LOGIQ 4 TURN FROM ISCAR IMPRESSES TURNING SPECIALIST SCHAUERTE

16th March 2023

Tool life doubled

“Being a leader through technology and service” is the motto of Wilhelm Schauerte GmbH & Co. KG. Looking for an innovative tooling solution, the specialist for precision turning found what they were looking for at ISCAR. Since they have been using indexable inserts from the LOGIQ 4 TURN series, tool life for the demanding machining of a component made of chrome-nickel steel has doubled compared to the previous solution, and the chip evacuation process, which was once so difficult, has been running totally smoothly now.

The tool from ISCAR’s LOGIQ 4 TURN series is a positive double-sided insert which achieves significant process advantages at turning specialist Schauerte.

Founded in 1892 as a craftsman’s business, the company, based in Lennestadt-Grevenbrück in the Sauerland region of Germany, began mass-producing precision turned parts in the 1930s. Today, the company is managed by the fourth generation, Stefan W. Schauerte. “We strive to always being at the most recent technological forefront and count on qualified employees. The quota of skilled workers is over 80 percent,” he describes. With a ten percent quota of apprentices – mainly for the profession of cutting machine operator – it is ensured that the next generation comes from the company’s own ranks. “The complexity of machines and tasks is increasing. It is part of our corporate culture to educate skilled workers.”

175 employees produce precision turned parts from various materials in an area of around 11,000 square meters. Among other things, they process steel of different grades and special alloys. Customers come from automotive suppliers (40 percent), mechanical engineering and the sanitary industry. “We are well-diversified and strive to spread risks,” says Stefan W. Schauerte. In a well-equipped machine park, batch sizes between 500 pieces and the seven-digit range are produced. 3-D printers, CNC lathes, multi-spindle – and rotary transfer machines are used. Re-work processes such as grinding are also carried out in-house. Schauerte meets customer requirements for quality and delivery reliability. Qualified employees use modern technology to ensure that the various part geometries and batch sizes are produced economically.

Chip behaviour problems

In order to keep machinery always up to date with latest technology, Schauerte invests a large amount in new production equipment every year. The continuous improvement process is practiced every day. “We are constantly looking for new solutions and have been testing innovative tools. In this way, we want to optimise the availability of machines and reduce unit costs,” describes Kai Milich, who is responsible for technical controlling and tool purchasing at Schauerte. Problems appeared in roughing a 1.4301 stainless steel component on a multispindle machine. “The chips were too long and were not evacuated. We had to stop the machine frequently to clean it up so that no damage would occur,” outlines Milich. He was also dissatisfied with the tool life: The tool used until then wore too quickly during the complex machining process.

Chips are produced during machining and can be easily evacuated, thus ensuring uninterrupted processes.

A solution became apparent when Kai Milich attended an ISCAR presentation. The LOGIQ 4 TURN series was also presented on the occasion of this event with features that can sort out the problems from his point of view. Thus, the ISCAR 4, consisting of Dirk Baumhof, Application Engineering and Consulting, Rolf Behrendt, Regional Sales Manager, Marco Rötzel, Consulting and Sales and Jonas von Kahlden, Product Manager, were all on board. Just a while later the specialists ran first tests on the spot, while achieving impressive results. Processing stainless steel on an eight-spindle machine with a cutting depth of 2.5 millimeters, tool life could be increased from 1,000 to 2,000 pieces. Furthermore, chip evacuation was much better: for Kai Milich a clear sign to make the deal.

The inserts in ISCAR’s LOGIQ 4 TURN series reliably produce stainless steel components of consistently high quality.

Positive Geometry reduces Cutting Force

LOGIQ 4 TURN is a positive double-sided insert with four usable cutting edges, two more than conventional CCMT inserts. “This design with positive 80-degree geometry enables significantly reduced cutting forces. The efficient, pin-pointed coolant supply ensures longer tool life, better chip flow and higher productivity,” describes Jonas von Kahlden. The dove-tailed pocket results in a very high degree of machining stability. Schauerte uses the CXMG-M3M type with a cutting width of two millimeters. It allows cutting depths between 0.8 and 3 millimeters and feeds between 0.15 and 0.5 millimeters per revolution.

By using the positive double-sided inserts tool life has doubled compared to the previous solution.

Clear Process Benefits with LOGIQ 4 TURN

Since the turning specialist has been using LOGIQ 4 TURN, processes have improved significantly. “Tool lives have doubled. In the past, the tool was in operation for 102 minutes before wear, but today it’s 204 minutes,” says Kai Milich. 2,000 components per shift can be processed without any problems. “Today, we have to open the machine door much less often for insert indexing.” Schauerte has considerably reduced tool and unit costs with LOGIQ 4 TURN. They are also very satisfied with the chip removal behavior. “The chips are formed in such a way that they can be evacuated without difficulty. This is one of the major advantages of the ISCAR tool,” says Kai Milich. He is also pleased about the high process reliability. This is essential, he says, because the dimensional tolerances on the product are very low and the material is expensive and, depending on the batch, it is tricky to machine.

The challenges are put on the table and tackled together (from left): Marco Rötzel, Consulting and Sales, Rolf Behrendt, Regional Sales Manager (both ISCAR), Kai Milich, Technical Controlling at Schauerte, Managing Director Stefan W. Schauerte, Jonas von Kahlden, Product Manager at ISCAR, and Dirk Baumhof, Application Engineering and Consulting at ISCAR.

The cooperation with the ISCAR employees is also highly praised. The cooperation has existed for almost 20 years and is based on mutual trust and transparency. One man from the very beginning is Dirk Baumhof. There is a special connection with him. “He visits our company quite often. When we call, he’s always on the spot with good advice,” says Stefan W. Schauerte in appreciation, at the same time emphasizing how important a good relationship with suppliers is to him. Regional Sales Manager Rolf Behrendt also appreciates the open communication between the partners. “If there is anything new, it is communicated to us right away.” Schauerte now has been using LOGIQ 4 TURN on four components and identifies further potential. Kai Milich: “We also try to achieve positive results in other applications.”

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

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NEW WHISPERLINE ANTI-VIBRATION DEEP GROOVING AND PARTING BLADES

16th March 2023

ISCAR introduces new anti-vibration blades, designed to eliminate vibrations in deep grooving applications.

Due to the increased demand for deep grooving applications that often tend to cause vibrations, ISCAR has designed new WHISPERLINE blades for deep grooving and parting off operations. The new blades eliminate vibrations, improve surface quality and increase the insert’s tool life.

Vibrations occur as a result of several factors: machine and clamping system rigidity, part shape, cutting tools, insert design and cutting parameters.

In many cases, especially in deep grooving applications, it is not possible to design cutting tools that avoid vibrations in a conventional way.

ISCAR’s new WHISPERLINE blades feature a damping unit that absorbs vibrations and enables a stable machining process even at high cutting conditions. The damping unit is located under the insert pocket. It consists of two plates situated in a rhombic frame, connected by a screw that pushes the plates against the walls through an O-ring.

The WHISPERLINE blades reach a new range of grooving depths at which other conventional blades cannot function and enable machining at higher cutting conditions, which increases productivity. Fewer vibrations dramatically increase insert tool life, and this advantage can be used also at lower grooving depths.

The blades feature an excellent surface finish, while internal frontal cooling (K-Type) improves insert tool life and chip evacuation.

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

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THE NEW ByBend Star 40 and 80 – TWO MOBILE BENDING MARVELS

15th March 2023

The compact mobile press brakes ByBend Star 40 and ByBend Star 80 impress with a new design and a new drive system. Bending often still means producing small to medium-sized parts on press brakes that are too large. This limits you, because processing bent parts on presses that are too large comes at the cost of time, space, and sometimes also quality.

Advantage: Small

For parts of up to about 1,500 millimetres in bending length and a maximum thickness of 20 millimetres, you do not actually need a large-scale bending station, but rather a small and versatile powerhouse.

The mobility of the two ByBend Star bending machines is a significant advantage over large-format press brakes

The new ByBend Star 40 and 80 were developed precisely for such requirements – compact, fast press brakes that fit into almost any production environment. Large presses must be placed in a fixed position in production and often take up a lot of space due to their design.

The larger of the two small systems: The ByBend Star 80 with 80 tons of press capacity.

Compact and even more compact

This is not the case with the new ByBend Star 40 and 80: The smallest in Bystronic’s range bend as reliably as their big counterparts within the tightest of spaces. Bystronic thus offers an ideal bending solution for production landscapes that are subject to constant change.

Compact and fast

The new servo-hydraulics enable bending speeds of up to 30 millimeters per second. This makes the ByBend Star 40 and ByBend Star 80 three times faster than a large press brake.

80 tons of strength

Compared to the ByBend Star 40, the ByBend Star 80 offers more bending length and more pressing power. This expands the range of applications. On a bending length of around 1.5 meters, the ByBend Star 80 deploys a pressing force of 80 tons. The footprint of the machine is less than 6 square meters.

Intelligent functions also save energy

Bystronic paid particular attention to the subject of energy consumption during the development of the entire ByBend Star series: The economical “Dynamic Drive System” drive concept allows for dynamic bending sequences without energy loss. The ByBend Star 40 and 80 supply the exact force required for each bent part.

Easy to operate: Programming the ByBend Vision software on a 21.5-inch screen.

Added to this are intelligent functions such as the Energy Saver and an automatic start-stop function. Compared to large models, the two ByBend Star press brakes thus offer almost unbeatable energy efficiency throughout the entire bending process.

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

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MAZAK INTEGREX J-200

15th March 2023

The INTEGREX J-series multi-tasking machines designed to provide you the maximum value

The INTEGREX j-200 is a compact machine designed for large workpieces with maximum machining size of 500 mm diameter and maximum machining length is 500 mm. The orthogonal Y-axis machine construction is the same as INTEGREX i-150 and INTEGREX e-series and allows face milling, end milling, and drilling to be performed in the large machining area without C-axis indexing thanks to long Y-axis stroke: 200 mm.

INTEGREX j-series is designed to meet the requirements of customers who are using CNC turning centres and machining centres while being interested in multi-tasking machines, but feel they are too complicated to operate and expensive. These machines are also ideal for users who need multi-tasking machines with a long Y-axis stroke that are easy to operate and offer high performance in order to quickly produce high value-added components. Last but not least these machines are for customers who need multi-tasking machines, but without the full range of features found in the other INTEGREX machines.

For more information,please contact Hitech Machine Tools – Tel: 011 608 0088.

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TOUGH FOR A LONGER TOOL LIFE

15th March 2023

With the W1211/W1210 copy turning system, Walter is transferring to internal machining the positive features of its W1011/W1010 turning system for external machining that is already established on the market. The boring bars and indexable inserts with WL positive engagement solve a common problem. High forces occur when copy turning with V-style inserts, which cause micro movements of the insert in the toolholder and therefore widen the insert seat. This results in increased wear, less precision and a lack of indexing accuracy with indexable plate types such as VBMT or DCMT. Due to their positive-locking insert seat design with three-point support, the W1211/W1210 boring bars and WL25 inserts achieve outstanding stability. This increases the tool life while enabling users to use the tools in both directions of travel, which increases the indexing accuracy by 50%.

Walter Turn W1211W1210 copy turning system

Walter offers two versions of the boring bars with diameters of 25, 32 and 40 mm: W1210 for profiling angles of up to 72.5° and W1211 for profiling angles of up to 50°. The positive WL25 indexable inserts with three cutting edges are available in four insert types, depending on the requirements of the application. Neutral, left-hand, right-hand and full-radius versions fit into the same tool. In addition to the wear-resistant Walter Tiger·tec® Silver grades that are currently used, Tiger·tec® Gold inserts will be available soon. The dual rake face cooling and the optional axial cooling for flushing out the chips during blind-hole machining also result in longer tool life and therefore greater cost-efficiency. These special features and the versatility of the system make it the current benchmark for the market.

For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144.

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TOOL LIFE INCREASE AROUND 50%

15th March 2023

With the WPP10G grade for continuous cuts and occasionally interrupted cuts, the WPP20G universal grade and the tough WPP30G grade for interrupted cuts and unfavourable machining conditions, Walter offers its customers three Tiger·tec® Gold grades specially designed for turning operations. After the extremely successful market launch at the end of 2021, the manufacturer is now doubling its range. The positive CCMT and DCGT inserts, as well as negative, single-sided CNMM and SNMM inserts, and WL25 copy turning inserts are now being added to the previously launched indexable inserts with double-sided negative basic shape (CNMG, DNMG, etc.). They are expanding the Walter Tiger·tec® Gold portfolio with three cutting tool materials, now taking the total to 21 geometries and more than 1100 items – including special geometries with improved chip breaking (MP6) and for roughing large forged parts (HU7).

Like the existing inserts, steel is the primary application of the newly added turning grades (cast iron is the secondary application). In 130 customer tests, they increased tool life by an average of around 50%. The reason for this is a special layered structure. A patent-pending, highly textured, multi-layered MT-TiCN layer increases toughness and reduces flank face wear, resulting in lower production costs. The highly textured Al2O3 layer also minimises crater wear; the final gold-coloured top layer improves wear detection. On top of this, Walter provides a multi-stage post-treatment. This produces an unusually smooth rake face, therefore reducing friction and also increasing toughness. This ultimately ensures high process reliability in automated processes. With this expansion of the product range, users can now benefit from maximum flexibility and minimal component costs when turning too, thanks to Tiger·tec® Gold.

For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144.

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100 PER CENT INCREASE IN PRODUCTIVITY AND QUALITY

15th March 2023

Walter launches new FW4 and MW4 wiper geometries

With the FW4 and MW4 wiper geometries, Walter is launching two turning indexable insert geometries which combine the “wiper effect” with new chip breaker geometries and extremely wear-resistant Walter Tiger·tec® Gold grades. The curved wiper edge sweeps over the surface again, making it possible either to double the feed and increase productivity by 100 per cent, or to double the surface quality while maintaining the same feed. With the new geometries, Walter is now also transferring this effect from the FW5 and MW5 double-sided cutting inserts to indexable inserts with a positive basic shape. The result is the FW4 geometry with a narrow chip breaker for finishing operations and the MW4 geometry with an open chip breaker groove and longer radiused wiper cutting edge for medium machining.

Both geometries are designed for universal application in ISO materials P, M and K, as well as for secondary applications in ISO S. Both the FW4 and MW4 geometries make it possible to achieve improved surface quality, productivity and process reliability. Thanks to the wiper edge with its curved design, this also applies when the machine is not aligned 100 per cent precisely (for example after a crash or if the turret is slightly offset). The new chip breakers also increase the chip breaking range resulting in less machine downtime caused by bird nesting. Higher feeds lower the tool’s machining and therefore contact times, increasing its tool life and reducing the indexing times. The combination of double the productivity and/or surface quality is particularly appealing for series producers, as the aforementioned benefits are multiplied in series production.

For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144.

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ALPHA X SERIES – WORLD’S FINEST CNC COMBINATION LATHES

15th March 2023

The Alpha X Series from Colchester Machine Tool Solutions offers a wide choice of advanced technology CNC Combination Lathes to suit all types of high-precision turning applications, including secondary operations such as milling, drilling and tapping.

All Alpha X Series lathes are perfectly suited to producing detailed and intricate one-offs to the highest standard of finish and accuracy. With their advanced Fanuc control and software systems, they are ideal for turning small-to medium sized batches with fast, high quality repeatability, excellent accuracy and surface finish and, most importantly of all, lower component production costs.

Alpha quality, plus a wide range of training options, has made Alpha lathes the favourite choice for industry, colleges and training centres around the world. Ideal training features include compatibility with industry standard ISO programs and Colchester’s AlphaLink software which enables multi-desk training to be given.

Machine Bed

Colchester Machine Tool Solutions’ cutting-edge lathe design and construction quality begins with the machine bed. Alpha beds use high performance cast iron, with a unique ‘Warren’ type construction for maximum strength and optimum swarf clearance.

In addition, all Alpha lathe beds are mounted on cast-iron plinths to neutralise stress in the machine bed, and slideways are hardened and specially ground to ensure high-precision, parallel operation of the lathe at all times.

Operators Console

The operator’s console is located, for optimum operator convenience and efficiency, directly in line-of-sight with the cutting tool. The hand wheels are installed at the ideal ergonomic height for ease of use and have the Alpha’s popular “one-click-one-micron” rotational feel sensitivity.

The complete operator’s control panel moves on its own independent carriage which allows it to be moved quickly and effortlessly aside during loading and setting up.

Drive Train

Into the design and development of all Alpha lathes goes the technical expertise of specialists from Colchester Machine Tool Solutions’ partner company Pratt Burnerd chucking systems. Their combined research programs ensure that all new Alpha XS lathes feature the most advanced developments in spindle bearing technology and chuck design. This provides the highest possible spindle speeds and optimum chuck performance for high accuracy turning with maximum load carrying capacity.

Headstock

Crucial to turning precision and quality is the design and capability of the headstock. These lathes have top rated Fanuc spindle motors for extra power and more torque in all speed ranges. This means that ‘bottom end’ torque has been increased by over 75% giving excellent, extremely accurate metal cutting performance at lower speeds.

All Alpha XS lathes are equipped with auto gearbox change – maximising efficiency and productivity.

Manual Guide i for Alpha XS and XC

Automatic Turning

Manual Guide i is the latest and most powerful conversational programming system from Fanuc. It offers the most comprehensive and feature laden aid that any lathe programmer could want and becomes available on the Alpha XS when the keyswitch on the control panel is turned to the automatic position.

Customised Pages

Despite the enormous strength of the Manual Guide I system, our engineers have been able to bring their turning experience into play to develop customised cycles especially for the needs of a manual/CNC type of lathe. These Colchester unique developed cycles will save you a considerable amount of time and button pushing.

This is the most user friendly and cost effective entry level combination lathe control in the world! The absolute minimum of training is needed to get these machines cutting metal and making you money.

Simulation and Animation

Manual Guide i has a more powerful graphics package than many commercial CAD/CAM systems. After a programme has been created, a simulated component can be viewed in any direction, or as a 3D model that can be cut or sectioned or magnified to see detail.

This simulated component can then be animated to show the cutting process, the toolpath, metal removal and the finished component to ensure that what you get is what you have programmed and exactly what you want.

CNC Turning

The real strength of Manual Guide i is that it is effectively a CNC Graphical user interface. All the time you are working in Manual Guide i, the 0i TF is creating a CNC programme in the background. This means that conversion from conversational mode to CNC mode is instant. It also means that you can work in either CNC or conversational mode or even both at the same time. Furthermore it means that industry standard CNC programmes can be loaded into and out of the control at any time.

The Alpha XS and XC are powerful conversational lathes that can also run CNC programmes developed elsewhere or to create CNC programmes for use on other machines.

The Alpha XC introduces full milling, drilling and tapping functions to the Alpha range, fully harnessing the Fanuc Oi-TF control combined with the Manual Guide i conversational programming system to reduce the need for second machine load and operation production – specifically for one-off components and small batch production.

The Alpha XC 3-axis CNC combination lathe is identical in functionality to the Alpha XS range of machines, but now has the addition of a fully interpolating c-axis, while still retaining the operational simplicity that makes the Alpha range the leading choice worldwide.

The manual / CNC lathe is mounted with a newly developed headstock, allowing programmed selection of the c–axis drive, allowing milling / drilling cycles to be achieved with the use of driven tooling.

To allow for these extra lathe operations, full c-axis cycles are available through the Manual Guide i conversational programming system.

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

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LYNX 2100/2600 SERIES HIGH-PERFORMANCE COMPACT TURNING CENTRE

14th March 2023

A complete machining solution, the newly-designed Lynx 2100 and Lynx 2600 2-axis horizontal turning centres have a small footprint but deliver huge productivity gains. The machines are tough, reliable and get down to business fast.

If you make complex parts out of tough-to-machine materials, the PUMA 2100/2600(II) Y-axis series is your new go-to. The Y-axis is a beautiful thing. Thanks to its integrated Y-axis and integral drive spindles, the PUMA 2100/2600(II) lets you handle the part from beginning to end on one machine, put simply, it’s a productivity godsend.

While delivering superior machining performance, the machines are equipped with a 15kW high-power motor together with the Lynx 2600Y/SY featuring an 18kW motor, respectively. The maximum turning diameter is 300mm and maximum turning length 510mm with the Lynx 2600Y/SY featuring 380mm and 610mm, respectively. Providing excellent cutting capability and high reliability, the Lynx 2100 and Lynx 2600 are equipped with a low vibration/noise spindle, a servo-driven turret and a full slideway cover to prevent leakage and chip ingress.

EOP, grease type lubrication and a rear side double-purpose chip conveyor are supplied for improved user convenience.

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

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FACTORY AUTOMATION WITH HYUNDAI WIA

30th November 2022

With Hyundai WIA’s experience as a world-class FA (Factory Automation) business, the company delivers automation systems to diverse industries all over the world, while continuously improving productivity.

Gantry Automation

Gantry automation is an automation method using a stocker and gantry loader. The gantry loader transfers raw material from a stocker to the machine automatically in order to start the machining process. Gantry automation provides good equipment access during operation, easy work monitoring, program modification and maintenance. In addition, a small installation area facilitates optimized factory layout.

Click to view: F650 – LFA CARRIER

Click to view: L280, i-CUT420T – CAM SHAFT

Click to view: HS5000i – TM CASE

Click to view: LF2600-2SP(3unit)

Click to view: HD2200

Click to view: Valve Body Gantry Line

PLS (Pallet Line System)

Hyundai WIA PLS is an unmanned automation system for horizontal machining centres with two-storied pallet stackers.

The easy to operate and highly efficient system facilitates high productivity improvement, while flexibly responding to changes in production volume.

Click to view: Pallet Line System

Robot Automation

Hyundai WIA has delivered more than 10,000 robots around the world. With its know-how and experience, the company is globally recognized as a giant in the field of automation.