Specialist journal from Mikron Agie Charmilles AG for the Milling Technology

Issue 15
Selling price: Euro 3,00 CHF 4,50 US $ 3,00

Page 2-3:

Precision golf club with the UCP 1350

Page 4-6:

Swiss precision for the aviation industry

Page 10:

UCP 600 Vario sets a new standard

Page 13:

Prototype production using a Mikron XSM 600U

Page 16:

Camel races with jockeys from Switzerland

Mikron celebrates delivery of its 1,000th machine with 42,000 rpm

Mikron delivered an HSM 400 U equipped with motor spindle with 42,000 rpm to E.S. Tooling in Belgium. It is the 1,000th machine with a spindle from this power class, a world record in the area of chip removal. Jens Thing For years, Mikron machines with motor spindles have won popularity by virtue of their high reliability. When integrated in a complete machine system, they enable cost-efficient production. The motor spindle has become the standard today for high performance and high speed milling machines due to a range of user benefits. These advantages include: - High power density (high torques and speeds using little space), which, with good accessibility to the workpiece, permits high performance to 54,000 rpm, to tool holders such as HSK 32 E, HSK 40 E, HSK 50 E, HSK A 63, ISO 40 and torques up to 200 Nm. The maximum number of motor spindles will be removed in the range of 12,000 to 24,000 rpm, whereby those with HSK A 63 interface will be preferred. Together with numerous users of its machining centers, Mikron, has over many years, consolidated high speed machining in mold making and in the production of high-quality parts. Therefore, the motor spindle with 42000 rpm and HSK 40 E interface has proved to be a good choice. Mikron is, thus, in the position to celebrate this record of 1,000 machines with 42,000 rpm in industrialized application. Mikron expresses its gratitude to the users of its machining centers for their continued trust in this technology. A spindle, which is delivered 1,000 times in the 42,000 rpm power class, must be distinguished as a chine Module APS (Advanced Process System), ITC (Intelligent Thermal Control) and SPS (Spindle Protection System) developed by Mikron. The smart machine module As a system, APS is in the position to continuously demonstrate the vibration arising during the milling process and to visualize it for the user. With new access to the milling process, the production process can be optimized with a positive influence on surface quality, workpiece precision, tool endurance and spindle service life. Mikron delivers APS as standard with all machines which are equipped with Step-Tec motor spindles. ITC is an automatic compensation of ensuing thermal changes in the Z-axis, which ensures that the machine precision remains in a lower tolerance range over time. SPS constantly monitors the current status of the motor spindle and in case of deviation from the normal status, can stop processing and thus prevent or reduce possible damage to the motor spindle. The Smart Machine has other interesting modules which Mikron would be happy to present at any time. Our distributors in various countries are happy to provide information. Good service is a must Motor spindles in general, and even high capacity motor spindles such as the spindles with 42,000 rpm by Step-Tec, cannot assert themselves on the market with their excellent technology alone. In the event of failure due to wear or other influences, the user needs reliable and quick spare parts. Over the years Mikron has developed a logistics system which ensures high reliability and enables quick

delivery worldwide. Thus, users of Mikron machining centers have shorter downtimes during possible failures. E.S. Tooling gets the 1,000th Mikron machine E.S. Tooling a Belgium company relies on Mikron machines and services. The company was founded in 1996 by the current CEO, Erik Schildermans. E.S. Tooling flourished within a few years. Today, it manufactures molds and tools for the automobile industry and even parts for the medical and optics industry. The deciding factor for acquiring a Mikron HSM 400 U was that this machining center allows 5-axis milling simultaneously, and therefore fully automated operation is possible. Also its important not to forget that Mikron machines have first class ergonomics. The new HSM 400 U for E.S. Tooling is naturally equipped with a high performance motor spindle with 42,000 rpm. It will be integrated in a production cell which consists of a handling system and another HSM 600 U. The target is to operate the plant in 3 shifts 7 days a week. Mikron wishes E.S. Tooling continued great success.

and high speed milling. - Quiet running and concentricity precision which enables good surface quality and precision. Large selection of motor spindles The selection of Mikron motor spindles ranges from 12,000 rpm

reliable product owing to production and assembly safety. For years, Mikron machines have been equipped with spindles made by Step-Tec. Like other spindles too, even the spindle with 42,000 rpm was developed further and with integration into a complete machine system, comes with the smart ma-

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Universal machining Editorial Jens Thing

Brand Manager Mikron

HSM today Nr. 15

Precision golf club with a UCP 1350 by Mikron

For more than 25 years, KRAMSKI has stood for quality, innovation and precision. It is the provider and high-end solutions partner for complicated and sophisticated stamping and injection molding products
The KRAMSKI Group is an independent family concern based in Pforzheim, Germany. In 1978, Wiestaw Kramski, together with a partner, founded KRAMSKI GmbH as a production unit for the manufacture of precision tools. Gordana Uzelac Today, the company designs and manufactures punching dies with which stamped metal parts are manufactured for electrical engineering. The medium-sized proprietary company is among the best in its field worldwide. With over 350 employees at three production locations in Germany, North America and Sri Lanka, KRAMSKI has been a reliable partner for 27 years. In 1999, the company acquired a factory built according to the latest standards in Pforzheim, in the industrial belt of Wilferdinger Hhe, Heilbronner Strasse 10. The key technologies developed by KRAMSKI, such as rivet insertion of Ag and Ag Sn O wires in the punching die, punches of roll-bent parts, use of ceramic, integration of welding technology, measuring technology and assembly in the tool at high speeds resulted in the company taking a pole position in its field. Wiestaw Kramski, a golf player at heart and company leader with

Dear Readers, For months, Mikron has registered an above average number of new orders. Obviously, we are delighted. We owe this success to all those who have trusted us and have been satisfied with the quality of our machining centers. Due to the high load, we are expanding our production unit and are hence looking for additional personnel. By doing so, we would like to improve our current delivery situation significantly. Companies for chip removal in tool and mold making as well as in production are running to capacity worldwide. A geographical shift can be seen for various chip removal tasks, which is however not rigid, but rather always keeps pace with new production technologies and concepts. Thus, Mikron presented seven new machines and further developments at the EMO 05 in Hanover. These innovations are in line with the Mikron philosophy and represent high quality machine construction. We have placed special emphasis on the integrated and optional automatic feature. Thereby, it is always ensured that the best possible access to the work area is provided. More modules will be added to the area of smart machines. Consequently, we will offer our customers more comfort, safety and technology feedback. Our field representatives will be happy to offer personal consultation. For more detailed information on Mikron products, please contact our distributors or visit www.mikron-ac.com. We strive to improve your success with our commitment.

foresight comments on how they reached the top position: This success is attributed to our worldwide approved and popular high performance punching and precision tools as well as to the capability of applying our skills profitably, oriented towards requirements and the market. Today, we manufacture punching dies, plastic parts, and compound parts as well as subassemblies and samples for all fields and industries with a consistent zero-error philosophy. The tools designed and manufactured

by us are the guarantee for high parts volumes, low follow-up costs and maximum productivity. From tool-maker to golfer How does an entrepreneur from the tool and mold-making industry design his own golf putter? What was the background? What was the personal motivation? So many questions that cannot be answered easily in one sentence. So we asked W. Kramski to clarify. In 1987 when the first golf course opened in Pforzheim, I seized the opportunity and started playing golf. The first putter I bought was an old second-hand putter. I liked the grip and feel. Since then, Ive played with many different kinds of putters. As if in a cycle, I added a new putter to my collection every year. Whether in Singapore, Dubai, Japan or Portugal I could never walk past a professional shop. So I tested all kinds and brands of putters. I was not satisfied with any of them putters. This didnt improve even when I started wearing bifocals. On the contrary. The glasses were finally the real reason why I decided to get intensively involved with putters. That is how the idea was born. The HPP putter collection is a trendsetter in functionality, precision and harmony. W. Kramski invested almost three years to

HSM today Nr. 15

Universal machining
High quality materials with perfect processing Whether made of metal or plastic, the products and the high performance precision tools from the house of KRAMSKI are inimitable in the literal sense, as we always work in compliance with the company philosophy: Ideas realised with perfection. And this principle was naturally also the force behind the design and manufacture of the High Precision Putter line. The KRAMSKI High-Precision Putters are processed on a UCP 1350 high speed Mikron milling machine. Milled precisely from extremely high grade materials, threedimensional and individually. Finally, the putters are handpolished for the final finish, until the conical shape is created with the harmonious striking geometry. The putter design is discreet. The shape and line of the High-Precision Putter collection (HPP) is extremely geometric. These are purists in the true sense, which must be especially emphasised in view of the predominantly futuristic design of putters today. Putter already in the top class Within only one year, W. Kramski succeeded in pushing forward his putter to the top class in the world. Some of the best players already have this putter in their golf bags, others are in the process of testing it. It is popular even with new players. Sean Einhaus, the current best German young player three times German Master 2004 and winner of the current German Masters title 2005 in the age group of 16 years, plays with the HPP 325 and is impressed. A quick look at the statistics shows that golf as a sport offers enormous economic potential. Thus, in 2004 in America over 27 million golf tournaments were

design the ideal putter. In fact, with the HPP product line, he has successfully introduced an extraordinary putter range, with which pros, amateurs and even spectacle-wearers experience sensational putts! Development and production With his wealth of experience in tool-making and injection molding, by applying the most modern 3D computer technology, and with the help of high tech processing machines, such as the Mikron UCP 1350, the putter development got a steady boost. Under strict observance of the Rules of Golf as well as through regular consultations with Club Pros and Golf Friends with single-digit handicap and 30 months of development time, the HPP 330 was finally created. In all, ten development stages were required to present the HPP putter line in its perfected form.

Putter HPP 325, ground view

Kramski Milling Shop Manager, Alexander Dukart, during putter manufacture on the Mikron UCP 1350
organised. In Germany, there are already about 500,000. So, W. Kramski assumes that in about two or three years, he will produce between 25,000 to 30,000 putters per year. The charismatic businessman, W. Kramski, knows how to inspire others with his ideas, visions and his courage to set new trends. In the last 27 years, he has won many awards and accolades for his excellent entrepreneurial development. KRAMSKI, the company is seen as a partner of all companies. With its solutions, it supports over 300 companies from 20 industries in Europe, overseas and Asia. Day by day it helps its customers to manufacture precise, process-oriented and, above all, profitable products.

Professional golfer Scott Drummond (right), just 36 hours before start of his game, decides to play with the newly tested Kramski Putter HPP 330 and reached a sensational 7th place at the Volvo Masters in Valderrama 2004, a prize money of 103,125 and qualification on the US PGA Tour. Michael Torres (left) responsible for Marketing and Sales at Kramski accompanies professional players on the tour.

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Universal machining

HSM today Nr. 15

Mikron... on time...on budget

5.33pm Christmas Eve... When many UK companies were preparing to close down for the holiday break and British workers were either making a beeline to the local pub or frantically doing some last minute Christmas shopping or even just collapsing in front of the TV a Mikron VCP 1350 high-performance milling machine was being delivered to BAE Systems facility in Samlesbury. Ged Scully The arrival of the new machine, due for installation at the companys High Technology Tooling Facility (HTTF), had been eagerly anticipated by everybody at BEA Systems involved in the planning and procurement process started just 3 months previously! A similar adrenalin rush was also being collectively felt amongst staff from Agie Charmilles - as this machine was the first Mikron machining center to be installed at BAE Systems and was the culmination of many months hard work and intensive planning. With a requirement that the Mikron VCP 1350 be fully operational by Week 8 in order to start production on wing and fuselage tooling for state-of-the-art jet aircraft ... it was vital that a strong, highly-focused and proactive partnership was created between the two companies so that the time critical deadlines could be achieved. Target reached in time Due to the commitment and dedication of the project teams from BAE Systems and Agie Charmilles the Mikron machine was installed, commissioned and ready for action by the Week 8 deadline. Phil Green, Facilities Engineer at BAE Systems, the man responsible for ensuring that the project went to plan, gives us his view. Volumetric accuracy is essential We knew that the Mikron VCP 1350 was an excellent machine and would suit our requirements perfectly. We were, and still are, particularly impressed with its accuracy and versatility. The tools we require are intricate. Volumetric accuracy, even when machining large workpieces with complex geometries and, irrespective of the materials being machined (aluminium, titanium, tool steels etc.) is essential. We are often working to extremely tight tolerances and thats why we need machine tools that guarantee high accuracy. Such precision is vital in the manufacture of the jet aircrafts outer shape to ensure that its low

BAE Systems install a Mikron VCP 1350 at its Samlesbury facility to make wing and fuselage tools for stateof-the-art jet aircraft

BEA System also produces parts for the airbus. Here the A 380 at the landing after its maiden flight in April 2005
observability (stealth) characteristics are maintained. But in addition to the technology its equally important that we have suppliers and partners that have the necessary project management skills and people who can deliver. The culmination of many months hard work and intensive planning With the tight deadlines we work to teamwork and communication are vital. Our team composed of specialists from Operations and Engineering worked closely with the Agie Charmilles team ... and the results were impressive. The whole process, from start to finish, ran smoothly. Good communication meant that everyone involved was kept up to speed with the latest developments and everyone knew what was expected from them ... and each other. The effort of all concerned meant that we achieved schedule adherence and costs to budget in 3 months! Usually a process of this complexity and magnitude would take 12 months to complete. Although the Mikron machine is the first to be installed at BAE Systems Agie Charmilles technology is widely used across the aerospace sector. Tony Steels, managing director of Agie Charmilles, gives us his view. The installation at BAE Systems is great news for Agie Charmilles. We knew that when we embarked on this project that the competition would be fierce. And we were right. However, we knew that we had the best product (VCP 1350) for BAE Systems requirements and we were right with that assessment too ... because the Mikron VCP 1350 is an incredibly versatile and accurate machine. We were also confident about our project management and the ability to hit the Week 8 deadline. The experience and knowledge of our staff coupled with the expertise of BAE Systems project team dovetailed perfectly. The result achieved are down to the partnership approach adopted. Its a case of great teamwork delivering great results.

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HSM today Nr. 15

Universal machining

When machining engine parts, MTU relies on Mikron machines with Sinumerik 840D

The aerospace engine manufacturer MTU Aero Engines has chosen UCP 1150, five-axis machines made by the Swiss company Mikron for machining turbine and compressor disks. Christoph Manegold MTUs prerequisite was the inclusion of a Sinumerik 840D. This control has been available for a short time as an option for this machine series. The Siemens control was successfully installed in cooperation with Siemens Chemnitz. Excellent results are being achieved with the Mikron UCP 1150 in this configuration. With approximately 5000 employees, MTU Aero Engines in Munich is the companys headquarters and its largest location. A sizeable number of airliners feature engines equipped with components from MTU. The Airbus A 380, the largest passenger aircraft in the world, was recently introduced to the public in Toulouse, France and will be

propelled with engine components from MTU. One important part of turbo engines for airliners include the individual rotor disks in the low pressure and high pressure section. These rotor disks have radial slots into the individual turbine blades are inserted and secured. The rotor disks are made of extremely high temperature, ductile steels with over 50 percent nickel content. Milling machines that must fulfill the highest technological demands are required to machine these disks. Absolute process control during machining is imperative with theses components, as even the slightest uncontrolled structural changes in the material can detrimentally affect operating safety in the air. Machining these components, which are subjected to extremely high temperatures and pressures during operation, requires a high level of technological know-how and first-class machine tool equipment that optimally meets the requirements for turbine production.

The search for the ideal milling machine... Consequently, MTU left nothing to chance in procuring new milling machines with which to machine the turbine disks. MTU conducted a lengthy selection process. A series of machines of well-known manufacturers was selected and intensely tested as to stability, accuracy and surface finish. During test machining of a turbine wheel, a clear favorite was soon established Mikron, a company which is headquartered in Nidau, Switzerland. The five-axis milling machine Mikron UCP 1150 proved to be a very stable machine capable of very quickly and accurately milling the turbine materials, which are extremely difficult to machine. The UCP 1150 is equipped with a motor spindle that can be swiveled over 135 degrees. Together with the directly driven round table that can be clamped hydraulically, it achieves the optimum machining flexibility on five axes with a level of rigidity equal to that of a 3-axis machine. The tool magazine features 46 tool locations with optimum clamp-to clamp time. ... but with Sinumerik 840D please While MTU found the Mikron machine to be an ideal solution in terms of rigidity and kinematical performance, there was still a challenge regarding the control: the Mikron machine was not as yet equipped with a

Sinumerik control. Thanks to its positive experience with Sinumerik controls, MTU Munich standardized on them and tailored its machining programs accordingly. Now there was a challenge for technicians on both sides. Joint meetings were held to discuss how to proceed together. They were soon in agreement that installation of a Sinumerik 840D into the five-axis machine UCP 1150 could begin. Good combination in Chemnitz I was an excellent situation that the Mikron machine series UCP 1150 and 1350 are built in a Mikron partnership plant in Chemnitz. Siemens was already delivering the control cabinets for the Mikron machines from its company WKC (plant for combination technology), which is also located in Chemnitz. Therefore it was not difficult to expand the cooperation to include controls. After the machine for MTU Aero Engines was set up in Chemnitz, it was taken to the Siemens laboratory in Chemnitz for several weeks, where the necessary adaptation and parameterization of the machine to the Sinumerik 840D tool place. Work proceeded with speed and expertise. During commissioning, only a very few readjustments were left to make, summarized Stefan Fahrni, Product Manager at Mikron. Customized production for MTU For MTU, the Mikron UCP 1150 was equipped with a number of non-standard options that are required for machining highly critical turbine and compressor disks. These include continuous process monitoring, e.g., of spindle speed, pressure of the cooling lubricant and quantity of the cooling lubricant.

For the cutting process at MTU, special oil is employed that requires installation of an oil fume extractor with a spark detector system and explosion flaps. This avoids the risk of explosion for the most part and, in an extreme case, pressures that develop are drawn off to the outside. Each work piece is calibrated with an infrared sensor because the MTU pursues a zero-error policy with a 100 percent quality control. Sinumerik, now as an option Four machines have been delivered to MTU already and they have performed with excellence. Further machines are planned. Thanks to MTUs positive experience with the machines, Mikron now expects to sell the five-axis machine UCP 1150 and the somewhat larger UCP 1350 in larger quantities, also with the Sinumerik 840D control.

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Universal machining

HSM today Nr. 15

Electrohilo S.L. A company in constant upswing!

Electrohilo S.L uses a Mikron VCE 800 Pro especially in component manufacture for the aviation industry
In January 1996 Pedro L. Dez founded his own company with the name Electrohilo S.L. Before that, he worked with different companies in the area of blanking and punching dies. Ferran Santandreu Electrohilo S.L. began as a supplier in metal processing and concentrated on blanking and punching dies with the help of wire electro erosion. This was because Pedro L. Diez knew a lot about this industry. With the purchase of a wire machine, Charmilles Robofil 310, he started the adventure with his own company. In 1997, he expanded the company to the aviation sector. Until today, Electrohilo S.L. has been active in both industries. When the company was first set up, there were only two employees; today it employs over 11 workers. Two Mikron machines, six Charmilles machines and two Act Spark machines are part of the machine park. In January 2004, Diez once again proved his trust in the Agie Charmilles Group by buying the Mikron VCE 800 Pro. The VCE 800 Pro helps in processing blade carriers in low pressure turbines in different engines. Due to the high satisfaction with the surface grinding results and the precision during rough grinding and finishing, the managing director decided to acquire another Mikron machine. With the purchase of the VCE 600 Pro, Electrohilo S.L. could expand its customer base to the aviation sector. With the production of hundreds of workpieces using the Mikron machining centers, a stepwise optimization of the manufacturing methods was achieved. Already during the first year, the company has succeeded in achieving excellent productivity in the area machining. One of the most important requirements for business in the aviation sector is meeting the requirements of large manufacturers. For this reason, companies active in this industry must show a variety of certificates. Electrohilo was awarded the quality certificate ISO 9001-2000 and the aviation certificate EN 9100-2003. It also complies with the environmental directives of the European Union. The company is in a constant process of optimization. For this reason, it also applied for the NADCAP certificate for large engine manufacturers, including Rolls Royce, General Electric, Honeywell etc. The close association with aviation projects of Rolls Royce and Airbus (A 380 and TP 400) shows that Electrohilo is a powerful company in the aviation industry. In the foreseeable future, Diez is already considering the purchase of a machine that will also meet requirements for precision and finishing of surfaces during the processing of workpieces with larger dimensions. Without doubt, this is the Mikron VCE 1600 Pro which is designed for traverse paths of 1600 x 900 x 875 mm. At present, Electrohilo S.L. is experiencing a continuous upswing. In its workshop, the company exclusively uses machines from the Agie Charmilles Group, which also include Mikron and Act Spark.

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HSM today Nr. 15

High-speed machining

Shinyoung Precision Co., Ltd., the HSM 400, HSM 400U and XSM 400U by Mikron. A success story from South Korea
The mold designer, Shin Young Precision Co. Ltd. from South Korea, offers highest precision and high performance within a short delivery turnaround and without subsequent machining with Mikron HSM and XSM machines Hocheorl Seong Shinyoung Precision Co., Ltd., the mold designers, was established in 1993. Over the last 12 years, the company continued its growth in mold and injection mold making for components for beepers and telecommunication devices. In 1998, Motorola picked Shinyoung Precision as supplier for its cellular phone network. Shinyoung Precision used this opportunity to customize its mold making and the plastic injection mold making to state-of-the art and to become a top company. In May 1999, Shinyoung Precision was listed on the stock market for the first time. With its constant technical innovations, automation and standardization of the work process, its productivity grew steadily. Even the delivery system was improved and the shorter delivery periods impressed customers. Production round the clock without shifts Under the slogan 1105, Shinyoung Precision had devised a strategy that was to help achieve the following ambitious goals: - only few days (less than 9 days) must be needed for manufacturing a mold - the machining time for an injection mold must be less than 9 seconds - no more finishing work must be required - everything must be completed by the year 2005. With a view to success, the Shinyoung Precision Machines Management decided to purchase machines from Mikron. In the past, Shinyoung Precision had used conventional milling machines with spindles from 6000 to 12000 rpm for manufacturing molds. But when the company had to work with the Slogan 1105 to achieve the target innovations, the old machines had to be replaced with new ones. Machines enabling the use of

spindles with over 40,000 rpm were required. This was the only way to meet the set targets. In April 2002, Shinyoung Precision engineers visited the "International Machine Tool Show 2002" in Busan. There, for the first time, they saw Mikron machines and were impressed. During subsequent meetings with Otra Co Ltd., representative of Mikron in South Korea, the Shinyoung Precision President, Chang-Seok Shin, observed how, who and for what the Mikron machines could be used. He observed that many tool and mold makers were using machines from the Mikron VCP Series for milling, and were successful too. However, the Management decided on a Mikron HSM 400 with automatic pallet changer. Unfortunately, at that time machines with automatic pallet changers were not immediately available on the Korean market, and Shinyoung Precision had to be patient. The company wanted to kill two birds with

one stone: on the one hand, a precise machining of workpieces and, on the other, the possibility of automation. However, it was not easy to wait until August, when this machine would be available on the Korean market. Shinyoung Precision competitors working abroad were already very successful with the Mikron machines and Chang-Seok Shin was afraid of missing the boat. However, his personal wish could not sway the management decision, as it was his company policy to avoid night shifts for employees, but still produce 24 hours, round the clock. First experiences with the HSM 400 By August 2002 things were in place. The HSM 400 was installed at the Shinyoung Precision production premises. They could finally take the first steps in the direction of high speed milling. After a short training period, machining times could be significantly reduced with

the HSM 400 as opposed to the conventional milling machines. Even the surface quality of workpieces was significantly better. No more finishing work was required. Instead of the spindle used before with 12000 rpm, a high speed spindle with 42,000 rpm was now used. At the same time, even the tool selection could be increased by around 0.3 mm spherical cutters. All of the afore-mentioned factors contributed towards reducing the total machining time for a complete set of molds from 25 to 13 days. The Mikron high speed centers are distinctly faster than the cavity sinking EDMmachines used in the past. These entirely positive experiences encouraged Shinyoung Precision to scrap all conventional milling machines. In March 2003, the company purchased two more Mikron HSM 400 machines. The machine park expanded by two HSM 400U and two XSM 400U machines If we observe the market situation for mobile phones, it is apparent that the lifetime of models is very short indeed. Naturally, this is a favourable situation for a mold maker such as Shinyoung Precision, as there is a constant demand for new models. However, on the other hand, customers are continuously demanding better surface and higher precision of molds and obviously with shorter delivery periods. This is only possible with 5-axis machining centers. Because of the good experiences with Mikron, on recommendation from Otra, Shinyoung Precision purchased two HSM 400U

machines to meet market demands. After moving to new and larger company premises, the machine park was once again expanded, this time with two Mikron XSM 400U. Both machines are equipped with spindles with 54,000 rpm. With the help of Mikron, Shinyoung Precision became more and more successful. Now there is no longer any doubt that it will achieve its goals by the end of 2005. In the meanwhile, the company has three Mikron HSM 400, two HSM 400U and 2 XSM 400U machining centers.

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HPM 1850U for large parts

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Universal machining

HSM today Nr. 15

UCP 600 Vario sets new standards

Sustained success requires trend-setting concepts. The UCP 600 Vario, together with the pallet changer and the new tool changer is one of a kind

Perpetual positive results in production and the sale of machining centers are based on constant market observation and consideration of customer requirements. This results in innovative developments, which set new standards for the entire market. Following fashionable trends alone does not always guarantee long-term success, but trend-setting design of unique series does. Urs Hnni Mikron is known for its spirit of innovation, and in recent years has

defined many trends in the area of standard, high speed and high performance machining centers. Developments for the automated tool and workpiece changeover are particularly pioneering. The huge market acceptance of the UCP 600 Vario clearly shows that in the first place, the customers demand is not for reliable and powerful individual components, but rather for an efficient, economical system, which is complete in itself, and which can also react to inputs from outside the system (external robots, clamping devices from different

manufacturers etc.). All requirements of a modern machining centre which contributes to the sustained success of a company. The UCP 600 base machine together with the pallet changer and the new large tool changer is unique and extremely attractive for customers. In the past, the Mikron HSM series has already shown that the automation approach makes sense especially for high speed machining centers. Now, even the Vario gets more potential with the automation of the tool changeover

Top: Roughing the head part with a milling head and internal coolant feed (IKZ) The operator always has optimum access to the workpiece

Processing in the shaft area with a roughing mill

5-axis simultaneous machining of the teeth

All necessary components for a successful production are located over the smallest installation area

Finished part before separation

HSM today Nr. 15

Universal machining

11

customers in market regions with high salary costs who recognise the business advantage of an UCP 600 Vario with automation. With new options, the UCP 600 Vario does more justice to its claim to universality. A powerful vacuum unit for dust particles turns the UCP 600 Vario into a machining center which is suitable for versatile processing of different metals and also for occasional milling of graphite electrodes.

Powerful graphite suction: For occasional production of graphite electrodes

process and with the 120, 170 or 220 times tool changer. Price/ performance is optimum in this combination and a machine with such a configuration is, as already proved, very cost-efficient. The UCP 600 Vario is suitable for an extremely versatile range of

The robot interface enables combining the Vario with external robots
applications. This includes customers who want to produce high quality parts in 5-side processing, like production companies, who will have to manufacture mediumsized series and various parts in 5-side processing more economically in the future. It is especially

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HSM 300
The new optimal solution for dusty materials
The new HSM 300 GraphiteMaster is the optimal machine for milling dusty materials. Together with the Heidenhain iTNC530 control system, the machine corresponds to the latest technological features and replaces the previous HSM 300. The HSM 300 GraphiteMaster is especially suitable for machining graphite electrodes for tool and mold making as well as for the manufacture of electrodes made of copper, for highly precise molds, stamps and matrixes. Mikron supports tool and mold manufacturers with the HSM 300 GraphiteMaster in order to cover the rapidly growing graphite electrode market. The Base The HSM 300 GraphiteMaster overhead version has a polymer concrete base. This ensures best damping properties and maximum stability. Linear jigs and highly accurate drive stems ensure precise positioning and high rigidity on axis acceleration XYZ of up to 17 m/s2 (1.7G). The digital drive technology is also a guarantor for best machine dynamics when undertaking complex 3D machining. The user friendly and soundabsorbing cabin with ample access to the machining room completes the concept. The latest Heidenhain control generation is used. iTNC 530 imparts the necessary control speed to the machine to meet the requirements of very complex arithmetical problems. Effective suction system To ensure clean and efficient machining of graphite electrodes, a powerful extraction system including extraction frame, is included in the standard scope of delivery. Special attention was paid to the air supply to the machining area. Within a few minutes, the extraction frame which is mounted on the machining table can be easily removed and installed again. The automatic tool changer is protected against any form of contamination in the best possible way. In other versions of the HSM 300, the extraction system can also handle metal chips. Tool changer A suitably large tool changer is of great importance for the intended area of application of the HSM 300 GraphiteMaster. Here, an 18x tool changer (pick-up system) is machine standard. A 27x tool changer is offered as an optional upgrade. This quantity of tools enables proper selection of cutting tools in the magazine and consequently simplifies handling. The spindle The ceramic hybrid suspension of the heavy duty spindle permits speeds of up to 30,000 rpm. The HSK 40-tool holding fixture with optimum concentricity allows precise smoothing with the smallest cutting tools of up to 0.2 mm diameter, as well as roughing with tools having a maximum diameter of 13 mm. It is designed for stability and long life. Thanks to lifetime lubrication, there are no oil drips from the spindle head which is a very important issue when manufacturing graphite electrodes. Cooling / lubrication To economically mill hard materials, the HSM 300 GraphiteMaster is equipped with a programmable (via NC programme) minimum oil lubrication system. This lubrication system is outstanding especially due to its low consumption of lubricants. At the same time, the maintenance and disposal of possible cooling emulsions is not required. spindle power rating 6`kW at 100% duty ratio Tool changer: Standard 18-tool capacity HSK 40 (optional 27-tool capacity HSK 40) Machine base: Overhead version made from concrete polymer, machine weight 2900 kg Drives: Digital drive technology, linear jigs free from play Graphite dust extraction: Well thought-out extraction system built in the machine which is highly effective Control unit: Heidenhain iTNC 530 Operator console: With an ergonomically arranged membrane keyboard and 15" flat screen.

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Technical specifications: Traverse paths: X 380 mm, Y 390 mm, Z 255 mm Spindle characteristics: Speed range 5,000 30,000 rpm,

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Universal machining

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The new VCE Pro-X Line from Mikron

Mikron presents the VCE 800 Pro-X and VCE 1000 Pro-X which are further developments of the proven VCE Pro machining centers.
VCE Pro-X machines qualify themselves through faster feeds of up to 36 m/min and through new powerful motor spindles with up to 16,000 rpm at an 14.75 KW rating (40% duty ratio). Excellent value for money makes them particularly interesting. Stefan Fahrni The HSM and HPM milling technologies are more cutting edge than ever. Continuous development and increasing simplification over the last decade has made these technologies advance to enjoy an increasing market share. This trend is unbroken. HSM and HPM technologies have continued to increase the pressure on conventional milling techniques. In order to make them integrate into the HSM and HPM areas, Mikron has developed the new VCE Pro-X machines. An important feature of HSM machining is the high feed rates and spindle speeds. On the new VCE Pro-X a great deal of attention was devoted to these technical "pillars". The performance of the feed drives has been increased dramatically and allows feed rates of up to 36 m/min at the same time as an increase in acceleration. All axes are equipped with a linear measuring scale. A particular highlight of the VCE Pro-X is the elaborately developed and carefully produced Inline motor spindle which is manufactured by the company Step-Tec in Switzerland. These spindles reach speeds of up to 16,000 rpm at a 14.75 kW rating (40% duty ratio). To date, milling spindles have frequently been driven either by a gearbox or a belt or motor spindles have been used. Gearbox spindles are used for speeds of up to 10,000 min-1 and high torque - belt spindles are used in areas of application with speeds up to approx. 14,000 rpm. The non plus ultra of the spindle drive is the motor spindle. With speeds from 12,000 to 60,000 rpm it covers the largest application area and at the same time achieves a high torque. As a new feature, Inline motor spindles are being used in VCE Pro-X standard machining centers. On the basis of our consistent implementation of the technical pillars (high spindle speed and high feeds), the VCE Pro-X line is universally used on shop floors. These machines make it possible to achieve considerably shorter machining times and therefore, larger order sizes. Even difficult jobs, such as the production of thin walled workpieces, are now even easier. A further feature of greater spindle performance is the protection of the milling tools and therefore longer life. With fast feed rates, individual parts such as perforated plates, which include a large number of travel times, can be machined more economically. Of course it is also possible to carry out conventional machining with the VCE Pro-X. With a spindle torque of 94 Nm (40% duty load) it is possible to carry out large swarf volumes such as in the manufacture of molds and in the aviation industry but also those arising in general mechanical machining, without further ado. In this market segment, the Mikron VCE Pro-X line offers unbeatable advantages. The Mikron VCE Pro-X Line machines are extensively equipped as standard with: Actively cooled Step-Tec work spindle Cooling through the ICS tool Glass measuring rods on all axes Heidenhain Control Unit Cleaning jets in the workspace Options 4th axis Laser tool measurement Programmable coolant jet Bandpass filter and more

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Impressum
HSMtodayTM
Specialist journal from Mikron Mikron Agie Charmilles AG Ipsachstrasse 16, CH-2560 Nidau Tel. +41 32 366 11 11, Fax +41 32 366 11 66, E-Mail: mikron@mikron-ac.com Brand Manager: Jens Thing Managing and Design Editor: Jrgen Maurer Photo adaptation: Vik Furer Circulation: 45000 Published in German, French, English, Italian, Polish, Spanish and Chinese Photos: Cliff Design&Development, EADS, Electrohilo, E.S. Tooling, Kramski, Mandatec, Mikron, MTU, Shinyoung, Step-Tec Print: Stmpfli AG, CH-3001 Bern Issue 15, November 2005 Mikron Agie Charmilles AG 2005

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Agie Charmilles Group

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High-speed machining

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Prototype production using a Mikron XSM 600U

Cliff Design & Development, a Swedish company, set itself the goal of making its customers prototypes within 24 hours and delivering the parts within the same time-scale. Fredrik Gedda, Martin Brun Cliff Design & Development is one of Sweden's top component development and design companies. With their skilled staff and technical setup, they specialise in product development, industrial design, producing prototypes and creating 3D illustrations and visualisations. They aim to support all companies, however large, in their development and design processes, and thus improve their competitive edge. Cliffs clients include well-known companies such as Volvo, Saab, Volvo Car Corporation, Siemens-Elema, Orrefors, Kinnarps, BT and Stiga. The company's objective is to get to know and understand their client's market so that they can implement the client's vision more accurately and efficiently. They employ their expertise to improve the form and function of finished components so that the client will gain a competitive advantage in the marketplace. Cliff also aims to become the most advanced and successful product development and virtual solutions supplier in Northern Europe. To achieve these aims, however, they need to change their work procedures within the bounds of their corporate philosophy. This means that they have to alter not only their working methods but also their machinery base. So they are investing in new software and hardware. For producing prototypes, Cliff already owns one of the fastest machines in Sweden a Mikron XSM 600U. Time savings and standardisation helped massively reduce production costs, with no negative impact on the quality required by clients in terms of surface finish and dimensional accuracy. The new concept is called Speed 24 Cliff set up a new team to achieve this goal. Managing Director Patrik Sjstrand explained, "We created what was almost another 'company' within the company. It consisted of a team leader, machine operators, CAD/CAM specialists and model builders. Working hours are flexible, but the team has to be on permanent standby to tackle new jobs. The clock begins to tick once the order is confirmed. Before we started using the XSM 600U it was sometimes difficult to meet customers deadlines. But the Mikron machine has eliminated that problem completely." The company is currently pushing ahead with automation. This means that the 7-pallet pallet changer and Mikron's 'smart machine' modules are due to be integrated into the work process. For any company involved in prototype production, the components' surface finish is crucial. Cliff is no different. Mats Carlsson, one of their operators, told us, "We do our machining on the XSM 600U. The thermally stable 36,000 rpm spindle and the 'smart machine' modules with the laser measuring system enable us to achieve accurate form on every job. Cliff have also begun to use the XSM 660U to machine aluminium components and even glass. First the operators went on a programming course at the local Mikron dealership, TL MaskinPartner, to ensure they had a first-class grounding. They then learned how to use the HSM milling technology on a course at the manufacturer's own HSM skill centre. "We have gone a long way towards achieving our objectives simply by purchasing the XSM 600U", says Christian Wadell, Cliff's corporate planning and purchasing manager. "The expert advice we got from Fredrik Gedda, the Sales Manager at TLMaskinPartner, had a major influence on our decision to purchase, while our visit to the top HSM machine manufacturer, Mikron, completely convinced both Boris Uvalic and me. Fredrik Gedda saw from the very beginning that the XSM 600U is the best machine for our requirements.

Machine type XSM 600U

Work range: X: 800 mm Y: 600 mm Z: 500 mm 80 m/min 25 m/s2 B: + 30 / -110 C: 360

Working spindle: Feed drives X, Y, Z: Acceleration X, Y, Z:

54000 min-1, 42000 min-1 B, C: 200 min-1, 360 min-1 B, C: 30 rad/s2, 125 rad/s2

Control: Mikron Cyclone Expert / Heidenhain iTNC 530, 2 processors smart machine moduls: APS, APS extented, OSS, ITC-5X, RNS

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High-speed machining

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High speed spindles The passion of Step-Tec

Step-Tec delivers the best spindles in the world for high machining performance, high power density and outstanding quality

For more than 10 years, Step-Tec has been designing, manufacturing and selling motor spindles for leading manufacturers of machining centers. The company has been based in Luterbach since 2000, very close to Solothurn, Switzerland. Jrgen Maurer The Step-Tec specialty is fast, high performance spindles with integrated motors. Workpieces machined with it boast of excellent surfaces and only require finishing in special cases. Machining times are distinctly reduced together with the corresponding machining centers. The Step-Tec spindles are used largely for milling and drilling applications in tool and mold making as well as for production. International companies like Grob, Emag and numerous suppliers for the aviation and space industry are some of its customers. Close cooperation with research institutes, know-how coupled with high innovation potential and, naturally, close cooperation with its customers and its interesting applications explain Step-Tecs passion for design, production and customer service. The requirements for spindles vary greatly. Thanks to StepTecs vast experience, the most important prerequisites are known. Close cooperation with machine manufacturers enables Step-Tec to be involved as early as in

the design stage of new machine generations. Hence, the spindles on prototype machines can be subject to higher loads in several ways. The spindles are, therefore, subject to continuous operation phases, before being launched onto the market. With this cooperation, Step-Tec knows in advance if there is something new in tools, materials and processes. Thus, the spindles can be adapted accordingly and therefore increase customer benefits. Advantages of Step-Tec spindles: Step-Tec spindles guarantee extremely high chip volume, precision and optimum surfaces. The usage time of tools, processing machines and spindles, as well as operational safety, are increased. Good machining results are obtained even with thin and long tools. These advantages are achieved through the synergy of many special design features of Step-Tec spindles: - Motors with a large bore hole on the rotor are design prerequisites for high rigidity. - Hybrid bearings (rings made of steel, balls made of ceramic) and specially designed lubrication systems enable low-vibration operation at high speeds. - The special spindle structure for minimum axial dislocation of the spindle shaft. - The integrated sensor mecha-

nism with temperature and length measurement, vibration analysis and permanent recording of operating data. Over 2 million tool changes! Production spindles, and their clamping systems, are exposed to

New products for more productivity Gerhard Zuber, Manager of Sales, Service and Marketing at Step-Tec spoke to us in an interview. Mr. Zuber, what design trends can we expect? Machine tools define the trends in spindle engineering. A constant concern in the market for many years has been achieving high pro

on expensive finishing work. Thus, we too must adapt our spindles accordingly. What main points will Step-Tec focus on when designing spindles? First, a more consistent orientation to a modular structure. A lot will change in the spindle interior. For example, we are considering water bearings. For very high speeds, i.e. for more than 60,000 rpm, magnet bearings will probably be the future. Memory metals can take over the initial tension regulation.

an extremely high number of tool changes. The following example gives an idea of what wear and load the material must endure: - 5 tool changes per minute - produces 300 tool changes per hour - computed running time of spindles 7, 000 hours - total results 2.1 million tool changes Added to this are release time cycles of 200 ms and highly changing speeds. The demands on materials and the entire clamping system are thus comparable with a formula 1 engine.

ductivity. Tool manufacturers try to reach that goal. So, more chip production, but with high precision, given that precise machining saves

Can one reckon with more innovative designs? Possibly, with an active vibration damping through the magnetic field of the motor coil. Special

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High-speed machining
tomer demands with relation to high torques, compact systems and main spindle drives and B-axes, which correspond to the required process safety. The high diversification and increasingly shorter delivery times demand both defined design standards and reliable calculation methods and prognosis with regard to statistic and dynamic properties. Using the most modern working tools, Step-Tec transforms the digital product into reality. Calculations and simulations are carried out on the same CAD model, which is later used in production for programming with the help of CAM. Only by applying this uniform process can it be ensured that quality is complied with, in the global sense.

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alloys can produce improved control of radial and axial dislocations, e.g. by deriving the ensuing loads from the dislocations. Even new concepts in clamping tools will show us the future, likewise the replacement of steel disk springs, e.g. with carbon fiber. Contactless sensors and active cooling of the rotating shaft will be other design trends. Step-Tecs philosophy Step-Tec AG designs and manufactures spindles according to market requirements. Whether tool-making, production or aerospace, owing to the close cooperation with universities, research institutes and customers, as well as the immense motor spindle knowhow and the ideal utilization of the innovation potential, Step-Tec is in the position to meet special cus-

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The Step-Tec spindles are used largely for milling and drilling applications in tool and mold making as well as for production. International companies like Grob, Emag and numerous suppliers for the aviation and space industry are some of its customers.

smart machine
Mikron has combined different modules (software and hardware) under the term smart machine. Each module has a special function to optimize the milling process. Mikron Advanced Process System (APS) The APS module is a monitoring system which opens up new opportunities for the user to observe and control the milling process. This system was especially designed for high performance and high speed machining. However, also be used for other milling work. With the help of an acceleration sensor integrated in the spindle, vibrations during the milling process are recorded and displayed to the operator on the console. Through this, it is possible to intervene in the process to optimize it. Remote Notification System (RNS) A new era of communication and flexibility is obtained with this module. Thus, it is now possible to obtain information about the operation status of the Mikron machining centre as well as the

smart machine makes the milling process simpler and easier for the operator to control
process in accordance with the quality and specifications. The target variables for speed, precision and surface quality as well as workpiece weight and machining complexity can be set and modified at any time with the user-friendly interface. Maximum utilization of the Mikron machine is guaranteed with this process-oriented work. with current Heidenhain controls. Some of the modules already form part of the standard configuration of machines. Others are available as an option. Each smart machine module fulfils a specific function. Like a modular system, the user can choose the modules that he finds most suitable for improving the milling process. Thus, workpieces can be manufactured precisely and according to the process, reliability is increased during unmanned operation, the service life of machines is extended and the production costs are reduced significantly. Since "smart machine is a modular system and new modules are constantly designed, the current combinations, Mikron machine and module, can be viewed on the Mikron website at www.mikron-ac.com.

Intelligent Thermal Control (ITC) With the ITC, the machine operator no longer needs to wait for thermal equilibrium of the machine. It can concentrate fully on the workpiece-specific re-

milling process regardless of the location. The operator can receive information about the operating status or program status of the machine via SMS to a mobile phone. Consequently, the operator can work extensively and flexibly because a standby facility is easily achieved with this module.

Operator Support System OSS OSS is the first unique intelligent Operator Support System used worldwide. Using the workpiece, it optimizes the machining

quirements. The Mikron machine already has the thermal process knowledge, as well as the 5-axis machining centers of course (ITC-5ax).

Benefits of the different smart machine modules: Higher precision at shorter machining times Increase in workpiece surface quality as well as accuracy of shape Detection of critical machining strategies Improvement of process safety Reducing the use of the machine by increasing the service life of the machine Increasing the availability Increased operation comfort even in automatic mode Essential increase in reliability during unmanned operation Economical overall approach improves through optimization in all process areas. The "smart machine" modules can be used on all Mikron machines

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Together with a Mikron HSM 600U ProdMod and the Erowa MTS clamping system, Lorze AG - Mandatec performs the shortest reaction and delivery times with simultaneously long machine running times

Robots as camel jockeys made in Switzerland

HSM 600U ProdMod. The new series of ProdMod machines originated from the HSM series, which even today, is the standard for high speed machining. The results include high speed machining centers with best dynamics for economical machining of exacting precision parts for medium to large batches. The HSM ProdMod machines are especially designed for production. They are equipped with highly dynamic direct drives for the B and C axis. With a pallet changer system and an automated tool changer, machines from the ProdMod series are especially good for automatic production. The powerful motor spindles, in different versions for different speeds and torque ranges, have also contributed to the success of this machine series. Now spindles with HSK-A63 tool holder and internal coolant feed are available on the new HSM ProdMod. This addition to the existing range of spindles allows for the use of larger and subsequently even longer tools. With this, Mikron closes a gap in the present range of HSM machines. At the same time, it addresses a new application segment, the production of medium and larger series. Tool changer was crucial for Mandatec Some criteria were particularly important for Mandatec in the selection of machines, e.g. 5-axis machining, automation or even access to a large number of tools. Even the ProdMod versions of Mikron machines can be adapted to individual requirements and are equipped with a modular tool changer system. 120, 170 or 220 memory spaces can be selected. The separation of the pickup mechanism and delivery handling result in short changing cycles. Thanks to the "Double-Tool-Handling", changing cycles of less than 3 seconds area achieved, the chip to chip time is about 5 seconds. Even the pickup time in the modular Mikron changer system is less than 10 seconds. Hence, even tools with very short usage times (e.g. drilling, countersinking, tapping) can be used economically on the next tool without waiting. Parts manufactured with the Mikron HSM 600U ProdMod no longer need to be machined manually. Similarly, this results in optimum safety during reproduction. Together with Mikron and Erowa, Mandatec has achieved its goal of maximum flexibility. Subsequently, the company only produces what the relevant customer needs at present, even small quantities. Expensive storage is omitted. As system manufacturer for complex sub-assemblies and devices, today, Lorze AG - Mandatec is the leading company in Switzerland.

Whether robots for camel races or for clock manufacture, parts for machine tools or chip conveyors, Mandatec in Biel, Switzerland has grown from an average parts manufacturer to a highly efficient business in component manufacture. Jrgen Maurer Lorze-AG - Mandatec was founded in 1985. Today, it employs approx. 70 people. Naturally, the company also has its own training department. Orders for Mandatec come from the most varied industries, e.g. from semi-conductor industry, machine tool manufacture, medicine industry, clock industry etc. Production is carried out round the clock, with two fully automated shifts. Continuous shorter production development times or the aim of processing repeated

orders (same workpieces) within 24 to 48 hours, has induced Mandatec to rethink the entire production process and to make fundamental changes. A uniform clamping system by Erowa (MTS) was introduced. It can be used on all machine sizes and can clamp not only pallets, but also individual chucks, precise and stable. While all machines are equipped with the MTS, Mandatec started converting the existing clamping tools to MTS even for the complete production. Moreover, some machines, including a Mikron HSM 600U ProdMod, were equipped with loading and unloading robots. Mandatec could achieve its ambitious goals. Thus, process safety was improved, production processes and clampings were standardized, batch sizes were reduced, 80% of all workpieces are manufactured in only two clampings,

the machine running times are extended and the working hours flexibly organized. Robots for Qatar At present, Mandatec has received a very special order. It is manufacturing robots for use as camel jockeys in Qatar. Normally, in traditional camel races, young boys handle the camels. But as this has resulted in constant criticism from human rights organizations, the Sheiks of Qatar had to look for alternatives. They chose the Swiss company, K-Team Project & Services from Yverdon-les-Bains and hired them for the development. After successful tests in Qatar, the Mandatec robots are now produced in Biel, Switzerland. The HSM 600U ProdMod Some components for the robot jockeys will be milled on a Mikron

The HSM 600U ProdMod also makes big chips

A specialty of Mandatec is the treatment of cubic parts

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