cutting edge - danobatgroup´s customer magazine
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DANOBATGROUP, boosting productivity through sustainability
DANOBAT, projects that revolutionize sectors
SORALUCE achieves the highest precision, productivity and reliability levels in milling, boring and turning.
SEPTEMBER 2013
Dear reader,We are delighted to present to you the irst issue of Cutting Edge Magazine, a DANOBATGROUP initiative for sharing with you our latest projects and innovations developed in
close collaboration with our customers.
On this occasion, you will have the unique opportunity to
read real customer testimonies about different cases of cutting edge projects developed hand in hand with them.
DANOBATGROUP has a long track record of offering turnkey solutions to worldwide featured customers. Each project is taken as a new challenge where new developments will be
implemented to bring real solutions and create value for the customer.
In this issue, we will also share our knowledge of the latest state of the art technologies and processes developed at our own Research & Development Center. Applied research and technological innovations that are created to meet our
customers’ needs and to go beyond market requirements.
Likewise, you will ind a section dedicated to one of the existing worldwide challenges; sustainability. DANOBATGROUP has already been working for many years on sustainable production systems by implementing
new measures to improve energy eficiency, looking for new solutions to the scarcity of resources and preventing emissions, and developing new smart systems to improve
the quality of machine operations.
We will also take this opportunity to invite you to visit our
different manufacturing solutions at the main world trade fair for metalworking technology, EMO 2013. Aware of the importance of this exhibition, this year we have made a major effort to showcase the latest and most outstanding products over more than 1700 square meters arranged by technology on four different stands. This way, DANOBATGROUP is setting itself out as one of the industry leaders by showcasing our new capabilities and our commitment to high technology
in a wide range of technologies.
DANOBATGROUP
EDITORIAL
© DANOBATGROUP 2013. This document is not a contract. DANOBATGROUP reserves the right of making changes to all models without prior notice. The illustrations in this magazine remain property of DANOBATGROUP.
PAGE 3
content
From Germany to
Germany; the local addedvalue through
DANOBAT-OVERBECK and
BIMATEC SORALUCE
Boosting productivity
through sustainability
DANOBAT & LUCCHINI,the perfect partnership for the most advanced railway
axle line
Ultraprecision
DANOBAT grinding and
turning machines
SORALUCE milling-boring and vertical turning
machines
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DANOBAT sawing, drilling
and 3D plasma cutting machines
LATZ cutting tools
SORALUCE SL-8000 A well designed machine:
ergonomics and user
friendly
SORALUCE VTC-3200 When versatility improves
productivity
BEL VALVES enjoys signiicant savings since installing a DANOBAT
vertical band saw
DANOBAT VG: a machine
to speciically meet the high metal removal
rates and ine tolerances required
DANOBAT HG-92; all in one single machine
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DANOBAT NA horizontal
lathes to get the required
precision levels
SORALUCE FXR-16000 Precision, productivity and
reliability.
A speciic example, the results obtained at MPC
SORALUCE F-MT 4000 Multitasking, lexible and dynamic
MONDRAGON
Corporation receives the“Boldness in Business”
prize awarded by the
Financial Times and
Arcelor Mittal
OPEN HOUSES 2013; Latest developments and
technologies on-site
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35 |
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DANOBATGROUP
Outstanding Projects
Humanity @ work
Open House News
EMO 2013 Highlights
CONTENT
SEPTEMBER 2013
German customers are some of the most demanding in the world, not just
for technology but also as regards quality, reliability and precision. They
insist on only highly reliable, top-end
products, and their service requirements
are equally rigorous. So, for many years now, DANOBATGROUP has ensured
it can provide an accessible local
service with highly qualiied staff and a suficient response capacity to meet customers’ needs, able to complement
and customise its products to fulil all expectations (compliance with German regulations, inclusion of German accessories, manuals and machine
controls in the home language, etc.). We
offer a genuinely local and trustworthy service.
DANOBATGROUP provides the utmost
guarantee and is a benchmark for success in Germany, offering highly reliable products with cutting-edge
technology, eficient customer service, and, particularly, with a large enough staff to make waiting time unnecessary, highly
qualiied and able to solve any problem customers may have or any technical
incident that may arise.
DANOBATGROUP has been committed
to this market for a long time, investing major resources to guarantee success.
After more than 20 years working in Germany together with our subsidiary
From Germany to Germany; the local added value through DANOBAT-OVERBECK and BIMATEC SORALUCEGermany is Europe’s leading manufacturer, consumer and exporter of machine tools,
and has been the top destination for DANOBATGROUP’s sales for many years. For a
company to be successful in the German market, its brand name must be well-known
and acclaimed in this country.
company BIMATEC SORALUCE, we are now leaders in the German milling
machine market, with over 1000 SORALUCE milling-boring machines installed at the facilities of more than 500 customers, including the main German
multinationals (Alstom, Siemens, BMW, etc.). In 2012 we consolidated this position by opening a new extension to our Limburg plant, with investment of 6.2 million euros. This new showroom will give customers a irst-hand view of the range and capacities of SORALUCE milling-boring machines.
Also, in late 2002, DANOBATGROUP took over the German company
OVERBECK GmbH, greatly enhancing the brand image of DANOBAT grinding machines in this key market, facilitating access to the German decision-making
centres and their area of inluence in Eastern Europe and opening up new
market niches. The complementary
nature of DANOBAT’s products has enabled it to extend its range, with mutual beneit resulting from technology exchange and joint R&D investment. As regards customer support, our increased
presence all over Germany has enabled
us to offer a more accessible qualiied technical service, increasing the offer of products from the Elgoibar plant in Spain.
In total, the two German factories employ around 10% of all DANOBATGROUP staff.
DANOBAT-OVERBECK
Q: What is the main distinguishing
feature of DANOBAT-OVERBECK?
Josu Tornay: DANOBAT-OVERBECK is a machine tool developer and
manufacturer specialized in high precision internal grinding machines.
Applications span from single part to volume production across a wide
range of industry sectors, such as bearings, cutting tools, gears, and so
on. However, ‘internal grinding’ does not adequately convey the lexibility of machine tools that are also capable
of external and face grinding, radius grinding, and, in the case of the IED range, simultaneous machining of internal and external diameters. But our main characteristic is the ability to meet
the customer’s speciic requirements even in very speciic applications. We use a modular machine concept for our design as a basis, which is completed
with a speciic design work on each machine in order to be able to design
the one-off “especials” as well.
Each DANOBAT-OVERBECK machine is built on a standard natural granite
base and is equipped with linear motors.
However, the machine coniguration, while making use of standard elements, will be different, depending on the application and the customer’s individual
preferences.
PAGE 5
DANOBATGROUP
Q: 90 years of history have gone a long way. How do you assess the evolution of the company?
Josu Tornay: Nowadays, due to the
OVERBECK’s extensive applications experience we specialize in providing a complete tailor made solution
within the shortest possible lead time
and at a competitive price that will
satisfy every customer’s demand for accuracy, repeatability, ease of use and increased productivity. This is veriied in stringent machine trials that take
place in our factory prior to delivery and commissioning, with full traceability of every aspect of the machine build and test sequence. Customers are secure and know that the machine will be
subject to extensive testing and that even in the newest concepts, the performance is guaranteed.
The modular concept, which makes use
of common elements across a range of machines contributes to long-term machine reliability and maintainability
which is especially important in
applications involving high quality inish machined components direct to an
assembly line.
This emphasis on quality is relected in the fact that almost a quarter of the workforce is devoted exclusively to machine design and software development, with R&D initiatives made
in close cooperation with our DANOBAT
colleagues at Elgoibar, Spain.
Q: How does the customer value the closeness of the company?
Josu Tornay: That question should
be answered by our customers.
Anyway, my opinion is that they really
think of DANOBAT-OVERBECK and of DANOBAT as companies completely
integrated in the German market.
OVERBECK has a very long story in the market and DANOBAT established itself also in a very natural way in the German
market. We have local production, local
product development, local service, etc.
and this makes everything easier for us in the German market.
Q: DANOBAT-OVERBECK has its own training workshop to train professionals. What is its added value for the company?
Josu Tornay: Historically OVERBECK used to have an apprenticeship, but it was dismantled
in different dificult situations. Some training and education structure survived,
but with a very different approach. We decided to recover a complete
apprenticeship system some years ago
and up to now all our apprentices have
joined the company after completing their studies. We are very selective
with the trainees that we accept for the company and we are really proud of the results. We have had for example the best results in our region in the practical
examination during the last 3 years, we have also a training period of 8 weeks for the last year apprentices in our factory in Spain and nowadays our assembly department receives all the new itters directly from our Apprenticeship Area.
Mr. Josu Tornay - Managing Director of OVERBECK GmbH
SEPTEMBER 2013
BIMATEC SORALUCE
Q: In view of the recent successes in sales, it is clear German customers
appreciate SORALUCE technology. In your opinion what makes a customer
choose SORALUCE milling boring machines from among others?
Fred Bisgwa: Our German customers
not only appreciate the high quality
and performance of our machines, but also the comprehensive support in
particular. This is the reason why almost
90% of our customers have more than one SORALUCE machine in use.
Q: Customization requires great knowledge of customer’s needs. How does BIMATEC SORALUCE deal with these projects?
Fred Bisgwa: It has been our ambition
since the beginning to deliver process
optimized machines on all levels to our
customers. To achieve this, we have
been working with leading technology
partners for many years focusing
on tool, clamping and measuring
technology. Thus we can ensure our
machines and equipment are state-of-the-art.
Q: Local service is essential for some companies when making the decision
to purchase one brand or another one.
What does BIMATEC SORALUCE offer its clients in this respect?
Fred Bisgwa: Our service hotline has
existed for many years and is currently available around the clock with ive qualiied service engineers. In addition to our service centre in Limburg
with its own milling head workshop,
we have over eight regional service
ofices from where we can reach our customers in the shortest time possible.
Our service technicians have many
years of experience combined with vast technical knowledge. All service
vehicles contain the common spare and
consumable parts. We already have
48 short term milling heads available to guarantee the high availability of our machines.
Q: You have recently expanded your facilities. What does the new technological centre offer customers?
Fred Bisgwa: Process optimization
in mechanical processing has been
important to us from the beginning. At our new technology centre in Limburg
we are able to demonstrate our large
milling and boring centres in a process-
optimized manner and can inish work pieces weighing up to 40 tons. Thus, we have introduced practical proof for economical machining, including bulky
heavy work pieces.
Mr. Fred Bisgwa, Co-founder member and Managing Director of BIMATEC SORALUCE
PAGE 7
Boosting productivity through sustainabilityDANOBATGROUP offers sustainable production systems in harmony with the economy,
ecology and society
The tendency to energy eficiency represents the beginning of a paradigm shift for the machine tool sector. For a long time, the machine tool industry has been driven by the motivation
to provide the most productive, the most precise and the
most reliable machines to customers. Competitiveness has been deined and determined by manufacturing excellence. In the last few years, however, the machine tool sector has begun to invest in sustainable machinery since it has been
proved that optimizing the design, the energy consumption
and reducing material waste can have a positive effect on life-cycle costs of machine tools, improving the productivity and competitiveness of the machine. The world paradigm is changing and the machine tool sector
has to face the new global social and economic challenges too. The constantly growing energy consumption, associated
with more CO2 emissions and overuse of natural resources and raw materials, endangers our society. Besides, the
market demands require increasingly sophisticated machines
to manufacture workpieces increasingly complex, with higher quality in less time.
In order to face these new global social and economic challenges DANOBATGROUP innovates and progress
through new developments and projects that boost the
sustainability of its products, designing new machine concepts that are optimized and that include more eficient
components, which lead to higher performance of machining processes.
For DANOBATGROUP increased competitiveness and
sustainability go hand-in-hand. Putting stronger emphasis
on eco-eficiency does not represent a shift away from traditional elements of competitiveness such as precision, speed or reliability, safety or ergonomics. What is more, for DANOBATGROUP this approach is the key to ensure the
manufacturing excellence for the upcoming decades.
DANOBATGROUP
SEPTEMBER 2013
Solutions for scarcity of resources
and avoiding emissions
Optimized process cycles based on
more sophisticated technology support,
shortens machining time and save
coolant and lubricant use, waste chips
and energy consumption.
DANOBATGROUP implements an
intelligent machining planning from the beginning of the life cycle of the equipment, deining the most appropriate production design in order
to minimize the environmental impact.
New developments that
DANOBATGROUP is currently
implementing on machines:
• Eficient cooling systems: good sizing of cooling unit, MQL (Minimum Quantity of Lubrication), cryogenization, nozzle design
• End of live management: material re-use, eficient components
• Simulation and modelization in order to save machining time,
space occupation and tools, and
avoid collisions
• Less environmental contamination:
noise, pollution and emissions
Solutions for social sustainability
DANOBATGROUP machines
incorporate smart control systems
that help to operate and maintain the
machines. These systems make the
machines easier to use, and increase
safety and work quality, boosting the work and life quality of machine operators.
Research and implementation areas:
• Context-adaptive assistance for fault diagnosis
• Mobile, personalized tutoring
systems
• Location-based. Maintenance and
planning assistance
• Assistance in complex work processes
• Human-machine interaction
01 |
DANOBATGROUP is currently working
on different sustainability research areas to increase the energy eficiency on machines, to ind new solutions to face the scarcity of resources and avoid emissions, and to increase safety and work quality of machine operators through smarter control systems and
tools.
Solutions to improve the energy
eficiency
Machine designs are based on minimized
material weight of moving machine components. Stiffness of a structure is guaranteed by high dynamic axis-control functions, which saves the energy consumption.
DANOBATGROUP is developing and
implementing cutting-edge solutions in
different areas:
• Energy management: CNC stand-by options, regenerative braking
• Eco-design: less weight components
• Eficient machining process: integration of operations
01- Reduction measures to boost energy efficiency 02- Human-centered based assistance 03- New nozzle design
PAGE 9
DANOBATGROUP
Human-centered based assistance
Advantages at a glance:• Context-adaptive assistance for fault
diagnosis• Mobile, personalized tutoring
systems• Location-based maintenance and
planning assistance• Assistance in complex work
processes
Efficient cooling in grinding; an optimized process cycle to face the scarcity of resources and avoid emissionsAdvantages at a glance:• Improvement of lubrication and
cooling efficiency• Grinding wheel wear decrease /
productivity increase • Reduction of pumping pressure and
flow rate / energy saving
02 |
03 |
SEPTEMBER 2013
The project was completed in record
time, with the line beginning full-capacity production just 18 months from DANOBAT’s receipt of the order to manufacture it.
This production line was supplied as
a “turnkey facility”, with DANOBAT supplying all the equipment (some of its own and some produced by other
specialist companies) and installing and
starting up the entire line for full-scale production to begin.
The work was done by DANOBAT
in coordination with a project team
specially formed by LUCCHINI RS and including the company’s most
experienced engineers.
The line is undoubtedly the most
advanced in the world for manufacture of railway axles, both for the complexity
DANOBAT & LUCCHINI, the perfect partnership for the most advanced railway axle lineDANOBAT has created for LUCCHINI RS a new automatic
line for machining and testing railway axles, mainly for
high-speed trains. This investment forms part of a long-term
plan for renovation of the Lovere plant, geared to innovation
of products and processes that are essential for maintaining
international leadership.
of its system, totally integrated and automated, and for the variety of innovative solutions on each individual
machine making it up.
The installation consists of an axle identiication and loading unit, an end milling machine, roughing and inishing lathes, a grinding machine, ultrasonic
and magnetic particle inspection
equipment, a robotised system for axle handling and tool change and a sophisticated line control system.
The line has a production capacity
of approximately 12.000 inished and inspected axles per year, and several different types of axles from the LUCCHINI RS catalogue can be processed automatically.
Q: Why did LUCCHINI RS choose DANOBAT as its partner for such a complex and important project?
Zaverio Tignonsini: Setting up an automatic line for high-speed train axle manufacturing is an extremely complex project, and LUCCHINI RS wished to work with a partner with experience in the sector who would adapt to our
needs and be able to offer us a turnkey project ensuring the high precision
and quality required for high-speed train axles. DANOBAT met all those requirements.
Q: What are the main advantages of this custom-made production line?
Zaverio Tignonsini: It has numerous
advantages: less workers are needed
and there is no manual handling
involved, which increases worker safety,
PAGE 11
production times are shorter, there is
less waste produced and it has lower
dimensional tolerances that improve
considerably the inal product and reduce manufacturing costs. Moreover, WIP inventory was signiicantly reduced and the throughput time was drastically
shortened.
Q: Joint work teams made up of engineers from both LUCCHINI RS and DANOBAT have taken part in
the project. How do you rate this teamwork?
Zaverio Tignonsini: Our relationship
with DANOBAT was free-lowing and positive at all times. The mixed multicultural and multilingual work
teams responded well to all the
complex challenges involved. We were all working towards the same goal,
facing together the issues that such a
complicated line brought up during the
start-up period.
Q: Over the last few years LUCCHINI RS has been working on an ambitious plan to modernise its production
resources. How has the investment in the new line affected this plan?
Zaverio Tignonsini: The project has
made a positive contribution to our
modernisation plan, that affected the entire range of rolling stock products of Lucchini RS. Considering the axles in particular, the innovative production line
supplied by DANOBAT was integrated
with other relevant investments, such
as the new axle forging line and the molybdenum coating line, that made
Lucchini RS the most modern and advanced railway axle manufacturer in the world.
LMF3 line at Lucchini SP
DANOBATGROUP
Mr. Zaverio Tignonsini, Group industrial Coordinator and Project Manager at Lucchini SP,
Photo by courtesy of Lucchini RS
SEPTEMBER 2013
DANOBAT centerless grinding machine with natural granite bed
PAGE 13
UltraprecisionThe precision requirements of manufactured products have
increased their levels of demand, efficiency and functional
reliability.
In the manufacture of parts that demand a high level of precision, there are three aspects that the equipment
used in manufacture must ensure: thermal stability, repeatability of results and the capability of the axes to carry out minimum movements and very slow
feeds. To solve part of these problems, DANOBATGROUP has undertaken two
applied research projects: the use of natural granite in both the moving and
ixed parts of the machine structure and the elimination of physical contacts and joints between the ixed and moving parts of the machine.
Natural granite has properties that
make it very suitable for ultra-precision systems. It is a natural material with
high geometric stability, as it does not
undergo slow stabilisation processes
and in response to thermal stimuli it has
very low diffusivity and a low expansion coeficient. Speciically, its linear expansion coeficient (α) is 6•10-6 1/ºC, half that of cast
iron or steel, and a quarter of that of aluminium. Furthermore, it has added advantages: its density is
lower (structures are lighter) than that of structural materials normally used in machine tools and its damping
coeficient is high (suppression of vibrations). The economic impact of the use of these materials depends on the design, for this reason it is very important to design for manufacture in the speciic material, and not to transfer a design considered for one material to manufacture in another.
In order to be able to carry out very
slow feeds without there being large variation in the true speed of the slide, the elimination of contact areas is necessary between the ixed and moving parts of the machine structure, this allows optimal dynamic precision to
be achieved and a minimum veriiable displacement increment. Dimensioning
and positioning of the motors, ideal data capture scales, the design and
use of bearings based on luids and machine structures optimised both in
geometry and materials, allow high
accelerations to be achieved and
excellent dynamics, as well as much reduced transmission of disturbances that hinder positioning precision.
DANOBATGROUP
SEPTEMBER 2013
TECHNICAL SPECIFICATIONS
Max. grinding diameter 1000 mmMax. grinding length 6000 mmMax. weight between centers 8000 kgMax. grinding wheel diameter 915 mmHydrostatic spindlesWheelhead with two external grinding wheelsCross slide conigurationTouch probe
Integrated balancing system
AFS pump exhaustersMulti-diameter measuring system MDM-500
WT-92-6000
TECHNICAL SPECIFICATIONS
Max. grinding diameter 200 mmMax. work swing 400 mmB axis swivelling range +95º/-15ºNatural granite bed
Linear motors
Two parallel spindles
Full integrated automation with two line parts
storage
IRD-400
TECHNICAL SPECIFICATIONS
Max. grinding diameter 300 mmMax. grinding length 400 mmNatural granite bed
Linear motors
Diamond wheel
Superabrasive technology (120 m/s)In-process measuring system
Robot + pallet loading/unloading system integrated in the machine
LG-400
TECHNICAL SPECIFICATIONS
Max. grinding diameter 200 mmMax. work swing 400 mmB axis swivelling range +95º/-15ºNatural granite bed
Linear motors
Multi-spindle turret
Diamond wheel
IRD-400
PAGE 15
EMO 2013 HIGHLIGHTS
DANOBAT grinding and turning machines
HALL 11 STAND D55
TECHNICAL SPECIFICATIONS
Max. internal grinding diameter 700 mmMax. grinding length 600 mmMax. work swing 900 mmNatural granite bed
Linear motors
Spindle turret with max. 4 spindlesConventional & CBN wheel
ID-600
TECHNICAL SPECIFICATIONS
Grinding diameter 0.5-50 mmMax. grinding length 200 mmNatural granite bed
Linear motors
Gantry type frontal loading unitIntegrated out-process contact measuring
unit
Possible to load two parts per cycle
Electrospindle for the grinding wheelIntegrated electric cabinet
E-315-FV
TECHNICAL SPECIFICATIONS
Max. turning diameter 330 mmMax. turning length 500 mmLoading/unloading integrated into the machine
Main elements made of stabilized pearlitic cast iron
Linear guideways with recirculating linear
Pearlitic roller bearing
External linear scales on machining X-Z axesExtra slide for load/unload operations
TH-500
TECHNICAL SPECIFICATIONS
Max. grinding diameter 1000 mmMax. grinding height 700 mmPrecision radial and axial hydrostatic bearing on C axisMain elements made of stabilized perlitic cast iron
Independent slides for vertical and traverse movements
VG-1000/700
Linear guideways with recirculating linear
roller bearings
External linear scales on all machine axesMulti-spindle turret
Measuring system and data handling
softwareDoGrind conversational software
SEPTEMBER 2013
TECHNICAL SPECIFICATIONS
Control Siemens 840DTurning diameter 3200 mmTable diameter 2800 mmTable drive motor 105 kWTable speed 175 rpmTable torque 52800 NmMax. height table to Ram 2600 mmRam size 250 mm x 250 mmRam stroke (Z axis) 1500 mmSlide/Ram traverse (X axis) 3730 mmRam with live spindle (30 kW / 3000 rpm, 1200 Nm)C axisElevating crossrail 1000 mm
VTC-3200 VERTICAL TURNING
CENTER
TECHNICAL SPECIFICATIONS
F-MT 4000Longitudinal traverse, “X” axis 4000 mmVertical traverse, “Z” axis 1800 mmCross traverse, “Y” axis 1300 mmFixed table dimensions 4000 x 1250 mmRotary table dimensions 1600 mmSpindle power 37 kW
F-MT 4000 MULTITASKING MILLING-TURNING MACHINE
HEADS• Universal head
0,001ºx0,001º / 5000 rpm / 32 kW (S1)• Turning head
6000 rpm / 32 kW
PAGE 17
EMO 2013 HIGHLIGHTS
SORALUCE milling-boring and vertical turning machines
HALL 13 STAND B36
TECHNICAL SPECIFICATIONS
FXR-16000Longitudinal traverse, “X” axis 16000 mmVertical traverse, “Y” axis 6500 mmCross traverse, “Z” axis 1900 mmQuill traverse, “W” axis 1000 mmSpindle power 71 kW
HEADS• Modular quill spindle
Ø180 / 2500 rpm / 71 kW (S1)• Orthogonal head
1ºx1º / 3750 rpm / 46 kW
FXR-16000 FLOOR TYPE
MILLING-BORING CENTRE
TECHNICAL SPECIFICATIONS
SL-8000Longitudinal traverse, “X” axis 6500 mmVertical traverse, “Y” axis 1600 mmCross traverse, “Z” axis 1300 mmFixed table dimensions 8000 x 1100 mmSpindle power 32 kW
SL-8000 FIXED TABLE TRAVELLING COLUMN MILLING CENTRE
HEADS• Orthogonal head
1ºx1º / 5000 rpm / 32 kW
SEPTEMBER 2013
DANOBAT sawing, drilling and 3D plasma cutting machines
HALL 15 STAND D36
TECHNICAL SPECIFICATIONS
Maximum round capacity 2000 mmMaximum square capacity 2000x2000 mmMain motor power 22 kWBlade dimensions 16140x80x1.6 mmBlade speed 11-90 m/minDownfeed speed controlIntelligent delection controlIntelligent cutting software
TDS 20.20
TECHNICAL SPECIFICATIONS
Maximum round capacity 800 mmMaximum square capacity 800x800 mmMain motor power 11 kWBlade dimensions 8700x67x1.6 mmBlade speed 14-110 m/minAutomatic feeding stroke 500 mmLaser fast approachDownfeed speed controlIntelligent delection controlIntelligent cutting software
HDS 8A
TECHNICAL SPECIFICATIONS
Maximum round capacity 520 mmMaximum square capacity 600x520 mmMain motor power 11 kWBlade dimensions 7690x54x1.6 mmBlade speed 18-150 m/minAutomatic feeding stroke 500 mmLaser fast approachDownfeed speed controlIntelligent delection controlIntelligent cutting software
iDS 5A
PAGE 19
EMO 2013 HIGHLIGHTS
Let´s go – AustriaLATZ cutting tools essential for Walter Maringer Ges.m.b.H., one of the leading Austrian
suppliers for all sorts of cutting tools, abrasives and machines
The CEO of Walter Maringer Ges.m.b.H. started his enterprise in 1983 only with the help of his spouse Gudrun. He encountered the challenge of working the all Austrian market with cutting tools and abrasives successfully and is nowadays managing director of one of the leading Austrian suppliers for all sorts of cutting tools, abrasives and machines. A team of 30 employees, of which 10 visit end users all over Austria, helps him complying with the challenges coming from high-tech companies and their demanding requirements. The
headquarters consist of a large exhibition and training room, 660 m² ofice space and, last, but not least, 900 m² storage. Most of his customers manufacture automotive, aerospace and general engineering parts in serial production and depend
on a 100% reliability of the tools they are using.
Rapid growth made the careful selection of long term strategic partners a priority. About 3 years ago, Walter Maringer Ges.m.b.H. started cooperating with LATZ Cutting Tools on a very basic level. Hence, LATZ Cutting Tools, being well-known for their high precision, reliability and cutting edge technology has become an essential partner in a very short period of time. The company has a long track record designing, producing
and commercializing standard and special HSS and carbide cutting tools for the main industrial sectors (aeronautics, automotive industry, etc.).
Walter Maringer: “LATZ is our main supplier for high-performance cutting tools and has never failed us with any of the aspects, our partners need to comply with for the needs of our demanding market. We serve high-performance twist drills made of HSS-Co and solid carbide, with and without internal coolant to customers from all important industrial areas in Austria and only get positive feedback. Performance wise we have absolutely no problems to compete against the
best European manufacturers of cutting tools. For us – and our market – LATZ is a prime manufacturer and one of our most reliable partners. I see a promising future for a long-term relationship.”
The state-of-the-art production facilities of LATZ and the quality
controls guarantee consistent quality from batch to batch and the necessary lexibility for short-term design and production of special tools according to customer requirements - whether for drilling, reaming, chamfering or milling.
“The very demanding requirements of our customers make it essential, that we work only with the best and reliable partners in our area of activity. The quality of their products must be first choice. As I feel personally responsible for the perfect functioning of our customers’ production, the quality is only one aspect of our suppliers. Communication, response time, availability, logistics and price-performance-ratio are the other aspects, which are crucial in the selection of our business partners.”
Mr. Walter Maringer, CEO of Walter Maringer Ges.m.b.H.
LATZ cutting tools
HALL 03 STAND H05
01- Special tools according to customer requirements 02- MARINGER Headquarters in Kobenz, Austria
01 |
02 |
SEPTEMBER 2013
SL-8000 fixed table travelling column milling centre
THE MACHINE
The SL machine offers high versatility for exceptional machining results, based on traditional and unique machine
architecture: table attached column
supported by a separate rear guide,
which improves machine stability, whilst
maintaining its centre of gravity very low.
The machine is equipped with an
orthogonal head, a very lexible and user friendly solution for programming directly on the machine and which additionally
enables inverse machining (machining in negative positions), this saving setups
for complex part production. Other heads from SORALUCE’s wide range are available for this machine.
The SL machine is a large capacity machine with a compact and ergonomic
format design. Thanks to its coniguration, the table provides front and rear access for component itting and veriication, keeping the foundation costs under control as all the machine lies on the same level.
PAGE 21
THE APPLICATION
Pole shoe is a key component in the
large dimensions electric generators. A
good accuracy will prevent any run-out
produced during rotation of the rotor shaft.
The component is machined in just two
set-ups; one set-up for the stator face and another for the rotor face, including lateral faces.
The machine is equipped with an
orthogonal head, which enables inverse
machining (machining in negative positions), likewise machining of the complete pole shoe top and lateral sides
in one set-up. This eliminates the necessity
for additional setups, resulting in improved overall cycle times and inish quality with less component manipulation. This
head enables the user to beneit from full machine travel: eliminating the need for additional workpiece support ixtures, due to close table head spindle accessibility for both front and lateral milling.
SL-8000A well designed machine:
ergonomics and user friendly
01- Accura heads
01 |
MORE ACCURACY IN THE WORKING AREA
It compensates for any head articulation positioning deviation.
• Calibration for any type of head.• Calibration for any position in
the working area.• Calibration for any angle, not
just orthogonal.• Offset error compensation due to
thermal expansion.• Distance between head spindle
noses is measured.• Easy-to-use interface, 100%
integrated with HEIDENHAIN iTNC530 HSCI and SIEMENS 840D SL.
OUTSTANDING PROJECTS
SEPTEMBER 2013
VTC-3200 Vertical Turning Centre
PAGE 23
When versatility improves productivityNASOSENERGOMASH Pump & Power Engineering Works Sumy is one of the Ukraine’s most
important industrial companies, specialising in pump manufacture for the nuclear, oil & gas,
thermal power and water supply sectors.
Its state-of-the-art pump design, manufacture, processing and testing facilities are the base
from which it designs and launches new pump models to meet the most rigorous demands of
the sectors it supplies.
NASOSENERGOMASH has recently purchased three machines from DANOBATGROUP: a VTC-1800 vertical lathe, a VTC-3200 vertical lathe and a SORALUCE FR-10000-W travelling column milling-boring machine, to optimise its
production process and the precision of its components.
We spoke to Vladimir Kushko, Nasosenergomash’s Technical Manager, about the advantages of using the VTC-3200 vertical lathe in the production process.
Q: What kinds of components do you machine?
Vladimir Kushko: We use the vertical lathe for machining pump bodies for the nuclear power sector, pumps for oil transportation and pumps for electric power stations.
Q: How complex are these components?
Vladimir Kushko: Their complexity lies in the precision of their parts. The largest diameters have to be within 0.01 mm tolerance (quality class 6). Machine precision and reliability are two very important aspects required by the sectors we
work for, and high productivity is also essential.
Q: How has your pump body production improved with the new VTC-3200 vertical lathe?
Vladimir Kushko: There has been a great improvement as
regards precision and productivity.
Previously, the pump bodies were processed on six different machines to undergo all the machining operations required.
With the VTC-3200, all the operations are carried out on just one machine and with a single clamping process. This has
increased our productivity, reduced the idle time needed for part clamping, and it has improved precision as there is only
one clamping process.
The machine also includes a head with four turning positions, allowing four tools to be used with no stoppage times for tool change, and this optimises the machining times.
Q: What are the main operations performed on the VTC-3200?
Vladimir Kushko: The basic operations required by the
pump bodies are turning, drilling, milling and threading.
The VTC-3200 turning centre is equipped with a variety of different heads and we can carry out all these machining operations and other on the same machine and with a single
clamping process.
Q: How do you rate DANOBATGROUP’s work on this project?
Vladimir Kushko: DANOBATGROUP has been an
exceptional partner. We explained our machining problems and our requirements to them and DANOBATGROUP
proposed a very precise, highly productive solution. They
showed great know-how and lexibility, adapting to our speciications and putting forward improvements that have a very positive effect on the end product.
Vladimir Kushko, Nasosenergomash’s Technical Manager
OUTSTANDING PROJECTS
SEPTEMBER 2013
The company have in the region of 50,000 valves installed across the globe, some of which operate in the most inhospitable environments on
the planet, often in ultra-deep waters of up to 10,000 feet and under high pressures as well as extremes of temperature.
With valve sizes ranging up to 48” in diameter and tolerances typically
less than one micron, ultra precision
Leading the ieldCritical oil & gas valve manufacturer enjoys significant
savings since installing a DANOBAT vertical band saw
As industry leaders in the design and manufacture of critical oil and gas valves for both surface and subsea applications, Newcastle based BEL VALVES concentrate their energies on serving evolving markets that demand the very highest quality and reliability.
machining is of the utmost importance, so when BEL VALVES needed to upgrade the cutting operation during
the production of their 24” diameter split gate 4A topside through-conduit valves, they naturally turned to Prosaw
to provide the solution.
Although the existing process utilised avertical bandsaw, it was very wasteful of material, typically deviating from it’s true path by up to 1/2” on either side of the
01- 02- 03- DANOBAT band saw at BEL VALVES
PAGE 25
blade, requiring a considerable amount
of post cutting additional machining in order to form a true surface.
Prosaw’s response was to specify a DANOBAT VL vertical bandsaw, which
has drastically reduced the cutting time
for this product from 18 hours to just 6 hours, whilst simultaneously reducing
waste material due to the appreciably
more accurate cutting path, amounting
to cost savings in the region of £1,500 for each valve.
Additionally, further signiicant cost savings have been achieved by the use
of a new type of carbide saw blade, that has a life of more than 50 times that of the previous machine.
“We have been very impressed by this new DANOBAT machine. It is far more accurate and much faster compared to our previous system, and has created huge cost savings. It has also been responsible for relieving bottlenecks in production, causing work to flow more smoothly through the workshop.”
“DANOBAT and Prosaw have been with us every step of the way with this project, giving us excellent service and full sales and technical support which has assisted us greatly in bringing this product along.”
Commented Shop Manager, Mr. Adam Leggett
01 | 02 |
03 |
OUTSTANDING PROJECTS
SEPTEMBER 2013
DANOBAT VG vertical grinding machine
“A machine to speciically meet the high metal removal rates and ine tolerances required”Cooper are the world leader in Split Roller Bearing technology having been in the business
for over 120 years. They offer a standard catalogue range of bearings plus special custom
engineered bespoke, split to the shaft bearings and housings for shaft sizes from 30mm
to over 1250mm. The Cooper solution is specified by industry around the globe, by large
international companies and small niche companies, all valuing the quality and expertise
offered by the company and the products it produces.
Q: In 2010 Cooper Roller Bearings contacted DANOBAT to develop a vertical grinding machine. What process was
used in those days for machining parts? What did you see in DANOBAT to contract them for this project?
Pat Smith: After extensive research, including performing trials on test components, DANOBAT was selected as a
company able to offer the required mix of ield experience, depth of technical know how and support, combined with the requirement for acceptable return on capital investment. Right from the early project stages it became evident that an out of the box option would not satisfy the needs of Cooper and DANOBAT immediately went to work on machine design modiications, incorporating enhancements and upgrades
to prepare a machine to speciically meet the high metal removal rates and ine tolerances required.
One key point for Cooper has been the locality of the Newall business which is part of the DANOBAT group as it is located just a few miles from Cooper. The previous service experience offered by Newall on a number of other smaller DANOBAT machines played a major part in their selection for the bigger machines.
Q: After analysis and work done together by Cooper and DANOBAT engineers, the latter proposed changing the
machining process from hard turning to grinding with CBN wheels. How was this technological challenge perceived?
01 | 02 |
PAGE 27
Pat Smith: When initiating the project Cooper had a clear vision for incorporating hard turning and grinding processes together on the new machine. As it turns out we still utilise
both technologies but hard turning is used to a lesser
degree than originally envisaged and CBN grinding is used far more. Working closely together Cooper and DANOBAT have developed CBN grinding processes and the associated machine design requirements to handle this and as a result,
for some process elements, this is by far the quickest means of high stock removal for roughing and pre- inishing.
Q: How did you eventually beneit from the development of a machine with this technology?
Pat Smith: The implementation of this new technology has allowed Cooper to add overall capacity and process parts more quickly, which in turn has resulted in greatly reduced
customer lead times for large bearings.
Q: These DANOBAT machines have been equipped with
a external setting table. This reduced the setting times considerably. Could you explain the beneits of this system on your application?
Pat Smith: In the previous process, the part was set inside
the machine and this required the machine to be stopped
to carry out this operation. Depending on the component,
03 | 04 |
the machine could be stopped for one or two hours. Now with the external setting station, the operator can set the part while the machine is running. We believe that this is a
big improvement in the overall process as now there is no
machine down time.
Q: Bearing in mind this experience and the two already installed DANOBAT vertical grinding machines, would you
consider DANOBAT a partner to continue with in developing
future solutions?
Pat Smith: The overall experience of working together with DANOBAT has been very positive, both parties have gained
new knowledge and beneited from the experience. We would certainly work with DANOBAT again in the future.
01- External part set up station 02- Hard turning in VG machine 03- Pallet changing system 04- Mr. Pat Smith, Site Director in Cooper Roller Bearings, Kings Lynn
OUTSTANDING PROJECTS
SEPTEMBER 2013
MAN Diesel & Turbo is one of the world market leader for large diesel engines for use in ships and one of the leading suppliers of diesel power stations and turbo machines. The company operates
more than 100 international locations and the range of products and services that they offer includes complete marine drive systems, turbo-machinery trains
for both the oil and gas industries and process engineering, as well as turnkey
power plants.
All, in one single machineA complete solution on one single machine for grinding
different ship engine turbo compressors, providing a great
precision
The client approached DANOBAT looking
for a complete solution for grinding different ship engine turbine wheels for each model of ship. These are parts of between 183 mm-420 mm in diameter and 320-720 mm in length with blades made of Inconel.
The process up to then consisted of using two machines: one for grinding the different diameters and faces of the shaft and the other for machining the blades,
01- 02- 03- Grinding of ship engine turbo compressor
which required a different grinding wheel for each piece.
To ind a solution for grinding this set of parts, DANOBAT presented the horizontal
grinding machine model HG-92-2000-B6 with different systems in order to optimise the process to the maximum, so all machining operations could be
performed on one single machine set-up. Among the most important features of this machine model are the following:
01 |
PAGE 29
• Double wheel head assembled on a B
axis. One set up, one inished part.• New design of grinding wheel and contouring process. Grinding wheel
designed by DANOBAT for grinding the different diameters of the blades using a contouring process, thus cancelling the
need for different grinding wheels for each part model.
• Both spindles assembled on
hydrostatic bearings. Maximum rigidity and maximum vibration damping capacity.
• Motorised tailstock with automatic
programmable positioning and
blocking. Part changing has a negligible
inluence on the set-up time.• Continuous dressing system, dressing the wheel during grinding, resulting in a
signiicant increase of productivity.• Several measuring systems• Software DAN-OP. A powerful technological development allowing
very friendly conversational programming and powerful calculations.
The standard HG-92 easily achieves the precision requirements for this project
because of its construction and the gauging systems. However, the desired working methods demand for speciic solutions:
• MDM absolute contact measuring
system designed and manufactured by DANOBAT, suitable to measure
in-process all and each diameter to
be ground. At the end of the grinding cycle, in automatic mode and by
program, all diameters, its geometry,
and faces can be measured and a Test Report can be issued.
• Touch probe showing the part
clamped between centres with axial references.• Blade measuring non contact
system by laser allowing to measure
the different shapes of the blades, hence avoiding the use of measuring standards used previously for each type of blade.
DANOBAT was able to offer a complete solution on one single machine for grinding different ship engine turbo compressors, providing a great
precision (surface tolerance IT5 and roughness Ra0,4), which made MAN Diesel & Turbo opt for this technology and entrust DANOBAT with this and
future projects.
02 | 03 |
OUTSTANDING PROJECTS
SEPTEMBER 2013
“DANOBAT NA horizontal lathes to get the
required precision levels”Founded in 1969, DONGFENG Motor Corporation is one of the 3 giant car makers in China.
Its main business includes passenger vehicles, commercial vehicles, engine, auto parts &
components, and equipment.
Through over 40 years of development, a set of R&D and manufacturing facilities have been established as well as an extensive distribution and after-sales network.
Currently, DONGFENG is taking delivery of a new lathe in its facilities from DANOBAT based in Elgoibar, Spain. Taking advantage of the occasion, we spoke to Mr. Xiao Guang Sheng, senior engineer at DongFeng Motor Co. Ltd.
Q: What type of components do you manufacture?
Xiao Guang Sheng: Right now, our main product is high
power diesel engines and parts. Our range includes three
models: DCi11, EQ4H and EQX7.
Q: What was the machining process for your crankshafts before investing in DANOBAT lathes?
Xiao Guang Sheng: We were using local machines as well
as NTC Japanese lathes. At that time we were manufacturing cast crankshafts. Many years later we changed our manufacturing process to steel crankshafts due to their lighter weight, more compact dimensions and better inherent
damping but this material is harder and it is more dificult to machine.
10 years ago we visited VOLVO Trucks in Spain and they were using DANOBAT lathes for the manufacturing of their
components and we realized they had several advantages
when using these lathes, and we saw that it could be a good
solution for machining our steel crankshafts. Finally, in order to get the required precision levels, we decided to invest in
DANOBAT NA horizontal lathes.
Q: Do the DANOBAT lathes live up to your expectations?
Xiao Guang Sheng: The NA lathes offer the precision our products require and furthermore, due to their design, take up less room in the plant. For machining large crankshafts, the NA-1500 2TS-2CM model was selected, which is capable of machining components of up to 450 mm in diameter and 1500 mm in length, we used this to turn the ends and supports of the various crankshafts.
PAGE 31
01- Crankshaft turning 02- Mr. Xiao Guang Sheng, senior engi-neer of DongFeng Motor Co. Ltd.
DANOBAT lathes are equipped with two top turrets, two
headstocks (one of them mobile to adapt to the different sizes of crankshafts) and it has retractable jaws which make it possible to turn the end faces. Thanks to these features, the parts are machined using a single set up and even with
the two turrets turning at the same time, thus considerably
improving the cycle time.
Q: Have the parts to be machined undergone changes in recent years?
Xiao Guang Sheng: Over the years, our parts have
undergone changes in their design (size, shape, etc.) but DANOBAT has been capable of adapting to these changes and offering us a full, appropriate solution for our products and always equipped with the latest technology.
Q: How do you value the relationship between the two companies DONGFENG and DANOBAT?
Xiao Guang Sheng: As I have mentioned, the relationship
started several years ago, the irst lathe was purchased in 2005. Since then, we have invested in several lathes and the fact that the DANOBATGROUP is present in the Chinese market and has a highly qualiied service team has helped in the successful development of all the projects. We are convinced that in the future the two companies will continue working together.
01 | 02 |
OUTSTANDING PROJECTS
SEPTEMBER 2013
In addition to being fast, the machine is also powerful and responds very well when rough machining – Mr Cervo explains – the high rigidity of the machine enables large roughing operations which reduce machining time and the machine with roller recirculation linear guideways offers the advantage of lower maintenance costs compared to a hydrostatic machine.
PAGE 33
Working for the energy sector requires very speciic skills and machines capable of ensuring maximum precision on heavy duty components, to guarantee the
productivity and reliability demanded by
this sector to compete on the market.
In addition to centesimal tolerances
on large workpieces, which can weigh
hundreds of tons, today, a machine dedicated to the energy sector must
be capable of dealing with extremely complex machining operations, reducing the number of workpiece set-ups as far as possible and likewise, cycle times
and possible errors. The machine must
respond to multitasking and versatility
requirements not to mention inishing the workpiece in a single set-up.
The “right” solution: versatility and
single set-up
MPC, a company located in Vicenza (Italy) and specialized in working for the energy sector, is one of the customers with whom SORALUCE has established a very close relationship over the years.
FXR-16000 Precision, productivity and reliability
A speciic example, the results obtained at MPCPrecision, productivity and reliability: three key features of the solution proposed by
SORALUCE for the energy sector.
The company performs high precision machining of turbines, turbine cases, generator cases, hubs, housings and
many others key components from power systems (gas, steam, wind, hydroelectric and nuclear), as well
as other components like engines,
gearboxes and compressors. The common denominator of these components is the large workpiece
size, their complexity and the need for absolute precision. Another prerogative
is the variety of processed materials: such as special steel alloys, duplex steel, stainless steel and others. It requires,
therefore, both versatility and reliability.
MPC has 3 SORALUCE milling-boring machines. The latest is the highly lexible FXR-16000 model (X: 16000 mm, Y: 7000 mm, Z: 1900 mm, W: 1000 mm). MPC purchased this machine to meet speciic needs and problems, and especially for processing workpieces in a single set-up.
Before the FXR-16000 was installed at
MPC, the workpieces were machined irst in a turning machine and then in a milling-boring machine, with the resulting
disadvantages in terms of workpiece setup, accuracy loss likewise processing
costs.
The new FXR-16000 machine, equipped with an NC facing head, has meant elimination of the turning machine operation, releasing the lathe from work overload, which generated an
organizational “bottleneck”.
Multitasking coniguration The machine supplied is equipped
with the following peripherals, thereby converting the machine into a
multitasking unit:
• Orthogonal head 1°x1°, 46 kW• Step-less universal head
0,001ºx0,001º, 46 kW • Modular quill, 71 kW at S1 (Ø 180
mm, 1000 length)• Angular head 2,5°x2,5 °, 60 kW at
S1
OUTSTANDING PROJECTS
SEPTEMBER 2013
MILLING AND BORING: FINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL
The system interchanges the modular quill spindle with the rest of the heads totally automatically.
Allows for different quill spindles with different diameters and lengths.
GEOMETRICAL ACCURACY (STRAIGHTNESS AND PARALLELISM) OF THE RAM TRAVERSE OVER THE Y AND Z TRAVELS
Specially suitable for machines equipped with extensive traverses and head changing system.
It compensates the weight of the different heads.
• NC facing head for turning up to Ø 2500 mm.
• Angular head with C axis, 1000 mm length, 22 kW.
• Pick-up for 7 heads.• Rotary travelling table 5000 x 5000
mm, cross traverse 3500 mm, loading capacity 150 Tn.
• Tool magazine for 120 tools. Precision, speed and high stock
removal capacity
Another aspect particularly appreciated
by MPC is the large vertical traverse (7000 mm), which enables very tall workpieces to be machined in a single
set-up.
The new SORALUCE FXR-16000,
as Mr Giuliano Cervo explains, also
resolves the problem of possible
centrifugal forces arising on the vertical
lathe.
Most workpieces machined in MPC
have special geometric shapes.
When machining those pieces on a
vertical lathe, this may lead to non-
homogeneous centrifugal forces and
consequently a possible oval shape
results. When working these pieces on
the SORALUCE FXR-16000 milling-
boring machine, this problem is
completely solved since the workpiece,
unlike the lathe, remains stationary
and does not undergo potential
deformations due to its geometry.
Furthermore – Mr Cervo continued,– by
using the new SORALUCE milling and
boring machine, we have reduced
the cycle time by about 20%, which
is certainly an important advantage
for us in terms of productivity and
competitiveness”
Ergonomy and customization
When machining of large workpieces, machine ergonomics play a fundamental role too. SORALUCE has taken this aspect into consideration, so the
operator will have full visibility of the process while working comfortably and safely. Complex expensive pieces such
Claudio Cervo, Renzo Cervo, Giuliano Cervo -owners of the company MPC- and Giancarlo Alducci -Managing Director and Vice-Chairman of SORALUCE ITALIA-
as those destined for the energy sector cannot be subject to human error, so
while operator performance is also linked to ergonomics, the ergonomic design of the machine is a determining factor. For this purpose, MPC and SORALUCE have established a collaborative relationship and the
“teamwork” resulted in the machine
coniguration and adjustment. Optimum machine coniguration arises from indepth dialogue and discussion
between both sides, i.e. producer and
user, which starting from the objective analysis of problems enabled them to ind the best answer to these problems.
PAGE 35
THE MACHINE
Any kind of machining in one machine, in a single setup. This is what Multitasking
means, and this is the real solution
given by SORALUCE for heavy duty components.
Based on the technology of the successful FL model, this machine enables the
processing of big size / load components with high performance machining strategies thanks to its high dynamics and
with a full guarantee of machining stability derived of its robust cast iron structure.
Universal and Orthogonal heads are
available for milling operations with high power and torque, while an exclusive system is provided for turning tools which protects the head bearings and, at the
same time, enables the fully automatic tool change and head position change.
A large size working area, fully protected, enables different conigurations as just the ixed table, ixed table + Turning / Milling
F-MT 4000Multitasking, lexible and dynamic
table and even the integration of pallet changing systems.
THE APPLICATION
A demonstration part has been developed
to show the full lexibility and multitasking capacities of a SORALUCE F-MT machine.
Live machining demonstration will be
done on a 2,5 Ton component, which is composed of areas of steel and of cast iron. The specially designed part includes
operations such as:
• Turning
• Recess turning
• Millturning
• High performance milling• Gear Milling
• Reverse surface milling• Drilling with different technologies• Countersinking
OPTIMUM PERFORMANCE UNDER CONTROL
• Consists of an automatic adjustment of the defined cutting parameters depending on the real machining situation.
• Automatically speed up and slow down depending on the real stock removal.
• Unattended machining.• Cost efficient production process.
01- F-MT 4000 Multitasking Milling-Turning machine
01 |
OUTSTANDING PROJECTS
SEPTEMBER 2013
Josu Ugarte Arregui is a renowned expert in corporate internationalization and multi-localization with a degree in Economics from the University of the Basque Country, whose professional career has been in MONDRAGON Corporation. His last 14 years have been linked to the international world, and for the last two and a half years he has been the President of MONDRAGON International managing its 9 branches throughout the world: BRIC, México, Chile, USA, Vietnam and Taiwan.
PAGE 37
MONDRAGON Corporation receives the “Boldness in Business” prize awarded by the
Financial Times and Arcelor MittalDANOBATGROUP is the machine tool division of MONDRAGON Corporation, one of the
largest European holding companies. The Corporation is a solid diversified group, whose
innovative attitude, capacity for cooperation and commitment to internationalisation are its
hallmarks. It has an innovation network made up of 15 technological centres with more than
2000 people devoted to R&D, and it has a production and commercial presence throughout
the world.
It is a business project that has proved to be a successful alternative in a complex economic context, as MONDRAGON represents a model in which people play the true leading
role in the company and in which commitment, social
responsibility, participation and transparency are part of its corporate DNA.
A project that little by little has become a world benchmark
for cooperative working.
Q: MONDRAGON is recognised for its different way of understanding work. What does this different way of doing things consist of?
Josu Ugarte: Our corporate company model encourages
the participation of workers in the company: in ownership (the workers are partners in the company); in management (through their contributions for improving products, processes and services); and in the results (depending on the work undertaken).
Q: You’ve recently been awarded the “Boldness in Business”
award organized annually by the Financial Times and Arcelor
Mittal in their “drivers of change” category. What does this award mean for you?
Josu Ugarte: It should be remembered that there were
a total of 260 companies at a world level selected for this international award by the jury, organised jointly by the
Financial Times (FT) and Arcelor Mittal (AM). The inalist companies for this award were the American Oil Company, Continental Resources; the Chinese industrial machinery corporation, Sany Heavy Industry; the multi-sector Indian Group, Tata Group; the Japanese entertainment holding
company, Square; the German publisher, Axel Springer, and MONDRAGON Corporation.
To get a more accurate idea of the extent of these awards, it should be noted that the last three winners in this category
were Fiat in 2009, Apple in 2010 and Amazon in 2011, and among the inalists were companies of the size of Al Jazeera, Google and Master Card.
MONDRAGON Corporation was the winner of the award “as it represents “Humanity at work” in terms of a new real business model proposal, based on cooperation, collective
work, solidarity, and on the involvement of people in the working environment”.
Q: Why do you consider it such an important award?
Josu Ugarte: Firstly, because it is awarded by the most
prestigious inancial newspaper in the world: the Financial Times. Secondly for its scope, these are awards that recognise your merits among a selection of world level companies. Third, because its international impact is
very signiicant, it is not for nothing that these awards are considered the Oscars for business.
Q: The workers are owners of the company. Does this allow effective management with assurances?
Josu Ugarte: The eficiency of the organisations is measured in objective terms through its capacity to compete in the
markets and generate positive results. And in this we are
equal to conventional companies.
HUMANITY @ WORK
SEPTEMBER 2013
What differentiates us from the rest is our way of organizing ourselves, our co-operative identity, due to our members
being full company stakeholders in terms of ownership, management and results. It is we, the members, who
make important decisions in the co-operative. Therefore, this identity allows greater involvement of our people and a greater guarantee of success. Even more so bearing in mind that the beneit obtained is returned in the development of the society where a co-operative is located through the creation of jobs.
Q: In your opinion, what is the role of DANOBATGROUP within MONDRAGON? Has this role had a positive impact on MONDRAGON receiving the award?
Josu Ugarte: The contribution of DANOBATGROUP in MONDRAGON is very important in two aspects. On the one
hand, because it leads a typical industrial sector in Spain, the machine tool sector, which requires technological and
innovative aptitudes which have been carefully nurtured within the group.
Furthermore, the attitude of people in DANOBATGROUP has always surprised me, the “cooperative coherence” and their
good sense in making efforts for collective beneit. Therefore, both the aptitudes and the attitudes of DANOBATGROUP have always helped to add to and make MONDRAGON a
more diverse and enriching experience.
Q: How do DANOBATGROUP customers beneit from MONDRAGON?
Josu Ugarte: Primarily, due to the possible synergies
that can derive from belonging to such a diverse business group, in such a way that they are able to access integrated
solutions through the full range offered which is always very positively valued by customers.
Furthermore, our R&D capability at the service of all our customers should also be highlighted, as we have 15 technological centres specialising in different sectors. And internationally, which affects me most directly, we have a wide range of services (from outsourcing, through business parks where they can be implemented, both in China and India, and an excellent corporate diplomacy service) which we make available to all DANOBATGROUP customers.
Lastly, it should be noted that when doing business with
potential customers, they have to see that the organisation is
competitive, its products are excellent, it offers an unbeatable service, and furthermore it generates conidence through its solidity, stability, inancial capacity and business rigour. And in these latter aspects, MONDRAGON is a key player.
Mr. Ugarte at FT ArcelorMittal Boldness in business award ceremony
PAGE 39
OPEN HOUSES 2013; Latest developments and technologies
on-site DANOBATGROUP owns sales & service facilities in 11 coun-
tries and has a professional representation network and
factories all over the world. In 2013 DANOBATGROUP opened
the doors of several manufacturing plants around the globe
in order to offer key stakeholders the unique opportunity to
visit the latest developments and technologies on-site.
Open House in DANOBAT
04-10 March
Open house at DANOBATGROUP
India factory
DANOBATGROUP India organized its
annual Open House at the “State-of-art facility” at its factory in (Shirwal) Pune.Visitors had the unique opportunity
to visit DANOBATGROUP India’s
manufacturing plant and see in action the SORALUCE KB-150-W Horizontal Boring Machine and the SORALUCE FP-6000 Milling-Boring Machine.
DANOBATGROUP India provides
top-end, comprehensive Machine Tool
solutions to enterprises in India, thereby,
developing their competitiveness and
committing to provide them sustained
support.
06-07 March
Grinding-machines exhibited in
Herborn (Germany)
New developments in internal, external
OPEN HOUSE NEWS
SEPTEMBER 2013
and radii precision grinding machines
were exhibited from 6th to 7th March in the DANOBAT-OVERBECK manufacturing plant in Germany.
DANOBAT-OVERBECK showed its production area of approx. 1600 m² with different innovative solutions launched by the engineering
department of the company. Qualiied experts informed the visitors individually about the speciic grinding solutions needed for their applications.
In addition, selected suppliers
presented their products while providing
information and related issues.
June
The month of LASER
DANOBAT received key people from the sheet metal processing ield during the month of June who had the unique opportunity to see at irst hand the advantages of the new laser cutting machine model IRIS.
The DANOBAT ibre laser cutting machine, IRIS model, enables a great reduction in production costs
associated with energy saving, in
addition to signiicant reductions in ixed maintenance costs and consumables.
04-10 June
10th Turning and Grinding Open
House
DANOBAT grinding and turning
solutions developed for top customers in leading industries were exhibited during the 10th open house days.
The visitors had the opportunity to
understand DANOBAT’s way of developing advanced solutions hand in hand
with its customers and seeing the specialized Research & Development
Centre. 04-10 June
SORALUCE milling and boring
machines at a glance
SORALUCE opened the doors of the
milling and boring machines assembling
workshop from the 4th to the 6th of June.
It consisted of a guided tour visit for key customers and stakeholders
showcasing the Advanced Head Manufacturing Centre, the sub-assembly of different machine parts and the inal assembly facilities of milling and boring machines, with machines already inished and in the assembly process.
01 |
01- Open House in SORALUCE 02- Open House in BIMATEC SORALUCE
PAGE 41
FEATURED UPCOMING EVENTS:
OCTOBER
DANOBATGROUP Shared
Innovation Space: DANOBATGROUP
will organize during the month of October 2013 a special event to showcase the latest research projects
and innovations at its different factories in Spain. DANOBAT and SORALUCE solutions as well as the latest cutting
edge innovations from the specialized Research & Development Centre will be showcased to featured institutions, customers and employees.
02 |
NOVEMBER
Open House: BIMATEC SORALUCE will hold its annual open house from 12th to 16th November presenting its new outstanding milling, boring
and turning technology products.
BIMATEC SORALUCE will showcase live machining trials on more than
10 milling-boring machines and vertical turning machines at the new
Technology Centre located in Limburg.
Arriaga kalea, 2
P.O. Box 33
E-20870 ELGOIBAR Spain
Tel.: +34 943 74 83 00
Fax: +34 943 74 36 74
danobatgroup@danobatgroup.com
www.danobatgroup.com
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