss quality mechanical engineering
Starting out as a metal-ware business, Karl Mägerle founded Gebrüder Mägerle GmbH in 1929 jointly with his brother. This was followed by the acquisition of the Fritz Wunderli AG grinding machine business three years later, enabling the company’s entry into grinding technology. This laid the foundation stone for an unparalleled success story in Swiss quality mechanical engineering.
Mägerle sells the first flat grinding machines in the F7 series with hydraulic drive
A design principle retains its validity
Mägerle set the most important milestone in 1980. Its flat and profile grinding machines – now established worldwide – were built with a fully enclosed hydro-static guide system for the first time. This ground-breaking design principle still distinguishes Mägerle’s cutting-edge technology today, and forms the unique basis for the unsurpassed results in precision, cost effectiveness, reliability and long working life.
Recognised performance in demanding conditions
The worldwide reputation of Mägerle flat and profile grinding machines is long established. With their equally high removal capacity and machining precision, they are recognized on the market as top-class machines. They demonstrate their performance and versatility daily in demanding applications in the turbine industry, the automotive and aircraft industry, the hydraulics industry and the energy sector, as well as machine tools and tool making. All industries that make the highest demands in respect of mechanical, ergonomic and operational qualities.
Hawema’s CNC tool grinding machine built on granite for precision
High-precision machine components
Precision in every detail: reliable machine components from HAWEMA. The chain is only as good as each individual link. For this reason, Hawema attaches particular importance to high-quality machine components. Our motor spindles have a run-out of less 2µ. The precision guides are pre-stressed for maximum rigidity and precision, and are permanently lubricated. The kinematic action, patented worldwide, with grinding column in double bearings (y- and b-axes) assures maximum rigidity and precision with exceptional freedom of movement.
Properties
- Complete granite based machine frame fully integrated in the mineral compound machine bed, resulting in highest rigidity and lowest thermal expansion of the whole system.
- All axis built on granite base plate, with direct measuring system (X, Y and Z axis) and high precision guides, direct drives in the rotation axis.
- Double supported grinding spindle axis integrated in the granite base.
Hawema KINEMATICS (patented worldwide)
- Short travel paths
- Optimal cycle times
- Compact design
- Modular construction
- High rigidity
- Highest precision
- Excellent grinding possibilities
Gearspect offers gear cutting machinery and testing instruments in the field of automotive, defense industries.
Inheriting from 100-year-old tradition TOS Čelákovice and Praga Praha, Gearspect Group is incorportaed in 1995 in Czech Republic. Gearspect produces gear specialized technologies including gear cutting machinery and gear testing instruments in the field of automotive, defense industries.
Gearspect offers modern gear technologies including gear shapers, grinders, hobbers, profile gear grinders, bevel gear grinder and bevel gear hobbers including the gear-measuring technologies.
- Gear Cutting Machines
- Gear Grinding Machines
- Gear Hobbing Machines
- Gear Shaping Machines
- Bevel Gear Grinding Machines
- Bevel Gear Hobbing Machines
- Gear Deburring Machines
- Gear Measuring Instruments
- Gear Testers for geometric deviation of cylindrical gears and gear cutting tools
- Gear Testers for inspection of cylindrical gears by double flank rolling method
- Gear Testers for inspection of cylindrical gears by single flank rolling method
- Gear Testers for Bevel Gears
Since 1924 Blohm has delivered 15,000 flat and profile grinding machines worldwide.
Since 1924 Blohm flat and profile grinding machines have been used worldwide wherever precision, performance and productivity are required. More than 15,000 delivered machines reflect the international recognition of Blohm grinding machines. Constant advancements and a spirit of innovation have characterized the company’s varied history since its foundation.
WURI II machine tool. (1937)
Creep feed grinding machine HFS (1962)
Today Blohm grinding machines are known for their precision and productivity. Blohm is widely recognized as technology leader of aviation turbine industry and has strong presence in general mechanical engineering, bearing, automotive, hydraulic, tool making and turbine industry.
HAUSER – Jig grinding machine with new wheelhead
A major development has been achieved in the product area, HAUSER jig grinding, in Biel. A new wheelhead has been developed for the model series 45 and 55.
HAUSER jig grinding machines traditionally cater to the niche of highly accurate grinding work in tool and mold fabrication, as well as grinding production of demanding small series. The new development realized by HAUSER is aimed at a pronounced increase in productivity as well as a significant improvement in achievable processing precision. At the same time, the ability to do hard machining by grinding is supplemented with expanded possibilities for fine milling, analogous to HSC milling.
To be precise, this is achieved through a new jig wheelhead. This, with the classic characteristics of the Z axis combined with the C and U axes, represents a new, previously unknown dimension of performance and capacity on the market.
Here, a Z axis with highly dynamic oscillation capabilities was realized using linear motors. The C axis is designed with a hydrostatic bearing, which permits highly accurate planetary grinding with roundness in the sub-micron range. The new design of the U axis also has a unique, large capacity for movement.
A great deal of attention was paid to preventing the effects of thermal expansion, to ensure that the sought-after improvements in precision were actually achieved.
Overall, an unusually high degree of system rigidity, previously unknown in jig grinding, has been achieved by this new solution, providing a range of improvements, such as
- a pronounced increase in performance capabilities.
- new combinations of use with grinding and hard milling
- clear improvements in precision in respect to achievable bore roundness
- previously unimagined possibilities for automation and variations in bore grinding, mold grinding, profile grinding and every kind of conical processing
HAUSER jig grinding machines fitted with this new wheelhead are available immediately in the new model series H45 and H55. The machine frames take into account the performance increases of the new wheelhead, which is why they have been given a heavier construction. On exhibition at the AMB is the HAUSER H45-400 and corresponds, in terms of size, to the previous S45-400. A full scale machine can be viewed in Hall 8, Stand D16.
New & Efficient Fitting Polishing Technology
Issue:
When producing ASME BPE, Semiconductor or Japanese standard fittings the elbows must be polished to remove all marks and imperfections. When bending the tube there are always ‘orange peel’ marks and marks from calibrating the elbow (making it round).
Practice Today:
Today, it is polished manually or polishing using mechanical polishing machine. For manual polishing, it is usual to have a team of 40+ people manually polishing with abrasive paper.
Mechanical polishing is slower, produces a dust/metal particles during operations, and leaves residual oil. Mechanical polishing also produces less than satisfactory quality.
New Solution:
ECM Methodology developed by pECM Systems and introduced by OTRA in Korea produces far superior and consistent surface finish while reducing cost per parts significantly.
pECM Systems provides turn-key systems for the manufacture of a variety of ASME BPE stainless steel pipe fittings. The systems include machine tool, control system, electrolyte management and tooling. In addition to the tooling all process parameters are supplied so that the system can enter production immediately after installation.
Applications ‘BioPharma’ and “ultra-high purity (semiconductor)” elbows and Tee’s are produced with our technology to ensure ultimate quality and performance (below)
Benefits
- Very fast Return on Investment (ROI)
- No abrasive polishing material >$200k saved PER YEAR. (Based on 100,000 elbows)
- High Production rates (One operator being able to produce > 10000 elbows per month!)
>150 per hour 1” elbows
> 60 per hour 1 1⁄2” elbows - Zero Cathode wear – 1000’s of components can be produced
- Simple to use
Systems for manufacturing BPE components by ECM
The machine is set up in two stations. One station is for loading/unloading and another for ECM process. ECM process is carried out on each station alternatively.
The machine tool is of composite granite and stainless steel construction to ensure precision, stability and long life.
- Designed to Machine to final dims and tolerances
- Special attention to surface finish
- Simple operation
- Very few consumables
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