cutting edge - danobatgroup´s customer magazine

DANOBATGROUP, boosting productivity through sustainability

DANOBAT, projects that revolutionize sectors

SORALUCE achieves the highest precision, productivity and reliability levels in milling, boring and turning.

SEPTEMBER 2013

Dear reader,We are delighted to present to you the irst issue of Cutting Edge Magazine, a DANOBATGROUP initiative for sharing with you our latest projects and innovations developed in

close collaboration with our customers.

On this occasion, you will have the unique opportunity to

read real customer testimonies about different cases of cutting edge projects developed hand in hand with them.

DANOBATGROUP has a long track record of offering turnkey solutions to worldwide featured customers. Each project is taken as a new challenge where new developments will be

implemented to bring real solutions and create value for the customer.

In this issue, we will also share our knowledge of the latest state of the art technologies and processes developed at our own Research & Development Center. Applied research and technological innovations that are created to meet our

customers’ needs and to go beyond market requirements.

Likewise, you will ind a section dedicated to one of the existing worldwide challenges; sustainability. DANOBATGROUP has already been working for many years on sustainable production systems by implementing

new measures to improve energy eficiency, looking for new solutions to the scarcity of resources and preventing emissions, and developing new smart systems to improve

the quality of machine operations.

We will also take this opportunity to invite you to visit our

different manufacturing solutions at the main world trade fair for metalworking technology, EMO 2013. Aware of the importance of this exhibition, this year we have made a major effort to showcase the latest and most outstanding products over more than 1700 square meters arranged by technology on four different stands. This way, DANOBATGROUP is setting itself out as one of the industry leaders by showcasing our new capabilities and our commitment to high technology

in a wide range of technologies.

DANOBATGROUP

EDITORIAL

© DANOBATGROUP 2013. This document is not a contract. DANOBATGROUP reserves the right of making changes to all models without prior notice. The illustrations in this magazine remain property of DANOBATGROUP.

content

From Germany to

Germany; the local addedvalue through

DANOBAT-OVERBECK and

BIMATEC SORALUCE

Boosting productivity

through sustainability

DANOBAT & LUCCHINI,the perfect partnership for the most advanced railway

axle line

Ultraprecision

DANOBAT grinding and

turning machines

SORALUCE milling-boring and vertical turning

machines

04 |

07 |

10 |

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DANOBAT sawing, drilling

and 3D plasma cutting machines

LATZ cutting tools

SORALUCE SL-8000 A well designed machine:

ergonomics and user

friendly

SORALUCE VTC-3200 When versatility improves

productivity

BEL VALVES enjoys signiicant savings since installing a DANOBAT

vertical band saw

DANOBAT VG: a machine

to speciically meet the high metal removal

rates and ine tolerances required

DANOBAT HG-92; all in one single machine

18 |

19 |

20 |

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24 |

26 |

28 |

DANOBAT NA horizontal

lathes to get the required

precision levels

SORALUCE FXR-16000 Precision, productivity and

reliability.

A speciic example, the results obtained at MPC

SORALUCE F-MT 4000 Multitasking, lexible and dynamic

MONDRAGON

Corporation receives the“Boldness in Business”

prize awarded by the

Financial Times and

Arcelor Mittal

OPEN HOUSES 2013; Latest developments and

technologies on-site

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35 |

36 |

39 |

DANOBATGROUP

Outstanding Projects

Humanity @ work

Open House News

EMO 2013 Highlights

CONTENT

SEPTEMBER 2013

German customers are some of the most demanding in the world, not just

for technology but also as regards quality, reliability and precision. They

insist on only highly reliable, top-end

products, and their service requirements

are equally rigorous. So, for many years now, DANOBATGROUP has ensured

it can provide an accessible local

service with highly qualiied staff and a suficient response capacity to meet customers’ needs, able to complement

and customise its products to fulil all expectations (compliance with German regulations, inclusion of German accessories, manuals and machine

controls in the home language, etc.). We

offer a genuinely local and trustworthy service.

DANOBATGROUP provides the utmost

guarantee and is a benchmark for success in Germany, offering highly reliable products with cutting-edge

technology, eficient customer service, and, particularly, with a large enough staff to make waiting time unnecessary, highly

qualiied and able to solve any problem customers may have or any technical

incident that may arise.

DANOBATGROUP has been committed

to this market for a long time, investing major resources to guarantee success.

After more than 20 years working in Germany together with our subsidiary

From Germany to Germany; the local added value through DANOBAT-OVERBECK and BIMATEC SORALUCEGermany is Europe’s leading manufacturer, consumer and exporter of machine tools,

and has been the top destination for DANOBATGROUP’s sales for many years. For a

company to be successful in the German market, its brand name must be well-known

and acclaimed in this country.

company BIMATEC SORALUCE, we are now leaders in the German milling

machine market, with over 1000 SORALUCE milling-boring machines installed at the facilities of more than 500 customers, including the main German

multinationals (Alstom, Siemens, BMW, etc.). In 2012 we consolidated this position by opening a new extension to our Limburg plant, with investment of 6.2 million euros. This new showroom will give customers a irst-hand view of the range and capacities of SORALUCE milling-boring machines.

Also, in late 2002, DANOBATGROUP took over the German company

OVERBECK GmbH, greatly enhancing the brand image of DANOBAT grinding machines in this key market, facilitating access to the German decision-making

centres and their area of inluence in Eastern Europe and opening up new

market niches. The complementary

nature of DANOBAT’s products has enabled it to extend its range, with mutual beneit resulting from technology exchange and joint R&D investment. As regards customer support, our increased

presence all over Germany has enabled

us to offer a more accessible qualiied technical service, increasing the offer of products from the Elgoibar plant in Spain.

In total, the two German factories employ around 10% of all DANOBATGROUP staff.

DANOBAT-OVERBECK

Q: What is the main distinguishing

feature of DANOBAT-OVERBECK?

Josu Tornay: DANOBAT-OVERBECK is a machine tool developer and

manufacturer specialized in high precision internal grinding machines.

Applications span from single part to volume production across a wide

range of industry sectors, such as bearings, cutting tools, gears, and so

on. However, ‘internal grinding’ does not adequately convey the lexibility of machine tools that are also capable

of external and face grinding, radius grinding, and, in the case of the IED range, simultaneous machining of internal and external diameters. But our main characteristic is the ability to meet

the customer’s speciic requirements even in very speciic applications. We use a modular machine concept for our design as a basis, which is completed

with a speciic design work on each machine in order to be able to design

the one-off “especials” as well.

Each DANOBAT-OVERBECK machine is built on a standard natural granite

base and is equipped with linear motors.

However, the machine coniguration, while making use of standard elements, will be different, depending on the application and the customer’s individual

preferences.

DANOBATGROUP

Q: 90 years of history have gone a long way. How do you assess the evolution of the company?

Josu Tornay: Nowadays, due to the

OVERBECK’s extensive applications experience we specialize in providing a complete tailor made solution

within the shortest possible lead time

and at a competitive price that will

satisfy every customer’s demand for accuracy, repeatability, ease of use and increased productivity. This is veriied in stringent machine trials that take

place in our factory prior to delivery and commissioning, with full traceability of every aspect of the machine build and test sequence. Customers are secure and know that the machine will be

subject to extensive testing and that even in the newest concepts, the performance is guaranteed.

The modular concept, which makes use

of common elements across a range of machines contributes to long-term machine reliability and maintainability

which is especially important in

applications involving high quality inish machined components direct to an

assembly line.

This emphasis on quality is relected in the fact that almost a quarter of the workforce is devoted exclusively to machine design and software development, with R&D initiatives made

in close cooperation with our DANOBAT

colleagues at Elgoibar, Spain.

Q: How does the customer value the closeness of the company?

Josu Tornay: That question should

be answered by our customers.

Anyway, my opinion is that they really

think of DANOBAT-OVERBECK and of DANOBAT as companies completely

integrated in the German market.

OVERBECK has a very long story in the market and DANOBAT established itself also in a very natural way in the German

market. We have local production, local

product development, local service, etc.

and this makes everything easier for us in the German market.

Q: DANOBAT-OVERBECK has its own training workshop to train professionals. What is its added value for the company?

Josu Tornay: Historically OVERBECK used to have an apprenticeship, but it was dismantled

in different dificult situations. Some training and education structure survived,

but with a very different approach. We decided to recover a complete

apprenticeship system some years ago

and up to now all our apprentices have

joined the company after completing their studies. We are very selective

with the trainees that we accept for the company and we are really proud of the results. We have had for example the best results in our region in the practical

examination during the last 3 years, we have also a training period of 8 weeks for the last year apprentices in our factory in Spain and nowadays our assembly department receives all the new itters directly from our Apprenticeship Area.

Mr. Josu Tornay - Managing Director of OVERBECK GmbH

SEPTEMBER 2013

BIMATEC SORALUCE

Q: In view of the recent successes in sales, it is clear German customers

appreciate SORALUCE technology. In your opinion what makes a customer

choose SORALUCE milling boring machines from among others?

Fred Bisgwa: Our German customers

not only appreciate the high quality

and performance of our machines, but also the comprehensive support in

particular. This is the reason why almost

90% of our customers have more than one SORALUCE machine in use.

Q: Customization requires great knowledge of customer’s needs. How does BIMATEC SORALUCE deal with these projects?

Fred Bisgwa: It has been our ambition

since the beginning to deliver process

optimized machines on all levels to our

customers. To achieve this, we have

been working with leading technology

partners for many years focusing

on tool, clamping and measuring

technology. Thus we can ensure our

machines and equipment are state-of-the-art.

Q: Local service is essential for some companies when making the decision

to purchase one brand or another one.

What does BIMATEC SORALUCE offer its clients in this respect?

Fred Bisgwa: Our service hotline has

existed for many years and is currently available around the clock with ive qualiied service engineers. In addition to our service centre in Limburg

with its own milling head workshop,

we have over eight regional service

ofices from where we can reach our customers in the shortest time possible.

Our service technicians have many

years of experience combined with vast technical knowledge. All service

vehicles contain the common spare and

consumable parts. We already have

48 short term milling heads available to guarantee the high availability of our machines.

Q: You have recently expanded your facilities. What does the new technological centre offer customers?

Fred Bisgwa: Process optimization

in mechanical processing has been

important to us from the beginning. At our new technology centre in Limburg

we are able to demonstrate our large

milling and boring centres in a process-

optimized manner and can inish work pieces weighing up to 40 tons. Thus, we have introduced practical proof for economical machining, including bulky

heavy work pieces.

Mr. Fred Bisgwa, Co-founder member and Managing Director of BIMATEC SORALUCE

Boosting productivity through sustainabilityDANOBATGROUP offers sustainable production systems in harmony with the economy,

ecology and society

The tendency to energy eficiency represents the beginning of a paradigm shift for the machine tool sector. For a long time, the machine tool industry has been driven by the motivation

to provide the most productive, the most precise and the

most reliable machines to customers. Competitiveness has been deined and determined by manufacturing excellence. In the last few years, however, the machine tool sector has begun to invest in sustainable machinery since it has been

proved that optimizing the design, the energy consumption

and reducing material waste can have a positive effect on life-cycle costs of machine tools, improving the productivity and competitiveness of the machine. The world paradigm is changing and the machine tool sector

has to face the new global social and economic challenges too. The constantly growing energy consumption, associated

with more CO2 emissions and overuse of natural resources and raw materials, endangers our society. Besides, the

market demands require increasingly sophisticated machines

to manufacture workpieces increasingly complex, with higher quality in less time.

In order to face these new global social and economic challenges DANOBATGROUP innovates and progress

through new developments and projects that boost the

sustainability of its products, designing new machine concepts that are optimized and that include more eficient

components, which lead to higher performance of machining processes.

For DANOBATGROUP increased competitiveness and

sustainability go hand-in-hand. Putting stronger emphasis

on eco-eficiency does not represent a shift away from traditional elements of competitiveness such as precision, speed or reliability, safety or ergonomics. What is more, for DANOBATGROUP this approach is the key to ensure the

manufacturing excellence for the upcoming decades.

DANOBATGROUP

SEPTEMBER 2013

Solutions for scarcity of resources

and avoiding emissions

Optimized process cycles based on

more sophisticated technology support,

shortens machining time and save

coolant and lubricant use, waste chips

and energy consumption.

DANOBATGROUP implements an

intelligent machining planning from the beginning of the life cycle of the equipment, deining the most appropriate production design in order

to minimize the environmental impact.

New developments that

DANOBATGROUP is currently

implementing on machines:

• Eficient cooling systems: good sizing of cooling unit, MQL (Minimum Quantity of Lubrication), cryogenization, nozzle design

• End of live management: material re-use, eficient components

• Simulation and modelization in order to save machining time,

space occupation and tools, and

avoid collisions

• Less environmental contamination:

noise, pollution and emissions

Solutions for social sustainability

DANOBATGROUP machines

incorporate smart control systems

that help to operate and maintain the

machines. These systems make the

machines easier to use, and increase

safety and work quality, boosting the work and life quality of machine operators.

Research and implementation areas:

• Context-adaptive assistance for fault diagnosis

• Mobile, personalized tutoring

systems

• Location-based. Maintenance and

planning assistance

• Assistance in complex work processes

• Human-machine interaction

01 |

DANOBATGROUP is currently working

on different sustainability research areas to increase the energy eficiency on machines, to ind new solutions to face the scarcity of resources and avoid emissions, and to increase safety and work quality of machine operators through smarter control systems and

tools.

Solutions to improve the energy

eficiency

Machine designs are based on minimized

material weight of moving machine components. Stiffness of a structure is guaranteed by high dynamic axis-control functions, which saves the energy consumption.

DANOBATGROUP is developing and

implementing cutting-edge solutions in

different areas:

• Energy management: CNC stand-by options, regenerative braking

• Eco-design: less weight components

• Eficient machining process: integration of operations

01- Reduction measures to boost energy efficiency 02- Human-centered based assistance 03- New nozzle design

DANOBATGROUP

Human-centered based assistance

Advantages at a glance:• Context-adaptive assistance for fault

diagnosis• Mobile, personalized tutoring

systems• Location-based maintenance and

planning assistance• Assistance in complex work

processes

Efficient cooling in grinding; an optimized process cycle to face the scarcity of resources and avoid emissionsAdvantages at a glance:• Improvement of lubrication and

cooling efficiency• Grinding wheel wear decrease /

productivity increase • Reduction of pumping pressure and

flow rate / energy saving

02 |

03 |

SEPTEMBER 2013

The project was completed in record

time, with the line beginning full-capacity production just 18 months from DANOBAT’s receipt of the order to manufacture it.

This production line was supplied as

a “turnkey facility”, with DANOBAT supplying all the equipment (some of its own and some produced by other

specialist companies) and installing and

starting up the entire line for full-scale production to begin.

The work was done by DANOBAT

in coordination with a project team

specially formed by LUCCHINI RS and including the company’s most

experienced engineers.

The line is undoubtedly the most

advanced in the world for manufacture of railway axles, both for the complexity

DANOBAT & LUCCHINI, the perfect partnership for the most advanced railway axle lineDANOBAT has created for LUCCHINI RS a new automatic

line for machining and testing railway axles, mainly for

high-speed trains. This investment forms part of a long-term

plan for renovation of the Lovere plant, geared to innovation

of products and processes that are essential for maintaining

international leadership.

of its system, totally integrated and automated, and for the variety of innovative solutions on each individual

machine making it up.

The installation consists of an axle identiication and loading unit, an end milling machine, roughing and inishing lathes, a grinding machine, ultrasonic

and magnetic particle inspection

equipment, a robotised system for axle handling and tool change and a sophisticated line control system.

The line has a production capacity

of approximately 12.000 inished and inspected axles per year, and several different types of axles from the LUCCHINI RS catalogue can be processed automatically.

Q: Why did LUCCHINI RS choose DANOBAT as its partner for such a complex and important project?

Zaverio Tignonsini: Setting up an automatic line for high-speed train axle manufacturing is an extremely complex project, and LUCCHINI RS wished to work with a partner with experience in the sector who would adapt to our

needs and be able to offer us a turnkey project ensuring the high precision

and quality required for high-speed train axles. DANOBAT met all those requirements.

Q: What are the main advantages of this custom-made production line?

Zaverio Tignonsini: It has numerous

advantages: less workers are needed

and there is no manual handling

involved, which increases worker safety,

production times are shorter, there is

less waste produced and it has lower

dimensional tolerances that improve

considerably the inal product and reduce manufacturing costs. Moreover, WIP inventory was signiicantly reduced and the throughput time was drastically

shortened.

Q: Joint work teams made up of engineers from both LUCCHINI RS and DANOBAT have taken part in

the project. How do you rate this teamwork?

Zaverio Tignonsini: Our relationship

with DANOBAT was free-lowing and positive at all times. The mixed multicultural and multilingual work

teams responded well to all the

complex challenges involved. We were all working towards the same goal,

facing together the issues that such a

complicated line brought up during the

start-up period.

Q: Over the last few years LUCCHINI RS has been working on an ambitious plan to modernise its production

resources. How has the investment in the new line affected this plan?

Zaverio Tignonsini: The project has

made a positive contribution to our

modernisation plan, that affected the entire range of rolling stock products of Lucchini RS. Considering the axles in particular, the innovative production line

supplied by DANOBAT was integrated

with other relevant investments, such

as the new axle forging line and the molybdenum coating line, that made

Lucchini RS the most modern and advanced railway axle manufacturer in the world.

LMF3 line at Lucchini SP

DANOBATGROUP

Mr. Zaverio Tignonsini, Group industrial Coordinator and Project Manager at Lucchini SP,

Photo by courtesy of Lucchini RS

SEPTEMBER 2013

DANOBAT centerless grinding machine with natural granite bed

UltraprecisionThe precision requirements of manufactured products have

increased their levels of demand, efficiency and functional

reliability.

In the manufacture of parts that demand a high level of precision, there are three aspects that the equipment

used in manufacture must ensure: thermal stability, repeatability of results and the capability of the axes to carry out minimum movements and very slow

feeds. To solve part of these problems, DANOBATGROUP has undertaken two

applied research projects: the use of natural granite in both the moving and

ixed parts of the machine structure and the elimination of physical contacts and joints between the ixed and moving parts of the machine.

Natural granite has properties that

make it very suitable for ultra-precision systems. It is a natural material with

high geometric stability, as it does not

undergo slow stabilisation processes

and in response to thermal stimuli it has

very low diffusivity and a low expansion coeficient. Speciically, its linear expansion coeficient (α) is 6•10-6 1/ºC, half that of cast

iron or steel, and a quarter of that of aluminium. Furthermore, it has added advantages: its density is

lower (structures are lighter) than that of structural materials normally used in machine tools and its damping

coeficient is high (suppression of vibrations). The economic impact of the use of these materials depends on the design, for this reason it is very important to design for manufacture in the speciic material, and not to transfer a design considered for one material to manufacture in another.

In order to be able to carry out very

slow feeds without there being large variation in the true speed of the slide, the elimination of contact areas is necessary between the ixed and moving parts of the machine structure, this allows optimal dynamic precision to

be achieved and a minimum veriiable displacement increment. Dimensioning

and positioning of the motors, ideal data capture scales, the design and

use of bearings based on luids and machine structures optimised both in

geometry and materials, allow high

accelerations to be achieved and

excellent dynamics, as well as much reduced transmission of disturbances that hinder positioning precision.

DANOBATGROUP

SEPTEMBER 2013

TECHNICAL SPECIFICATIONS

Max. grinding diameter 1000 mmMax. grinding length 6000 mmMax. weight between centers 8000 kgMax. grinding wheel diameter 915 mmHydrostatic spindlesWheelhead with two external grinding wheelsCross slide conigurationTouch probe

Integrated balancing system

AFS pump exhaustersMulti-diameter measuring system MDM-500

WT-92-6000


Max. grinding diameter 200 mmMax. work swing 400 mmB axis swivelling range +95º/-15ºNatural granite bed

Linear motors

Two parallel spindles

Full integrated automation with two line parts

storage

IRD-400


Max. grinding diameter 300 mmMax. grinding length 400 mmNatural granite bed

Linear motors

Diamond wheel

Superabrasive technology (120 m/s)In-process measuring system

Robot + pallet loading/unloading system integrated in the machine

LG-400


Max. grinding diameter 200 mmMax. work swing 400 mmB axis swivelling range +95º/-15ºNatural granite bed

Linear motors

Multi-spindle turret

Diamond wheel

IRD-400

EMO 2013 HIGHLIGHTS

DANOBAT grinding and turning machines

HALL 11 STAND D55


Max. internal grinding diameter 700 mmMax. grinding length 600 mmMax. work swing 900 mmNatural granite bed

Linear motors

Spindle turret with max. 4 spindlesConventional & CBN wheel

ID-600


Grinding diameter 0.5-50 mmMax. grinding length 200 mmNatural granite bed

Linear motors

Gantry type frontal loading unitIntegrated out-process contact measuring

unit

Possible to load two parts per cycle

Electrospindle for the grinding wheelIntegrated electric cabinet

E-315-FV


Max. turning diameter 330 mmMax. turning length 500 mmLoading/unloading integrated into the machine

Main elements made of stabilized pearlitic cast iron

Linear guideways with recirculating linear

Pearlitic roller bearing

External linear scales on machining X-Z axesExtra slide for load/unload operations

TH-500


Max. grinding diameter 1000 mmMax. grinding height 700 mmPrecision radial and axial hydrostatic bearing on C axisMain elements made of stabilized perlitic cast iron

Independent slides for vertical and traverse movements

VG-1000/700

Linear guideways with recirculating linear

roller bearings

External linear scales on all machine axesMulti-spindle turret

Measuring system and data handling

softwareDoGrind conversational software

SEPTEMBER 2013


Control Siemens 840DTurning diameter 3200 mmTable diameter 2800 mmTable drive motor 105 kWTable speed 175 rpmTable torque 52800 NmMax. height table to Ram 2600 mmRam size 250 mm x 250 mmRam stroke (Z axis) 1500 mmSlide/Ram traverse (X axis) 3730 mmRam with live spindle (30 kW / 3000 rpm, 1200 Nm)C axisElevating crossrail 1000 mm

VTC-3200 VERTICAL TURNING

CENTER


F-MT 4000Longitudinal traverse, “X” axis 4000 mmVertical traverse, “Z” axis 1800 mmCross traverse, “Y” axis 1300 mmFixed table dimensions 4000 x 1250 mmRotary table dimensions 1600 mmSpindle power 37 kW

F-MT 4000 MULTITASKING MILLING-TURNING MACHINE

HEADS• Universal head

0,001ºx0,001º / 5000 rpm / 32 kW (S1)• Turning head

6000 rpm / 32 kW

EMO 2013 HIGHLIGHTS

SORALUCE milling-boring and vertical turning machines

HALL 13 STAND B36


FXR-16000Longitudinal traverse, “X” axis 16000 mmVertical traverse, “Y” axis 6500 mmCross traverse, “Z” axis 1900 mmQuill traverse, “W” axis 1000 mmSpindle power 71 kW

HEADS• Modular quill spindle

Ø180 / 2500 rpm / 71 kW (S1)• Orthogonal head

1ºx1º / 3750 rpm / 46 kW

FXR-16000 FLOOR TYPE

MILLING-BORING CENTRE


SL-8000Longitudinal traverse, “X” axis 6500 mmVertical traverse, “Y” axis 1600 mmCross traverse, “Z” axis 1300 mmFixed table dimensions 8000 x 1100 mmSpindle power 32 kW

SL-8000 FIXED TABLE TRAVELLING COLUMN MILLING CENTRE

HEADS• Orthogonal head

1ºx1º / 5000 rpm / 32 kW

SEPTEMBER 2013

DANOBAT sawing, drilling and 3D plasma cutting machines

HALL 15 STAND D36


Maximum round capacity 2000 mmMaximum square capacity 2000x2000 mmMain motor power 22 kWBlade dimensions 16140x80x1.6 mmBlade speed 11-90 m/minDownfeed speed controlIntelligent delection controlIntelligent cutting software

TDS 20.20


Maximum round capacity 800 mmMaximum square capacity 800x800 mmMain motor power 11 kWBlade dimensions 8700x67x1.6 mmBlade speed 14-110 m/minAutomatic feeding stroke 500 mmLaser fast approachDownfeed speed controlIntelligent delection controlIntelligent cutting software

HDS 8A


Maximum round capacity 520 mmMaximum square capacity 600x520 mmMain motor power 11 kWBlade dimensions 7690x54x1.6 mmBlade speed 18-150 m/minAutomatic feeding stroke 500 mmLaser fast approachDownfeed speed controlIntelligent delection controlIntelligent cutting software

iDS 5A

EMO 2013 HIGHLIGHTS

Let´s go – AustriaLATZ cutting tools essential for Walter Maringer Ges.m.b.H., one of the leading Austrian

suppliers for all sorts of cutting tools, abrasives and machines

The CEO of Walter Maringer Ges.m.b.H. started his enterprise in 1983 only with the help of his spouse Gudrun. He encountered the challenge of working the all Austrian market with cutting tools and abrasives successfully and is nowadays managing director of one of the leading Austrian suppliers for all sorts of cutting tools, abrasives and machines. A team of 30 employees, of which 10 visit end users all over Austria, helps him complying with the challenges coming from high-tech companies and their demanding requirements. The

headquarters consist of a large exhibition and training room, 660 m² ofice space and, last, but not least, 900 m² storage. Most of his customers manufacture automotive, aerospace and general engineering parts in serial production and depend

on a 100% reliability of the tools they are using.

Rapid growth made the careful selection of long term strategic partners a priority. About 3 years ago, Walter Maringer Ges.m.b.H. started cooperating with LATZ Cutting Tools on a very basic level. Hence, LATZ Cutting Tools, being well-known for their high precision, reliability and cutting edge technology has become an essential partner in a very short period of time. The company has a long track record designing, producing

and commercializing standard and special HSS and carbide cutting tools for the main industrial sectors (aeronautics, automotive industry, etc.).

Walter Maringer: “LATZ is our main supplier for high-performance cutting tools and has never failed us with any of the aspects, our partners need to comply with for the needs of our demanding market. We serve high-performance twist drills made of HSS-Co and solid carbide, with and without internal coolant to customers from all important industrial areas in Austria and only get positive feedback. Performance wise we have absolutely no problems to compete against the

best European manufacturers of cutting tools. For us – and our market – LATZ is a prime manufacturer and one of our most reliable partners. I see a promising future for a long-term relationship.”

The state-of-the-art production facilities of LATZ and the quality

controls guarantee consistent quality from batch to batch and the necessary lexibility for short-term design and production of special tools according to customer requirements - whether for drilling, reaming, chamfering or milling.

“The very demanding requirements of our customers make it essential, that we work only with the best and reliable partners in our area of activity. The quality of their products must be first choice. As I feel personally responsible for the perfect functioning of our customers’ production, the quality is only one aspect of our suppliers. Communication, response time, availability, logistics and price-performance-ratio are the other aspects, which are crucial in the selection of our business partners.”

Mr. Walter Maringer, CEO of Walter Maringer Ges.m.b.H.

LATZ cutting tools

HALL 03 STAND H05

01- Special tools according to customer requirements 02- MARINGER Headquarters in Kobenz, Austria

01 |

02 |

SEPTEMBER 2013

SL-8000 fixed table travelling column milling centre

THE MACHINE

The SL machine offers high versatility for exceptional machining results, based on traditional and unique machine

architecture: table attached column

supported by a separate rear guide,

which improves machine stability, whilst

maintaining its centre of gravity very low.

The machine is equipped with an

orthogonal head, a very lexible and user friendly solution for programming directly on the machine and which additionally

enables inverse machining (machining in negative positions), this saving setups

for complex part production. Other heads from SORALUCE’s wide range are available for this machine.

The SL machine is a large capacity machine with a compact and ergonomic

format design. Thanks to its coniguration, the table provides front and rear access for component itting and veriication, keeping the foundation costs under control as all the machine lies on the same level.

THE APPLICATION

Pole shoe is a key component in the

large dimensions electric generators. A

good accuracy will prevent any run-out

produced during rotation of the rotor shaft.

The component is machined in just two

set-ups; one set-up for the stator face and another for the rotor face, including lateral faces.

The machine is equipped with an

orthogonal head, which enables inverse

machining (machining in negative positions), likewise machining of the complete pole shoe top and lateral sides

in one set-up. This eliminates the necessity

for additional setups, resulting in improved overall cycle times and inish quality with less component manipulation. This

head enables the user to beneit from full machine travel: eliminating the need for additional workpiece support ixtures, due to close table head spindle accessibility for both front and lateral milling.

SL-8000A well designed machine:

ergonomics and user friendly

01- Accura heads

01 |

MORE ACCURACY IN THE WORKING AREA

It compensates for any head articulation positioning deviation.

• Calibration for any type of head.• Calibration for any position in

the working area.• Calibration for any angle, not

just orthogonal.• Offset error compensation due to

thermal expansion.• Distance between head spindle

noses is measured.• Easy-to-use interface, 100%

integrated with HEIDENHAIN iTNC530 HSCI and SIEMENS 840D SL.

OUTSTANDING PROJECTS

SEPTEMBER 2013

VTC-3200 Vertical Turning Centre

When versatility improves productivityNASOSENERGOMASH Pump & Power Engineering Works Sumy is one of the Ukraine’s most

important industrial companies, specialising in pump manufacture for the nuclear, oil & gas,

thermal power and water supply sectors.

Its state-of-the-art pump design, manufacture, processing and testing facilities are the base

from which it designs and launches new pump models to meet the most rigorous demands of

the sectors it supplies.

NASOSENERGOMASH has recently purchased three machines from DANOBATGROUP: a VTC-1800 vertical lathe, a VTC-3200 vertical lathe and a SORALUCE FR-10000-W travelling column milling-boring machine, to optimise its

production process and the precision of its components.

We spoke to Vladimir Kushko, Nasosenergomash’s Technical Manager, about the advantages of using the VTC-3200 vertical lathe in the production process.

Q: What kinds of components do you machine?

Vladimir Kushko: We use the vertical lathe for machining pump bodies for the nuclear power sector, pumps for oil transportation and pumps for electric power stations.

Q: How complex are these components?

Vladimir Kushko: Their complexity lies in the precision of their parts. The largest diameters have to be within 0.01 mm tolerance (quality class 6). Machine precision and reliability are two very important aspects required by the sectors we

work for, and high productivity is also essential.

Q: How has your pump body production improved with the new VTC-3200 vertical lathe?

Vladimir Kushko: There has been a great improvement as

regards precision and productivity.

Previously, the pump bodies were processed on six different machines to undergo all the machining operations required.

With the VTC-3200, all the operations are carried out on just one machine and with a single clamping process. This has

increased our productivity, reduced the idle time needed for part clamping, and it has improved precision as there is only

one clamping process.

The machine also includes a head with four turning positions, allowing four tools to be used with no stoppage times for tool change, and this optimises the machining times.

Q: What are the main operations performed on the VTC-3200?

Vladimir Kushko: The basic operations required by the

pump bodies are turning, drilling, milling and threading.

The VTC-3200 turning centre is equipped with a variety of different heads and we can carry out all these machining operations and other on the same machine and with a single

clamping process.

Q: How do you rate DANOBATGROUP’s work on this project?

Vladimir Kushko: DANOBATGROUP has been an

exceptional partner. We explained our machining problems and our requirements to them and DANOBATGROUP

proposed a very precise, highly productive solution. They

showed great know-how and lexibility, adapting to our speciications and putting forward improvements that have a very positive effect on the end product.

Vladimir Kushko, Nasosenergomash’s Technical Manager


SEPTEMBER 2013

The company have in the region of 50,000 valves installed across the globe, some of which operate in the most inhospitable environments on

the planet, often in ultra-deep waters of up to 10,000 feet and under high pressures as well as extremes of temperature.

With valve sizes ranging up to 48” in diameter and tolerances typically

less than one micron, ultra precision

Leading the ieldCritical oil & gas valve manufacturer enjoys significant

savings since installing a DANOBAT vertical band saw

As industry leaders in the design and manufacture of critical oil and gas valves for both surface and subsea applications, Newcastle based BEL VALVES concentrate their energies on serving evolving markets that demand the very highest quality and reliability.

machining is of the utmost importance, so when BEL VALVES needed to upgrade the cutting operation during

the production of their 24” diameter split gate 4A topside through-conduit valves, they naturally turned to Prosaw

to provide the solution.

Although the existing process utilised avertical bandsaw, it was very wasteful of material, typically deviating from it’s true path by up to 1/2” on either side of the

01- 02- 03- DANOBAT band saw at BEL VALVES

blade, requiring a considerable amount

of post cutting additional machining in order to form a true surface.

Prosaw’s response was to specify a DANOBAT VL vertical bandsaw, which

has drastically reduced the cutting time

for this product from 18 hours to just 6 hours, whilst simultaneously reducing

waste material due to the appreciably

more accurate cutting path, amounting

to cost savings in the region of £1,500 for each valve.

Additionally, further signiicant cost savings have been achieved by the use

of a new type of carbide saw blade, that has a life of more than 50 times that of the previous machine.

“We have been very impressed by this new DANOBAT machine. It is far more accurate and much faster compared to our previous system, and has created huge cost savings. It has also been responsible for relieving bottlenecks in production, causing work to flow more smoothly through the workshop.”

“DANOBAT and Prosaw have been with us every step of the way with this project, giving us excellent service and full sales and technical support which has assisted us greatly in bringing this product along.”

Commented Shop Manager, Mr. Adam Leggett

01 | 02 |

03 |


SEPTEMBER 2013

DANOBAT VG vertical grinding machine

“A machine to speciically meet the high metal removal rates and ine tolerances required”Cooper are the world leader in Split Roller Bearing technology having been in the business

for over 120 years. They offer a standard catalogue range of bearings plus special custom

engineered bespoke, split to the shaft bearings and housings for shaft sizes from 30mm

to over 1250mm. The Cooper solution is specified by industry around the globe, by large

international companies and small niche companies, all valuing the quality and expertise

offered by the company and the products it produces.

Q: In 2010 Cooper Roller Bearings contacted DANOBAT to develop a vertical grinding machine. What process was

used in those days for machining parts? What did you see in DANOBAT to contract them for this project?

Pat Smith: After extensive research, including performing trials on test components, DANOBAT was selected as a

company able to offer the required mix of ield experience, depth of technical know how and support, combined with the requirement for acceptable return on capital investment. Right from the early project stages it became evident that an out of the box option would not satisfy the needs of Cooper and DANOBAT immediately went to work on machine design modiications, incorporating enhancements and upgrades

to prepare a machine to speciically meet the high metal removal rates and ine tolerances required.

One key point for Cooper has been the locality of the Newall business which is part of the DANOBAT group as it is located just a few miles from Cooper. The previous service experience offered by Newall on a number of other smaller DANOBAT machines played a major part in their selection for the bigger machines.

Q: After analysis and work done together by Cooper and DANOBAT engineers, the latter proposed changing the

machining process from hard turning to grinding with CBN wheels. How was this technological challenge perceived?

01 | 02 |

Pat Smith: When initiating the project Cooper had a clear vision for incorporating hard turning and grinding processes together on the new machine. As it turns out we still utilise

both technologies but hard turning is used to a lesser

degree than originally envisaged and CBN grinding is used far more. Working closely together Cooper and DANOBAT have developed CBN grinding processes and the associated machine design requirements to handle this and as a result,

for some process elements, this is by far the quickest means of high stock removal for roughing and pre- inishing.

Q: How did you eventually beneit from the development of a machine with this technology?

Pat Smith: The implementation of this new technology has allowed Cooper to add overall capacity and process parts more quickly, which in turn has resulted in greatly reduced

customer lead times for large bearings.

Q: These DANOBAT machines have been equipped with

a external setting table. This reduced the setting times considerably. Could you explain the beneits of this system on your application?

Pat Smith: In the previous process, the part was set inside

the machine and this required the machine to be stopped

to carry out this operation. Depending on the component,

03 | 04 |

the machine could be stopped for one or two hours. Now with the external setting station, the operator can set the part while the machine is running. We believe that this is a

big improvement in the overall process as now there is no

machine down time.

Q: Bearing in mind this experience and the two already installed DANOBAT vertical grinding machines, would you

consider DANOBAT a partner to continue with in developing

future solutions?

Pat Smith: The overall experience of working together with DANOBAT has been very positive, both parties have gained

new knowledge and beneited from the experience. We would certainly work with DANOBAT again in the future.

01- External part set up station 02- Hard turning in VG machine 03- Pallet changing system 04- Mr. Pat Smith, Site Director in Cooper Roller Bearings, Kings Lynn


SEPTEMBER 2013

MAN Diesel & Turbo is one of the world market leader for large diesel engines for use in ships and one of the leading suppliers of diesel power stations and turbo machines. The company operates

more than 100 international locations and the range of products and services that they offer includes complete marine drive systems, turbo-machinery trains

for both the oil and gas industries and process engineering, as well as turnkey

power plants.

All, in one single machineA complete solution on one single machine for grinding

different ship engine turbo compressors, providing a great

precision

The client approached DANOBAT looking

for a complete solution for grinding different ship engine turbine wheels for each model of ship. These are parts of between 183 mm-420 mm in diameter and 320-720 mm in length with blades made of Inconel.

The process up to then consisted of using two machines: one for grinding the different diameters and faces of the shaft and the other for machining the blades,

01- 02- 03- Grinding of ship engine turbo compressor

which required a different grinding wheel for each piece.

To ind a solution for grinding this set of parts, DANOBAT presented the horizontal

grinding machine model HG-92-2000-B6 with different systems in order to optimise the process to the maximum, so all machining operations could be

performed on one single machine set-up. Among the most important features of this machine model are the following:

01 |

• Double wheel head assembled on a B

axis. One set up, one inished part.• New design of grinding wheel and contouring process. Grinding wheel

designed by DANOBAT for grinding the different diameters of the blades using a contouring process, thus cancelling the

need for different grinding wheels for each part model.

• Both spindles assembled on

hydrostatic bearings. Maximum rigidity and maximum vibration damping capacity.

• Motorised tailstock with automatic

programmable positioning and

blocking. Part changing has a negligible

inluence on the set-up time.• Continuous dressing system, dressing the wheel during grinding, resulting in a

signiicant increase of productivity.• Several measuring systems• Software DAN-OP. A powerful technological development allowing

very friendly conversational programming and powerful calculations.

The standard HG-92 easily achieves the precision requirements for this project

because of its construction and the gauging systems. However, the desired working methods demand for speciic solutions:

• MDM absolute contact measuring

system designed and manufactured by DANOBAT, suitable to measure

in-process all and each diameter to

be ground. At the end of the grinding cycle, in automatic mode and by

program, all diameters, its geometry,

and faces can be measured and a Test Report can be issued.

• Touch probe showing the part

clamped between centres with axial references.• Blade measuring non contact

system by laser allowing to measure

the different shapes of the blades, hence avoiding the use of measuring standards used previously for each type of blade.

DANOBAT was able to offer a complete solution on one single machine for grinding different ship engine turbo compressors, providing a great

precision (surface tolerance IT5 and roughness Ra0,4), which made MAN Diesel & Turbo opt for this technology and entrust DANOBAT with this and

future projects.

02 | 03 |


SEPTEMBER 2013

“DANOBAT NA horizontal lathes to get the

required precision levels”Founded in 1969, DONGFENG Motor Corporation is one of the 3 giant car makers in China.

Its main business includes passenger vehicles, commercial vehicles, engine, auto parts &

components, and equipment.

Through over 40 years of development, a set of R&D and manufacturing facilities have been established as well as an extensive distribution and after-sales network.

Currently, DONGFENG is taking delivery of a new lathe in its facilities from DANOBAT based in Elgoibar, Spain. Taking advantage of the occasion, we spoke to Mr. Xiao Guang Sheng, senior engineer at DongFeng Motor Co. Ltd.

Q: What type of components do you manufacture?

Xiao Guang Sheng: Right now, our main product is high

power diesel engines and parts. Our range includes three

models: DCi11, EQ4H and EQX7.

Q: What was the machining process for your crankshafts before investing in DANOBAT lathes?

Xiao Guang Sheng: We were using local machines as well

as NTC Japanese lathes. At that time we were manufacturing cast crankshafts. Many years later we changed our manufacturing process to steel crankshafts due to their lighter weight, more compact dimensions and better inherent

damping but this material is harder and it is more dificult to machine.

10 years ago we visited VOLVO Trucks in Spain and they were using DANOBAT lathes for the manufacturing of their

components and we realized they had several advantages

when using these lathes, and we saw that it could be a good

solution for machining our steel crankshafts. Finally, in order to get the required precision levels, we decided to invest in

DANOBAT NA horizontal lathes.

Q: Do the DANOBAT lathes live up to your expectations?

Xiao Guang Sheng: The NA lathes offer the precision our products require and furthermore, due to their design, take up less room in the plant. For machining large crankshafts, the NA-1500 2TS-2CM model was selected, which is capable of machining components of up to 450 mm in diameter and 1500 mm in length, we used this to turn the ends and supports of the various crankshafts.

01- Crankshaft turning 02- Mr. Xiao Guang Sheng, senior engi-neer of DongFeng Motor Co. Ltd.

DANOBAT lathes are equipped with two top turrets, two

headstocks (one of them mobile to adapt to the different sizes of crankshafts) and it has retractable jaws which make it possible to turn the end faces. Thanks to these features, the parts are machined using a single set up and even with

the two turrets turning at the same time, thus considerably

improving the cycle time.

Q: Have the parts to be machined undergone changes in recent years?

Xiao Guang Sheng: Over the years, our parts have

undergone changes in their design (size, shape, etc.) but DANOBAT has been capable of adapting to these changes and offering us a full, appropriate solution for our products and always equipped with the latest technology.

Q: How do you value the relationship between the two companies DONGFENG and DANOBAT?

Xiao Guang Sheng: As I have mentioned, the relationship

started several years ago, the irst lathe was purchased in 2005. Since then, we have invested in several lathes and the fact that the DANOBATGROUP is present in the Chinese market and has a highly qualiied service team has helped in the successful development of all the projects. We are convinced that in the future the two companies will continue working together.

01 | 02 |


SEPTEMBER 2013

In addition to being fast, the machine is also powerful and responds very well when rough machining – Mr Cervo explains – the high rigidity of the machine enables large roughing operations which reduce machining time and the machine with roller recirculation linear guideways offers the advantage of lower maintenance costs compared to a hydrostatic machine.

Working for the energy sector requires very speciic skills and machines capable of ensuring maximum precision on heavy duty components, to guarantee the

productivity and reliability demanded by

this sector to compete on the market.

In addition to centesimal tolerances

on large workpieces, which can weigh

hundreds of tons, today, a machine dedicated to the energy sector must

be capable of dealing with extremely complex machining operations, reducing the number of workpiece set-ups as far as possible and likewise, cycle times

and possible errors. The machine must

respond to multitasking and versatility

requirements not to mention inishing the workpiece in a single set-up.

The “right” solution: versatility and

single set-up

MPC, a company located in Vicenza (Italy) and specialized in working for the energy sector, is one of the customers with whom SORALUCE has established a very close relationship over the years.

FXR-16000 Precision, productivity and reliability

A speciic example, the results obtained at MPCPrecision, productivity and reliability: three key features of the solution proposed by

SORALUCE for the energy sector.

The company performs high precision machining of turbines, turbine cases, generator cases, hubs, housings and

many others key components from power systems (gas, steam, wind, hydroelectric and nuclear), as well

as other components like engines,

gearboxes and compressors. The common denominator of these components is the large workpiece

size, their complexity and the need for absolute precision. Another prerogative

is the variety of processed materials: such as special steel alloys, duplex steel, stainless steel and others. It requires,

therefore, both versatility and reliability.

MPC has 3 SORALUCE milling-boring machines. The latest is the highly lexible FXR-16000 model (X: 16000 mm, Y: 7000 mm, Z: 1900 mm, W: 1000 mm). MPC purchased this machine to meet speciic needs and problems, and especially for processing workpieces in a single set-up.

Before the FXR-16000 was installed at

MPC, the workpieces were machined irst in a turning machine and then in a milling-boring machine, with the resulting

disadvantages in terms of workpiece setup, accuracy loss likewise processing

costs.

The new FXR-16000 machine, equipped with an NC facing head, has meant elimination of the turning machine operation, releasing the lathe from work overload, which generated an

organizational “bottleneck”.

Multitasking coniguration The machine supplied is equipped

with the following peripherals, thereby converting the machine into a

multitasking unit:

• Orthogonal head 1°x1°, 46 kW• Step-less universal head

0,001ºx0,001º, 46 kW • Modular quill, 71 kW at S1 (Ø 180

mm, 1000 length)• Angular head 2,5°x2,5 °, 60 kW at

S1


SEPTEMBER 2013

MILLING AND BORING: FINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL

The system interchanges the modular quill spindle with the rest of the heads totally automatically.

Allows for different quill spindles with different diameters and lengths.

GEOMETRICAL ACCURACY (STRAIGHTNESS AND PARALLELISM) OF THE RAM TRAVERSE OVER THE Y AND Z TRAVELS

Specially suitable for machines equipped with extensive traverses and head changing system.

It compensates the weight of the different heads.

• NC facing head for turning up to Ø 2500 mm.

• Angular head with C axis, 1000 mm length, 22 kW.

• Pick-up for 7 heads.• Rotary travelling table 5000 x 5000

mm, cross traverse 3500 mm, loading capacity 150 Tn.

• Tool magazine for 120 tools. Precision, speed and high stock

removal capacity

Another aspect particularly appreciated

by MPC is the large vertical traverse (7000 mm), which enables very tall workpieces to be machined in a single

set-up.

The new SORALUCE FXR-16000,

as Mr Giuliano Cervo explains, also

resolves the problem of possible

centrifugal forces arising on the vertical

lathe.

Most workpieces machined in MPC

have special geometric shapes.

When machining those pieces on a

vertical lathe, this may lead to non-

homogeneous centrifugal forces and

consequently a possible oval shape

results. When working these pieces on

the SORALUCE FXR-16000 milling-

boring machine, this problem is

completely solved since the workpiece,

unlike the lathe, remains stationary

and does not undergo potential

deformations due to its geometry.

Furthermore – Mr Cervo continued,– by

using the new SORALUCE milling and

boring machine, we have reduced

the cycle time by about 20%, which

is certainly an important advantage

for us in terms of productivity and

competitiveness”

Ergonomy and customization

When machining of large workpieces, machine ergonomics play a fundamental role too. SORALUCE has taken this aspect into consideration, so the

operator will have full visibility of the process while working comfortably and safely. Complex expensive pieces such

Claudio Cervo, Renzo Cervo, Giuliano Cervo -owners of the company MPC- and Giancarlo Alducci -Managing Director and Vice-Chairman of SORALUCE ITALIA-

as those destined for the energy sector cannot be subject to human error, so

while operator performance is also linked to ergonomics, the ergonomic design of the machine is a determining factor. For this purpose, MPC and SORALUCE have established a collaborative relationship and the

“teamwork” resulted in the machine

coniguration and adjustment. Optimum machine coniguration arises from indepth dialogue and discussion

between both sides, i.e. producer and

user, which starting from the objective analysis of problems enabled them to ind the best answer to these problems.

THE MACHINE

Any kind of machining in one machine, in a single setup. This is what Multitasking

means, and this is the real solution

given by SORALUCE for heavy duty components.

Based on the technology of the successful FL model, this machine enables the

processing of big size / load components with high performance machining strategies thanks to its high dynamics and

with a full guarantee of machining stability derived of its robust cast iron structure.

Universal and Orthogonal heads are

available for milling operations with high power and torque, while an exclusive system is provided for turning tools which protects the head bearings and, at the

same time, enables the fully automatic tool change and head position change.

A large size working area, fully protected, enables different conigurations as just the ixed table, ixed table + Turning / Milling

F-MT 4000Multitasking, lexible and dynamic

table and even the integration of pallet changing systems.

THE APPLICATION

A demonstration part has been developed

to show the full lexibility and multitasking capacities of a SORALUCE F-MT machine.

Live machining demonstration will be

done on a 2,5 Ton component, which is composed of areas of steel and of cast iron. The specially designed part includes

operations such as:

• Turning

• Recess turning

• Millturning

• High performance milling• Gear Milling

• Reverse surface milling• Drilling with different technologies• Countersinking

OPTIMUM PERFORMANCE UNDER CONTROL

• Consists of an automatic adjustment of the defined cutting parameters depending on the real machining situation.

• Automatically speed up and slow down depending on the real stock removal.

• Unattended machining.• Cost efficient production process.

01- F-MT 4000 Multitasking Milling-Turning machine

01 |


SEPTEMBER 2013

Josu Ugarte Arregui is a renowned expert in corporate internationalization and multi-localization with a degree in Economics from the University of the Basque Country, whose professional career has been in MONDRAGON Corporation. His last 14 years have been linked to the international world, and for the last two and a half years he has been the President of MONDRAGON International managing its 9 branches throughout the world: BRIC, México, Chile, USA, Vietnam and Taiwan.

MONDRAGON Corporation receives the “Boldness in Business” prize awarded by the

Financial Times and Arcelor MittalDANOBATGROUP is the machine tool division of MONDRAGON Corporation, one of the

largest European holding companies. The Corporation is a solid diversified group, whose

innovative attitude, capacity for cooperation and commitment to internationalisation are its

hallmarks. It has an innovation network made up of 15 technological centres with more than

2000 people devoted to R&D, and it has a production and commercial presence throughout

the world.

It is a business project that has proved to be a successful alternative in a complex economic context, as MONDRAGON represents a model in which people play the true leading

role in the company and in which commitment, social

responsibility, participation and transparency are part of its corporate DNA.

A project that little by little has become a world benchmark

for cooperative working.

Q: MONDRAGON is recognised for its different way of understanding work. What does this different way of doing things consist of?

Josu Ugarte: Our corporate company model encourages

the participation of workers in the company: in ownership (the workers are partners in the company); in management (through their contributions for improving products, processes and services); and in the results (depending on the work undertaken).

Q: You’ve recently been awarded the “Boldness in Business”

award organized annually by the Financial Times and Arcelor

Mittal in their “drivers of change” category. What does this award mean for you?

Josu Ugarte: It should be remembered that there were

a total of 260 companies at a world level selected for this international award by the jury, organised jointly by the

Financial Times (FT) and Arcelor Mittal (AM). The inalist companies for this award were the American Oil Company, Continental Resources; the Chinese industrial machinery corporation, Sany Heavy Industry; the multi-sector Indian Group, Tata Group; the Japanese entertainment holding

company, Square; the German publisher, Axel Springer, and MONDRAGON Corporation.

To get a more accurate idea of the extent of these awards, it should be noted that the last three winners in this category

were Fiat in 2009, Apple in 2010 and Amazon in 2011, and among the inalists were companies of the size of Al Jazeera, Google and Master Card.

MONDRAGON Corporation was the winner of the award “as it represents “Humanity at work” in terms of a new real business model proposal, based on cooperation, collective

work, solidarity, and on the involvement of people in the working environment”.

Q: Why do you consider it such an important award?

Josu Ugarte: Firstly, because it is awarded by the most

prestigious inancial newspaper in the world: the Financial Times. Secondly for its scope, these are awards that recognise your merits among a selection of world level companies. Third, because its international impact is

very signiicant, it is not for nothing that these awards are considered the Oscars for business.

Q: The workers are owners of the company. Does this allow effective management with assurances?

Josu Ugarte: The eficiency of the organisations is measured in objective terms through its capacity to compete in the

markets and generate positive results. And in this we are

equal to conventional companies.

HUMANITY @ WORK

SEPTEMBER 2013

What differentiates us from the rest is our way of organizing ourselves, our co-operative identity, due to our members

being full company stakeholders in terms of ownership, management and results. It is we, the members, who

make important decisions in the co-operative. Therefore, this identity allows greater involvement of our people and a greater guarantee of success. Even more so bearing in mind that the beneit obtained is returned in the development of the society where a co-operative is located through the creation of jobs.

Q: In your opinion, what is the role of DANOBATGROUP within MONDRAGON? Has this role had a positive impact on MONDRAGON receiving the award?

Josu Ugarte: The contribution of DANOBATGROUP in MONDRAGON is very important in two aspects. On the one

hand, because it leads a typical industrial sector in Spain, the machine tool sector, which requires technological and

innovative aptitudes which have been carefully nurtured within the group.

Furthermore, the attitude of people in DANOBATGROUP has always surprised me, the “cooperative coherence” and their

good sense in making efforts for collective beneit. Therefore, both the aptitudes and the attitudes of DANOBATGROUP have always helped to add to and make MONDRAGON a

more diverse and enriching experience.

Q: How do DANOBATGROUP customers beneit from MONDRAGON?

Josu Ugarte: Primarily, due to the possible synergies

that can derive from belonging to such a diverse business group, in such a way that they are able to access integrated

solutions through the full range offered which is always very positively valued by customers.

Furthermore, our R&D capability at the service of all our customers should also be highlighted, as we have 15 technological centres specialising in different sectors. And internationally, which affects me most directly, we have a wide range of services (from outsourcing, through business parks where they can be implemented, both in China and India, and an excellent corporate diplomacy service) which we make available to all DANOBATGROUP customers.

Lastly, it should be noted that when doing business with

potential customers, they have to see that the organisation is

competitive, its products are excellent, it offers an unbeatable service, and furthermore it generates conidence through its solidity, stability, inancial capacity and business rigour. And in these latter aspects, MONDRAGON is a key player.

Mr. Ugarte at FT ArcelorMittal Boldness in business award ceremony

OPEN HOUSES 2013; Latest developments and technologies

on-site DANOBATGROUP owns sales & service facilities in 11 coun-

tries and has a professional representation network and

factories all over the world. In 2013 DANOBATGROUP opened

the doors of several manufacturing plants around the globe

in order to offer key stakeholders the unique opportunity to

visit the latest developments and technologies on-site.

Open House in DANOBAT

04-10 March

Open house at DANOBATGROUP

India factory

DANOBATGROUP India organized its

annual Open House at the “State-of-art facility” at its factory in (Shirwal) Pune.Visitors had the unique opportunity

to visit DANOBATGROUP India’s

manufacturing plant and see in action the SORALUCE KB-150-W Horizontal Boring Machine and the SORALUCE FP-6000 Milling-Boring Machine.

DANOBATGROUP India provides

top-end, comprehensive Machine Tool

solutions to enterprises in India, thereby,

developing their competitiveness and

committing to provide them sustained

support.

06-07 March

Grinding-machines exhibited in

Herborn (Germany)

New developments in internal, external

OPEN HOUSE NEWS

SEPTEMBER 2013

and radii precision grinding machines

were exhibited from 6th to 7th March in the DANOBAT-OVERBECK manufacturing plant in Germany.

DANOBAT-OVERBECK showed its production area of approx. 1600 m² with different innovative solutions launched by the engineering

department of the company. Qualiied experts informed the visitors individually about the speciic grinding solutions needed for their applications.

In addition, selected suppliers

presented their products while providing

information and related issues.

June

The month of LASER

DANOBAT received key people from the sheet metal processing ield during the month of June who had the unique opportunity to see at irst hand the advantages of the new laser cutting machine model IRIS.

The DANOBAT ibre laser cutting machine, IRIS model, enables a great reduction in production costs

associated with energy saving, in

addition to signiicant reductions in ixed maintenance costs and consumables.

04-10 June

10th Turning and Grinding Open

House

DANOBAT grinding and turning

solutions developed for top customers in leading industries were exhibited during the 10th open house days.

The visitors had the opportunity to

understand DANOBAT’s way of developing advanced solutions hand in hand

with its customers and seeing the specialized Research & Development

Centre. 04-10 June

SORALUCE milling and boring

machines at a glance

SORALUCE opened the doors of the

milling and boring machines assembling

workshop from the 4th to the 6th of June.

It consisted of a guided tour visit for key customers and stakeholders

showcasing the Advanced Head Manufacturing Centre, the sub-assembly of different machine parts and the inal assembly facilities of milling and boring machines, with machines already inished and in the assembly process.

01 |

01- Open House in SORALUCE 02- Open House in BIMATEC SORALUCE

FEATURED UPCOMING EVENTS:

OCTOBER

DANOBATGROUP Shared

Innovation Space: DANOBATGROUP

will organize during the month of October 2013 a special event to showcase the latest research projects

and innovations at its different factories in Spain. DANOBAT and SORALUCE solutions as well as the latest cutting

edge innovations from the specialized Research & Development Centre will be showcased to featured institutions, customers and employees.

02 |

NOVEMBER

Open House: BIMATEC SORALUCE will hold its annual open house from 12th to 16th November presenting its new outstanding milling, boring

and turning technology products.

BIMATEC SORALUCE will showcase live machining trials on more than

10 milling-boring machines and vertical turning machines at the new

Technology Centre located in Limburg.

Arriaga kalea, 2

P.O. Box 33

E-20870 ELGOIBAR Spain

Tel.: +34 943 74 83 00

Fax: +34 943 74 36 74

[email protected]

www.danobatgroup.com

cutting edge - danobatgroup´s customer magazine

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