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A TRIUMPH OF INNOVATION AND RESILIENCE – EUROBLECH 2024 WRAPS UP WITH ENCOURAGING RESULTS

Amidst ongoing global challenges, the sheet metal working industry showcased its dedication to progress and growth at the 27th International Sheet Metal Working Technology Exhibition, EuroBLECH 2024. With 38,946 trade visitors from 114 countries and 1.317 exhibitors on 160,000sqm gross space, the event reaffirmed its role as the world’s leading platform for innovation and business in this sector. A sense of cautious optimism dominated the halls, with many exhibitors securing substantial orders.

Despite the slowing global economy, there was widespread agreement that key markets will eventually bounce back and grow, together with a clear commitment to driving the necessary transformational change. Determined to focus on new opportunities, the industry has been intensifying its push for innovation. The proactive stance on technological progress was matched with a notable willingness from buyers to consider new investment.

The four-day event delivered massively on visitor quality, with the majority of visitors classifying as key decision makers. The number of unique visitors increased by 3%, with a strong presence from Germany, which has recently gained in market importance for certain technology sectors. Besides Germany, the top visitor countries in 2024 were the Netherlands, Italy, Poland, Sweden, Turkey, Austria, Spain, Belgium, Denmark, and Switzerland. There has been a significant growth in visitor numbers from Asia (Japan, Taiwan, India) and South America (notably Argentina), pointing towards promising new markets for the sheet metal working industry.

Pressure to innovate continues to spur significant technological advancements

EuroBLECH’s impressive nine exhibition halls hosted a wealth of product launches and ground-breaking innovations, sending a bold signal for technological progress and growth opportunities within the sector. Throughout all 15 technology areas, machine makers displayed a clear commitment to enhancing production efficiency through technical innovation.

Key technologies included, but were not limited to a new AI vision system for fully automated sorting of laser-cut parts; remote machine diagnostics and monitoring for fast troubleshooting and servicing; highly automated factory systems that integrate people, machines, and data into smart production flows; folding machines with fully automatic tool changer; simplified and robust laser-cutting machines particularly suited for new users; modular or compact bending cells for smaller production environments; a substantial 20kW high-speed and high-precision fibre laser cutting machine for extra demanding applications; AI-driven robotic software for complex and adaptive applications; and many other advancements.

Transformative power of innovation – realised and recognised

Of the many innovation leaders on the exhibition stands, 76 companies were shortlisted for the prestigious EuroBLECH 2024 Award, organised in partnership with blechnet and MM MaschinenMarkt.

The six winners, chosen by public vote, were recognised for their commitment to advancing technical excellence in:

  • Stamping and Forming: Amada, for their fully automatic bending robot cell ‘EGB-1303ARse’.
  • Cutting Technology: TRUMPF, for their bevel cutting on 2D laser cutting machines.
  • Joining Technology: Weil Technology, for their laser welding system ‘LWC-RT4-BPP’.
  • Surface Technology: Q-Fin, for their small parts finishing machine ‘Q-Fin F250’.
  • Automation and Handling: Reis Robotics, for their robot controller ‘ROBOTstar VII’.
  • Sustainability: Bosch Rexroth, for their energy-efficient, servo-hydraulic drive solution for deep-drawing presses.

The runner-ups were: Airco, BENEVA, Bystronic, CNC Europe/LASERMACH, EMC, ENGMAR, EPCM Expert, Hans Weber Maschinenfabrik, MicroStep Europa, Schuler and Wilson Tool. Visitors were also invited to explore the new Award Trails, featuring all 76 shortlisted companies and their innovations.

On and off the show floor – Energising mix of knowledge, engagement and fresh talent

Two dedicated Presentation Areas in Halls 26 and 27 hosted live talks by prominent change-makers, covering key developments in automation and digitalisation. A special Panel Discussion focused specifically on solutions for small and medium-sized businesses. On the show floor, the new Guided Tours launched with success, offering visitors new opportunities to efficiently engage with interesting productivity trends and suppliers.

EuroBLECH 2024 also reinforced its commitment to championing young talent and fresh approaches within the industry. One in five exhibitors was new at EuroBLECH, adding valuable input to the event. This included a group of promising start-ups in the ‘Young Innovators’ Pavilion in Hall 15 which highlighted young businesses and innovations from Germany. On Friday’s Careers Day, EuroBLECH welcomed students and apprentices who benefitted from free admission and the unique opportunity to engage with ground-breaking technologies and world-class suppliers.

Industry’s benchmark event sparks positive outlook and optimism for the future

The event ended on a high note after four productive days of fostering connections across the sheet metal supply chain and unlocking new potential for industry players. The successful turnout added to a sense of optimism and achievement among participants.

“This year’s EuroBLECH has proven vital for the sheet metal working community, which has shown remarkable resilience and innovation amid economic challenge”, says Evelyn Warwick, Event Director of EuroBLECH, on behalf of RX. “This year’s event marked a strategic milestone for many companies as it delivered – once again – an impressive showcase of technological advancements in a promising business environment. We thank all our participants for making EuroBLECH such a vibrant platform for exchange and growth – their enthusiasm and active engagement in meaningful conversations, ideas, and business ventures is what drives our industry forward.”

Looking ahead with confidence: EuroBLECH returns in October 2026

The industry remains strongly committed to EuroBLECH as their primary platform for innovation, business, and growth. Following this year’s success, many exhibitors have already confirmed their participation for the next edition. EuroBLECH 2026 is set to take place from 20 – 23 October 2026 in Hanover again.

BMW GROUP PLANT ROSSLYN OPENS NEWLY BUILT LOGISTICS WAREHOUSE SERVICING THE PRODUCTION OF THE NEW BMW X3 PHEV

BMW Group Plant Rosslyn synergises logistics materials flow with new warehouse. The 5,200 m² warehouse is used for the storage of parts for the new BMW X3 PHEV manufactured at the plant.

BMW Group Plant Rosslyn recently unveiled a newly built logistics warehouse on its premises. The building will primarily store various parts for the new BMW X3 plug-in hybrid vehicle (PHEV) and ensure timely delivery of components to the assembly line for seamless production. As BMW Group Plant Rosslyn begins the start of production of the new model, the 5,200 m² logistics warehouse is uniquely designed and constructed to aid the process.

A modular approach was used to enable future expansions for efficient spaces and lean logistics in line with BMW Group Plant Rosslyn’s long-term development plan. The building is equipped with translucent panels providing natural light into the building, individually dimmable smart LED lights, surveillance cameras with integrated artificial intelligence technology and weather resistant dock houses which maintain the integrity of parts delivered to the warehouse.

Sustainable building

In cementing BMW Group South Africa’s commitment to zero-waste-to-landfill, BMW Group Plant Rosslyn partnered with Envirolite – an eco-friendly building supplier – to transform some of its waste into sustainable and eco-friendly building bricks. Envirolite bricks consist of over 70% recycled material, including polystyrene waste generated from the plant. As a reflection of BMW Group South Africa’s principles of a circular economy, a total of 7,700 Envirolite bricks were used for the construction of the logistics warehouse.

The Envirolite brick has higher thermal insulation properties compared to a standard clay brick. This plays a key role in making the building more energy efficient by helping to reduce the energy required for heating or cooling. The daytime energy requirements are achieved through solar photovoltaic (PV) infrastructure. The combination of the solar PV, energy-efficient lighting and Envirolite bricks contributes to the warehouse being one of the most sustainable buildings at BMW Group South Africa.

BMW Group Plant Rosslyn Director Dr Niklas Fichtmüller commented, “Sustainability is at the core of our strategy, and we endeavour to build better futures as we build products of the future. This new warehouse reflects our vision for this state-of-the-art facility, especially as we gear up to produce the new BMW X3 PHEV.”

Sustainable community development

BMW Group South Africa is committed to community engagement and development as demonstrated in the building process of the new warehouse at its production facility. A total of 42 Rosslyn community labourers worked on the construction site including plasterers, bricklayers, painters and tilers. As the workers had not used the Envirolite brick type before, they were upskilled in its unique installation.

Head of Real Estate Management South Africa at BMW Group Plant Rosslyn, Reshard Sayed commented, “Green principles were considered in the conceptualisation of the building from inception. For the BMW Group, conscious use of primary materials plays a key role in building a circular economy. After five months of LEAN construction, excluding rain delays, we are excited to hand over a logistics facility that is pivotal to the launch of the new BMW X3 model at our Rosslyn plant.” BMW Group Plant Rosslyn also aims to extend its new warehouse, citing the current construction as phase one of three phases.

AMADA AUTOMATION SOLUTIONS

Ever-growing need for production has resulted in companies looking for unique methods of manufacturing with faster production times, less human intervention and ultimately less cost.

Labour costs play a huge role in production and the faster a product can be produced, the higher the profits.

In sheet metal applications, this is a difficult target due to the various stages of production such as blanking, bending, welding, grinding, painting, assembly, testing and packaging. These various processes are each a headache on their own.

Beginning with the blanking process, the designer needs to have a good understanding of the completed product and its intended use or application. This person also needs to have a good understanding of the capabilities of the machinery being used as well as the materials being processed.

The automation process begins by use of a CAD drawing system. Rendering a 3D model in Amada’s Sheetworks 3D software, the full product can be viewed, operated / animated and broken down into single part items. This process eliminates trial production and the waste of materials, time and resources.

Ultimately, all proto-typing can be done on a PC in the 3D environment, while the customer can sign off for the start of production before a single part or sample is physically produced. The process from creating the drawing to tool fitting and programming is executed by a few clicks on the PC mouse. The automated system will then separate material types and material thicknesses, it will nest the parts according to the parameters set and will program it accordingly for the selected machine.

Once completed at the programming stage, the programs are transferred from the PC to the machine by employment of a job card with a bar code attached. The use of a bar code scanner at the machine control will instantly display the program and rendering it immediately ready for production.

The scanning of the bar code will ensure that production throughput is handled in the correct sequence, thanks to the programmer who creates a production schedule according to the importance of the work. Once ready to begin with actual production, there is an additional automation option for material storage and material handling, too. These systems (ASF-H or ASR tower storage systems) & MPL (material manipulation system) are capable of loading the raw materials onto the table of the machine, ready for production to begin. All of this is possible without the operator having to touch the sheet. Once the sheet has been processed, it is offloaded by means of the manipulator system. It then is either stacked on a pallet complete with skeleton and parts or it can be separated by means of a “TK” system. The TK system is ideal for the removal and sorting of cut parts from a nested sheet. This “picker” will remove each individual part by means of numerous suckers and will place them onto different stacking pallets – sorting parts for their next processes needed onto individual pallets. Different customers’ jobs that were nested onto the same sheet can now be separated and stacked individually without any human intervention.

Bending can also be automated according to customers’ needs by utilizing Amada’s 4ie Bend software and creating all bending programs from the initial drawing. Sequencing and tool fitting is done on the PC and trial bending on the machine is eliminated. The “teach” function on the control of the bender will assist and indicate the precise positioning of each tool as required, while prompting the operator through the bending process. In the case of the ATC (Automatic Tool Changer), the machine will automatically load and unload tooling as required for the job at hand. The ATC will drastically reduce setup times between jobs as it can load a full three meters of top and bottom tooling in just 3 minutes. Suddenly the small batch runs or single part production becomes a much faster process with far less down-time.

For long constant production runs, robotics are available to replace operators. The robotic benders are ideal for constant bending of the same parts or very large production runs. These systems are available from very small robotic systems on the EGB press brakes, right up to the large – heavy duty press brakes handling parts that are too heavy for the operator.

Amada provides a total automation solution for all requirements from single sheet manipulation (MPL), to multiple sheet storage and manipulation (ASFH or ASR) to high volume sheet storage and manipulation (MARS). Everything is programmed through a central Amada data-base (VPSS4ie) and fully backed by Amada’s dedicated service and applications teams.

For more information, please contact Amada – Tel: 011 453-5459.

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M1 SURFACER DEBURRING GRINDING MACHINE

Locally available from Duncan Macdonald, the manually operated Assfalg new deburring and grinding machine, the M1 Surfacer is user-friendly and suitable for various machining processes such as grinding, deburring, edge rounding and polishing of metal surfaces, including stainless steel, steel, copper, brass and aluminium parts e.g. laser, stamped and plasma parts.

While 5 machining processes are possible in one machine, the swivel arm can rotate 180° and enables the simultaneous mounting of two machining discs. The machine is equipped with a vacuum system that fixes the workpiece on the table.

For more information, please contact Duncan MacDonald – Tel: 011 444 4345

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THREADING WITH TS-THREAD

To machine threads quickly and precisely, TaeguTec offers the TS-THREAD line, which enhances the efficiency of the thread-making process by cutting processing time and costs, while minimizing the likelihood of manufacturing defective products.

TaeguTec offers a large selection of thread milling cutters that meet the standards for both, internal and external threading.

For the manufacturing of internal and external, as well as right- and left-hand full-profile threads, TaeguTec offers the TTMT line as an indexable insert type, which offers excellent chip control with high precision and high surface quality.

For thread milling applications that use indexable inserts, TaeguTec recommends either the MTE D EndMill line or the MTF shell mill tool.

Since these tools can mount different thread inserts with varying profiles, one tool can produce a variety of thread standards and both right-hand and left-hand threads. Internal coolant that is directed toward the cutting region is present in both lines.

The MTE D end mill type improves overall machining performance, due to its high rigidity feature, and the MTF is recommended for large thread diameters with high accuracy and uniformity.

For thread milling operations, TaeguTec provides a complete line of solid carbide end mills that have a diameter ranging from 0.72 mm to 20 mm and are suitable to machine a variety of materials, including cast iron, steel, stainless steel and more. Cutting geometry, helix angle, number of flutes, length and grades differ between the tools.

Solid carbide thread mills without coolant channels from the MTEC line are typically suitable for internal and external thread milling. With the exception of gummy and sticky materials, this family can be used to produce thread from any sort of material.

To improve tool life in all thread milling applications, the MTECB line is a group of solid carbide thread mills with a coolant hole that is intended for milling internal threads in blind holes but can also frequently be used to produce external threads.

For extremely exact profiles on small internal and exterior threads, TaeguTec offers the TS-THREAD MTECS solid carbide thread mills. The cutting zone of these one-of-a-kind thread mills is only three teeth long, has three flutes, and has a released neck between the cutting zone and the shank.

Solid short left-hand cut MTECSH carbide thread mills are used to create small internal threads in hard materials. These thread mills have a released neck between the cutting zone and the shank and a short 3-tooth cutting with 3 flutes.

MTECI partial-profile solid carbide thread mills with coolant holes offer a universal solution for a variety of pitch and thread sizes.

For internal deep thread milling, the TS-THREAD MTECQ family of solid carbide thread mills with coolant holes and smaller neck diameters between the cutting zone and the shank is advised. Thread lengths up to 3.2 x DC can be machined with this tool.

TaeguTec strives to provide threading tools that enhance overall performance, lower costs, and increase the efficiency of the threading process.

For more information please contact TaeguTec – Tel: 011 362-1500.

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PRODUCTIVE AND RELIABLE DEEP HOLE DRILLING SOLUTIONS

Precihole Machine Tools provides the best value in deep hole drilling technology

 

By Paul Savides, Managing Director, PBS Machine Tools

Precihole Machine Tools is a global leader in providing hi-precision deep hole drilling and hole finishing technology. The company’s focus on this niche technology over the last three decades has made Precihole the only recognized brand with the most complete range of solutions offered in this technology. The company’s strength is creativity, while customizing engineering solutions that are perfectly suited to the needs of customers. This is by no means an easy task, since deep hole drilling and hole finishing solutions have over 150 different applications spread across 20+ industries. The company’s business strategy revolves around customer success by combining a state-of-the-art machine tools, application support and excellent service.

Precihole solutions are most suited in industries, such as Defence and Firearm, Oil & Gas, Mining, Automotive, Aerospace, Medical Implants, Seamless Tube Manufacturing, Energy, Die and Mould, Hydraulic Cylinders etc. The company prides itself in the ability to truly offer world class solutions, while guaranteeing outstanding performance and productivity. Precihole offers solutions for gun drilling, BTA (STS) / ejector drilling, pull boring, trepanning, counter boring, vertical and horizontal honing, lapping, pull reaming, skiving and roller burnishing, bottom forming and bottle boring. Precihole’s business processes and operational methodologies ensure that total cost, including material and labour, tends to be substantially lower than the competition. They are an ISO 9001:2015 certified company that values product quality, customers and employees.

Gun Drilling Solutions with automation

Precihole is proud to offer a high production gun drilling machine that can be operated by a robot. It is highly precise and productive at the same time. The machine is extremely easy to tool up and designed to work in challenging work environments 24/7.

The machine features a compact footprint and produces impressive results in terms of hole straightness, bore tolerance and surface finish. Installation takes just a few hours and training is a breeze. The machine is specifically suitable in the Firearm, Oil & Gas, Automotive and Thermowell industries.

BTA (STS) Deep Hole Drilling Solutions

Precihole Machine Tools offers a complete line of BTA (STS) Deep Hole Drilling machines. These machines are capable of drilling holes from Φ 20 mm to Φ 400 mm up to 10 m in length. While new patent pending features achieve top quality output, this machine is robust enough to allow high feeds in process and withstand the high torque experienced during cutting operation. This is a complete solution that includes cutting elements, oil filtration, oil chiller, chip conveyor with options of a chip shredder and oil centrifuge. These machines find applications mainly in Defence, Mining, Oil & Gas and Energy industries.

Precihole continues to innovate and introducing new products to market. The company’s strategy is to spend time learning new application requirements from customers and investing in R&D. Precihole works very closely with their tooling partners all over the world to ensure that their solutions keep up with new trends and developments in cutting tool technology.

South African Market

Precihole Machine Tools solutions are exclusively imported and sold in the South African market by PBS Machine Tools, based in Boksburg near Johannesburg. PBS Machine Tools has been in business for over 30 years and enjoys an excellent reputation in the industry to offer technical solutions.

For more information please contact PBS Machine Tools – Tel: 011 914-3360.

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ISCAR IS ABOUT TO CHANGE METAL CUTTING… AGAIN!

ISCAR is set to revolutionize metal cutting once again with its latest product launch, “LOGIQUICK”. This new brand name signifies ISCAR’s new marketing theme and encompasses three key words: “Logic”, “IQ”, and “Quick”. The previous campaigns by ISCAR have already highlighted the importance of intelligent cutting tools for advanced machining, providing logical solutions that meet the primary of modern production. These tools have become a market standard in numerous workshops worldwide. However, the addition of “Quick” in the logo brings forth a sense of anticipation. What new challenges will the campaign products present? Is it simply a catchy brand name or a fundamental concept? Let’s explore the meaning of the logo and its implications.

In the field of metal cutting, the productivity is directly linked to the metal removal rates (MRR). To enhance machining rates, the metalworking industry strives for “fast metal removal”, which refers to processes that efficiently and swiftly remove material using cutting methods. These processes involve the utilization of machines, strategies, techniques and cutting tools that enable faster more effective machining, thereby reducing cutting time. However, in many cases, the primary obstacle to fully harnessing advanced, highly engineered machine tools and promising machining strategies lies in the cutting tool itself. The cutting tool often becomes the weakest link in the entire machining process, limiting potential gains in productivity and impeding the reduction of machining costs and the growth of profitability.

ISCAR believes that the ultimate objective of a tool manufacturer is to supply cutting tools that ensure efficient metal removal. These tools should not only possess effective working characteristics to enable metal removal rates, but also exhibit qualities such as repeatability, versatility, user-friendliness and a high utilization factor. These attributes collectively represent the IQ of tool, which is essential for leveraging the full potential of advanced machine-tool capabilities. This principle guides the development of cutting tools, harnessing the expertise of tool-design engineers, technologists, metallurgists, manufacturers and all those involved in creating innovative tool solutions for intelligent machining in the metalworking industry.

ISCAR’s latest campaign unveils a range of ground-breaking cutting tools, including turning, parting, grooving, hole making, and milling products. Let’s take a closer look at the LOGIQUICK portfolio to fully immerse ourselves in the campaign’s essence and delve into the details of these exciting new developments.

Rotating tools

Steel construction beams play a crucial role in building structures and frameworks, requiring the drilling of numerous holes prior to assembly. However, the clamping mechanisms on machines often lack rigidity, posing a challenge for drilling tools. To address these limitations, it is essential for drilling tools to have an adaptive design that compensates for non-rigid conditions and optimal drilling performance. Currently, finding an efficient drilling tool for beams is a top priority. ISCAR has developed a new solution based on the-established SUMOCHAM concept of assembled tools with an exchangeable drilling head made from tungsten carbide. This solution incorporates three key elements, such as cutting material, cutting geometry and body design. The specially developed PVD-coated IC954 carbide grade offers exceptional resistance to deformation. The new IHP-BP exchangeable head features a dedicated-centring cutting edge, ensuring secure material penetration, while the sharp corners of the head effectively prevent the formation of burrs. Additionally, the reinforced drill body enhances dynamic rigidity. As a result, the new SUMOCHAM product provides an effective solution for drilling relatively thin beam sections under unstable conditions.

Introducing another innovative rotating product, the modular SUMOCHAM drill head with MULTI-MASTER adaptation, combines the strengths of two leading ISCAR product lines. This new drill head is designed to accommodate any of the SUMOCHAM exchangeable heads, providing the versatility of a modular tool assembly. It is specifically designed to be on a wide range of MULTI-MASTER shanks, allowing for easy customization in terms of shape, overall length and diameter. This not only reduces the tool inventory but also minimizes the need for special drills. The combination of SUMOCHAM and MULTI-MASTER creates a promising synergy effect, offering tremendous potential.

Efficiently removing a large volume of material through milling is crucial in the production of critical duty loaded parts, such as aircraft components made from titanium alloys. Extended flute indexable milling cutters, also known as “milling porcupines”, are highly effective for this type of machining, particularly, when milling cavities, pockets and wide edges. The success of such tools depends on a combination of productivity, reliability and cost-effectiveness. Iscar introduces the QUICK-X-FLUTE, a new family of 90-degree extended flute shell mills with double-sided square inserts. These mills are designed with an optimized flute shape that strikes a balance between tool rigidity and effective chip flow, enabling high metal removal rates (MRR) with substantial radial engagement. The developed flute profile enhances vibration resistance, especially during workpiece entry and exit, allowing for increased cutting data and improved productivity. The inner channels of the mill have replaceable nozzles and frontal outlets, facilitating direct high-pressure coolant supply (HPC) to the cutting zone. This improves cooling and lubrication, contributing to effective chip control. Additionally, the double-sided square insert offers 8 indexable cutting edges greatly increasing insert material utilization.

Non-Rotating Tools

To achieve success in machining high temperature super alloys (HTSA), the selection of the right cutting tool material is crucial. While introducing IC1017, a new tungsten carbide grade specifically designed for ISO-standardized inserts used in turning HTSA, this grade boasts a high-hardness submicron structure and is coated with PVD enabling higher cutting speeds for enhanced productivity.

Iscar also introduces LOGIQ-6-TURN, a newly designed triangular insert that offers a cost-effective solution for semi-finish and finish turning with a focus on achieving high surface quality. This double-sided insert features a 55° corner angle and positive rake cutting geometry, providing 6 indexable cutting edges. It presents a significant alternative to the standard ISO-type rhombic insert of DCMT type, which only offers 2 cutting edges. One key advantage is the ease with which LOGIQ-6-TURN inserts can be mounted on turning tools, designed for triangular TNMG inserts.

Maximizing profitability through efficient use of raw materials during the parting process is crucial. ISCAR’s highly regarded DO-GRIP parting and grooving family has recently grown with the addition of three new sizes of double-sided inserts, specifically designed for narrow parting operations. These inserts are primarily targeted for Swiss-Type lathes, enabling optimal material savings when parting small-diameter bars, tubes and thin-walled workpieces.

The new tools are just a few examples of the various products introduced by ISCAR as part of the LOGIQUICK campaign. The numerous other product releases have significant interest and will soon be tested by manufacturers. With the increasing demand for quick metal removal, the need for advanced cutting tools continues to grow. This drives the development of tool designs and shapes the logic behind intelligent tool development.

For more information, please contact ISCAR South Africa (PTY) LTD – Tel: 011 997-2700.

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MAZAK SHOWCASED CUTTING-EDGE MACHINES AT AMB

 

Mazak recently participated in the AMB Exhibition 2024 in Stuttgart, where it showcased seven cutting-edge machines with highlights including Multi-Tasking capabilities, advanced automation, innovative auto gear technology and comprehensive remote service and support for increased productivity.  

A world debut specialist gear-cutting machine was among the seven solutions on show from Yamazaki Mazak, while another world debut was the first in a new range of turning centres that will offer customers increased levels of productivity and efficiency.

A central component of the show was the company’s Go Green environmental manufacturing initiative, highlighted by the new NEO range of machines that have been designed to help customers achieve a more sustainable future with higher productivity, accuracy and environmental performance.

There were two NEO machines on display at AMB that have been purposely designed with a range of technological advancements to be able to deliver up to a 30% reduction in energy consumption compared to the original models.

The VARIAXIS i-700 NEO is one of two new machines from Mazak’s new NEO range.

The VARIAXIS i-700 NEO, a high-rigidity, next-generation 5-axis machining centre has an exceptionally wide machining area making it ideal for large workpieces, as well as a tilting/rotary table for high-accuracy machining over an extended period. The VARIAXIS is equipped with the advanced SmoothAi CNC.

The HCN-4000 NEO, which was displayed with a 20,000-rpm high-speed, high-output spindle for maximum productivity was exhibited with a two-pallet changer that ensures it can machine workpieces on the first pallet, while a second pallet is prepared.

­ The HCN-4000 NEO is equipped with 20,000-rpm high-speed, high-output spindle for maximum productivity.

Gear machining was an important part of Mazak’s stand with a specialist gear-cutting machine on show. The INTEGREX i-250H ST AG seamlessly brings together Mazak Multi-Tasking technology with gear cutting and measurement capability. The INTEGREX is capable of three different gear machining methods – gear skiving, hobbing and end-milling – making it ideal for high-mix, small-volume production and large production batches.

­A specialist gear-cutting INTEGREX Multi-Tasking machine with optional equipment.

The QUICK TURN 250 MSY with Turn Assist and equipped for skiving applications, was also on display. The machine has a milling function, second spindle and Y-axis, 5,000-rpm spindle with the option of 10,000 rpm for ultimate productivity. It is controlled by SmoothG CNC, providing machine users with complete ease of use and ensuring high-speed, high-accuracy machining performance. The QUICK TURN 250 MSY was exhibited with a TA robot, making it ideal for lights-out and unmanned machining.

­Mazak’s QUICK TURN 250 MSY machine equipped for gear cutting.

Also on display was the VARIAXIS C-600 tended by a part-loading and unloading third-party automation system.

Visitors were able to witness a live digital twinning demonstration involving a CV5-500 5-axis machining centre. The process was shown to create an identical digital copy of the machine in an office environment, saving operator time during setup, programming, fixturing and tooling to improve process and quality control.

The CV5-500 is one of Mazak’s entry-level machining centres, offering a cost-effective 5-axis solution that can be easily integrated with automation to further enhance productivity.

Visitors were able to view more information about Mazak iCONNECT – a digital service for existing Mazak customers that has a suite of free services including access to product manuals and e-learning options – along with a Machine-2-Mazak (M2M) subscription service. M2M enables remote real-time machine monitoring for proactive maintenance strategies including remote support to detect problems, remote optimization of machining processes with increased uptime, as well as access to Mazak applications, project engineers and service operators.

Newly available through Mazak iCONNECT is MAZATROL DX, a new productivity software that provides users with the capability to optimize their production process with the ability to generate rapid and automatic quotations, automated part programming, virtual machine simulation and machine process analysis and optimisation.

A variety of machined parts were on display to showcase some of the innovative ways Mazak is closely collaborating with its customers to drive innovation and push boundaries of what is possible.

­CV5-500 entry-level machining centre offering a cost-effective 5-axis solution.

Marco Casanova, Managing Director at Yamazaki Mazak for the DACH region, said “Our machines and technologies are designed to make our customers better, faster and more competitive. The new NEO machines combine best-in-class performance with exceptional environmental credentials; our gear-cutting machines bring a new age of productivity to a specialist machining process and our MAZATROL DX CNC offers even greater process optimization.

 

 

For more information, please contact HI-TECH Machine Tools – Tel: 011 608 0088.

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MAZAK NEW 2D LASER MACHINE FOR SHEET METAL CUTTING

 

Yamazaki Mazak last year completed the development of a new 2D laser machine for top-notch sheet metal cutting operations. The brand-new Cutting Head MCT3 and the innovative MAZATROL SmoothLX CNC Control system are just a few of the technical standouts installed on the OPTIPLEX 3015 NEO.

The large working area allows processing workpieces up to 1525 mm x 3050 mm through a 15 kW fiber laser resonator. The unique Beam Shaping Technology automatically adjusts the beam diameter and energy concentration to ensure the best possible result on various materials and thicknesses.

Automation is the key word here. The newly-designed Cutting Head MCT3 boasts multiple intelligent functions to streamline the operator’s job even more: Auto Nozzle Changing to optimise laser cutting and reduce assist gas consumption, Auto Focus distance adjustment for faster cutting speeds, and Auto Calibration of the nozzle-workpiece distance drastically improve productivity.

Automating the overall setup time can lead to 95% quicker preparations compared to standard laser machines. Moreover, Intelligent Cutting functions such as Flash Cutting and Fine Power Ramping can enhance the overall process even more. Instead of stopping at each axis, the laser is turned on and off through Flash Cutting—synchronising the axis and laser movements leads to greatly reduced cutting times. Fine Power Ramping is used instead to adjust the laser power and feed rate when cutting corners and straight lines to minimise dross without compromising the cutting speed.

A wide assembly of sensors installed on the cutting head enable the OPTIPLEX 3015 NEO to accurately monitor piercing and cutting operations and detect processing abnormalities and defects. For example, when plasma is detected, the Plasma Detection function adjusts the cutting speed to ensure good edge quality and minimise cutting imperfections. If instead burning occurs when cutting mid to thick mild steel plate, the Burn Detection function automatically stops the process to reduce failure. The Pierce Detection function detects when piercing has been completed and automatically begins the cutting process, reducing downtime considerably.

The OPTIPLEX 3015 NEO has been specifically engineered to help operators in their daily work. Before the actual cutting takes place, Mazak Smart System can generate process data – thanks to two sets of cameras above the work area – to optimise sheet utilisation in order to handle urgently required work and exploit the machine’s full potential. The new MAZATROL SmoothLX’s large 21.5” screen displays parts nesting at a glance, and the touch panel provides easy access to necessary information such as cut conditions or nozzle settings. Nest Programming, Cut Monitoring, Production Scheduling, and Machine Maintenance are just some of the many functions available to the operator. Also, the optional dual monitor allows multiple applications to run simultaneously.

Excellent Accessibility completes the picture. Large front and side access doors reduce the floor space needed and make material loading and unloading hassle-free; the tilting and rotating CNC control panel allows the operator to work at the front or at the side of the machine; the easily accessible work area enables direct control over the material while the nozzle centring camera allows <1 min adjustment times.

For more information, please contact HI-TECH Machine Tools – Tel: 011 608 0088.

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BYSTRONIC IMPRESSES WITH AUTOMATION AT EuroBLECH 2024

 

Bending automation, laser automation, a new laser cutter configuration system, electric bending, software, services and sustainability – these were the Bystronic highlights at EuroBLECH 2024 in Hanover/Germany.

Bystronic’s primary goal is to offer customers solutions that help them to stay ahead of the competition on a daily basis. This includes state-of-the-art machines, tailor-made automation solutions, process-optimizing software and first-class service.

Bystronic presented high-performance laser cutting and bending cells that ensure the competitiveness of customers thanks to the perfect interaction of various systems. This is precisely why Bystronic was focusing on automation at Euro BLECH.

Bending automation

Bystronic presented the ByCell Bend Star M, the bending cell with the ByBend Star 120 press brake for small and medium-sized parts, thus closing a gap. With its high performance and compact dimensions, it fits into practically any production hall. This brand new, fully automatic bending cell with the “Optical Part Detection” function offers small and large production companies’ maximum efficiency and flexibility in bending. The ByCell Bend Star M is ideal for processing job lists as well as for changing orders from small batch sizes to large series. In combination with the new ByBend Star 120, the agile robot completes bending jobs fully automatically and error-free.

ByCell Bend Star M automates the bending of small and medium-sized parts.

Mobile Bending Cell

If you need a bending cell in the smallest of spaces, you can rely on the Mobile Bending Cell 80, which develops a press force of up to 80 tons over a bending length of around 1.5 meters. This is made possible by the powerful ByBend Star 80 press brake, which can be easily upgraded to a fully automated Mobile Bending Cell if you already have a manual press. The Mobile Bending Robot is simply docked onto the ByBend Star and connected and referenced within ten minutes.

Mobile Bending Cell for automated bending in the smallest of spaces.

Laser automation

Bystronic has the right solution for entry into laser automation with the ByCut Eco laser cutter in combination with the ByLoader Flex automation solution.

Simple, robust, affordable – these are the attributes of the ByCut Eco. The new Bystronic ByCut Eco 3015/4020 with a choice of 3, 4 or 6 kilowatts of laser power is the right choice for entrepreneurs who want to get into the laser cutting business or want an uncomplicated fiber laser without many extras.

The ByLoader Flex is the ideal automation system for handling sheet metal on a Bystronic laser cutting system. If customers have more than one laser cutting system, the “2-for-1 principle” of the ByLoader Flex is the perfect solution; a single automation system serves two laser cutting systems. Two laser machines can be managed simultaneously with one ByLoader Flex.

The simple operation and low price are the plus points of this cutting cell. Customers can leave the loading and unloading process to it and take care of more important tasks.

The ByLoader Flex can be used on two laser cutting machines simultaneously.

Laser Packages

Bystronic is taking a new approach for the future of its laser cutting systems. Customers no longer select predefined machines in various classes with existing features, but instead assemble their Bystronic laser cutting system themselves according to their production requirements.

The proven ByCut laser cutter forms the basis. Depending on requirements, an Autonomy Package, Power Package, Dynamic Package, Quality Cut Package or a Convenience Package is added. This means that customers receive exactly what they really need, while the packages can also be combined.

ByCut, the proven laser cutter forms the basis for the individually configurable laser cutting system.

The laser cutting cell with laser packages on show included a complete automation system with the ByCut 30-kilowatt laser cutter, a third shuttle table (Shuttle Table Extension) and the ByTower Compact combined loading and unloading system including storage tower.

Bending novelty

ByBend Smart E, powerful and energy-saving sheet metal bending thanks to electric drive.

The next generation of bending technology – clean and highly efficient bending of sheet metal thanks to compact dimensions and an electric drive – that is the new ByBend Smart E with its clever features. It provides Bystronic customers with another pioneering machine to keep them ahead of the competition.

With the impressive bending capacity of 350 or even 550 kilonewtons (kN), which corresponds to a press force of 35.7 or 56.1 tons, respectively, users in the sheet metal working industry reduce cycle time and thus increase productivity.

In times when sustainability is a top priority, new machines with better energy consumption have an advantage. The ByBend Smart E also scores here, because thanks to the intelligent electric drive, energy consumption can be significantly reduced.

Software

With the BySoft Suite, customers digitize their sheet metal processing business from quotation preparation to delivery of the end product. The software developed specifically for the sheet metal processing industry won the EuroBLECH Award in the “Handling and Automation” category at EuroBLECH 2022 and has since become a model for success. Whether with individual modules for the respective application area, the “Digital Plans”, the “Digital Solutions” or the entire package for the complete digitalization of production, the BySoft Suite optimizes and accelerates the sheet metal working process.

BySoft Suite helps customers to digitize their production and thus achieve full transparency.

Services

Whether laser cutting, bending, automation or software, the experienced Bystronic experts support customers throughout the entire life cycle of their systems so that they can achieve maximum performance. In every situation, customers can rely on Bystronic’s expertise to meet all their requirements.

Bystronic solutions ensure smooth production for many years to come.

Bystronic also offers its customers useful digital tools such as eProActive Service or ePartsFinder, which simplify the life of sheet metal workers and extend the life of the machines.

Sustainability

Bystronic builds sustainable systems and helps its customers to produce sustainably themselves.

With Bystronic systems, customers optimize their use of energy and resources and reduce CO2 emissions.

Sustainability plays a central role in Bystronic’s corporate strategy. The aim is to shape a sustainable future with sheet metal. To this end, Bystronic has developed an ambitious sustainability strategy that is consistently implemented across all areas. In this way, Bystronic helps its customers to produce in a more environmentally conscious manner, save costs and reduce their footprint.

Bystronic Solution Forum

The Solution Forum, designed to inspire, was Bystronic’s keynote stage at EuroBLECH in Hanover. Every day, four inspiring keynotes took place, making the future of sheet metal processing and global trends tangible.

Visitors experienced exciting customer stories first-hand, immersing themselves in the world of green steel, while discovering how artificial intelligence and the industrial metaverse are revolutionizing the industry. Customers, experts and partners shared their visions for a sustainable future, while showing how state-of-the-art technologies are driving the industry forward.

At the Solution Forum, interested parties experienced what their future could look like in presentations, panel discussions and demos.

For more information please see www.bystronic.co.za or contact Bystronic on 010 410 0200.

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