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RISING CARBIDE PRICES SHOULDN’T CUT INTO YOUR PROFITS

Raw tungsten material pricing continues to climb, and for many shops that pressure shows up quickly right on the bottom line. When raw material costs rise, the gap between a “good enough” machining setup and a truly optimized one becomes measurable in dollars per part, spindle uptime and how often tools are being changed. In today’s environment, productivity and tooling strategies aren’t just technical decisions, they’re margin protection.

ISCAR is addressing this challenge head-on with its MAXOUT strategy, a calculated approach designed to help manufacturers achieve MINIMUM COST and MAXIMUM OUTPUT. The message is simple, when you choose ISCAR, MAXOUT becomes MAXVALUE, higher productivity and improved machining economics.

ISCAR’s MAXOUT strategy provides productive, stable machining with improved tool economy for turning, milling, holemaking, parting and grooving.

ISCAR’s approach centres on stable, repeatable machining performance that supports aggressive cutting data, while protecting consistency and tool life. The goal is to maintain throughput even when input costs are moving in the wrong direction, using tooling solutions that balance performance with economics.

MAXIMUM OUTPUT – More Parts

High-performance turning geometries combined with rigid, stable setups help shops increase feeds and speeds without sacrificing process stability. The payoff shows up in shorter cycle times, improved chip control and more parts out the door per shift, more parts, less time.

MINIMUM COST – Spend Less Per Cutting Edge

The cost of tooling, specifically solid round endmills and drills, increase significantly when carbide prices rise. Substituting these expensive tools for indexable insert options reduces cost since only the cutting edge is replaced not the entire tool. In many cases, ISCAR’s indexable options can meet the machining economics of the best round tools reducing cost per cutting edge, improving tool utilization and reducing disposal requirements for used tools.  ISCAR solutions help stretch tooling budgets further while maintaining production demands.  More parts, less carbide used, less tooling cost.

MAXVALUE – Repeatable Results That Protect Quality

Repeatability is critical, especially in long-running production. ISCAR’s insert grades and geometries are engineered for reliable, consistent results, supporting predictable surface finish and dimensional control, while reducing the risk of rework and scrap. With the rising cost of inputs in the machining process, rejected parts are not acceptable.  Consistency of process is a competitive advantage.  Less inputs, less time, MAXVALUE.

When rising material costs squeeze margins, ISCAR’s MAXOUT strategy is a practical way to maximize machining performance and minimize machine shop inputs.

Stop profit erosion, MAXOUT your machining performance with ISCAR.

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

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FERROUS HIGH PRECISION ENGINEERING CELEBRATES 45 YEARS OF PRECISION ENGINEERING

Ferrous High Precision Engineering was founded on March 10, 1981, by Giuseppe Cadamuro from Italy and Norman Carradus from Britain. Both founders brought a wealth of experience from their careers in the engineering industry.

Guiseppe Cadamuro was working at OIL Precision Engineering at the time and felt that he didn’t get enough support from the owner to take on complicated high precision engineering jobs at the time. Machining to high precision standards and tolerances had always been his passion.

During its initial years, the company operated from rented premises, focusing on meeting the growing demand for precision-engineered components. The business expanded steadily, necessitating the purchase of additional machines to enhance production capabilities.

Initially the company focused on maintenance items specifically for Natref, Sasol, Air Products, Dorbyl Roll Works etc. They concentrated on items that other companies were unable or unwilling to manufacture and made a name for themselves as a company who could do very high quality jobs that others couldn’t’ do. Later on they identified the need for producing trapezoidal lead screws and nuts.

Ferrous Engineering relocated to its own purpose-built facility on Fairbanks Street, Vanderbijlpark. This move marked a significant milestone, providing larger and more efficient premises to accommodate expanded operations and continued growth.

In April 2024, ownership of the company changed, marking a new chapter in Ferrous High Precision Engineering’s history. Under new leadership, the company continues its legacy of precision engineering excellence, serving diverse industries with innovative solutions and superior quality.

FERROUS HIGH PRECISION ENGINEERING’s equipment includes conventional lathes, milling machines, surface grinders, cylindrical grinders, CNC lathes, a VMC and lead screw manufacturing machines.

While working from a +/- 1200 sqm factory space, the company employs 23 people.

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DVF 5000 DESIGNED TO REVOLUTIONIZE PRODUCTIVITY AND MACHINING CAPABILITIES

 

The DVF 5000 Second Generation simultaneous 5-axis vertical machining centre from DN Solutions is designed to elevate productivity and machining capabilities to unprecedented heights.

Serving as the flagship 5-axis machining centre for DN Solutions, the DVF 5000 facilitates the seamless machining of complex shapes and curved surfaces in a single setup. By addressing issues of time, cost and quality inherent in repetitive setup processes, it streamlines operations while enhancing efficiency.

Building upon the success of its predecessor, the DVF 5000 Second Generation raises the bar even higher. Equipped with an industry-leading cooling system and standard thermal displacement compensation, it ensures unparalleled precision, even during prolonged operation. Its robust bed structure enables precise machining of workpieces weighing up to 400 kg, empowering manufacturers to tackle diverse projects with ease. The integration of a built-in Auto Workpiece Changer (AWC) and round magazine facilitates a compact automation system, while various features such as the auto kicking device enhance profitability for customers.

Productivity Enhanced with Astonishing Speed

With remarkable speed, the DVF 5000 Second Generation redefines productivity, boasting significantly faster X, Y, and Z-axis feed rates that double the speed of its predecessor, achieved through an acceleration and deceleration rate of 0.4g. Additionally, it showcases a 25% increase in B- and C-axis rotation speed, now at 25 r/min, alongside an impressive Tool to Tool (T.T.T) time of 1.3 seconds and a Chip to Chip (C.T.C) time of 3.8 seconds, making it 28% faster than its forerunner. This remarkable advancement positions the DVF 5000 Second Generation as the epitome of productivity in its class.

Moreover, the DVF 5000 Second Generation comes standard with a 15000 r/min spindle, elevating its versatility and performance. Equipped with a high-rigidity high-speed spindle and a robust columnar structured table, it delivers impeccable surface finishes, facilitating the machining of a wide array of materials, from high-speed aluminium to challenging-to-cut metals like titanium, Inconel, and CoCr (Cobalt Chromium). Furthermore, opting for the built-in spindle capable of achieving speeds of up to 20000 r/min enhances precision machining capabilities, enabling fine surface finishing and intricate 5-axis contouring. Additionally, the inclusion of a high-torque spindle (max. 230Nm) enables the machining of exceptionally tough-to-cut materials, further expanding its capabilities.

Advanced Thermal Displacement and Precision Compensation

The DVF 5000 Second Generation showcases a meticulously engineered symmetrical structure, designed to thwart any deformation. To curtail heat generation within the rotation and feed axes, it integrates multiple cooling units strategically positioned in key drive locations, including the spindle, feed axis and rotary table. Embracing a smart thermal displacement compensation function as standard, it guarantees impeccable precision even during prolonged machining sessions. Moreover, active sensors embedded within the spindle head, column and bed diligently monitor thermal displacement throughout the machining process, automatically adjusting to minimize thermal expansion and distortion.

Elevating productivity and machining stability, the DVF 5000 Second Generation includes a high-speed servo magazine as a standard feature. With its high-rigidity and precision roller-type LM guideways, capable of accommodating a maximum load of 400kg, it ensures steadfast machining performance. The incorporation of a 0.0001-degree high-precision B- and C-axis rotation mechanism guarantees exceptional accuracy. For added precision, the optional IKC (Intelligent Kinematic Compensation) solution adeptly compensates for rotary axis centre errors, mitigating deviations in workpiece shape with precision and finesse.

Upgraded Machining Flexibility

The DVF 5000 Second Generation presents expanded machining capabilities, providing greater flexibility with enlarged workpiece and clamping tool sizes. Featuring a table size of Ø630 x 450 mm and accommodating a maximum workpiece size of Ø600 x H500 mm, it boasts a remarkable 26% increase in table size and a substantial 32% expansion in maximum machining area. This enhancement opens doors to a wide spectrum of industries, catering to the needs of manufacturing diverse parts, from intricate, high-precision medical components to small and medium-sized parts vital to the automotive, aerospace, and semiconductor sectors.

Additionally, the DVF 5000’s extended travel distances for the X, Y, and Z axes—now at 650 mm, 520 mm and 480 mm, respectively, represent a significant 20% increase. This expanded space allows seamless integration of automation units for material loading and unloading, further enhancing operational efficiency and versatility.

Compact Automation Solutions

Positioned as the prime choice for compact automation, the DVF 5000 sets the standard for streamlined automation capabilities. Elevating its automation prowess, the DVF 5000 2nd Generation features an easy-to-install and operate AWC, a round magazine system that enables 24/7/365 unmanned operation, accommodating up to 40 workpieces. Notably, the AWC unit seamlessly integrates with the previous generation, ensuring compatibility and ease of transition.

Enhanced Operator Convenience Features

The DVF 5000 Second Generation offers users the flexibility to select and apply NCs from FANUC, HEIDENHAIN and SIEMENS, each equipped with cutting-edge NC technology. It boasts accelerated data and PLC (Programmable Logic Controller) processing speeds, spanning from programming and program verification to machine setup and actual machining. Notably, FANUC NCs stand out with their collision prevention system (CPS), which actively monitors internal materials, tools and axis feed units in real time to avert potential collisions and prevent damage.

Moreover, the machine enhances operator accessibility with the relocation of the magazine window for tool setup to the front, streamlining access. An auto kicking device has been incorporated to facilitate seamless tool changes, while the reduced distance between the operator and the table centre simplifies workpiece setup. Improvements in chip handling are achieved through the installation of six flood coolant nozzles on the spindle’s front, aiding cooling and chip removal during machining, alongside a flushing nozzle on the machine bed to minimize chip accumulation. As a testament to its commitment to environmental sustainability, the DVF 5000 Second Generation features grease lubrication as a standard feature, reducing oil consumption and rendering it a more eco-friendly machining centre.

For further information, please contact PUMA MACHINE TOOLS – Tel: (011) 976 8600.

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POWER SKIVING – AN INNOVATIVE GEAR MACHINING OPTION

It is expected that the machining of automobile transmission gears will continue into the future with 7-speed and 8-speed transmissions, even with the introduction of EV reducers. The core component of these gears and reducers is the planetary gear set, with the power skiving being an innovative method for machining ring gears.

Power skiving was conceived in the beginning of the 20th century. Though highly productive and flexible, this method was difficult to implement because it required precision equipment and tools. Today, however, the development of new geometries and grades of tools, as well as improved machine control, makes the power skiving process an interesting alternative for gear manufacturing.

Power skiving is basically an operation where a workpiece is machined into the shape of a desired gear. The two axes rotate according to the gear ratio, due to the intersecting angle between the gear axis and the tool axis, resulting in skiving cutting in the direction of the gear’s tooth line, and continuous skiving cutting occurs with a combination of hobbing and shaping.

Advantages of Power Skiving Machining Method

The advantages of the power skiving machining method are as follows:

Power skiving replaces most of the conventional gear machining methods: Such methods include broaching, shaping and hobbing, which are used depending on internal/external gear machining and interference issues. Power skiving is more flexible than broaching, because it can be applied to blind and through hole gears. Hobbing can only be applied to external gear processing but cannot be applied if there is interference, whereas power skiving can also be applied when there is interference with internal/external tooth processing. In shaping, compared to power skiving, the tool has a longer contact time with the workpiece and generates much cutting heat, which is disadvantageous to tool life. Another advantage to power skiving is its excellent profile accuracy in the lead direction.

High productivity: In the power skiving process, the cutting speed is in the tooth line direction of the gear, so the milling rotation speed of the cutter must be multiplied by sinΣ (intersection angle).

Although there is a difference, depending on the angle of intersection, the revolutions per minute (RPM) of the spindle must be about 4 times faster than that of conventional milling in order to obtain the desired speed with a carbide tool.

At this time, the workpiece rotates according to the gear ratio, and since continuous cutting is performed according to the way the gear is generated, the cutting speed becomes very fast.

Power skiving differs depending on conditions, such as the module and pressure angle, but it is generally 4 times faster than hobbing and about 10 times faster than shaping. Therefore, it is possible to significantly reduce the number of machines used in the machining process. For example, one power skiving machine can do the work of 10 installed shaper machines. This is the basis for reducing space, minimizing equipment investment and reducing manpower costs.

One machine for turning, milling and gear machining: Traditional gear machining requires separate machines for each process; for example, shaping is usually done on the shaping machine and hobbing is done only on the hobbing machine. However, in the case of power skiving, all the work is done on one 5-axis multitasking machine, making it possible for the operator to complete turning, grooving, milling, drilling and chisel machining, all in one setting. This eliminates the need for separate setup time and can dramatically shorten the cycle time.

High compatibility: With the same module and pressure angle tool, power skiving processes of spur gears and helical gears are machined within the range of formed crossing angles in the production of internal and external gear teeth. In addition, it is also able to machine the various numbers of teeth.

Less interference when machining: Hobbing can only be applied to external teeth and cannot be applied when there is workpiece interference, but power skiving can reduce the component size and weight when machining gear parts. Gear tooth profiling using shaping has relatively even less interference than hobbing, but the productivity is low and undercutting is essential when machining blind hole types. However, power skiving avoids this issue with a programmed tool path, even if there is no undercutting required.

Hard power skiving for internal gears: After gear cutting, partial deformation occurs when heat treatment is performed to increase the hardness of the gear surface. Hard power skiving refers to finishing the deformed part with a carbide power skiving tool. Previously, there was no way to efficiently process heat-treated small and medium-sized internal gears, therefore, power skiving will become a game changer in gear cutting in the future.

TaeguTec’s Power Skiving Tool Technology

TaeguTec is a leader and innovator of advanced metal cutting tools including insert types and head changeable solid carbide tools with advanced technology in the production of power skiving tools.

Essentially, carbide tools have very high cutting speeds and high hardness, compared to HSS tools; this reduces machining time and increases tool life. The insert type is applied to gears in large sizes with the diameter of the tool being relatively large. In addition, the head changeable solid carbide tool is suitable for the gear processing of small sizes, such as automobile parts.

Usually, there is a high probability of problems, such as chip tangling, due to the rotation of the workpiece during internal gear processing, but TaeguTec’s cutting tools solve these challenges using an internal coolant supply. The head changeable type solid carbide tools not only guarantee high-precision because of its rigid and precise fastening structure but also eliminates the need for setup intervals, due to simple indexable head replacement, which enables high cost reduction.

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

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THE DO-ALL MASTER – MULTI-MASTER FOR EVERY TASK

The MULTI-MASTER system, an innovative range of assembled tools with exchangeable cutting heads, was originally introduced by ISCAR at the start of the 21st century, making the product as old as the era itself. Despite its age, the MULTI-MASTER has demonstrated remarkable longevity and remains highly popular in the metal cutting industry. Moreover, although the concept provoked widespread doubts initially, it paved the way for numerous competitors to develop similar solutions based on the same elements.

The MULTI-MASTER design centers the cutting head in the tool body using a short taper, ensuring face contact through elastic deformation of the body’s female taper area, while the head is secured in place by a threaded connection. Initially, the use of threads was met with significant scepticism, as threading can act as a stress concentrator in cemented carbide, the hard but brittle material used for the exchangeable heads. Such conditions can present a potential weakness, an Achilles’ heel, in the design. However, the introduction of a specially engineered thread profile provided an elegant solution to this problem, effectively settling these hesitations. This innovation inspired many companies to adopt threaded connections for cutters with exchangeable carbide heads. As a result, almost every leading brand now includes such cutters in their product ranges.

What benefits of the MULTI-MASTER family explain its longevity? Which features contribute to the product’s enduring success in the industry? These frequently asked questions are worth further consideration.

First, the MULTI-MASTER concept is based on three key elements, the product’s design triad, taper centering, face contact and the connection thread, which together provide significant advantages. Taper centering ensures high accuracy, while face contact uses the head overhang within strict tolerance limits, resulting in excellent dimensional repeatability of the assembly. The threaded connection makes replacing the heads simple and operator friendly.

Owing to its high accuracy, the MULTI-MASTER stands as a strong competitor to solid carbide tools. Maintaining the head overhang within close tolerances meets the requirements of the important “no-setup time” principle, as replacing a worn head does not require additional setup operations. The head can be changed without removing the tool from the machine, which significantly reduces machine downtime. This is an important attribute of assembled tools for tomorrow’s smart manufacturing.

The thread connection allows the tool body to mount different cutting heads and vice versa, transforming the body into a universal holder and thereby reducing both tool inventory and storage needs. The bodies (referred to as “shanks” in MULTI-MASTER terminology) are made of steel, cemented carbide with considerable stiffness, or heavy metal, which offers excellent vibration-dampening properties. Moreover, the wide selection of MULTI-MASTER adapters, extensions and reducers simplifies tool customization, ensuring the optimal tool configuration for specific applications and diminishing the need for special tools.

All of this enables thousands of efficient assembled tool combinations for a broad range of machining applications, including milling, holemaking, threading, engraving and even gearing.

Additionally, the MULTI-MASTER system features another characteristic that makes it particularly relevant today. In recent years, the prices of tungsten-containing ores and raw materials have risen rapidly, due to various factors. This has led to a significant increase in the cost of tungsten carbide, a primary material for cutting tools, which in turn, has had a major impact on overall tooling costs.

As a result, manufacturers in the metalworking industry are reassessing their priorities, and the need for cost-effective tooling solutions that can substantially reduce expenses has become more important than ever. Given these circumstances, the MULTI-MASTER system stands out, as it offers impressive opportunities for economizing on tungsten carbide. This makes it a truly groundbreaking solution for today’s challenges.  A MULTI-MASTER assembly approaches the performance of a solid tool not only in terms of accuracy. The extremely rigid connection between the head and shank gives the assembly stiffness comparable to that of a monolithic design. In the MULTI-MASTER system, the advantageous combination of accuracy and rigidity, enhanced by the system’s versatility, offers a valuable, cost-effective alternative to solid carbide tools.

Over its more than 25-year history of continuous innovation, the MULTI-MASTER system has developed a rich product portfolio. Its application range includes milling shoulders, slots, planes, 3D surfaces, threads, gears, splines, chamfering, drilling and countersinking. Beyond exchangeable solid carbide heads, the system now incorporates heads with indexable inserts, significantly expanding its versatility. Though major developments have reached their natural limit, ISCAR engineers continue to introduce new products, keeping the MULTI-MASTER family fresh and dynamic. These new designs, whether prominent or subtle, demonstrate that the MULTI-MASTER story logically (logIQally!) continues. Let’s look at several recent additions.

Solid Carbide Milling Heads

The assortment of MULTI-MASTER’s standard-line solid carbide heads is extensive, encompassing a wide variety of shapes, including cylindrical, tapered, ball-nose, disc-type, toroidal and others, within a nominal diameter range of 5–32 mm. While it may seem that this diversity fully satisfies design requirements, ISCAR continues to expand the line with new products each year.

Among the latest additions are six-flute high-feed milling (HFM) heads for efficient roughing, capable of machining steels hardened up to HRC 65; six-flute dovetail groove milling heads with cutting edge angles of 120° and 135°; and four-flute, 32-mm-diameter heads for milling aluminium and other ISO N materials, featuring an anti-chatter design, sharp cutting edge and polished rake face. The increased number of flutes is intended to promote productive machining combined with rational and sustainable utilization of carbide material.

Shanks

Recently, ISCAR introduced new MULTI-MASTER anti-vibration shanks featuring an innovative assembled-structure concept, a carbide body integrated with a built-in vibration-damping mechanism. Such a combination of a high-stiffness material and an oscillation-absorbing mechanism dramatically improves dynamic performance by minimizing vibrations during cutting. As a result, these shanks enable enhanced performance in long-reach applications and under unstable machining conditions.

Another seemingly minor, yet highly valuable, addition is the double-sided shank design. This design incorporates two head pockets on opposite ends of the shank and a central through-coolant hole, offering a cost-effective solution that can help reduce customer tool inventory.

Threading Solutions

MULTI-MASTER threading products include various exchangeable heads with both full and partial thread profiles of 60° and 55°, known for their impressive reliability and dimensional repeatability. This range is continually expanding with the introduction of new heads. One of the latest developments is the high-performance thread milling head with spiral single-sided inserts.

The helical cutting edge ensures smooth and stable cutting, which significantly reduces cutting forces and power consumption. The benefits of the helical edge are especially pronounced when thread milling with a high tool overhang, particularly when using the new anti-vibration shanks.

Holemaking Products

In hole making applications, the MULTI-MASTER line now offers three-flute solid carbide heads. These heads combine the highly efficient three-flute concept, which originates from ISCAR’s LOGIQ-3-CHAM family, with the exceptional robustness of the MULTI-MASTER system. Thanks to this combination, the tool is particularly effective for shallow drilling operations, especially when machining materials that produce short chips.

A similar interfamily combination is seen in the modular drilling heads that incorporate key design elements from the successful SUMOCHAM family into the MULTI-MASTER platform.

This new development provides the customer with a flexible drilling solution that is easily adaptable and simple to set up for a range of applications.

The history of MULTI-MASTER, which began more than a quarter-century ago, continues to be a story of success. Its versatile tool system has not only withstood the test of time but has also made a significant impact on the development of cutting tools. The MULTI-MASTER concept has yet to reach its full potential and continues to evolve, consistently providing masterful solutions for a wide range of metal cutting operations.

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

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HOW DO YOU DETECT VALUE FOR MONEY IN MACHINE TOOLS

By Paul Savides, Managing Director, PBS Machine Tools

“Discussion sharpens one’s interest in any subject and accordingly inspires reading and corrects errors.”-Nelson Mandela (1918-2013)

When evaluating machine tools, value for money is not determined by purchase price alone. The real measure lies in the machine’s ability to produce quality parts profitably over its lifetime.

Paul Savides Managing Director, PBS Machine Tools

A more accurate way to assess value is through Total Cost of Ownership (TCO) and overall machine optimization, a combination of structural integrity, availability and utilization. In simple terms, the cheapest machine is not always the most cost-effective machine.

Key Indicators of Value for Money:

Structural Integrity

Machine weight is often used as an indicator of structural rigidity, which contributes to accuracy, vibration control and long-term durability. A rigid machine typically delivers better consistency and longevity.

However, true structural value goes beyond physical mass. The real question is, how quickly does the machine pay for itself? A machine that improves productivity, increases output, reduces scrap and lowers labour or maintenance costs often delivers stronger long-term value than a cheaper alternative.

High Uptime and Reliability

Reliability is one of the clearest indicators of value. A machine with minimal unplanned downtime, low maintenance requirements and dependable performance contributes directly to productivity and profitability. Lost spindle time is lost revenue.

Lower Cost per Part

Many manufacturers continue operating at traditional speeds and feeds without fully evaluating their cost-per-part performance. Cost per part is typically influenced by Machine Hourly Cost, Cycle Time, Tooling Cost and Number of Parts Produced.

When these factors are optimized, premium machine tools can often reduce cost per part by more than 15%, while significantly improving gross profit per component compared with lower-cost alternatives.

Practical Method for Assessing Value:

  1. Analyse Total Cost of Ownership (TCO)

TCO looks beyond the purchase price and considers the machine’s full lifecycle cost:

TCO = Acquisition+Operating+Maintenance+Training+Disposal-Residual Value

A lower-cost machine may appear attractive initially, but can result in significantly higher long-term costs, due to maintenance, downtime, inefficiency or poor resale value.

  1. Compare Market Value

Benchmarking similar new or used machines helps establish fair value. Factors such as machine age, condition, performance history and remaining useful life, should all be considered before making a purchasing decision.

  1. Evaluate Used Equipment Carefully

When assessing a used machine, maintenance history is critical. Review maintenance logs for signs of neglect, excessive wear or improper servicing. Machine hours should align with overall condition, as heavily worn components may be costly to replace or in some cases no longer available.

  1. Match the Machine to the Application

The best machine is the one suited to the job. Purchasing decisions should be based on production requirements, such as material removal rate, precision, repeatability and output expectations rather, than simply selecting the machine with the most advanced features or the machine with the fastest delivery time.

Value versus Price – Understanding the Difference

Quality over Cost

Higher-performance machines often generate a better return on investment than lower-cost alternatives. While the initial purchase price may be higher, improved productivity, reduced scrap, greater reliability, and lower cost per part frequently justify the investment.

Watch for Hidden Costs

The purchase price is only one part of the equation. Training, electricity consumption, spare parts availability, tooling compatibility, maintenance requirements and downtime costs, should all form part of the buying decision.

Consider Resale Value

High-quality machines generally retain value better over time, reducing ownership costs and improving long-term investment returns.

Final Thoughts/Conclusion

Although Total Cost of Ownership is still not a common purchasing approach in many manufacturing environments, it is becoming increasingly important for maintaining competitiveness.

In an industry facing growing pressure from imported products and tighter margins, investing in equipment based on lifecycle value rather than upfront cost, can provide a meaningful competitive advantage.

For more detailed, industry-specific guidance on calculating machine ownership costs and evaluating value for money, feel free to contact us.

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

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LEAD MACHINE TOOLS NOW SOLE SOUTH AFRICAN AGENT FOR GERMAN CNC MACHINERY GIANT – GROB

In a major development, Lead Machine Tools recently became the sole South African agent for German CNC Machinery giant, GROB.

With 100 years of experience and almost 10 thousand employees globally, GROB is one of the largest manufacturers Lead has ever signed with.

For half a century, the city of Mindelheim has been the headquarters and heart of the GROB Group. With a production space of more than 210,800 m² and around 6,100 employees, the German plant is the biggest employer in the Unterallgäu region and continues to offer more and more people from the region secure employment.

The Mindelheim plant is the central hub of the global growth strategy and, with the Research and Development Department, is home to two of GROB’s key competences. The large-scale production facility ensures the globally renowned vertical integration and guarantees the best value creation with maximum cost-efficiency.

From innovative manufacturing lines to complete assembly systems through to universal machining centers and electric drives – the company’s entire product range is made here in its headquarters.

GROB has production facilities in Germany, Brazil, China, USA, Italy and India, as well as worldwide service centers and sales subsidiaries.

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TAKISAWA MX-800 SERIES

Equipped with twin turrets and twin spindles this is a multi-tasking fully intelligent turning-milling CNC lathe for complex machining.

 

Opposed left and right spindles and turrets allow independent machining by each spindle/turret system with interchange between the systems to reduce cycle times for highly complex machining, while the compact working area with twin machining stations is designed for flexibility and fast component transfer for highly cost effective machining. Full roller guideways allow higher speeds that shorten cycle times to enhance capability for mass production. Increased distance between linear guideways on each axis improves rigidity and stability for highly accurate machining, while the gantry loading option allows high speed mass production with minimal operator intervention.

 

An option to equip the MX-800 with a gantry loading system and parts conveyor radically shortens component handling times and coupled with the design of the twin turret/twin spindle system for the highest machining speeds, it provides the perfect solution for high-speed mass production.

For more information, contact 600 SA Machine Tools – Cell: 072 157 6003.

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THE HELLER F 8000 HIGH-PERFORMANCE MACHINING CENTRE

 

Following the successful introduction of the F 5000 and F 6000 models, HELLER is recently extended its new generation 5-axis range at the top end with the F 8000. With numerous innovations that ensure extremely high performance and precision, as well as a small footprint, the F 8000 is suitable for applications in a wide range of industries. The high-performance machining centre has been on the market since September 2024.

Things move fast at HELLER: In the autumn of 2023, the Nürtingen-based machine manufacturer unveiled the F 6000, the first 5-axis machining centre in its new generation F series. Only six months later, another model was launched: the F 5000. And the larger F 8000 has been available since AMB 2024 in Stuttgart. Like its ‘siblings’, the machine is suitable for a wide range of users in many industries, from mechanical engineering and power generation to aerospace – from single-part manufacturing through to flexible 24/7 series production.

The F 8000 is based on the successful 5-axis F series, which has been on the market for more than a decade. However, it surpasses its predecessors in many areas. For example, at 4.20 metres wide, it has a much narrower footprint and the basic version takes up around 25 per cent less space. In addition, the optional PRO version offers the best technical specifications. Axis acceleration in X/Y/Z has been increased by 50% to 6 m/s2. Chip-to-chip time has been reduced by approx. 30 per cent. The F 8000 with PRO package also offers greater precision. Positioning tolerances in X/Y/Z are 6μm – a 25% improvement over the previous model.

Another advantage of the F 8000 is its large work envelope (X/Y/Z: 1,400/1,200/1,400 mm), which allows larger workpieces to be machined and, above all, the 150 mm longer stroke in the X-axis, which provides even greater machining flexibility. In addition to 800 x 800 mm pallets, it is also possible to use larger 1,000 x 1,000 mm pallets. Head of Development Dr Manuel Gerst explains: “The maximum pallet load is 2,000 kg, with an optional pallet load of up to 3,000 kg.”

Full compatibility with the previous generation

To make the transition to the generation F series as easy as possible, HELLER has ensured maximum consistency. This means, for example, that the pallets and tools are fully compatible with the previous 5-axis range.

The machine is equipped with the latest generation Siemens control system, SINUMERIK ONE. However, users can easily adopt all NC programs used on previous machines equipped with Siemens’ SINUMERIK 840D sl control. A main operating unit in console-design with a 24-inch touch screen and a host of other features makes the control system even more enjoyable to work with.

With the F series, but HELLER not only guarantees full continuity with previous generations the developers have also ensured a high level of compatibility with the H series 4-axis machining centres. Pallets and tools are interchangeable, and standardisation of structural components such as beds and columns enables the same strokes, pallet loads and part dimensions.

Small footprint provides more space for automated machining

The standardisation of the 5-axis machine within the range goes even further. The F 8000 uses the same modular system as the entire F series for key components such as heads, spindles and tool magazines. The machine structure is also standardised across the F series, resulting in the narrow footprint mentioned before.

Equally important to the compact design of the F 8000 are HELLER’s rack-type tool storage systems. All of them are almost two metres narrower than the previous versions. This is particularly useful when automating multiple machining centres. Four machines can be placed in a row where previously only three could be installed.

Machining units with tilt and swivel kinematics

Among the highlights of the F 8000, and the F series as a whole, are the completely redesigned swivel heads, which ensure maximum cutting performance. The integrated motor spindles, developed in-house, are manufactured by HELLER. Equipped with an HSK-A 100 interface as standard, the Dynamic Cutting Universal (DCU) unit achieves torques of 400 Nm and speeds of 12,000 rpm. The Speed Cutting Unit (SCU) provides 15,000 rpm with HSK-A 100. In conjunction with the optional HSK-A 63 tool interface, HELLER also offers spindles with speeds up to 18,000 rpm. For ultra-heavy machining, the Power Cutting Universal (PCU) unit with gear spindle is still available – delivering 1,146 Nm of torque and speeds up to 8,000 rpm.

In addition to the swivel heads, HELLER also offers a tilt head variant for the F 8000. It is characterised by a particularly high degree of flexibility in 5-axis machining. This is because the tilt kinematics make it possible to produce the recesses and undercuts required, for example, in the manufacture of integral components for the aerospace industry.

Ready for any type of automation

Whether it is for the manufacture of single parts or flexible series production, the F 8000 5-axis machining centre is always the right choice. For those who are not yet sure whether they want to equip the machine with pallet automation at the time of purchase, HELLER offers the ‘Automation-READY’ option for maximum flexibility. This means that the available standardised automation systems can be integrated quickly and easily at a later date. The F 8000 is equipped with an automatic pallet changer as standard. In addition, extended automation with linear or rotary storage systems or robots is available.

All in one – milling, turning and other technologies

In addition to automation, complete machining is playing an increasingly important role in many manufacturing companies. Following this all-in-one concept, HELLER offers an optional mill-turn function for combined milling and turning operations for the entire F series. At its heart is the high-torque DDT (Direct Drive Turning) rotary table. This means that in addition to milling and drilling, external and internal contours can be turned longitudinally or transversely in a single set-up, as well as a wide variety of undercuts and recesses. Even cutting of external and internal threads is possible. This eliminates the need for re-clamping on separate turning machines, improving part accuracy and reducing cycle times.

For further information, please contact RETECON – Tel: (011) 976 8600.

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VIBRATION FREE BORING BAR LINE WITH EXCHANGEABLE HEADS

Advance Machining has reached new levels with the vibration free SFEED-TEC HUSH-BORE, a line that efficiently performs deep internal turning at an incredible 10xD, 12xD and even 14xD . The steel and carbide-based 12xD and 14xD shanks offer outstanding machining performance even during deep internal machining because they have improved rigidity and hardness, which prevent shank breakage caused by bending.

In order to reach high speeds and feeds without damaging the workpiece, spindle, insert and so on, TaeguTec’s Advance Turning team developed a revolutionary damping system located inside the shank which results in a smooth surface finish as well as an internal coolant supply for longer tool life and stable machining, due to the rigid clamping system. All these technologically advanced features increase feeds and cutting speeds, making it highly productive. In order to provide a full range of options, HUSH-BORE is available in many different diameters and in a few tool lengths. The various exchangeable heads can be securely fastened with an unrivalled serrated coupling located in the boring bars.

Ø80 HUSH-BORE Assembly Instructions

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

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