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DVF 5000 DESIGNED TO REVOLUTIONIZE PRODUCTIVITY AND MACHINING CAPABILITIES

 

Unveiling the DVF 5000 Second Generation Simultaneous 5-axis Vertical Machining Centre Designed to Revolutionize Productivity and Machining Capabilities

DN Solutions unveils its latest marvel: the DVF 5000 Second Generation, a simultaneous 5-axis vertical machining centre designed to elevate productivity and machining capabilities to unprecedented heights.

Serving as the flagship 5-axis machining centre for DN Solutions, the DVF 5000 facilitates the seamless machining of complex shapes and curved surfaces in a single setup. By addressing issues of time, cost and quality inherent in repetitive setup processes, it streamlines operations while enhancing efficiency.

Building upon the success of its predecessor, the DVF 5000 Second Generation raises the bar even higher. Equipped with an industry-leading cooling system and standard thermal displacement compensation, it ensures unparalleled precision, even during prolonged operation. Its robust bed structure enables precise machining of workpieces weighing up to 400 kg, empowering manufacturers to tackle diverse projects with ease. The integration of a built-in Auto Workpiece Changer (AWC) and round magazine facilitates a compact automation system, while various features such as the auto kicking device enhance profitability for customers.

Productivity Enhanced with Astonishing Speed

With remarkable speed, the DVF 5000 Second Generation redefines productivity, boasting significantly faster X, Y, and Z-axis feed rates that double the speed of its predecessor, achieved through an acceleration and deceleration rate of 0.4g. Additionally, it showcases a 25% increase in B- and C-axis rotation speed, now at 25 r/min, alongside an impressive Tool to Tool (T.T.T) time of 1.3 seconds and a Chip to Chip (C.T.C) time of 3.8 seconds, making it 28% faster than its forerunner. This remarkable advancement positions the DVF 5000 Second Generation as the epitome of productivity in its class.

Moreover, the DVF 5000 Second Generation now comes standard with a 15000 r/min spindle, elevating its versatility and performance. Equipped with a high-rigidity high-speed spindle and a robust columnar structured table, it delivers impeccable surface finishes, facilitating the machining of a wide array of materials, from high-speed aluminium to challenging-to-cut metals like titanium, Inconel, and CoCr (Cobalt Chromium). Furthermore, opting for the built-in spindle capable of achieving speeds of up to 20000 r/min enhances precision machining capabilities, enabling fine surface finishing and intricate 5-axis contouring. Additionally, the inclusion of a high-torque spindle (max. 230Nm) enables the machining of exceptionally tough-to-cut materials, further expanding its capabilities.

Advanced Thermal Displacement and Precision Compensation

The DVF 5000 Second Generation showcases a meticulously engineered symmetrical structure, designed to thwart any deformation. To curtail heat generation within the rotation and feed axes, it integrates multiple cooling units strategically positioned in key drive locations, including the spindle, feed axis, and rotary table. Embracing a smart thermal displacement compensation function as standard, it guarantees impeccable precision even during prolonged machining sessions. Moreover, active sensors embedded within the spindle head, column and bed diligently monitor thermal displacement throughout the machining process, automatically adjusting to minimize thermal expansion and distortion.

Elevating productivity and machining stability, the DVF 5000 Second Generation includes a high-speed servo magazine as a standard feature. With its high-rigidity and precision roller-type LM guideways, capable of accommodating a maximum load of 400kg, it ensures steadfast machining performance. The incorporation of a 0.0001-degree high-precision B- and C-axis rotation mechanism guarantees exceptional accuracy. For added precision, the optional IKC (Intelligent Kinematic Compensation) solution adeptly compensates for rotary axis centre errors, mitigating deviations in workpiece shape with precision and finesse.

Upgraded Machining Flexibility

The DVF 5000 Second Generation presents expanded machining capabilities, providing greater flexibility with enlarged workpiece and clamping tool sizes. Featuring a table size of Ø630 x 450 mm and accommodating a maximum workpiece size of Ø600 x H500 mm, it boasts a remarkable 26% increase in table size and a substantial 32% expansion in maximum machining area. This enhancement opens doors to a wide spectrum of industries, catering to the needs of manufacturing diverse parts, from intricate, high-precision medical components to small and medium-sized parts vital to the automotive, aerospace, and semiconductor sectors.

Additionally, the DVF 5000’s extended travel distances for the X, Y, and Z axes—now at 650 mm, 520 mm and 480 mm, respectively, represent a significant 20% increase. This expanded space allows seamless integration of automation units for material loading and unloading, further enhancing operational efficiency and versatility.

Compact Automation Solutions

Positioned as the prime choice for compact automation, the DVF 5000 sets the standard for streamlined automation capabilities. Elevating its automation prowess, the DVF 5000 2nd Generation features an easy-to-install and operate AWC, a round magazine system that enables 24/7/365 unmanned operation, accommodating up to 40 workpieces. Notably, the AWC unit seamlessly integrates with the previous generation, ensuring compatibility and ease of transition.

Enhanced Operator Convenience Features

The DVF 5000 Second Generation offers users the flexibility to select and apply NCs from FANUC, HEIDENHAIN and SIEMENS, each equipped with cutting-edge NC technology. It boasts accelerated data and PLC (Programmable Logic Controller) processing speeds, spanning from programming and program verification to machine setup and actual machining. Notably, FANUC NCs stand out with their collision prevention system (CPS), which actively monitors internal materials, tools and axis feed units in real time to avert potential collisions and prevent damage.

Moreover, the machine enhances operator accessibility with the relocation of the magazine window for tool setup to the front, streamlining access. An auto kicking device has been incorporated to facilitate seamless tool changes, while the reduced distance between the operator and the table centre simplifies workpiece setup. Improvements in chip handling are achieved through the installation of six flood coolant nozzles on the spindle’s front, aiding cooling and chip removal during machining, alongside a flushing nozzle on the machine bed to minimize chip accumulation. As a testament to its commitment to environmental sustainability, the DVF 5000 Second Generation features grease lubrication as a standard feature, reducing oil consumption and rendering it a more eco-friendly machining centre.

For further information, please contact PUMA MACHINE TOOLS – Tel: (011) 976 8600.

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CHASE-8-SFEED PERFORMANCE FOR HIGH PRODUCTIVITY FACE MILLING

TaeguTec’s newly released WIN-SFEED CHASE-8-SFEED provides higher productivity than conventional double-sided 8-corner inserts due to its reinforced edge shape and unique insert pocket angle.

The high negative radial rake angle and high positive axial rake angle provide outstanding machining performance for roughing (45°) and high feed (20°) face milling under difficult cutting conditions. Coupled with the stronger body rigidity, excellent chip evacuation is achieved.

The CHASE-8-SFEED is a cost-effective solution due to the double-sided, multi-edge design and entry angle, as well as being a high-productivity solution that offers a low cost per edge.

For dependable and predictable machining, powerful, light-cutting geometries are combined with a big, sturdy insert seated in a stable area of the cutter. The special insert position facilitates quick and simple insert replacements, and the clamping is simple and incredibly secure.

The CHASE-8-SFEED inserts are available in two sizes, SQKU 11 and 14, and the same insert can be used interchangeably with 45° roughing cutters and 20° high feed cutters.

The line also offers superb surface roughness, and its reinforced edge is optimized for high feed machining. Compared to conventional cutters on the market, its improved body rigidity and chip evacuation make it perfectly suited for confined spaces, while its larger number of teeth increases productivity.

In a real-world environment, the CHASE-8-SFEED increased productivity by 33 percent, while increasing tool life by 43 percent during the machining of a workpiece made from SCM 440.

In another real-world comparison, TaeguTec’s CHASE-8-SFEED out-produced a competitor by 50 percent on the machining of a FCD 500 workpiece.

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

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SOLID ALLY

Since the late 1990s, solid carbide endmills (SCEM) have become one of the focal points in the metalworking industry. Several factors contribute to this prominence. Firstly, compared to indexable milling cutters, solid carbide endmills offer distinct advantages, such as greater precision, suitability for small-diameter mill designs and better options for engineering balanced tool structures. Additionally, SCEM outperforms their counterparts made from high-speed steel (HSS), as the harder carbide material provides higher wear resistance and maintains a sharp cutting edge longer, resulting in extended tool life.

Understandably, the known advantages alone were not sufficient to explain the rapid growth of the share of solid carbide endmills in milling products that began in the 1990s. There were additional elements that contributed to the increased use of SCEM in the industry. The advancements in CNC machining technology and the growing interest in high-speed milling (HSM) methods highlighted the need for tools that are suitable for high cutting speeds, and solid carbide endmills perfectly meet these demands. The quantum leap in tool grinding CNC machines and CAD/CAM systems played a crucial role in the major progress and growing popularity of SCEM during that period. This considerable leap forward was a key factor, a real game-changer, which gave rise to a significant breakthrough:

  • The enhanced capabilities of tool grinding CNC machines enabled substantially increased accuracy and the production of solid tools with high-precision geometries.
  • CAD/CAM systems enabled the design and manufacturing of endmills with complex geometries that were previously difficult to achieve. Tool grinding simulator software allowed for a virtual analysis of the grinding process, considerably contributing to the precise production of SCEM.
  • The integration of CAD/CAM systems with tool grinding CNC machines provided a powerful tool for endmill customization in accordance with the specific requirements of the customer.
  • The efficient tool grinding CNC technology diminished production times and reduced fabrication costs, making high-quality solid carbide endmills much more attractive and commercially viable for both the tool manufacturer and the customer.
  • Advanced tool grinding CNC machines and CAD/CAM systems also contributed to improved quality control, ensuring consistent tool parameters.

In addition, advancements in materials science and powder metallurgy led to the development of advanced carbide substrates with smaller grain sizes, providing higher hardness and wear resistance. Combined with new progressive coatings, such as TiAlN, these substrates formed carbide grades featuring prolonged tool life, making them almost ideal for SCEM intended for machining at high cutting speeds and milling hard materials.

Hence, solid carbide endmills have become essential tools for performing effective machining operations, and now SCEM hold a significant portion of the milling cutter market. According to various estimates, solid carbide endmills account for approximately 50% of this market. Moreover, the SCEM share does tend to grow.

The successive expansion of CNC machining, the rise of HSM processes, and the decreasing machining stock due to precise workpiece fabrication using accurate die-casting, forging, and injection moulding, on the one hand, and the further advances in carbide materials and coating technologies, on the other hand, determine the trends in SCEM development and present appropriate challenges to the tool manufacturer. These trends include:

  • In carbide grades, the increased usage of submicron carbides and wear-resistant coatings like TiAlN, AlTiN, diamond coating and others is prevalent.
  • In tool shapes and cutting geometries, more complicated and “intelligent” designs are becoming common. Unequal angular pitch, variable helix, and chip-splitting cutting edges are frequently utilized.
  • In high-efficiency machining, there is a distinct emphasis on SCEM optimized for high-speed milling (HSM) and high-feed milling (HFM).
  • In tool accuracy, the metalworking industry demands increasingly precise and balanced tools to maintain strict machining tolerances and enable stable operation at high rotational velocities, especially in finish cuts.
  • Customized solutions – to meet specific application requirements, tool manufacturers are developing specially tailored products comprising unique carbide grades and cutting geometries.
  • Multifunctionality – there is a growing demand for multifunctional SCEM that combine various cutting functions such as milling, drilling, chamfering and more.
  • Digitizing – the impact of Industry 4.0 on metalworking highlights the importance of digital tool companions, which include available digital twins, 3D models and 2D drawings, easy access to specified cutting data, engineering calculations, tool life estimation etc.

When examining two solid carbide endmills of similar dimensions, it is difficult to identify visible differences. Even using a magnifying glass or microscope may not always help in this search. However, these cutters can exhibit significantly different performance indicators, making the differences quite evident. Let’s consider the latest developments from ISCAR and understand how ISCAR addresses these challenges.

Even a quick glance at ISCAR’s solid carbide endmill product range reveals an interesting trend in SCEM products from an application perspective. In the past, the emphasis was on an all-purpose design concept that allowed endmills to be used across a broad spectrum of engineering materials. However, many of the new developments are now focused on providing the most effective for milling specific material groups.

For instance, the Ti-TURBO endmill family has been purposefully designed for machining titanium alloys. This family includes SCEM with precision-engineered cutting geometries, featuring a four-flute design for various operations, such as milling slots up to two-tool-diameter depth in solid material. Additionally, it offers seven- and eight-flute designs for high-speed milling using the trochoidal technique. The Ti-TURBO tool concept is based on different flute helix angles and variable pitch to enhance dynamic rigidity and improve chatter dampening when milling titanium alloys, including difficult-to-cut grades like “triple 5” (Ti-5-5-5-3), at high metal removal rates (MRR). The popular family has significantly expanded with new products during ISCAR’s latest LOGIQUICK campaign.

Chatter-free designs based on the concepts of variable helix, unequal tooth pitch and their combination characterize various ISCAR solid carbide endmills. These designs ensure high machining stability and allow for producing tools with enlarged cutting lengths. In recent years, the portfolio of chatter-free SCEM has been expanded with new products offering a great choice of corner radii, increased cutting lengths, a central coolant hole for easy chip evacuation and chip-splitting geometries to divide wide chips into small segments.

Another example is the EC-A2-T – a series of miniature, highly accurate two-flute endmills in the diameter range of 0.3 to 4mm, designed for high-speed machining of primarily pre-hardened and hardened steel. These tools have recently been upgraded with IC602, a high-hardness submicron carbide grade with an AlTiSiN PVD coating, enhancing performance when milling steel with hardness up to HRC 65 (ISO H group of applications).

For cutting aluminium and non-ferrous materials (ISO N group of applications), ISCAR offers newly introduced three-flute SCEM made from IC1508 – a submicron carbide grade with a diamond-like carbon (DLC) coating.

The multifunctional ECD-S2 solid carbide tools combine spot drilling and chamfer milling capabilities. In addition to the existing tools with a cutting tool angle of 45°, ISCAR has introduced tools with cutting edge angles of 30° and 60° to meet customer demands. These versatile tools find their use in almost every machine shop.

New products also feature the SOLID-FEED-MILL family of multi-flute SCEM for high-feed milling. Their design minimizes the radial component of cutting force to decrease the bending load and enable machining at high feed rates, even when machining with long overhang.

The recently unveiled NEOBARREL oval-shaped solid carbide endmills are intended for 5-axis machining of complex 3D surfaces. These tools ensure precise and productive cutting of complicated profiles.

In recent years, ISCAR has substantially expanded its digital tool component, which is based on the ISO 13399 standard. This component includes various options, such as 3D and 2D tool representations for computer modelling, CNC programming and process planning. It also generates a STEP (.p21) file for data exchange and offers enhanced functions for virtual assembly and tool search. Additionally, it provides the capability to select the optimal tool solution for specific applications among other features. As expected, all these options also apply to solid carbide endmills.

In the ISCAR electronic catalogue (e-catalogue), the tool search functions, including the SCEM selection, have been considerably extended. The new customer-oriented search options allow for finding a more suitable solid carbide endmill according to the type of machined material, adaptation, dimensions, cutting material grade, characteristic features, such as the number of flutes and other key parameters that make endmill selection easier and more effective.

The examples shown of new ISCAR products in the field of solid carbide endmills are good illustrations of the company’s response to the latest development trends in terms of performance, application range, accuracy and reliability. By staying up to date with these trends, ISCAR’s solid team continues to develop innovative solutions that meet the evolving needs of the metalworking industry.

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

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EMBRACING CIRCULAR ECONOMY PRACTICES FOR SUSTAINABLE MANUFACTURING IN SOUTH AFRICA

By Paul Savides, Managing Director, PBS Machine Tools

Sir Isaac Newton’s phrase, “Standing on the shoulders of giants” highlights the collaborative nature of scientific and intellectual progress, where new insights are often derived from the accumulated knowledge of previous generations. 

The Hawthorne Effect circa 1930 refers to the phenomenon, where individuals modify their behaviour or performance, simply because they are aware of being observed, and today we use camera’s i.e. AI.

Our machines are ergonomically designed, and robots are integrated to support operators, based on a study from 1953 that set guidelines for the recommended safe maximum weight for lifting at work.

In 2011, the German Research Alliance determined that the project Industry 4.0 be initiated with the aim of providing Cyber-Physical systems by 2020 and today, to be a Center for Manufacturing implies, embracing the 4th Industrial Revolution, powered by the internet because, the Internet of Things (IoT) establishes the bridge between both Virtual and Tangible Worlds.

Today’s Smart Factories are heterarchical, where the systems of the organization are unranked or can be restructured in different ways thus, becoming a flexible, dynamic factory.

The digital connectivity between all machines, tools, workpieces and factory workers already exists, thanks to the IIOT and Cyber-Physical Systems.

The introduction of the following six new Megatrends are:

  • Industrial AI – The application of artificial intelligence to industrial settings, like manufacturing, energy and logistics to improve efficiency, productivity and decision-making.
  • Edge Computing – A distributed computing paradigm, where data processing occurs closer to its source, typically at the “edge” of a network, such as a device or a local server.
  • 5G
  • Team Robotics – Those who collaborate on designing processes, programming and operating robots in the manufacturing environment.
  • Autonomous Intralogistics AGV Systems – The planning, implementation and optimization of all internal material flows, information flows and goods handling within a company.
  • Reliable Data Infrastructure

We have already reached the goal of having a Digital Twin image that, in real-time, automatically updates each Physical Object in the Process, interprets then, uses the data to alter Production by Condition Monitoring of Deviation through Adaptive Control Settings. While this is Digital Transformation (DX), now it’s time to embrace Sustainable Manufacturing.

Driving South Africa’s Manufacturing toward a Circular Economy, what are the challenges, opportunities and strategies we face?

As the global manufacturing sector accelerates toward net-zero and sustainable development, South African manufacturers face a series of critical questions, such as how can we implement circular economy practices in a resource-constrained environment, while balancing economic performance and environmental responsibility? Let’s explore the challenges, opportunities and actionable strategies that can help unlock South Africa’s potential on the path to a circular economy.

Challenges and Opportunities – Unlocking the Potential of the Used Equipment Market

For South Africa’s manufacturing sector, the transition to a circular economy presents several formidable challenges, including insufficient infrastructure, limited supply chain transparency and a lack of clear policy incentives. In addition, many traditional equipment manufacturers remain unfamiliar with the concepts of recycling and remanufacturing, slowing the adoption of circular practices. Particularly problematic is the disorganized used equipment market, which currently lacks standardization and certification frameworks, making businesses hesitant to participate.

Yet, this challenge also represents a significant opportunity. By restructuring the used equipment market and establishing standards and certification systems, manufacturers can promote equipment reuse, extend product life cycles and reduce waste generation. These are all essential pillars for embedding circular economy principles in South Africa’s manufacturing landscape.

Digital Transformation – The Core Driver of Sustainable Manufacturing

Digital transformation technologies are undoubtedly at the heart of advancing the circular economy and sustainable manufacturing. By integrating the Industrial Internet of Things (IIoT) and Artificial Intelligence (AI), manufacturers can comprehensively monitor energy consumption, implement predictive maintenance, optimize dynamic scheduling and even simulate production lines through Cyber-Physical systems (CPS) and digital twins to further enhance efficiency.

For example, in my specific industry, my supplier from Taiwan, Tongtai, has TLM, TIMS and Tioperator systems, which enable carbon footprint monitoring and the visualization of emissions data, thereby helping companies quickly identify carbon hotspots in their production processes. These digital tools not only enable real-time operational optimization but also empower companies to craft more precise carbon reduction strategies, significantly boosting sustainability outcomes.

Design-Driven Innovation – Crafting Products for Circularity

To successfully implement a circular economy, innovation at the design stage is just as critical. Manufacturers must first leverage carbon monitoring and production tracking systems to analyse resource inefficiencies and emission bottlenecks throughout design and production.

Based on these insights, they can adopt strategies, such as lightweight design by reducing material usage in casting processes to lower raw material consumption and energy use and component optimization by  improving part configurations, transmission systems and cooling mechanisms to cut electricity use and reduce carbon emissions.

Strategies should also include AI applications to predict machining paths, optimize cutting parameters and even deploy vision-based technologies for automated chip removal, such as Tongtai’s AI FlexJet system and modular design, to ensure products are easy to dismantle and recycle at the end of their life cycle, supporting closed-loop production.

An Example from Design to Usage

Utilizing the functions and attributes of the 4th / 5th Industrial Revolution, my supplier was able to demonstrate, how a machine alarm is triggered before there is a potential crash.

Having professional design capability that integrates advanced mechanical and electrical designs through the Industrial Internet of Things (IIOT), allows customized solutions to enhance customer productivity needs and maximize machining efficiency.

Thanks to Tongai’s self-developed 3D Collision Prevention System, you can simply import 3D CAD files and CAM-generated programs to verify the machining path and ensure real-time 3D collision prevention. Additionally, the Machine Protection System keeps axis bearings and peripheral devices in check, preventing unexpected downtime.

A game-changer for our industry is Chip Jamming Anomaly Detection, which ensures tool balance stays optimal, so you won’t risk ruining expensive workpieces, due to chip build-up or faulty tools. This is smart, reliable and stress-free technology.

Even though the economic system in the world is in turmoil, making it more difficult to plan for growth and profitability, the manufacturing sector can make a difference by implementing advanced manufacturing technology.

The inputs required to make us world competitive are all inexpensive and easily obtainable to anyone who makes the effort to use and apply them.

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

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FLEXIBILITY AND EFFICIENCY FROM BYSTRONIC

The new tube laser cutter ByTube Star 330

The new ByTube Star 330 is the most versatile tube laser on the market, with a loading length for tubes of up to 12.8 meters, a laser power of 6 or 10 kilowatts, and the capability to automatically process tubes and open sections within the entire range, from 19 to 305 mm, without set-up time.

The modular, large 3D fiber laser tube cutting machine ByTube Star 330 is the only one of its kind to automatically process tubes and open sections within the diameter range of 19 to 305 mm without set-up time. With minimal manual set-up, even processing up to 324 mm is possible.

With the ByTube Star 330, customers will experience a new level of efficiency. The tube laser offers a very high processing speed on the market for parts over 250 mm and 40 kg/m. Fully automatic feeding and sorting increases productivity and lowers the cost of labour significantly.

Enough power for everything

The laser source, available in a power choice of 6 kilowatts or 10 kilowatts, ensures sufficient power to cut even particularly large and thick tubes or profiles quickly and with the highest quality.

The ByTube Star 330 is the all-rounder that any production needs. It cuts all standard profiles (open profiles in boxes from 19.05 mm x 19.05 mm to 260 mm x 260 mm and open profiles C + L + H + I) and supports a broad range of diameters and different cutting processes.

The strengths of the ByTube Star 330

Versatility: The modular approach, with three different loading options that can be configured freely to accommodate a great number of possibilities, results in a custom-made solution for any floor space. Upgrades can be installed at any time.

Automation: The integration of processes such as drilling, tapping, marking, and phase cutting without manual intervention saves on time and cost.

Powerful: With a laser power of 6 or 10 kW, the ByTube Star 330 masters even special requests, such as cutting thick tubes with bevel cuts, without compromising cutting quality.

Expandability: Options such as Laserscan, Weld Search Camera, and Quick Cut guarantee the highest quality and safety in every work process.

Precision: The 3D cutting head and the Quick Cut option ensure the highest speed and quality, even with very small tubes.

User-friendliness: Due to the intuitive touch screen and tried-and-tested Bystronic HMI, operating the ByTube Star 330 is as easy as using a smartphone.

The ByTube Star 330 is the ideal solution for enterprises that want to optimize their production processes while increasing quality and efficiency.

Daniel Brenner, Global Head Marketing & Sales Tube says: “The new ByTube Star 330 sets new standards in tube laser cutting. Through unsurpassed flexibility and the combination of high power and a fully automatic set-up, our customers can significantly elevate their efficiency and quality. This is a great advancement for them. Thanks to the modular approach, the machine can be customized exactly according to any customer’s needs and offers all the technological highlights that provide the customer with the highest productivity, even when it comes to the most complicated components.”

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

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THE HELLER F 8000 HIGH-PERFORMANCE MACHINING CENTRE

Following the successful introduction of the F 5000 and F 6000 models, HELLER is now extending its new generation 5-axis range at the top end with the F 8000. With numerous innovations that ensure extremely high performance and precision, as well as a small footprint, the F 8000 is suitable for applications in a wide range of industries. The new high-performance machining centre has been on the market since September 2024.

Things move fast at HELLER: In the autumn of 2023, the Nürtingen-based machine manufacturer unveiled the F 6000, the first 5-axis machining centre in its new generation F series. Only six months later, another model was launched: the F 5000. And the larger F 8000 has been available since AMB 2024 in Stuttgart. Like its ‘siblings’, the machine is suitable for a wide range of users in many industries, from mechanical engineering and power generation to aerospace – from single-part manufacturing through to flexible 24/7 series production.

The F 8000 is based on the successful 5-axis F series, which has been on the market for more than a decade. However, it surpasses its predecessors in many areas. For example, at 4.20 metres wide, it has a much narrower footprint and the basic version takes up around 25 per cent less space. In addition, the optional PRO version offers the best technical specifications. Axis acceleration in X/Y/Z has been increased by 50% to 6 m/s2. Chip-to-chip time has been reduced by approx. 30 per cent. The F 8000 with PRO package also offers greater precision. Positioning tolerances in X/Y/Z are 6μm – a 25% improvement over the previous model.

Another advantage of the new F 8000 is its large work envelope (X/Y/Z: 1,400/1,200/1,400 mm), which allows larger workpieces to be machined and, above all, the 150 mm longer stroke in the X-axis, which provides even greater machining flexibility. In addition to 800 x 800 mm pallets, it is also possible to use larger 1,000 x 1,000 mm pallets. Head of Development Dr Manuel Gerst explains: “The maximum pallet load is 2,000 kg. And from the end of 2024, we will offer an optional pallet load of up to 3,000 kg.”

Full compatibility with the previous generation

To make the transition to the new generation F series as easy as possible, HELLER has ensured maximum consistency. This means, for example, that the pallets and tools are fully compatible with the previous 5-axis range.

The new machine is equipped with the latest generation Siemens control system, SINUMERIK ONE. However, users can easily adopt all NC programs used on previous machines equipped with Siemens’ SINUMERIK 840D sl control. A main operating unit in console-design with a 24-inch touch screen and a host of other features makes the new control system even more enjoyable to work with.

With the new F series, HELLER not only guarantees full continuity with previous generations. The developers have also ensured a high level of compatibility with the new H series 4-axis machining centres. Pallets and tools are interchangeable, and standardisation of structural components such as beds and columns enables the same strokes, pallet loads and part dimensions.

Small footprint provides more space for automated machining

The standardisation of the 5-axis machine within the range goes even further. The F 8000 uses the same modular system as the entire F series for key components such as heads, spindles and tool magazines. The machine structure is also standardised across the F series, resulting in the narrow footprint mentioned before.

Equally important to the compact design of the new F 8000 are HELLER’s new rack-type tool storage systems. All of them are almost two metres narrower than the previous versions. This is particularly useful when automating multiple machining centres. Four machines can now be placed in a row where previously only three could be installed.

Machining units with tilt and swivel kinematics

Among the highlights of the F 8000 – and the new F series as a whole – are the completely redesigned swivel heads, which ensure maximum cutting performance. The integrated motor spindles, developed in-house, are manufactured by HELLER. Equipped with an HSK-A 100 interface as standard, the Dynamic Cutting Universal (DCU) unit achieves torques of 400 Nm and speeds of 12,000 rpm. The Speed Cutting Unit (SCU) provides 15,000 rpm with HSK-A 100. In conjunction with the optional HSK-A 63 tool interface, HELLER also offers spindles with speeds up to 18,000 rpm. For ultra-heavy machining, the Power Cutting Universal (PCU) unit with gear spindle is still available – delivering 1,146 Nm of torque and speeds up to 8,000 rpm.

In addition to the swivel heads, HELLER also offers a tilt head variant for the F 8000. It is characterised by a particularly high degree of flexibility in 5-axis machining. This is because the tilt kinematics make it possible to produce the recesses and undercuts required, for example, in the manufacture of integral components for the aerospace industry.

Ready for any type of automation

Whether it is for the manufacture of single parts or flexible series production, the F 8000 5-axis machining centre is always the right choice. For those who are not yet sure whether they want to equip the machine with pallet automation at the time of purchase, HELLER offers the ‘Automation-READY’ option for maximum flexibility. This means that the available standardised automation systems can be integrated quickly and easily at a later date. The F 8000 is equipped with an automatic pallet changer as standard. In addition, extended automation with linear or rotary storage systems or robots is available.

All in one – milling, turning and other technologies

In addition to automation, complete machining is playing an increasingly important role in many manufacturing companies. Following this all-in-one concept, HELLER offers an optional mill-turn function for combined milling and turning operations for the entire F series. At its heart is the high-torque DDT (Direct Drive Turning) rotary table. This means that in addition to milling and drilling, external and internal contours can be turned longitudinally or transversely in a single set-up, as well as a wide variety of undercuts and recesses. Even cutting of external and internal threads is possible. This eliminates the need for re-clamping on separate turning machines, improving part accuracy and reducing cycle times.

For further information, please contact RETECON – Tel: (011) 976 8600.

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MC6100 SERIES OF CVD COATED CARBIDE GRADES FOR STEEL TURNING

The CVD coated grade MC6135 delivers substantially better fracture resistance under unstable conditions, such as interrupted cutting and during medium to low speed cutting of carbon and alloy steels.

The CVD coated carbide grade MC6115 is developed specially for high-speed machining. The combination of its high-hardness substrate with the new Al2O3 coating with improved wear resistance provides excellent performance during high-speed machining.

For a wide range of applications from continuous through to interrupted cutting, MC6125, also CVD coated, is the first recommended grade for steels under these tough machining conditions.

MITSUBISHI MATERIALS is pleased to announce the addition of positive inserts to the range in order to expand the area of applications.

The MC6100 series demonstrates high wear resistance by forming the coating with a dense and uniform crystal structure, while employing Super Nano Texture Technology.

The new bonding layer, Super TOUGH-Grip technology, improves the adhesion strength of the coating to the substrate and also suppresses peeling of the coating.

Crack growth due to impacts during unstable machining of the cutting edge is suppressed by alleviating the tensile stress of the coating layer. The MC6100 series coatings reduce residual tensile stress by 80% when compared to conventional products.

For more information contact Multitrade Distributors – Tel: 011 453 8034

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OPTIMIZING OEE FOR INCREASED OUTPUT AND HIGHER PROFIT

Continually improving our customers’ experience after sale and delivery of our CNC’s is very important to PBS Machine Tools.

By Paul Savides, Managing Director, PBS Machine Tools

 

Paul Savides Managing Director, PBS Machine Tools

How do we do it?

Simply, together with our suppliers; we create and test various advanced technologies that have been developed in order to assist our customers to improve their existing manufacturing impediments. Thus, optimizing their OEE and resulting in increased output and higher profit.

Leaning on previous Digital Transformational Control Systems, we have, in one instance, been able to adapt, replicate and evaluate alternative solutions, capable of addressing out of balance material deviations, predominantly experienced in castings and forged components.

Understanding the design and effective, operational capability of our CNC, we were able to adopt and test two solutions that can enhance machine and manufacturing process productivity, including

Pre and post component measuring through:

  • External, in-process measuring to pre-qualify the part
  • In machine measuring to asses and select the optimum machining program per situation
  • Post machining measuring to confirm machining conformity

Adaptive Cutting Condition Control by:

  • Monitoring the Axis load
  • Automatically adjusting the feed rate
  • Ensuring stable, efficient machining conditions

Through these guidelines our system can:

  • Automatically reject unbalanced out of gauge workpieces
  • Select appropriate machining programs
  • Adjust the feed rate in response to load variations

Ultimately, we can improve OEE through:

  • Achieving more stable machining outcomes
  • Better machine efficiency
  • Improved tool usage criteria
  • Saving significant input costs

In-process QC allows the user to make operational changes that occur during the machining process, resulting in higher quality, which in turn produces a higher Return on Investment (ROI) as a result of fewer production failures and defects, which simultaneously lowers manufacturing costs.

Also, when using Tongtai designed Edge Computing (TiMS), and/or Line Management (TLM) software, the gains experienced will exceed the increased cost expenditure of other defect prevention methods and once again, the benefit being an increase in profitability.

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

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MULTI-L-TURN VBMX INSERT AND HOLDERS WITH RIGID CLAMPING

TaeguTec developed a VBMX insert with increased rigidity holders for improved anti-rotating during operation.

The MULTI-L-TURN insert’s narrow corner angles mean the V-type insert is capable of various profiling operations. However, the clearance angle between the pressed type insert and the pocket causes the insert to rotate during machining, resulting in dimensional displacement.

To reduce dimensional displacement, TaeguTec offers a VBMX V-type positive insert and dedicated holders that reduce dimensional displacement caused by the pressed type insert’s rotation.

The VBMX insert and dedicated holders provide stable tool life, excellent machining performance and precise machining dimensions based on a rigid clamping design. The insert’s bottom face includes a groove that firmly seats it on a specially shaped shim, while the back end of the insert contacts to a specially designed pocket.

As the VBMX insert shares the same outline design as the ISO-V type insert, it is also compatible with ISO holders. To obtain precise machining dimensions, the dedicated holder must be used.

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

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T-TURN CHIP BREAKERS FOR STEEL MACHINING – FLP, MLP, MGP, RGP

To meet the market’s current requirements in automation and improved productivity, TaeguTec offers a series of optimized chip breakers and grades with improved coating for more stability, increased tool life, excellent chip control performance and a wide application range.

These inserts are easily distinguished by a designation system that clearly defines their application range. The chip breakers deliver optimal machining performance and high reliability in a wide range of operations.

The FLP chip breaker minimizes machining load at low depths of cut, has excellent chip control capability due to the wide, stable supporting area, and enables excellent workpiece dimensional accuracy.

The MLP chip breaker enables excellent chip control capability due to the side wave edge geometry in highly variable depths of cut, and with a specially designed edge that enables stable machining in a wide range of medium applications.

The MGP chip breaker, characterized by good chip control, is the first recommended machining solution for a wide range of operations. Also, the MGP is designed with cutting edge strength and has a wide support area that promotes stable and reliable machining.

The RGP chip breaker is suitable for roughing applications due to its reinforced cutting edge and wide chip groove, and can perform reliably without chipping even in extreme interrupted machining conditions.

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

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