RAPID PANEL BENDING WITH THE TRUBEND CENTER 7030 The new TruBend Center 7030 bends parts up to 30 percent faster than its predecessor – and its tool change cycles are up to 70 percent quicker. TRUMPF has included the option of equipping the panel bender with a loading and unloading station. Panel bending machines such as the TruBend Center 7030 are particularly adept at fabricating complex parts with radius bends, short side lengths, and narrow profiles.When it comes to producing parts with these kinds of specifications, this alternative bending technology is quicker than die bending machines. TRUMPF has focused on making the TruBend Center 7030 faster than ever. The engineers achieved this by splitting the machine’s drive unit into two parts. Instead of equipping the machine with just one central hydraulic cylinder, the new design features one cylinder on the left, and one on the right. That increases axis velocity, and boosts the machine’s productivity. The on-demand servo drive saves energy by only running the motor when the machine actually needs it.

Automated loading and unloading

The operator can stack various piles of metal blanks on the right-hand side of the machine. A suction cup initiates the automated loading process by picking up a sheet whilst simultaneously checking that it has not taken two by mistake. This gripper device deposits the blank on a brush table, with a positioning bar ensuring it is aligned correctly. A loading carriage then moves the blank into the machining area, simultaneously removing the most recently bent part from the machining area, and transporting it to a conveyor belt. During this loading and unloading process, the TruBend Center 7030 continues to operate. Change tools faster – program parts within a matter of seconds The task of changing bending tools is handled by the ToolMaster. As well as increasing its axis speed, the TRUMPF engineers have also added a feature that allows it to change multiple small tools at the same time. These improvements reduce machine setup time by up to 70 percent. The TruBend Center 7030 features the offline TecZone Fold programming solution that enables operators to program many parts in just a few clicks of the mouse. TecZone Fold takes a matter of seconds to generate the bending program and 3D simulation of the parts, including collision monitoring.

The TruLaser Series 1000 handles many cutting-related processes autonomously to drive down part costs.

Equipped with a robust laser and proven functions such as collision protection, these machines cut sheet metal in a process-reliable way. And the intuitive operating concept reduces training time. Beyond that, TRUMPF added features such as protective glass monitoring and BrightLine fiber. Previously available only in higher 2D laser classes, they serve to optimize processes and boost machine efficiency. The series consists of two types of machine, the TruLaser 1030 fiber and the TruLaser 1040 fiber with work areas three and four meters long, respectively. The TruDisk solid-state laser operates at constant power and is insensitive to reflections off copper, brass and other materials that reflect when cut. TRUMPF ships these machines out with data for cutting many commonplace materials and thicknesses of sheet metal. It enhances their process reliability – they can even cut copper with nitrogen. Machines with a four-kilowatt laser are equipped with BrightLine fiber. With this function, they can cut thick mild steel in a process-reliable way. In the event of a collision with tilted parts, a special protective mechanism deflects the cutting head to prevent damage.

The TruLaser Series 1000 deposits slag and small parts in five pull-out drawers below the machine’s frame. This re-engineered line of TRUMPF machines is far more dynamic than its predecessor. Positioning speed is up from 85 to 140 meters per minute. This speed is down to the design of the machine’s body, which combines a rigid machine frame with a lightweight motion unit and powerful drives. The machine cuts all materials and sheet thicknesses with the same cutting head. It changes nozzles automatically thanks to the optional nozzle changer. Sensors monitor the optics’ protective glass and let the operator know when it is time for a replacement. Visual inspections are a thing of the past. All this reduces the machine’s set-up time. The TruLaser Series 1000 also saves time during the cutting process. The PierceLine feature reduces piercing time by up to 80 percent and protects the machine and material. These machines operate very energyefficiently with an average power consumption of 13 kilowatts for the 3-kilowatt laser and 14 kilowatts for the 4-kilowatt laser. They also come with more energy- conserving features, as do their periphery modules. The TruLaser Series 1000 features a 18.5-inch multi-touch control panel. It displays the most frequently used menu items at the top level. If the operator interrupts an operation, the control unit enables processing to resume at the same point. The monitoring capability is not limited to the protective glass: Other sensors track the condition of components that impact the machine’s cutting performance. A traffic-light readout on the control panel called the Condition Guide indicates the status. It also offers guidance when the operator needs to take action.

Flow charts make it easier to forecast actionable events and provides a more efficient way of scheduling maintenance work. A semi-automatic pallet changer is a standard feature. The operator can prepare new sheets, while the machines are operating and sort or unload cut sheets parallel to the cutting process. Users may opt to equip the TruLaser Series 1000 with automated LiftMaster components. They load raw sheets and remove the cut sheets. TruLaser Series 1000 machines may be connected to the compact TruStore storage system or to a large Stopa storage system. The MobileControl app serves to operate the TruLaser Series 1000 using a touchpad situated near the machine. TruTops Monitor software tracks the machine’s status continuously and notifies the operator in the event of a malfunction. The TruLaser Series 1000 affords users the opportunity to access the machine’s digital enhancement. It contains five apps that assess machine data and deliver the results to users. AXOOM, a TRUMPF subsidiary, provides the cloud platform for processing these data. The apps provide an insight into tool and material usage and display the current machine status to users on the go.

To meet market demand, TaeguTec has released an expansion to the CHASE- 4-FEED family – BLMP 04, 11 inserts and cutters.

They are, smaller double-sided four corner BLMP 04 inserts for small and high feed machining applications. The smaller size inserts mean more inserts can be mounted to the same diameter cutters, which will greatly improve productivity over the existing BLMP 06 type under similar conditions.

Available in Ø8(1z) and Ø10(2z) sizes, these are an alternative to solid end mills for roughing operations. While both the BLMP 11 and BLMP 13 cover a similar machining range, the BLMP 11 inserts give an advantage as they make it a finer pitch same diameter cutter for better productivity.

The cutters come in all types, including face mill, end mill and modular types. While, as part of the new campaign, the design for the new CHASE-4- FEED line highlights TaeguTec’s new direction, the new CHASE-4-FEED logo will be applied to the BLMP 06, 09 inserts and cutters as well.

Thanks to the possibility of 5-axis machining, the CTX beta 800 TC closes the gap to the classical universal lathes as far as the high-performance area in the direction of maximum flexibility for chuck components, such as in mechanical engineering or in the fluid or hydraulics industry.

Its automatic tool changer provides outstanding flexibility in classical turning operations involving workpieces up to Ø 500 x 800mm. The highlight of the CTX beta 800 TC is the turning-milling spindle. The Y stroke of 200mm and the new compactMASTER ultra-compact turningmilling spindle open up a wide range of applications to users of Turn & Mill complete machining to the extent of 5-axis simultaneous machining. The compact design of this spindle with integrated release cylinder for the tool clamp makes it possible to have torque of 120 Nm with an impressive length of just 350mm. In comparison with a conventional spindle the increase in work area is 170mm, with 20 percent more torque at the same time. The B-axis is also equipped with a direct drive, which makes highly dynamic machining possible with a swivel range of ±110° and rapid traverse speeds of 70 rpm.

For complex milling operations right through to 5-axis simultaneous machining, the HSK-A63 (optionally Capto C6) compactMASTER turningmilling spindle has performance data of 12 000 rpm, 120 Nm and 22 kW. A 20 000 rpm high-speed version is also available as an option. The DMG Mori high-tech modular building block system allows customers to equip the machine individually in line with their particular range of components. Among other things, this includes different tool magazines with a capacity of up to 80 pockets rather than the 24 as standard.

In the standard version the machine has a main spindle, designed with a liquid-cooled integral spindle motor (ISM76) with 380 Nm and 34 kW or optionally as ISM102 with 770 Nm and 38 kW and an NC-controlled tailstock. The machine can also be equipped with a counter-spindle instead of the tailstock for 6-sided complete machining. The ISM52 PLUS with 6 000 rpm and 170 Nm is provided for this purpose. Chucks up to 400mm diameter can be used on the machine in conjunction with the ISM102 spindle motor. Steady rests, available for workpiece diameters of up to 200mm, are recommended for the machining of long workpieces.

The sturdy travelling column design stems from the larger CTX beta 1250 TC and has long since demonstrated its quality. Maximum stability and accuracy are achieved by means of combining with the direct measuring systems in all axes of the travelling column. The machine concept also has impressive ergonomics. Whereas the CTX beta 800 TC has a large work area, its advantages with regard to accessibility and space requirement are also remarkable. The 350mm distance from the front of the machine to the centre of the spindle is the ideal prerequisite for easy loading and unloading. The footprint is just 8.5 m² or 10.7 m² including chip conveyor.

The new CLX 750 impresses with its stability, a powerful spindle and forward-looking equipment options for digitalized production.

Designed for workpieces up to 600kg and a turning length of 1 290mm, the universal turning center is particularly suited to the machining of large shafts. With DMG MORI technology cycles, the IoTconnector as standard and modern 3D control technology, the CLX 750 is ready for any forwardlooking production. Customer-specific automation solutions complete the range of equipment.

Up to 1 290mm turning length and a maximum turning diameter of 700mm or 640mm in the version with the Y-axis make the CLX 750 a very versatile turning center in a wide range of industries. In the production of shafts, an optional steady rest supports turning operations up to a diameter of 430mm. A Y-axis traverse distance of an impressive ± 80mm is available for the eccentric machining of complex workpieces, while a sub spindle enables 6-sided complete machining. On spindle side, the CLX 750 impresses with regard to heavy-duty machining: 2 000 Nm torque and 46 kW power speak for themselves.

DMG MORI has made the CLX 750 future-proof in view of the growing digitalization in machining operations. Modern 3D control technology from SIEMENS or FANUC is available, while exclusive DMG MORI technology cycles like alternating rotational speed, the Easy Tool Monitor 2.0 or the Multi-Threading Cycle enable easy and efficient machining. The IoTconnector is part of the standard equipment of all CLX machines. It enables digital networking of the machines, provides the highest possible protection by means of integrated firewall and enables pioneering service solutions with SERVICEcamera and NETservice.

Future-oriented manufacturing is increasingly accompanied by automated production – a trend which is consistently followed by DMG MORI. This way, productivity of the CLX 750 can be improved lastingly with customized automation solutions – and in the well-known DMG MORI quality.

The process of properly controlling chip formations is important in order to prevent loss of production due to frequent halts in the machining process, as well as damage to the tools and work-piece.

The RhinoRush MK chip breaker is ideal for medium applications while machining stainless steel and heat resistant materials.

The MK chip breaker is a more stable insert that offers long tool life because of its sharp edge design that minimizes built-up-edges during machining operations.

Case studies prove the effectiveness of the MK chip breaker with tool life being increased by over 300 percent.

For example, during the product testing phase of a workpiece made from SUS 304, the MK chip breaker coated with TaeguTec’s TT9080 grade witnessed an increase of tool life by 343 percent during continuous cutting conditions with speeds of 160 meters per minute and same cutting conditions.

During another continuous cutting test, on difficult-to-cut Inconel 718, tool life was increased by 159 percent with all cutting parameters the same.

The RhinoRush FS chip breaker is specifically designed for excellent chip control on steel finish turning with superior evacuation under low feed and low depth of cut applications, while the insert’s sharp cutting edge drastically reduces machining load resulting in minimal vibration during operations.

TaeguTec’s range of boring bars with screw clamping function is available to suit C, T, V and W shape RhinoRush inserts.

With the screw clamping type boring bar, the current hook lever, T-Holder and wedge clamp types, the RhinoRush line of boring bars meets the needs of more demanding machining applications.

The screw clamping type boring bar has a simple clamping structure, minimizes chip evacuation interference during internal machining and is stable plus durable during demanding operations.

Advantages of the ground type ML chip breaker include reduced cutting force due to its very sharp cutting edge and extended tool life with improved surface quality due to minimal built-up-edge during machining.

By combining the chip breaker’s sharp geometry and polished uncoated grade, this addition makes the RhinoRush line the perfect choice for aluminium and super alloy machining.

RhinoRush’s mini turning inserts are very popular across many sectors within the manufacturing arena as they reduce machining cost and increase output.

RhinoRush is characterized by a tough and smaller double-sided insert that enables improved machining time and better surface finish.