by Kathrin Rehor, MAPAL The machine tool manufacturer bavius technologie gmbh was able to achieve impressive material removal rates of over 20 litres per minute on its new high-end model HBZ AeroCell 160 with a new generation of aluminium high-volume milling cutters from the tool manufacturer MAPAL. The result of this successful collaboration comes at the right time for the aerospace industry, which is taking off again following the downturn caused by coronavirus. The machine manufacturer, which emerged from the Handtmann Group, has been operating as an independent company under the name bavius technologie gmbh since a management buy-out in 2017 and has its headquarters in Baienfurt. Despite all the changes, the business area has remained the same for almost four decades. CNC machining centres are designed and built for the precise high-speed machining of large workpieces made of aluminium. “Over 80 percent of our work is for the aerospace industry, where our AeroCell machines are used primarily to produce large structural parts”, explains Amit Paranjape, Sales Manager at bavius. Customers are aircraft manufacturers and their first and second tier suppliers. Large volumes are required to make full use of the bavius systems. There are currently two different machine lines from Baienfurt. The PBZ profile machining centres are used, among other things, to machine seat tracks for aircraft. The HBZ horizontal machining centres are used to manufacture large structural parts from solid. “Everything long and wide is machined here”, explains Paranjape. “Users can machine all the necessary parts for the airframe of an aircraft on our machines.” The material removal rates are extreme, as one example from a bavius customer shows, who mills out finished parts weighing only 35 kilograms from blanks weighing 1.3 tonnes. Trend towards horizontal machiningThe aerospace industry is undergoing a transformation in terms of machine concepts. After decades of preferring to work on gantry machines or vertical machining centres, horizontal machines are now preferred for new investments, where the components are clamped upright and the spindle is moved horizontally. The main advantage of the horizontal design is the easier removal of the large quantity of chips, which practically fall into the chip conveyor by themselves. At bavius, it’s clear that the aerospace industry has recovered from Covid. Passenger numbers have already returned to pre-pandemic levels and are continuing to rise. As a result, new planes are needed again, which keeps machine manufacturers busy. Demand in Germany, France, Spain and other countries reveals that there is a lot of investment in Europe again. Dynamic machines with high spindle power are particularly sought after. bavius is currently expanding its high-end series HBZ AeroCell with the new AeroCell 160. With a range of mechanical changes, the manufacturer also achieves even greater dynamics with the new machine. Modifications in automation reduce non-productive times. Instead of functioning with hydraulic arms, it is now electrically powered. With the set-up station in front of the machine, a complete pallet change takes two to three minutes. If the pallet is already connected with the part, this takes less than a minute. Tool change has also been optimised with a chip-to-chip time now of 12 seconds. To the limits and beyondThe AeroCell 160 is designed for maximum material removal rates in aluminium. A powerful jet of coolant and a widened chip conveyor ensure that no chip particles can build up anywhere. “Thanks to our concept, we avoid problems that occur with gantry machines. In this way, we can optimally deploy modern tools”, explains Stefan Diem, Application Engineer at bavius. In order to test new machines and at the same time provide customers with references, bavius carries out milling tests that push them to their limits and beyond. “Lots of customers want to see evidence first before they buy a machine”, admits Diem. It is important for the machine manufacturer to use the most efficient tools currently available for the tests, which are then also available for customer demonstrations. bavius regularly tests various manufacturers’ tools. Due to the tight production deadlines, there are not many options. “To save time, it is important for us to have a good exchange with the tool manufacturer”, says Stefan Diem. “We’ve had a good relationship with MAPAL for many years and have always been very pleased with the roughing and finishing tools. I appreciate our close collaboration with MAPAL. We receive excellent advice and are in good hands.” Because milling cutters from the OptiMill-SPM series had previously been used at bavius and performed very well, MAPAL was asked again. It was perfect timing: the tool manufacturer had just finished developing a new solid carbide roughing cutter, the OptiMill-Alu-Wave, and also offered the new aluminium high-volume milling cutter NeoMill-Alu-QBig with indexable inserts for larger diameters. The milling tests are kept simple in design but put the tools through their paces. bavius mills a series of flutes in a large aluminium plate for this. Stefan Diem takes a very pragmatic approach: “if the tool can do the flute, we can also use it to mill pockets and do any other machining.” This means that the determined cutting data can be directly applied to customer parts. The tool could do even moreFor the tests with the OptiMill-Alu-Wave, bavius chose the largest diameter of this three-fluted cutter at 25 mm. At a spindle speed of 25,465 rpm and a cutting speed of 2,000 m/min, the spindle power was gradually increased. Slot number 6 delivered the best material removal rate with a record-breaking 20 dm3/min. This test run was performed with a spindle power of 175 kW, with a torque of 66 Nm, and a material removal rate of 30 mm. The machine stopped during tests at higher powers. “The tool can be fully deployed, the limiting factor is the spindle”, Diem comments on the result. “With the 25 mm OptiMill-Alu-Wave, we have achieved a new dimension in aluminium machining. The milling cutter is definitely better than anything we had previously used.” bavius used the Safe-LockTM system as pull-out protection. “In this speed range, symmetrical pull-out protection is very important in order not to create imbalance”, explains Tim Rohmer, Product Manager Solid Carbide Milling Tools at MAPAL. A Weldon flat, which is often attached to such tools as pull-out protection, is the wrong solution here. To guarantee the smooth running of the machine, there is no way around careful balancing, even with symmetrical tools. The tests in Baienfurt were also met with a great deal of satisfaction in terms of surface quality. The cord geometry of the OptiMill-Alu-Wave ensures optimum chip formation. The polished groove profile ensures seamless chip removal, which is supported by the central cooling of the tool in cooperation with the external cooling in the machine. In further tests, pockets were milled into the aluminium plate, with a material removal rate of 16 litres still being achieved with very good surfaces. For Application Engineer Thomas Jungbeck and Component Manager Alexander Follenweider, who monitored the tests for MAPAL, this is proof of the very good dynamics of the bavius machining centre: “Other machines often stop in the corners and cause high vibrations. This doesn’t occur at all with the AeroCell, which goes round corners almost unrestrained.” As an indexable insert tool, the new aluminium high-volume milling cutter NeoMill-Alu-QBig from MAPAL is an economic solution for larger diameter ranges. In the tests, the 50-mm milling cutter stood out with a high degree of stability and smooth running. It achieved a material removal rate of 18.4 dm3/min. ©bavius The tests at bavius with the new indexable insert tool NeoMill-Alu-QBig from MAPAL, for which the 50 mm diameter was selected, were also extremely positive.
The aluminium high-volume milling cutter achieved a material removal rate of 18.4 dm3/min. On the machine, the milling cutter stood out with its high level of stability, smooth running and low cutting forces. For use at spindle speeds up to 35,000 rpm, MAPAL fitted the tool body with four threaded bores for fine balancing. The high-precision peripherally ground indexable inserts achieve surface finishes of Ra 0.8 µm and Rz 4 µm during rough and fine machining. They are equipped with a polished chip guiding stage to reduce frictional resistance and heat release. Weight was also saved in order to reduce centrifugal forces. “For larger diameters, milling cutters with indexable inserts are the more economical solution”, explains Heiko Pup, Product Manager for tools with indexable inserts, contrasting the NeoMill-Alu-QBig milling cutters with solid carbide milling cutters. With a 25 mm diameter, the two systems merge. “Some of our customers always go for the more cost-efficient indexable inserts if possible, others prefer to save themselves an extra machining step and continue with the solid carbide milling cutter”, explains Stefan Diem. With different possible radii for its tools, MAPAL provides users with flexibility. With the horizontal machining centre AeroCell 160 and the aluminium high-volume tools, bavius and MAPAL provide users with a combination that takes machining structural parts to a whole new level.
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Hoffman Estates, IL – For the second year in a row, customers who choose best-in-class cutting tools, tool holders and workholding products from BIG DAISHOWA will support their local manufacturing training programs at the same time. From October 1–December 29, 2023, BIG DAISHOWA will once again donate a tooling certificate valued at 20 percent of every qualifying order to the buyer’s school of choice through the Tools for Schools program. Schools can redeem certificates for any BIG DAISHOWA product, including best-in-class tool holders, boring tools, cutting tools, workholding products and presetters. Last year’s program was a resounding success! BIG DAISHOWA issued nearly $30,000 in tooling certificates to high schools, vocational schools, colleges and universities. According to Jack Burley, President/COO of BIG DAISHOWA, it’s all in line with the company’s overall mission to support a new generation of skilled workers. “We are committed to workforce development. This program allows our customers to support local communities by providing their future workforce with the same tools they use in their shops,” said Burley. To participate in the program is as simple as 1-2-3:
Burley says that every dollar spent helps students develop skills they can apply in their careers. “By using BIG DAISHOWA tooling in school, students gain experience with the same tools they will use as future engineers and machinists.” BIG DAISHOWA offers nine product lines of precision tooling, workholding, and tool management systems aimed at reducing both the overall process time and the cost per part. Popular products include face mill holders, end mill holders, collet chucks, angle heads and tapping adaptors. The world-leading KAISER Boring System, high-performance Sphinx Drills and UNILOCK Workholding systems are also available, as are CAT, BT, HSK and BIG Capto systems. If your machine is equipped with a BIG-PLUS spindle, remember that BIG DAISHOWA is the officially licensed provider of BIG-PLUS tool holders in North America. Don’t accept any substitute dual-contact products on your valuable machines. About BIG DAISHOWAAs a member of the BIG DAISHOWA Group (Osaka, Japan), BIG DAISHOWA Inc. is a recognized global tooling provider, with manufacturing facilities in North America, Switzerland and Japan. BIG DAISHOWA is also the North American representative of Speroni tool measuring machines, Sphinx high performance drills, mptec measuring stands, Tekusa spindle cleaners and the UNILOCK zero-point workholding system
Are you looking for new ways to machine keyways? What about internal or external teeth or spline? Platinum Tooling has you covered with the Rev Broaching Tools for CNC lathes & Machining Centers. REV S.R.L., located in Northern Italy, is the manufacturer of innovative broaching solutions for CNC Lathes and Machining Centers. Ideal for machining simple keyways or internal and external profiles, both teeth and splines. Common profiles including square and hexagon are easily achieved; custom profiles are available. Platinum Tooling offers innovative broaching solutions from REV S.R.L. for both CNC Lathes and Machining Centers. All REV broaching tools offer excellent performance with long insert life and high surface quality. A wide variety of standard and custom profiles and sizes are available.
The REV System for CNC Lathes and Machining CentersStandard and Custom ProfilesA wide variety of standard and custom profiles and sizes are possible with REV broaching tools
Enhancing sustainability by tool reconditioning and recycling services by Masatoshi Kageyama | OSG Corporation As a global company manufacturing responsible products, OSG is committed to a healthy planet and society. In order to reduce environmental impact, OSG actively implements initiatives relating to resource and energy conservation, waste reduction, prevention of pollution, and material recycling in various processes throughout the OSG Group. OSG’s tool reconditioning program is a part of the company’s commitment to promote resource conservation and to improve energy efficiency in its business activities. The primary benefit of tool reconditioning is obvious: reduction in overall tooling costs. Although many shops regrind their own drills, few shops have given thought to regrinding high performance cutting tools, even though substantial cost savings can be obtained. These efforts not only save customers thousands of dollars each year but are also environmentally friendly and sustainable. As a comprehensive cutting tool manufacturer, OSG is capable of regrinding and recoating an array of products, such as solid carbide tools, HSS tools, PCD tools, rolling dies, specials, and more. Tool reconditioning services provided by OSG restore used tools to like-new condition. OSG’s tool reconditioning division uses original OSG manufacturing drawings for all regrinding processes. OSG Group companies also adhere to the OSG quality control manual and use the same inspection equipment used by the manufacturing division during the inspection procedures. With tool reconditioning facilities in 14 countries, OSG can respond to customer needs worldwide. In addition to tool reconditioning, OSG also offers customization services to help manufacturers optimize machining based on individual application needs. OSG USA's Regrind CapabilitiesOSG USA has comprehensive Regrind and Coating Capabilities for Drills, End Mills, Reamers, Taps and more! Get the best coating based on your application and tool. Additional Coatings available. Drills
End Mills
Reamers
How to Get the Ball RollingEvaluation Services Tailored for Your Needs
To begin, contact your nearest Next Generation Tool regional manager to set up an evaluation appointment. We will evaluate each and every one of your application before sending the tools off for reconditioning. Sacramento, CA — Next Generation Tooling, a prominent name in cutting-edge tooling solutions, is thrilled to announce its recent appointment as the exclusive manufacturer's agent for Ergo Advantage across its entire territory. This strategic partnership marks a significant milestone for both companies and reinforces their commitment to providing comprehensive solutions for safety and efficiency in manufacturing environments. Ergo Advantage, a leading producer of safety matting solutions, has garnered recognition for its innovative products designed to address key concerns in the industrial setting. Their extensive research and development efforts have resulted in the creation of two distinguished product lines—the Safe-Flex™ Floor System and the Stand-Safe™ Mat. The Safe-Flex™ Floor System is engineered to tackle a range of workplace challenges, offering features such as anti-fatigue, anti-microbial, anti-slip, anti-static properties. This system is a testament to Ergo Advantage's dedication to enhancing worker safety, comfort, and overall well-being. On the other hand, the Stand-Safe™ Mat exemplifies innovation in lean manufacturing initiatives. Crafted with precision and attention to detail, this mat complements ergonomic practices, providing an effective solution for reducing fatigue and improving productivity in workspaces. Next Generation Tooling's appointment as the exclusive manufacturer's agent for Ergo Advantage underscores their commitment to delivering comprehensive solutions to their clients. This collaboration enables Next Generation Tooling to provide access to Ergo Advantage's cutting-edge safety matting solutions, ensuring that businesses across their entire territory can benefit from the latest advancements in workplace safety. "We are thrilled to represent Ergo Advantage, a company synonymous with innovation and excellence in safety matting solutions," said Chris Savolainen, President & Founder at Next Generation Tooling. "This partnership aligns seamlessly with our commitment to offering our clients the latest and most effective solutions to enhance safety and productivity in their manufacturing processes." As Next Generation Tooling assumes the role of the exclusive manufacturer's representative for Ergo Advantage, customers can expect streamlined access to the full range of safety matting solutions, expert guidance on product selection, and unparalleled support for their ergonomic and safety initiatives. For more information about Ergo Advantage's safety matting solutions, please contact the team at Next Generation Tooling. About Next Generation ToolingNext Generation Tooling is a well respected provider of cutting-edge tooling solutions, offering a comprehensive range of high-quality products designed to enhance efficiency and performance in machining processes. With a commitment to innovation and precision, Next Generation Tooling serves as a trusted partner for businesses seeking advanced tooling solutions. About Ergo AdvantageErgo Advantage is a leading producer of safety matting solutions, specializing in anti-fatigue, anti-microbial, anti-slip, anti-static, and lean manufacturing initiatives. Years of research by industry experts have driven innovation in the design and application of their two product lines—the Safe-Flex™ Floor System and the Stand-Safe™ Mat. Ergo Advantage is dedicated to providing cutting-edge solutions to enhance workplace safety and well-being.
NEW YORK--(BUSINESS WIRE) - Techniks Tool Group (“TTG)”, one of the largest manufacturers and suppliers of branded highly engineered, consumable, high-cost-of-failure aftermarket and OEM tooling products in North America, announced that it has acquired Eppinger Group (“Eppinger”), a Denkendorf / Baden-Württemberg, Germany-based leading designer and manufacturer of sophisticated, high precision static and live tools, complete CNC (Computerized Numerical Control) tooling systems, rotary tables for CNC machines, and gears and gearboxes for robotics applications. TTG is a portfolio company of Z Capital Partners, L.L.C., the private equity fund management arm of Z Capital Group, L.L.C. ("ZCG"), a leading privately held merchant bank. The transaction is expected to close later this week. Founded in 1925, Eppinger is one of the leading mechanical engineering companies in the field of development and production of tool holders, specifically for CNC turning & milling centers and precision gears. Eppinger has three manufacturing and distribution facilities located in Germany, India, and the U.S. and holds extensive direct relationships with machine shops, machine OEMs and robot manufacturers in Europe and Asia. The combined business will be named Eppinger Technologies and will expand its broad product offering of highly engineered solutions to cover both milling and lathe CNC machines. Eppinger leadership, including CEO Uwe Eppinger, will remain with the combined business. Mr. Eppinger will also remain an investor in the combined company. "This transaction will enhance our global positioning and provide us with a broader platform, expanded manufacturing and distribution channels, and a wider customer set from which to grow," said Dean Glover, CEO of TTG. "The combined entity will be renamed Eppinger Technologies, and we will continue to build upon our industry-leading channel presence and diversified suite of products." “We are pleased to add Eppinger, a company with a rich German engineering history in providing the highest quality products to its customers, to our portfolio. Eppinger is a highly complementary business to Techniks Tool Group and together, they represent an extremely compelling partner in the attractive tooling market,” said James Zenni, Founder, President and Chief Executive Officer of ZCG. “We look forward to building on this strategic combination to continue to capture market share and drive substantial global growth.” “For nearly 100 years, Eppinger has focused on providing the finest high-quality solutions for our customers,” said Mr. Eppinger. “We were attracted to the ZCG team and Techniks Tool Group because they share our focus on innovation, superior quality, technical support and customer service, and we are excited to partner together to address the technical needs of an expanded customer base across the market spectrum.” About EppingerThe Eppinger Group is a company based in Denkendorf / Baden-Württemberg. The company has been specializing in precision tools for lathes for almost 100 years and is a leader in the design and manufacture of tool holders for CNC Turning & Milling Centres. Eppinger currently has more than 53 patents underpinning a product range that includes fixed and driven tool holders and complete tool systems. Recent Eppinger Innovations include rotary tables and industry leading precision gear units that are used in all areas of mechanical engineering. The product range includes angular and coaxial gear units as well as geared motors for a wide variety of applications in automation, robotics and mechanical engineering. The high-quality products occupy a leading position on the international market. Eppinger offers individual and end-to-end solutions from a single source: from development and design to production. For more information, please visit https://eppinger.de/en/. About Techniks Tool GroupTechniks Tool Group is the North American industry leader in high quality branded toolholding and workholding solutions for demanding and high precision CNC applications. TTG has an unparalleled network spanning the manufacturing and tooling industries with a focus on strategic supplier relationships, leading channel access, extensive engineering capabilities and unmatched customer support. For more information, please visit www.technikstoolgroup.com. About ZCG ZCG is a leading, privately held merchant bank comprised of private markets asset management, business consulting services, technology development and solutions.
For almost 30 years, ZCG Principals have invested tens of billions in capital and have industry leading track records in private equity and credit. ZCG has approximately $6.5B of AUM in asset management and its investors are some of the largest and most sophisticated global institutional investors including pension funds, endowments, foundations, sovereign wealth funds, central banks, and insurance companies. ZCG has a global team comprised of over 375 professionals. For more information, please visit www.zcg.com. Platinum Tooling now inventories a wide selection of Rineck Shrink Fit Tool Holders in the most common styles and sizes at thier headquarters in Prospect Heights, Illinois. These high-quality German made tool holders are produced for high accuracy and maximum rigidity.
Stock tools are available in imperial (inch) and metric sizes with slim 3° and standard 4.5° execution with the following machine connections:
For more information on Rineck Shrink Fit Tool Holders or any of our other precision machine tool accessory lines, contact us! |
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