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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.

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Industrial Hardware and Machine Parts

Easy it connectivity for machine tools

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The implementation of umati (universal machine tool interface), which enables machine tools to exchange and share information efficiently, has tremendous potential for optimising production. Mitsubishi Electric, together with more than 50 machine tool manufacturers, is helping to show how the digitalisation of production can be achieved in a joint live umati demonstration during the EMO 2019 exhibition.

The networking of machines, systems and software is described as “one of the most important trends in manufacturing” by the German Machine Tool Builders’ Association (VDW). The organisation also states that “today’s customers expect to be able to integrate new machines into their own IT ecosystems with no difficulty” and that umati is designed to achieve this “easily, quickly and securely”.

Using umati1  can help machines and devices to communicate efficiently through one language. It offers a common interface using the international interoperability standard OPC UA. The VDW is describing umati as representing “a quantum leap in the implementation of Industry 4.0 in production.”

Frederik Gesthuysen, Marketing Manager CNC, Factory Automation EMEA, Mitsubishi Electric Europe B.V., confirms “We are supporting umati, as we believe it is an important technology and one of the key tools for realising the digitalisation of machine tools in manufacturing industry.”

CNC and factory automation solutions from Mitsubishi Electric at EMO 2019 are located at: Hall 9 / D40.

Wire cutting and die sinking EDM machines from Mitsubishi Electric are located at: Hall 13 / B92.

1The acronym “umati” stands for “universal machine tool interface”. It is intended to become a standardised, open, flexible and secure interface to connect machine tools to higher-level IT systems in production environments (e.g. ERP, MES, or peripheral infrastructure like cloud storage).

Company and product names mentioned in this text are trademarks or registered trademarks of each respective organization. All third party trademarks and/or registered trademarks are the property of their respective owners and are acknowledged.

Continue Reading

Industrial Hardware and Machine Parts

Easy it connectivity for machine tools

Published

on

The implementation of umati (universal machine tool interface), which enables machine tools to exchange and share information efficiently, has tremendous potential for optimising production. Mitsubishi Electric, together with more than 50 machine tool manufacturers, is helping to show how the digitalisation of production can be achieved in a joint live umati demonstration during the EMO 2019 exhibition.

The networking of machines, systems and software is described as “one of the most important trends in manufacturing” by the German Machine Tool Builders’ Association (VDW). The organisation also states that “today’s customers expect to be able to integrate new machines into their own IT ecosystems with no difficulty” and that umati is designed to achieve this “easily, quickly and securely”.

Using umati1  can help machines and devices to communicate efficiently through one language. It offers a common interface using the international interoperability standard OPC UA. The VDW is describing umati as representing “a quantum leap in the implementation of Industry 4.0 in production.”

Frederik Gesthuysen, Marketing Manager CNC, Factory Automation EMEA, Mitsubishi Electric Europe B.V., confirms “We are supporting umati, as we believe it is an important technology and one of the key tools for realising the digitalisation of machine tools in manufacturing industry.”

CNC and factory automation solutions from Mitsubishi Electric at EMO 2019 are located at: Hall 9 / D40.

Wire cutting and die sinking EDM machines from Mitsubishi Electric are located at: Hall 13 / B92.

1The acronym “umati” stands for “universal machine tool interface”. It is intended to become a standardised, open, flexible and secure interface to connect machine tools to higher-level IT systems in production environments (e.g. ERP, MES, or peripheral infrastructure like cloud storage).

Company and product names mentioned in this text are trademarks or registered trademarks of each respective organization. All third party trademarks and/or registered trademarks are the property of their respective owners and are acknowledged.

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Industrial Hardware and Machine Parts

Hexagon displays machine tool innovation

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New solutions from Hexagon on display at EMO 2019 deliver faster, accurate, data-rich measurement integrated into the machine tool and a step-change in calibration technology.

Hexagon’s Manufacturing Intelligence division will display at EMO 2019 a range of ground-breaking technologies that address today’s machine tool measurement and calibration challenges while equipping manufacturers to evolve towards Industry 4.0.

Wolfgang Madlener, Product Line Manager Sensors at Hexagon, says: “Hexagon’s ongoing investment in developing smarter manufacturing hardware and software is resulting in innovative products that resolve manufacturers’ current issues and prepare production facilities for the future. For machine tool users this means new ways to more quickly and accurately take measurements on the shop floor and make real-time use of measurement data. Additionally, they can use ground-breaking solutions for calibrating and compensating machine tools.”

Among the innovations on display for the first time will be the LS-C-5.8 laser scanning solution for non-contact surface inspection on the machine tool. It meets customers’ growing demand for an easy-to-use, contactless solution for capturing surface measurement data quickly and directly on the production line. Hexagon is also showing its new ultrasonic touch probe for fully automated thickness measurement, the RWP20.50-G-UTP, which integrates directly with a machine tool. Measuring thickness often requires an elaborate manual setup, which includes the installation of external, manual ultrasonic measuring instruments. Hexagon’s RWP20.50-G-UTP ultrasonic touch probe automates and simplifies the procedure, as part of the machine tool installation, just like a regular touch probe.

EMO 2019 attendees will be able to see Hexagon’s most accurate touch probe for machine tools, the RWP20.50-G-HPP. This radio-wave probe deploys patent-pending laser-triangulation technology inside its measurement unit to achieve extremely high repeatability, low pre-travel variation and low 3D form error. It is ideal for capturing precise measurement results in 2D and 3D and measuring freeform shapes or checking machine kinematics. 

The data the LS-C-5.8, the RWP20.50-G-HPP and the RWP20.50-G-UTP capture will be available in real time on the shop floor, enabling manufacturers to quickly identify and address production issues. Data exchange is essential to smarter manufacturing and Hexagon will show how it has optimised the communication capabilities of its latest generation of radio-wave touch probes, with the introduction of the new RWR95.51 radio-wave receiver.

For manufacturers that rely on machining precision in the hundredths of millimetres or even micrometres, Etalon, part of Hexagon’s Manufacturing Intelligence division, has transformed the calibration of small and medium machine tools. The Etalon X-AX LASERBAR delivers a simpler, faster and more accurate way to monitor and calibrate small and medium machine tools and reduce the risk of expensive machining errors. It generates the complete geometrical fingerprint of a 3- to 5-axis machine tool in an automated way in one to two hours, replacing an entire toolbox of conventional calibration equipment for linear and rotary axes.

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