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FIRST CUT AND MESSER CUTTING SYSTEMS DISCUSS NEW STRATEGIES

First Cut, South African supplier of cutting, welding and grinding consumables and other equipment recently hosted a visit from the President and CEO Global of German company Messer Cutting Systems, John Emholz, in order to consolidate their existing relationship and discuss strategic new possibilities.

Emholz was joined by Martin Zeller, Division Manager Sales and Axel Vogelsang, Area Sales Manager, Oxyfuel Business Unit, who is also the main point of contact for First Cut and their customers regarding Oxyfuel Sales and Service.

In 2019 First Cut concluded an agreement with Messer Cutting Systems, which is a global supplier of cutting solutions for the metalworking industry, to take over the existing South African distribution agency.

Emholz explains: “The focus of this visit was largely at a strategic level, in order to understand how to bring in our cutting systems expertise and look at opportunities that we believed could be leveraged, including discussing market leads with First Cut for both the oxyfuel as well as the equipment side of our business.

“We believe that we have a viable opportunity to leverage some of the South African market developments on a global basis. We have a strong commitment to this market, and certainly this visit has clarified and strengthened our understanding of the significant long-term market potential in the South African market.”

Andrew Poole, Managing Director of First Cut adds: “Messer Cutting System’s participation in our local distribution and sales strategy development has really been demonstrated by John as their President and global CEO, visiting in person.

“This shows an invaluable and highly-appreciated long-term commitment on their part. Messer Cutting Systems is a large, global organisation which has given us great flexibility in the local distribution of their products. Having held joint discussions on how to position ourselves in the South African market, we have some very exciting new directions unfolding. In this regard, our safety offering has been very important, Poole says.”

John Emholz, President and CEO Global, Messer Cutting Systems, Germany

Safety is of paramount importance in First Cut’s key target cutting and welding market sectors, as reflected by its recent merger of interests with Gas Safety International (GSI), which provides certified gas safety training and quality gas equipment to a wide range of industrial sectors, while ensuring a safe and efficient working environment.

Andrew Poole, Managing Director, First Cut

This relationship has strengthened First Cut’s service offering, particularly due to the outstanding training experience and expertise offered by GSI’s Managing Director Peter Rohlssen, with regards to gas safety training, consulting and auditing.

“This holistic safety offering and the passion and experience demonstrated by First Cut and GSI are very attractive,” observes Messer’s Martin Zeller. “It immediately inspired us upon our arrival and it has only added to the overall relationship of trust which Messer Cutting Systems and First Cut share.”

Another key First Cut relationship involves its agreement with the Bolt and Engineering Distributors (B.E.D.) Group, whereby First Cut is a primary distributor to the fabrication – and other sectors, while B.E.D. focuses on the mining industry, where they are already well-established.

“We truly appreciate these initiatives which First Cut has engaged in – and how they work to strengthen the overall market offering and distribution of our products in South Africa,” Emholz enthuses. GSI’s safety knowledge, together with First Cut and Messer Cutting System’s own expertise, has resulted in the development of a trio of new products.

We are very pleased to play our part in this collaboration, which will be rolled out globally, yet with a ‘proudly South African’ flavour. This is indeed an illustration of the seriousness with which both First Cut as well as Messer Cutting Systems have approached this relationship.”

Zeller adds: “We are very enthusiastic about the features and potential uptake of these new products in the market. This demonstrates that First Cut and B.E.D. are truly value-adding partners, helping us to find solutions for the mining and industrial sectors. This is a pivotal development for Messer Cutting Systems and First Cut,” he says.

In conclusion Emholz adds: “Having seen the opportunities here in South Africa, Messer Cutting Systems is very keen to promote our footprint and traction accordingly. Furthermore, the excellent, value-adding collaboration between Messer, First Cut and its partners is a significant opportunity for us to learn from the local market.”

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HYUNDAI WIA XF6300 5-AXIS VMC

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.

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THE SAFANDARLEY E-BRAKE ERGONOMIC

With the Ergonomic design of the E-Brake, SafanDarley enables the operator and the press brake to work as a unit. The operator is partially seated inside the machine, surrounded by an edging table with his legs in a spacious cut-away below the lower beam, where the foot pedal is located.

Ergonomic ease of operation is assured as the seating position as well as the height and angle of the footrest can be adjusted. The SafanDarley E-Brake Ergonomic can easily be adapted to changing work situations, such as a different product or a different operator. The edging table can be adjusted enabling users to achieve perfect pick-up height, working height and cast-off height every time. In addition, the edging table can be fully or partially collapsed, enabling the operator to bend whilst standing up. Finally, the entire edging table can easily be removed from the machine to make the front freely accessible.

While the height of the rotating 17″ Touch Screen is adjustable, the unit can be placed to both the left and right of the operator, meaning that left-handed operators can use the machine with the same level of ease as right-handed operators.

The double-function safety light screen, integrated into the control panel secures the bending zone and allows the axis to move, while the operator turns, picks up or removes the product. These simultaneous actions of operator and machine lead to very fast cycle times.

While the innovative back gauge can be used across the full working length, it has a maximum depth of 1000mm and a height adjustment of 150mm. Combined with the possibility of setting the upper beam at a 5° angle, this means unparalleled flexibility. The back gauge comes with an X axis and an R axis as standard features, but can be expanded, depending on the model, with 5 optional axes.

For more information, please contact CML Machine Tools – tel: 083 232 9470.

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SAFAN M-SHEAR

The Safan M-Shear’s extremely functional design satisfies current and future requirements with possible expansion plans, such as material-handling systems, already provided for. At its core is the advanced hybrid drive for the cutting beam consisting of a servo-electronic motor and hydraulic pump, a combination producing a remarkably quiet and energy-saving system.

While the robust hydraulic systems are controlled by modern electronics increasing both productivity and quality of products, the servo-electronic motor powering the hybrid drive only runs when the cutting beam is in motion thus saving energy and reducing noise levels while cutting.

Maximum ease of operation is provided by the Safan Touch Screen control TS 200 while the settings are indicated by clear symbols on the TFT colour monitor. The control operates with Microsoft Windows®.

With blades having four cutting edges, on both top and bottom, shearing is done very economically as blade wear is spread over the blade’s entire length, thanks to the programmable starting position of the cutting beam. Another feature includes independent left and right clearance adjustment and built-in measuring sensor with an accuracy of ±0.01mm. Due to the special frame construction, clearance is self- compensating so that, even with a load in the middle of the shear, the clearance remains constant over the entire length. When the clearance is changed, the back gauge setting is automatically corrected. Size of cut can be directly entered, after which the position of the back gauge is adjusted. The back gauge adjustment occurs by means of play-free guides and ball screws. Setting precision is 0.01mm and repetitions are accurate to within ±0.03mm.

The shear has extensive guards on the back and sides. These consist of mechanical side covers on the right and left sides plus a photo-electrical guard on the back. The machine’s foot-operated console is fitted with an emergency stop. Robust finger guards have been installed. For up to and including 6mm cuts, openings have been made in these guards, allowing the operator to safely get closer to the blade.

As an option, the M-Shear can be supplied with pneumatic sheet support equipment making cutting easier, especially when dealing with largersize blank sizes. The sheet to be cut is supported at the back of the shear, ensuring it can be accurately positioned against the back gauge, which can be equipped with sheet support arms, if requested.

In combination with the pneumatic sheet support system, a scrap separation feature is available.

For more information, please contact CML Machine Tools – Tel: 083 232 9470.

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FANUC ROBODRILL ADVANCED VERSION

Versatility, Speed & Intelligence

The new-generation Advanced Version ROBODRILL promises unrivalled quality and precision at great hourly rates.

With an unbeatable tool change time of 0.7 seconds and a turret capable of handling tools weighing up to 4kg, the new advanced version is both the fastest and strongest Robodrill yet. With by far the shortest cycle times on most machining operations, all ROBODRILL machines offer incredible performance and unbeatable efficiency.

Designed to meet every need, the ROBODRILL α-DiB5 series comprises of six completely redesigned models in Space Saver, Medium and Long sizes, available in either standard or advanced versions. With a rigid servo drive control and a highly dynamic BT30 spindle, these high-speed all-rounders are suitable for all vertical machining applications, from short production runs requiring fast turnaround times to flawless mass production. With well over 200 000 machines installed worldwide, its future-proof versatility and easy adaptability make the ROBODRILL the best-selling machine in its class.

Spreading your machining work across several ROBODRILLs instead of relying on a dedicated transfer machine, allows you to benefit from cheaper production and higher flexibility in the face of changing production numbers. Inherently adaptable, FANUC ROBODRILL also represents a great addition to your production facilities, since you can use it to absorb extra demand, thereby freeing up your larger vertical machining centres for bigger jobs.

The Advanced Version offers many unique improvements:

Improved swarf evacuation

To maximize uptime, the ROBODRILL α-DiB5 series can be fitted with a number of swarf evacuation options: from the coolant tank and chip flush methods to a piping system for wall coolant. Advanced versions minimize swarf interference with a mountain-shaped Y-axis front cover. It also offers an optional fully-enclosed spindle cover that separates the machining area from the mechanism.

Stronger Turret for bigger Tools

At the heart of every ROBODRILL is a patented high-speed tool changer that can carry up to 21 tools and offers the best reliability in its class. Its manufactured efficiency lies in its solid metal construction and optional BIG-PLUS BBT30 spindle. This makes it extremely resistant to radial forces and enables it to deliver unbelievably efficient machining.

Advanced version ROBODRILLs feature an even stronger turret. Offering even more versatility, this enables the tool changer to handle heavy, customized cutting tools weighing up to 4kg while still realizing ultraquick tool changing times.

Power Failure Backup Module

Power interruptions can be costly. Avoid unnecessary workpiece damage or tool damage with FANUCs Power Failure Backup module. This will prevent the tool from dropping into the workpiece or the axis from slowly decelerating to a stop potentially causing a collision with the spindle, or jigs and fixtures.

All of the new model ROBODRILLS can be fitted with the improved Direct Drive 4th axis with built in brake. For ultra high speed indexing, or 4 axis simultaneous work, the new DDRiB offers unrivalled speed and accuracy.

When you have longer workpieces or want to put many on the table at the same time, the new DDR-TiB offers a factory built 4th axis with tail support, base plate, and angle brackets for a swing plate. Available in 300mm, 500mm or 700mm in X direction, this allows maximum use of the ROBODRILLS travel space.

Need a 5 axis machine? No problem!

ROBODRILLs are available with 5 axis simultaneous control allowing machining of complex workpieces. Control functions like Tool Certer Point Control and smart smoothing functions mean you can manufacture high quality parts quickly and accurately.

Smart Automation and Robotization

As the worlds largest manufacturer of Industrial robots, FANUC offers the advantage of full automation and robotization from a single supplier.

Through a single Package called QSSR, or Quick and Simple Start of Robotization, robot loading can be quickly configured.

IoT and Information Management

In todays world information is everything. FANUC offers a solution for production monitoring for the factory floor. Information from each machine is gathered and presented graphically. Production count or time, tool life information, alarm diagnosis, program details, feed & speed details etc can be viewed and stored for every machine connected to the system.

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.

 

For more information, please contact FANUC South Africa – Tel: 011 392 3610

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NEW – THE BYCUT SMART 6225

High productivity and performance in the XXL format at a favourable price

The ByCut Smart 6225 can be equipped with the Fiber 3000, 4000, 6000, 8000 or 10000 laser sources, depending on the user’s requirements.

More sheet metal, more parts: The 6225 format increases productivity thanks to a high degree of material utilization.

 

The new ByCut Smart 6225 from Bystronic provides a high degree of material utilization thanks to a cutting length of up to 6.2 meters and a width of 2.5 meters. The machine cuts not only large parts, but also many small parts with high efficiency thanks to its outstanding nesting processes.

High-end productivity and more parts per cycle are guaranteed, while a wide range of materials can be cut without interrupting the cutting process, hence reducing non-productive time. Users can now enjoy high productivity and performance in the XXL format at a favourable price.

While weighing 21 000 kg, the machine can accommodate a maximum workpiece weight of 3650 kg and produce a table change-over time of 72 s.

The latest version of the high-performance Bystronic cutting head excels with maximum precision and high speed thanks to laser outputs of up to 10 kW.

 

Using a 21.5-inch touch screen, Bystronic’s ByVision Cutting software is operated just as simply as a smartphone. Ease of use and an intuitive user interface guarantee excellent results even when operators are inexperienced.

Several automation solutions are available including the Byloader, which automatically lays plates onto the shuttle table of the laser cutting system, the ByTrans and ByTrans Extended which takes over loading – and unloading of the laser cutting system and the BySort for fully automatic sorting of parts. Also available are the ByTower, a flexible storage tower to store sheets for laser cutting, the ByTower Compact, which enables lightly manned or even unmanned  production for any size of company thanks to automated cassette changing and minimal space requirements. Finally there is the ByTrans Modular load and unload system providing a range of possibilities and layouts for ultimate automation needs both in large series or small job batches.

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

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WALTER EXPANDS TIGER·TEC SILVER WSM45X RANGE

Tiger·tec Silver WSM45X indexable inserts for other shoulder and copy milling cutters from Walter

Walter now offers the high-performance Tiger·tec Silver WSM45X indexable insert grade for ISO S and M for the Xtra·tec XT M5130 shoulder milling cutters, the Xtra·tec XT M5468 copying milling cutters, the Xtra·tec XT M5008 high-feed milling cutters and the BLAXX F5041 and F5141 shoulder milling cutters too.

The combination of the special substrate, which is wear-resistant yet tough, with an Al2O3 coating is the only one of its kind on the market and ensures a high level of process reliability. The coating protects the substrate against excessive heat ingress and enables a high level of productivity. This makes the Tiger·tec Silver WSM45X grade a proven problem-solver, particularly when it comes to roughing titanium alloys in the aerospace industry and when machining stainless steels. The extremely smooth surface of the Tiger·tec Silver indexable inserts reduces the formation of build-up on the cutting edge. A two-tone Tiger·tec Silver coating also makes reliable wear detection possible.

Typical components that are machined using WSM45X indexable inserts are exhaust turbochargers, turbine blades and titanium structural components for the aircraft industry. In addition to the new indexable inserts, the Tiger·tec Silver WSM45X range already includes cutting tool materials for many common Xtra·tec XT shoulder milling cutters, high-feed milling cutters, octagonal and copy milling cutters, and face and shoulder milling cutters from the M4000 series.
For more information contact Spectra Carbide – Tel: 021 555 4144

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PROFILE MILLING WITH A SIGNIFICANT TOOL LIFE INCREASE

presents Xtra·tec® XT M5460 milling cutter with internal coolant channel

With the Xtra·tec® XT M5460, Walter is launching a new profile milling cutter on the market. It has been designed specifically for highly precise machining of freeform surfaces and deep cavities. The profile milling cutter features an internal coolant channel, which enables chip evacuation using compressed air or minimum quantity lubrication.

This is necessary for deep pockets in particular, because it allows the user to blow out the chips. Walter offers the M5460 both with a Weldon and cylindrical shank, as well as with the cylindrical modular interface that is commonly used in mould and die making. When using the profile milling cutter, this potential group of customers enjoys benefits such as the possibility of continuing to use existing adaptors. As a first step, Walter is launching the milling cutter for diameters of 8–32 mm (or ⅜–1″).

The M5460 is a specialist for materials with difficult cutting properties, particularly for hard machining of steels up to 63 HRC. Alongside the geometry of the indexable inserts with extremely stable cutting edges, the key to its success is the WHH15X grade developed by Walter. This is extremely wear-resistant, therefore achieving high precision and long tool edge life. In field tests, Walter achieved increases in tool life of up to 500%. Thanks to an extensive range of cutting tool materials, the profile milling cutter can be used in steel, cast iron and stainless steels alike. This means that, in addition to mould and die making, it also offers advantages for the aerospace or energy industry. The M5460 promises high productivity with maximum process reliability.

For more information contact Spectra Carbide – Tel: 021 555 4144

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OPTIMIZED MILLING FOR VIBRATION-FREE MACHINING

Sandvik Coromant launches new high-feed milling solution

Leader in metal cutting, Sandvik Coromant has launched a new high-feed milling tool. The CoroMill® MH20 is primarily designed for milling cavities, or pockets, in ISO S, M and P materials. Ensuring secure and vibration-free machining, especially at long overhangs, the CoroMill® MH20 delivers best-in-class edge security for a variety of industries and is particularly suited for machining aerospace components.

The CoroMill® MH20 complements existing products in the CoroMill® range, and fills a strategic gap in the high feed indexable milling product line. Designed to deliver reliability with minimal vibration, the CoroMill® MH20 has been adapted for applications where components are notoriously difficult to machine, such as in the oil and gas, mould and die and aerospace sectors.

The tool’s ability to machine at long overhangs makes it especially beneficial to the aerospace sector. This method is an important requirement when machining deep, narrow pockets to produce the components that form an aircraft’s frame, such as its supporting beams found within the sub segment aerospace frame. These beams are often machined from forged titanium and when paired with the requirement for long overhangs, this creates a difficult machining environment with a high risk of vibration.

In contrast to the conventional four-edge concept, the CoroMill® MH20 is designed with a two-edge insert. This is especially beneficial as it means the weakest section of the insert is far away from the main cutting zone, delivering greater reliability and protection against wear. It also means that machining against a corner or wall will not impact the next edge or leading corner, ensuring an equal performance per edge.

Another area of innovation is the CoroMill® MH20’s insert cutting edge geometry. While the sloped edge design delivers a gradual and light-cutting action that requires less power consumption to enable the use of smaller machines, the optimized edge line of main cutting edge and insert corner radius delivers further process security and enables reliable, unmanned machining.

“Machining components for industries like aerospace, oil and gas and mould and die can be challenging,” said Sangram Dash, Application Manager at Sandvik Coromant. “In the aerospace sector alone, manufacturers must handle conditions such as thin floors and walls, deep pockets and tight corners. When designing the CoroMill® MH20, we kept the stringent requirements of all these sectors at the fore. For example, the tool is capable of completing several different operations to reduce the number of tools, changeovers and tool handling required during manufacturing, thus reducing cycle times and improving manufacturing economics. Furthermore, for the first time within high feed concepts, Sandvik Coromant is introducing dedicated insert geometries for different ISO areas to deliver greater optimized process security and productivity.

“In particular, engineers working in aerospace machining cannot afford to make mistakes, especially when the quality control standards for aircraft engine components are so high, so being able to deliver reliable tools with consistent tool life is a top priority for Sandvik Coromant.”

When designing the CoroMill® MH20, extending tool life with higher reliability was of great importance. In fact, when compared to another Sandvik Coromant high feed milling tool, CoroMill® 415, it demonstrated a 32% increase in tool life with a significantly better component quality when machining a titanium aerospace wing support component. In addition, further testing against competing tools has demonstrated superior reliability and a more secure machining performance when machining steel and stainless steel workpieces.

For more information contact Sandvic Coromant – Tel: +27(0)10 500 2295

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TANG-SFEED ALSO AVAILABLE IN ULTRA SMALL 05 SIZE INSERTS AND END MILLS

Soon after TaeguTec’s launch of the TANG-SFEED line, the manufacturer expanded the line with LPKU 05, LPHU 05 inserts and end mills by introducing a small 05 size insert to the Ø10 (2 teeth) end mill TANG-SFEED product line.

Along with the smaller size end mills, two new inserts have been added, namely the LPKU 05 utility type and a LPHU 05 precision type. Both inserts, along with the end mills modular head type, are available in a 10 to 32 mm diameter range and extended flute end mills in a 16 to 25 mm diameter range.

TANG-SFEED product features include a strong tangential type 4-corner insert, exact 90 degree shouldering and optimized geometry for smooth machining and improved stability.

Capable of straight and helical ramping machining, the tangential cutter’s larger diameter core offers a higher stiffness compared to the radial type cutter.

Radial type

Tangential type (TANG-SFEED)

 

For more information please contact TaeguTec – Tel; 011 362 1500

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