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FANUC ROBODRILL α -DIB5 PLUS SERIES

Further productivity enhancement with the same trusted reliability

It is already hard to improve upon such a well-balanced design. The new α-DiB5 Plus Series Robodrill therefore uses the same time-tested and trusted mechanical design while boasting the latest in FANUC CNC and Servo Technology.

FANUC 31i-B5 Plus Control Powerhouse

The new-generation CNC control offers many features as standard along with new intuitive iHMI screens. The Plus control now offers 4MB of part program storage as standard with the option of upgrading to 8MB. High speed skip is now a standard feature ensuring touch probe signals are as true as possible. Furthermore, Multi-functional ethernet eases the step to fully automate your Robodrill when the time comes to add a FANUC ROBOT. Smart rigid tapping cycle utilizes the maximum output of the spindle without compromising on accuracy and Smart overlap function overlaps command blocks between rapid traverse and cutting feed blocks to avoid speed loss at transition points.

Level-up of Ease-of-Use Screens

Not only are the conventional screens still available to make the transition easier to the latest Robodrill, but there is a whole array of new and improved screens to assist operators with Maintenance, Zero Position Recovery, Turret Restoration, Machining Cycle and CNC operation functions. These screens have step by step instructions and are intuitive in nature.

The iHMI Machining Cycle screens (Previously Manual Guide i) has been revamped and is now more capable of generating complex drawings while also being more user friendly.

The control is also capable of displaying up to 15 custom screens which can be used for your Robot automation project, pallet changer or precision measurement equipment. Custom-made switches and clamping setups can even be controlled with the use of the Custom PMC Ladder and the external interface screens enabling the user to program touch screen buttons to manipulate physical external equipment. This puts the power into users’ hands and makes the Robodrill the most versatile option when tackling automation projects.

Revised Spindle Line-up

The new 12,000 RPM Tapping spindle which taps perfectly in between our High Power Speed 24,000 RPM spindle and the Robodrill’s robust High Torque 10,000 RPM spindle opens a new spectrum of applications. Aluminium automobile, IT Parts and electrical parts are just some of the parts in which the Tapping spindle will come into to its own. This spindle in conjunction with the Smart functionality will yield the best results possible.

Spindle torque characteristic

FANUCs legendary reliability coupled with easy preventative maintenance procedures keeps downtime to an absolute minimum. And thanks to their extreme longevity, ROBODRILL machines also provide an unbeatable return on investment.

FANUC ROBODRILL is proudly made in Japan and comes with a 2 year mechanical and control warranty. The FANUC ROBODRILL α-DiB5 Plus series is available from FANUC South Africa.

For more information, please contact FANUC South Africa Sales on 011 392 3610, e-mail sales@fanuc.co.za or visit www.fanuc.co.za.

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TAEGUTEC HAS INTRODUCED THE CHASE-8-SFEED LINE FOR ROUGH AND HIGH FEED FACE MILLING OPERATIONS

The newly released CHASE-8-SFEED, for roughing (45°) and high feed (20°) face milling, provides higher productivity than conventional double-sided 8-corner inserts by applying a reinforced edge shape and unique insert pocket angle. Excellent machining performance, under harsh cutting conditions, is obtained due to the high negative radial rake angle and high positive axial rake angle. Coupled with the stronger body rigidity, excellent chip evacuation is the result. CHASE-8-SFEED inserts are available in two sizes, SQKU 11 and 14, and the same insert can be used interchangeably with 45° roughing cutters and 20° high feed cutters.

FEATURES

  • Economical double-sided 8-corner insert
  • Two entering angle cutters for roughing feed machining

40° cutters deep depth of cut for roughing.    20° cutters for high feed milling.

• Wiper edge for excellent surface roughness
Note: good visual roughness requires feed rate adjustment
• Reinforced edge optimized for high feed machining
• High negative radial rake angle and high positive axial rake angle

  • Excellent chip evacuation to reduced chip volume
  • Enhanced body rigidity for excellent machining performance
    under harsh cutting conditions
  • Fine pitch cutter maximizes productivity

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AUTOMATING YOUR MILLING OPERATION IS NOT ONLY PICK AND PLACE

By Paul Savides, Managing Director, PBS Machine Tools

Bankers are lucky, through interest they can make money even while they sleep. Yet, manufacturing challenges are increasing on a daily basis, so what about your engineering operation?

There are three methods to improve your efficiency:

  • Production Automation: Wages and salary increases without improvements in efficiency and the decline in young people wanting to work in a difficult work environment that is our industry.

Therefore, production automation reduces labour costs, while increasing value gained through predictable quality and reduced operational errors.

  • Information Automation: Constant working hours allows for errors due to fatigue and the loss of data when job/shift handover from one employee to another.

Therefore, information automation will provide transparent information and production status datalization with on time delivery and monitoring of product line from anywhere.

  • Management Automation: Information misinterpretation across shift changes and too much time spent on data capturing and report writing.

Therefore, data collection by the system reduces human error and digitization management builds up product traceability.

Depending on the variety of products you are manufacturing, it is sometimes difficult finding the right, suitable automation solution.

Mass production of a single product workpiece can be achieved through pairing an individual machine with a robot.

Increased production and quality rates can be achieved by integrating more than two machines that share the process, fixtures and tools.

High-Mix Medium-Volume production can be economically achieved by using a multiple pallet pool or flexible manufacturing systems that enable high frequency exchange of the production line through high accuracy fixture transfer.

High-Mix Low-Volume production means enabling production lines requiring high variety of products to be restructured with high frequency, making it a highly flexible manufacturing system.

The problems when implementing the various levels of required automation are mostly discovered after implementation and can include:

  1. Production rates that are lower than expected due to poor utilization rates including robotic idle time.
  2. Automation process errors requiring constant stopping, modification and testing due to unattainable targets.
  3. Complex data exchange and communication errors when connecting to other systems make integration difficult.
  4. Problems with monitoring and management of automation lines that suddenly stop due to equipment or system failures.
  5. Lack of quality management that ensures no defective parts are processed and eliminated from the system in time.

The above is where the Tongtai Group of Companies comes into play by using Analysis and Evaluation, Hardware and Software Integration and Datalization Management to assist users to predict and solve potential issues.

The simplest manufacturing can be achieved through using Multi-Tasking machines where you can integrate different processes into a single machine which reduces labour, thus saving money, saving floor space, while increasing production space utilization and reducing the number of operations required. Stability and accuracy is maximized and productivity improved.

What we have learnt working with our customers

In mass production environments change-overs occur least often, if at all. Whereas in jobbing environments change-overs are far more frequent and can cause loss of entire shifts.

One of the biggest losses of time during milling operations occurs during change-over. Changing over from one job to the next involves tooling, fixture, programs and operations. Having a 5-axis milling machine for example with multiple pallets can eliminate this loss of time completely.

APEC CNC, a member of the Tongtai group recently introduced their new high-speed, heavy-duty model HS-700 Horizontal 5 axis machining centre with multi pallet system at Timtos in Taiwan. This type of machinery can be used as a full 5 axis machine that is capable of machining 5 sides of a workpiece in one set up with an X-axis of 710mm, Y-Axis 910mm and Z-axis 810mm complete with 32, 60 or 120 tools ATC that provides flexibility and variety. In this case a good choice is to fill the ATC with pre-set tooling that can be used in a variety of different jobs and set up multiple pallets that can accomplish increased productivity and allow the machine to work unattended.

We are just a phone call away for a free consultation to discuss your application – and production needs.

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

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MAPLE ME-SERIES – THE ULTIMATE ALL-ROUNDER

Maple ME - Series

While every day presents different challenges, the Maple ME-Series has what it takes to tackle just about anything. Its super wide base design provides great balance providing a platform capable of supporting up to 2000 kg. With high-end servo motors that are directly connected to the ball screw no power is lost during transmission.

Featuring an innovative design combined with cutting-edge technologies make the ME-Series ideal for mould production and parts production. The machine has a clever solution for whatever challenge comes its way.

The ME-Series was designed with the most advanced FEM analysis software on the market. Maple consistently tests its design under many different stress conditions to perfectly satisfy customers’ requirements.

The advanced design of Maple’s spindles provides high axial- thrust capability, yet generates minimal heat. The spindle uses front and rear pre-load angular bearings with large spacer to enhance radial stability enabling heavy cuts on steel. To ensure long life of the spindle, high temperature grease is used to guarantee smooth operation of the spindle regardless of temperature.

The ME-Series is designed to carve through any material it meets-without sacrificing accuracy or finish along the way.

Without a perfect tool changer the machine cannot operate at its fully automatic potential. Therefore, the ME-Series uses the most high quality tool changer available. With a 1.8 second tool change time it is one of the fastest performing tool changers in the world.

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

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HIGH PRODUCTIVITY VERTICAL MACHINING CENTERS – DNM SERIES

New DNM series VMC

With a global installed base in excess of 30000 machines, the DNM series is a popular and proven mainstay in DN SOLUTIONS’s product line. With a range of different models, sizes and capacities, there is definitely a DNM machine to meet customers’ needs.

Featuring the largest machining area in its class the new DNM series vertical machining center offers increased Y-axis travel and a higher table load. The direct-coupled spindle for higher productivity improves the machines’ performance and environmental-friendliness, while higher productivity is achieved by reducing the tool change time and improving all axes feed rates plus acceleration/deceleration times.

DNM series VMC with the largest machining area in its class.

This environmental-friendly machine is designed for stable and easy operation with the EOP function that can be accessed via the pop-up window on the NC main screen. Grease lubrication for axis roller guideways is supplied as standard.

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

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KITAMURA INTRODUCES MEDCENTER5AX

ULTRA COMPACT SIMULTANEOUS 5-AXIS HIGH PRECISION VERTICAL MACHINING CENTER FOR THE MEDICAL DEVICE MARKET

Kitamura Machinery, the premier manufacturer of precision horizontal, vertical and 5-axis machining centers, adds to its 5-axis line up with the MedCenter5AX vertical machining centre. This ultra-compact 5-axis VMC brings with it the largest work envelope in its class and offers unparalleled precision, accuracy and speed for expanded machining capability in the machining of highly complex, multi-sided parts in one setup.

The MedCenter5AX employs an X, Y & Z axis, and additional tilting A-Axis (+/-120 deg.) and a rotary C-Axis (360 deg.) with a 0.001 deg. minimum indexing command. Machining of high precision, complicated parts like orthopedic implants or aerospace parts can be completed in one operation, reducing the overall machining process. The maximum work piece size (Dia. xHeight) of Ø220mm (8.7”) x 175mm (6.9”) and maximum table load capacity of 20Kg (44lbs) allow for incredible flexibility and versatility in the machining of smaller highly precise, highly intricate parts.

Standard high speed, direct drive 4th and 5th axis rotary tables offer smooth simultaneous 5-axis movement for complex cutting applications. Rigid in design and equipped with high resolution optical scale feedback on all axes, the MedCenter5AX offers the precise accuracies needed (positioning accuracy of ±0.002mm (±0.000079”))/full stroke for a wide variety of small part machining.

Kitamura’s standard high speed 30,000minˉ¹ 18kw (24.5HP) direct drive, HSK-E40 spindle offers superb rigidity an ultimate stiffness in spindle construction and function while allowing for super fine finish capabilities. Ideal for small diameter tools and hard milling, the MedCenter5AX offers a standard air through spindle feature for dry cutting and is also equipped to handle up to 1000psi coolant thru the spindle for deep hole drilling requirements.

The MedCenter5AX may be compact but it is equipped with a large 40 tool magazine – a great benefit when machining more complex parts. Tool changes are a lightning fast 1.5 seconds. To assure optimum operator access and convenience when setting up tools or performing routine maintenance, the tool magazine is located toward the back side of the machine.

For increased productivity, Kitamura offers an optional 12-station automatic pallet system for running long hours of unmanned operating in the machining of both highly mixed or highvolume production parts.

Kitamura combines many standard features in our feature-rich Arumatik-Mi control. With a 5-times faster processing speed, the Arumatik-Mi CNC Controller offers a super-smooth control process for super-fast machining of complex work pieces. Featuring the latest in advanced, ultra-intuitive touch screen technology, dedicated 5-axis control functions and advanced 5-axis NC simulation and verification software, the Arumatik-Mi is your solution for easier programming, part setup and operation of complex components.

For More information, contact WD Hearn – Tel: 021 534 5351

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HAAS VERTICAL MILLING MACHINES

Vertical milling machines are a fundamental tool in the manufacturing industry, used to shape and cut various materials such as metal, wood, and plastics. Haas Automation, Inc. is a renowned name in the industry, offering a range of high-quality vertical milling machines that provide precision and efficiency to their users.

Haas Automation, Inc. was founded in 1983 and has since then established itself as a leading provider of CNC machine tools. Their vertical milling machines are designed to cater to the needs of a variety of industries, including aerospace, automotive, medical and more. The company offers a range of models that cater to different requirements and budgets, ensuring that there is a Haas milling machine suitable for every customer.

One of the key advantages of Haas vertical milling machines is their precision. These machines are equipped with advanced features such as high-speed spindles, precise linear guides and accurate positioning systems that enable them to produce parts with tight tolerances. Additionally, the machines are designed with easy-to-use controls and are low maintenance, making them user-friendly and efficient.

Another advantage of Haas vertical milling machines is their versatility. These machines can handle a wide range of materials and can perform various operations such as drilling, milling, tapping and boring. They also come with a range of options and accessories, allowing customers to customize the machines to their specific needs.

Haas Automation, Inc. is also known for its exceptional customer support. The company provides comprehensive training programs to help customers learn how to use their machines and get the most out of them. They offer timely technical support and maintenance services, ensuring that their customers’ machines are always running smoothly and efficiently.

Haas Automation, Inc.’s vertical milling machines are an excellent choice for anyone looking for precision, versatility and efficiency in their machining operations. With a wide range of models, advanced features and exceptional customer support, Haas has cemented its position as one of the leading providers of CNC machine tools in the industry.

For more information, please contact Haas Factory Outlet – Tel: (011) 974-2301.

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HURCO MACHINING CENTRES SUPPORT SUBCONTRACTOR’S RAPID GROWTH

Installation of one Hurco vertical machining centre (VMC) per year between 2013 and 2017 plus the addition of a sixth in May 2021, partly to take advantage of the UK government’s 130% capital allowance, have coincided with a sustained improvement in the level of business at subcontract machining firm Kelvin Precision Products. Disregarding the first year, when the start-up firm’s income was relatively low and therefore unrepresentative, turnover has increased fivefold compared with the second year of trading.

Like many employees working at subcontracting firms, James Staniford dreamt of branching out on his own. After an eight-year stint at a company in nearby Horsham, he took the plunge in 2013 and started Kelvin Precision Products with Claire McGrath, now the Business Director, who invested capital and owned a suitable 4,000 sq ft unit within the Kelvin Business Centre in Crawley.

The enterprise had the help of his friend and mentor Alan Lamberth, who used his turning experience to help out at evenings and weekends. It boosted this side of the business at the time and allowed Kelvin to take on much more complex manual turning than would otherwise have been possible.

However it was prismatic machining that quickly took precedence and it now accounts for around 85% of turnover. An online auction on eBay secured the first contract to machine a range of small laboratory components from acetal and aluminium for a customer in the scientific industry, which was also a start-up. Soon afterwards a manufacturer of broadcasting equipment, another new company, discovered Kelvin via its website and placed an order for a range of milled components. Both companies are still regular customers, along with about a dozen others.

The contracts were fulfilled on a Hurco VM10 3-axis VMC, which was purchased new along with a manual lathe, a knee-type mill and a linisher when James started the business. A Hurco machine was chosen for the first major purchase due to the Windows-based conversational programming capability in the machine’s WinMax control.

James said, “At the outset we didn’t have a CAM system, so relied on WinMax and its menu-driven 3D graphics interface to prepare cycles for machining our customers’ components, some of which were quite complex.

“At that time, the other shortlisted machine had a G-code control and 2D graphics, so we regarded the Hurco offering as superior.

“As time went on and parts became even more complicated, we invested in Autodesk FeatureCAM Ultimate CAD/CAM software, but WinMax is quicker for programming simple components and we still use it about one-third of the time.”

Following the success of the first VMC, one year later another 3-axis machine was installed – a VM10i with more advanced control technology and diagnostics. Then the first 5-axis machine arrived, a VM10Ui, followed by a second in 2016. A larger VM20i 3-axis VMC with a 1,168 x 508 mm table was delivered a year later and then a third 5-axis VM10Ui in early 2021. Interspersed among these purchases were a sliding-head lathe in 2014 and a fixed-head lathe in 2018.

Having half of its prismatic metalcutting capacity able to produce components efficiently in fewer set-ups using three- plus two-axis cycles, with the rotary axes positioned and clamped, sets Kelvin apart from many of its competitors of similar size. It enables high quality work typically to tolerances of ± 0.05 mm to 0.10 mm to be turned around in short time scales. Normally, components are put on a 5-axis machine at Crawley for Op 1 and a 3-axis machine for Op 2 if it is relatively simple. Fully interpolative 5-axis milling and drilling on the Hurcos is available if suitable jobs come along.

Aluminium base plate for a customer in the pharmaceutical industry

Based close to Gatwick airport, the subcontractor offers machining services with delivery to the south-east of England and to the rest of the UK and Europe via a mail order service, with customers emailing a drawing or CAD file. A regular part of the company’s activity is working for other contract machining firms that require more capacity to get an important job out on time.

Today, prismatic machining of a wide range of plastics and metals including stainless steel, mild steel, cast iron, aluminium, brass and copper are the mainstay of the company’s day-to-day work, some parts being over one metre in length. Sliding-and fixed-head turn-milling of components from 1 mm to 350 mm in diameter accounts for around 15% of turnover.

For more information, contact Hurco – Tel: (011) 012 259 1375

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DMG MORI M1 FOR OUTSTANDING MILLING PERFORMANCE

The DMG MORI M1 milling machine locally available from Retecon offers perfect machining performance and high surface quality thanks to superior stiffness, while large heat capacity of the components guarantees thermal stability. The unique design of the machine is based on a monolithic bed.

The perfectly suited working area is combined with a compact footprint of only 6 m2 and the fixed and rigid table has a maximum load capacity of up to 600 kg assuring high machining performance.

The outstanding quality of the DMG MORI inline spindle is well proven with more than 3,000 units installed worldwide.

Design based on monolithic Bed

APPLICATION EXAMPLES

Bracket (Aerospace)
Support plate (Automotive)

 

Assembly plate (Engineering)
Electronic housing (Engineering)

 

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

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LOGIQ-8-TANG NEW 90° CUTTERS CARRYING TANGENTIALLY CLAMPED INSERTS WITH 8 CUTTING EDGES

ISCAR is introducing new cutters that carry tangentially clamped inserts with 8 right-hand cutting edges, intended for face and shoulder milling. They are suitable for a wide range of workpiece materials including different types of steel, stainless steel and cast iron and are designed for roughing and finishing operations in the automotive, die and mould industries and for general engineering.

The new T890HT cutters feature 90° cutting edge angle and a rigid dovetail clamping configuration. Coolant channels are directed to each cutting edge, while polished coating of the cutter body facilitates chip flow and protects against corrosion and wear.

The tools include T890HT ELN endmills in 32 and 40 mm diameters with cylindrical and Weldon shanks and T890HT FLN Face mills in 40, 50, 63, 80, 100 and 125 mm diameters with coarse and fine pitch. The endmills and face mills are intended for machining square shoulders, slots and face milling.

The following new inserts are produced from ISCAR’s latest SUMO TEC carbide grades, which significantly increase productivity:

  • T890 LNHT 1306PNTR, a four-sided tangentially clamped insert for general use, featuring 8 right-hand cutting edges, 0.8 mm corner radii and a 9.5 mm maximum depth of cut.
  • T890 LNAT 1306PN-W, a wiper insert with 4 cutting edges for finishing operations, 0.6 mm x 45 deg. chamfer and a wiper for high surface quality.

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

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