Nakamura-Tome Precision Industry Co introduced a new two-turret two-spindle precision CNC multitasking lathe the WY-100V. The new machine features many new technologies which reduce cycle time drastically.
Shogo Nakamura, CEO at Nakamura-Tome Precision Industry says: “Seven years after the predecessor WY-100II was released, the WY-100V was developed to present a higher value-added multitasking machine. The most significant feature is its high-speed capability. To minimize idle time, we have developed a new technology called “ChronoCut” and achieved significantly higher spindle speeds and milling speeds, while improving torque on the hardware side. As a result, we have successfully reduced cycle time by 30% in an actual machining case.”
New hardware and software solutions have been developed to improve accuracy, while promoting faster mass production. Moreover, in terms of control, various techniques have been incorporated to reduce idle time. It is a completely new multitasking machine that is faster, while enormously enhancing productivity.
Sample Workpiece of a Hydraulic Valve Component.
In a multi-turret machine, speed is of utmost importance. By reducing cycle time with a fast machine, customers can make a large number of workpieces within the same amount of time and effort. This subsequently is saving manufacturing costs in challenging cost-cutting situations, while alleviating concerns about tight delivery deadlines.
“The WY-100V is a machine that embodies the concept of “Faster than the fastest.” It aims to reduce the burden on the shop floor. Even a few seconds of cycle time reduction can bring great satisfaction. Still, we have set a high goal of aiming for a 30% reduction with the sample workpiece demonstrated above and developed the machine from scratch with the dedication of our team. It is a machine that incorporates all our hardware, software, and machining expertise. We invite you to experience our new flagship two-turret machine,” concludes Shogo Nakamura.
For More information, contact WD Hearn – Tel: 021 534 5351
Featuring ultra-fast speeds and an expanded cutting spectrum, the ByCut Star now cuts with 30 kilowatts of laser power.
Impressive high cutting speed, intelligent cutting process and a new design – this is how the new ByCut Star presents itself. With 30 kilowatts and an optimized cutting process, it now cuts steel, aluminium, stainless steel, brass and copper precisely and reliably for even more quality.
Higher cutting quality and productivity is provided thanks to more laser power and smart features. Bystronic has advanced into a new dimension of fiber laser cutting, the ByCut Star with impressive 30 kilowatts of laser power. The high-end fiber laser stands for high-precision Bystronic technology, a stable cutting process up to the highest laser powers and for a wide range of applications.
However, sheet metal workers not only need a lot of laser power, but also intelligence, reliability and sustainability; this combination makes the laser cutting process really satisfying and successful.
Thus, at Bystronic, customer success is built on a concept of three pillars, namely Power, Intelligence and Cutting Process Improvement, including MixGas technology.
Smart features, such as the “Intelligent Cutting Process (ICP)”, the “Nozzle Control Tool (NCT) with KerfScan” or the “Parameter Wizard” optimize the entire cutting process, while ensuring that it stays on track. Users enjoy optimum capacity utilization and remarkable production uptime.
30 kilowatt of laser power
The technological leap from the previously available 3- to 20-kilowatt levels to the new 30-kilowatt level is considerable and opens new possibilities for Bystronic customers to optimize production and thus remain at the forefront of the ever more fiercely contested competition.
The “Advanced Applications” option enables expanded applications in steel and aluminium of up to 50 millimetres (15 kilowatts laser power and above).
Cutting speeds on the ByCut Star increase twice as fast compared to 15 kW and MixGas with sheet thicknesses between 6 mm and 15 mm, and more than twice as fast with thicknesses starting at 20 mm. Piercing times are shorter for sheet thicknesses of 15 mm and above. Sheet metal processors thus benefit from higher productivity at low unit costs, because with 30 kilowatts, the new ByCut Star cuts steel, aluminium and stainless steel precisely and reliably. The 30-kilowatt laser power enables maximum flexibility for large series and spontaneous customer orders. Whether aluminium or steel, the powerful Bystronic cutting head impresses with maximum precision in thin and thick sheets. In addition, with the “Advanced Applications” option, high laser power (starting from 15 kilowatts) now also enables expanded applications in steel and aluminium of up to 50 millimetres. The new power level is exclusively available on the ByCut Star 4020.
Smart features make the difference
NCT & KerfScan is a smart feature package for oxygen cutting which increases process reliability, even in low-manned operations. This feature offers process monitoring, problem solving and continuation of the cutting process in a fully automatic way.
The “Parameter Wizard” ensures that the correct quality of the cut parts is always selected within minutes. This feature determines the perfect parameters with N2 and MixGas for steel from 4 to 15 mm in thickness.
Intelligent Cutting Process ICP is a new feature, where a coaxial camera is filming through the nozzle and looking directly into the cutting process. This feature currently offers the following functionalities:
Cut Quality Detection – The system automatically detects cut interruptions during the cutting process and re-cuts the area where it occurred.
Cut Quality Protection – AI-controlled cutting process maintains reliable quality throughout low manned production.
Nozzle Loss Detection – Down time and material waste caused by nozzle loss are significantly reduced.
While Bystronic customers benefit from outstanding cutting results with clever features, the new powerful Bystronic flagship is also controlled from a 21.5-inch touchscreen. Handling is as simple as operating a smartphone.
The new ByCut Star’s modern, sharp contours provide a striking appearance and match the performance of the machine.
Significantly increased user-friendliness and outstanding flexibility are major advantages provided by the new ByCut Star. Thus, there is front and/or side access as well as several windows with a view directly to the cutting process. In general, the new design offers better accessibility to the interior, and the machine is easier to place on the store floor thanks to more flexible layout.
Additional accessibility with the all new, sharp designed ByCut Star thanks to several gates.
Fiber laser cutting with mixed gas ensures better cutting quality and higher productivity
In laser cutting, cutting gas (especially N2 and MixGas) is used to keep both the laser and the sheet free of impurities and remove molten material. Nitrogen is used for so-called fusion cutting and oxygen for flame cutting. Gas mixing combines the benefits of O2 and N2 and thus is an alternative to pure nitrogen or oxygen cutting. Cutting with MixGas (a specific blend of Nitrogen/Oxygen) ensures perfect quality on steel at increased cutting speed. This helps even an inadequate steel to achieve a good result after the cutting process.
For in-house gas production with a N2 generator, Bystronic has a solution ready that is attractive from a cost perspective and environmentally friendly. The advantages are obvious: There is no need for transports by trucks when gas is delivered. One produces only as much nitrogen as is needed, and all the previous additional costs are eliminated – from filling the cylinders to replacing them. The sheet metal processor works completely autonomously and – independent from any gas supplier – is doing something for the environment in the process.
For more information please see www.bystronic.co.za or contact Bystronic on 010 410 0200.
The TruLaser Tube 3000 fiber is suitable for companies that want to enter this technology and for companies that want to expand their manufacturing capacity.
New TRUMPF machine for getting started with laser tube processing or as an addition to existing machinery – Cost-effective even with low capacity utilization – Easy to operate thanks to numerous automated features
TRUMPF recently announced the launch of a new laser tube cutting machine, the TruLaser Tube 3000 fiber, a cost-effective choice even at low to medium capacity utilization. It is therefore equally suitable for companies that are entering this technology as it is for companies seeking to expand their production capacity. The machine enables the versatile processing of tubes and profiles and replaces conventional tube processing steps such as sawing, drilling and milling.
Starter kit to enter the world of tube processing
The TruLaser Tube 3000 fiber covers a broad range of applications including profiles, round tubes and flat steel bars. It also offers the option of L and U profiles. The two-kilowatt solid-state laser performs high-speed cutting of mild steel, stainless steel, aluminium and nonferrous metals such as copper and brass. An extensive set of cutting data is already stored on the machine. The TruLaser Tube 3000 fiber can cut tubes with diameters of up to 152 millimetres and profiles with an outer circumference of up to 170 millimetres. The self-centring clamping technology, which is designed to hold the tube in place and position it correctly during machining, adapts automatically to the tube dimensions without requiring manual setup by the operator. The TruLaser Tube 3000 fiber also configures other important settings automatically.
The self-centring clamping system fixes and positions the tube, thus ensuring optimal finished part quality.
The AdjustLine function modifies cutting parameters at the touch of a button to ensure reliable cutting of lower-quality materials. SeamLine Tube detects weld seams and markings on the inner and outer surfaces of the tubes, helping operators check that the tubes are correctly aligned in the machine and that the weld seam is in the desired position in the finished part. With its easy setup and high degree of automation, the TruLaser Tube 3000 fiber is a user-friendly machine that represents a cost-effective option for small batch sizes.
Reliable and precise parts handling
The TruLaser Tube 3000 fiber cuts tubes weighing up to 18.5 kilograms per meter with material thicknesses of up to 8 millimetres. It is available in two lengths that accommodate either 6.5 or 8 meters of material. Thanks to the optional LoadMaster Tube automated loading system, the machine is also a cost-effective choice for high-volume production runs.
Thanks to the LoadMaster Tube loading automation, the machine can profitably perform large-scale production as well.
An integrated materials store known as the “bundle space” provides a buffer store that can hold up to 4 metric tons of raw material, or up to 5 tons with the machine version designed for an 8-meter loading length. The LoadMaster Tube system separates and measures the tubes parallel to production and transfers them to the machine. To ensure top-quality parts, step rollers support the tubes and guide them to the machining station.
Step rollers support and guide the tubes to the processing station. They can be manually adapted to the respective tube diameter in no time.
These rollers can be adjusted to the current tube diameter in one simple action. The machine also features guide rollers on the unloading side which provide more support to long tubes during processing. The TruLaser Tube 3000 fiber ejects finished parts onto a rack. Set to the correct ergonomic height, this allows the operator to remove them comfortably while the machine continues working. Shorter parts can be ejected straight into a box. The TruLaser Tube 3000 fiber automatically separates cutting slugs and scrap metal from the finished parts and disposes of them in containers.
Key components easy to access at any time
Thanks to the design of the machine’s beam guard, the operator can easily access the loading and unloading sides of the machine at any time – for example to load individual tubes into the machine to process a smaller job between bigger ones. There is no need for a complete housing. A large, laser-safe viewing window makes it easy to keep an eye on the machining process.
Ready for the smart factory
Users can make changes to the machine’s production schedule or keep an eye on the machine using an app, making it even easier for the operator to keep track of the entire machining process in the TruLaser Tube 3000 fiber. A secure, OPC UA-based data interface is included to connect the machine to an ERP or MES system or to a cloud application, for example. TRUMPF machine apps provide information on program runtimes and machine capacity utilization.
For further information, please contact RETECON – Tel: (011) 976 8600.
Neway CNC Equipment Co offers a cost effective range of vertical machining centres, which are manufactured at the company’s modern manufacturing plants in Suzhou China.
Neway’s excellent manufacturing and quality control capabilities are maximized by the use of latest equipment from well-known international brands including Zayer, Kellenberger, Starragheckert, Swiss SIP, Renishaw and Shenck. They hold ISO and CE certification.
Neway’s Chinese manufacturing operation is supported by the group’s head office in Texas USA and a sales and support centre in Germany.
Neway CNC Equipment currently offers a range of moving table vertical machining centres which range in table size from 750 x 420mm to 1800 x 800mm. This range is available in the following table sizes, VM740 – 750 x 420mm, VM950 – 950 x 520mm, VM1150 – 1100 x 520mm, VM1260 – 1200 x 600mm, VM1360 – 1350 x 600mm, VM1580 – 1500 x x800mm, VM1780 – 1700 x 800 and VM1880 – 1800 x 800mm.
The VM740, VM950 and VM1150 models are fitted with BT40 spindle tapers. These three models are available as a lower specification S series with a Fanuc 0i-Mate-MD controller or a higher specified H series which are supplied with a Fanuc 0i-MD controller. The VM1260 and VM1360 models are fitted with BT 40 spindle taper as standard and can be supplied with a BT50 spindle taper as an option.
The VM1580, VM1780 and VM1880 are only available as H series specification with Fanuc 0i-MD controllers and have BT50 spindle tapers as standard. With the exception of the VM740, which has a 20 tool magazine, all models in the range come with a 24 tool magazine and arm type tool changer.
The complete series of models from VM740 to VM1880 in the S and H range have linear guideways on all three axis. The additional HR series which is available in sizes from VM950 to VM1780 feature box guideways as opposed to linear guideways. Full enclosure guarding and chip conveyors feature as standard equipment across the entire range.
Factory fitted optional equipment includes 4th axis rotary tables, through spindle coolant, workpiece measuring and toolsetting probes systems. Spindle oil cooling systems and coolant water/oil separators are available on request.
To complement the range of vertical machining centres, Neway CNC Equipment offers the VM640D drilling and tapping machine. This machine has a table size of 650 x 400mm, a 16 position cam type tool changer with a 1.6 second tool change, a spindle speed of 15 000 rpm, X and Y axis rapid feed rates of 48 meters per minute and a Z axis rapid feed rate of 60 meters per minute. They come fitted with the Fanuc 0i MD controller.
For more information, please contact Machine Tool Promotions – Tel: 016 931 1564.
A2C has been refurbishing bearings for over 28 years, and customers include companies, such as ArcelorMittal, Ultragear, Highveld Steel, Geared-up, Sasol Mining, Wheels & Bearings etc. A2C refurbishes SKF and Timken products on a continuous basis and accepts any bearing size from diameter 80mm ID to3 meters OD. A2C also manufactures new bearings on request. The company is based in Johannesburg and easily accessible from the M2.
Managing Director Andries Heydenrych says,”we have never had come-backs and give a 100% guarantee on all our workmanship. Our customers receive a Warranty Certificate, and everything we do is strictly according to OEM specifications. Delivery period is +/- 10 working days from landing in our workshop to going out of the door.
While all quotations on bearings stripped are free of charge, we offer extremely cost effective solutions on refurbished bearings.
For more information contact Andries Heydenrych at 082 788 5999
REIME NORIS expands its product portfolio for wrought aluminium and cast aluminium alloys with two newly developed cold forming taps.
Both tool types, like all taps of the “NEO” series, are made of HSSE-PM substrate. However, they differ in geometry and coating in order to achieve outstanding results in the respective field of application.
NORIS SPANLOS NEO AL
The NORIS SPANLOS NEO AL cold forming tap has been developed especially for the machining of wrought aluminium alloys. The geometry with an asymmetrical pressure point shape acts in the forming direction through a relatively steep stroke with very low torque. The stroke on the back is much flatter and thus has a supporting effect. This combination results in an enormous increase in tool life. A DLC (diamond like carbon) coating reliably protects against cold press welds, which are found frequently in these materials.
NORIS SPANLOS NEO GAL
The NORIS SPANLOS NEO GAL cold forming tap has been developed especially for thread forming in cast aluminium alloys. The geometry has a steeply pronounced symmetrical stroke both in the forming direction and at the back. The special feature is a sliding surface in-between, which offers targeted resistance to the particularly high abrasiveness of these cast materials. A multi-layer TICN coating, which has proven particularly effective in cases of abrasive wear, functions as a coating here.
In the standard product portfolio, the metric dimensions common for these materials, up to and including M10, are available, from M4 also with coolant hole. As in the entire range of NORIS SPANLOS tools, these two new types are also available from stock only with lubrication grooves.
The XF6300 5-axis vertical machining center provides high speed, simultaneous 5-axis precision and optimal rigidity combined with outstanding user convenience.
The XF6300 comes with a 19″ large monitor for enhanced visibility and the SIEMENS ShopMill customized technology package as standard. ShopMill provides simple operation, supporting all operator actions with graphic help displays and functions for quick and practical machine setup, including calculating the workpiece position in the machine. The control panel has the same configuration as a computer keyboard for easy usage. Mold Package is provided as standard for a highly efficient mold process with the aid of various NC options and automatic tool measurement.
While the integrated bed and column have been designed by using HYUNDAI WIA’s unique analysis method, the XF6300 features a 4-way structure box type saddle inside the cross-beam to increase stiffness and minimize thermal displacement. The Box-in-Box structure design accomplishes thermal equilibrium, while minimizing thermal deformation. The direction of the main axis’ center of gravity and z-axis moving direction are in the same line, providing more precise machining.
The XF6300 features X-axis 650mm, Y-axis 600mm and Z-axis 500mm with 60 m/min rapid traverse and 1G of X/Z-axis acceleration and deceleration and a linear scale to all linear axes plus rotary scale to rotating axes as standard.
XF6300 is a 5-axis vertical type machining center designed by European R&D center in Germany
Various multipurpose built-in spindles are available, providing 15,000 rpm or optionally 24,000 rpm and 40,000 rpm for high quality mold machining. The main spindles produce almost no noise and vibration even at high speed machining, while ensuring highly stable machining performance.
The XF6300 main spindle features an oil cooling device as standard promoting high accuracy for long periods of time and a HSK tool holder for high positioning accuracy and precision.
The XF6300 is designed with a 5-axis rotary table which can be moved 30 degrees to the front side of the machine and 120 degrees to the rear side of machine based on A-axis and C-axis and can rotate 360 degrees. A-axis and C-axis achieve 70rpm and 110rpm, respectively.
The rack-type magazine providing various options equipped with 34 tools and has a single layer as a standard. Tool magazines can be upgraded to accommodate 68 tools and 102 tools, respectively.
For more information, contact Spectrum Africa – Tel: 011 865 4090.
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.
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
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:
Production rates that are lower than expected due to poor utilization rates including robotic idle time.
Automation process errors requiring constant stopping, modification and testing due to unattainable targets.
Complex data exchange and communication errors when connecting to other systems make integration difficult.
Problems with monitoring and management of automation lines that suddenly stop due to equipment or system failures.
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.
