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Industrial Hardware and Machine Parts

Custom hobbing tool enables 45-degree angles

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To machine helical gears at 45-degree angles, Gurecky Manufacturing Service Inc. installed a customized multifunctional machine from DMG Mori Ellison Technologies with a hobbing tool from Heimatec.

As the competitive nature within a market increases, so does the need for increased productivity and through put by handling the parts less. One way to meet this need is to accomplish more operations in one setup. Gurecky Manufacturing Services Inc. of Rosenberg, Texas, decided to enhance its manufacturing operations by purchasing a machine that could act as a regular CNC lathe and machine helical gears at the same time. However, a custom hobbing tool from Heimatec Inc. (Prospect Heights, Ill.) was necessary to achieve a desired 45-degree helix angle.

 

 

Gurecky was founded in 1983. Today, the company operates out of a 43,000-square-foot facility, serving the oil, gas and energy industries. The company produces multifaceted precision parts ranging from prototypes to mass production. To remain competitive, Gurecky constantly invests in advanced manufacturing equipment. For example, since buying its first DMU 50 ecoline from DMG Mori (Hoffman Estates, Ill.), the company has moved production from traditional vertical machining centers (VMCs) to the more versatile five-axis DMG Mori machines.

 

In late 2012, Gurecky President John Dorman decided it was time to purchase a CNC machine specifically for gear hobbing. The company approached DMG Mori Ellison Technologies and decided to install its customized multifunctional NLX 2500SY/700 with the ability to hob gears. What made this particular application challenging was the fact that Gurecky needed to machine helical gears at a 45-degree angle. This was a problem because standard hobbing units only allow ±30 degrees of helix angle adjustment due to loss of rigidity.

 

 

Undaunted by the task, Heimatec said it could design a custom hobbing tool with ±45 degrees of adjustment to use in conjunction with the new machine. According to Preben Hansen, president of Heimatec, lathes and their coordinating controls are more sophisticated these days, so a dedicated hobbing machine isn’t always necessary. “As long as the machines can handle it, we can build a tool to do it.”

 

After a few months of testing, the tool was complete and ready to be put to work. Rigidity is the key to tackling this difficult machining operation, he says. “It’s a pretty difficult operation, and when you’re twisting that tool, there’s a lot of leverage. You have to be concerned with the rigidity of the tool. When you’re turning at 45 degrees and milling at the same time, you tend to lose rigidity,” he says.

 

To combat this loss, Mr. Hansen says Heimatec’s hobbing units are designed with a strong bearing structure. In turn, this structure provides the rigidity necessary to reduce backlash and increase tool life. It also increases the performance of the hobs that do the cutting, he says.

Türkiye endüstrisine, alana özel, spesifik yayınlar üreten MONETA Tanıtım’ın sektörel dergilerinin editörlüğünü yapmaktayım. Yeni nesil, dinamik yayıncılık anlayışıyla, dijital ve basılı mecralarda içerik geliştirmek için çalışmaktayız.

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Industrial Hardware and Machine Parts

Hermle large part machining centres in mould and tool making

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HETEC’s claim of “Performance is not a matter of chance” exactly expresses the philosophy and strategy of the machining services supplier from Breidenbach! And that philosophy was born out of Friedhelm Herhaus’ experience: For too long he felt hampered in his desire to put his specialist knowledge and skill to practical use and to the customer’s benefit. In such cases there is only one way forward: setting up one’s own operation. Together with his brother Günter Herhaus, he founded HETEC OHG, originally in Bad Laasphe. As the scope of the business grew, brother Werner Herhaus joined the company as well, and in 2000 the next milestone was reached with the founding of HETEC GmbH.

That meant anything but standstill, however, and in rapid succession the company invested in CAD/CAM systems (3-axis) and, in 2002, in the first five-axis machining centre as well as the associated data processing and organizational environment. In 2003, a new production hall focusing on large part machining was built at the present company headquarters in Breidenbach. Each shouldering executive responsibility for specific business areas, the three brothers systematically invested in more CAD/CAM systems, CNC machine tools, workflow optimization and remote monitoring of processes. This put them into a position to provide their growing customer base with state-of-the-art manufacturing technology for highly demanding, complex tool and mould construction components as well as large scale basic tools at all times.

 In order to meet the exacting and ever increasing customer requirements with sustainable reliability, HETEC has included five-axis machining centres from Maschinenfabrik Berthold Hermle AG in its machine park since 2009.This began with a C40 machining centre that was followed by a C 30 U and – as soon as they became available – the first large machines of the C 60 U and C 50 U series. In the course of time, a C 400 U was purchased for machining smaller items, and more recently by another large machine, a C 52 U.

 Friedhelm Herhaus has this to say about the cooperation with Hermle AG: “We have always received very good and fair advice from Hermle and we were and still are delighted with the 5-axis concept, with the performance, the very high degree of precision, the accessibility, the excellent and fast service as well as the very good support in all phases of a project.” As a practical and graphic illustration of this, he pointed out that to date the C 40 U machining centre purchased in 2009 has already clocked up over 30000 spindle running hours – and it is still using the original spindle! Not to mention the fact that the precision values recorded in a measurement log from 2016 simply repeated those that had been recorded seven years previously!

 It is worth mentioning that, despite the broad range of applications in the areas of full processing and finishing work, the Hermle machining centres are ‘only’ equipped with the standard tool magazines. The plausible reason for this is that HETEC has developed its own tool/magazine management system that allows all the milling machines and machining centres (each of which has the same HSK-A63 tool holding fixture, by the way) to be tooled according to the order and the work to be done. Altogether this involves around 2000 ‘sharp’ tools, each provided with a chip, including around 250 different milling tools and around 300 for drilling and thread cutting. This means that the tools can be changed ‘blind’, i.e. deployed as required and with drastically reduced changing and equipping times.

With the purchase of the new C 52 U five-axis machining centre, HETEC went another step further by ordering the HIMS (‘Hermle Information Monitoring Software’) base package for the first time. HIMS provides a display of the life status and transmission of the information by email as required. This fits perfectly to HETEC’s manufacturing and (remote) monitoring strategy: single-shift normal operation and otherwise (monitored) automatic operation. With a working range of X = 1000, Y = 1100, Z = 750 mm and the 700 mm swivelling rotary table with a load-bearing capacity of 2000 kg, the C 52 U machining centre is ideally suited to full/finishing machining of extremely intricate tool and mould components or base plates.

 In conclusion, Friedhelm Herhaus was full of praise regarding the teamwork with Hermle, remarking amongst other things that: “Despite their increasing complexity, the Hermle machining centres can be set up very simply, commissioned quickly and they are operator friendly. The good accessibility also enables us to carry out a full redeployment on the large machines from one workpiece to the next within 15 minutes. This means that even without further automation, we achieve spindle running times of 400 hours per month and machine as a single-part manufacturer. Another example of Hermle’s performance capabilities can be seen in the C 52 U five-axis machining centre project, which we needed very quickly to satisfy urgent customer requirements. We received our order on condition that capacity for 8 x 140 hours of manufacturing performance should be available on schedule. With Hermle’s help, we managed to set up and commission the C 52 U in a short space of time, and to meet the availability requirements not just temporarily, but in the long term as well. It really isn’t every supplier that can supply such a consistent and comprehensive package exactly on time – even in Germany with its reputation for machine construction there is not a great deal of choice.”

 Hermle’s five-axis machining centres are now operating in an air-conditioned hall, where they can supply the required degree of precision (e.g. 2/100ths mm deviation on a 500 mm milling stretch over long periods) giving the HETEC team a significant edge over the competition!

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Industrial Hardware and Machine Parts

ABB and Formula E partner to write the future of e-mobility

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“ABB FIA Formula E Championship” brings pioneering technology leader ABB as title sponsor to the world’s first fully electric international FIA motorsport series.

ABB and Formula E are teaming up in a ground-breaking partnership to champion e-mobility for a sustainable future. Since its first race in Beijing in September 2014, Formula E has established itself as the number one all-electric international motor sport. In the next level of development, global pioneering technology leader ABB is bringing its name and innovation and technology leadership to the series, which will be now known as the “ABB FIA Formula E Championship.”

With its unrivalled expertise in electrification and leadership in electric vehicle charging solutions, with the largest installed base of fast-charging stations for electric vehicles worldwide, ABB is the ideal industry partner for Formula E. Formula E serves as a competitive platform to develop and test e-mobility-relevant electrification and digitalization technologies, helping refine the design and functionality of electric vehicles and infrastructure as well as the associated digital platforms. By joining forces, ABB and Formula E will be ideally positioned to push the boundaries of e-mobility.

“We are extremely excited to partner with Formula E in writing the future of e-mobility,” said ABB CEO Ulrich Spiesshofer. “Today, two pioneers are uniting. ABB and Formula E are a natural fit at the forefront of the latest electrification and digital technologies. Together, we will write the next phase of this exciting sports activity and foster high-performance teams. Together, we will write the future – one electrifying race at a time.”

Alejandro Agag, founder and CEO of Formula E, said: “This is a historic day for Formula E and I’m honored to welcome the global technology leader ABB as the title partner of Formula E, with its background and expertise in the field of electrification and digital technologies. Our two companies are synonymous with pushing the boundaries of what is possible. Together, as partners, we will showcase breakthrough technology on a global scale to fans and consumers who follow the ABB FIA Formula E Championship.”

As the world leader in electric vehicle infrastructure, ABB offers the full range of charging solutions for electric cars, electric and hybrid buses as well as electrification solutions for ships and railways. ABB entered the EV-charging market back in 2010, and today has a fast growing global installed base of more than 6,000 fast chargers.

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Industrial Hardware and Machine Parts

Secure remote access for industrial machines for dummies

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HMS Industrial Networks announces the release of the book “Secure Remote Access for Industrial Machines for Dummies” eWON® Special Edition. After-sales service and support for industrial machines are costly and time-consuming. Experienced engineers and technicians travel to customer sites to diagnose issues, answer questions, provide training, and resolve problems. Wouldn’t it be awesome to be able to quickly and securely perform diagnostics and resolve most of those issues remotely?

This is underlying theme for the book “Secure Remote Access for Industrial Machines for Dummies,” from HMS Industrial Networks.

The book describes how eWON products from HMS work and how they allow readers to:

  • Learn the business benefits of remote Access
  • See how to ensure secure access via the Internet and clouds
  • Understand how to can diagnose and solve problems remotely

The target audience for this book are automation engineers or field technicians working for a machine builder or original equipment manufacturers (OEM’s). With a strong understanding of the machines that they build or support, they are not necessarily as comfortable with new technologies such as cloud computing, remote access, information security and how Internet works in general. The book addresses these topics and more, and is written primarily for “non-techie” readers.

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