Insert accommodates low and deep cut depths

By combining two different geometries on the same insert, Walter has created the NRF indexable insert for simultaneous heavy duty rough- and finish-turning applications in the same setup.

The insert can be applied on both low- and high-alloy steels and with the same tool, effectively halving the number of geometries users may need.

In addition, because NRF features a strengthened double groove at the main cutting edge, the doubled chip compression generates short chips.

The V-shape chip-forming area at the cutting radius leads to optimum chip breaking at low depth of cut.

Available in five basic shapes - CNMM, DNMM, SNMM, TNMM and WNMM - and in a variety of Tigertec coatings, NRF inserts can accommodate machining at low (0.8mm) and deep (15mm) cut depths, and cutting forces can be reduced because the curved cutting edge generates a soft flow of swarf.

Cutting-tool PIPs pay dividends for subcontractor

Sandvik Coromant has helped a Dutch CNC turning and milling specialist to cut cycle times, create extra capacity and see-off competition from developing economies.

The growing threat from competition based in developing economies led Abrahams Metaalbewerking to consider participating in productivity improvement programmes (PIPs) around six months ago.

PIPs helped Sandvik Coromant to save its European customers more than EUR70m (GBP60.1m) in 2007.

A PIP improves profitability by increasing machining efficiency, reducing individual unit cost and eliminating unnecessary time and material waste.

Each PIP is tailored specifically to individual customer needs and encompasses many pre-defined steps: bottlenecks and areas of potential improvement are identified; extensive data is gathered and assessed on targeted jobs; potential solutions are examined; reports are run to determine possible benefits; solutions are tested on the shop floor; the customer chooses which solutions to implement; operators are trained on new tooling and processes; and follow-up visits are scheduled to ensure full realisation of savings.

Abrahams Metaalbewerking handles batch sizes as large as 10,000, manufactured from a variety of materials on its range of high-specification Okuma CNC turning, milling and turn-mill machines.

The company turns parts of between four and 250mm diameter, while milling capacity is 1000 x 500 x 400mm.

Reduced or unmanned staff at night and weekends provide 24/7 operations.

The company wanted to accelerate machining times but without buying additional machines or employing more people.

One of the biggest gains was achieved by running pre-release tests using Sandvik Coromant's new GC1125 and GC1515 light turning grades.

Sandrino Rizzo, sales engineer for Sandvik Coromant, said: 'We used GC1125 on AISI304 austenitic stainless-steel components and GC1515 on ST52 steel.

'Both gave a much more reliable process and doubled throughput of turned products.' Based on the latest developments in cemented carbide and coating technologies, the new GC1125 and GC1515 inserts are ideal where applications demand a sharp cutting edge with high edge-line integrity in light turning.

Typical applications include interrupted cuts, machining into shoulders and internal finishing.

GC1125 provides high edge sharpness for secure, burr-free machining of stainless steels and gives the toughness needed for intermittent cuts.

It also performs well in sticky materials and is a good choice for vibration-free machining.

The improved edge line strength and sharpness maintain good chip control, surface finish and tool life at lower feed rates.

GC1515 grade for steel machining combines wear-resistant coating and a tough edge.

This provides the potential to produce more components per cutting edge while maintaining close tolerances, with a minimal number of off-set corrections.

Richard Cornet, who acquired the company in January 2007, said: 'The next step was to improve machine feeds and speeds to create shorter overall lead-times.

'From the results of four PIPs implemented in a short period of time, we managed to gain an extra 600 hours of machine capacity.

'On average we now have actual machine cutting time of 130 hours per week - up from 90 hours previously - a gain of 45 per cent.'.

Corocut XS inserts from Sandvik Coromant feature a front angle increased

Corocut XS inserts from Sandvik Coromant feature a front angle increased to 20deg to improve component quality in parting operations.

The main application is in sliding head machines without a sub-spindle.

Here, customers can achieve higher productivity and better component finish as the insert edge design offers pip and burr-free surfaces.

The inserts are precision ground and available in grade GC1025 for material groups ISO P, ISO M and ISO K.

When parting with a sub-spindle it is more productive to use a straight cutting edge as this is a more stable parting method and will generate the best surface finish.

However, when parting without a sub-spindle it is recommended to use an insert with a minimum insert angle of 15deg to minimise the risk of burr and pips on the component.

Corocut XS parting geometry is designed specifically for precision-made components.

The geometry makes the chip narrower than the groove, which provides chip control.

Parting-off inserts are available in widths down to 0.7mm.

Sandvik Coromant's Corocut XS is a tangentially mounted system for precision machining using sliding head machines.

As well as parting-off, the system is available for a number of other external turning operations, including grooving.

Grooving inserts are available in 0.5, 1.0, 1.5, 2.0 and 2.5mm widths.

In terms of toolholders to accompany Corocut XS, parting and grooving sets high demands on accessibility since the inserts are often fed deep into the material.

This means narrow machining and therefore the length of the tool increases in line with the diameter.

Tools and tooling systems with high stability are therefore very important.

For best economy, Sandvik Coromant recommends its QS holding system as a productive alternative to conventional toolholders when used on sliding head machines.

In comparison with the 12 steps required when changing conventional one-piece toolholders, the QS system offers an efficient two-step set-up procedure to reduce downtime.

The single screw release design of the QS tool holder will reduce toolchange times by around 66 per cent, while the spring-loaded wedges ensure quick and safe extraction and reduce the risk of dropping the holder.

Taegutec coated inserts raise turning output

For high-speed machining of steel, Taegutec has developed its Alpha-AL CVD coated inserts for external and face turning.

Available in Taegutec's TT8115 and TT8125 grades, the Alpha-AL has been designed for high speed and high feed interrupted and continuous turning applications for steel.

With its wear resistance and toughness, the Alpha-AL is suited to mass production operations in the automotive and heavy industry sectors, offering an extended tool life.

The Alpha-AL design is aimed at delivering consistent performance when conducting long batch runs.

The inserts are suited to a diverse range of applications.

The TT8115 grade is applicable to high-speed machining of low-carbon steel and low-carbon alloy steels at feeds of 300 to 800m/min, with carbon steel and alloy steel having a machining range of 100 to 400m/min.

More applicable to lower speed and higher feed machining, the TT8125 is suitable for machining mild steel, low-carbon steel and low-carbon alloy steel at between 200 and 500m/min.

The TT8125 will replace the current TT3500 grade that is being phased out for the new grade that delivers higher performance across a wider feed and speed range.

For cutting carbon and alloy steel the TT8125 comfortably machines at 100 to 350m/min.

The grade guarantees outstanding tool life and productivity, while feeds and speeds are beyond competitor products, said Taegutec.

WNT diamond inserts feature lasered chipbreakers

WNT is offering a range of diamond-tipped turning inserts with a choice of two precision chipbreaker forms, developed for the high-performance machining of aluminium components.

The range of inserts from WNT (UK) are available in polycrystaline diamond (PCD) in fine and coarse grains sizes as well as synthetic diamond (CVD).

A range of laser machined diamond tipped turning inserts from WNT finely controls swarf when machining aluminium and light alloys.

Swarf can now be finely controlled using either the CB1 or CB2 designated chipbreakers that are lasered into the diamond segment of the insert.

'The fine control that we can now achieve with the laser process allows us to remove micron-thick layers of diamond to achieve extremely precise chipbreaker forms to virtually any shape,' said Tony Pennington, managing director, WNT (UK).

'Being able to control the swarf produced means that productivity can be increased and the finished component is protected against damage caused by swarf nesting,' he added.

The inserts are available in a variety of ISO standard shapes, including CCGT, DCGT, RCGT, SCGT, TCGT and VCGT, and with a selection of corner radii between 0.1mm and 1.2mm.

Combined with the two chipbreaker forms and three grades of diamond, this ensures that the range suits the vast majority of turning operations.

The CB1 chipbreaker style is suitable for finishing and super finishing to a depth of cut between 0.05mm and 1.5mm.

The extremely sharp cutting edge creates the minimum of cutting pressure, which also makes it suitable for machining thin-walled components and unstable workpieces.

For semi-finishing and finishing operations the CB2 geometry features a negative edge preparation, produces high surface quality at depths of cut between 0.5mm and 2mm and operates best on solid workpieces under stable conditions.

The three grades of diamond are PCD, PCD-S and CVD-D.

PCD features a fine grain structure to provide a sharper cutting edge and lower cutting forces, and is designed for fine finishing in materials with low levels of abrasiveness.

PCD-S has a more coarse grain structure and is better suited to cut materials with higher levels of abrasiveness.

The CVD-D grade is aimed at super finishing due to its extremely fine grain structure and its ability to be formed to very close tolerances.

Turning grades machine stainless steel

Taegutec has launched its next-generation TT9200 series of TT-Inox inserts for machining stainless steel.

The company offers three grades to cater for a wide range of speed and feeds for the external and face turning of stainless steel: TT9215, TT9225 and TT9235.

The grades have been designed to cover the full spectrum of speeds and feed for stainless-steel turning while delivering high fracture and wear resistance.

The TT9215 operates at high cutting speeds and is suitable for continuous cutting of stainless steel.

On martensitic and ferritic, austenitic and duplex stainless steel, the TT9215 is capable of machining at cutting speeds of 170-250m/min, 140-220m/min and 130-190m/min respectively.

The TT9225 has been developed for general turning applications on stainless steel.

With its combination of wear and fracture resistance, the grade is more robust than the TT9125.

The TT9225 operates at cutting speeds of 130-220m/min, 110-200m/min and 90-150m/min on martensitic and ferritic, austenitic and duplex steel respectively.

For difficult-to-machine applications and interrupted cutting of stainless steel at low cutting speeds, the TT9235 offers toughness and fracture resistance that guarantees exceptional tool life in the most difficult of applications, said Taegutec.

Suited to cutting in a lower speed range than the TT9215 and TT9225, the TT9235 delivers cutting speeds of 110-170m/min, 90-150m/min and 80-130m/min.

The three grades are available in a diverse range of inserts for all stainless-steel turning needs.

Plastics filters for EDM have long life

Plastics filters for wire and die-sinking EDM machines cover a filter fineness range of 1 to 25 micron, have up to 30% less weight than comparable metal filters and have long service life.

Mann+Hummel will extend the range of its large-size H34 series with the addition of new plastics filters.

The new filters for wire and cavity-sinking EDM filters cover a filter fineness range of 1 to 25 micron, have up to 30% less weight than comparable metal filters and are characterised by a long service life.

The new filters will improve the ability of EDM machine operators to match the filtration to the respective process.

At the 2006 Bi-Mu Italian machine tool trade fair in Milan, Mann+Hummel, the development partner and series supplier to the international automotive and mechanical engineering industries, presented its complete range of plastic large-size filters for wire and die-sinking EDM machines.

Additions to the range include the H 34 2090 and the H 34 1390/1.

Mann+Hummelwill extend its range of products for European EDM machines for OEM and aftermarket with the H 34 2090, which has a filter fineness of 3-5 micron.

The new filter in plastic offers EDM operators a weight advantage and improved economy compared to the H 34 2240 metal version.

The H 34 2090 in plastics therefore replaces the H 34 2240 in metal.

For Japanese manufacturers, Mann+Hummel will present the H 34 1390/1.

This is an economic alternative in plastics to the corresponding metal filter.

The H 34 1390/1 plastic filter from Mann+Hummel achieves the same peformance levels regarding filter fineness and service life obtained by the conventional metal version.

A new filter medium with a mixed-fibre fabric enables a filter fineness range of 1 to 2 micron and ensures clean dielectric fluid right from the start thanks to a high initial separation efficiency.

The implementation of new double bellows technology and the deflection of the dielectric fluid into the plastic end cap enable a large filtration surface area and result in a longer service life.

Mann+Hummel recommends use of this filter in wire-EDM processes with the highest requirements for purity of the dielectric fluid.

Such requirements are especially present for surface finishing processes.

There are further versions of this filter with filter finenesss of 3-5 micron, 10 micron and 25 micron.

The filter fineness range of 3-5 micron represents the quality level mostly used for wire EDM machining where standard materials such as tool steel are processed.

The version with 10 micron satisfies the requirements for filter fineness on cavity-sinking EDM machines.

And last but not least, the 25 micron filter offers excellent performance, service life and filtration quality for processes with critical materials such as aluminium or copper.

In addition, all the filters benefit from the advantage of up to 30% less weight against comparable metal filters.

As a result customers save money on the costs for transportation and disposal.

The filters also have integrated handles to facilitate handling during fitting and removal and are equipped with splash protection to ensure higher process reliability.

During product development Mann+Hummel works together with machine manufacturers to optimise the process parameters.

The EDM filters are internally tested and validated for specific process parameters on an EDM machine under long-term service conditions.

In order to achieve high quality EDM results, the filtration of the dielectric fluid has to be matched to the process.

This involves separation of the coarse particles and reducing the amount of contamination.

The coarser the filtration, the more contamination remains in the dielectric fluid which in turn leads to corrosion and electrolytic elution.

Therefore, in wire and cavity-sinking EDM processes, a high filter fineness is an important factor in order to reproduce a defined surface quality and achieve high process reliability.

Filters of inferior quality compromise the results of the machining process and lead to blocked cleaning nozzles, dirt particles in radiators and piping, and can cause high consequential costs.

* About Mann+Hummel - the Mann+Hummel Group is an international company.

In 2005, the company achieved sales of EUR 1.38 billion.

The Mann+Hummel Group currently employs around 9,500 people at 41 locations worldwide.

The company develops, produces and sells technically complex automotive components such as air filter systems, intake manifold systems, liquid filter systems and cabin filters for the automotive industry, and filter elements for vehicle servicing and repair.

For general engineering, process engineering and industrial manufacturing sectors the company's product range includes industrial filters, filter systems, and materials handling systems and equipment.

Mann+Hummel's customers come from a large number of sectors, with series production for the automotive industry occupying a key position.

Electrosion unveils compact ECM machine

Electrosion has launched a compact ECM machine that brings very small electrode gaps, speed and fuzzy logic to electrochemical machining.

The ECM 500 uses Electrosion's Impulse technology, which simultaneously pulses the power and the electrode so that extremely fine detail can be accurately reproduced in very hard materials such as tungsten carbide, making the machine ideal for use in the manufacture of cutting inserts, punches and dies.

ECM differs from EDM in that the workpiece dissolves into the sodium nitrite electrolyte.

The advantages of ECM are that metal removal rates are up to 100 times faster than EDM, and electrode wear is virtually zero, making it unnecessary to manufacture multiple electrodes, and there is no stress or heat introduced into the workpiece.

The disadvantage up until now has been that, due to the significant electrolyte flush rates required by the process, large gaps had to be used, making it virtually impossible to manufacture fine detail.

With its Impulse pulsed flushing technology, the ECM 500 enables engineers to achieve electrode gaps down to 10 micrometres, which makes it possible to produce precise and intricate part geometry, while retaining the advantages of rapid metal removal.

Cavities and parts produced with the machine will require little or no polishing, with surface finishes of 0.1 micrometres Ra easily achievable.

Steve Duffield, managing director of Electrosion, said: 'Oscillating the electrode and the current has made it possible for us to produce a machine which can erode any conductive material, irrespective of its hardness, achieve metal removal rates of 1000mm3 per minute and, with care, surface finishes of 0.03 micrometres Ra with no electrode wear.' Working in a joint venture with the Moscow State Aviation University, Electrosion has created a control system for the ECM 500 that uses fuzzy logic principles.

The technology eliminates the skills required by the operator to achieve repeatability, making ECM a process which will fit into any manufacturing environment.

The ECM 500 can now machine tungsten carbide and titanium.

The machine can erode tungsten carbide 10 times faster than a laser, and produce a surface finish of 0.2 Ra or better.

For manufacturers, the technology will enable parts such as titanium femoral implants and tungsten carbide punches, dies and cutting inserts to be machined economically.

B-axis indexer increases EDM devices' flexibility

System 3R has introduced a B-axis indexer that adds greater flexibility to the operation of wire EDM and sink-erosion EDM machines.

The indexer is a CNC-controlled unit with pneumatic Macro chuck.

It is made from rust-resistant stainless steel and is sealed against dielectric and de-ionised water.

It is fully submersible and available in two options.

Machine-specific units for Agie, Charmilles, Fanuc, Makino and Mitsubishi operate via the host machine's controller.

The unit can alternatively be supplied with a separate programmable CNC controller for machines without additional axis drivers.

When mounted horizontally, this unit measures 230 x 278 x 104mm and weighs just 18kg.

Workpieces fixed to Macro holders are turned automatically to pre-set positions from the machine program.

The unit is also robot ready.

The indexing range is 0-360 degrees with a minimum incremental step of + 0.001 degrees, guaranteeing accuracy.

There are integral air connections for open/close of the chuck as well as a turbo-locking and reference face cleaning.

The B-axis indexer is easily installed and can either be specified when buying a new machine or can be quickly retrofitted.

Agie Charmilles launches automation initiative

Agie Charmilles has launched a new initiative, aimed at precision manufacturers in the UK and Ireland, promoting the business benefits that can be achieved via automation.

The initiative, which focuses on five-axis machining and automation, demonstrates the improved profitability, increased productivity and reduced operational costs that can be achieved by embracing automation.

According to GF Agie Charmilles, there are a number of different reasons why manufacturers could and should consider automation solutions.

These include: cost down pressures; new business won or new business quoted for; need to improve profitability; need to improve cash flow; need to reduce operational costs and overheads; need to improve production flexibility; and need to reduce lead times.

But while these catalysts are increasingly commonplace, the company said many manufacturers have appeared slow on the uptake.

Steve Burrows, milling product manager at Agie Charmilles, identified that a major problem among UK manufacturers' that has affected their acceptance and take-up of automation, are the misconceptions and half-truths that surround the whole automation issue.

Burrows said: 'The take-up of automation in the UK and Ireland lags behind that evidenced in the rest of Europe and the US.

'Popular misconceptions that have affected automation investment include a belief that automation is only viable for large (OEM-type) organisations, and not for smaller SMEs; that automation only works in high-volume production environments; that automation isn't suitable for high-precision, complex part production; and that automation is an expensive course of action, and that a satisfactory ROI takes years to achieve.' Burrows said that 'nothing is further from the truth' and that 'there is compelling and substantial evidence, certainly among GF Agie Charmilles' five-axis customers, where automation is delivering the goods'.

One of the key elements of the automation initiative is to clarify the different types (or levels) of automation that are available to customers.

In essence, there are three types of automation that can be integrated with five-axis machines, and these differ in terms of their purpose, functionality, sophistication and cost.

The three levels of automation are self-contained automation via large capacity ATCs and integrated workpiece pallet changers - all available and equipped as standard on GF Agie Charmilles' five-axis machines; externally-integrated rotary and linear workpiece handling/changing systems and robots (for example, System 3R, Erowa, Fanuc systems), that can be integrated with/to a five-axis machine; and sophisticated flexible manufacturing cells and systems (for example, Fastems systems), that can be integrated to different machine tools and different manufacturing processes.

These different levels of automation are not mutually exclusive and customers can progress from say level one to either level two or three, should their manufacturing requirements and priorities change in the future.

However, irrespective of the optimum 'level' of automation selected at any given time, there are a number of prerequisites, Burrows said, that exist 'before automation can be successfully introduced or even attempted'.

These prerequisites are essentially concerned with ensuring there is a stable and reliable manufacturing process in place and that can accommodate the introduction of automation.

Burrows added: 'Automation is primarily concerned with improving productivity, increasing profitability and reducing operational costs - often a combination of all three.

'These are achieved by increasing the working week to enable the manufacturing process to operate overnight and at the weekends.

'These benefits are virtually impossible to achieve if automation building blocks such as: datum setting; workpiece measurement and inspection; in-process tool setting; powerful, fast and adaptive control system technology and software; sophisticated high-capacity swarf management systems and large-capacity ATCs are not in place.' To ensure the integration and transition to automation, GF Agie Charmilles adopts a technically consultative approach with its customers.

This approach begins with GF Agie Charmilles' turnkey project management staff and applications engineers auditing and acquiring an in-depth understanding of a customer's current and future manufacturing priorities, needs and requirements, as well as an appreciation of the key business drivers that have led the customer to consider automation in the first place.

Automated cutting and forming machinery shown

Intelligent, automated machinery for cutting and forming steel and aluminium includes automatic profile cutting machines, saws, and copy routers.

Elumatec will be showing a whole range of metal cutting and metal forming machinery, including a wide range of profile cutting machines, saws, and copy routers, at the UK's MACH 2008 machine tool exhibition.

Managing director of Elumatec, Phil Heavey, said: "Companies that cut and route aluminium and steel for a variety of needs, have to be assured that the machinery that they use is reliable, efficient and cost effective.

We can offer intelligent, automated machinery for a massive range of applications where the fashioning of metal is required".

Demonstrating Elumatec's advanced technology in aluminium and steel fabrication will be a wide range products, including the advanced SBZ151 5-axis profile machine centre capable of drilling, routing, taping, cutting and notching.

The SAS142 represents the company's extensive range of automatic saws suitable for cutting high-volumes of aluminium profiles for window manufacturing and industrial applications.

The SLK118 copy router will also be on display.

* Software - Also on display be Elumatec's Puma Systems software package that allows the full presentation and extrapolation of technical data for the manufacture of long pieces of aluminium on screen and in 3D.

Specifically developed to serve multiple axes profile-machining centres, this highly advanced software system simplifies the programming sequence, which enables shorter running times and effects time and cost savings for aluminium fabricators.

Heavey said: "This is a significant piece of software for the industry.

The SAT interface accesses data from a huge range of 3D compatible software products and includes clamp management and path and tool optimisation, all clearly visible in 3D to allow the operative maximum visualisation of the component.

Quite simply, the package facilitates greater, faster and more accurate productivity for aluminium fabricators and we are very excited to be able to demonstrate its capabilities in conjunction with our CNC profile machining centres at the exhibition".

Heavey told manufacturingtalk.com: "Our products have massive potential to enhance and improve the production processes involved in all areas of the industrial market, involving metal working and fabrication, and this has been proved by our diverse and ever-growing customer base".

He continued: "As the foremost show in the industry, MACH 2008 provides the perfect forum for us to display our comprehensive product range and to demonstrate the unbeatable versatility, reliability and speed of some of our most popular machines.

Expert advice will also be on hand throughout the show and we relish this exciting opportunity to educate the engineering and manufacturing technologies sector in the advanced capabilities of our machinery".

MACH 2008 is the essential exhibition for this market sector, with the last show attracting over 500 exhibitors and in excess of 22,000 visitors through the NEC doors.

Visitors encompass a broad range of industrial disciplines, including engineering, metal goods, aerospace and automatic industries.

The show is the only venue where all those involved in these industries can find out about new product and system development under one roof, said Elumatec.

Sencon unveils micro-leak tester

Sencon offers a micro-leak tester (MLT), which tests metal can ends for very small or hidden leaks using factory-supplied compressed air.

The MLT filters and de-humidifies the compressed air to the standard required for gauge testing.

The system is available as either online or offline sampling units.

It can be used with a very wide range of diameters, from standard beverage (202) to very large food ends (502).

Sencon offers LST22 compound liner for can-ends

Sencon's LST22 spray timer maximises the efficiency and benefits of electro-pneumatic guns on stationary end-liners, which apply sealant to food-can lids.

The LST22 was originally developed to overcome the problem of solenoid latency on internal spray applications for drinks cans.

A calibrated application of power to the solenoid allows the gun-nozzle to be tightly and consistently opened and closed.

On static compound lining machines, the combination of Sencon LST driver and electro-pneumatic gun improves the consistency and precision of gun-triggering.

Two Sencon sensors co-ordinate gun-triggering with the presence of ends in the station.

This results in more accurate and reliable end-lining operations.

Roboform forms edge-conditions on metal components

DV has released Roboform, a low-maintenance robotic system for forming a variety of edge conditions on metal components.

It has been developed by DVA to produce options such as angled flanges or flat-hemmed safety edges.

The Roboform is suitable for automotive applications.

Michigan component-supplier Ogihara is using the system to produce a curved flange to retain a rubber seal on the window frame of the rear door of Lincoln's MKT crossover SUV.

Soprem leveller/straighteners from Shear-Form

Two series of component part leveller/straighteners from Soprem Automation are now available from Shear-Form Machine Tools.

These Schubert and Soprem design leveller/straighteners are designed to correct any deviations in flatness caused by inner material tensions, which can occur during punching, laser- or plasma-cutting, hardening, nibbling, shearing and coating of steel, aluminium, copper, brass, bimetallic and special alloys.

They are ideal for use in industries making building industry components, electro-technical parts, mechanical and automotive components, perforated parts, drop wires as well as sawing and cutting tools.

The Schubert leveller/straighteners use drive and control technology and are available with either 19 x 6mm diameter leveller rolls to straighten material thickness from 0.5-1mm and up to 23 x 45mm diameter leveller rolls for material thicknesses from 0.5-8mm.

Both models can handle parts from 5-630mm wide and up to 2m long.

Features of the Schubert design include motor-driven or hand-operated worm-gear positioning of the straightening rolls, speed-controlled drives, minimised roller axes.

Bending of the straightening rolls is minimised using support rolls and, as an option, each roll support of the lower part of the straightener can be designed as height-adjustable, resulting in bending of the rolls to eliminate part inner waving.

The Soprem low-cost leveller/straighteners are hydraulically powered to save energy with reduced mechanical parts deterioration for a longer working life.

They have 19 x 12mm up to 19 x 35mm diameter leveller rolls to straighten material thicknesses from 0.5mm up to 4mm and parts from 5mm up to 450mm wide in lengths up to 2m.

Features of this leveller/straightener include motorised or hand-operated longitudinal inclination of the roller bed to help overcome material ductility.

Both the Schubert and Soprem design leveller/straighteners are available with automatic part feed and part ejection as an option.

Seco expands Duratomic process into separate chain

Seco Tools has expanded its Duratomic process technology into a separate and optimised grade chain for grooving and parting-off applications with the TGP25 for steels and TGP45 for various materials.

In the Duratomic process, the aluminium oxide (AL2O3) is arranged at the atomic level to adjust the coating to fit specific applications and workpieces.

Both of the new grades also feature tailored substrates.

When compared to previous Seco grades, the TGP grades offer major improvements in durability and versatility.

While TGP25 is developed mainly for machining steel and TGP45 for parting off steel, both are also suited for stable and high-speed applications in stainless steel and as a tough alternative for cast iron.

Features include: good levels of heat resistance resulting in faster feeds and speeds; prolonged and predictable tool life enabling unmanned production; extreme flank wear resistance for accurately machined parts over a long period of time; low risk of edge build-up resulting in superior surface finish; and a wide application window for flexibility and versatility.

TGP25 is being offered in inserts for groove turning to complement Seco's multi-directional turning program.

When compared against Seco's existing solution for this market, TGP25 offers a 10 per cent to 20 per cent increase in cutting speed to improve productivity while maintaining tool life.

TGP45 is available in Seco's 150.10 insert range.

When compared to competitive Seco products, cutting speeds can be increased by 10 per cent to 15 per cent for a gain in both productivity and tool life.

Cutting-tool PIPs pay dividends for subcontractor

Sandvik Coromant has helped a Dutch CNC turning and milling specialist to cut cycle times, create extra capacity and see-off competition from developing economies.

The growing threat from competition based in developing economies led Abrahams Metaalbewerking to consider participating in productivity improvement programmes (PIPs) around six months ago.

A range of parts machined by Abrahams Metaalbewerking.

PIPs helped Sandvik Coromant to save its European customers more than EUR70m (GBP60.1m) in 2007.

A PIP improves profitability by increasing machining efficiency, reducing individual unit cost and eliminating unnecessary time and material waste.

Each PIP is tailored specifically to individual customer needs and encompasses many pre-defined steps: bottlenecks and areas of potential improvement are identified; extensive data is gathered and assessed on targeted jobs; potential solutions are examined; reports are run to determine possible benefits; solutions are tested on the shop floor; the customer chooses which solutions to implement; operators are trained on new tooling and processes; and follow-up visits are scheduled to ensure full realisation of savings.

Abrahams Metaalbewerking handles batch sizes as large as 10,000, manufactured from a variety of materials on its range of high-specification Okuma CNC turning, milling and turn-mill machines.

The company turns parts of between four and 250mm diameter, while milling capacity is 1000 x 500 x 400mm.

Reduced or unmanned staff at night and weekends provide 24/7 operations.

The company wanted to accelerate machining times but without buying additional machines or employing more people.

One of the biggest gains was achieved by running pre-release tests using Sandvik Coromant's new GC1125 and GC1515 light turning grades.

Sandrino Rizzo, sales engineer for Sandvik Coromant, said: 'We used GC1125 on AISI304 austenitic stainless-steel components and GC1515 on ST52 steel.

'Both gave a much more reliable process and doubled throughput of turned products.' Based on the latest developments in cemented carbide and coating technologies, the new GC1125 and GC1515 inserts are ideal where applications demand a sharp cutting edge with high edge-line integrity in light turning.

Typical applications include interrupted cuts, machining into shoulders and internal finishing.

GC1125 provides high edge sharpness for secure, burr-free machining of stainless steels and gives the toughness needed for intermittent cuts.

It also performs well in sticky materials and is a good choice for vibration-free machining.

The improved edge line strength and sharpness maintain good chip control, surface finish and tool life at lower feed rates.

GC1515 grade for steel machining combines wear-resistant coating and a tough edge.

This provides the potential to produce more components per cutting edge while maintaining close tolerances, with a minimal number of off-set corrections.

Richard Cornet, who acquired the company in January 2007, said: 'The next step was to improve machine feeds and speeds to create shorter overall lead-times.

'From the results of four PIPs implemented in a short period of time, we managed to gain an extra 600 hours of machine capacity.

'On average we now have actual machine cutting time of 130 hours per week - up from 90 hours previously - a gain of 45 per cent.'.

Corocut XS inserts have 20deg front angle

Corocut XS inserts from Sandvik Coromant feature a front angle increased to 20deg to improve component quality in parting operations.

The main application is in sliding head machines without a sub-spindle.

Here, customers can achieve higher productivity and better component finish as the insert edge design offers pip and burr-free surfaces.

The inserts are precision ground and available in grade GC1025 for material groups ISO P, ISO M and ISO K.

When parting with a sub-spindle it is more productive to use a straight cutting edge as this is a more stable parting method and will generate the best surface finish.

However, when parting without a sub-spindle it is recommended to use an insert with a minimum insert angle of 15deg to minimise the risk of burr and pips on the component.

Corocut XS parting geometry is designed specifically for precision-made components.

The geometry makes the chip narrower than the groove, which provides chip control.

Parting-off inserts are available in widths down to 0.7mm.

Sandvik Coromant's Corocut XS is a tangentially mounted system for precision machining using sliding head machines.

As well as parting-off, the system is available for a number of other external turning operations, including grooving.

Grooving inserts are available in 0.5, 1.0, 1.5, 2.0 and 2.5mm widths.

In terms of toolholders to accompany Corocut XS, parting and grooving sets high demands on accessibility since the inserts are often fed deep into the material.

This means narrow machining and therefore the length of the tool increases in line with the diameter.

Tools and tooling systems with high stability are therefore very important.

For best economy, Sandvik Coromant recommends its QS holding system as a productive alternative to conventional toolholders when used on sliding head machines.

In comparison with the 12 steps required when changing conventional one-piece toolholders, the QS system offers an efficient two-step set-up procedure to reduce downtime.

The single screw release design of the QS tool holder will reduce toolchange times by around 66 per cent, while the spring-loaded wedges ensure quick and safe extraction and reduce the risk of dropping the holder.

Taegutec coated inserts raise turning output

For high-speed machining of steel, Taegutec has developed its Alpha-AL CVD coated inserts for external and face turning.

Available in Taegutec's TT8115 and TT8125 grades, the Alpha-AL has been designed for high speed and high feed interrupted and continuous turning applications for steel.

With its wear resistance and toughness, the Alpha-AL is suited to mass production operations in the automotive and heavy industry sectors, offering an extended tool life.

The Alpha-AL design is aimed at delivering consistent performance when conducting long batch runs.

The inserts are suited to a diverse range of applications.

The TT8115 grade is applicable to high-speed machining of low-carbon steel and low-carbon alloy steels at feeds of 300 to 800m/min, with carbon steel and alloy steel having a machining range of 100 to 400m/min.

More applicable to lower speed and higher feed machining, the TT8125 is suitable for machining mild steel, low-carbon steel and low-carbon alloy steel at between 200 and 500m/min.

The TT8125 will replace the current TT3500 grade that is being phased out for the new grade that delivers higher performance across a wider feed and speed range.

For cutting carbon and alloy steel the TT8125 comfortably machines at 100 to 350m/min.

The grade guarantees outstanding tool life and productivity, while feeds and speeds are beyond competitor products, said Taegutec.

Electric wire strand annealing furnace cuts costs

By replacing a gas furnace with an electrically heated furnace, a UK speciality wires producer has reduced energy costs and the mill's 'carbon footprint'.

The UK's oldest manufacturer of specialty wires, Webster and Horsfall, has replaced a gas furnace with an electrically heated furnace from Meltech Engineering.

The electric furnace has cut energy costs and reduced the company's carbon footprint.

The Meltech MT1100 is used for strand annealing Webster and Horsfall's range of austinitic and super duplex stainless steel wires.

Founded in 1720 by James Horsfall, Birmingham-based Webster and Horsfall manufactures carbon steel spring, music and rope wire, stainless steel spring wire, low alloyed steel spring wire and strip for springs, clips and pressings.

Over the past 12 months its energy costs have increased by over 50%.

"We needed to cut our energy costs and contacted Meltech Engineering," said Charles Horsfall, managing director, Webster and Horsfall.

"The MT1100 is far more energy efficient than our gas furnaces.

It also gives us greater versatility in our manufacturing operations.

Until now we've had to start the gas furnace the night before using it to give it time to heat up to temperature; the cost against demand for annealing means we can no longer justify keeping the gas fired furnace on all the time.

With the MT1100 we can turn it on as we need it; and the furnace is up to temperature within a fraction of the time," he explained.

The MT1100 furnace is being used to strand anneal stainless steel wires from 0.7mm - 4mm at 1,100 deg C.

It is designed on the Meltech 'low thermal mass' principle and features multi-zone temperature control.

Customisation of element design allows optimisation of the MT1100's performance to fine tune temperature zoning and increased element operational life.

In addition, the MT1100 uses advanced ceramic and insulation materials to give 90% thermal efficiency, leading to more consistent and manageable heating across the length of the furnace and reduced furnace heating running cost.

Horsfall sees the move away from gas to electric as both inevitable and welcome.

"The switch from a gas furnace to the MT1100 will have two positive benefits to our business, as well as reducing our energy costs.

It will improve the quality of our heat treatment and significantly reduce our carbon footprint ahead of any government legislation.

Electricity can be generated from various fuel sources which hopefully will improve long-term security of supply.

Ultimately we plan to replace all our gas furnaces with electric," he said.

Nitrogen gas wiping improves steel surface finish

Nitrogen gas wiping process - used to improve strip steel surface finish for automotive body painting - reduced nitrogen consumption by up to 50% when compared with other systems.

At the Tube 2008 International Tube and Pipe Trade Fair in Dusseldorf, Germany, the Gases Division of The Linde Group will show a 'breakthrough' process for steel strip gas wiping using nitrogen.

Linde's process reduces nitrogen consumption by up to 50% compared to other patented methods using nitrogen, said the company.

Linde told manufacturingtalk.com that surface wiping with nitrogen is quickly gaining popularity among automotive body strip producers.

The reason is that the process produces a smooth finish and superior look and feel when painted.

"Our new process significantly improves surface wiping quality in continuous strip annealing and galvanising lines compared to conventional solutions using air," said Akin Malas, project manager at the Heat Treatment, Applications Development, The Linde Group.

He explained: "Linde's improved nitrogen wiping application is most appropriate for medium to large size steel strip manufacturers in the semi-finished segment, as well as in integrated iron and steel works".

Nitrogen wiping provides a smooth surface finish and makes higher line speeds possible.

This quality improvement comes at half the cost of current nitrogen wiping processes, due to a significant reduction in nitrogen consumption.

Linde is currently exploring partnerships with wiping knife manufacturers in order to further develop and commercialise this new technology.

There are currently plans to offer a complete system, including heat treatment services for the furnace atmosphere, such as strip heating and annealing.

* About the Linde Gases Division - the Gases Division of The Linde Group is a leading supplier of industrial and medical gases and related services.

From March 31 to April 4, 2008, Linde Gas at the Tube 2008 International Tube and Pipe Trade Fair in Dusseldorf will be on Stand B17 in Hall 8a.

The Linde Group is a world leading gases and engineering company with around 50,000 employees working in about 100 countries and achieved sales in the 2007 financial year of EUR 12.3 billion.

The strategy of The Linde Group is geared towards earnings-based growth and focuses on the expansion of its international business with forward-looking products and services.

Three steel coating mass control systems ordered

Steel Dynamics has ordered three zinc coating mass control systems, which use a proven physics-based coating mass model to generate accurate references and control the knife to strip distances.

Steel Dynamics in the USA has placed an order with Industrial Automation Services (IAS) to design, supply and commission three zinc coating mass control systems.

Two systems will be delivered to the Butler, Indiana, plant and the third to the Jeffersonville plant.

Engineering for the three systems will be executed in parallel with commissioning of the Butler systems occurring first.

For control of the zinc coating, IAS will install the system, which uses a proven physics-based coating mass model to generate accurate references and control the knife to strip distances and stripping gas pressure.

During order transitions, advanced signal processing algorithms enable the controls to estimate coating thickness during order transitions within one coating gauge scan.

Resulting control actions minimise the generation of out-of-spec material and the minimised coating standard deviation allows for zinc savings and a typical return on investment within a few months.

The open architecture control system incorporates IAS's easy to maintain graphical programming interface, and takes advantage of IAS's considerable process know-how and local support.

The new control system will operate in concert with existing Sentek coating gauges to provide improved strip coating performance.

IAS will execute engineering design, project management, installation assistance, commissioning and operator/maintenance training from IAS's offices in Pittsburgh, PA., USA and Newcastle, NSW, Australia.

Meech introduces Jetstream air knife technology

Meech has introduced Jetstream, an air knife system designed for challenging steel-drying applications.

It is accepted throughout industry that compressed air is an expensive and energy inefficient option for many drying applications Meech International said Jetstream is a drying technology that can cut the costs associated with moisture removal An example is rolled and strip steel production, where the cost of drying steel using compressed air delivered through nozzles can be large.

Jetstream removes the moisture from the steel strips in a more cost-efficient manner than compressed air alternatives and, according to the company, delivers better moisture removal, producing a drier and better quality product.

The basis of operation of the Jetstream system is that high-pressure air is generated at a blower unit, delivered to the air knives via ducting and then discharged from the air knives at a high velocity.