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HWACHEON XXL CNC LATHES FOR HIGH PRECISION IN HEAVY-DUTY MACHINING

Case Study

The machining of long and several tons of heavy parts is particularly demanding when at the same time high precision and tightest tolerances are required. It is not only the technical competence of the machine operator that is important, the turning center must also be able to comply with the high demands of the machining process for large, accurate and heavy workpieces. In order to be able to produce even small and smallest batch sizes economically and precisely, Hyss Metallberarbeitung in Lennestadt, Germany, for many years has been counting on large turning centers from Hwacheon, a South Korean machine tool manufacturer.

Gerhard Hyss (right) and his son Steffen (left) invested in the extremely robust and precise turn-mill center Hi-TECH 850L YMC
Hyss Metallverarbeitung produces large and heavy turned parts in small batch sizes on its XL lathes

The contract manufacturer specializes in turning of large and heavy parts, up to 8 tons, 1,100 mm in diameter and 3,500 mm in length. These are often one-off productions or small series in small quantities.

While in 1982 Gerhard Hyss started his business with two partners and the production of small turned parts, they envisaged manufacturing larger parts and decided to invest in machines for processing maximum diameters of 550 mm and peak weights of 1.5 tons. “This allowed us to expand our range of services and gain new market segments,” explains Hyss.

“The concept worked, and more and more orders for large precision turned parts were received. Eventually, the previously available production area reached its capacity limits and subsequently a new production facility was built in 1999 at the current location. The new halls offered space for even larger machines and thus also for machining larger and heavier work-pieces.

FIRST LATHE FROM HWACHEON – Hi-TECH 700

With the rigid Hi-TECH 700 from Hwacheon, workpieces up to a diameter of 700 mm and a turning length of 2,000 mm can be processed.

At the Metav exhibition in Düsseldorf, Gerhard Hyss spotted the Hwacheon Hi-TECH 700, a horizontal turning center for heavy-duty machining, which offers an extremely rigid spindle design. The high-precision cylindrical roller bearings and the particularly impact-resistant angular roller bearings of the headstock are specially designed for tough and hard turning operations. Torques of up to 3,071 Nm at 115 rpm can be achieved via the integrated gearbox. Hyss was fascinated with this extremely stable and qualitatively well-processed lathe in XL format and decided to buy his first Korean machine: “With the Hi-TECH 700, new doors opened for us. Now we were able to machine parts up to a diameter of 700 mm and a turning length of 2,000 mm and achieve more flexibility and speed in production,“ he says.

With the new machine, more new orders came for even larger workpieces. The company had found its niche market and at the same time acquired a reputation as a specialist in the manufacture of large parts for the engineering industry. In the period that followed, the order backlog continued to grow, so another Hi-TECH 700 was purchased to adjust the production capacity.

NEW OPPORTUNITIES.

While space available for storing raw material was no longer sufficient, an additional hall was added. At the same time, the contract manufacturer received more and more inquiries for larger size turned parts with integrated milling work. Therefore, the procurement of a turning-milling center was planned

Steffen Hyss, son of the company founder and co-managing director, saw the Hi-TECH 850L YMC turning and milling center at the opening of the new Hwacheon European headquarters in Bochum. With this XXL machine, workpieces up to eight tons and diameters of up to 920 mm can be precisely machined up to a turning length of 3,500 mm. In addition to classic turning tasks, milling work can also be carried out in one setup in combination with an additional Y axis. This increases precision of machined parts, because clamping errors that can occur when changing from the turning to the milling machine are excluded. Hyss was so impressed with the Hi-TECH 850L YMC that the company decided to buy the machine.

EXTREMELY RIGID MACHINE BED AND FLAT GUIDE WAYS.

The spindle, tailstock and extremely rigid machine bed of the Hwacheon Hi-TECH 850L YMC are designed for large, heavy workpieces. The machine bed is bevelled by 45 degrees for optimal heat management. This prevents excessive heating of the workpiece and machine, while ensuring high precision.

The stable and robust machine has a particularly rigid monolithic machine bed with a weight of 23.5 tons, which is manufactured in Hwacheon’s own foundry. For optimal heat management, it is bevelled by 45 degrees so that hot chips can be reliably removed. This means that the machine and workpiece are not excessively heated, even during roughing operations with a large amount of chips. All flat guides of the machine are hand scraped and polished. Especially with this time-consuming work process, the manufacturer’s more than 75 years of mechanical engineering experience become clear. The flat guides have significantly lower vibrations even for heavy-duty machining tasks and thus ensure greater stability for greater precision and longer tool life.

Thanks to the massive design of the extra wide turret with a width of 250 mm, even large boring bars up to a diameter of 100 mm and a turning length of 1,000 mm can be clamped. The four-stage main spindle gear offers exceptionally high torque, especially in the lower speed range. The bearings are lubricated and cooled using the oil cooling system specially developed by Hwacheon. The temperature of the four-stage gear is continuously regulated in order to minimize thermal expansion, while ensuring accuracy during long operating times and heavy machining. With a drive power of 45 kW, the machine achieves a maximum torque of 6,873 Nm.

On the Hi-TECH 850, the company is able to machine all materials from structural steels, tempered steels, quenched and tempered steels, stainless steels, brass to plastics and super duplex steels.

For more information, contact Lead Machine Tools – Tel: 021 534-5351

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TONGTAI MACHINE & TOOL COMPANY COMMITS TO ADDING ECONOMIC VALUE FOR THE END-USER

By Paul Savides, Managing Director, PBS Machine Tools

When a company makes a product like a CNC Lathe, that may be considered homogeneous i.e. with few differences from that of a competitor, it is very easy to offer some simple features or add-ons that give it a perception of value for money.

Adding value can be done in many ways but adding true Economic Value must be innovative. At Tongtai, we have spent many years improving our products so that we can match the high pace of today’s production requirements and at the same time meet the challenges of competitiveness that manufacturers face as they strive to survive.

The first step for Tongtai was to use available technology to keep costs contained and even use it to get prices marginally down without affecting quality. This has allowed us to keep the same reliability of our existing CNC lathe ranges that have been in 24/7 production in South Africa for more than 20 years. Enabling the upgraded ranges with technologies like Direct Torque Control have allowed Tongtai to improve the serviceability of all machines and at the same time, improve their overall efficiency resulting in major cost savings for the end-user.

This is done by extending tool life and reducing cycle time while at the same time maintaining accuracy of parts within very tight limits.

In a practical example at a user in South Africa we experienced the following:

Competitor Part Cycle Time Tool Wear
xxx 57 Sec/Pc 33 Parts/ Edge
Tongtai 19 Sec/Pc 100 Parts/Edge

 

This also means overtime and rework due to low output is avoided, eliminating late deliveries, unhappy customers and waste accordingly, driving down end-user costs.

Integrated Root Cause Analysis

To understand what a problem is, how to record it, how to analyse it, how to solve it and how to apply it, is truly what adding value really means.

The more refined machines become the more important it is for maintenance staff to keep them in production, this is why we have incorporated into the machines rudimentary systems that enhance end-user productivity and competitiveness. Enabling the many new technologies, developed by Tongtai, and incorporating them into our new machines takes care of all the SPC, Lean Six Sigma, Overall Equipment Effectiveness and Lean Manufacturing processes.

This is all achieved through a range of Intelligent Sensors and Software developed by Tongtai including:

  • Vibration sensors
  • Machine levelling sensors
  • Pressure sensors
  • Temperature sensors
  • Current sensors
  • Intelligent tool holders
  • Tool wear monitoring
  • Real-time cutting monitoring
  • RFID reader for tool identification
  • Integrated communication channel linking all sensors to an Industrial PC

By capturing and interpreting these parameters, we can check and diagnose the condition against the known machine and cutting tool characteristics to ensure the machine continues to produce and keep its quality of performance.

All this helps with process optimisation, improves machine operational performance and reduces unexpected or unplanned machine stoppages.

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

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TONGTAI TD SERIES MULTI-TASKING TURNING CENTER

With rising energy costs and strict international environmental laws, equipment efficiency is a key factor that can influence the production costs. By this trend, the latest machine tools not only need to satisfy the requirements of high speed and high precision, but also need to pursue the goals of high efficiency and environmental protection. In recent years, Tongtai has worked hard on developing products which are environmentally friendly. Furthermore, energy saving accessory products are a primary concern to this manufacturer.

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Rigidity is better than the past                                             

All components are made of high quality cast-iron, while due to its excellent design, the structure decreases the influences of distortion and vibration. In addition, by applying Finite Element Analysis (FEA) the structure is optimized satisfying the requirements of high dynamic rigidity and stability.

Inheriting the outstanding machine rigidity from TB series, the TD series is the brand new multi-tasking turning center with single power turret which is standard equipped with 12 tool stations and linear Y axis to process milling functions. In addition, the 16 tool stations turret and sub-spindle are also available for more complex machining processes, while helping to reduce labour costs and increasing floor utility.

Spindle/Sub-spindle CS axis with brake unit

The CS axis is fed back by a rotary encoder with multi-points positioning function. The minimum indexing increment of 0.001 degrees allows various machining needs with different angles.

With synchronous temperature control, the spindle cooler prevents sub-spindle from thermal distortion. This ensures high precision machining for long-term operation.

75 degree machine bed structure

Different from the 90 degree slant bed on TB series, the TD series features a 75 degree slant bed design. It not only keeps the advantages of excellent chip disposal and accessibility, but also lowers the machine’s gravity center, while enhancing the entire structure rigidity.

Linear Y axis structure

The TD series features a symmetrical saddle design, while the X/Y/Z axes are perpendicular to each other with a real linear Y axis. It allows servo compensation on each axis to optimize the positioning accuracy.

Different from the virtual Y axis, the real Y axis has excellent straightness and positioning accuracy which is able to ensure high machining quality. With a highly rigid sliding carrier design, the TD series has outstanding machining capability.

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

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TUBE PROCESSING – LIMITLESS APPLICATIONS

 

The application of processed tubes and profiles is manifold, whether in the automotive industry, furniture design, architecture, petrochemical industry or commercial vehicle construction. In many industries, the laser-assisted processing of tubes and profiles offers an almost unlimited manufacturing spectrum for components and unique design possibilities.

With diameters ranging from 10 to 324 millimetres and pipe and profile lengths up to 12.5 meters, our system solutions offer the largest available selection for the flexible production of small and large series.

CO₂ and fiber laser technology

The right cutting technology for every requirement is important. Depending on the materials that are to be processed and the desired cutting quality and level of productivity, users have the choice between CO2 laser cutting systems and fiber laser cutting systems.

Fiber lasers achieve high cutting speeds in thin material thicknesses. Additionally they boast low power consumption while requiring little maintenance. The special properties of this laser cutting technology enable applications in steel, stainless steel, aluminium and non-ferrous metals, such as copper and brass.

CO2 lasers are characterized by their high cutting quality. Their primary area of application lies in the medium to high range of material thicknesses. The cutting edges achieved with the laser beam excel through burr-free cutting and low scoring. This means that the cut parts can be processed further without reworking.

2D and 3D processing

The ability to choose between 2D and 3D laser cutting technology opens up the possibility of individually customized and precise cutting of parts in a very wide variety, such as tubes with round, square, and rectangular shapes as well as profiles with diverse open cross-sections (for example H, L, T, and U cross-sections). In addition to straight cutting edges, the 3D technology also enables bevel cuts up to 45 degrees. This versatility eliminates the need for costly milling, drilling, punching, or sawing processes.

BYTUBE STAR 130 WATCH VIDEO

All you need for your tube laser business is quality and performance in one machine – now also for open sections

  • The easiest step into the tube laser process is established technology, user-friendly interface (ByVision Tube) plus one machine which does it all without set up/change over.
  • Fully automatic set up also with open profiles and ellipses from 10 to 130 mm full range and for open profiles, no down time for set up, therefore more time for cutting, less human mistakes and more safety for the operators.
  • Quick cut performance and quality in just one feature. Additional linear axis of the cutting head for highest speed and quality in all cutting circumstances and quality guaranteed even with very small tubes.
  • Laserscan and active tube support during the cutting process with real time compensation of tube bending to improve cutting precision and accuracy also for low quality material and with minor impact on process speed.
  • While machine configurations are suitable for all logistics needs, the machine can be left hand or right hand depending on specific flow of the material, resulting in cost reduction thanks to optimization of space and logistic operation.

FL 170 WATCH VIDEO

 

The fiber laser for fast and versatile applications

 Concentrated technology with the cutting system combining the unique benefits of fiber laser technology with the versatility of 3D cutting.

  • Wide range of applications for the cutting of steel, stainless steel, aluminium and non-ferrous metals in diameters from 12 to 168 millimetres and workpiece lengths up to 6 meters.
  • More profit per part as fast cutting processes are combined with comparatively low operating costs and low maintenance requirements.
  • In addition to straight cutting edges, the 3D technology also enables bevel cuts of up to 45 degrees. This versatility eliminates the need for costly milling, drilling, punching or sawing processes.

FL 300

The tube laser for highest demands on productivity and flexibility

FL 300 WATCH VIDEO

  • Outstanding cutting quality right up to high material thicknesses: The CO₂ laser technology achieves excellent cutting edges with minimal scoring. In addition to straight cutting edges, the 3D cutting head also enables bevel cuts of up to 45 degrees. This versatility eliminates the need for costly milling, drilling, punching or sawing processes.
  • Wide spectrum of applications: Users cut steel, stainless steel and aluminium in diameters between 20 and 324 millimetres and workpiece lengths up to 12 meters.
  • Flexible loading from bundle loading or from chain loading system for open profiles is provided, while subsequently, the precise clamping of the tubes and profiles ensures high-precision processing.
  • Intelligent unloading increases system productivity and reduces downtime when removing finished parts.
  • For longer workpieces, the unloading system’s controllable axes enable any type of tube or profile to be clamped during processing.

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

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SBX500 DOUBLETURN M.C.Y

The SBX500 DoubleTurn M.C.Y is a high productivity turning center of a rigid design suitable for medium to large production of simple as well as complex geometrical shapes. Machine execution with Y-axis and live tools allows machining of complex shaped workpieces on a single machine which significantly reduces production time and increases workpiece accuracy. The machine seriously contributes to increased productivity while decreasing investment costs.

 

Notable features include a modular conception allowing configuring the machine for a wide range of technologies and materials, a counter spindle with passing hole clamping allowing complete machining, Y axis with saddle wedge contributing to increased stability of cutting process and a fast turret with 12 live tools size VDI 40.

Add to this the C-axes with independent servomotors for achieving precise and stable work piece positioning, linear roller guide ways with bearing capacity dimensioned for hard roughing but also precision of finishing operations, while increased spindle bores extend the machining possibilities for a wider assortment of work pieces.

The integrated control panel improves machine control ergonomics for the operator, while programming in 3D through cycles is provided.

Servo drives with electric energy saving features and an option for industrial robot integration for manipulation of raw material and work pieces add to an impressive line-up.

The SBX500 DoubleTurn M.C.Y  features a max swing diameter of 650 mm, max turning diameter of 550 mm and a max bar diameter of  74/117* mm. The max diameter of bars with spindle reduction sleeve or with spindle prolongation is 66/103* mm.

The max weight of workpiece in centres is 1000 kg with the max weight of overhung workpiece 372 kg.

*valid for optional execution

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

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TRENS SN32 UNIVERSAL CENTRE LATHE

SN32 is universal centre lathe with main motor output of 4 kW. A wide operating speed range and its unique design ensure high stability during material turning. This machine delivers outstanding performance and is also suitable for vocational schools. Designed for piece and small-lot production, the SN32 is frequently used in maintenance and repair divisions. TRENS lathes are precise and reliable machines in wide range of versions and optional accessories.

Main characteristic features include a simple and ergonomic control and high precision during machining. Add to this long life time, low operating costs and easy maintenance.

While all important parts are hand scraped, the requirements of safety standard EN ISO 23 125 are provided.

The machine can cut various types of threads with a wide range of pitches.

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

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TRENS SBL500 SINGLETURN M.C.Y

TRENS SBL500 SINGLETURN M.C.Y

The TRENS SBL500 turning centre with rigid construction slant bed is designed not only for heavy roughing but for demanding finishing operations with focus on high accuracy and surface quality too. Exceptional steadiness of cutting process is ensured by high stiffness of the individual machine components.

Long-term operational reliability designates this machine for turning workshops with continuous operation and high productivity demands. The turning centre can be operated in fully automated mode when equipped with devices for automatic workpiece manipulation.

The machine is equipped with a 12-position turret VDI 40 with live tool positions, C-axis with independent servomotor for achieving precise and stabile work piece position during cutting forces loading and comes with remote diagnostics and data management. Other features include 1500 mm distance between centres, direct measuring of spindle position – high precision at out-of-axis machining of large diameter workpieces, a  wide range of executions and accessories –  hydraulic clamping with chucks or collets, bar feeders, tool probes, automatic door opening, oil mist filtration from work area and covers with reinforced zones providing high level of operator´s safety.

The TRENS SBL500 features a max swing diameter of 600 mm, max turning diameter of 410 mm,     max bar diameter of74/117* mm and a max diameter of bars with spindle reduction sleeve or with spindle prolongation of66/109* mm.

The max weight of workpiece in centres  is 420 kg and max weight of overhung workpiece 215 kg.

*valid for optional execution

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

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RHINO-M-TURN

ECONOMICAL DOUBLE-SIDED MINI SIZE INSERTS AND HOLDERS

RHINO-M-TURN is a compact, double-sided mini size insert that is suitable for the internal and external turning of small parts and can replace standard positive small inserts like CCMT 06 and DCMT 07.

Although the insert is a double-sided type, it has the same edge angle as the conventional positive insert type when mounted to the holder. This results in minimal vibration due to the low cutting force, as well as good workpiece surface finish and machining accuracy particularly at low depths of cut. In addition, the strong screw clamping design exerts stable machining during operations.

The inserts are available as CNMX, DNMX, WNMX type for finishing and a precise DNGX type suitable for Swiss type automatic lathes. The square holders are available in shank sizes 1212, 1616 for Swiss type automatic lathes and 1616, 2020 for general machining, while the boring bars are available in Ø12 mm and Ø16 mm.

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THE TAEGUTEC POS-S-TURN LINE

The POS-S-TURN line dramatically improves productivity due to its all-directional and high feed turning capabilities.

The XNMV 1105 is a double-sided 4-corner insert with a 70-degree angle. It combines the advantages of the ISO CNMG and DNMG inserts for various machining applications such as external turning, face turning and external profiling.

Highly efficient machining with a maximum 3.5 mm depth of cut in external forward turning and face turning as well as good chip control.

An additional advantage of the XNMV 1105 insert is its unique high feed backward turning capability. This technologically advanced capability is made possible due to the insert’s helical cutting edge that works to reduce cutting forces as well as the insert’s lower entering angle – both features greatly contribute towards higher productivity.

In addition, the insert’s rigidity is strengthened by its increased thickness, while its stability is improved by the insert’s wide support surface.

 

The T-holder’s strong clamping mechanism enhances stability, which offers excellence in the mass production of automotive parts. By using the existing TXJNR/L-TB high-pressure coolant holder, customers can expect improved productivity, good tool life and chip control.

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GRADE UPGRADE FROM ISCAR

Building a house begins with laying the foundation. The strength and the reliability of the whole house depend on how strong the foundation is. In cutting tool engineering, this foundation is a cutting material. There are various types of cutting materials, such as cemented carbide, polycrystalline diamond, high speed steel, ceramics etc., and each type contains different grades. At various stages in metal cutting history, the introduction of each cutting material and its use has led to a significant change in the level of cutting speeds and, consequently, productivity. However, if the previous century, especially its second half, was marked by the rapid progress of tool materials, today we do not see any significant new solutions in this field. Does this mean that the development of new tool materials has already reached its peak and is experiencing stagnation?

Of course not, it is simply that the new developments are deep within the cutting material and are focused on its structure and can be observed only with the help of scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBCD), and other sophisticated methods. They cover a tremendously complicated world of coatings that is extremely diverse despite its very small thickness, measured only by microns.

The most commonly available cutting material today is cemented carbide, primarily coated. In terms of performance, it represents a reasonable balance between efficiency, tool life and cost. Cemented carbide is known also as “hard metal”, “tungsten carbide” or simply “carbide.” A combination of cemented carbide, coating, and post-coating treatment produces a carbide grade. Only one of these components – the cemented carbide – is an essential element in the grade, the others are optional.

Cemented carbide is a composite material comprising hard carbide particles that are cemented together by binding metal, mainly cobalt. Most cemented carbides used for producing cutting tools integrate wear-resistant coatings. There are also various treatment processes that are applied to already coated cemented carbide, for example the rake surface of an indexable insert. New developments in cemented carbide as a tool material are concentrated in three directions, such as carbide production technologies, advanced coating methods and innovative post-coating techniques. Considerable success has been achieved in each of these directions, which is reflected in the wealth of new products introduced to the market by leading cutting tool manufacturers.

Cutting tool customers might analyze the grades using parameters such as productivity, tool life and performance. Indeed, the question of how a new product was created to meet customer requirements fades into the background as applicability and efficiency form the main measure of progress from the customer’s point of view.

In upgrading carbide grades, ISCAR is very sensitive to a challenge faced by the metalworking industries. In this context, ISCAR’s tool material solutions, which are developed considering the trends of modern metalworking, can be quite indicative. Take, for example, difficult-to-cut materials such as titanium and heat-resistant steels and exotic super alloys. Recently, the share of their application in industry has increased significantly. Along with the aircraft industry, a traditional consumer of these materials, they may be increasingly found in power engineering, automotive and oil and gas branches. The growing usage of the materials demands technological solutions, including machinery and cutting tools. The new tools require an appropriate foundation made of advanced cutting tool materials to achieve the desired cutting geometry. And for the construction of this foundation, ISCAR offers its new effective “bricks” – upgraded carbide grades developed by company metallurgists in the last few years.

In milling, ISCAR has developed PVD coated IC882 and CVD coated IC5820 grades– two chocolate-color carbide grades for cutting titanium, high-temperature alloys, and stainless steel. An integral component of the grades is a post coating treatment that facilitates longer tool life, due to increased resistance to chipping, notch wear and build-up edge formation. The IC882 grade demonstrates impressive performance when machining conditions are hard, and the advantages of the IC5820 are most fully manifested when applied to milling with pinpointed high-pressure coolant supply.

For drilling applications, the company introduced IC5500, a new grade that features a multi-layer CVD coating and a post-coating treatment to prolong tool life. Following the grade’s success, IC5500 has been utilized in milling products as well, while the new round insert in cutters for machining 3D surfaces such as blades in turbomachinery, for example, are produced solely from this grade.

The PVD coated carbide grade IC806 was designed especially for turning high-temperature superalloys. As a result of the high mark that the grade received from the manufacturers of aerospace components, ISCAR expanded the application range of IC806 for laydown threading inserts.

In addition to cemented carbide, the metalworking industry consumes other hard cutting materials such as ceramics, diamond and cubic boron nitride (CBN). Their application to machining difficult-to-cut materials facilitates considerable increases in productivity. In recent years, ISCAR has enriched its cutting material range by introducing several new non-carbide grades, including the SiAlON grades IS25 and IS35 for cutting high-temperature alloys and the CBN grade IB20H for hard part turning.

At the same time, customer demands are not limited to the effective machining of exotic superalloys or titanium. Steel is still the main structural material, and cutting tool manufacturers are constantly searching for the most advanced appropriate solutions, including the development of advanced cutting material grades. ISCAR also does not stand aside. An example may be the last innovation in parting and grooving, namely the two new PVD coated carbide grades, IC1010 and IC1030, which were utilized in inserts from the TANG-GRIP and DO-GRIP families.

The grades are intended for machining stainless steel and steel. While the hard submicron grade IC1010 is recommended for productive parting and grooving with high cutting speed, the tough IC1030 is more suitable for interrupted cut and unstable machining conditions.

Upgrading cutting material grades is an essential component for tool manufacturers’ success, and innovations in cutting tools should have a strong foundation. This is why ISCAR’s motto “to be on the upgrade” guides and inspires new tool material developments.

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

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