38 - vogel.defiles.vogel.de/vogelonline/vogelonline/issues/etmm/2009/008.pdf · volume xi number 8...

VOLUME XI NUMBER 8 � AN ACCESS COMMUNICATIONS INC. PUBLICATION OCTOBER 2009

Direct-Side-Gating NozzleSeries Adds New VersionsFakuma visitors will see Ewikon’s expandedseries of nozzles for direct side gating, withangled-tip versions and new gating geometry. 52

Brush Wellman’s copper-alloy mould materialsenhance tool wearresistance andproductivity.

Your guide to Fakuma2009, this year’s mostimportant eventfor the Europeanplastics industry.

38

47

• Swiss Watchmaker Relies on CNC Tools• Deep-Hole Drilling Tackles Tough Steel• A New Four-Component Mould Design• Tooling Design Saves Moulder Millions

IN THIS ISSUE

For more product information visit www.tool-moldmaking.com

http://www.tool-moldmaking.com


Progressive’s Collapsible Cores are the world’s most trusted alternative to

traditional gear/rack moulds. Proven in thousands of applications across

the packaging, medical, and irrigation industries, C-Cores™ consistently

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� Faster cycle times, often producing 1/3 more parts per hour

� Straightforward mould maintenance and lower lifetime ownership cost

Contact Progressive at [email protected] for an application review

so that you may join those who consistently consider this approach for

every upcoming programme.

DEL IVER ING REL IABLE PROF ITS

CONSISTENT PERFORMANCE.

ACCESS ANIMATIONS AND TECH INFOAT WWW.PROCOMPS.COM/DEMO

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mailto:[email protected]

Sustainable manufacturing is already amajor consideration in many areas ofproduction. However, in the future, sus-tainable methods will have to be inte-grated into every aspect of product man-ufacture. More and more, engineers willbe trained specifically to take sustain-ability into account in every design,

from the start of the engineering process. This will affect themould making industry.

A tool or mould maker might ask, Is sustainability reallyapplicable and achievable in our industry? The answer isyes. This industry is a big consumer of energy, for one thing.And there are many other areas where sustainability can beachieved through tool and mould design. The InternationalSpecial Tooling & Machining Association (ISTMA) recog-nizes this and has taken steps to help its members under-stand more about sustainability, such as working with ini-tiatives like the Manufuture-EU platform.

I recently attended the second European Tooling Forum,held in Milan and organized by ISTMA Europe. Its interest-ing presentations impressed me. The forum touched onmany aspects of the tool and mould making industry.Speeches by the Italian parliamentarian Alberto Torazziabout productivity and globalization and by Claude Rieg,programme officer for New Generation Products at thedirectorate-general for research of the European Commis-sion, were excellent. The session tracks covered such sub-jects as the current situation of the tooling industry and theindustry’s role in manufacturing, and included presenta-tions from Mercedes-Benz and other tooling customers.

But, for me, one of the most important aspects of theforum was the working relationship between ISTMA andManufuture-EU. As a platform focused on sustainability,Manufuture-EU has over the past few years created an out-standing networking community to address sustainabilityissues. This relationship will not only help ISTMA memberswith these issues, but also strengthen ISTMA’s position as anassociation clearly oriented toward the future.

Contacts made at the forum should lead to editorialcontent appearing in upcoming issues of ETMM. Mean-while, congratulations to ISTMA for a successful event.

Douglas SellersMANAGING DIRECTOR/EDITOR-IN-CHIEF

ISTMA Is Smart to Be Working with Manufuture-EU

Editor’s MessageEditor’s Message

October 2009 � European Tool & Mould Making 3

www.etmm.info/2009/10/002

http://www.delcam.com


http://www.etmm.info/2009/10/002

October 2009

9 Mold-Masters Forms Strategic Alliancewith Preform Insert ManufacturerABBA Systems

10 Sescoi Addresses a Growing Market byParticipating in Regional Series of Dieand Mould Seminars across India

10 Seconded by Exhibitors, Organizer of FirstFIP Trade Fair Held in Lyon Pronouncesthe Event a ‘Clear Success Story’

11 D-M-E Europe Introduces 3D Libraryfor Economy Moulds Programme

11 Faro Names Lynn Brubaker to Its Board12 Industry News in Brief

EuroMold News14 International Wohlers Conference at

EuroMold 2009 Will Focus on Futureof Additive Manufacturing

ISTMA News17 Swedish Tool and Die Association

Promises ISTMA Meeting Attendees aWarm Wintertime Welcome

Featured Supplier18 PCBN and Ceramic Cutting-Insert

Grades Are Engineered to Provide High Productivity in Hard Turning

Technology20 Brushes for Deburring and Finishing

Small Parts: Proper Selection CanEnhance Manufacturing Productivity

22 Machining at the Material Frontier:Deep-Hole Drilling Tackles theToughest, Hardest Tool Steel on the Market

Special Report24 A Four-Component Mould Concept

Automates the Mould withoutModifying the Standard InjectionMachine

Table of ContentsTable of Contents

Industry News7 German Employment Agency Supports

Seminars in Metrology Conducted byNewly Certified Wenzel Group

8 ‘Metal Meets Medical,’ a Special Showat METAV 2010, Will Unite MachineTool and Medical Engineering Sectors

20 ��

�� 7

Kitagawa Europe Ltd.

New pull-back quick-changecollet chucks provide secure,

accurate componentclamping on machine tool

worktables.

Wenzel GroupGmbH & Co. KGA German employment agencysupports seminars in metrologyconducted by the newly certifiedWenzel Group.

Brush ResearchMfg. Co. Inc.

The proper selection of brushesfor deburring and finishing

small parts can enhancemanufacturing productivity.

40 ��

MAG Europe GmbHEnergy efficiency is one benefit of a modular VMC thatcan be configured for 3-, 4-, or 5-axis machining.

42 ��

4 European Tool & Mould Making � October 2009

An article on page 17 in the ETMM Buyer’sGuide about Vero Software’s MachiningStrategist CAM system noted that its benefits“will accrue even to those who use Vero’slibrary components within their own systemsrather than Vero’s CAM products.” We’d liketo clarify that the benefits are not only forVero CAM users but also for those usingVero’s library components within their ownCAM systems.We regret any misunderstand-ing that our wording may have caused.

CCllaarriiffiiccaattiioonn

Products & Services34 Recently introduced equipment and

services from all over

Fakuma200947 In our

exclusive“find-it”guide forvisitingFakuma,the mostimportantplastics-processing show in Europe this year,we show tool and mould makers whatto look for at the show

Volume XI Number 8

Case Studies26 Reports from the field: a detailed look

at how different shops resolved theirreal-world problems

Company Index58

50 ��

26 ��

Friedrich Freek GmbHInnovations in process heating technologyfor plastics processors address the trendtoward miniaturization.

Ceratizit Austria GmbHA cutting-tool supplier’s applicationsexpertise enables one Swiss fittings

manufacturer to cut production times.

Haas Automation Europe N.V.An extra-large VMC with many options can accommodate voluminous monolithic parts.34 ��

www.etmm.info/2009/10/003 �

Türk+Hillinger GmbH78532 Tuttlingen Germany

Tel. +49 74 61 70 14 0 Fax +49 74 61 70 14 110

[email protected]

www.tuerk-hillinger.de

since 1963

we are your best choice forheating elements

wide product range

large repertory of stock types

customer-specific executions

modern, rational manufacturing methods

over 30.000 heating elements daily

certified according to DIN ISO 9001:2000

high life span

500 qualified employees

over 270 patent applications

made in Germany

Visit us from

13.10.–17.10.09

at the Fakuma in Friedrichshafen

Hall B3, Stand B3-3305

Nov./Dec. 2009:The EuroMold Issue“Sneak Peeks” and completepreview coverage of the world fairfor tool and mould making

Buyer’s Guide 2010Coming in November: our annualindustry directory/sourcing guidefor electrical discharge machining

NEXT ISSUESNEXT ISSUES

http://www.tuerk-hillinger.de



European Headquarters, Comeniusstr.2, 40670 Meerbusch, Germany.

Tel +49 2159 91890 email [email protected]

CHOOSE JAPAN’S NO. 1

www.mitsubishicarbide.com

VF2WB END MILLS

MOULD AND DIE TOOLS WITHADVANCED COATINGS ANDGEOMETRIES FOR TODAY’S

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FROM JAPAN’S N0.REVOLUTIONARY TOOLS

VF SERIESRoughing and finishing

tools with through coolant

Special ball nose geometrywith 220º cutting area

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V O L U M E X I N U M B E R 8 O C T O B E R 2 0 0 9

EUROPEAN TOOL & MOULD MAKINGAn Access Communications Inc. publication

Contract-published 9 times per year by SellersMedia

PUBL ISHER

Clay [email protected]

EUROPEAN AGENCY

SELLERSMEDIA*Otto-von-Guericke-Ring 3A, 65205 Wiesbaden, Germany

Tel: +49 6122 95590 • Fax: +49 6122 [email protected]

MANAGING DIRECTOR/EDITOR- IN-CHIEF

Douglas Sellers*[email protected]

OPERATIONS MANAGER

Robert Bonds*[email protected]

PRODUCTION, C IRCULATION & INFORMATION SERVICES MANAGER

Sylvia Zwick*[email protected]

GRAPHIC DESIGNER

Jason Sellers*[email protected]

Law Wai [email protected]

INFORMATION TECHNOLOGY SPECIAL IST

Markus Müller*[email protected]

SALES MANAGER EUROPE

Britta Solloway*[email protected]

ADVERTIS ING SALES FRANCE

Evelyne Gisselbrecht33 Rue du Puy-de-Dôme, 63370 Lempdes, France


REPRESENTATIVE AGENT FOR TAIWAN, CHINA & HONG KONG

Robert Yu, Worldwide Services Co. Ltd.11F-B, No. 540 Wen Hsin Road, Section 1, Taichung 408, Taiwan


NORTH AMERICA CORPORATE HEADQUARTERS30765 Pacific Coast Highway, PMB 351

Malibu, CA 90265-3643 USATel: +1 310 589-0066 • Fax: +1 310 457-7658

[email protected]

BUSINESS MANAGER

MiSook [email protected]

EDITORIAL CONTRIBUTIONS: Product/service information bulletins and press releases should besubmitted in English and should be accompanied by a colour photograph or transparency. Thepublishers assume no responsibility for return of artwork, photographs, or manuscripts. NOTICE:Every precaution is taken to ensure accuracy of contents; however, the publishers cannot acceptresponsibility for the correctness of the information supplied or advertised or for any opinionexpressed herein.

SUBSCRIPTIONS: European Tool & Mould Making is published 9 times per year, plus the supplementalEDM Europe Buyer’s Guide, and is distributed free of charge to qualified readers in Europe.

Nonqualified readers in Europe: US$100 (1 year), US$175 (2 years)Readers outside Europe: US$150 (1 year), US$275 (2 years)Single copies: US$25. Payments to be made in US dollars.

Subscription inquiries, back issues, address changes: send your request to EUROPEAN TOOL & MOULD MAKING

by e-mail to [email protected] or by fax to +49 6122 51090.

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Printed at: Kössinger AG, www.koessinger.de

Copyright © 2009 ACCESS COMMUNICATIONS INC. ALL RIGHTS RESERVED






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http://www.mitsubishicarbide.com



The metrology system manufacturerWenzel Group GmbH & Co. KG hasbeen training coordinate measurementtechnicians for many years. The grouphas now been certified for further edu-cation and training by the agency DQSin accordance with the AZWV officialGerman licensing standard.

The certification agency checked thecompetence of Wenzel’s trainers, inves-tigated the record of customer satisfac-tion, and appraised the equipment thecompany uses in conducting training.Its visit to the application-specific train-ing centres that house Wenzel’s state-of-the-art coordinate measuring machines(CMMs) and sensors confirmed theservice provider’s well-rounded ap-proach to training.

In addition to the training facilitybeing certified, the Wenzel practice ofqualification management and theprocesses relevant to its seminars werealso subjected to an audit.

These new higher-level qualifica-tions constitute an important basis forhelping customers innovate during dif-ficult economic times. Immediate plansare to continue training manufacturingcompany employees with support fromthe Federal Employment Agency ofGermany.

All Wenzel seminars are sponsored.The company has been one of the earli-est providers of supported seminarsdesigned to the standards of AUKOM(Ausbildung Koordinatenmesstechnike.V.), the German association that over-sees training in metrology.

The Wenzel Group has expertise inthe technology of CMMs, gear metrolo-gy, computed tomography, high-speed

German Employment Agency Supports Seminars inMetrology Conducted by Newly Certified Wenzel Group


Industry NewsIndustry News

measuring and digitizing systems, andreverse engineering.

With 17 subsidiaries worldwide andsales and service partners in more than50 countries, the company providesservice to customers in the automotiveand aerospace industries, mechanicalengineering, and electrical motor man-ufacturing, as well as subcontractors tothose sectors.

Wenzel Group GmbH & Co. KGWIESTHAL, GERMANY




http://www.mastercam.com/X4




The medical engineering market, in-creasingly important to the Germanmanufacturing sector, represents anattractive customer base that has faredrelatively well during the economicdownturn. Because it is highly innova-tive, it occupies a leading position inthe world market. It demands highquality from its suppliers, includingextreme precision and perfect surfacefinishes, along with high process relia-bility and traceability of all manufac-turing steps. All of these are strategicattributes of German manufacturingtechnology.

VDW (the German Machine ToolBuilders’ Association) finds this reasonenough to demonstrate the cumula-tive technological competence of theindustry at METAV 2010, its manufac-turing technology trade fair that willtake place February 23–27 in Düssel-dorf. Under the banner “Metal MeetsMedical,” suppliers serving the medicalengineering sector will appear withinthe framework of a special show to beintroduced at METAV.

“The machine tool industry has alot to offer to the medical engineeringsector,” suggests Dr. Wilfried Schäfer,executive director of the VDW. “That’swhy we want to provide an attractivespecial show at METAV 2010 for suppli-ers and their customers, an exhibitionwhere suppliers can highlight theirexpertise to their full advantage.”

In a highlight of the special show,Siemens will join with partners fromthe machine tool, tooling, and metrol-ogy sectors to present a “digital facto-ry” that covers the complete processchain for the production of medicaldevices and equipment. The conceptfocuses on integrated scheduling andimplementation of the basic produc-

tion steps to which the workpiece issubject, on the efficient use of re-sources, and on the standardizationand continuous improvement of pro-duction processes. In live demonstra-tions on the Siemens stand, saysKarsten Schwarz, head of applicationtechnology at Siemens AG, SectorIndustry, Drive Technologies, MotionControl Systems, several differentmachine tools will be employed tomachine products representing a vari-ety of medical-related technologies.

The aim is the optimized integra-tion of all components in a dynamic,

ultramodern process chain for the pro-duction of medical implants, prosthe-ses, instruments and devices. The les-son for visitors is that collaboration onan ongoing basis with competent part-ners results in the best planning quali-ty and reliability, prerequisites for thesustained control of complex productsand manufacturing processes.

The Metal MeetsMedical show will becomplemented by anexpert forum featur-ing informative lec-tures and roundtablediscussions coveringsuch topics as manu-facturing processes,technical and busi-ness conditions, andregulations and legis-lation governing med-ical manufacturing.

“More and moremanufacturing tech-nology suppliers whowant to expand theircustomer base areturning to the med-ical engineering mar-

ket,” says the VDW’s Schäfer. Theyoffer machines and tooling for theprocessing of high-strength materialsinto dental implants, bone screws,titanium nails, connecting pins, mini-ature pump parts, packaging-machinecomponents, and many other preci-sion technical parts.

“With our special event at METAV2010, we want to help all of them suc-cessfully address the needs of this mar-ket,” concludes Schäfer.

‘Metal Meets Medical,’ a Special Show at METAV 2010,Will Unite Machine Tool and Medical Engineering Sectors

METAV 2010DÜSSELDORF, GERMANY


Above: Karsten Schwarz,head of applicationtechnology at SiemensAG. Right: Themanufacture of hipjoints places greatdemands on theproduction technologyinvolved. The MetalMeets Medical show atMETAV 2010 willdemonstrate how thesedemands are met.


PHOTOS:SIEM

ENS

AGERLAN

GEN



http://www.cgtech.com



Mold-Masters Europa GmbHBADEN-BADEN, GERMANY


A 72-cavity 50 x 40-pitch mould recently introduced by iPET.

Mold-Masters Forms StrategicAlliance with Preform InsertManufacturer ABBA Systems

At the Drinktec 2009 trade fair, the hot runner specialistMold-Masters and preform insert manufacturer ABBA Sys-tems announced that they were combining forces to sellcomplete PET preform mould solutions under the brandname of iPET Systems. Using the resources, knowledge andmanufacturing capacity of both partners, iPET Systemsoffers new moulds, conversions, retrofits, refurbishments,spare parts and service from five manufacturing locationsand 40 sales and service offices worldwide.

Moulds and hot runners in the iPET line are directlyinterchangeable with existing PET mould platforms and fitin all makes of injection moulding machines. Available with2 to 192 cavities, iPET moulds are designed to offer preformmoulders new features and advantages, including a propri-etarily designed hot runner manifold that has less pressuredrop, fills more uniformly, and generates less preferentialshear stress than conventional gun-drilled manifolds. Thevalve gate has been purpose-engineered for moulding PET,and patented iCool technology enables iPET moulds to coolparticularly evenly and efficiently. These technologiestogether result in preform moulds that run fast, use littleenergy, allow for quick colour changes, run at low AA levels,deliver long uptimes, and are easy to service.

“We have recently spoken with a number of mouldersand machine suppliers about iPET, and they have beenextremely positive about our approach,” says Patrick Ben-nett, executive vice president of Mold-Masters. “The marketis looking for another global supplier of PET moulds, and webelieve that iPET will fill this need.”

http://www.plastpol.com




Sescoi International SASMACON, FRANCE


FIP 2009LYON, FRANCE


Sescoi Addresses a Growing Market by Participating in Regional Series of Die and Mould Seminars across India

Seconded by Exhibitors, Organizer of First FIP Trade Fair Held in Lyon Pronounces the Event a ‘Clear Success Story’

Sescoi is building on the success of itsWorkNC CAD/CAM system and enter-prise resource planning (ERP) solutionsin the Indian market by participatingin a series of regional die and mouldseminars organized by the IndianMachine Tool Manufacturers Associa-

The first edition of the French plasticsindustry trade fair FIP to take place inLyon was “a clear success story,”according to IDICE S.A., the event’sorganizer. FIP 2009, which was held inJune, brought together 406 exhi-bitors—almost 20% more than therehad been at Oyonnax in 2006—whosevote was essentially unanimous: theshow exceeded all their expectations.

This year’s FIP—along with the newvenue that hosted it—was popularwith event participants for a numberof reasons cited by IDICE. First, the5,837 visitors representing some 4,650

companies general-ly possessed a levelof decision-makingresponsibility thatall the exhibitors ap-preciated. About 9%of these high-levelbusiness profession-als came from else-where than Franceto attend. Also note-worthy was the factthat the number ofcompanies they rep-resented exceededthe 2006 total.

Exhibitors indicated that the num-ber of times they engaged with visitorsin consultations on short- to medium-term projects was a pleasant surprise.Indeed, some sales of equipment werenegotiated from start to finish at thefair. One company reported that it hadsold six machines over the four days ofthe event.

Finally, the Lyon venue was hailedby all for its accessibility, comfort, andconviviality. The general feeling wasthat holding the fair in the regionalmetropolis improved opportunities forprofessionals to meet their confreres.

tion (IMTMA). The fourth was held inHyderabad in late July. There, Sescoiexperts explained the cost advantagesof an automated CAD/CAM system toowners and engineers representing dieand mould companies based in south-ern India. They also outlined the bene-

fits of using an ERP system such asSescoi’s MyWorkPlan and WorkPlanEnterprise software.

In the latter presentation, a SescoiERP consultant explained how ERPsystems use historical and real-timedata to define the status of the factoryat any moment. He showed how man-agers can use an ERP system to ensurethat the price for a job is realistic, totrack job progress in order to ensureon-time delivery, to monitor job quali-ty, and to check for cost overruns. Fol-lowing the seminar, attending engi-neers visited the toolroom of a localcompany that had recently acquiredSescoi’s MyWorkPlan job managementsystem, to see the technology in action.

The success of the first four semi-nars has prompted the IMTMA toreplicate the sessions in other Indiancities in the future.





D-M-E EuropeMECHELEN, BELGIUM



D-M-E Europe Introduces 3D Library for Economy Moulds Programme

This past spring, D-M-E Europe intro-duced its economical Quick Ship Basicmould series. Now, this series is sup-ported by an easy-to-use download-able 3D library. A simple configurationhelps the user to select all of the 3Dparts of a complete basic mould quick-ly. D-M-E offers the range of 27 econo-my-priced moulds and the timesaving3D part library in order to help its cus-tomers achieve competitive advantage.

D-M-E’s off-the-shelf range of mouldcavity plates in stress-relieved 1730and Toolox 33 steels are available insizes of 156 x 156 to 446 x 596 mm.The Quick Ship Basic standard in-cludes not only the basic mould plates,but also alternative low-cost plates,including a broad range of P-plates.

D-M-E has been supporting mouldmakers, moulders and designers world-wide ever since it innovated the stan-dard mould base in 1942. Today,through aggressive new product devel-opment, global product standardiza-tion, and a combination of in-housemanufacturing centres of excellenceand strategic global partnerships, thecompany helps customers meet indus-try challenges. It offers a comprehen-sive line of hot runner systems, con-trol systems, mould bases and othercomponents, and mould making andmoulding equipment and supplies, allbacked by expert technical service.

The manufacturer of portable meas-urement and imaging systems Farohas appointed Lynn Brubaker to itsboard of directors. She brings to Faro30 years of experience in aviation andaerospace, 13 years of corporate boardexperience, and 4 years of experiencein advising multi-industry companies.

Her experience includes also fouryears as a member of the board of di-rectors of Hexcel Corp., a publiclytraded $1.2-billion multinational com-pany that manufactures advancedstructural materials and composite

Faro Names Lynn Brubaker to Its Boardstructures used in commercial aero-space, space and defense, electronics,and industrial applications. In addi-tion, Brubaker serves on the board ofthe Nordam Group, the largest privateaerospace company specializing inhigh-technology manufacturing andrepair, and she is actively involvedwith Graham Partners, a US privateequity firm focused on middle-marketmanufacturing companies.

Faro Europe GmbH & Co. KGKORNTAL-MÜNCHINGEN, GERMANY


Faro’s international headquarters in Lake Mary, Florida, USA.



http://www.rosmould.com



Industry News in BriefIndustry News in Brief

Ritemp Technologies Pty. Ltd.EDWARDSTOWN, AUSTRALIA


First Cut Prototype, a service of ProtoLabs, has recently added aluminiummachining to its Internet-based CNCmachined–parts service. Working froma 3D CAD model submitted by the cus-tomer via its FirstQuote interactive on-line quoting system, First Cut can sup-ply CNC-machined aluminium partsin one business day, just as it can dowith plastic parts. The First Cut serviceis offered as an alternative to additive

Alltec GmbH, a manufacturer of lasersystems for marking and coding, hasacquired Foba Technology + ServicesGmbH, a specialist in precision lasersfor marking and engraving. The legallyrecognized merger brings togethercompanies with more than 65 years ofcombined experience in laser markingand engraving. Foba will become part

Machined Aluminium Parts in One Day

Laser Marking Expert Alltec GmbHAcquires Foba Technology + Services

The cutting tool manufacturer Tunga-loy, headquartered in Japan, has re-structured its business completely inorder to cultivate the future marketeffectively. The company formerlyknown as Tungaloy Europe GmbH, forexample, has transferred its Europeanmarket activities to regional branchesthroughout several countries. At thesame time, the company headquartersin Langenfeld has become TungaloyGermany GmbH.

The newly established TungaloyGermany will be concentrating onserving the German-speaking marketsof Germany, Switzerland and Austria,and is recruiting an extended fieldsales force with which to do so. Thenew business approach should get afurther boost from the planned marketintroduction of innovative new prod-ucts this autumn.

Restructuring atTungaloy Europe

OGP UK Ltd.FOSTON, DERBYSHIRE, UK


Tungaloy Germany GmbHLANGENFELD, GERMANY


The Tooling TrustSOUTH CROYDON, SURREY, UK


First Cut PrototypeTELFORD, SHROPSHIRE, UK


OGP UK Ltd. has launched a new,more user-friendly website. The up-graded site (www.ogpuk.com) offersinformation about the company andits machines and multiprobe capabili-ties, along with metrology informa-tion and news. The improved structur-al design and look of the clean, morenavigable site should help visitors findexactly what they are looking forquickly. OGP customers will find regu-

OGP UK Launches New Website

Foba Technology + Services GmbHLÜDENSCHEID, GERMANY


The growing market acceptance of itspatented Ritemp™ mould cooling tech-nology has encouraged Ritemp Tech-nologies Pty. Ltd. of Australia to ex-pand its presence globally. This pastsummer, Ritemp’s technology enteredthe North American market via the ap-pointment of the Canadian companySWM & Associates as its representativeand strategic partner for the region.Ritemp Technologies has also namedUnimark, based in Mumbai and Ban-galore, as its technology partner forthe Indian subcontinent, and back inJanuary 2008, Matrix Technology Spe-cialists became the Australian compa-ny’s Asia technology partner. Now,Ritemp is in the final stages of securinga strategic partner in Europe in orderto complete its expansion of capabilityto the American, Asian and Europeanmarkets.

Ritemp ContinuesGlobal Expansion

The immediate aim of The ToolingTrust, which succeeds the Gauge &Toolmakers Educational Trust in thisrole, is to support training initiativesfor companies operating in the UK’sprecision manufacturing technologiessector. The organization’s ultimateobjective is to retain and develop theinherent strengths of the nation’smanufacturing sector. It supports ini-tiatives such as the GTMA YoungApprentice of the Year competition,designs courses for the gauge and tool

Tooling Trust Grants Support Trainingmaking sector, and conducts theGTMA Business Development Trainingprogramme. Recently, for example, thetrust helped GTMA member SolentMould Tools, a blow moulding tech-nology specialist, by defraying some ofthe cost of developing its sales andoperations manager’s theoretical skillsthrough his pursuit of further educa-tion in business management.

rapid prototyping processes. After thequotation is sent (typically hours afterthe model is received) and accepted,software automatically writes toolpaths for the company’s high-speedCNC milling machines.

The service involves no nonrecur-ring engineering charges.

of the Alltec Laser Business Unit, whichis the technology centre for laser mark-ing within the US-based DanaherCorp.’s Product Identification Plat-form. The acquisition of Foba providessynergistic benefits on both sides.

lar updates to the pages featuring casestudies, special applications, news, andevents. They can download productdata sheets for in-depth information.Further, they can use the site to re-quest a demonstration; an OGP salesstaffer will discuss how the companymight fulfill a measurement need.







A cooperation agreement signed bythe German tool and mould makerZahoransky Formenbau GmbH andthe US mould maker American Tool &Mold (ATM) means that the former’sUS customers and the latter’s Europeancustomers can now expect to receivefaster service.

The partners’ joint global networkand plants in the United States,Europe and India will make it possiblefor multinational companies to beserved with greater efficiency. ATMspecializes in precision high-cavitationmoulds, and also injection-mouldsparts and components.

Zahoransky specializes in multi-component moulds and system tech-nology for complete plants and equip-ment. The synergies made possible bythe cooperation can benefit every in-dustrial sector.

Zahoransky Partners with US Company

Zahoransky Formenbau GmbHFREIBURG, GERMANY



The ninth powder metallurgy (PM)summer school organized by the Euro-pean Powder Metallurgy Association(EPMA) took place in Kosice, Slovakia,this past June. Hosted by Dr. EvaDudrova and her team at the Instituteof Materials Research of the SlovakAcademy of Science, the weeklongcourse for 52 students from through-out Europe featured a programmecoordinated by Prof. José Manuel Tor-ralba of the University Carlos III ofMadrid with support from Joan Hall-ward of the EPMA.

Slovakian Academy Hosts EPMASummer School in Powder Metallurgy

European Powder Metallurgy AssociationSHREWSBURY, SHROPSHIRE, UK


To strengthen local support for cus-tomers in Central and Eastern Europe,Husky Injection Molding Systemshas opened a facility in Moscow thatwill provide refurbishment services forusers of PET (polyethylene terephthal-ate) moulds and hot runners through-out the region. The complete serviceoffering includes mould and hot run-ner inspection, mould and hot runnerdisassembly and assembly, cleaning ofmanifolds and moulding inserts, andmould shoe repair. Maintenance of in-jection moulding equipment helpssustain high product output levels andthus the profitability and competitive-ness of moulders.

Husky’s other refurbishing centresare in Canada, Luxembourg, China,Japan, Brazil and Mexico.

Husky Opens NewMoscow Facility

Husky Injection Molding Systems S.A.DUDELANGE, LUXEMBOURG



Leading academic and industrialexperts in PM technology gave presen-tations, led group discussions anddirected practical laboratory activity.The EPMA hopes to run another PMsummer school in 2010.

The EPMA, which is celebrating its20th anniversary this year, promotesthe use of the powder metallurgicalmanufacturing process as an alterna-tive to other production processes.

Meusburger Georg GmbH & Co KG | Standard moulds | Kesselstr. 42 | A-6960 Wolfurt

T 00 43 (0) 55 74 / 67 06-0 | F -11 | [email protected] | www.meusburger.com

Precise, stress relieved standard mould parts

Very high supply availability from stock

Accessories for electrical discharge machining

» Many different electrode blanks made of copper and graphite

» Head electrodes and square bars made from high-grade spark erosion graphite in various grain grades

Moldstick

» Mobile data storage device (2 GB) that can be mounted in the tool itself

» Made of sturdy industrial material; for the purpose of saving all kinds of tool-specific data

Pre-drilled insulation boards

» Extensive range of pre-drilled insulation boards

» For extremely quick disassembly of thetool

Products online underwww.meusburger.com/new-items

Shaping

steel.

Friedrichshafen (D)13.-17.10.2009Hall A2, Stand 2313

Frankfurt (D)02.-05.12.2009Hall 9, Stand C36



http://www.meusburger.com/new-items


http://www.meusburger.com




DEMAT GmbH, organizer of EuroMold2009, and the US consulting firmWohlers Associates Inc. will presentthe 11th annual international WohlersConference on additive manufactur-ing during the EuroMold trade fair inFrankfurt, Germany. Titled “The Futureof Additive Manufacturing,” this year’sconference will take place December 4.

In the past, this conference—chaired by Terry Wohlers (right), whose

yearly Wohlers Re-port provides aquantitative andqualitative analy-sis of new devel-opments in ad-ditive fabrica-tion technologyw o r l d w i d e —has covered thelatest trends inrapid product

development and addi-tive manufacturing (AM).This year, the confer-ence will look at howcompanies in the aero-space, defense, medicaltechnology, dentistryand other industries areusing AM systems tomanufacture high-quali-ty parts and products,including custom con-sumer products. Thefuture of AM applications will be theevent’s central theme, however.

Nine speakers, from Belgium, Eng-land, Germany, the Netherlands,South Africa and the USA, will addressconference attendees. All have beenasked by the conference organizers todiscuss the opportunities and chal-lenges of the AM field, as well as les-sons learned in applying the technolo-

gy to date. Attendeeswill learn when usingAM for part productionmakes sense and whenconventional manufac-turing methods are tobe preferred.

“EuroMold is said tobe the largest and mostimportant event world-wide on additive manu-facturing technology,”explains Dr. Eberhard

Döring, chief executive of DEMAT. “So,discussing its future is both fitting andtimely.” Döring calls the annual con-ference the “perfect complement” tothe fair, since EuroMold always in-cludes the top AM system and materialmanufacturers and service providers.

International Wohlers Conference at EuroMold 2009Will Focus on Future of Additive Manufacturing

Wohlers Associates Inc.FORT COLLINS, CO, USA


EuroMold NewsEuroMold News




http://www.etmm.info



Visit us inHall A1

Stand 1413

http://www.eberhard.de


ISTMAISTMA

The International Special Tooling &Machining Association (ISTMA) is awell-established international organi-zation representing some two dozennations’ special tooling and machin-ing organizations on three continents:North America, Europe, and Asia.

ISTMA Europe represents the indus-try in matters concerning industrialrelations in the European Union.Among its many activities, it conducts

a dynamic schedule of exchanges ontechnical subjects in the special tool-ing and machining sector; promotescommunication among its memberson a wide variety of industry concerns;maintains an information pool ontechnical investigation subjects; trans-fers performing management actionsamong its member associations; andsupports European fairs and exhibi-tions focusing on special tooling.

For information, contact:Mr. Fausto RomagnaniSecretariat, ISTMA Europec/o Cefamol · Av. D. Dinis 17, Aptdo. 2572430-263 Marinha Grande, PortugalTel. +351 244 575150 · Fax +351 244 [email protected]

CZECH REPUBLICTool Factories AssociationMr. Vaclav Klicka · [email protected] NastrojarenCeskoslovenske Armady 118156215 Usti nad OrliciTel. +420 465 557101 · Fax +420 465 525128www.svaz-nastrojaren.cz

ESTONIAEstonian Special Tooling AssociationMr. Andres [email protected] tee 1 · 74001 Viimsi vald, Harjumaa Tel. +372 620 5902 · Fax +372 620 5901www.emliit.ee

FINLANDTechnology Industries of FinlandMr. Veli Matti [email protected]äranta 10 · 00130 HelsinkiTel. +358 9 1923373 · Fax +358 9 624462www.techind.fi

FRANCEAFIM (Association Française desIndustries du Moule, Modèle et Maquette)Mrs. Catherine [email protected]/41 Rue Louis Blanc · 92400 CourbevoieTel. +33 1 47176412 · Fax +33 1 47176360www.afim-france.com

GERMANYVDMA Die and MoldDr. Wolfgang [email protected] Strasse 18 · 60528 Frankfurt/MainTel. +49 69 66031251 · Fax +49 69 66032251www.vdma.org

HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr. Sándor Markos · [email protected] u. 31/C · 1139 BudapestTel. +36 1 3402972 · Fax +36 1 3295425www.szmsz.hu

ITALYUCISAP (Unione Costruttori ItalianiStampi & Attrezzature Precisione)Mrs. Fausta Antinori · [email protected] Fulvio Testi, 12820092 Cinisello Balsamo (MI)Tel. +39 02 26255392 · Fax +39 02 26255214www.ucisap.it

LATVIALatvian Tool and Prototype ProducerAssociationMrs. Natãlija Ivanova · [email protected] str. 2c · Riga 1046Tel. +371 678 07794 · Fax +371 678 07780www.lipra.lv

POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr. Maksymilian [email protected], ul. Graniczna 1005-816 MichalowiceTel. +48 22 7233812 · Fax +48 22 7235201www.stts.com.pl

PORTUGALCefamol (Associaçao Nacional da Industria de Moldes)Mr. Manuel [email protected]. D. Dinis 17, Aptdo. 257 2430-263 Marinha GrandeTel. +351 244 575150 · Fax +351 244 575159www.cefamol.pt

SLOVENIAChamber of Commerce and Industry ofSlovenia (Metal Processing Association)Ms. Janja [email protected] 9 · 1504 Ljubljana Tel. +386 158 98308 · Fax +386 158 98100www.posvet-orodjarstvo.com

SOUTH AFRICAToolmaking Association of South Africa(TASA)Mrs. Alet Balaam · [email protected] Alexander Road, WestmeadKwazulu Natal · P.O. Box 661 · 3600 PinetownTel. +27 31 7005563 · Fax +27 31 7005562www.tasaweb.co.za

SPAINFEAMM (Federación Española de AsociacionesEmpresariales de Moldistas y Matriceros)Mr. Josep Font · [email protected] Tecnològic del Vallès, Ceramistes 208290 Cerdanyola del Vallès (Barcelona)Tel. +34 93 5944747 · Fax +34 93 5944737www.feamm.com

SWEDENSvensk Industriförening (SINF)Mr. Niklas Eidersjo · [email protected] 14, P.O. Box 22307104 22 StockholmTel. +46 8 4401170 · Fax +46 8 4401171www.sinf.se

SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr. Peter Vogel · [email protected] 4, 8032 ZürichTel. +41 44 3844811 · Fax +41 44 3844846www.swissmem.ch

TURKEYTool Manufacturers’ Association of Turkey (UKUB)Mrs. Solmaz Ugurlar [email protected] Karaer Cad. Cigdem 2 Sok. PK:41 DOSAB, BursaTel. +90 224 2615892 · Fax +90 224 2615893www.ukub.org.tr

UNITED KINGDOMGTMA (Gauge and Tool Makers Association)Mrs. Julia Moore · [email protected] Forge House, Summerleys RoadPrinces Risborough, Bucks HP27 9DTTel. +44 1844 274222 · Fax +44 1844 274227www.gtma.co.uk

Listing of ISTMA Europe Member Associations

http://www.svaz-nastrojaren.cz

http://www.ucisap.it

http://www.feamm.com

http://www.emliit.ee

http://www.lipra.lv

http://www.sinf.se

http://www.techind.fi

http://www.stts.com.pl

http://www.swissmem.ch

http://www.afim-france.com

http://www.cefamol.pt

http://www.ukub.org.tr

http://www.vdma.org

http://www.posvet-orodjarstvo.com

http://www.gtma.co.uk

http://www.szmsz.hu

http://www.tasaweb.co.za


http://www.istma-europe.com


The next meeting of ISTMA Europe is scheduled to takeplace in Göteborg (Gothenburg), Sweden, from November30 through December 1 in association with the 2009 Manu-future Conference (www.manufuture2009.eu). In fact, thismeeting of the European special tooling and machiningindustry’s umbrella association includes the benefit, for allISTMA members, of free participation in the three-dayManufuture Conference, whose theme this year is “Imple-mentation of a Sustainable European Manufacturing Indus-try.” The official host of the ISTMA Europe Meeting is NiklasEidersjö, president of Svensk Industriförening (SINF), theSwedish tool and die association.

The formal ISTMA Europe Meeting will be held onDecember 1 following the Manufuture closing session andlunch. Taking part in the full Manufuture Conference givesISTMA an opportunity to promote the sector while meetingand networking with other industrial professionals, policymakers and representatives of R&D centres.

The full Manufuture schedule includes workshops on theafternoon of November 30 and study visits to a selection ofSwedish industrial and R&D organizations the next after-noon. ISTMA members intending to bring a guest to Manu-future should make sure that the new person registers on theManufuture homepage, as attendance at the conference istechnically by invitation only. The invitation extended toISTMA members includes the Sunday evening reception,Monday dinner, and lunches on Monday and Tuesday.

Questions about practical arrangements and Göteborgcan be directed to Manuel Oliveira of the ISTMA Europe Sec-retariat ([email protected]) or Jan Larsson of SINF([email protected]).

Sweden Promises a WarmWintertime Welcome to ISTMA Meeting Attendees


Svensk Industriförening (SINF)STOCKHOLM, SWEDEN


http://www.thermoplay.com




Featured SupplierFeatured Supplier

As an economic alternative to grindingtechnology, the cutting-tool manufac-turer Tungaloy offers a variety ofhigh-performance polycrystallinecubic boron nitride (PCBN) andceramic cutting grades for hard-turning that enable most complexcomponents hardened up to 65 HRc tobe precision-machined. The manufac-turer’s successful BX cutting gradeseries is now extended by the intro-duction of the coated-PCBN BXC50and BXC30 grades that offer extremelylong tool life. Even at high cuttingspeeds, these new grades yield excel-lent surface quality and high dimen-sional accuracy in both continuousand interrupted cutting.

Short setup, dry-machining poten-tial, and high flexibility make hard-turning various workpiece profilesincreasingly attractive in applicationsranging from one-offs to batch pro-duction. Modern cutting gradesproduce surfaces better than 3μm Rz, ensuring high dimension-al and contour accuracy with verygood process reliability. With asophisticated service package of PCBNand ceramic grades, Tungaloy providessolutions to handle every machiningrequirement.

Many Grades and SubstratesWith the BX series, Tungaloy offers sixhigh-performance cutting grades thatdiffer in PCBN content and ceramicbinder composition. These have beenoptimized to meet the requirements ofturning hardened steel and other hardmaterials.

BX310 is a coarse-grained PCBNwith a special binder and relativelylow PCBN content. It is best suited forcontinuous cutting at high speeds.

BX330, meanwhile, is a fine-grainedPCBN with medium PCBN contentand a special binder. Suitable for con-tinuous to light interrupted cutting,this grade resists wear and providessuperior surface finish.

The medium-grained BX360 PCBNwith medium PCBN content, intendedfor light to heavy interrupted cutting,features high impact resistance. And

BX380, with a slightly higher PCBNcontent, is suited for heavy interrupt-ed cutting.

Cutting grades with low PCBN con-tent are employed only for finishingoperations involving continuous cut-ting at high speeds to 350 m/min. Asthe PCBN content increases, cuttingspeeds for continuous and interruptedcutting top out at 280 m/min.

Completing Tungaloy’s BX series,the versatile new coated-PCBN cuttinggrade BXC30 has a medium PCBNcontent that suits it for continuous tolight interrupted cutting, while BXC50offers high PCBN content with a spe-cial binder and can be used for heavyinterrupted cutting.

The perfect interaction of groundcutting edge and PVD coating enablesthe new coated-PCBN grades to handlemany different applications. Excellentwear resistance maximizes tool lifewhile allowing higher cutting speedsin both heavy interrupted and contin-

uous cutting, along with a fine surfacefinish. The TiN coating applied to theBXC30’s fine-grained substrate makesa very smooth cutting edge. This,along with the special wiper designand corresponding corner radii, opti-mizes workpiece surface quality andextends tool life.

Cutter MicrogeometryNext to choice of cutting grade, themicrogeometry of the insert’s cuttingedge is the most important factor inmaximizing productivity in modernhard-turning. The ratio of chamferangle to chamfer length can be manip-ulated to develop various cuttingforces. Because the passive force isresponsible for generating notch andcrater wear, this force should be kept aslow as possible.

The microgeometry of chamferangle and chamfer length representsenormous productivity potential. By

PCBN and Ceramic Cutting-Insert Grades Are Engineered to Provide High Productivity in Hard Turning

Top: Tungaloy offers a great variety of PCBN and ceramic cutting grades forprecision-machining complex components hardened up to 65 HRc.

Left: All cutting edges of the coated BXC50 insert are indexed to simplify use and save production costs.

modifying this aspect of the standard microgeometry, Tun-galoy optimally adapts its cutters to particular machiningprocesses to obtain productivity improvements as great as50%. An optimized chamfer surface combined with a high-performance insert coating enables users to take full advan-tage of the supplier’s superhard cutting grades.

A couple of cases exemplify the performance capabilitiesof Tungaloy’s coated-PCBN grades. In machining a specialtoolholder having a hardness of 62 HRc, a BXC30 insertexhibited a 66% longer tool lifetime than conventionalinserts while achieving excellent surface quality. Anotherexample is provided by the use of a BXC50 grade in turninga machine part in interrupted cutting mode, with the con-stantly changing lead angle between the insert’s cuttingedge and the workpiece making the operation difficult.Tungaloy’s negative four-corner insert generated a surfacequality of 2.0 μm Rz—much better than the conventionallyachieved 6.3 μm.

Another advantage of the BX series is its multicornerdesign, an economical alternative to the conventional one-corner design. Both negative and positive inserts are avail-able in the series.

Ceramics for Hard/Soft CuttingMachining of inductive or case-hardened workpieces maycause problems for PCBN and carbide cutting materials.Though the BXC30 grade shows good results for this appli-cation, for greater cutting depths Tungaloy offers the LX11TiN-coated, fine-grained ceramic cutting insert based onaluminium oxide with embedded TiCN. This grade allowsworkpieces with a hard/soft cutting zone to be machinedeconomically in one operation.

Tungaloy Germany GmbHLANGENFELD, GERMANY


The specific grade characteristics of the PCBN cutting materials BX310, BX330,BX360, BX380, BXC30 and BXC50 enable high-speed precision machining invarious continuous and interrupted cutting modes.

The smaller the PCBN substrate grain, the better the achievable surface quality.


http://www.hasco.com



Small parts that require deburring,edge blending or other surface fin-ishing can present manufacturerswith production challenges. Usinghandheld tools to perform intricatesecondary finishing off the produc-tion line can produce inconsistentresults, and slows productivity. Buteven when the process is fullyautomated, success—improvementin the part’s performance and lifespan—still depends on specifyingthe appropriate finishing brush forthe application. Making the rightselection of deburring tool oftenrequires engineering assistancefrom the tool manufacturer, ac-cording to Brush Research Mfg.Co. Inc., a firm that designs andproduces miniature finishingbrushes in an assortment of de-signs, sizes and materials.

Several types of miniature debur-ring brushes are available to meetthe productivity and quality chal-lenges involved in the manufacturingof small parts of various materialsand contours, including edge blendingand achieving tight tolerances. Thesebrushes vary not just in size but also in

filament type. Carbon steel, stainless-steel, brass, nylon and abrasive-fillednylon filaments, all offered by BrushResearch, are common. Abrasive-fillednylon can contain silicon carbide, alu-minium oxide or diamond abrasive.

Naturally, the brush choice is gov-erned by the nature of the applicationand such variables as contours re-quired, the material being worked, andthe amount of material to be removed.Factors that apply to brushes used in

automated applications includethe speed of the machine tool,feed rates, and the brushes’ op-timum wear life.

Brush Research manufacturesbrushes for bores upward of0.024 in. (0.6 mm) and varyingin length and tip style. Itsnewest brush, filled with dia-mond abrasive nylon, is de-signed to cut harder materials,perform rapid deburring, andlast a long time.

The company’s popular Flex-Hone® is also available in minia-ture sizes as small as 4 mm(0.156 in.). This ball-style honefeatures globules of abrasive gritpermanently laminated to theends of its nylon filaments. Thishone is about 95% pure grainabrasive at the point of need, soit can do an effective job.

The manufacturer recom-mends against using it forthreads, however; abrasive ny-

Brushes for Deburring and Finishing Small Parts: Proper Selection Can Enhance Manufacturing Productivity

TechnologyTechnology

The Flex-Hone is available in 8 different abrasive types and 11 different grit selections in diameters from 4 mm (0.156 in.)to 3.6 in. (91 mm) as standard. It is the preferred tool for applications with a bore size of 4 mm or greater.

Miniature deburring brushes range in both size and filament type. Filament choices include carbon steel, stainless steel, brass,nylon and abrasive nylon. Abrasive nylon brushes are available from Brush Research in silicate, silicon carbide, aluminiumoxide and now diamond, in diameters as small as 0.032 in. (0.8 mm). These tools are best suited for applications involvingtight tolerances, edge blending, deburning and other finishing requirements for bores as small as 0.024 in. (0.6 mm).


Abrasive Nylonnow in diamond

Stainless Steel

Flex-Hone® Tool

Brush Research Mfg. Co. Inc.LOS ANGELES, CA, USA


lon is better for removing burrs in such applications, andfor polishing thread peaks and flank angles, particularly intapped aluminium holes.

Thread processing can be automated, although at sizes of1/16 in. (1.6 mm) and smaller, cleanup by hand with anabrasive nylon or stainless-steel brush may be best. Small-diameter brushes are not usually rotated under power, sincethe brush stem wires may bend. A commercial series ofholders and pin vises is available that can grip such brushes.

Abrasive nylon brushes have gained in popularity. Nylonis not reactive, for one thing, so the brush imparts no car-bon impurities to the surface being worked. Also, nylondoesn’t oxidize. Nylon brushes are safer than wire brushes,because metal filaments can develop wire fatigue over time.

Grit selection is another important variable for whichthe supplier may have to provide technical support. Forexample, parts with very fine finish requirements may ben-efit from brushes with finer grit material. Hard materialssuch as ceramics and glass may require diamond grit. Butmetal brush filaments are often sufficient. Brush Researchoffers an all-stainless-steel brush in diameters down to0.024 in. (0.6 mm), which is effective for clearing chips fromholes or removing protruding and break-through burrs.

The choice of brush abrasive depends on the surface-finish specification or, sometimes, on whether greaterdeburring power than usual is necessary. The applicationmay involve a combination of requirements—say, cross-hole deburring plus attainment of a fine surface finish. Onebrush may not accomplish both. It may be best to use acoarse brush or Flex-Hone to remove the burr and then afiner brush to produce the required finish or contour.

Customers may have concerns about brush specification.Whether to automate the brush operation is a primary con-cern, although, argues Brush Research, most users quicklycome to see the benefits, in terms of productivity and con-sistency, of automating a process and avoiding the need forsecondary operations.

Offering such a broad selection of miniature brushes,Brush Research urges customers to consult its engineeringdepartment for answers to questions about operatingparameters. Parts needing deburring or finishing can besent to the company’s surface-finishing laboratory for

analysis. After this study and subsequent testing, BrushResearch offers suggestions on the optimal processing toolsfor the application and recommends operating parametersand, if required, surface finishing measurements.

For 50 years, this supplier has been solving difficult fin-ishing problems with technology for use in both generalindustrial applications and sophisticated environments.

Brush Research manufactures miniature brushes ranging in size from 0.024 to 0.500 in. (0.6 to 12.7 mm) in various filament types.



THE RIGHT CHOICE FOR MOULD DESIGNERS.

RENOWNED FOR EFFICIENCY AND PRICE!

STANDARD GUIDING ELEMENTS THATARE ANYTHING BUT STANDARD:

High-precision standard and special design guiding elements.

WWW.AGATHON.COM

AGATHON AG | CH-4503 Solothurnphone +41 32 617 45 01 | fax +41 32 617 47 [email protected] | www.agathon.com


http://www.agathon.com


http://www.agathon.com



In recent years, more and moremould and die makers have beentrying to avoid applying heattreatments to their finished toolsto enhance their wear resistanceand hardness. Responding to thisincreasing interest in avoidingheat treatments, steelmakers havebeen manufacturing and supply-ing harder, more-wear-resistantmould and die steels. The steelnow in the market that offers thehighest toughness and hardnessis Toolox 44 prehardened toolsteel from the Swedish steelmakerSSAB Oxelösund AB.

The benefits to mould and diemakers in not heat-treating theirtools post-machining are several.Obviously, costs will be lower anddelivery times shorter. Also, heattreatment poses a risk to materialproperty consistency that is betteravoided. And owing to the difficulteconomic conditions widely prevail-ing in manufacturing today, the situa-tion is more critical than ever. Mouldand die makers have to be especiallycompetitive in terms of their costs,and, crucially, they have to be able todeliver products with the fastest possi-ble turnaround, particularly sincemany tentative end customers areplacing orders belatedly.

Toolox 44 features a high hardnessof 45 HRc, excellent machinabilityowing to its low carbon content, andhigh homogeneity. But some customersexperience machining difficulties thefirst time they use this steel. The mostcritical operation has been deep-hole(or long-hole) drilling, also called gun-drilling. In mould and die making,deep-hole drilling is typically used to

create cooling channels in the tool.In an effort to discover procedures

for successfully performing deep-holedrilling in Toolox, SSAB collaboratedwith the tool supplier Botek and thedeep-hole drilling specialist firm RenéDevaux in a technical developmentproject.

After optimizing the drilling param-eters and the tooling, René Devaux didnot find the deep-hole drilling opera-tion too difficult to carry out. In onetest, five 12-mm-diameter holes weredrilled to a depth of 650 mm. No com-plications arose during this 3,250 mmof drilling, and the drill needed noresharpening.

Based on the test results, Botekoffered these comments on deep-holedrilling in 45-HRc Toolox steels: Gun-drilling operations can certainly beperformed in Toolox 44, but parame-

ters have to be adapted for each appli-cation. No vibration can be tolerated.Using coated tools made from theright type of carbide is extremelyimportant. Having the recommendedangle on the drill tip—not too sharp—is crucial. Pure drilling oil must beused; no mixture is acceptable. And,for holes deeper than 40 times diame-ter, the drill has to be supported.

The development of special steelsand of new parameters in toolingmarks the path of progress, but thetechnical know-how for capitalizing onthese innovations is crucial to successin using them. Collaborations such asthat of SSAB, Botek, and René Devauxshow how a total solution can befound and offered to end customers.

Machining at the Material Frontier: Deep-Hole Drilling Tackles the Toughest, Hardest Tool Steel on the Market

SSAB Oxelösund ABOXELÖSUND, SWEDEN


TechnologyTechnology



http://www.saglammetal.com



http://www.easymetal.com


mally bigger than a standard mould,and it requires, for instance, neitherthe usual platen enlargement norguide pillar extensions. Comparedwith an existing 16-cavity three-com-ponent mould with index platen, thenew SCPS mould exactly halved theplaten size and, hence, reduced themachine’s clamping force accordingly.

Control SystemThe entire control sequence of themould, comprising also the drives forall other injection units and the hotrunner control equipment—even thecore pullers, including the needlevalve—is now handled by the mould’sown, newly developed control system.All the movements in the mould areservo driven with thehighest positioningaccuracy, and inde-pendently of the ma-chine hydraulics.

Zahoransky Formenbau GmbH, aGerman producer of high-speed multi-component injection moulds, has de-veloped an entirely new and uniquefour-component mould concept anddesign. The process sequence of thismulticomponent mould differs sub-stantially from the previous designvariants with rotary-table, index plat-en, or stack turning technology. Theadvantage to plastics processors of thepatented new SCPS (servo cavity posi-tioning systems) mould technologylies in its suitability for use with con-ventional standard injection mouldingmachines withoutany extra equipmenthaving to be speci-fied by the machinemanufacturer.

Owing to itsconstruction,the four-com-ponent mouldis only mini-


A Four-Component Mould Concept Automates the Mould without Modifying the Standard Injection Machine

Special ReportSpecial Report

As Zahoransky Formenbau puts it,the innovation automates the mouldwithout modifying the standard ma-chine. This claim is applicable as wellwhen the mould is used on any otherinjection moulding machine.

All-electric injection units can bemounted on standard injection mould-ing machines as additional injectionunits. These, too, are managed via Za-horansky’s control system. Also, the hotrunner controls, those of the servo-driven needle valve, and the mouldmonitoring system can all be integrat-ed into the Zahoransky control.

Function SequenceThe mould opens after the pre-injec-tion-moulded parts are injected at sta-tion 1. Then, the parts are taken to thesecond injection station via a spindledrive, where they are finished and car-ried by spindle drive to the removalstation after the mould has opened. Ahandling unit takes charge of the fin-ished parts during the next injectionphase so that their removal requiresno extra cycle time.

The empty mould halves are hand-ed over to the nozzle side and, duringthe mould-opening phase, are carriedby means of a second spindle drivefrom the removal station to the pri-mary injection station (station 1). Themould closes, the cycle is completed,and a new process begins. During eachcycle, the pre-injection-moulded partsand the finished parts are injectedsimultaneously, and the finished partsare taken from the removal station.Just 3 seconds is needed for openingthe mould, carrying the mould insertsto the next station, and closing themould.

The new SCPS mould technologyreceives its first public demonstrationat Fakuma 2009. The dry-run exhibi-tion presents a four-component mouldwith removal station, the last stationoutside the mould. The parts are car-ried along to the next station in syn-chronization with the spindle drive.

Zahoransky Formenbau GmbHFREIBURG, GERMANYwww.etmm.info/2009/10/037



Established in 1994, OpenMind TechnologiesAG, a wholly ownedsubsidiary of Mensch undMaschine SE, is a leadingdeveloper of CAD/CAMsoftware and postprocessorsfor designing andmanufacturing complexmoulds and parts. Thecompany offers an extensiveselection of products, rang-ing from 2D feature-oriented solutions for mill-ing simple standard parts to software for complex 5axis simultaneous ma-chining, which are designedto fulfill the highest requirements of theautomotive, tool and mould manufacturing,mechanical engineering, medical, aerospace,and watch and jewellery industries.

hyperMILL®—the complete CAM solutionhyperMILL offers a comprehensive CAMconcept that integrates 2D, 3D, HSC, 5axismilling, and turning strategies, as well asspecial applications, under one uniform userinterface. This concept is supplemented byCAD software, CAD-integrated functions,CAD direct interfaces, and postprocessors that are developed to the specific needs of the individual user, so that the entire process

An efficient and all-encompassing CAM solution

HeadquartersGermany:Argelsrieder Feld 582234 WesslingTel.: +49 8153 933500Fax: +49 8153 933501Internet: www.openmind-tech.comE-mail: [email protected]

Branch officesUnited Kingdom:Open Mind Technologies UK LimitedJohn Eccles HouseRobert Robinson AvenueOxford Science ParkOxford OX4 4GPTel.: +44 1865 338026Fax: +44 1865 338100E-mail: [email protected]

Italy:Open Mind Technologies Italia S.r.l.Via Pomè 1420017 Rho (MI)Tel.: +39 02 93162503Fax: +39 02 93184429E-mail: [email protected]

France:Open Mind Technologies France SARL 1, rue du Baron ChouardBP 50056 Monswiller67701 Saverne CedexTel.: +33 388 031795Fax: +33 388 031776E-mail: [email protected]

Switzerland:Open Mind Technologies Schweiz GmbHZürichstrasse 258185 WinkelTel.: +41 44 8603050Fax: +41 44 8603051E-mail: [email protected]

chain can be handled from one source. Asimple and intuitive user interface, easy-to-useand graphically supported input masks, andRapid Result Technology allow for easylearning and operation. Feature technologyand a macro database, clear job lists, and drag-and-drop programming ensure that NCprogrammes are generated more quickly and efficiently than ever before.

The hyperMILL CAD integrations for Autodesk® Inventor® SolidWorks®,thinkdesign and the company’s ownhyperCAD® system, based on the think3®

kernel, make it possible to implementintegrated process chains. The CAD-integrated Open Mind solution has beencertified by Autodesk Inc. for use withInventor. Furthermore, Open Mind’s CADintegration hyperMILL in SolidWorks® is aCertified Gold Product.

The CAD and CAM systems always access the same data model. This guarantees morereliability throughout the entire process. Aseries of direct and standard interfaces are alsoavailable for hyperMILL. High-performancepostprocessors supplement this comprehensiveCAM concept. These postprocessors transferthe performance and quality of the CAMprogrammes to the controller and themachine by making optimal use of eachcontroller’s intelligence.

ADVERTISEMENT

Mirroring—symmetrical geometries can be copied very easily (above).Milling and turning strategies under one user interface (below).


http://www.openmind-tech.com







Case StudiesCase Studies


Such is the depth of cutting-tool appli-cation knowledge at Ceratizit that,when its engineers are invited to lookat a company’s metal-cutting prob-lems, the consequences can be far-reaching. JRG, a Swiss manufacturer offittings for water and heating with afacility in Sissach near Basel, has hadthe good fortune to discover this. Afterappraising the company’s situation,Ceratizit recommended use of its Maxi-Mill 211 milling cutters. Adoption ofthis milling concept has enabled JRGto recapture lost production time.

In Search of Lost TimeOwing to the number of specialisttools and work-holding fixtures re-quired to machine its water and heat-ing system fittings efficiently, JRG hasmaintained an in-house toolroom fa-cility. There are several reasons whythe company decided to develop andproduce special tools itself, explainsStefan Ochsner, head of the JRGmould and die production depart-ment. However, he notes, the decisivefactors are time and flexibility.

“Within the toolroom, we have thenecessary know-how to implementboth development and production ofspecial tools very quickly,” Ochsnergoes on to elucidate. “The employeesunderstand the materials that aremachined, the final product, and themachine tools, so we can make thingsimmediately, and the distances arevery short. Furthermore, we are in theposition to maintain the tools our-selves and to analyze production prob-lems immediately.”

The toolroom at JRG employs 40people, whose chief responsibility is toensure that tools are developed andconstructed rapidly. To help theseemployees achieve greater effective-ness in their optimization efforts,management at JRG invited Ceratizitto look closely at its operation in termsof the variety of cutting tools beingused and their application. Ceratizitsent help in the form of Robert Denny,the sales manager at Utilis, the Austria-based company’s Swiss distributionpartner.

“We had reached a plateau,and the pressure to increaseproductivity was rising,” saysOchsner. “Therefore, we had tomake changes that would keepthe department in good shape.This is why we investigated allour machining processes withthe help of Ceratizit’s cutting-tool specialists.”

Projects undertaken in themould and die sector are char-acterized by small batch sizesand short lead times. Mouldand die makers generally recog-nize that savings derived di-rectly from cutting-tool designand performance are minimal(even though cutting data andtool life are, of course, impor-tant factors to consider) andthat thus the greatest potentialfor optimization lies in econo-mizing within applications andin minimizing the variety ofcutting tools to be used.

In the past, JRG maintaineda diverse stock of cutting tools,which was responsible for a great dealof lost time. “We had to change thetools often, which led to machinedowntime,” remarks Stefan Ochsner.“Due to the numerous milling cuttersand inserts that we stocked, we werenot able to keep consistent data sheets.In addition, processing small ordersfrom all the different cutting tool sup-pliers sapped our resources.”

Simplification, SatisfactionFollowing an analysis of JRG’s cutting-tool inventory and tool-use pattern,Ceratizit suggested that the companyemploy its versatile new tooling con-cept, MaxiMill 211.

“The MaxiMill 211 milling conceptfulfills all our wishes,” Ochsner exults.“It is exactly what we need: a tool witha smooth cutting action suitable formultiple applications. The high-preci-sion manufacture of these milling cut-ters and inserts ensures that the cut-ting edges can be quickly changedwithout our having to adjust the tool,which means additional time savings.”

Ochsner continues: “By reducingthe number of tools that we stock, wecan now easily keep data sheets andshare our experiences within the team.So, trial and error is a thing of thepast.” Ochsner believes that attainingapplication optimization by means ofadopting the Ceratizit MaxiMill 211system was essential for JRG, observingthat it additionally proved that “youcannot simply swap cutting tools: youalso have to be able to use the newtool. It is here that the technical advicemust be appropriate.”

With the assistance of Utilis’ RobertDenny and the backup available fromCeratizit, JRG is now exploiting thefull potential of the MaxiMill cutters,using them extensively in a range ofroughing and peripheral milling oper-ations. In fact, through the use of opti-mized cutting data, even the olderCNC machine tools and conventionalmachines in the JRG toolroom areachieving high chip volumes.

A Cutting-Tool Supplier’s Applications Expertise Enables One Swiss Fittings Manufacturer to Cut Production Times

The high-precision manufacture of Ceratizit’s MaxiMill 211 millingcutter and inserts ensures that cutting edges can be changedquickly with no need to adjust the tool.

Ceratizit Austria GmbHREUTTE, AUSTRIA





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A major mobile phoneOEM that works withlarge Asian-based con-tract manufacturers hasexperienced problemsfrom time to time dur-ing production ramp-up that are caused byunstable moulding pro-cesses and longer-than-necessary cycle times.When this occurs, thecompany enlists theservices of AST Tech-nology GmbH, whichworks with the clientand its suppliers to re-solve the issues. AST’stooling design andmoulding process opti-mization services have saved this cus-tomer millions of euros.

The OEM’s senior technology man-ager reports that AST experts respondquickly in providing assistance to re-solve problems.

“They are providing support notonly in optimizing the moulding pro-cess,” says this manager, “but also inhighlighting areas of the part designand tooling design and constructionwhich have made significant improve-ments to part quality and cost.” Levelsof capacity and quality have improvedalong with cost-efficiency.

AST Technology specializes in com-prehensive services that are tailored tosupport OEMs with production tool-ing needs. The company’s serviceoffering includes component designfor manufacturing (DFM), standardtooling and engineering, mouldingprocess optimization, and assessmentsand training.

For example, AST’s DFM support forthe process of design developmentinvolves the provision of DFM reviewservices that comprise tooling andmoulding equipment, product costand capacity estimations, and custom

processes and templates.And its cycle time opti-mization (CTO) service isa standardized, systemat-ic approach to deliveringan optimized process forinjection mould tooling.This is performed at themoulder’s site, with aseries of defined steps re-sulting in savings in cycletime and reductions inpart defects and materialconsumption.

André Eichhorn, thegeneral manager of ASTTechnology, explains thatAST takes a fresh look atthe client’s unsatisfactorystatus quo and then ap-

plies a proven system to generate amore profitable process. The firm’stechniques have been deployed bothfor new moulds under developmentand to resolve production and qualityissues with existing components.

In the case of the mobile phoneOEM, cycle time reductions of 10 to40% for moulded parts were achievedwith AST’s help, equating to reduc-tions in piece-part prices of 5 to 20%.

AST can play a large part in imple-menting customers’ tool standards.Satisfied clients praise AST for apply-ing value engineering and reengineer-ing to achieve significant cost reduc-tion and make the tool standard moresensible to produce; for maintainingand refining the CAD automation sys-tem and maturing the tool design sys-tem; and for simplifying the mouldbase solution to make reuse easier. Theservice provider also supports theclient’s supply base by assisting withapplication-related tooling solutions.

An OEM that cannot justify main-taining a full-time staff of experts inevery area can access AST’s expertiseon an as-needed basis. The on-demandsource can deliver significant benefitswhere they are most needed: in designfor manufacturing, tooling optimiza-tion or process improvement.

Experienced Support Services Provider Saves OEM Moulder Millions of Euros Through Optimization of Tooling Design

An AST technician works with an OEM moulding supplier to find ways of improving its work flow.

Standardized and controlled tooling that resulted from AST’s consultations with the OEM mould supplier.

AST Technology GmbHHERFORD, GERMANY




http://www.pagev.org.tr

http://www.tuyap.com.tr

http://www.plasteurasia.com




The AE Group provides ready-to-assemble aluminium die castings andcomponents primarily to automotivemanufacturers and their suppliers. Itreports that quality requirements forthese pressure die castings—pressure-tightness, oil-tightness, and freedomfrom porosities—are always increasing.Variable wall thickness and overlongflow distances, which reflect the prac-tical limits of this die-casting technol-ogy, commonly result in unacceptableporosities in the castings.

In 2005, quality issues traceable tovarying wall thicknesses associated

with long flow paths prompted the AEGroup to investigate the LaserCusingtechnology developed by ConceptLaser GmbH. This fibre-laser-basedmetal-powder fusion process can beused to create large components layerby layer from 3D CAD data. It is a com-pletely automatic process; no operatoris required.

Successful test runs convinced AEGroup specialists that die cores fusedfrom metal powder were at least asdurable as the inserts the companyhad previously produced with conven-tional technologies. Thus, in 2006, the

group invested in a Concept Laser M3linear industrial laser machine with abuild envelope of 300 x 350 x 300 mmand a modular design, which it foundideally suited for use in aluminiumpressure die-casting. The M3 linearbuilds cores from fused-powder layerstypically 20 to 50 μm thick. The com-pany now utilizes LaserCusing as astandard technology for preventingproblems caused by wall thickness var-iation and long flow paths.

LaserCusing’s strength, as AE sees it,lies in optimizing component quality.It enables the company to produce a

cooling system in the tool insertclose to the shaping-surface con-tours—a system designed toaccelerate cooling of the moltenaluminium—that minimizes thephenomenon of porosity causedby shrinkage in the finished cast-ings. Consequently, scrap rateshave been halved and cycletimes reduced in almost all cases.

The AE Group produces diecores for series production from atough, 48-HRc hot-work steelusing a hybrid constructionmethod. The lower part of thetool is produced in the conven-tional way, while LaserCusing isemployed for the die core withits close-to-the-forming-surfacecooling channels. This procedurereduces manufacturing times byas much as 80%.

Laser Technology Used to Create Optimized Tool Insert Cuts Scrap Rates in Die-Casting Applications

A part insert formed by LaserCusing incorporated into a tool cavity for the test run.

A pump housing in series produc-tion illustrates the benefits LaserCust-ing technology brought the AE Group.Unacceptable porosity was showing upafter machining of the pump chamberjacket in 8 to 10% of the components.In a test run, the forming tool wasoptimized with a LaserCused insertwith close-contour cooling in the con-choid of one core cavity. Producing acore ready to be finished and insertedinto the tool took just a few hours.

When used to pressure-cast parts, thetool with the hybrid core insertreduced local shrinkage porosity andoptimized heat transport, as intended.The scrap rate was more than 50%lower than before. Encouraged by this,the AE project team readily decided toequip all four tool cavities with Laser-Cused part inserts.

A cost-benefit analysis pitting extrapump-housing tooling costs requiredby the innovative inserts vs. savingsfrom scrap reduction found that just1% less scrap would have been suffi-cient to offset the additional expense.



Concept Laser GmbHLICHTENFELS, GERMANY


Left image: The test-run tool cavity without the part insert made via LaserCusing.Right image: The test-run tool cavity with the part insert made via LaserCusing.



http://www.pmssystems.com



Case StudiesCase StudiesVMCs for Machining EDM Electrodes Ensure That Even Low-End Swiss Watches Can Support a Cultural ReputationFor every high-end Swiss watch brandthere is a mass-market product thatrelies on suppliers like the family-owned precision engineering firm—and Haas Automation customer—Pierre Bercher S.A. These relatively low-cost timepieces may not be as covetedas Piquets or Pateks, but they trade ontheir Swiss-ness just as much as theirpur sang cousins. And they, too, tell thetime well.

Bercher S.A. makes plastic parts forsome of Switzerland’s best-knownwatch brands, though Pierre Bercher,the company founder and CEO (photobelow), would rather not discuss hiscustomers. He prefers to talk abouthow his company makes what it

makes. Several of its CNC machinetools from Haas constitute an impor-tant element of his facility setup.

“Seventy percent of our work is forSwiss watch companies,” says Bercher.“Typically, these companies want fastturnaround and the peace of mindthat comes from knowing that theirsuppliers know what they are doing.”Another important reason that theycontinue to use local companies isthat, naturally, people would not wanta so-called Swiss watch that was madein China, even if it were a low- or mid-

price brand. It’s very much aboutprovenance.

Most Swiss watchmakers operate inwhat the country’s tourist office callsWatch Valley: a narrow corridor thatstretches from Geneva north to Basel,along the arc of the Jura mountains.Bercher S.A. is based in Cernier, nearthis zone and strategically well situat-ed to serve the in-dustry’s big names.

The company’sworkshop is dividedin two by a wall ofwindows. On oneside of the glass are17 Arburg plastic-injection moulding

machines. The space on the other sidecontains a variety of manual and semi-automatic machine tools, along withthree Haas CNC machines. Two of thelatter are 15,000-rpm Haas VF-2 verti-cal machining centres (VMCs). Each ofthese is flanked by an Agie Spirit die-sinking electrical discharge machine(EDM) in a pairing that makes a self-contained cell. The Haas machinesproduce copper electrodes used by theSpirits to make the steel moulds thatare employed on the Arburg mouldingmachines.

“The moulds we make on the AgieEDMs are complex,” explains PierreBercher, “so we often need multipleelectrodes to produce the desired form.The shape of the electrode is, in part,that of the object to be moulded. Eachelectrode is machined in copper,which is why we chose the Haas VF-2swith 15,000-rpm spindles: because the

material is relatively soft and yet weneed to achieve and maintain highprecision and excellent surface finish.”

Electrode walls are often machinedto a thickness of less than 0.5 mm andto heights of 5 to 6 mm, which meansthat they can easily burn or break up.

Bercher S.A. has been able to pro-duce runs approaching 1 million plas-tic parts from a single steel mould.Says Bercher, “Over the course of a typ-ical year, we may make as many as 40moulds and produce up to 14 millionfinished parts. Runs of a million or lessare small numbers for one or two ofour customers, which is why they pre-fer to source them from outside.”

Forty moulds a year may not soundlike much machining, but the com-plexity of some moulds calls for the


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application of more than adozen copper electrodes, andsome electrodes take hours todesign, let alone the machin-ing time.

“With a die-sink EDM,there’s an electrical impacton the electrode but no con-tact with the workpiece,”says Bercher, “so an electrodelasts quite a long time. Evenso, it’s rare that we’ll reuseone.” Customers will changetheir designs frequently, heexplains, because their prod-ucts tend to be thought of asfashion accessories instead of“investments.”

The other Haas machinetool in the Bercher workshopis an Office Mill OM-2 with a30,000-rpm capability. Thiscompact unit is presided overand operated by Dan Bercher,Pierre’s son (photo, right).

“This is our latest machinetool investment,” says Bercher

père. “It’s a great small machine withexcellent accuracy and capabilities. Weare using it to make even smaller elec-trodes with wall thicknesses of as littleas 0.3 mm.”

As with most of the parts his com-pany makes, explains Pierre Bercher,the customer supplies a 3D CAD file,from which Bercher S.A. generates aprogramme for the electrodes via Vir-tual Gibbs computer-aided manufac-turing (CAM) software (this is Gibb-sCAM as marketed in Europe).

“It’s a powerful combination,” saysBercher, referring to the Haas machineand the GibbsCAM software. “With its30,000-rpm spindle, the Haas OM-2machines perfect surfaces.”

Why spend more? the CEO asksrhetorically before going on to answerthe question.

“A Haas costs an awful lot less thansome alternative machines, but it doesthe job just as well.”

Haas Automation Europe N.V.ZAVENTEM, BELGIUM



http://www.euromold.com



Significant developments are evidentin the latest releases of the range ofCAD/CAM software solutions avail-able from Planit Software Ltd. Planithas enhanced its metalworking soft-

The new American-built VF-12 verticalmachining centre (VMC) from HaasAutomation is designed to easily ac-commodate large-volume ma-chining requirements of theaerospace, automotive, andmould and die industries. Itsmassive cast-iron construc-tion, triangulated wide-stancecastings and heavy-duty out-riggers prevent flex anddampen vibration in orderto ensure high accuracyand consistent repeatability.High-productivity options includelinear scales for extremely precise posi-tioning, high-pressure through-spindlecoolant, 4th- and 5th-axis drives, high-speed-machining software, and a wire-less probing system.

The VF-12 VMC features x-y-z trav-els of 150 x 32 x 30 in. (3,810 x 810 x760 mm) and has a 150 x 28-in (3,810x 710-mm) T-slot table. It is availablein both 40- and 50-taper configura-tions, with spindle speeds to 10,000rpm. Standard equipment includes aside-mount tool changer, a chip auger

ware packages for 2010, includingAlphacam and Edgecam for prismaticand cylindrical machining and Radanfor sheet material, to keep pace withadvancing manufacturing industry

demands. With each release, Planit’sdevelopment teams focus on ensuringthat each software package provides itstargeted users with the functionalitythey need to get the most from theirmachine tools and work as efficientlyas possible.

Recognizing that software develop-ment is as essential to its customers’business as to its own, Planit has engi-neered the new releases of Alphacam,Edgecam and Radan to deliver indus-try-leading CAD/CAM performanceand functionality.

The latest industry reports releasedby CIMData show that Planit contin-ues as the world’s fastest-growingCAD/CAM supplier and has the largestinstalled user base.

New Releases of Industry-Leading CAD/CAM Solutions forMetalworking Keep Pace with Manufacturing Demands

Products & ServicesProducts & Services

Planit Software Ltd.ASHFORD, KENT, UK


Haas Automation Europe N.V.ZAVENTEM, BELGIUM


Extra-Large VMC with Many High-Productivity Options Can Accommodate Voluminous Monolithic Parts

system, a programmable coolant noz-zle, rigid tapping, a 95-gal (432-l) floodcoolant system, and a 15-in. (380-mm)colour LCD monitor with USB port.

The 40-taper VF-12 comes equippedwith a 20-hp, 7,500-rpm vector dual-drive spindle that provides 102 Nm oftorque. A 24+1-tool tool changer isstandard, and a 40+1-tool changer isavailable. A 10,000-rpm spindle can besupplied for high-speed work, and atwo-speed geared-head spindle thatyields 339 Nm of torque is available in

7,500- and 10,000-rpm configurations.The 50-taper version has a 7,500-

rpm geared-head spindle that provides610 Nm of torque for heavy cutting; itis powered by a 30-hp vector dual-drive system that features on-the-flywye-delta switching for a wide con-stant-horsepower band. A 30+1-toolchanger is standard, and a 10,000-rpmgeared-head spindle is available.



Vero Software plc, a providerof CAD/CAM and CAE solu-tions for the tooling industry,now offers the latest releaseof its flagship CAD/CAMsoftware, VISI 17. Develop-ments in this version furtheremphasize end-user produc-tivity in all aspects of design andmachining. Also, the system graphicshave been dramatically improvedthrough collaboration with AMD andNvidia.

A key CAD enhancement in Version17 of VISI is model thickness analysis,which lets the user quickly identify thethickest and thinnest areas of themodel and validate the model’s in-tegrity. Other advances in CAD includeintelligent body/face mating, im-proved annotation, updated printing,and numerous improvements in draw-ing-file management. Significantly,pages from other work files can nowbe imported and the solid geometrylinks rebuilt, facilitating collaborativework on one 3D design by multipleusers at separate workstations.

CAM developments include en-hancements to geometry feature rec-ognition. Complex and simple holeson both solid and surface models canbe recognized, as can features viewedfrom a predefined direction and fea-tures within a localized, user-definedregion. In addition, the separation ofpasses and linking increases productiv-ity and reduces calculation time. The

Vero Software plcCHELTENHAM, GLOS, UK

www.etmm.info/2009/10/049www.etmm.info/2009/10/050

user can now inspect the tool path forquality before going on to build high-speed-machining linking movements.In addition to CAM engine develop-ments that save valuable calculationtime, VISI 17 introduces incrementalstock, automatic tool-path tilting, andfurther improvements to multiaxismachining.

Developments in VISI Flow includeenhanced integration of plastic-flowtechnology into a real CAD environ-ment. VISI Mould benefits from theVISI Flow integration by virtue of theinclusion of a combined material data-base containing data on more than7,000 materials. The dedicated VISIProgress module for the metal-stamp-ing industry has been updated viadevelopment focused on complexmultistep forming for deep-drawncomponents.

Finally, a new collaboration withCADENAS, the largest external libraryof 3D standard components and nowintegrated into VISI 17, benefits usersof both VISI Progress and VISI Mould.

Flagship CAD/CAM Suite in Its 17th Major Release Boosts End-UserProductivity through Many Innovations




Reflecting its investment in develop-ing FeatureCAM feature-based ma-chining software since acquiring it in2005, Delcam plc is launching a newversion of the software at EMO thatincludes enhancements across the fullrange of its functionality, from 2Ddrilling and wire EDM to 5-axis mill-ing and mill-turn operations.

FeatureCAM was the world’s firstfeature-based programming system. Itshigh degree of automation always hasmade programming in FeatureCAMfaster than in other CAM systems.Now, enhancements in the 2010 ver-

Expandable mould cavities have beenemployed as a custom mould-building

solution for years. Now, ProgressiveComponents, a supplier to

the global productiontooling indus-

try, has released the Ex-Cav™ series ofexpandable cavities as standardizedoff-the-shelf components. The Ex-Cav,designed for moulding undercuts lo-cated under the part surface, such asbarbs and protrusions, is offered infour sizes ranging from 20 to 50 mm.

Expandable cavities simplify moulddesigns by eliminating the need

for complex side-actionassembl ies .

They help moulders to save money byreducing mould width and maximiz-ing cavitation. In addition, their com-pact design enables smaller mouldbases and a smaller press to be used.

The Ex-Cav standard comes in twomounting styles, with CAD geometryavailable to facilitate integration intomould designs. All Ex-Cavs can beordered with moulding details alreadymachined. When special configura-tions are required, custom compo-nents in this series can be supplied.

sion make the software even quicker.The most important of these devel-

opments is support for multithreadingin the generation of 3D tool paths.This allows calculations to be spreadacross multiple cores in today’s in-creasingly popular dual- and quad-corecomputers. Average time savings arearound 25% on a dual-core PC.

Improved algorithms within theuser interface accelerate the editingof features and switching betweenmachine tool setups, while greaterefficiency in handling stock modelsreduces memory requirements.

The most innovative new program-ming option is combined drilling andmilling functionality that makes holecreation on machines fitted with auto-matic tool changing more efficient. Itgenerates roughing and finishing toolpaths to produce any holes for whichthe appropriate drill is not loaded byutilizing tooling already within themachine’s crib. Benefits of this optionare available even to companies whosemachines do not have automatic toolchanging.

Other new options include spiralfinishing, which results in a better sur-face finish with no dwell marks, andautomatic rest roughing, which mini-mizes air-cutting when a series of pro-gressively smaller roughing cutters isapplied. In addition, improvementshave been duplicated from PowerMillto provide faster machining and bettersurface finish, and simulation hasbeen made faster and more accurate,particularly for simultaneous 5-axismachining.

Finally, the range of postprocessorsavailable with FeatureCAM has beenextended for both 5-axis and mill-turnequipment.

Feature-Based Software That Automates Programming of Several Types of Machine Offers Enhanced Speed, Capabilities

Standardized Expandable Mould Cavities Enable Tool Buildersto Simplify Mould Designs and Shorten Lead Times

Delcam plcBIRMINGHAM, UK


Progressive Components Europe Ltd.MIDDLETON, MANCHESTER, UK






Portable measurementand imaging systemsare constantly beingdeveloped by Faro, aspecialist company andworld leader in themanufacture of suchequipment as coordi-nate measuring ma-chines (CMMs), meas-urement arms, and laserscanners. The equip-ment allows high-preci-sion 3D measurementsand 3D comparisons ofparts and complete sys-tems to be made in pro-duction and quality as-surance contexts. Farosystems are used for inspection, align-ment, calibration, reverse engineeringand as-built documentation.

Measurement systems that Faro hasbeen exhibiting at recent trade fairsthis year include the Faro Gage person-al CMM, the Quantum, Platinum andFusion measurement arms, the FaroLaser ScanArm, the Faro Laser Tracker,

Machining honeycomb-type workpieces placessome special demands onclamping technology. Nei-ther conventional clamp-ing methods nor vacuumsystems are able to createideal conditions for the 3Dmachining of such parts.Freeze-clamp technology,however, has gained in-creasing acceptance forclamping filigree and hon-eycomb workpieces. HorstWitte Gerätebau Bars-kamp KG has developedthe Mobile ice duo freeze-clamp system specificallyfor this purpose.

The system works withtwo chucks at one time.While one of the chucks is

involved in the working process, partscan be prepared on the second chuck.The clamping, or freezing, of work-pieces takes about 30 seconds, and re-lease via thawing is effected in aboutthe same length of time.

To clamp parts, the user moistensthe chucks with a little water manual-ly, then places the part and freezes itby activating a switch. Temperature isthen continuously monitored, ideallyat –10°C.

System supply components, such asthe refrigeration compressor, coolanttank, circulation pumps, and so on,are housed in an 800 x 800 x 1,500-mm cooling unit. The Mobile ice duounit is equipped with casters to facili-tate its use with multiple machines.

and the Photon laser scanner.The Gage is a high-precision port-

able 3D CMM with a working range of1.20 m and measurement accuracy of±0.005 mm (±0.0002 in.). A variety ofattachment options make it possiblefor the unit to be deployed rapidlyeither on the shop floor or in a pro-cessing centre. With the PowerGage

model, components canbe measured and in-spected on the basis ofCAD data, as well.

The flexibly deploy-able FaroArm 3D meas-uring system meets thehigh accuracy require-ments of developmentand production process-es. The FaroArm 3Dmeasures, digitizes orperforms a completeCAD-component analy-sis right in the produc-tion area or duringproduct assembly.

Like the Gage andthe FaroArm, Faro’s

Laser Tracker—which uses a laser beamto measure the 3D coordinates of largecomponents, machines and otherequipment—can be utilized across abroad range of machine tool–relatedapplications.

Versatile Measurement and Imaging Systems with Portability Are Easy to Use in Production and Quality Assurance

Clamping System Uses Ice to Hold Workpieces for Machining

Faro Europe GmbH & Co. KGKORNTAL-MÜNCHINGEN, GERMANY


Horst Witte Gerätebau Barskamp KGBLECKEDE, GERMANY






Schott Systeme GmbH hasincluded parallel processingfunctionality within Picturesby PC 3.4 CAD/CAM andtechnical documentationsoftware, the latest release ofits flagship product. This inno-vation can reduce tool-pathcalculation times up to 60%.As machining strategies be-come more complex, especial-ly for high-end 5-axis simulta-neous milling and engravingtechniques such as Schott Sys-teme offers, tool-path calcula-tion naturally takes longer.However, company developersrecently rewrote Pictures by PCto ensure that the latest 32-and 64-bit versions can parallel-process tool-path calculations.

By dividing tool-path processingamong several cores in a computer’s

CPU, the software gains instant accessto the extra processing power offeredby dual- and quad-core PCs, powerthat is totally transparent to the user.

Schott Systeme cites imme-diate speed gains of 30–50%for its 32- bit version run-ning on a dual-core proces-sor, and anticipates gains asgreat as 60% when Picturesby PC runs on a quad-core.This lets users realize imme-diate savings on every jobmachined—without chang-ing the way they work.

Parallel processing capa-bility complements SchottSysteme’s previous innova-tion of background calcula-tion, which makes it possi-ble for users to calculatecomplex tool paths whilesimultaneously working on

other parts within a different drawing.

Introduction of Parallel Processing FunctionalityDramatically Shortens CAM Tool-Path Calculation Times

processing. MoldMAX mould materi-als with special surface coatings areavailable for applications requiringgreater wear resistance.

MoldMAX copper alloys are avail-able in several hardness ranges, eachoffering a distinctive level of thermal

conductivity. Mold-MAX can be sup-plied with a typicalmaximum hardnessof HRc 40. Maxi-mizing the thermalconductivity of themoulding systemminimizes cycletimes and enablesthe moulder to real-ize the highest pos-sible productivity.Often, MoldMAXhas sufficient inher-ent surface hardnessto resist any wear orabrasion effect im-parted by the inject-

The MoldMAX family of copper-basedalloys supplied by Brush Wellman areprocessed so as to be able to providethe optimal combination of hardnessand thermal conductivity for each of avariety of possible injection and blowmould tooling applications in plastics

ed resin or the mould parting line. Inhigh-wear applications, however, suchas when glass-filled resins are mould-ed, or in a high-contact shutoff area,use of a mould coating may be advis-able. The appropriate type of coatingwill increase wear resistance measura-bly and thus enhance the service lifeof the mould.

Various coatings can be used toenhance the surface characteristics ofplastic-injection or blow mould tool-ing. They can be applied in order toimprove wear resistance, corrosionresistance, or mould release properties.Also, in mould repair or recoatingapplications, they can extend thetool’s service life.

An understanding of the parametersof the particular moulding operation isfundamental in deciding whether tocoat a mould and, if so, which type ofcoating to employ.

Surface Coatings for Copper-Alloy Mould Materials Enhance Tool Wear Resistance, Improve Productivity


Schott Systeme GmbHMUNICH, GERMANYwww.etmm.info/2009/10/055

Brush Wellman GmbHSTUTTGART, GERMANYwww.etmm.info/2009/10/056



sterilized for medical device or surgicaljigs and fixtures. And ABS-M30i, likePC-ISO a biocompatible material suit-ed for medical, food and pharmaceuti-cal equipment industry applicationswith ISO 10993 or ethylene oxide ster-ilization requirements, offers muchgreater tensile, impact and flexuralstrength than Stratasys’ previous ABSformulation.

Stratasys offers four new build materi-als, plus an additional, performance-enhanced soluble support material,that are compatible with its Fortus900mc™ 3D production system for di-rect digital manufacturing (DDM) oftools such as jigs and fixtures and ofend-use parts in low volumes. TheUltem 9085, PC-ABS, PC-ISO, andABS-M30i DDM and rapid prototyp-ing materials more than double thenumber of materials available for usewith the Fortus 900mc. Other Stratasysmaterials compatible with the ma-chine are ABS-M30, polycarbonate(PC), and the polyphenylsulphonematerial PPSF/PPSU.

The new prototyping and produc-tion materials, which feature suchwide-ranging mechanical propertiesas flame, smoke, and toxicity (FST)compliance, heat resistance, medicalsterilization capability, strength, andflexibility, make the Fortus 900mc asolution for more-advanced DDM andprototyping applications in the aero-space, medical technology, and otherindustries.

Ultem 9085, a SABIC material, is astrong, flexible, lightweight thermo-plastic widely used in aircraft interiorsand other transportation applications.Heat resistant to 320°F (160°C), it isfully FST compliant and offers a highstrength-to-weight ratio.

The industrial thermoplastic blendPC-ABS provides the same strengthand heat resistance as Stratasys’s PCmaterial but more flexibility. Featuringhigh impact and flexural strength andhigh-temperature tolerance, PC-ISO isa tough polycarbonate that can be

Four New Production Materials Extend the PrototypingCapabilities of a Direct Digital Manufacturing System


Stratasys GmbHFRANKFURT/MAIN, GERMANYwww.etmm.info/2009/10/057



http://www.toolflo.com





Quick-change colletchucks in the newDHP 52 and DHP 65series feature a power-ful pull-back action tosecurely and accuratelyclamp components onmachine tool work-tables. These compactDHP-series chucks nowavailable from work-holding and machin-ing equipment special-ist Kitagawa EuropeLtd. handle compo-nents up to 52 mm andup to 65 mm in diame-ter, respectively. Suit-able for first-operationwork, they come stan-dard with standard A5, A6 and A8mounts to suit all popular types ofmachine tool.

DHP 52 models provide a maxi-mum grip force of 94 kN and can be

used at machining speeds to 6,500rpm, while the larger DHP 65 unitsachieve up to 105 kN of grip and fea-ture a maximum operational speed of6,000 rpm. Kitagawa has designed these

chucks to be compat-ible and rapidly inter-changeable with otherpopular 52- and 65-mm quick-change col-let clamping heads,and to not require spe-cial-purpose adapters.The new DHP-seriesdevices can also be fur-nished with an option-al collet-changing de-vice to ensure thatchangeover will be fastand effective.

Collets for KitagawaDHP-series chucks areavailable for compo-nents down to 4 mmin diameter and in 0.5-

mm increments up to the maximumcapacity of each model.

Pull-Back Quick-Change Collet Chucks Provide Secure,Accurate Component Clamping on Machine Tool Worktables

M&H machine tool probe integrationwith PC-DMIS NC for CNC machinetools being considered among themost significant.

The core product of the EMS suite isPC-DMIS CMM, which is used primari-ly on automated coordinate measuringmachines (CMMs) of the HexagonMetrology group and other brands. InPC-DMIS 2009, it offers functional and

Wilcox Associates, a Hexagon Metrol-ogy company, has released PC-DMIS2009 CAD-based metrology software.PC-DMIS 2009 is a family of softwareproducts covering a variety of metrolo-gy hardware platforms and solutionssubsumed under the enterprise metrol-ogy solutions (EMS) concept. It intro-duces enhanced versions of PC-DMISCMM and PC-DMIS Vision software,and premieres two new products, thePC-DMIS Planner and the PC-DMISReporting Suite.

The 2009 edition of PC-DMIS is notan incremental release of the softwarebut rather the culmination of develop-ment projects lasting years. Accordingto the developer, it represents thetightest integration yet of the productsuite. It also brings together new hard-ware categories that have been addedto the Hexagon Metrology group sincethe last major release of PC-DMIS, the

visual improvements across theboard. A new feature is ProtectedMode Execution, a run-only modewith password protection againstediting or changing of the pro-gramme or reports.

New visual programming en-hancements are another highlightof this release of the software. PC-DMIS 2009 additionally offers en-hanced geometric dimensioningand tolerancing (GD&T) supportfor all standard GD&T calculation

methods. Newly introduced measure-ment capabilities for noncontact 3Dlaser probes include the display of laserstripes, measured features, and meas-ured points. Laser hole and coneauto–feature measurement has alsobeen added.

Capabilities of Measuring Software Are Enhanced by Features in Tightly Integrated New Release

Kitagawa Europe Ltd.SALISBURY, WILTS, UKwww.etmm.info/2009/10/059

Hexagon MetrologySTUTTGART, GERMANYwww.etmm.info/2009/10/060




Adjustable-Height Blast-Cleaning Cabinet Lets Operators Clean Components in Maximum Comfort

Guyson International Ltd.SKIPTON, N YORKS, UKwww.etmm.info/2009/10/061


O p e r a t o r scan adjust theSelect via afloating pedalto obtain themost comfort-able height interms of armaccess, viewingposition, andfoot pedal loca-tion. Workingin an optimized

standing positionhelps reduce userfatigue and thus

enhance pro-ductivity.

A m o n gthe numerous

options for tailor-ing the standard pro-

duct to specific workenvironments are armrests

The Guyson Select variable-height blast cleaningcabinet, which is in-tended for multioper-ator workshops andproduction sitesand is now avail-able from GuysonInte r na t iona lLtd., was designedto promote opera-tor comfort andproduction effi-ciency. The operatorcan adjust the cabinet’sheight electrically or manu-ally to suit, eliminatingthe need to stoop oroverreach. The elec-trical version fea-tures 300 mm of verti-cal adjustment potential, while themanual hydraulic option offers 158mm of travel.

fitted to enlarged armholes equippedwith extra-large gauntlets, whichenable the blast gun and componentsto be maneuvered more easily insidethe chamber. Components can be ro-tated under the blast stream from aModel 400 or Model 900 gun on anoptional turntable. Special lightingdesigned to reduce glare and shadowsis available, as is a cat-flap cabinetoption that allows smaller compo-nents to be loaded and unloaded with-out letting blast media escape throughthe larger doors.

The Guyson Select is available asthe Select 4 and Select 6, with internalcabinet dimensions of 800 x 540 x 715mm and 1,050 x 740 x 880 mm, re-spectively. Suction- and pressure-fedoptions are available, and all systemscome complete with a dust collector.


http://www.tagmaindia.org



The Hüller Hille NBH machine brandfrom MAG represents a long traditionof robust and productive horizontalmachining centres. Now, MAG offersthe proven quality of this series in avertical main spindle. The NBV 400vertical machining centre (VMC) isthe first model of the new NBV series

to be introduced. Apart from its smallfootprint, this machine’s most strikingcharacteristic may be its modulardesign. It can be configured with afixed table for 3-axis machining, witha tilting a-axis table for 4-axis machin-ing, with a rotary/tilting c-on-a-axistable for simultaneous 5-axis milling,

or with a c-on-a-axis table for 5-axismill-turning at 1,000 rpm.

The NBV centre is capable of ac-commodating a wide range of machin-ing requirements in die and mould,aerospace, medical technology, generalmachining, and job shop applications.Linear guideways on the x-, y-, and z-axes provide good machine dynamicsindependent of the weight of theworkpiece. This results in traverse ratesup to 60 m/min and acceleration ashigh as 6 m/sec2 for high-performancemachining and high productivity.

Innovative design has eliminatedhydraulics and hydraulic oil from thisVMC. Tools are clamped by means ofdisk springs and unclamped pneumat-ically, a feature that minimizes operat-ing costs and energy consumption.Other NBV-series innovations includea fast pickup-type tool changer andenergy monitoring.

Many of the new machine’s corecomponents are provided by Corcom,MAG’s technology group for precisioncomponents.

Energy Efficiency Is One Benefit of a Modular VMC That Can Be Configured for 3-, 4-, or 5-Axis Machining


MAG Europe GmbHSTUTTGART, GERMANY



Specializing in tooling and service so-lutions for complex machining tasks,Gühring oHG is introducing a varietyof cutting tools this autumn, includingthreading tools, milling cutters, ream-ers, and drilling systems. The compa-ny’s programme of drilling tools fea-tures three innovations this season.

The RT 100 T spiral-flute deep-holedrill is available from Gühring as astandard tool for drilling depths up to40 times the hole diameter, beginningthis October. Even in drilling holes ofthe maximum depth, the user enjoysconsiderable cost-efficiency with thistool, which is capable of very highfeed rates and cutting speeds.

Gühring’s new solid-carbide preci-sion microdrill with internal cooling isanother autumn premiere that offers

extremely high feedsand cutting speeds.Two models are pro-vided for producingholes of 3 mm in di-ameter and less. Oneis capable of depthsup to eight times di-ameter, and the othercan drill as deep as 15times the diameter ofthe hole.

Gühring has com-pletely revised its HT800 WP indexable-insert drilling systemprogramme. New ge-ometries for inserts and holders pro-vide new opportunities for efficientdrilling using an indexable-insert tool

in the diameterrange of 11 to 25.99mm. Because therevamped HT 800WP system is com-pletely compatiblewith the holdersand inserts withwhich users of theprior system havebecome familiar,the advantages ofthe new system arereadily available tothose who haveworked with thelegacy system.

Programme of Deep-Hole Drills and Microdrills Combines High Performance with Economy in Complex Operations

Gühring oHGALBSTADT-EBINGEN, GERMANYwww.etmm.info/2009/10/063





Mountains 5.1 surface imaging andanalysis software, the latest version ofthe solution Digital Surf SARL offersfor all surface metrology instruments,contains powerful new features for 3Doptical microscopy, for dimensionalanalysis of 2D component geometry,for dynamic statistical analysis of sur-face parameters, and for evaluation ofthe statistical capability of the manu-facturing/fabrication system to repeatitself. In addition, the new versionexploits current multicore and 64-bittechnology to accelerate analysis, andincludes video tutorials to optimizethe learning curve for first-time users.

Imaging and analysis of multichan-nel topography (Z), colour (RGB) andintensity (I) information acquired with

The German clamping device manu-facturer Hainbuch GmbH SpannendeTechnik offers a new generation ofsegmented mandrels for series produc-tion. The design of these Mando seg-mented mandrels makes replacementof old mandrels convenient; the con-nection geometry, length, end stop,

and segmented clamping bushingsremain the same. To switch from oldHainbuch technology to the newrequires changing neither the zeropoint nor the NC programme.

New with Mando is the air-sensingcontrol. And so are the optimizedinner workings, which have been

adapted to matchthe current Hain-buch product look.The air supply con-trol provides greaterprocess reliability,longer machine runtimes, and longermaintenance inter-vals. Despite this,the new Mandostandard mandrelsare no more expen-

sive than their predecessors.Hainbuch offers the Mando man-

drel system in two variants, one withthe air-sensing control system in-stalled and one merely prepared forsuch a system. The latter is fully com-patible with the Hainbuch modularsystem and can be changed over to theair-sensing control system in 2 min-utes via an optionally available thread-ed adapter. Thus, a customer need notpuzzle long over the question whetherto purchase a mandrel with or withoutan air-sensing control system; thechangeover later to the new systeminvolves only changing the adapterwith a simple tool, not purchasing anew mandrel.

3D confocal microscopes is providedby new Z-RGB-I functionality inMountains 5.1. All three kinds of in-formation can be manipulated simul-taneously, for example when zoomingin on a surface feature. Also, true-colour and intensity information canbe superimposed on 3D topographicalheight information.

Dynamic statistical analysis ensuresthat statistics are updated whenever anew sample is measured in a produc-tion environment; an analysis tem-plate that is applied automatically toall samples in the measurement datapopulation, including the new sample,makes it easy to monitor the trend of

surface parameters so as to ensure thatupper and lower tolerance limits arerespected. Analysis in 4D of the evolu-tion of 3D surface parameters—a fea-ture unique to Mountains—has beenenhanced so that the T-axis (for time,temperature, magnetic field or someother fourth dimension) can store non-linear information. Intelligent dimen-sional analysis of component geometryis provided by the optional MountainsAdvanced Contour module.

The new release is available free ofcharge to all users of Mountains 5.0.

Software for Multichannel 3D Surface Microscopy,Accelerated Surface Analysis, and Enhanced Statistics

Upgraded Standard Segmented Mandrels Now Include an Air Supply Control for Improved Process Reliability


Digital Surf SARLBESANÇON, FRANCE


Hainbuch GmbH Spannende TechnikMARBACH/NECKAR, GERMANYwww.etmm.info/2009/10/067

Mountains 5.1: multichannel information about a surface’s (left to right) topography, colour and intensity.

The new-generation Mando mandrel is available in two variants: with an installed(left) or prepared (right) air-sensing control system.



The high-performance Picomax 825Versa™ 5-axis machining centre fromFehlmann AG Maschinenfabrik hasbeen developed from the ground upfor the high-precision five-side or 5-axis machining of larger workpieces.Among its notable features are a sturdyportal design, a tilting rotary tableintegrated along the x-axis, and opti-mized ergonomics. Uses include tooland mould production and the manu-facture of precision parts for mechan-ical engineering, automotive, aero-space, defense, medical technology,and other applications.

Precision linear guides with directtravel-measurement systems in allaxes, broadly supported guide blocks,and ball screws all help to deliverhigh feed rates and acceleration forextremely precise high-speed cutting(HSC). The FEM-optimized machinestructure of gray cast iron featuresthree-point support, and mountingsurfaces are shaved to create the bestpossible geometries. Optimum damp-ing and homogeneous thermal con-ductivity further contribute to themachine’s high geometrical precisionand great rigidity.

Fehlmann AG MaschinenfabrikSEON, SWITZERLAND


The rigid tilting rotary table of thePicomax 825 Versa has dynamictorque drives, mechanical clamps, anddirect travel-measurement systems onboth axes. With three carriages perguide rail, it can take loads up to 350kg, and can handle parts with palletsizes up to 400 x 400 mm or diametersto 560 mm. The machine’s 5-axissimultaneous processing capabilityincludes high dynamics and a large,230° tilt range (±115°). The centre canbe equipped with zero-point clampingsystems supplied by any of severalmanufacturers.

The heart of the Picomax 825 Versais the low-vibration, high-concentrici-ty Fehlmann HSC motor spindleoffered either at 14,000 or 20,000 rpmwith an HSK-A63 taper or at 30,000 or36,000 rpm with an HSK-E50 taper.Other standard machine features are atool changer with room for 44 tools upto 130 mm in diameter, a stainless-steel-lined workspace, good accessibili-ty for manual or automated loading,and a Heidenhain iTNC 530 control.



High-Performance 5-Axis MachiningCentre Has Tilting Rotary Table

http://www.mastip.com





Designed for use in dynamic controlapplications that involve short cycletimes, the R-Series Ethernet Power-link linear-position sensor is an addi-tion to the portfolio of absolute, non-contact sensors for real-time feedbackincluding EtherCAT interfacing thatMTS Sensor Technologie GmbH &Co. KG has developed.

Conscious of the pricepressures created bythe current economicsituation and of theongoing drive to re-duce manufacturingcosts, WNT has intro-duced its new PluslineMastertool range of solid-carbidedrills to supplement and enhance theexisting Mastertool range.

Where Mastertool drills are offeredin 0.1-mm increments over the fulldiameter range of 3–20 mm, and comein many diameter-to-length ratios, thenew economy line consists of fewer,but the most popular, diameters andonly two standard drill lengths—threeand five times diameter—in solid andthrough-coolant formats. The smaller,more-selective Plusline range allows

the manufacturer to increase produc-tion volumes and pass the lower unitcosts on to its customers, primarilysmall to medium-sized subcontractors.

Users of Plusline drills will see per-formance equivalent to that offered bythe earlier product line. Typical cut-ting data for a 9.8-mm-diameter 5xDdrill with through coolant, drilling a1.7225 (42CD4) steel, include a feedrate of 80 m/min at 0.22 mm per revo-lution (depending on the material spe-cification, machine tool, and setup).

The full range of Plusline Master-tool drill sizes has been designed tocater to most common drilling appli-cations. While these drills are normal-ly supplied with whistle notch shanks,users in the UK tend to prefer Weldonor cylindrical shanks. Consequently,those configurations have been madea standard feature of the PluslineMastertool range.

A resolution of 1 μm is possible overdistances of 25 to 20,000 mm. Positionand velocity measurements can beprovided for up to four locations onthe sensor in order to ensure optimumcontrol even in driving very complexmultiposition tasks.

The Temposonics R-Series Power-link sensors can easily be integrated

into networks by means of the Power-link V2 open protocol with an M12connector in star topology. The IPaddress can be entered through thesoftware or manually via DIP switchesintegrated into the sensor head. Thus,the sensor can be incorporated intothe network without further program-ming. The programmable logic con-troller identifies the sensor by meansof XDD files and accesses its parame-ters as needed. Diagnostic LEDs in thesensor head convey visual Ethernetcommunication and sensor operationstatus to service personnel.

Various housings are available tosuit different applications, includingan aluminium profile for externalmounting on the motion axis. Fordirect installation in the hydrauliccylinder, a stainless-steel measuringpipe inserts into the open piston rod.Also offered are models with a flexiblemeasuring rod or with detached elec-tronics for limited-space applications.

Linear-Position Sensor Supporting Ethernet Powerlink Is Designed for Dynamic Control Applications

Economical Line of Carbide Drills Consisting of Popular Sizes and Formats Offers Strong Cutting Performance

MTS Sensor Technologie GmbH & Co. KGLÜDENSCHEID, GERMANY


WNT (UK) Ltd.SHEFFIELD, UK




http://www.ewikon.com






http://www.moldmasters.com

http://www.hasco.com


http://www.dme.net




http://www.braunform.com



http://www.ctma.com/2010




Agathon Ltd. 21

AST Technology GmbH 28

Braunform GmbH 55

Brush Research Mfg. Co. Inc. 20

Brush Wellman GmbH 38

Ceratizit Austria GmbH 26

CGTech Ltd. 8

CNC Software Inc. 7

Concept Laser GmbH 30

Cumsa 27

Delcam plc 3, 36

Die & Mould India 2010 41

Digital Surf SARL 44

D-M-E Europe 11, 53

Easymetal GmbH 23

Eberhard GmbH & Co. KG 15

EuroMold 2009 33

European Powder Metallurgy Association 13

European Tool & Mould Making 14, 59

Ewikon Heißkanalsysteme GmbH & Co. KG 51, 52

FAKUMA 2009 48

Faro Europe GmbH & Co. KG 11, 37

Fehlmann AG Maschinenfabrik 45

FIP 2009 10

First Cut Prototype 12

Foba Technology + Services GmbH 12

Friedrich Freek GmbH 50

Gühring oHG 42

Günther Heisskanaltechnik GmbH 55

Guyson International Ltd. 41

Haas Automation Europe N.V. 32, 34

Hainbuch GmbH Spannende Technik 44

Hasco Hasenclever GmbH + Co. KG 19, 53

Hexagon Metrology 40

Horst Witte Gerätebau Barskamp KG 37

Hotset Heizpatronen und Zubehör GmbH 60

Husky Injection Molding Systems S.A. 13

Institut für Kunststoffverarbeitung (IKV) 55

ISTMA Europe 56

Kalip Istanbul Mould Fair 2009 43

Kistler Instrumente AG 51

Kitagawa Europe Ltd. 40

MAG Europe GmbH 42

Mastip Technology Ltd. 45, 50

METAV 2010 8

Meusburger Georg GmbH & Co. KG 13, 54

Mitsubishi Carbide 6

Mold-Masters Europa GmbH 9, 52

MTS Sensor Technologie GmbH & Co. KG 46

OGP UK Ltd. 12

Open Mind Technologies AG 25

Planit Software Ltd. 34

Plast Eurasia 2009 29

Plastpol 2010 9

PMS Systems Ltd. 31

Progressive Components Europe Ltd. 2, 36

Ritemp Technologies Pty. Ltd. 12

RosMould 2010 11

Saglam Metal A.S. 22

Schott Systeme GmbH 38

Sescoi International SAS 10

SSAB Oxelösund AB 22

Stratasys GmbH 39

Sulzer Metaplas GmbH 54

Svensk Industriförening (SINF) 17

Tekis Teknik Erozyon Kalip Sanayi Ve Ticaret A.S. 35

The Tooling Trust 12

Thermoplay S.p.A. 17

Tool-Flo Mfg. Inc. 39

Tungaloy Germany GmbH 12, 18

Türk + Hillinger GmbH 5

Vero Software plc 35

Wenzel Group GmbH & Co. KG 7

WNT (UK) Ltd. 46

Wohlers Associates Inc. 14

Zahoransky Formenbau GmbH 13, 24

Company IndexCompany IndexCOMPANY PAGE NO. COMPANY PAGE NO.COMPANY PAGE NO.

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