With Accure·tec, Walter provides a damping system specially for turning and milling using tools with a long projection length. The vibration damping provided by the axially and radially flexibly positioned damper element is preset at the factory. The tools can therefore be used immediately without any time spent on adjustment.
Turning operations up to 10 x D can be manufactured with high process reliability and with very good surface finish quality using the A3000 boring bars. Examples include H7 engineering tolerances and the counterboring of generator shafts to Rz 6.3. The equally new QuadFit quick-change heads enable rapid tool changes and increase repeat accuracy (±2 µm). When milling, Accure·tec AC001 adaptors up to 5 x D can be used with cutting data up to three times higher than conventional tools.
Accure·tec AC001 adaptors are ideally suited to the Walter milling cutter range. This applies in particular to high-feed milling cutters, which have their main cutting force in the direction of the spindle. This means that the system is highly versatile: For example, for components with deep cavities in aircraft construction, as well as in mechanical engineering, the aerospace industry and the automotive industry. With turning applications, the focus is on the energy sector (e.g. valves for the oil industry) and/or on the aerospace industry (e.g. landing gear). Users benefit from good vibration damping and a system with low noise levels. Accure·tec promises longer tool life, productivity and process reliability and protects tools and machine spindles – despite higher cutting data. Walter offers Accure·tec AC001 (milling) and A3000 (turning) with all popular machine interfaces: Walter Capto, HSK/HSK-T, SK, MAS-BT and parallel shank.
Wear-resistant parts are used wherever there is friction between two surfaces. To help users quickly get their special solution made of a suitable material, igus has now integrated the Print2Mould process in its online 3D printing service. With a printed tool, the component is manufactured by injection moulding. To do this, the user simply uploads the STEP file of the wear-resistant part into the 3D printing service, selects the material and requests a quotation. Specifications on the material properties as well as the precision, flexural strength and the price help with the choice.
55 iglidur high-performance polymers
If customers are looking for a wear-resistant plain bearing, they can choose from a large selection of igus materials. However, if wear-resistant parts are required – from gears up to special bushings – in any special shape, the user can either machine the component from a suitable iglidur bar stock or use igus’ 3D printing for more complex geometries.
For the individual component to be made from the ideal iglidur material for the respective application, igus offers the Print2Mould process. An injection moulding tool is printed for the special solution and is then used in the injection moulding machine.
The main advantage: the user can freely use the iglidur material range with its 55 lubrication-free, high-performance polymers. These include, the FDA-compliant materials iglidur A350 and A181 for use in the food industry, iglidur L500 for the automotive sector, and iglidur X for high-temperature applications.
The production of special parts by this process is characterised above all as a time-saving solution for prototype development and for small batches. This gives the customer the opportunity to obtain identical components in batches at an early stage of development.
The growing purchasing power of middle-class consumers in Asia has led to an increase in spending on consumer goods. In a rush to meet the escalating demand, manufacturers catering to the APAC region are investing in new production plants and machines, creating a requirement for machine tools in the process. An analysis by Frost & Sullivan reveals that this requirement will push the Asia-Pacific machine tool market to grow at a CAGR of 2.2 percent from 2018 to 2023, reaching $10.5 billion in revenue.
Frost & Sullivan’s latest research, Asia-Pacific Machine Tool Market, Forecast to 2023, explores the trends and factors influencing the machine tools industry in the Asia-Pacific region and provides a thorough analysis of the current market scenario. The report examines the key market drivers and restraints and presents detailed market share analyses and revenue forecasts through the year 2023. The research also offers strategic recommendations to leverage the growth opportunities identified in this sector.“Business expansion strategies and plant localisation of end-user industries are set to drive the growth of the machine tool industry in the APAC region,” said Divya Saiprasad, Principal Consultant, Industrials at Frost & Sullivan. “The rise in demand for machine tools can be attributed to the increase in the production of auto components and growth of the automotive industry.”
Japan, South Korea, and Taiwan are expected to remain the top three markets for machine tools in the region in 2023, contributing 69.5 percent. Additionally, emerging economies such as Vietnam, Indonesia, and Thailand are anticipated to showcase strong growth over the next three years, driven by foreign direct investment (FDI) inflow in the manufacturing sector.
“On the end-user vertical front, engineering and automotive sectors are projected to remain dominant,” noted Saiprasad. “The aviation sector is also expected to further supplement the market for machine tools, given the demand from the burgeoning upper-middle-class population.”
Machine tool vendors can tap into further growth by:
Integrating new features and technologies into additive manufacturing to increase the overall efficiency of multi-tasking machine tools.
Including new technologies such as IoT and Big Data for preventive and predictive maintenance of machines to help machine tool companies enhance their customers’ rate of operations in manufacturing, thereby increasing their brand recognition in the market.
Developing and selling smart machines equipped with AI, robots, and software technologies to expand sales and improve the productivity of customers in ASEAN countries.
Increasing production efficiency, shortening delivery times, and maintaining price competitiveness to increase sales and improve market profitability.
Expanding sales, distribution, and aftermarket service channels in emerging Asian countries to retain customers.
In an unprecedented move to provide potential users of every size and from across all industry sectors with unrivalled levels of technical support – and machine prove-out – Starrag China has opened a technical centre in Shanghai to serve the Swiss-based machine tool solutions provider’s ever-growing customer base throughout China.
As well as housing a number of Starrag machines that are under power to demonstrate their cost-effectiveness and production efficiencies – the new 2,200 m2 Starrag Shanghai TechCenter also offers visitors world-class applications engineering expertise coupled with superlative training for machine operators and programmers so that customers can quickly attain a seamless, integrated route to ‘Engineering precisely what you value’.
The in-situ Starrag LX 051 (for turbine blades) and NB 251 (for impellers and blisks) machines are currently complemented by the multi-axis Bumotec s191 and s181 multi-tasking machining centres – ideal for use in the luxury goods, jewellery, medical and watchmaking industries, for example – as well as a Heckert H50 machining centre which is targeted at a wide range of different parts across varying industrial sectors.
“All over the world, Starrag succeeds not only because of our high-performance machines but also due to the effectiveness of our ‘smart technology solutions’,” says Starrag China’s Managing Director, Tony Liu. “And it is no different in China where, now with the TechCenter, we have created the perfect platform on which to co-operate closely with our customers. Imparting the correct high-level machine operating and manufacturing skills is equally important to us.”
Walter has reached an agreement to acquire the privately owned US based company Melin Tool Company, a manufacturer of solid carbide and HSS end mills, drills and countersinks. Melin is a growing company, supported by innovations in the solid carbide endmill product family making the acquisition a strategic fit to enlarge Walter’s milling business in the United States.
The US is a key market for Walter and the acquisition strengthens the company’s round tool offering, especially for the aerospace industry and the US channel partner market. The acquisition gives Walter customers access to advanced cutting tool solutions and responsive support. A stronger footprint presence of Walter in the USA allows to grow the inch assortments in line with local market requirements and to support the market with customised tooling solutions even better.
“The acquisition is aligned with our focus on expanding our milling business in round tools and reconditioning capabilities close to customers in the American market.”, says Richard Harris, President of Walter.
“I am very pleased that we have reached an agreement to acquire Melin Tool Company as it increases our market presence and has a strong innovation focus and high service level that is aligned with Walter’s approach to doing business.”
The TRUMPF Group recorded a renewed increase in sales in the 2018/19 fiscal year that ended June 30, 2019, while orders received and profits declined. Sales rose by 6.1 percent to 3.78 billion euros (3.57 billion euros in the 2017/18 fiscal year). Orders received decreased to 3.68 billion euros (3.80 billion euros in the 2017/18 fiscal year). This equals a reduction of 3.1 percent. Earnings before interest and taxes (EBIT)amounted to 349.3 million euros, which was 34.7 percent below the prior year figure (fiscal year 2017/18: 534.7 million euros). The EBIT margin was 9.2 percent (fiscal year 2017/18: 15.0 percent).
Development in the business divisions
In addition to the high backlog of orders from the previous year, the expansion of the EUV business field was a key driver of the TRUMPF Group’s growth in sales revenue. TRUMPF supplies special lasers to ASML, a customer in the Netherlands. These lasers are integrated into systems that use extreme ultraviolet radiation to expose chip surfaces for the computer industry.
The Machine Tools and Laser Technology business divisions were, by contrast, unable to maintain the high growth rates achieved in the previous year. Revenues for the Machine Tools division rose by a slight 1.2 percent to 2.39 billion euros (previous year: 2.36 billion euros). The Laser Technology division posted revenues of 1.38 billion euros, marginally (-2.1 percent) below the prior-year level of 1.41 billion euros. This decline was attributable to the slowing market in Asia (in particular in China and South Korea) as well as to the automotive industry’s reluctance to invest.
Nicola Leibinger-Kammüller, TRUMPF President and Chairwoman of the Managing Board, explains: “As a company operating in the investment goods sector, we are particularly exposed to the impact of cyclical highs and lows. That is currently the case. Given the uncertainty due to the U.S.–China trade conflict and the structural change in the automotive industry, many customers have become more cautious and are postponing investments.”
Investments and acquisitions
TRUMPF further pursued its strategy to enhance its technological expertise with new acquisitions. Effective April 1, 2019, TRUMPF completed the acquisition of Photonics GmbH from Philips, which it had announced in December 2018. As of the same date, the company set up a new business field, TRUMPF Photonic Components. In May 2019, TRUMPF acquired the remaining shares in the Chinese subsidiary JFY and now owns the company outright. To reflect this change, TRUMPF introduced a new organisational structure with a CEO China.
Investments in climate change mitigation: CO2-neutral production by the end of 2020
TRUMPF aims to achieve a CO2-neutral energy balance at its production sites worldwide by the end of 2020 and therefore intends to increase investments in measures to protect the climate. By its own reckoning, the company currently emits around 90,000 metric tons of CO2 worldwide per year. Of this amount, 80 percent is accounted for by electricity consumption. In this area, TRUMPF is pursuing a policy of concluding further green power contracts and purchasing certificates under carbon trading schemes to offset emissions from the combustion of heating oil, natural gas and other fossil fuels. A similar approach is being applied in markets with limited availability of renewable energies in the electricity mix. All TRUMPF sites in Germany already cover 100 percent of their electricity needs through green power contracts. Worldwide, 60 percent of the electricity needs are covered by green power contracts.
Between now and June 2021, in addition to efforts to close this gap and become 100 percent green, if necessary, by purchasing certificates, TRUMPF intends to invest some 6.4 million euros in improving energy efficiency.
In the third quarter 2019, the UCIMU index showed an 18.6 percent fall of machine tool orders compared with the same period of the previous year. The absolute value of the index was 69 (basis 100 in 2015). The overall outcome was due to the negative trend registered both in the domestic and in the foreign markets.
In particular, the orders collected by the manufacturers in the domestic market highlighted a 19.3 percent downturn compared with the period July-September 2018. Even on the foreign front, the manufacturers registered a considerable reduction in their orders, down by 14 percent versus the third quarter 2018.
Massimo Carboniero, President of UCIMU-SISTEMI PER PRODURRE, stated: “Unfortunately, 2019 has confirmed to be a year of contraction for the Italian manufacturers of machine tools, robots and automation systems, who experienced a drop both in the domestic and in the foreign markets.”
“The trade conflict between the two economic powers, (the United States and China), the recession of driving sectors for the manufacturing industry, (principally the automotive), and the outbreaks of war in hot spots of the world make the activity of the manufacturing enterprises particularly complicated and the future decidedly uncertain.”
In this scenario, already complex in itself, the Italian industrial system risks being even more penalised by the still undecided attitude of the Government authorities, engaged with the definition of the Budget Law 2020 and with the allocation of the (scarce) resources available.
“Now more than ever, our country needs a plan that can support the investments and development of the manufacturing industry, which is also the real “activator” of employment. In this connection, the reduction of tax wedge to the benefit of employees is appreciable, provided that it has an appropriate economic coverage. However, this is not enough,” said Carboniero.
An overall package of provision for the enterprise growth should be implemented, with the aim of encouraging the continuation of modernisation and transformation within Italian factories to improve the country’s competitiveness. The Package for the Enterprise Growth should include all tax benefits related to Research & Development and to Super- and Hyper-Depreciation for the investments in new machinery, software and automation, and for the technologies related to environmental issues.
Furthermore, a programme of professional education and training 4.0 should be planned also for 2020, which can allow staff updating according to the new requirements of digitalised factories. Currently, tax credit is calculated only on the costs of the personnel involved in professional education and training for the refresher hours attended. On the contrary, the tax credit should be reviewed in such a way as to include the cost of teachers and trainers, the most onerous expense item especially for a SME.
“We ask the Government authorities to plan a special action to support the creation of enterprise networks for the study and analysis of specific areas or sectors of destination. Preparatory to the definition of the trade activity, the projects concerning the study and analysis of a particular market are often onerous and thus difficult to bear for a SME. In this connection, an enterprise network certainly represents a valid solution to this need,” concluded Carboniero.
At EMO 2019, GEORG, as pilot customer of Siemens, is going to present, as a first, digital twins of two of its machine tools. This makes Georg a pioneer in implementing in practice the next stage of the digital transformation in machine tools, using the new CNC generation “Sinumerik ONE”.
In the construction of complex machine tools, engineering and manufacturing often used to be two successive processes. First prototypes were designed and constructed, then the software was programmed, and processes and procedures could not be optimised and harmonised until during the commissioning phase.
The digital twin introduces a fundamentally different approach: The Sinumerik ONE software, which Siemens is going to present for the very first time at the upcoming EMO trade fair, maps all development processes in a virtual environment. Long before real prototypes are available are tasks transferred from the real world into the virtual world. An example: As early as during the manufacturing of a machine the control software is not only written, but also tested – in the virtual world. In parallel, the future operators of the machines can be trained on control pulpits that are of exactly the same design as those coming with the ordered machine.
The digital twin also offers considerable advantages in terms of service: GEORG’s experts can use it to trace the customer’s machining programs at the Kreuztal plant and provide advice on optimisation.
Also when it comes to clarifying and specifying with a customer what features the machine he is considering to buy should have, the digital twin is extremely helpful, as it is possible to show the customer the desired configuration and functions of the machine in every detail.
GEORG has already implemented digital twins for two of its machine types: for the grinding machine, ultragrind SG2 and for the moving column milling machine, ultramill H. Of the latter, the company is currently manufacturing one unit for its own workshop and one for a German customer.
The company is going to successively offer more machine tools from its range equipped with the new, entirely digitalisation-oriented control system, for example, machining centers for turning and milling as well as roll grinding machines for the steel and aluminum industries.
As the operation of high-capacity machines for the machining of highly complex work pieces demands special control and operating requirements– on the basis of Sinumerik ONE – developed the proprietary control software, smartcontrol UG. A special feature of this software is the highly intuitive HMI which allows the digital twin to be operated for training and testing purposes either via the real operator pulpit or its virtual counterpart.
Dr.-Ing. Wieland Klein, CTO of GEORG, is convinced that the digital twin will provide his customers with numerous important advantages: “The GEORG Digital Twin is the key to the digital transformation of our machines. It makes it possible to simulate and test our customers’ operations in a completely virtual environment. From the integration of the virtual and the real machine along with GEORG’s engineering knowhow, its high-capacity machines and the new high-performing Sinumerik ONE software, our customers will benefit in the form significant potential for productivity improvements. Being a pilot customer of Siemens, we are the first to offer applications on the basis of this groundbreaking new system.”
Vibration often occurs during machining. This leads to dynamic instability of the system. Inadequate surface finishes, insufficient accuracy, high machining noises, shortened tool lives and, in extreme cases, broken tools and cutting edges can be the result.
In order to minimise these vibrations and their consequences, MAPAL has now developed an innovative system for vibration damping in the tool shank, as particularly tools for boring and milling with very long projection length tend to vibrate due to an inadequate dynamic rigidity of the overall system. When designing the new system, the developers took into account all factors arising from the interaction of the machine tool, the tool and type of clamping as well as the component. The result: A system for vibration damping that is matched to all common types of machine stiffness. It can be used for machining different materials with different tools.
The self-contained system of auxiliary mass and several steel spring packages counteracts the deflection of the tool body and minimises it. The vibrations can be up to 1,000 times lower compared to tools without absorber system. Despite the long projection length, quiet, stable running is achieved. This makes it possible to work at higher cutting speeds and significantly increases the material removal rate.
In addition, significantly better surface finishes are achieved thanks to vibration damping. When milling case hardened steel (16MnCr5), for example with a 250 mm long combination of milling cutter arbor and milling cutter with five cutting edges and ISO indexable inserts (diameter 50 mm), the Rz value was halved from 7.8 µm to 3.9 µm for material removal ae of 18 mm and ap of 3 mm compared to the same tool system without vibration damping.
What is the next stage in the evolution of ISO turning? Ever smaller, ever lighter – many developments across vastly different industries are driven by the trend towards miniaturisation or lightweight construction. For mechanical engineering and suppliers, this results in entirely new challenges for metal machining. Article by Walter AG.
Application example – impeller: The surfaces produced using the HIPIMS PVD process are extremely smooth. This reduces build-up on the cutting edge and the generation of heat thanks due to reduced friction. (Image Walter AG)
Even though it is most apparent in the field of communication and entertainment electronics, the trend towards miniaturisation is shaping many areas of industry: From the medical industry, to the automotive industry, right through to aircraft construction. For producers, this means that they must adapt their processes to increasing demands for dimensional stability and surface quality or even switch to new materials.
Particularly hard, but also particularly tough, materials (such as Inconel 718DA with 42 HRC in the aerospace industry or Ti-6Al-4V in the medical and food industry) have complex requirements for the indexable inserts during ISO turning. This is because tough materials have a high tendency for adhesion, especially when they have a high nickel content (Ni). This results in the chips sticking to the cutting edge forming a build-up on the cutting edge. The dimensional stability and the surface quality suffer. The fact that cutting edges become worn relatively quickly had to be accepted until now, especially in the case of high-strength materials.
During ISO turning operations with high to medium depths of cut, the CVD-coated indexable inserts which have previously dominated the market offer good to outstanding possibilities. However, they reach their limits in machining applications such as finishing and fine finishing, particularly where precision and tool life are concerned. This is where Walter’s machining specialists identified major potential for optimisation.
Gerd Kußmaul, Senior Turning Product Manager at Walter, describes the concept behind the new HIPIMS PVD-coated indexable inserts as follows: “Even if the fine finishing and finishing of ISO M, ISO S, ISO P and ISO N materials with the highest requirements for surface quality are still special or niche applications at the moment, we see great potential here due to dynamic growth in the market right now. Fine finishing involves turning operations which are designed to achieve a consistently good surface quality. This is in the range from Rz 1.6 µm to Rz 6.3 µm – throughout the entire tool life of the indexable insert. This is why for some time Walter has been looking for geometries and cutting tool materials that achieve this with process reliability. The new PVD HIPIMS coatings demonstrate ideal properties for achieving this with their extremely smooth surface and great layer adhesion on sharp cutting edges.”
Innovative Coating Technology To Ensure Best Performance
Walter is one of few indexable insert manufacturers to perform the new PVD HIPIMS process in-house and continuously expand the application possibilities with a dedicated PVD development team. HIPIMS stands for “High Power Impulse Magnetron Sputtering”. In contrast to conventional DC sputtering processes, the HIPIMS process involves subjecting the targets to short pulses of a few kilowatts of power. This produces a plasma density of 1013 ions per cubic centimetre, which have a high content of target metal ions. The bonding of the layers to the substrate is also excellent.
Indexable inserts with extremely sharp geometries, such as the FN2 or the MN2 “Aluminium geometry”, benefit from this coating process in particular because extremely stable cutting edges are produced. Even under high loads, the layers do not chip off and the cutting edges do not break away. In addition, the high level of edge stability ensures that the cutting edge is not only subjected to less wear, but that this wear also occurs evenly. The even wearing ensures dimensional stability and defined surface quality, even right up to the end of the tool life. Another advantage of the HIPIMS process is that the coatings are extremely smooth making them ideal for machining sticky aluminium alloys, for example; materials which would otherwise stick to the cutting edge during machining now reliably glide over it. Typical forms of wear such as built-up edges or significant flank face wear caused by chemical and physical reactions with the adhering material rarely occur. Walter’s new HIPIMS PVD grades WNN10 and WSM01 also have a long tool life.
Finishing of Inconel 718 DA – 40 HRC with Vc: 80 m/min: With identical cutting data, the new HIPIMS PVD-coated DCGT11T304-FM2 WSM01 indexable insert increased the tool life from nine minutes to 18 minutes compared to the DCGT11T304-PF2 WXN10 indexable insert and consistently achieved a surface quality between Rz 2 and Rz 4 μm throughout the entire tool life. (Image: Walter AG)
Long Tool Life, Increased Machining Volumes
Since the launch in 2017, sales for the HIPIMS PVD indexable inserts has grown consistently. Walter is pleased with the positive response from many customers who have already made the change from the previous WXN10 or WK1 cutting tool materials to the PVD-coated WNN10 or WSM01 indexable inserts. Walter Product Manager Gerd Kußmaul reports: “There must be good reasons to change the cutting tool material in established processes. Among other factors, the outstanding results achieved by the new HIPIMS grades with regard to tool life and surface quality speak in their favour. This is clear to see from the comparative tests. For instance, when performing finishing operations on tool steel X40CRMoV5-1 (DIN1.2344) with 54 HRC, it was possible to increase the tool life by 275 percent. And the surface value of Ra 0.8 µm was achieved throughout the entire tool life with process reliability. Another application was finishing Inconel 718DA at a cutting speed of 80 m/min, with the new grade WSM01 and achieving a cutting time of 18 minutes. In comparison to this, the previous grade WXN10 was only able to achieve nine minutes. In addition, a consistently good surface quality between Rz 2 µm and Rz 4 µm was achieved throughout the entire tool life.”
Process Reliability And Cost Reduction
Walter’s new HIPIMS PVD indexable inserts have potential to be effectively used anywhere that maximum precision, surface quality and process reliability are required. At the same time, these inserts have a positive effect on costs because the HIPIMS PVD coating, in conjunction with a carbide substrate, results in a cutting tool material that offers a long tool life with consistently high machining quality right to the very end. This is especially true for difficult machining steps such as fine finishing and for very sticky materials such as aluminium alloys with a high silicon content. In fact, the tool life and surface quality differences compared to previous indexable inserts are so significant that they result in a noticeable cost reduction in production.
In comparative tests, Walter achieved a 73 percent increase in tool life quantity with the WNN10 indexable inserts (compared with previous cutting tool materials) for machining red bronze. (Image: Walter AG)
Optimal Surface Quality When Finishing And Roughing
Walter developed the new WNN10 grade for finishing and roughing of ISO N materials such as aluminium-, copper- and magnesium-based alloys. The indexable inserts are available in two geometries. The FN2 geometry with 18° rake angle is ideal for finishing operations and for long, thin shafts that tend to vibrate. The MN2 geometry with 25° rake angle can be used universally for medium machining of non-ferrous metals.
The new grade WSM01 is available in the FM2, MM4 and MN2 positive geometries and in the MS3, NMS and NRS negative geometries. Its main area of application is finishing and medium machining of nickel- and cobalt-based high-temperature alloys (ISO S) but it is also used with stainless materials (ISO M) such as austenitic stainless steel 1.4301, 1.4404 or duplex steel 1.4462. It is used, for example, for machining engine components in the aerospace industry or for producing surgical instruments in the medical industry. Its applications also include machining stainless steels or hard turning tool steel such as X40CrMoV5-1 with 54 HRC. To summarise, it can be said that the new HIPIMS PVD grade WSM01 is the ideal solution for fine finishing of hard materials.
