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MAZAK INTEGREX J-200

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

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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%

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).

Walter MWS4 turning indexable insert

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

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.

Walter MW4 turning indexable insert

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

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

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

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.

Click to view: L300A, i-CUT380T BRAKE MASTER CYLINDER

Click to view: HS6300 & L400C 

Click to view: LV800AW-TT

Semi-Automation

Semi- automation is an automation system which is operated by attaching simple automation devices to a machine tool.

Click to view: KIT450 – RING GEAR

Click to view: KIT450 – MIDDLE SHAFT

Click to view: KIT450 PISTON

NC Rotary Table

A rotary precision positioning device enabling the machine to drill or mill work at exact intervals around a fixed axis enhancing productivity.

Click to view: F650/50 – CARRIER

Click to view: F650/50 & LV300R KNUCKLE

For more information, please contact Spectrum Machine Tools – Tel: 011 865-4090

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A.P. DESIGN – A PROUD SOUTH AFRICAN MANUFACTURER

Advertorial

Established 45 years ago, manufacturer of cut to length lines, machine tools and special purpose machinery A.P. Design has always taken advantage of new technology, including intelligent servo drives. While even today small machines are fitted with PLC’s, we now upload links via the internet to PLCs & HMIs.

Together with latest technology available, comes the need for smart interfaced advanced field devices. These range from a sub miniature infra-red sensor to vision recognitions systems. With the vast amount of options available we can build machines that are much more cost effective and user friendly.

At our company all design work is done on Autodesk Inventor 2019 work stations. These software packages allow A.P. Design engineers to system check the functionality of machines prior to being built, which includes FEA (Finite Element Analysis).

All components used in the building of machines including electronic and system interfaces are manufactured in-house.

While A.P. Design provides press shop turnkey solutions and automation of presses and guillotines, the company also manufactures vibratory bowl feeders for small parts, servo drive roll feeders and eccentric presses. Our servo roll feeders come in any length required. While the units are controlled by a closed loop servo drive, models are available from 200mm to 1 250mm wide. We have strip feeders available up to 400mm wide and 400mm feed length x 4mm thick. Smallest available 38mm wide and 50mm feed length x 1mm thick with feed accuracy ± 0,15 per 0,5m.

Our range of products also includes two-in-one decoiler straighteners used to straighten material from coil for subsequent use in a strip feeder or electronic roll feeder; this material will then be fed to a press or guillotine. Coils over 2 000kg and more than 1 100mm in diameter and 200 to 1250mm width can be fed.

A wide range of custom made hydraulic presses are available from 30 to 1 000 tons. These are either simple machines with a cylinder and platens or maybe more complex with die cushion.

We manufacture decoilers in a number of varieties, widths and tonnage with small units from 500kg and a width of 100mm to 30 tons and 2 500mm wide. These units can be non-motorized (Haul-off ) or fully motorized with electronic controls.

Our cut to length lines (CTLL) will comprise of a decoiler, feeding the coil into a leveler. The leveler will straighten the steel and an encoder will measure the steel to the correct length for cutting. Most CTLL have guillotines fitted which will do the cutting. Some CTLL have slitters fitted (blanking line) which will cut the material into strips and then recoil the steel onto spools or into coils. Most CTLL are run by a PLC and HMI screen which are programmed to do batch cutting and setting parameters. The operator will programme the length and number of pieces required, and the unit stops when the programme is finished. For increased production a flying shear is incorporated. These units can handle 30 ton coils and widths of material up to 2 020mm.

Our vibratory bowl feeders are used to orientate parts and feed them to down line assembly machinery by means of a vibrator pack and an aluminium spiral track bowl ranging in diameter from 150mm to 710mm and various track sizes. Typical feed rates are 40 to 200 parts/minute.

We have manufactured special purpose machinery for the production of roll-on deodorants, making bricks and even roof tiles. Most car manufacturers have A.P. Design equipment in their plants. We help to keep the railways running and help to make industrial diamonds.

For more information, please contact A.P. Design – Tel: 011 010-0495.

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HIGH-TECH FORD FRAME LINE COMMENCES MANUFACTURING FOR NEXT-GENERATION RANGER

The final and largest piece of Ford Motor Company’s R15.8-billion investment puzzle for its South African operations has slotted into place with its new Frame Line commencing operations in preparation for the start of Next-Generation Ranger production later this year.

Located in the Tshwane Automotive Special Economic Zone (TASEZ) adjacent to Ford’s Silverton Assembly Plant, the Frame Line is the only Ford-owned and operated chassis manufacturing facility in the world. It measures a vast 100 000m2 and boasts the most advanced robotic manufacturing and quality control systems currently available.

“Our objective with the Next-Gen Ranger is to achieve the highest-ever production volumes and quality for the Silverton Assembly Plant, ensuring that the vehicles we deliver to our customers in South Africa and in more than 100 global export markets are world-class in every sense,” says Ockert Berry, VP Operations, Ford South Africa.

“The ladder-frame chassis of the Ranger pick-up is fundamental to its overall quality, performance and durability, whether used as an everyday family vehicle or in hard-working commercial applications,” Berry says. “Accordingly, as with our new on-site Stamping Plant, bringing the manufacturing of the frame in-house allows us to carefully monitor and control every step of the production process.

“We invested in the latest robotic technologies for the welding and handling of the frame components, along with a fully automated e-coat system and robotic wax application,” Berry adds. “Rigorous quality checks are performed using advanced inspection and measurement systems, including the sophisticated three-dimensional blue light scanner system, to ensure that there are no compromises in quality.”

At the heart of the Frame Line are two identical lines that manufacture these large and heavy steel components, with 15 derivatives produced to support the various model iterations, as well as the local and export market requirements. A total of 387 hourly employees and 25 salaried staff run the Frame Line in a two-shift operating pattern – all of whom have undergone extensive in-plant training.

“The facility is 95-percent automated, relying on 585 robots to assemble and weld the frames,” says Yetheen Gengan, Area Manager for the Frame Line. “We use the latest SKS automated intelligent welding system with I&K Pulse technology to guarantee the highest level of precision welding and consistency.

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“Additionally, we have more than 1 000 tools on the lines, which includes buffers and robot grippers, resulting in a seamless production process that eliminates manual handling and operations that could introduce variances in manufacturing quality,” Gengan adds.

Alongside the production area is a sophisticated multi-stage e-coat facility where the frames are completely immersed in a range of cleaning and phosphate solutions, before being submerged in an electrically charged tank where the paint is uniformly bonded to the metal. Thereafter a robotic station applies a protective wax inside the frame to provide rust protection and durability.

Rigorous quality control measures are implemented throughout the Frame Line, including in-line Perceptron measurement of every chassis produced in the plant. Furthermore, the high-tech GOM ATOS ScanBox blue light scanner system is used to create highly detailed 3D models of the entire chassis or individual sections, with the results compared to a stored design specification.

“With these advanced and extremely accurate measurement and scanning systems we are able to track real-time data to quickly identify and address any quality issues before the frame leaves the plant,” Gengan says. “All of the data is stored in our quality management system to monitor trends, and we can access the measurements and imaging data at any point should a concern be raised on any chassis we produced.”

As part of the extensive quality checks, the plant also incorporates a weld tear-down facility with world-class macro cutting and etching processes that assess the strength and integrity of the individual welds.

Once the frames are completed, they are stored in a below-ground finished goods area with a storage capacity for 6 000 units. Thereafter the frames are processed through an automated sequencing facility and moved across to the Silverton Assembly Plant where the suspension and brake components, differentials, engine, gearbox, exhaust and fuel tank are fitted in sub-assembly areas before being mated with the cab and load box on the Trim, Chassis and Final line.

“Having the Frame Line located right next door to the assembly plant is immensely advantageous, as it not only ensures that the frames are sequenced onto the assembly line in the most efficient manner, but it also eliminates the damage incurred when handling and transporting the parts by road,” Berry says. “All of this contributes to improved quality and greater customer satisfaction.”

SUCCESSFUL EUROBLECH 2022

Industry gathered in Hanover to shape the future of sheet metal working

The 26th International Sheet Metal Working Technology Exhibition, EuroBLECH 2022, ended recently after four days of flourishing business. A total of 38,076 trade visitors (FKM audited)

from around the world came to Hanover to shape the future of sheet metal working and defy current challenges. This year’s show hosted 1,300 companies from 39 countries on a net exhibition space of 86,136 square metres. A euphoric atmosphere and full order books were the results of a successful comeback of the show.

A closer look at this year’s visitor numbers reveals that a total of 35.944 unique visitors came to the exhibition grounds in Germany. Practically matching the previous edition’s stats, this is an exceptional result, especially given the difficult general conditions. Industry experts from all parts of the world came to the show for shorter but therefore more productive visits.

“It is hard to describe how we’re feeling after giving everything we had in the past four years to make this show possible. We are overwhelmed by the fantastic outcome and proud that EuroBLECH continues its critical role in bringing the global sheet metal working industry together,” says Evelyn Warwick, Exhibition Director of EuroBLECH, on behalf of the organisers Mack-Brooks Exhibitions. “This year’s edition was both special and hugely important for the whole sheet metal working industry. Judged by the exhibition space itself, you can tell as we came pretty close to the record numbers in 2018,” continues Evelyn Warwick.

A total of 62% of exhibitors came from outside of Germany to this year’s show. This represents a further increase in international attendance by 4%. According to the preliminary results of the exhibition survey, this trend continuous throughout the visitors: more than half of the trade visitors (56%) made their way to the event from outside of Germany, making EuroBLECH a truly international exhibition. Major visitor countries, next to Germany, included the Netherlands, Poland, Italy, Sweden, Turkey, Austria, Belgium, Denmark and France.  Furthermore, 37% of all visitors do not attend any other trade show, which is an increase of 10% compared to the show in 2018 and underlines the importance of the event.

As the key marketplace for the industry, EuroBLECH 2022 offered its visitors the opportunity to find solutions for the current challenges in the industry and connects them with businesses from all over the world to help them integrate the latest machinery and software into their manufacturing process. The hot topics this year were digitalisation, sustainability and Industry 4.0. Many of the products and innovations shown at EuroBLECH 2022 have been developed with a focus on cost and resource efficiency.

“The visitors this year meant serious business. Almost every second person entering the gates to EuroBLECH 2022 came with the intention to invest. That’s an increase of 4% compared to the previous edition”, concludes Evelyn Warwick. Both exhibitors and visitors were highly satisfied with the show and their newly established business relations. The visitors praised the comprehensiveness and international range of the products on display, as well as the quality of the exhibition stands and the many live demonstrations of digital processes. The exhibitors appreciated the highly qualified and international audience with its high percentage of decision-makers (80%).

A great majority of the visitors came from the industry (72%), followed by visitors from trade workshops and services. The most important sectors visitors belonged to included engineering, steel and aluminium construction, sheet metal & products, the automotive industry and its suppliers, iron and steel production and electrical engineering.

In addition to the innovations and numerous live demonstrations at the exhibition stands, attendees were able to appreciate the EuroBLECH 2022 Presentation Area. The new show feature delivered 27 sessions throughout the four exhibition days, offering exciting insight into innovative companies and projects, interesting discussions and valuable networking opportunities.

Many exhibitors at this year’s show have already announced that they will exhibit again at the next EuroBLECH in 2024, which will take place from 22 – 25 October 2024 at the Hanover Exhibition Grounds in Germany.

 

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