Universal and flexible are the features of the new S33 CNC universal cylindrical grinding machine from STUDER. It can grind small to large workpieces in single batch, small or large series and is available with centre distances of 400mm, 650mm, 1000mm, 1600mm and a centre height of 175mm. The changeover from grinding between centers to live spindle grinding takes place in record time.

Complex workpieces are easily ground in just one clamping. The basis for the universal cylindrical grinding machine S33 is the machine bed made of solid Granitan® S103. Thanks to its favorable thermal behavior this offers a high degree of dimensional stability, while short-term temperature fluctuations are largely compensated for by the mineral casting. STUDER has redesigned the machine base geometry and supplemented it with an innovative machine base temperature control, which ensures fast and stable production. The mounting of the dressing unit on the double T-slot of the longitudinal slide massively reduces time needed for set-up or changeover of the machine. While the S33 is based on the STUDER T-Slide concept, which now features an extended X-axis stroke of 370mm, STUDER offers various wheelhead versions. The turret wheelhead with a 1° Hirth coupling and automatic swivel can accommodate up to two external and one internal grinding spindle and is equipped with the latest generation of contact detection. The external wheelhead with a grinding wheel right, can be manually set to 0°, 15° and 30°. The machine set-up and changeover costs can be For more information, please contact Retecon – Tel: 011 976- 8600.

The new Studer S33. Harp Waytrain horizontal bandsaws are manufactured in Taiwan. The company was established in 1983, and is well known for producing high quality machines. Sizes range from 180mm diameter cutting capacity, up to 330mm diameter. Rigidly constructed, with great attention to detail, these saws are ideal for all engineering companies. Harp Waytrain horizontal bandsaws combine quality, reliability and affordability. Five models are available ex-stock, such as the UE-712A, UE916A, UE-250, UE918S and the UE-330. All machines are complete with coolant systems, blade tension control and electrics 380V/3/60. Features: Model 330A: Capacity 90° round 330mm, rectangle 330mm x 480mm / 225mm x 530mm, capacity 45° round 255mm, rectangle 280mm x 255mm, blade size 34mm x 1.1mm x 4100mm, blade speeds (belt change) 28/40/56/78 mpm, motor 3 hp, net weight 600kg, tool box, material stopper, machine manual. Model 250A: Capacity 90° round 250mm, rectangle 250mm x 415mm / 200mm x 450mm, capacity 45° round 190mm, rectangle 250mm x 190mm, blade size 27mm x 0.9mm x 3300mm, blade speeds step pulley 25-71 mpm, motor 2 hp, net weight 320kg, tool box, material stopper, blade speeds (belt) machine manual. Model 918S: Capacity 90° round 225mm, rectangle 225mm x 430mm, capacity 45° round 225mm, rectangle 225mm x 295mm, blade size 27mm x 0.9mm x 3345mm, blade speeds (belt change) 82~259 mpm, motor 2 hp, net weight 420kg, swivelling saw-bow, variable speed, machine manual. Model 916A: Capacity 90° round 225mm, rectangle 225mm x 340mm, capacity 45° round 165mm, rectangle 225mm x 165mm, blade size 27mm x 0.9mm x 3035mm, blade speeds (belt change) 25/40/51/71 mpm – motor 1½ hp, net weight 300kg, tool box, material stopper, machine manual. Model 712A1: Capacity 90° round 180mm, rectangle 180mm x 280mm / 65mm x 300mm, capacity 45° round 110mm, rectangle 180mm x 110mm, blade size 19mm x 0.9mm x 2360mm, blade speeds (belt change) 23/33/45/65 mpm, motor 1 hp, net weight 130kg, tool box, material stopper, machine manual. For more information, please contact Harp Machine Tools – Tel: (011) 918-5138.

Harp Waytrain Horizontal Bandsaw, Model 330A. reduced thanks to the turret wheelhead with multiple grinding wheels and the fast set-up software Quick-Set. The S33 can easily handle internal-, external- and face grinding in one clamping which leads to an even higher efficiency in complete machining. The C-Axis, with an option of either a direct or indirect measuring system, allows the grinding of forms and threads. The S33 can also be equipped with a chuck workhead, specially designed for grinding chuck parts. More than a hundred years of grinding experience is integrated in StuderWIN, which enables safe programming and efficient use. StuderTechnology requires just a few parameters to automatically calculate precise grinding parameters in just seconds. Good quality and a stable process is assured right from the beginning. The optional integrated modules such as StuderForm, StuderThread or StuderContourBasic extend the functionality of the machine. The hand-control device PCU makes it possible to set up the machine close to the grinding process. With electronic contact detection, downtimes can be reduced to a minimum. With the standardized loader interface, the S33 can also be automated.

For more information, please contact Retecon – Tel: 011 976-8600.

While TaeguTec has supplied the most advanced state-of-theart cutting tools and tooling services to South African industries including automotive, mold and die, metals and electronics, the Asian metalworking giant offers a myriad of tools capable of cutting cost and increase productivity on any material. One of the most important areas of manufacturing is hole-making and TaeguTec offers several options for companies looking to perform efficient drilling operations no matter if the factory relies upon the speed of production, the amount of savings shops are targeting, the materials being drilled or a combination of all these factors. One of the industry’s favourite choices catering for drilling into everything from alloy steel to stainless steel is TaeguTec’s DrillRush – the versatile indexable drill that is constantly being expanded to provide dependable, optimal hole drilling performances on any material. The various DrillRush geometries and sizes such as 1.5xD, 3xD, 5xD, 8xD and 12xD not only increase productivity but improve tool life due to its reinforced edges and coating, which are suitably designed for optimal chip control and hole quality on any material. TaeguTec introduced two new sizes – the 12xD drill that produces deep holes accurately, repeatedly and economically and the DrillRush 6 millimeter to 6.9mm diameter range drill heads, which were designed to handle 1.5xD, 3xD and 5xD drilling depths. All DrillRush products eliminate the need to remove the entire drill from the spindle in order to replace the head; a process that shortens cycle times and substantially increases productivity. TaeguTec’s SpadeRush line generates higher productivity and outstanding performance due to its optimized cutting edge and unique rigid clamping system.

Available as a standard drill in 3xD and 5xD for a diameter range of 26mm to 41mm, the SpadeRush’s unique clamping technology enables operators to quickly change drill heads without removing the clamping screw from the holder. For cost effective machining and higher productivity, the TopDrill line has been built to satisfy a growing market demand for flexibility and excellent performance. Also, its true 4-corner inserts are suitable for both internal and external pockets, reduces inventory and promotes cost reduction. From top to bottom, the TopDrill has been built for improved tool life and is equipped with a new insert grade for enhanced durability. Last but not least is the newest member of TaeguTec’s drilling family, the TwinRush – a product that guarantees excellent performance and high productivity on large diameter holes. The noticeable feature of the TwinRush joins together a centering insert with a pair of precise square inserts on either side in order to combine two different drill types onto one drill body and protects them with TaeguTec’s TT9080 PVD multi-layered coated grade.By doing so, this double effective design increases productivity.

For more information please contact TaeguTec – Tel: 011 362-1500.

No two customers’ needs are exactly alike. Finding the right solution means thoroughly understanding objectives and configuring a solution that matches them precisely. Our engineers have decades of industry experience which promote achieving specified goals with a process that fits and enhances a customer’s work flow. From the early beginnings of bandsaw machinery produced by Amada, (many of which are still running today), Amada has strived to offer machines that not only meet customers’ needs, but exceed them by offering features that were once considered impossible. The technology of the bandsaw demonstrates the ability and limitations of the blade. As blades advance in technology, so do the machines utilizing them. Amada, as a proud manufacturer of both the machines and the blades, continues to research these developments and incorporates customer feedback to produce constantly evolving solutions. Amada supplies bandsaw machinery and blades, such as the HK / HD series for mitre cutting, the semi-automatic H series, fully automatic HA / HFA series and the VM vertical series. The latest bandsaw technology is reflected in models such as the Dynasaw 430, the PCSAW with pulse cutting technology and CMB high speed circular saws. Some features include out of square cutting detection, motion detectors to monitor the blade for jamming or breakage while cutting and quick approach arms. Add to this no work limit switches and work lights, hydraulic blade tensioning, variable blade speed control, vice pressure control units and positively driven wire brushes. 9 times feed for cutting long lengths and cut-off counters ensure the correct number of cuts. All these features, assist semi-skilled workers in the operation of the machines. Certain models can be left to run unmanned on larger batch runs, thus allowing staff to do other important jobs at the same time. Take-up conveyors and tripod stands are available making material handling simple during the loading and cutting process. Models available start with the entry level of 250mm capacity, which are highly popular and favourably priced. With larger steel suppliers all utilizing Amada bandsaws daily, testimony is given to their accuracy, reliability and longevity. Cutting accuracies are obtained right down to 0,2mm. With such accuracies, the need for secondary machining processes is greatly reduced and in some cases eliminated. The latest additions to the Amada bandsaw range is the PCSAW, with either single pulse cutting action or double pulse cutting action. The PCSAW series is designed to offer high cutting rates, high precision, low noise and long blade life. Vibration has always been an unwanted characteristic of metal sawing when cutting too fast. It leads to decreased blade life, noise and uneven or inaccurate cutting. By introducing a controlled pulsating motion to the blade through either an induction motor or a servo motor, all unwanted vibrations are eliminated and most efficient metal cutting is achieved. Blade temperature is reduced considerably during the process, and this together with positive chip removal through a twin wire brush system and a large area chip conveyor all enhanceblade life and reduce running costs. All PCSAW bandsaws are operated through the on-board user-friendly CNC control. The HPSaw (High Performance Saw) is possibly the fastest bandsaw in its class with the latest in cutting speed innovation and the ability to cut at up to 1.5 times faster than the high speed circular saws. The specially designed AXCELA HP1 blade for this machine also reduces material wastage by up to 60% and guarantees accurate cutting. Circular sawing machines are the optimal technology for realizing reduction in cycle time and high-precision cutting needed for steel bar cutting at high speed. An automatic loading table for continued cutting operation is supported by a CNC powered cut-in control for ease of operation. In perfecting functionality of these machines, Amada has developed a unique carbide tip

circular blade that cuts cleanly, generating virtually no burrs. A full range of bi-metal bandsaw blades are produced by Amada to compliment machine technology. As mentioned previously, a bandsaw demonstrates the ability and limitations of a blade. This means th

at a machine is only as good as the blade being used. Amada blades have earned the reputation of extreme reliability and longevity. All blades are manufactured in Japan to the most

stringent quality standards and utilizing the latest in electron beam welding methods. These measures ensure that premature blade breakage is almost unheard of. The comprehensive range of blades available is tailor-made for all types of cutting conditions on all types of steels and profiles.

By Barry Page

For more information, please contact Amada – Tel: 011 453-5459.

ISCAR is introducing the CHAMFMILL family of indexable milling cutters carrying PNMT 06 pentagonal inserts with five cutting edges for front chamfering and five for back chamfering, providing an economical machining solution. The new economical cutters carry star-shaped (pentagonal) doublesided inserts with 10 cutting edges and are produced from ISCAR’s advantageous IC830 SUMO TEC carbide grade. The CHAMFMILL family ensures cost-effective milling of 45° chamfers and productive machining due to the high cutting speed. Main applications include machining main engineering materials: steel (ISO P), stainless steel (ISO M) and cast iron (ISO K). The tools are intended for front chamfering, back chamfering and removing burrs, which eliminates hand de-burring. The maximum width of a machined 45° chamfer is 1.5 mm. Two shank configurations are available: cylindrical shank and replaceable milling heads with MULTI-MASTER adaptation. The tools are available in 11.70, 16.70 and 18.70mm tool diameters and are suitable for back milling chamfers in 10mm minimum diameter holes. A polish coating ensures better chip flow and tool protection from corrosion and wear.

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

By Barry Page, AMADA

Machinery is becoming more eco-friendly, thanks to the reduction or in some cases elimination of oils in their drive systems. Some of the latest technological advances allow more machinery and bigger machinery to be operated with less power consumption and a smaller carbon footprint, while ensuring higher throughput. These advantages are seen through the new A.C. servo drive systems used on punching, bending and stamping machines, as well as through the newer fiber technology on lasers.

As a market leader in the design, production, supply and support of sheet metal machinery, AMADA has taken the efficiency challenge one step further, by ensuring that machine manufacturing facilities and processes are also as efficient and eco-friendly as possible. Amada has been able to incorporate many unique features in their manufacturing plants around the world which all contribute towards environmental wellbeing. Today’s technology in the fiber laser field is something that not many people saw coming. The efficiency of fiber systems is greatly attributed to the eradication of costly internal components such as tubes, internal optics, turbo blowers, vacuum pumps etc, as well as the elimination of laser gas being used to generate the laser beam. The latest generation 3 fiber laser systems is even more compact and efficient than the 1st and 2nd generation units. Amada has incorporated features that subsequently contribute towards reducing costs, such as automatic nozzle changing, automatic nozzle cleaning and automatic nozzle recalibration. An added advantage is a scheduler function, which can be used, while full production planning and scheduling is executed in the planning office.

Automatic material handling systems can be supplied with machines or retro-fitted at a later stage. These systems are capable of storing materials, while automatically feeding them to the machine as required. Amada offers automated material storage and manipulation systems for full blanking and bending operations. The “entry level” manipulation systems referred to as “MPL’s” consist of two material pallets and are capable of holding up to 2000kg raw material each. There is a third pallet for offloading of finished sheets with parts either held in by micro-joints or not.

The MPL uses an array of vacuum suction cups to lift and separate the sheets from sticking together, while loading the cutting or punching table. Checking of material thickness according to the part or nesting program is accomplished by the sheet thickness detector. While the sheet is being processed, the MPL will then prepare and lift the next sheet and get ready for changeover. Priority is given to unloading the cut sheet and reloading a new sheet before the stacking of the processed sheet happens. This ensures speedy changeover and minimal machine idle time. The same principle applies to the Amada ASF series of sheet storage and manipulation systems. These systems have various shelves for raw materials with each shelf holding up to 2 tons of different thickness and types of materials. The advantage of these systems is that longer, uninterrupted production runs are possible. Both these systems, MPL & ASF, can be enhanced with the addition of a “TKL” automatic parts removal system which can be retro- fitted. The TKL also uses an array of different sized suction cups to pick desired components out of the skeleton and sorting them into desired piles depending on the next process required. This is especially advantageous when cutting nestings of different jobs. Parts are automatically sorted from the skeleton before the operator intervenes. Up to 3 different packing stations are available for part-sorting. A higher level of automation can be achieved with the Amada MARS system, which is designed according to customers’ requirements. Accessible from either side, each shelf can hold up to 2 tons of different materials. Machinery is then connected to the MARS system via intermediate MPL systems. Material is fetched, checked for thickness and loaded automatically. Once sheets are processed, the full sheet can be removed or the TKL can be used before the skeleton is taken away for storage. Parts are then returned to the MARS system for storage until they are needed for the next process. By utilizing this latest technology, 24 hour production is possible without the need for staff to be present.

Semi-automatic or fully automatic bending available from Amada, offers the latest technology, namely the HG – ATC press brake series. Available in either a 100 ton x 3 meter or 220 ton x 4 meter configuration, these ATC machines are ideal for the reduction of tool change down-time, especially in today’s production environment of small batch runs, requiring quick change over times.

All programming, sequencing and tool fitting is done in the production office before reaching the shop floor. The programs are sent via network to the machine, where the operator can see a full 3D view of the component, both blank and bent. The machine automatically loads the required tooling into position from the onboard tooling magazine. Once the bending process is completed, the machine will automatically change tooling again. A full 3 meter tool change can now be done in just over 3 minutes, while a similar manual tool change would take 15 to 45 minutes. Tool life is substantially extended and incorrect tool usage and tool damage are eliminated. Programming software identifies tool capabilities such as maximum permitted tonnages etc. thanks to each tools’ unique identification code. For longer production runs together with total operator elimination, Amada offers the “AR series” of robotic benders. These benders incorporate robotics which pick the parts, bend the parts and stack or place as required. These, too, are available for different tonnages Added to these advantages is the fact that Amada has a fully trained service department, fully capable of backing up all equipment through their local offices.

ENSIS-3015AJ 9kW/6kWis designed for high-speed stable cutting over the entire range of machining, from thin to thick sheet metals, which has been made possible by the evolution of AMADA’s original beam control technology (ENSIS technology) and the expansion of oscillator output from the conventional 3kW to 9kW/6kW. High quality cutting over the thick material range is achieved by overcoming problems related to fiber lasers through reduced dross and bevel and improved surface roughness. NC equipment is provided with the AMNC 3i, which can be operated easily like a smartphone. It is adapted to AMADA IoT V-factory and visualizes machine operating results including power consumption and processing costs, contributing to performance. Furthermore, it enables smart manufacturing through maintenance and support to maximize machine capacity, as well as proposals to improve production efficiency. AMADA’s high-output oscillator provides for maximum output of 9kW/6kW to enable high-speed and high-quality cutting over the entire processing range (thin, medium thickness and thick sheet metals), based on energy saving and high-quality beams. ENSIS technology allows the laser beam to be controlled freely into the optimum beam form according to material quality and thickness. Additionally, the auto collimation mechanism is provided as a new feature. The variable range of the condensing diameter has been expanded greatly to achieve excellent stable cutting over the entire thickness range. Furthermore, combined with a high-output oscillator, the technology enables high-speed stable cutting of thick sheet metals, cutting with reduced dross and bevel and improved surface roughness. The fiber laser cutting machine employs Clean Fast Cut (CFC) technology and Easy Fast Cut (EZFC) technology to dramatically reduce the consumption of assist gas during nitrogen cutting, which is used mainly to cut stainless steel. It applies an original non-contact nozzle developed by AMADA that supplies assist gas at a low pressure to reduce processing costs, while maintaining cutting quality.

The Durma HDF/HDFL 3015 fiber laser machine features a rigid stress-relieved welded steel frame construction with a stiff gantry axis system moving the cutting head. Highly accurate parts even when cutting with fastest speeds and under highest accelerations are guaranteed. An integrated shuttle table maximizes productivity and minimizes material handling times. The shuttle table and pallet change system allows convenient loading of new sheets or unloading of finished parts, while the machine is cutting another sheet inside the working area. The available shuttle table is fully electric and maintenance free; there are no hydraulic oils to handle and table changes are fast, smooth and energy-efficient. An optional lateral automatic scrap conveyor allows the removal of scrap pieces from the working area without the need to interrupt the cutting process. The sideways operation of the short conveyors allow for easy maintenance and trouble-free running. The Durma HDF/HDFL 3015 fiber machine achieves highest dynamics and fastest laser processing cycle times thanks to the combination of rigid mechanics and a state-of-the-art numerical control and drive system.

Programmes can be loaded easily into the machine with a USB stick or over a fast Ethernet connection with the company network. In the high-pressure auto-focus cutting head for the fiber laser the cutting lens is shielded from the laser process by an exchangeable lowcost protection window. The 1μm wavelength light is very sensitive to dust or other contamination produced in the cutting or piercing process, therefore the cutting head is being well protected in an additional cover to ensure that all critical parts remain as clean as possible.The integrated capacitive distance sensor is capable of having the head follow height differences in the sheet even at the extreme high cutting speeds that can be achieved with the fiber laser technology, while stateof- the-art linear motors promote accuracy and increase productivity. The CAD/CAM software provided has all the tools to import or draw parts, prepare and optimize automatically different geometries for the laser cutting process and make efficient nests. The all-solid-state fiber laser technology reduces maintenance requirements, and offers the lowest possible running cost with a wall-plug efficiency of 30% and without the need of any laser gas. When the application requires a broader spectrum of material types to be cut and the maximum thickness range is limited, the fiber laser is the ideal solution and it will cut faster at lower cost than any CO2 laser at the same laser power.

The Eco-Bend Expert CNC hydraulic press brake offers a wide variety of options on top of its standard features. The machine is user-friendly and provides a cost effective production solution. A high resolution controller comes standard with all Eco-Bend press brakes, while the 2D screen and high programming capacity are the two major features enjoyed by users. Available at a low investment cost the machine offers high efficiency, ergonomic and compact design, minimum space requirement, high resolution 2D graphic screen and a 1 axis (X) motorized backgauge. While the Ecobend Expert CNC hydraulic pressbrake is a durable choice for precise cutting, the machine is easily installed. Specifications include a bending force of 80 ton to 200 ton, bending length of 2600mm to 4100mm, 3 axis – Y1, Y2, X as standard and optional manual crowning.

As the need for machining smaller volume work pieces made from cast iron and steel has grown, so has the need for smaller size tools that can enhance productivity and reduce operating cost. Therefore TaeguTec offers a smaller size insert for its highly popular Chase2Hepta milling line. The Chase2Hepta 6mm inserts and cutters are available to meet the challenges posed by technical trends in forging and casting technologies which is demanding higher productivity and economical tools that can handle lower depth of cut conditions. The Chase2Hepta line is renowned for offering 14 corners on one insert.

The double-sided and highly effective 45 degrees entry angle is the ideal solution for high performance on cast iron and steel machining, while its positive cutting edge geometry lowers cutting loads during rough machining making it an efficient and smooth set of tools. Covering a wider range of machining applications, the dual usage TaeguTec Chase2Hepta 6mm inserts are screw type. The line of mini cutters comes in three geometries – the M, MM and ML.

The M geometry 6mm Chase2Hepta line is used for roughing applications of steel and cast iron work pieces and its smooth machining with good tool life is due to its reinforced, positive rake angle. For general cast iron machining applications, the optimized cutting edges of TaeguTec’s MM geometry chip breakers on the Chase2Hepta 6mm line means low cutting forces in cast iron machining.

The ML geometry for the 6mm line is ideal for cast iron light machining and difficult to cut materials such as stainless steel and heat resistant alloys. Its sharp, positive cutting edge was designed for minimal cutting force.

Ermaksan heavy duty press brakesmeet the needs of all sectors engaged in the production of heavy machinery such as transportation, wind turbines, power plants and the defence industry. Benefits of this remarkable machine include a 17″ 3D, LCD touch screen controller, perfect configuration for heavy tonnage bends, while offering an absolute solution for deep and full-sized bends. Continuous precision with a dynamic motorized crowning system, a 6 axis servo motor backgauge system and AP3 / AP4 front sheet support system complement each other. This machine is a durable choice for precise cutting works and special top and bottom tools with 610mm throat depth. The Ermaksan heavy duty press brake allows for work at maximum capacity putting an end to time consuming manufacturing processes.