All The Right Moves With Sutton Tools Harmony 5-Axis Endmill
Available with barrel, taper, lens and oval configurations, Harmony 5-Axis endmills have the ability to reduce cycle times by up to 90%, compared with ball nose endmills.
Grind On A New Level With Studer WireDress
According to Fritz Studer AG, it has been possible to increase grinding power in the grinding process by 30% and reduce grinding wheel wear by 70% in comparison with ceramic and resin bonds.
Shot Blasting, Mass Finishing And Cleaning Solutions From One Single Source
Perfectly adapted to the requirements of a job shop operation.
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Joining Forces For Continuous Operation
How polymer knife-edge rollers are making maintenance-free conveyor belts and packaging systems possible, enhancing performance.
Article by igus.
Krones AG produces systems and machines for making, filling, and packaging beverages and liquid food. The industry never sleeps. So it is hardly surprising that Krones systems have to break their own speed records again and again. This becomes a problem when a part cannot withstand the pressure and there is no alternative that can perform better. That is why igus GmbH developed knife-edge rollers made of tribo-polymers for Krones, helping them achieve new records. In 2005, Krones faced a challenge with the Variopac Pro, a fully automatic all-round packaging system: the system’s performance had to be increased by 20 packs per minute. There was therefore an urgent need to change the conveyor belt deflection. Originally, metal rollers with needle roller bearings were used here, but they couldn’t meet the higher performance requirements and were cost-intensive. Looking for an alternative, Krones Design Engineer Jürgen Werner came upon igus GmbH products.
Full Article Available >> https://bit.ly/39VLJig
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Espirit Keeps The Success Flowing For Wet Design
Founded in 1983 by former Disney Imagineers, Southern California’s WET Design creates water features that are quite a few cuts above the fountains you might see at your local mall or city park. Their expansive portfolio is an impressive showcase of what’s possible when water, light, music, and human ingenuity come together.
Article by WET Design.
If you’ve ever scrambled for a prime spot to watch the Fountains of Bellagio in Las Vegas, booked a once-in-a-lifetime experience at The Dubai Fountain at Dubai’s Burj Khalifa skyscraper (the tallest building in the world), or stopped to rest at the fountains at Salt Lake City’s City Creek Center, you’ve enjoyed WET’s work. WET installations can be found on three continents and have even made an appearance in the opening and closing ceremonies of the 2002 and 2014 Winter Olympics.
Full Article On Integrating A Variety Of Machines With Ease >>https://bit.ly/3orAFlE
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Sandvik Aims To Lead In Premium Solid Round Tools With New Acquisition
Sandvik has signed an agreement to acquire 67 per cent of Chuzhou Yongpu Carbide Tools Co., Ltd, a China based premium solid round tools company, with a call option to buy the remaining part in three years’ time. Chuzhou Yongpu Carbide Tools Co., Ltd is mainly focused on global and local OEMs and connected suppliers operating in China. Its capabilities include the full solid round tools manufacturing value chain with an offer covering blanks, cutting tools, reconditioning and coating services. The company will be reported in Sandvik Coromant, a division within Sandvik Manufacturing and Machining Solutions.
Stefan Widing, President and CEO of Sandvik, says, “The acquisition of Chuzhou Yongpu Carbide Tools Co., Ltd is part of our strategy for our machining solutions business to increase our market share and take a leading position in solid round tools, and at the same time expand further in the Asian market. We are looking forward to welcoming Chuzhou Yongpu Carbide Tools Co., Ltd to the Sandvik Group.”
Chuzhou Yongpu Carbide Tools Co., Ltd will continue to operate under its own brand and focus on developing its offer and market share with the ambition to become a leading premium provider of solid round tools in China. The combined expertise and footprint of Sandvik Coromant and Chuzhou Yongpu Carbide Tools Co., Ltd will drive further geographical expansion in the region, particularly for cutting tools.
“We have long-term strategic commitment to strengthen and develop our business. China is a fast-growing market for solid round tools, and the acquisition of Chuzhou Yongpu Carbide Tools Co., Ltd will further strengthen our presence and enhance our offer to customers in this important region. With its premium position and strong customer focus, Chuzhou Yongpu Carbide Tools Co., Ltd is a great fit for Sandvik Machining Solutions“, says Nadine Crauwels, President of Sandvik Machining Solutions.
Chuzhou Yongpu Carbide Tools Co., Ltd is headquartered in Chuzhou, China, and has around 500 employees. It had revenues of approximately SEK 400 million for the twelve month period Q2 2020 to Q1 2021, an EBIT margin slightly dilutive to Sandvik Manufacturing and Machining Solutions. Impact on earnings per share will initially be neutral.
The transaction is expected to close during the third quarter of 2021.
Artificial Hip Joint Manufactured For Precision Fit
Artificial hip joints must be manufactured with high precision, especially in the area where the hip stem and the ball joint connect. CERATIZIT has developed an economical production solution for precise interface between hip stem and ball joint.
If a hip joint is affecting quality of life by restricting movement and causing chronic pain, and if conservative treatment methods are no longer helping, the only option is to have an artificial replacement joint implanted – over 200,000 such operations are performed in Germany-alone each year. Those who take this route are hoping for long-lasting improvements. In order to make this hope a reality, as well as a good surgeon and first-rate care, the highest quality ‘spare parts’ are needed.
Prosthetics like this usually consist of a hip stem with ball joint, a hip socket and an intermediate piece to ensure movement is as smooth as possible. Particular attention must be paid to the connection between the hip stem and the ball joint. For the conical surfaces to fit together perfectly, they need to be produced with the highest precision and surface quality. Therefore, the tools used play a crucial role when manufacturing these components.
“An artificial hip joint consists of difficult-to-machine materials, which not only need to be machined within the narrowest tolerances but also as economically as possible. Ultimately, an artificial hip replacement should be affordable for as many people as possible. We work with great dedication to find suitable tool solutions for these tasks,” explained Dirk Martin, Application Manager Medical at CERATIZIT and member of Team Cutting Tools.
Meeting Machining Requirements
CERATIZIT is a full-range provider in the machining sector that has a wide range of standard and specially-made tools as well as in-depth machining expertise at its disposal. “With our huge product range and the expertise of our application specialists, we are extremely well equipped for tasks like machining the area where the hip stem and joint ball connect,” stresses Martin. “With our range of tools, we can test all manner of approaches to ultimately find the optimal solution.”
In the case of the artificial hip joint, the customer has particularly demanding and varied requirements. For the hip stem, made from high-strength titanium alloy Ti6Al4V, an angle tolerance of just +/-5‘ must be achieved in the conical connection area. Other tolerances are 3 µm for straightness, 8 µm for roundness and 60 µm for the diameter. It is also important that the specified contact ratio for the cone is achieved and a precisely defined groove profile produced.
The ball joint is made from a cobalt-based alloy (Co-Cr-Mo). Its conical hole must have the same shape, angle and dimension tolerances, as well as the specified contact ratio. However, there must be no marks, ridges or grooves made during machining. Martin mentions another crucial factor: “We need a production solution that is suitable for mass production. This means the machining must be process-secure and require as little monitoring as possible.”
Flexible u-Axis and Special Conical Reamer
To produce the conical outside profile, CERATIZIT’s application specialists opted for pre-machining with a solid carbide conical milling cutter. The subsequent roughing and finishing are then completed using a CERATIZIT u-axis system.
“This is an interchangeable, freely programmable NC axis for machining centres, which can be used to machine contours or for turning.” explains Martin.
“Attachment tools and indexable inserts can be used to create contours in holes and external machining work. This usually means that production times can be reduced considerably, while providing optimal surface quality and higher shape accuracy than usual,” he continued.
This means the desired groove structure can be produced on the stem cone even on a machining centre. This has the benefit that all machining processes can be done on a single machine. Using the conventional process, a lathe and a milling machine would be required, which means additional clamping, aligning, time and money.
To make the conical hole in the ball joint, CERATIZIT’s solution involved the following steps being carried out on a lathe: First, the part is faced to provide a flat surface for the subsequent special solid carbide 180 deg drill with four cutting edges. This is then used to make a hole with a flat bottom. After this an EcoCut Classic drill and turning tool is used to produce the cone with close-contour boring, while a special solid carbide conical reamer ensures the ideal contact pattern and perfect surface quality and tolerance is achieved. The regrinding capability also saves the user further production costs.
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Global Orthopaedic Devices A Lucrative Market For CNC Tool Cutting Industry
Growth in the global orthopaedic devices market offers an attractive diversification strategy for the CNC tool cutting industry.
CNC Machining & 3D Printing: A Mixed Approach To Precision Manufacturing
Peter Jacobs, Senior Director of Marketing at CNC Masters shares how a meaningful combination of CNC machining and 3D Printing can help manufacture even the most intricate parts and boost overall productivity.
The advancing 3D printing capabilities have made it convenient for manufacturers to use additive manufacturing to develop parts from a wide variety of materials. These materials include polymers such as ABS, PLA, TPE, and carbon fibre composites, polycarbonates, and nylon.
Alongside 3D printing, precision CNC machining also enjoys a crucial role in the additive manufacturing process, with a new process called hybrid manufacturing quickly assuming its hold in the industry.
Combining CNC machining and 3D printing can meet all crucial design requirements and eliminate limitations in these individual domains.
Benefits of Combining Machining and 3D Printing
Here’s why the combination of CNC machining and 3D printing is relevant and the benefits that will follow:
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Conservation of Time
The process of 3D printing a part and then having it delivered to the next section for CNC machining involves too many steps; however, this process is relatively less time-consuming relative to injection moulding.
In Injection moulding, the design and development of a specialised tool must go through every workpiece in the moulding process, making it more time-consuming.
While we can alternatively use 3D printed injection moulds to reduce production time, incorporating the potential of CNC machining can be more fruitful.
We can seamlessly tweak the digital files that end up getting 3D printed as prototypes rather than making alterations to an existing injection moulding machine tool.
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Higher Tolerance Rate
3D printing has encountered hindrances in its progress due to the tolerances of modern 3D printers. Many end-use parts have specific tolerances and other vital requirements that are only feasible by incumbent manufacturing methods.
Unlike 3D printing, CNC machining is consistent. It offers a more refined product because its equipment does not exhibit sensitivity to heat as a 3D printer, which might warp and distort the product and result in uncertain runs of products.
Merging the two domains provides us with the perks of rapid prototyping brought to the table by 3D printers. It also enables us to dial in the tolerance from 0.1 mm to 0.3 mm as anticipated from a DMLS or SLS 3D printer to about 0.025 to 0.125 mm rendered by CNC Milling Machines.
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Use a Bigger Workpiece
A congregation of these two domains involves 3D printing a part and then forwarding it to CNC milling to balance the final tolerances and providing it with the desired finish.
There has been excitements about merging these two technologies into one machine. This scenario could result in something that resembles the industrial-scale hybrid milling machines.
Such machines are speculated to harbour a build volume of about 40 feet in diameter and 10 feet in height. These hybrid 3D printing-milling machines can mill the surface of a new 3D print while the operation would still be underway.
With state-of-the-art CNC Benchtop Milling Machines, you can enjoy peak performance while occupying a minimum floor.
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On High RPM
Andrei Petrilin, Technical Manager of ISCAR discusses the importance of high-speed spindle and the requirements in high-speed machining (HSM).
High-speed machining (HSM) has not only led to a significant difference between machine tools but has also brought awareness to the high-speed spindle; perhaps, the most important and central component of high-speed machine tools and a key factor for the success of HSM.
High Speed Machining
Operating a spindle with high rotation speed and gaining the optimal balance between the provided speed and torque is the main task of high spindle engineering. The spindle’s performance depends on several different factors. One of the main factors relates to the design concept of a single- or combined twin-motor bearing system, seal components, and a tool retention method.
When machining, the spindle is not in direct contact with the workpiece but interacts with it through another technological system – the cutting tool. This connection acts as a conductor and should transform the impressive capabilities of a high-speed spindle into improved machining results. Another element between the cutting tool and the spindle is the toolholder which is fitted into the spindle. The poor performance of this small assembly, the cutting tool and toolholder, may reduce the function of the spindle to zero. Therefore, HSM toughens the accuracy, reliability, and safety requirements for the assembly of the spindle extension.
High-speed rotation generates centrifugal forces. In HSM, when compared with traditional machining methods, these forces grow exponentially and turn into a significant load on a cutting tool which determines the tool’s durability. In indexable milling, high centrifugal forces may cause insert clamping screws to break, inserts to loosen and a cutter body to fail. Formed fragments can not only damage a machine and a machined part but can be very dangerous to the operator.
In such conditions, cutting tool manufacturers are compelled to consider the design and technological means necessary to ensure appropriate reliability of their products. Hence, the focus on indexable milling cutters should consider secure insert mounting and a robust body structure.
Reliable Milling
Let us start with a clamping screw, the smallest and weakest element of a whole technological system with a great impact on the system’s reliability. The same can be said about the clamping screw in relation to a high-speed indexable milling cutter. Applying dynamometric keys controls the tightening of the clamping screw. (Fig. 1). However, ensuring the torque is tightened sufficiently is not enough to reliably operate the cutter. Intelligent design is directed to minimise the dynamic load on the clamping screw.
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