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THE ULTIMATE IN CUTTING

By Donovan Hoole, Sales Engineer, Amada

We believe quality work begins with quality tools, designed and built from the ground up to deliver outstanding performance, time after time. Every feature, function and configuration we offer has been developed to address the needs of our customers. We understand productivity is the heart of your business, and we can help you optimize it in multiple ways. The Amada Group is one of the leading international machine tool manufacturers.

No two manufacturing needs are exactly alike. Finding the right solution means thoroughly understanding your objectives and configuring a solution to match them precisely. Our engineers bring decades of industry experience to help you achieve your specified goals with a process that fits and enhances your workflow.

Amada is committed to helping its customers to deliver dependable service and top- quality work with exceptional sawing solutions. Whatever the sawing needs, we have the right solution for your specific application.

Throughout the steel processing world, the Amada name is known for its quality and dependability. Our line-ups of industry -leading saws brings a host of innovations designed to improve your productivity from operator friendly controls and intuitive CNC software to our patented pulse-cutting technology that offers dramatically improved cutting times while extending blade life.

Utilising years of research, Amada can supply band sawing machinery and blades to meet any requirements from the HK series for mitre cutting to the H series large diameters (semi-automatic), HA/HFA (fully automatic) or the VM (vertical series). The latest bandsaw technology is available from the Amada PC saws for pulse cutting, CM Dyna Guide high speed circular saws and the VT Series for vertical mitre cutting.

Some features of Amada bandsawing machines include out of square cutting detection, motion detectors to monitor the blade for jamming or breakage, while cutting, quick approach arms, no work limit switches and work lights to assist in quick set up of work pieces, hydraulic blade tensioning, variable blade speed control, vice pressure control units, positively driven wire brushes, 9 times feed for cutting long lengths and cut off counters to ensure the correct number of cuts. Through using these features, semi-skilled operators can operate these machines at high through- put rates. Certain models can also be left to run unmanned on larger batch runs, thus allowing your staff to do other important jobs at the same time. Take up conveyors and tri-pod stands are supplied in order to make material handling simple during the loading and cutting process.

HA 250 AND HFA 400W BANDSAWS

HA 250
HFA 400W

 

Various size models are available throughout the range with the entry level being a 250mm capacity. These 250’s, being the most popular, are favourably priced, and along with the professional back-up service from Amada and all larger steel suppliers utilising Amada bandsaws daily, testimony is given to their accuracy, reliability and longevity. With cutting accuracies obtained right down to 0,2mm, the need for secondary machining processes is greatly reduced and in some cases eliminated, resulting in reduced processing time and thus larger profit.

CM DYNA GUIDE HIGH SPEED CIRCULAR SAW

Dyna Guide is a completely new technology that is not available in conventional machines. It places a movable middle guide close to the cutting start point in order to suppress vibrations and swinging when the saw blade engages the material. Dyna Guide technology enables excellent cutting surface finish and high precision cutting by utilizing the combination of a servo motor and a high rigid saw head.

CMII 75-100DG

HPSAW310 – “HYPERSAW” CNC HIGH-PERFORMANCE BAND SAW

Extremely powerful bandsaw for section lengths up to 600mm

Pursue the fastest cutting performance by machine and blade and realize the amazing cutting speed with Amada’s new technology. The HPSAW310 high performance saw is the latest in speed innovation, making it the fastest bandsaw in the world, cutting at 1.5 times faster than a high speed circular saw.

The Axcela HP 1 blade design should be used in combination with the HPSAW310 for excellent anti- chipping, wear and stable cutting, plus highly accurate high speed cutting.

HPSAW310

MITRE SAWS

Flexible mitre saws in space-saving design

VT- Series

  • Vertical tilt cutting method (60˚left- 0˚- 60˚ right) improves work process and reduces operator’s burden.
  • VT-series simplifies cutting of complicated products.
  • VT-4555M bandsaw is a manual feeding machine, easy to set up for bundle cutting, single cutting and angle cutting in both directions (-60˚ :0˚ & 60˚)
  • VT-3850A fully automatic bandsaw, featuring programmable tilt left or right, including feeding.
VT 3850A

BANDSAW BLADES

Amada SGLB – High Production M-42 Bi-Metal Blade for Metal Cutting Band Saw

               

Amada AXCELA G Series – High-performance Carbide Tipped Blade for Metal Cutting Band Saw

A full range of bandsaw (Bi-Metal) blades are produced by Amada to compliment machine technology. A bandsaw demonstrates the ability and limitations of a blade, meaning that a machine is only as good as the blade being used. Amada blades have earned the reputation of extreme reliability and longevity. Manufactured in Japan to the most stringent quality standards and utilising the latest in Electron Beam Welding methods, Amada blades have become the benchmark of the industry. These strict manufacturing measures ensure that premature blade breakage is almost unheard of.  The comprehensive variety of blades offered is designed to cater for all types of cutting conditions on all different types of steels and profiles.

CIRCULAR SAW BLADES

For each application AMADA offers the appropriate tool. Like the machines, the saw blades are permanently improved and advanced. By using AMADA tools on AMADA machines, a perfect cutting result is always achieved.

In summary, benefits of these blades include longest possible blade life, higher cutting rate, minimal or no warpage during cutting operation and minimal burr, due to consistent chip-load.  Add to this accurate cuts with high quality surface finish and lowest cost per cut in all types of material.

Through the dedicated backup of Amada, the robustness of their machinery, the longevity of their blades and the reputation built over many years, peace of mind is the most important part of owning an Amada.

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

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NEW TECHNOLOGY FROM UNITED GRINDING GROUP

C.O.R.E. – Customer-Oriented Revolution

When the public discussion about the fourth industrial revolution, Industry 4.0, intensified a few years ago, the UNITED GRINDING Group made the decision to invest more in the digital future together as a group — not only in the future of the group but above all the future of its customers. And thus the development of C.O.R.E. began. The aim and central focus of this development were to ensure increasing connectivity, i.e. the exchange of data between people, machines and the production environment plus to create the basis for the operation of modern IoT applications. In addition, an intuitive operation was to be enabled to make the work easier for machine setters, machine operators and maintenance staff. C.O.R.E. has turned this vision into reality in a revolutionary way.

Intuitive Operation

It is reminiscent of a gigantic smartphone: The 24-inch full HD multitouch display identifies the next-generation machine tools equipped with the new C.O.R.E. technology. Navigation works like on a smartphone, using “touch” and “swipe.” Customers can also configure the user interface according to their individual requirements and arrange the most important functions and operating displays according to personal preferences similar to the app overview on a smartphone home screen.

Thanks to the new access system, which works via a personalized RFID chip, the individual user profile is automatically loaded. This not only makes it easier to log in and out of the machine, but is also significantly more secure. Another advantage is that a  roles profile is stored for each user, so users only see information relevant to them, which reduces complexity and helps prevent errors.

When it comes to reducing complexity, it is also noticeable that the new C.O.R.E. panel has virtually no keys. There is a prominent rotary switch for feed rate override, allowing the axes to be regulated with a simple turn.

The uniform use of the C.O.R.E. Panel across all brands also simplifies machine operation and makes training easier, meaning that anyone who knows how to operate one UNITED GRINDING machine can operate all of them.

C.O.R.E. is “More than Just an Innovative Control Panel”

The eye-catching new control panel is, of course, only the visible aspect for machines equipped with the new C.O.R.E. technology. “There were also major innovative developments behind the machine enclosure,” stresses Christoph Plüss, CTO of the UNITED GRINDING Group. C.O.R.E. OS. A full operating system is installed on a high-performance industrial PC, the C.O.R.E. IPC which serves as an IoT gateway and is home to all software applications. C.O.R.E. OS is also compatible with all CNC controls used at UNITED GRINDING.

Furthermore, the new technology opens up a wealth of opportunities for connectivity. Not only can all machines with C.O.R.E. technology from the UNITED GRINDING Group be networked, but also third-party systems via implemented interfaces such as umati. This opens up direct access to UNITED GRINDING Digital Solutions’ offerings on the machine from remote service to the service monitor and production monitor. For example, support from the Group’s Customer Care Team can be requested directly at the C.O.R.E. panel. A chat feature ensures fast and easy support, and the integrated front camera even enables video calls.

Highest Benchmark – User Experience

In the development process of C.O.R.E., which lasted several years, software and process experts from all brands of the UNITED GRINDING Group pooled their expertise to design an unparalleled software architecture. “The user experience, i.e. the immediate experience of the users, has always been our top priority,” explains CTO Plüss. It is for a good reason that the abbreviation C.O.R.E. stands for Customer Oriented REvolution.

In the area of operating systems and software architectures of machine tools, C.O.R.E. is a quantum leap, emphasizes company CEO Stephan Nell. “This means that our machines are ready for the digital future.” The C.O.R.E. technology presented for the first time at the EMO 2021 in Milan is still under development. “It lays the foundation upon which we can build,” explains Plüss. “Development will continue on an ongoing basis. Thanks to the flexible, modular structure of the software architecture, we will continuously add new features and applications. We intend to harness the concentrated software development power of our group for the benefit of our customers.” Our goal is to inspire customers with a regular stream of new C.O.R.E. software releases and thus actively help to shape the digital future. In this way, the Group remains true to its ultimate goal of making its customers even more successful.

The industrial production of the future is connected. Machine connectivity is the key phrase. A number of requirements must be met before networking is either possible or usable. UNITED GRINDING C.O.R.E. – Customer Oriented REvolution ensures these requirements. “The digital future begins with C.O.R.E.,” stresses CEO Stephan Nell. The groundbreaking new hardware and software architecture was developed by the group’s specialists and premiered at the EMO 2021 in Milan. It opens up remarkable possibilities for networking, controlling and monitoring the production process and thus also for process optimization. And more: C.O.R.E. brings the user experience of operators into the world of the smartphone generation.

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

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AMADA – A MARKET LEADER THROUGH TECHNOLOGY DEVELOPMENT

By Barry Page, Amada

With ever-changing technology in the sheet metal bending industry, Amada prides itself as a market leader through technology development, taking both, the environmental – and customers’ concerns into consideration.

Amada for many years perfected the production of machinery in order to meet the needs of the global market. These machines have evolved drastically as time has passed and as technology has improved. From fully hydraulic machines, Amada developed the servo hydraulic machines and then added to this with the fully electric machines.

Although there is still a large market for the older technology of hydraulic or servo hydraulic equipment, many customers are starting to realize the benefits of the latest fully electric technology. In Amada’s bending line-up, first the EG range was launched which became popular worldwide, then the EGB range of equipment was made available with even more enthusiasm shown in the market.

The latest EGB series of benders offer a fully electric drive system coupled with ergonomics which reduce operator fatigue.

The entry level EGB4010 is one of the most popular high production press brakes which offer up to 40 tons bending pressure over the 1 meter bed. This compact, high-speed bender is capable of approach & return speeds of up to 250mm per second and bending speeds of up to 25mm per second. The on-board AMNC 4i CNC controller has various operator level controls and functions which ensure access levels within the operating system through face recognition or passwords.

The standard inclusion of the infra-red Digi-Pro digital protractor make angle measuring and adjustment as simple as pressing a button, while the Digi-Nogi Digital Vernier ensures accurate measuring and size adjustments also through the infra-red communication with the machine control.

Options such as the Bi-S angle measuring system and the Amada Tool Set Up assistant or “ATSA” must be factory ordered if required. These features further enhance the ease of use of the machines as well as the safe storage of tooling while assisting in making tool loading and unloading easier for the operator.

The EGB range is not only limited to small machines. The range extends through from the 40 ton x 1 meter (EGB4010e) to the 60 ton x 2 meter (EGB6020e), the 80 ton x 2,5 meter (EGB8025e), the 130 ton x 3 meter (EGB1303e) and then the top of the range with automatic tool loading and unloading, the EGB6020 ATC and the EGB1303 ATC.

These ATC (Auto Tool Changer) models are especially suited to small batch runs with high tool changes in between. The skill, speed and effort of the operator is not important in the setting up of the machinery between jobs. The software and machine take care of the full change-over. Tool life is drastically extended as the human hand does not touch the tooling like with a manual machine.

With a number of both EGB’s as well as EGB-ATC’s already installed in the market, Amada is confident that your bending requirements can be met through our product range available.

Amada’s electric technology also extends beyond the bending department. For many years now, Amada has offered both the AE and the EM range of punching machines. These machines too make use of the Amada servo drive systems which eliminate the need for oils etc., while ensuring high speed repeatability and accuracy.

The AE uses a single servo drive system, while the EM range use a twin servo drive system, both of which are extremely reliable, as well as maintenance & cost efficient.

With the different proven technologies employed by Amada for such a long period of time already, we are able to confidently supply reliable products that will outlast most competitors, whilst offering top returns on investments and trouble-free operation for many years to come. Testimony to this is the age of some Amada equipment running in the market for 25 years plus and still in demand.

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

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RUSHING MACHINING WITH VERSATILE INDEXABLE MAXI-RUSH SOLID CARBIDE HEADS

 

With its innovative head-indexable feature and overall outstanding advantages, the SFEED-TEC MAXI-RUSH end mill replaces most of the existing conventional solid carbide end mills in its class.

Along with its exceptional accuracy and optimum grades, the line’s quick and simple head replacement makes it a perfect solution for today’s machining needs and a superior performer that boosts productivity on a range of applications.MAXI-RUSH is available in a variety of head types and shank holder lengths – such as flat, ball, corner radius, chamfer and slot, to mention a few – to provide the greatest versatility in tooling solutions.

Its rigid and precise double contact fastening system houses a flat contact surface area for precise axial runout accuracy, has a conical taper contact for self-centring and precise radial runout accuracy and is highlighted by its quick and rigid unique threading.

TaeguTec has added oval and lens-shaped solid carbide heads that are 3D profiling capable in order to solve industry-wide disadvantages, such as excessive machining time and poor surface finish that plague profiling operations.

The MAXI-RUSH 5-axis profile heads are designed for high-pitch, semi-finishing and finishing profiling parts used in the aerospace, power generation, medical and mould and die industries.

Even in high-pitch conditions, the same surface finish can be obtained compared to solid carbide ball type end mills, making the MAXI-RUSH 5-axis profile heads capable of high-productivity machining.

Machine shops of all sizes have taken a special interest in the metalworking giant’s highly rigid MAXI-RUSH line because of its excellent machining precision, simple indexable head replacement and shorter setup time. The line now includes a wider variety of tools that are capable of handling a broad range of operations.

The expanded features include a wider cutting edge contact area for improved machining stability and longer tool life, and are ideal for machining difficult-to-cut materials such as titanium alloys, Inconel, and stainless steel.

Recently, TaeguTec added the TT5513 grade to the technologically advanced MAXI-RUSH line. The ingenious grade has an ultra-fine substrate with optimum toughness features and excellent abrasion resistance. It has a nano-crystalline structured AlTiN layer, an anti-abrasion and cracking-resistant PVD-coated layer and is ideal for mould steels and pre-hardened steels.

The MAXI-RUSH’s versatility and range are only matched by its incredible machining prowess.

A range of shapes and lengths are available, including straight shanks with necks and tapered necks made of different materials. These are available in steel, carbide and tungsten and are internal through coolant capable.

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

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EFC ll LASER CUTTING MACHINE

 A high-performance mid-price laser machine equipped with TruFiber Cut Laser up to 6 kW.Smart design and material flow ensure maximum productivity at minimal investment costs.

The EFC ll laser cutting machine from leading Chinese manufacturer JFY, a member of the Trumpf Group, is locally available from Puma Machine Tools.

The machine’s CNC control system is based on the Windows platform and has been proven to be extremely reliable and high-performing.

The cutting head is designed with built-in protective glasses, ensuring reliable and optimized cutting quality. These protective glasses safeguard the optics from potential debris or damage that may come from the process zone. Overall, this results in a significantly higher durability of the cutting head, as well as higher cutting precision.

TruFiber is the ultimate fiber laser solution for all cutting needs. In fact, TruFiber delivers excellent process stability and consistent process results. Furthermore, the technology requires a minimum of maintenance.

Using offline programming software can improve material utilization and process efficiency. On the one hand, programming software can optimize the nesting process to reduce material waste, and  on the other hand, it can simplify the programming process by converting simple and complex part drawings into processing programs, which results in faster production times. The Lantek programming software is a proven solution based on latest technology.

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

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QUICK HOLEMAKING

The design concept of assembled drills with exchangeable solid carbide cutting heads, adopted by ISCAR at the turn of the century, significantly altered the company’s hole-making product program. In this concept, a precise carbide head is mounted in a steel holder using the “self-clamping” principle, which relies on the holder’s elastic deformation, without any mechanical clamping means. This approach is characteristic of various successful ISCAR products such as the SELF-GRIP and MULTI-MASTER tool lines, which have not only substantially improved machining performance, but also revolutionized traditional perspectives on cutting tool design.

In the assembled drills with carbide heads, the cutting head has a specially shaped rake surface to optimize chip formation, a centring area to ensure high accuracy, with stoppers and locking sections for reliable security. The holder – the drill body – that is produced from a high-strength steel grade, features the innovative design of the head pocket, helical flutes and internal channels for coolant supply. The advancement in technology, particularly in powder metallurgy processes and CNC machining, has made this design feasible.

The concept of assembled drills with carbide heads guarantees several key advantages:

  1. Due to its rigid structure, reliable clamping principle, unique cutting geometry and advanced carbide grade of the heads, the drills guarantee productive results. This significantly reduces cycle times and enables high-quality holes. These drills can be used for machining a wide range of materials including steel, stainless steel, cast iron, titanium and high temperature alloys.
  2. High repeatability and ISCAR’s “no-setup-time” principle promise that a worn head can be replaced without removing the drill from a machine, eliminating additional setup operations and considerably decreasing downtime. The simple change of the heads makes the drills easy to handle and user-friendly.
  3. The drills are available in a wide range of diameters and overall lengths to suit various applications.
  4. The use of interchangeable heads diminishes the need for a large drill inventory.

ISCAR’s drills with exchangeable carbide heads provide customers with a valuable tool solution to enhance the profitability of hole-making operations. Over the past 20 years, these drills have undergone significant changes.

Beginning with the CHAMDRILL family, each new phase in the concept’s enhancement has led to new products that outperform their predecessors. Today, SUMOCHAM is ISCAR’s most popular family of assembled drills with exchangeable carbide heads and is highly regarded by customers. The continuous search for a way to increase drilling productivity, particularly when machining materials that produce fine chips, has resulted in the creation of LOGIQ-3-CHAM – a family of three-flute drills that utilize the same self-clamping approach. ISCAR’s development of carbide-headed drills continues to aspire. Unsurprisingly, ISCAR’s latest product campaign, LOGIQUICK, has unveiled innovative designs that not only enrich the existing product families and broaden their scope but also pave the way for new areas of application.

The new holder with three-flute heads allows a 10:1 drilling depth-to-diameter ratio. The holder’s main feature is a specific flute design that minimally affects the tool’s structural strength.

Another innovation is the expansion of the LOGIQ-3-CHAM family application to include counterboring.

The specially designed three-flute heads are mounted on existing tools and transform them into highly efficient counterbores. The unique design features of the heads, including a corner chamfer for rapid chipping, specialized deflectors for improved chip formation, and a unique margin for enhanced support and guidance, significantly boost performance when machining materials like sticky steel, stainless steel, and high-temperature superalloys (HTSA). This design facilitates a broad spectrum of counterboring operations, ensuring high-quality holes, even when machining cross-holes with inclined surfaces.

The CHAM-SPADE-IQ is a new family of hole-making tools with exchangeable heads. Introduced as part of the LOGIQUICK, the family provides a solution for drilling steel profile construction beams. Machining beams often take place under non-rigid technological conditions, presenting a significant challenge for manufacturers. To address this issue, it is crucial that drilling tools have an adaptive cutting geometry to compensate for the lack of rigidity. The newly introduced family, specifically dedicated to profile construction, includes two-flute carbide drilling heads and reinforced steel holders. The heads feature a specific self-centring cutting edge for secure hole penetration, and sharp corners to prevent deformation. The durable structure of the holders maximizes the dynamic stability of the tools when drilling at a depth-to-diameter ratio of up to 5.

New drills with MULTI-MASTER adaptations that carry exchangeable carbide heads essentially serve as a “bridge”, connecting the successful SUMOCHAM and MULTI-MASTER families. These drills are a component of a versatile modular tool assembly which allows mounting drilling heads on a wide range of MULTI-MASTER tools facilitating not only an easy and quick change of the heads but also of the drill bodies.

Moreover, the modular concept provides straightforward customization and flexibility regarding overall length, diameter and finding the optimal tool configuration.

It’s worth noting that the hole-making innovations in the LOGIQUICK campaign are not solely represented by assembled tools with exchangeable heads. Several products of another design concept can also be highlighted. One such product is the three-flute flat-bottom solid carbide drill with internal coolant channels. The drill features a small isle for improved penetration, wavy cutting edges for assured chip control, an optimized core diameter to increase tool rigidity and narrow wiper sections to reduce friction for a surface finish in combination with internal coolant supply that extends tool life and improves chip evacuation. These incredible attributes contribute to the promising prospects of this product line.

In the boring line, a new series of boring heads with extra fine digital adjustment has replaced the existing heads with an MB connection. In the milling line, the portfolio has been enhanced with the addition of the QUICK-D-MILL – a family of multi-functional indexable cutters. These versatile “all-in-one” cutters are suitable for a wide range of machining applications, embracing milling of shoulders, slots, pockets, as well as drilling flat-bottom holes.

The overview of the mentioned products highlights that ISCAR’s focus on hole-making continues to drive their development efforts. With the metalworking industry seeking solutions to enhance hole-making performance, ISCAR is confident that their latest LOGIQUICK drilling developments will effectively meet the industry’s demands.

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

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EFFICIENT LASER CUTTING WITH INTELLIGENCE – THE ALL NEW BYCUT STAR

Featuring ultra-fast speeds and an expanded cutting spectrum, the ByCut Star now cuts with 30 kilowatts of laser power.

Impressive high cutting speed, intelligent cutting process and a new design – this is how the new ByCut Star presents itself. With 30 kilowatts and an optimized cutting process, it now cuts steel, aluminium, stainless steel, brass and copper precisely and reliably for even more quality.

Higher cutting quality and productivity is provided thanks to more laser power and smart features. Bystronic has advanced into a new dimension of fiber laser cutting, the ByCut Star with impressive 30 kilowatts of laser power. The high-end fiber laser stands for high-precision Bystronic technology, a stable cutting process up to the highest laser powers and for a wide range of applications.

However, sheet metal workers not only need a lot of laser power, but also intelligence, reliability and sustainability; this combination makes the laser cutting process really satisfying and successful.

Thus, at Bystronic, customer success is built on a concept of three pillars, namely Power, Intelligence and Cutting Process Improvement, including MixGas technology.

Smart features, such as the “Intelligent Cutting Process (ICP)”, the “Nozzle Control Tool (NCT) with KerfScan” or the “Parameter Wizard” optimize the entire cutting process, while ensuring that it stays on track. Users enjoy optimum capacity utilization and remarkable production uptime.

30 kilowatt of laser power

The technological leap from the previously available 3- to 20-kilowatt levels to the new 30-kilowatt level is considerable and opens new possibilities for Bystronic customers to optimize production and thus remain at the forefront of the ever more fiercely contested competition.

The “Advanced Applications” option enables expanded applications in steel and aluminium of up to 50 millimetres (15 kilowatts laser power and above).

Cutting speeds on the ByCut Star increase twice as fast compared to 15 kW and MixGas with sheet thicknesses between 6 mm and 15 mm, and more than twice as fast with thicknesses starting at 20 mm. Piercing times are shorter for sheet thicknesses of 15 mm and above. Sheet metal processors thus benefit from higher productivity at low unit costs, because with 30 kilowatts, the new ByCut Star cuts steel, aluminium and stainless steel precisely and reliably. The 30-kilowatt laser power enables maximum flexibility for large series and spontaneous customer orders. Whether aluminium or steel, the powerful Bystronic cutting head impresses with maximum precision in thin and thick sheets. In addition, with the “Advanced Applications” option, high laser power (starting from 15 kilowatts) now also enables expanded applications in steel and aluminium of up to 50 millimetres. The new power level is exclusively available on the ByCut Star 4020.

Smart features make the difference

NCT & KerfScan is a smart feature package for oxygen cutting which increases process reliability, even in low-manned operations. This feature offers process monitoring, problem solving and continuation of the cutting process in a fully automatic way.

The “Parameter Wizard” ensures that the correct quality of the cut parts is always selected within minutes. This feature determines the perfect parameters with N2 and MixGas for steel from 4 to 15 mm in thickness.

Intelligent Cutting Process ICP is a new feature, where a coaxial camera is filming through the nozzle and looking directly into the cutting process. This feature currently offers the following functionalities:

  • Cut Quality Detection – The system automatically detects cut interruptions during the cutting process and re-cuts the area where it occurred.
  • Cut Quality Protection – AI-controlled cutting process maintains reliable quality throughout low manned production.
  • Nozzle Loss Detection – Down time and material waste caused by nozzle loss are significantly reduced.

While Bystronic customers benefit from outstanding cutting results with clever features, the new powerful Bystronic flagship is also controlled from a 21.5-inch touchscreen. Handling is as simple as operating a smartphone.

The new ByCut Star’s modern, sharp contours provide a striking appearance and match the performance of the machine.

Significantly increased user-friendliness and outstanding flexibility are major advantages provided by the new ByCut Star. Thus, there is front and/or side access as well as several windows with a view directly to the cutting process. In general, the new design offers better accessibility to the interior, and the machine is easier to place on the store floor thanks to more flexible layout.

Additional accessibility with the all new, sharp designed ByCut Star thanks to several gates.

Fiber laser cutting with mixed gas ensures better cutting quality and higher productivity

In laser cutting, cutting gas (especially N2 and MixGas) is used to keep both the laser and the sheet free of impurities and remove molten material. Nitrogen is used for so-called fusion cutting and oxygen for flame cutting. Gas mixing combines the benefits of O2 and N2 and thus is an alternative to pure nitrogen or oxygen cutting. Cutting with MixGas (a specific blend of Nitrogen/Oxygen) ensures perfect quality on steel at increased cutting speed. This helps even an inadequate steel to achieve a good result after the cutting process.

For in-house gas production with a N2 generator, Bystronic has a solution ready that is attractive from a cost perspective and environmentally friendly. The advantages are obvious: There is no need for transports by trucks when gas is delivered. One produces only as much nitrogen as is needed, and all the previous additional costs are eliminated – from filling the cylinders to replacing them. The sheet metal processor works completely autonomously and – independent from any gas supplier – is doing something for the environment in the process.

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

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LASER TUBE CUTTING FOR BEGINNERS AND EXPERTS

The TruLaser Tube 3000 fiber is suitable for companies that want to enter this technology and for companies that want to expand their manufacturing capacity.

A TRUMPF machine for getting started with laser tube processing or as an addition to existing machinery – Cost-effective even with low capacity utilization – Easy to operate thanks to numerous automated features

TRUMPF introduced a new laser tube cutting machine, the TruLaser Tube 3000 fiber, a cost-effective choice even at low to medium capacity utilization. It is therefore equally suitable for companies that are entering this technology as it is for companies seeking to expand their production capacity. The machine enables the versatile processing of tubes and profiles and replaces conventional tube processing steps such as sawing, drilling and milling.

Starter kit to enter the world of tube processing

The TruLaser Tube 3000 fiber covers a broad range of applications including profiles, round tubes and flat steel bars. It also offers the option of L and U profiles. The two-kilowatt solid-state laser performs high-speed cutting of mild steel, stainless steel, aluminium and nonferrous metals such as copper and brass. An extensive set of cutting data is already stored on the machine. The TruLaser Tube 3000 fiber can cut tubes with diameters of up to 152 millimetres and profiles with an outer circumference of up to 170 millimetres. The self-centring clamping technology, which is designed to hold the tube in place and position it correctly during machining, adapts automatically to the tube dimensions without requiring manual setup by the operator. The TruLaser Tube 3000 fiber also configures other important settings automatically.

The self-centring clamping system fixes and positions the tube, thus ensuring optimal finished part quality.

The AdjustLine function modifies cutting parameters at the touch of a button to ensure reliable cutting of lower-quality materials. SeamLine Tube detects weld seams and markings on the inner and outer surfaces of the tubes, helping operators check that the tubes are correctly aligned in the machine and that the weld seam is in the desired position in the finished part. With its easy setup and high degree of automation, the TruLaser Tube 3000 fiber is a user-friendly machine that represents a cost-effective option for small batch sizes.

Reliable and precise parts handling

The TruLaser Tube 3000 fiber cuts tubes weighing up to 18.5 kilograms per meter with material thicknesses of up to 8 millimetres. It is available in two lengths that accommodate either 6.5 or 8 meters of material. Thanks to the optional LoadMaster Tube automated loading system, the machine is also a cost-effective choice for high-volume production runs.

Thanks to the LoadMaster Tube loading automation, the machine can profitably perform large-scale production as well.

An integrated materials store known as the “bundle space” provides a buffer store that can hold up to 4 metric tons of raw material, or up to 5 tons with the machine version designed for an 8-meter loading length. The LoadMaster Tube system separates and measures the tubes parallel to production and transfers them to the machine. To ensure top-quality parts, step rollers support the tubes and guide them to the machining station.

Step rollers support and guide the tubes to the processing station. They can be manually adapted to the respective tube diameter in no time.

These rollers can be adjusted to the current tube diameter in one simple action. The machine also features guide rollers on the unloading side which provide more support to long tubes during processing. The TruLaser Tube 3000 fiber ejects finished parts onto a rack. Set to the correct ergonomic height, this allows the operator to remove them comfortably while the machine continues working. Shorter parts can be ejected straight into a box. The TruLaser Tube 3000 fiber automatically separates cutting slugs and scrap metal from the finished parts and disposes of them in containers.

Key components easy to access at any time

Thanks to the design of the machine’s beam guard, the operator can easily access the loading and unloading sides of the machine at any time – for example to load individual tubes into the machine to process a smaller job between bigger ones. There is no need for a complete housing. A large, laser-safe viewing window makes it easy to keep an eye on the machining process.

Ready for the smart factory

Users can make changes to the machine’s production schedule or keep an eye on the machine using an app, making it even easier for the operator to keep track of the entire machining process in the TruLaser Tube 3000 fiber. A secure, OPC UA-based data interface is included to connect the machine to an ERP or MES system or to a cloud application, for example. TRUMPF machine apps provide information on program runtimes and machine capacity utilization.

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

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WIN-SFEED MACHINES FOR IMPROVED BOTTOM LINE

Paying attention to what economists say about the nation’s manufacturing patterns is like riding a rollercoaster, it rises and falls dramatically at different times.

No matter what economists say, the reality of the cost of manufacturing is felt in the shop, and that is where TaeguTec comes in with cutting tools that increase productivity and cut costs, both important factors to help with the bottom line.

The premium next-generation WIN-SFEED line of cutting tools, the metalworking giant’s newest machining marvels, are fast, accurate, productive and profitable in order to offer end users a competitive edge.

For turning operations, the WIN-TURN`s 6-corner negative TNMV inserts and holders provide high productivity and multidirectional turning without replacing the holder.

The outstanding high feed feature is due to the small entering angle that enables higher productivity for both longitudinal turning and facing in the backward direction with one tool. Using the same T-HOLDER design, this user-friendly holder has a strong clamping force.

In the parting and grooving family, TaeguTec offers the WIN-CUT and CUT-SFEED lines, which are designed as a thicker height insert that includes a specialized three-area contact with a bottom-stopper that is more robust and stable than the conventional self-grip type.

This amazing addition to the line enables improved surface roughness, insert position repeatability and tool life even under tough machining conditions.

The holders are available in three types, such as a square shank type (SFER/L), a blade type (SFGB) and a reinforced triangular blade type (SFTB). In particular, the triangular blade type (SFTB) and dedicated holder (THTBR/L-TB) products enable very stable machining in parting and deep grooving applications.

In either high feed or interrupted cutting conditions, WIN-CUT ensures an excellent surface finish with minimal vibration.

In addition, the holder and blades include internal through-coolant channels directed to the insert’s cutting edge, significantly increasing productivity and tool life.

Milling operations have a slew of incredible options that cater to specific machining parameters as well as general production.

The WIN-MILL line, including CVKT inserts and holders, are small-size end mills optimized for the miniature industry.

Featuring indexable inserts with Ø8 mm and two-effective teeth end mills, the WIN-MILL line is an excellent choice for cost reduction.

The increased number of teeth means it is a high-productivity solution that replaces carbide end mill machining.

Further, WIN-MILL end mills can be applied to various milling applications as the inserts are available in shoulder milling and high feed machining types. The contact between the V-bottom insert and the cutter pocket maximizes clamping stability for both high feed and ramping machining, enabling excellent performance in multiple applications.

Catering to diverse applications, TaeguTec’s premium WIN-MILL line also features AVKT inserts and dedicated holders, which enhance productivity in the single-sided, two-corner shoulder milling insert market.

The insert includes a V-shape bottom contact for stronger and more stable clamping, providing excellent machining performance even in both ramping and step-down machining. In addition, the AVKT insert includes a higher ramping angle over similar inserts to provide higher productivity.

WIN-SFEED’s CHASE-8-MILL line, with its double-sided inserts, performs true 90-degree machining. Its high axial geometry reduces cutting loads and vibration yet achieves high productivity.

The line’s optimized design enables minimal mismatch during 90-degree deep shoulder milling, and the flat-bottom wiper insert improves surface roughness. CHASE-8-MILL’s variety of inserts and cutters for end mills, modular types and face mills enables excellent performance on a variety of applications.

Building on the success of previous series, TaeguTec offers the powerful premium high feed milling solution WIN-4-FEED with BLMV inserts and dedicated cutters.

The BLMV line’s V-shaped contact face, which prevents insert rotation during ramping and plunging operations, contributes to its steady machining performance and increased productivity. These features not only ensure a high ramping angle but also enable deeper step-down machining, boost productivity, and provide a range of machining entry operations.

Next is the MAXI-RUSH, with its innovative head-indexable feature and overall outstanding advantages. The technologically advanced end mill line replaces most of the existing conventional solid carbide end mills in its class.

The quick and easy replacement of the line’s heads, coupled with its excellent accuracy and optimized grades, make it a superior performer that increases productivity on a variety of applications and a superb choice for today’s machining needs.

To combine the widest flexibility in tooling solutions, MAXI-RUSH is offered in many head types as well as various shank holder lengths.

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

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RGC REMAINS DEDICATED TO ADVANCING THE QUALITY STANDARDS OF PRODUCTION IN SOUTH AFRICA

 

Article supplied by RGC Engineering

RGC Engineering has been a beacon of innovation in providing quality solutions and equipment for Dimensional and Non-destructive testing and Tooling for the South African manufacturing engineering landscape since its inception in 1960.

Originally established as a precision engineering manufacturing company, RGC Engineering has evolved into a leading Precision Metrology and Inspection Equipment provider.

Over the decades, we have not only grown but also solidified our position in the industry through strategic partnerships with industry giants such as Mitutoyo, Marposs and GOM, now Zeiss GOM Metrology. These partnerships are a testament to our unwavering commitment to our core values: Quality, Precision, Efficiency, Service and Expertise, and they have significantly contributed to our ability to provide top-notch solutions and equipment.

Our mission is not just about providing quality solutions for the manufacturing sectors in South Africa. It’s about empowering our workforce through education and training, both for our personnel and customers, on the use of advanced inspection systems. At RGC Engineering, we believe that investing in the best and most efficient technology is not enough. We also invest in our people, because we know that they are the key to achieving our goals and maintaining our commitment to excellence.

Zeiss GOM Metrology – ScanBox 5130: Revolutionizing Automated Inspection

The ScanBox 5130 is a game-changer in automated inspection and digitization. Designed to handle complex parts such as hang-on parts, assemblies, and airfoils, the ScanBox 5130 stands out as an all-in-one solution. It optimizes series inspection and provides full-field measuring results for CAD comparison in record time. This capability is crucial for visualizing deviations from GD&T standards accelerating production, maintenance and repair processes.

One of the standout features of the ScanBox 5130 is its ability to operate autonomously. This feature significantly increases machine utilization, reduces measuring cycles and allows our clients to obtain quicker and better results, allowing them to deploy their staff more efficiently. The ScanBox 5130 is not just a tool but a vital component that enhances productivity and ensures precision in every measurement.

GOM Scan 1: Compact Precision with Advanced Technology

The GOM Scan 1 from Zeiss GOM Metrology is a testament to how advanced technology can be packaged into a compact and robust design. Featuring Blue Light Technology and the stereo camera principle, the GOM Scan 1 delivers exact 3D data, making it indispensable for quality control.

The lightweight solution allows you to capture 3D data intuitively. Easy to operate, GOM Scan 1 is the specialist for simple and fast measurements of small to medium-sized parts – even in confined spaces. This synergy ensures that quality control is not only precise but also efficient. The GOM Scan 1’s advanced capabilities and user-friendly design make it a perfect fit for R&D, enabling reverse engineering of parts with remarkable accuracy.

Mitutoyo Solutions: LH600F, MiSTAR 555, and Measurlink Software

Mitutoyo LH600F: The LH600F height gauge is an advanced tool offering easy operation through a keypad and touchscreen navigation, making it suitable even for beginners. It boasts a best-in-class accuracy of ± (1.1+0.6L/600) μm. The LH600F is used for various measurements, including 2D and perpendicularity measurements, with enhanced data output functions that simplify measurement data management. The contextual guidance on the large-screen touch panel supports operators, ensuring they understand each step in the measurement sequence, making it easy to obtain accurate and repeatable measurements.

Mitutoyo MiSTAR 555: The MiSTAR 555 is a cornerstone of our precision inspection capabilities. Known as the shop-floor CMM, it can be used next to or even on the production line. The MiSTAR 555 combines inline and near-line precision measurements with easy usability, unprecedented versatility, and a space-saving design. Its three-sided open architecture simplifies moving workpieces on and off the measuring table, reducing operator workload and enhancing efficiency.

Mitutoyo Measurlink Software: Coupled with Measurlink software from Mitutoyo, we have transformed our data management and analysis processes. Measurlink supports real-time data collection with live SPC charts to alert operators and additional analysis tools and reports for quality control and operations. Its customizable interface allows for the addition of photos and videos, guiding operators on specific measurements. Designed with Industry 4.0 and Smart Factory in mind, Measurlink provides the scalability and interoperability needed in today’s factories.

Marposs Inline Inspection Equipment: Ensuring Real-Time Quality Control

At RGC Engineering, real-time quality control is paramount, and Marposs’ inline inspection equipment plays a critical role in achieving this. Marposs offers various inspection equipment for industrial inline, next-to-line, or during-production analysis. Currently, the M1 Star gauges are the most used equipment for internal bore diameter measurement. Coupled with the Merlin gauge computer, measurements can be seen directly, and the part can be evaluated and processed on the spot.

The Marposs M1 Star gauges, with the Merlin gauge computers, are widely used in the automotive industry to measure the finest tolerance bore diameters. These probes provide real-time dimensional feedback while simultaneously machining the part. The probes also enable parts to be marked correct or incorrect on the spot before they move to the next production stage.

Integration and Future Vision

Each piece of equipment has its own role in inspection, but when combined, they enable a comprehensive overview of the production process from start to finish. At RGC Engineering, we strive to help customers achieve the best quality end products by training their operators or inspectors on using the instruments or helping them set up a metrology inspection area. Our new building renovations include a state-of-the-art metrology, training, and inspection area, complete with the ScanBox 5130, Mitutoyo Crysta Apex models, and the Mitutoyo MiSTAR 555, alongside all Zeiss GOM scanning systems and Marposs gauges.

RGC Engineering is not just about providing cutting-edge equipment and solutions. We are also about building a brighter future for the industry. That’s why we are in the process of establishing a training institute where Inspection Instrument Operators and Metrologists can enrol in training to use their tools and understand their measurements thoroughly. This initiative is a clear demonstration of our commitment to improving workforce skills and maintaining high-quality standards in production, and we are confident that it will contribute significantly to the industry’s growth and development.

In conclusion, RGC Engineering remains dedicated to advancing the quality standards of production in South Africa. Through our strategic partnerships and unwavering commitment to innovation, we are excited to continue leading the way in precision engineering and inspection.

For more information, please contact RGC Engineering – Tel: 011 887-0800.

Visit RGC Engineering

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