results today - gf machining solutions · 2020-06-12 · solutions’ customer magazine, results...

9Results Today

Progressive procurement professionals are challenging conventional approaches to by looking at procurement through a different lens—one that considers more than direct and indirect costs of an asset over its entire life cycle.

Beyond TCO: lowestprice not always best

GF Machining Solutions

Milling technology | 16 Dedicated Solutions | 18 Automation | 18 Customer Services | 19

Milling productsfor productivityand precision

Liechti: leader insolutions forairfoil machining

System 3Rsolutions withFanuc robots

rConnect takesyour operationinto the future

+ Woodward | 6-7A tradition of integrity,innovating for the future

+ Expert insights | 8-9WEDM proving itself infir tree slot production

+ Lotus F1 Team | 14-15Using ‘best technologies’is key to competitiveness

+ Spindles | 17 Step-Tec Spindlerepair and maintenance

+ Laser | 17 LASER 400 range isthe future of texturing

+4Customersuccesses

+Productnews

Expert insights

The global customer newspaper — English edition

« We are looking not only for machines, but solutions. We need great partners who make great products. »Florian Alber, Project Leader, ThyssenKrupp Presta, Oberegg factory

Shopping for the lowest price has long pitted buyers and sellers on opposite ends of the negotiating ta-ble, but internationally recognized supply chain management and outsourcing expert Kate Vitasek says there’s a better way. Nego-tiating for best total cost of own-ership (TCO) in combination with best value means a win for both buyer and supplier.

“We’re definitely seeing, especially among more sophisticated types of business, companies really look-ing at both cost and value,” said Vitasek, a faculty member at the University of Tennessee’s Center for Executive Education, and author of “Vested: How P&G, McDonald’s and Microsoft are Redefining Win-ning in Business Relationships.“

In a white paper, “Unpacking Best Value: Understanding and Em-bracing Value Based Approaches for Procurement,” Vitasek and col-leagues conclude that the the 21st century demands a sober second thought that challenges the tradi-tional competitive bidding process for establishing a fair price.

A manufacturing perspective

Florian Alber is already taking a value-based machine tool pro-curement approach as Project Leader at the Oberegg (CH) fac-tory of global car parts supplier ThyssenKrupp Presta.

“We produce steering and mass forming parts in Liechtenstein, and it is important that we can produce the highest quality tools in our tool shop in Oberegg,” he explained. “Before we buy a ma-chine, we have to really know what we want and need. In our case, ei-ther we have an existing machine that is at the end of its life and requires replacement because it is too expensive to repair, or we need capacity to make more tools.”

When expanding tool making capacity, ThyssenKrupp Presta calculates how much it can earn for one tool and how much it can pay for a new machine—factoring in hard costs like production time, return on investment, installation location, and capacity forecast. But soft factors—like employees’ machine preferences, services, distribution network and technol-ogy transfer—play an important role, too.

“There is a lot you can’t calculate. For example, we consider our ma-chine operators’ preferences for direct view into the machine tool, the machine control, ergonom-ics and features that make the machine tool easier to operate,” Alber said. “We are looking not only for machines, but solutions.”

Relationships with supply part-ners can be a valuable path to those solutions and a win-win for both parties, he added.

“It’s very important to me to work with partners who know what I’m talking about when I say TCO. For me, this is the requirement and foundation for future coopera-

tions,” said Alber. “In the end, we get a great machine at an accept-able price, and this helps both us and the supplier be successful—a win-win. We are looking not only for machines, but solutions. We need great partners who make great products.”

« We’re definitely seeing, especially among more sophisticated types of business, companies really looking at both cost and value. »Kate Vitasek, author and University of Tennessee Center for Executive Education faculty member

Dear readers,

Welcome to the ninth edition of GF Machining Solutions’ customer magazine, Results Today.

With our expanded offering of machining technologies essential to your productivity and precision, we are your solutions provider, delivering the best value you need to get ahead and stay ahead in today’s highly competitive global manufacturing environment.

In these pages, we invite you to read up on trending topics addressed by experts, get to know some of our most successful customers worldwide, and take a look at how our technologies, products and services come together to resolve your distinct manufacturing challenges.

Our broad technology portfolio ranges from Milling—including high-precision airfoil machining systems

from Liechti Engineering and our Step-Tec in-house Spindle manufacturing—and wire, die-sinking, and hole-drilling EDM, to fully digitized Laser texturing, and a full range of Automation, Tooling and software solutions. Moreover, with the world’s broadest Customer Services offering, we keep you going strong with Machine Support, Operations Support and Business Support.

As evidenced by our customers’ stories, as well as by our global installed base of over 100,000 machines, GF Machining Solutions is here for you—today, tomorrow and beyond.

Pascal Boillat, President, GF Machining Solutions

EDITORIAL

GF Machining Solutions Results Today 092 Expert insights

Asia, and China in particular, be-came known as the “factory of the world,” thanks to low labor costs and a skilled, diligent workforce. But the days when a “made in China” label was synonymous with low-quality products are gone—and so are the low labor costs.

Today, China is facing some di-lemmas, said Laurent Castella, GF Machining Solutions Head of Market Region Asia.

Investing in efficiency

“Labor costs in China have risen significantly over the last decade. As a result, companies are now ei-

ther reshoring to their homeland, like the USA or Japan, or moving their plants to emerging manufac-turing destinations like Vietnam, the Philippines or even Myanmar,” Castella explained. “So, China faces very important challenges and is taking big steps to rapidly overcome them.”

Investing in efficiency is one of those steps. According to the In-ternational Federation of Robotics (IFR), China last year surpassed Japan to become the world’s big-gest market for industrial robots. Some 200,000 industrial robots were operating in China at the end of 2014.

“GF Machining Solutions is in an especially good position to help manufacturers in China gain ef-ficiency,” said Castella. “With very efficient Milling, EDM and Laser products, rigid and ultra-precise Tooling systems, and Automa-tion solutions that fit a variety of needs, we have the widest offering in mold and die Automation. Our long experience in automating cells in high-cost countries has given us a broad perspective that benefits our customers in Asia.”

Careful analysis essential to success

But is Automation the key to suc-cess as China enters a new manu-facturing age? Castella said the answer is: “Yes, but with a careful analysis and approach to the cur-rent manufacturing process.”

“Automating an inefficient process will still result in widely inefficient output,” he said. “One also has to distinguish between autonomy, or unattended processes during certain periods, and Automation, where the system can make some decisions by itself. That’s why every discussion about our Automation solutions starts with a thorough

analysis of the customer’s manu-facturing process and skills before any equipment proposal is made.”

Moreover, senior management’s throughput and quality output ob-jectives must be clearly stated.

“Only then will our engineers be able to design a performing and competitive manufacturing cell that delivers full satisfaction,” said Castella. “Our objective is to provide a solution—not just sell equipment.”

Support for China’s efficiency driveAs labor costs rise year after year in China, the nation faces pressing challenges, including companies reshoring or moving plants to Southeast Asian countries. GF Machining Solutions is particularly well positioned to support Chinese companies as they work toward greater efficiency.

Laurent Castella,

Head of Market Region Asia

Market Region Asia, GF Machining Solutions

GF Machining Solutions Results Today 09 3

Cool and casual—three-day stub-ble is all the rage. But whether the fashion-conscious male chooses to go with the trend or prefers a clean-cut alternative, he should always look well-groomed. A good razor that delivers chiseled con-tours or perfectly smooth skin is an essential part of this.

Braunform is a tool making business based in Bahlingen am Kaiserstuhl, a small town in southwest Germany. It creates the injection molds that are used by various manufacturers, including the market-leaders in cosmetic care products, for the highly so-phisticated plastic components in their razors. These intricate struc-tures, accurate to a thousandth of a millimeter, carry up to five ex-tremely sharp blades, individually sprung for a smooth finish. This

represents a real challenge for all designers and manufacturing experts at Braunform, especially if you bear in mind that these in-jection molds are used for mass products and therefore have to deliver perfect results a million times over. “We supply renowned razor manufacturers throughout the world,” revealed Timo Steine-brunner, Sales Manager, but without mentioning any names; discretion is paramount. Hidden champions like Braunform are usually secretive and avoid high-profile publicity. Instead they rely more on their achievements to make a name for themselves in their particular industries.

Braunform certainly has no reason to hide away: Its customers come from the cosmetic care industry as well as from the automotive

and pharmaceutical sectors and all of them are truly global play-ers. Braunform produces an impressive range of tools for the manufacture of plastic compo-nents—from parking brake ac-tuators to inhaler parts—and this is predominantly due to the fact that the company has opted for GF Machining Solutions’ high-end EDM solutions. Since mid-2015 the family business has oper-ated two AgieCharmilles CUT 3000 wire EDM machines, one Agiecut Excellence, five AgieCharmilles FORM 3000 ED die-sinking ma-chines and two Agietron Hyper-sparks, all equipped with modular Automation systems for loading and unloading workpieces and electrodes. These are the best that GF Machining Solutions has to offer and represent top-of-the-range EDM technology.

The machines are highly efficient in eroding multi-component molds that allow various parts made from different materials to be manufactured in a single operation, as well as multi-cavity molds that are especially eco-nomical for the mass production of high-quality parts. By using GF machines, among others, Braun-form has succeeded in developing a groundbreaking product: MED molds®, injection molds that are optimized for cleanroom applica-tions. The high level of process accuracy ensures maximum safety for customers in the medi-cal industry, including companies that produce contamination-free insulin and infusion accessories.

Thanks to its extraordinary exper-tise, Braunform now has around 320 employees and an annual

turnover of 35 million euros. This is a success story that began in 1977 when Erich Braun set up the busi-ness. The Agie erosion technology captured the pioneering entrepre-neur’s attention in the early days when he attended a trade fair. There has been a close partnership ever since: “Braunform has been a very loyal customer of ours since 1977. In those 37 years the company has purchased 35 EDM machines, al-ways the latest and best model,” re-called Frieder Nothacker, Sales En-gineer at GF Machining Solutions, who has looked after Braunform for over 20 years. The statement may seem surprising at first. After all, the acquisition of very sophisticated machines is associated with high investment costs that have to make economic sense in the long term. So why does it always have to be the latest machine?

Precision for that perfect look

Braunform GmbH’s Timo Steinebrunner,

Sales Manager, (left) and Martin Kohl,

Head of Eroding (right)

Braunform GmbH specializes in high-precision injection molds and since 1977 the company’s production process has relied on GF Machining Solutions’ electrical discharge machining (EDM) technology. At the same time this medium-sized business is not afraid of trying out prototypes and getting them ready for the market. Consequently Braunform is a step ahead of many competitors.

Braunform

GF Machining Solutions Results Today 094 Europe

Mold insert

SGW: eight-fold tool for euro

bottle pack cap

Insert for coffee pad

“Since the very beginning we set out to be an innovation leader, as that is the only way we can sur-vive in the face of competition,” explained Sales Manager Timo Steinebrunner. “We simply do not offer off-the-shelf tools. Every injection mold is an individual de-sign that is the result of intensive communication with our custom-ers. And our customers have very stringent requirements. So it’s not just a question of keeping pace

with the times; we always want to be one step ahead.”

A strategic partnership has de-veloped between Braunform and GF Machining Solutions, built on decades of close cooperation and trust. Martin Kohl, Head of Die-sinking and Wire Erosion, took a look back: “At one time we perfected the EDM technique with graphite in collaboration with GF Machining Solutions and then we

were involved in the technologi-cal development over the years as cooperation partner. So every new generation of machines has undergone its final trials with us. And that is still the case today: we also helped with the development of the latest machines last year.” All customers of GF Machining Solutions benefit from this—as do all the men who want to be per-fectly groomed.

www.braunform.com

GF Machining Solutions EDM and System 3R Automation help keep Braunform GmbH ahead of competitors.

« We want to be an innovation leader, as that is the only way to survive in the face of competition. »Timo Steinebrunner, Sales Manager at Braunform

Braunform GmbH, Kunststoff- und Pharmatechnik

Unter Gereuth 7+14, D-79353 Bahlingen, Germany

Tel: +49 (0)7663/93 20-0

GF Machining Solutions machines

2 AgieCharmilles CUT 3000

1 Agiecut Excellence

5 AgieCharmilles FORM 3000 HP

2 Agietron Hyperspark

System 3R automation systems


Founded in Rockford, IL (USA) as The Woodward Governor Compa-ny, Woodward today is the world’s oldest and one of the largest independent designers, manu-facturers, and service providers of control systems and their components for aircraft engines, industrial engines and turbines, power generation and mobile in-dustrial equipment.

One hundred and forty-five years after the company’s founder was granted a patent for his mechani-cal non-compensating water-wheel governor, a device to regu-late the speed of waterwheels and turns, that legacy of innovation is alive and well at Woodward. In fact, “Always innovating for a bet-ter future,” is at the core of their

brand story. Woodward designs, manufacturers and services a wide range of products, includ-ing fuel pumps, engine controls, actuators, air valves, fuel nozzles and electronics.

Woodward, Inc. employs approxi-mately 7,500 people across more than 25 locations in 14 countries worldwide, and reported 2014 net sales of $2 billion. The company’s systems control aircraft engines for the aerospace industry heavy-weights, including General Electric, Boeing, Safran, UTC, Honeywell, Rolls Royce, Bell, Lockheed Martin, Raytheon and other air framers and engine makers.

Geoff Anderson, Director of Manu-facturing with Woodward, said

GF Machining Solutions’ wire-cut-ting, die-sinking and hole-drilling EDM technologies, along with ap-plication expertise and Customer Services, are important assets to the company.

“Our relationship with GF Machining Solutions began in July 2012. We had hired a new manufacturing engineer with a lot of EDM expe-rience. He was able to make our EDM machines from a former supplier more productive, but when it was time for us to expand our EDM capacity, he kicked off an effort to look at new resources,” said Anderson who, like Wood-ward’s founder, began his career as a machinist. “He led a team that looked at several EDM sup-ply partners and proved, working

with GF Machining Solutions, that the same parts we had been producing with our old machines could be made in a more produc-tive manner on AgieCharmilles EDM machines.”

Attacking new parts in different ways

Today, Woodward uses GF Machining Solutions EDM technology as their preferred machine of choice.

“What differentiated GF Machining Solutions initially was productivity. But as we signed a long-term con-tract for all of North America and our new Rock Cut (Ill.) Campus (RCC), it became service, the com-plete offering, and our experience working with the whole team,” said

Anderson. “Application support is particularly valuable to us. We work with GF Machining Solutions to attack new parts in different ways. For example, an automated or semi-automated process capa-bility allows us to better allocate our labor resources and to better control the process.”

Innovation answers technical challenges

Anderson said tight tolerances and recast layer are among the EDM technical challenges Woodward faces—and that GF Machining Solutions answers with innovation.

“We achieve minimal recast layer and extremely tight tolerances, thanks to the superior spark

Backed by a tradition of integrity, Woodward, Inc. is innovating for a better future

Geoff Anderson, Director of Manufacturing and

Parts Manufacturing Leadership, Woodward, Inc.

When Amos T. Woodward founded The Woodward Governor Company—today known as Woodward, Inc.—in 1870, he set in motion a tradition of integrity and a legacy of innovation that continues today, and is supported with products, application support, and Customer Services from GF Machining Solutions.

« Application support is particularly valuable to us. We work with GF Machining Solutions to attack new parts in different ways. »Geoff Anderson, Director of Manufacturing and Parts Manufacturing Leadership, Woodward, Inc.

Woodward, Inc.

GF Machining Solutions Results Today 096 Americas

Closeup: An AgieCharmilles DRILL 300 burns

wire thread holes on a workpiece that will

subsequently be transferred to the CUT 200 Sp

for wire EDM machining.

An AgieCharmilles DRILL 300 burns wire thread holes.

control for which GF Machining Solutions is known,” he explained.

That’s the kind of innovation Woodward values. At its Fort Collins, CO facility, the com-pany uses AgieCharmilles die-sinking EDM to burn openings in fuel metering spool valves. Two CUT 200 Sp machines comprise a cell producing small links and levers for fuel metering devices in its Loves Park, IL facility. On July 1, Woodward opened its new 450,000-square-foot Rock Cut Campus facility—just a few miles

from where the company’s found-er set the wheels of innovation in motion. GF Machining Solutions is there, too. A DRILL 300 will be used to create starting holes for fuel metering spool valves, and a CUT 200 Sp will burn metering ports in those valves. Two System 3R linear Transformer cells will ensure autonomy and flexibil-ity for an additional product line, where Woodward has a takt time of minutes.

www.woodward.com

Woodward, Inc.

PO Box 1519

Fort Collins, CO 80522-1519

USA

Phone: +1 (970) 482-5811

Contact

[email protected]

LinkedIn http://www.linkedin.com/

company/woodward

Twitter http://www.twitter.com/

woodward_inc

YouTube https://www.youtube.com/

user/woodwardinc


1 FORM 300 Sp

1 FORM 20 with iRTC

4 CUT 200 Sp

1 DRILL 20

2 DRILL 300

2 System 3R Transformer cells

An AgieCharmilles DRILL 300 (left) and an AgieCharmilles CUT 200 Sp, staged and ready

at Woodward’s new Rock Cut Campus for a System 3R Automation line. Automation makes it

possible for Woodward to make the best possible use of the machines.

Woodward, Inc. Director of Manufacturing Geoff Anderson

(far right) discusses a part detail with Director of

Manufacturing Paul Blee (far left) and Manufacturing

Engineer Eric Johnson (center).

Woodward, Inc. Manufacturing Engineer Eric Johnson (right) discusses with Directors of

Manufacturing Paul Blee and Geoff Anderson the process that the parts will flow through

from the DRILL 300 to the CUT 200 Sp as part of the System 3R transfer system.


Due in large part to a body of evi-dence generated by David Welling at the Laboratory for Machine Tools and Production Engineering (WZL) at RWTH Aachen University (DE), WEDM seems to be capable to replace broaching as the go-to machining technology in the pro-duction of fir tree slots for high-pressure compressor and turbine disks. Fir tree slots are the spaces in turbine disks into which blades’ fir tree roots fit.

Welling, Team Leader of the Re-search Group Electro Discharge Machining at the Chair of Manu-facturing Technology at WZL un-der the leadership of Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke, is driving much of that research. Welling’s interest in aerospace machining technolo-gies was triggered by an advanced internship at one of the industry’s

main original equipment manu-facturers (OEMs). Following that internship, he finished his study of mechanical engineering for his diploma degree, and in 2010 authored the first of three break-through studies on WEDM in the manufacture of jet engine com-ponents. Welling was part of the EU-funded ADMAP-GAS project to investigate alternatives to broach-ing for fir tree structures in gas turbine blades and disks.

“Jet engines must become more fuel efficient, and that means developing advanced high tem-perature materials which are hard to machine,” he explained. “The topic of fir tree slot production with WEDM was initiated during dis-cussions with the Research Group at WZL and GF Machining Solu-tions demonstrating the needs of jet engine manufacturers.”

Finding solution to industry problem

As a candidate for a German Dr.-Ing. at RWTH Aachen University, Welling was required to take an industry problem, break it down to the fundamentals, and work on it to solve the problem. With the soaring demand for new aircraft by the year 2030, and with every passenger jet requiring more than 500 fir tree slots, it was obvious to Welling that an efficient and secure fir tree slot manufacturing method was needed.

“I was motivated by the need in aerospace manufacturing for a machining process to replace broaching,” he said. “Broaching tools are reaching their limit, due to the high tool wear that results from the increased toughness of aerospace materials. Broaching

machines require a lot of floor space, have a high initial invest-ment cost, and offer low flexibility. For example, you need a longer period to change a tool, and you need a specific tool for every fir tree slot. And that tool—which is very expensive to replace—will take more than six months from the order to implementation into the manufacturing.”

WEDM has long been considered a mature technology with little in-novation potential and, until about 10 years ago, was not considered a viable process for full fir tree slot production due to the recast white layer left on components by earlier generation WEDM technol-ogy. But Welling’s research has shown that WEDM compares well to broaching in terms of surface integrity and part tolerances for fir tree slots in turbine disks.

Exploring the WEDM edge

So far, Welling’s research has shown through component high cycle fatigue studies that WEDM compares to broaching in terms of component fatigue life, and that WEDM is actually capable of machining fir tree slots with the required accuracy. In addition, Welling said, WEDM offers an edge when it comes to automation since it offers the process monitoring capabilities that will be necessary in the future to assess machining quality.

“Broaching, on the other hand, is perceived as a difficult process to automate,” said Welling.

“WEDM is a fully controlled pro-cess. You can monitor the control data, trace it back, and make the

WEDM can replace broachingfor fir tree slot productionAs aerospace original equipment manufacturers and value chains face increasing pressure to produce more fuel-efficient aircraft, wire-electrical discharge machining (WEDM) is emerging as a key machining technology.

Expert insights

« As I come to the end of my doctoral research, I see that WEDM is capable to replace broaching from a technical and economical point of view. »David Welling, Team Leader of the Research Group Electro Discharge Machining at the Chair of Manufacturing Technology, WZL at RWTH Aachen University

GF Machining Solutions Results Today 098 Expert insights

correlation to the surface to get an in-process quality assessment,” he explained. “Furthermore, WEDM does not present the tool wear challenges inherent to broach-ing. With WEDM, since the tool is wire that is being unwound from the spool, there’s a new tool being used for every process second.”

Welling’s research has also shown that, while broaching uses brute

force to produce forms, WEDM is a nearly force-free process capable of cutting the very fine geometric radii of fir tree slots.

Confirmation by the industry

In his doctoral thesis, scheduled for fall 2015 publication, Welling investigates the causes of the white recast material layers left

on aerospace components by both the EDM and broaching processes.

“As I come to the end of my doc-toral research, I see that WEDM is capable to replace broaching from a technical and economical point of view,” he said, explaining that over-all cost comparisons show that WEDM is less costly than broach-ing, due primarily to broaching’s high tooling costs.

“One essential result is that over that past two years, I conducted further low cycle fatigue (LCF) component life testing at a jet en-gine manufacturer and they con-firmed that WEDM is comparable to broaching. It is motivating to

see this confirmation from the in-dustry. I also know that first OEMs are using WEDM in turbine disk fir tree slot manufacturing.”

« WEDM is a fully controlled process. You can monitor the control data, trace it back, and make the correlation to the surface integrity to get an in-process quality assessment. »David Welling, Team Leader of the Research Group Electro Discharge Machining at the Chair of Manufacturing Technology, WZL at RWTH Aachen University

Inconel 718 ir tree slot demonstrator machined with wire EDM

(40 mm workpiece height)

Wire EDM machined fir tree slot demonstrator with ± 5 µm tightest

geometrical tolerances of fir tree slots

Production mechanic and EDM processes expert Aron Salm prepares a wire EDM

machine tool for research work.

A single fir tree slot machined with wire EDM (case study with a tilted fir tree slot

for economic process analysis)


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4

5

6

3

Founded in 1962, VECA today has annual revenues of € 30 million and counts F1 teams Honda, Ferrari, Toyota, Renault and Scuderia Toro Rosso among its customers along with multina-tional helicopter manufacturer AgustaWestland S.p.A. Those im-pressive relationships are based on a foundation of passion for innovation and trust, said VECA President Alessandro Verasani.

“Our goal is to satisfy every cus-tomer’s need regarding quality and delivery time,” he said. “We want to amaze our customers with the absolute best quality and de-livery times.”

If they say they can do it, they do

Quality, Verasani explained, is related to precision, but precision alone is not enough to satisfy cus-tomers—or VECA.

“Precision means reliability and being able to maintain the same precise characteristics over time to be synonymous with quality and standardization of processes and process security,” he declared. “What sets us apart from our competitors is that we meet the demands that our competitors do not, especially in F1.”

Customers’ needs aretop priority for Italy’s VECA

VECA President Alessandro Verasani checks

the status of the machine with an employee.

Situated in the heart of Italy’s Modena Province—known as “the capital of engines”—the VECA Group is intent on amazing its customers. VECA relies on GF Machining Solutions in its quest to achieve stunning quality and fast delivery times.

VECA

Some VECA products, their materials,

and the GF Machining Solutions

products used to manufacture them:

1. Pump housing (MgZK60),

Mikron HSM 600U

2. Propeller (SAE 4340),

Mikron HPM 800

3. Front-rear axle (MAR 350),

Mikron HPM 800

4. Manifold (Ti 6.2.4.6),

Mikron HPM 800

5. Body hydraulic system (15-5PH),

Mikron HPM 800

6. Steering rack housing (AA2099),

Mikron HPM 800


Another example is VECA’s abso-lute pledge to follow through on commitments.

“AgustaWestland asked us if it was feasible to produce a certain kind of product and we did it, be-cause when we tell a customer we can do something, we do it,”

Verasani explained. “The same thing happened a few years ago when McLaren asked us to make a rocker arm—a rocking lever in an engine that works a valve and is operated by a pushrod from the camshaft—that they had always done in three welded parts. We found a solution for making the

rocker arm from a piece billet. Three or four years later, McLaren is still happy with that idea.”

Such great ideas do not just fall out of the sky. Verasani said they’re the result of expertise and experi-ence VECA has gained over its half century of executing demanding applications.

“This allows us to know if a piece is feasible and how long the ma-chining will take. Another positive point is that in our area, there are requirements that are different from one another and we can sat-isfy those diverse demands: elec-trical discharge machining (EDM), Milling, heat treatment, peening, shot peening and carry overs.”

GF Machining Solutions is VECA’s go-to provider of EDM solutions. In fact, VECA uses only AgieCharmilles EDM machines. Mikron high-performance and high-speed Milling machines, along with System 3R CellMan-ager software for pallet manage-ment, also play a key role at VECA.

“We chose the Mikron HPM 800U HD because we needed five-axis vertical Milling machines with a work area of 800 mm on the X axis and pallets. It replaced a DMG machine that didn’t have these features,” Verasani explained. “We also value this machine’s Machine Spindle Protection sys-tem and the great number of pal-lets it accommodates.”

And, thanks to GF Machining Solutions Customer Services’ Nadcap certification support, VECA delivers added value to customers who appreciate that extra assur-ance of security.

“Our main EDM customer, Ferrari, has always required sample sizes for each batch by freezing the product to identify any recast white layer. And for the past couple of years, Mercedes has been taking the Nadcap certification to do a thorough check of the machines,” he said. “Compared to competi-tors, GF Machining Solutions is very concentrated on after-sales service and this, for me, is a very good sign.”

www.veca.it

VECA GROUP

Via Morello Mezzo, 101/105

41019 Soliera (MO) Italy


1 Mikron HPM 800U HD

1 Mikron HPM 800U

2 Mikron HSM 600U ProdMod

3 AgieCharmilles Robofil 440CC

1 AgieCharmilles CUT 300

1 AgieCharmilles Robofil 6030 SI

1 AgieCharmilles Roboform FO 55

2 AgieCharmilles Roboform FO 55 P

1 AgieCharmilles FORM 300

1 AgieCharmilles HD 8

System 3R Cell Manager

System 3R Macro and Delphin zero-point systems

VECA’s fleet of GF Machining Solutions products includes both EDM and Milling.

« We chose the Mikron HPM 800U HD because we needed a five-axis vertical Milling machine with a work area of 800 mm on the X axis and pallets. »Alessandro Verasani, President, VECA Group

Die-sinking operation on AgieCharmilles FORM 300

VECA EDM Department includes a total of 10 AgieCharmilles machines


A subsidiary of Tianjin Huayuan In-dustrial (Group) Company, REFULL Tianke started in 2006 with just one machine: a GF Machining Solutions ROBOFORM die-sinking EDM machine.

“We were looking for the best-in-class machines in the world, and GF Machining Solutions has a very good reputation in EDM,” said REFULL Tianke General Manager Lizheng Wang.

In the past nine years, the compa-ny has grown from a small mold-and-die producer to a 300-em-ployee, full-service specialist in designing and manufacturing pre-cision injection molds, stamping dies and precision parts. Today, REFULL Tianke is a partner to numerous global brands, includ-ing Toyota, Samsung, Sony, Nestlé and Schneider Electric, and its expertise ranges from information and communications technology (ICT) to automotive and medtech.

“What makes me most proud is how competitive we have become in mold design,” Wang said.

Seeing unmet needs in a booming market

Wang attributes REFULL Tianke’s success to the parent company’s ability to identify an unmet need, along with location, a stellar re-search and manufacturing team and experience in mold design and manufacturing—particularly

for complex molds. The Tianjin re-gion has been a major seaport and gateway to China’s capital, Beijing, since the mid-1800s, and is home to major industries, including car manufacturing and metalworking.

“The mold and die market in North China is booming, but there are few companies focusing on this specialty. We knew there was room to develop in mold and die when we started in 2006,” said Wang. Close proximity to an

educated labor pool due to nearby universities, is a another plus, and REFULL Tianke enjoys easy ac-cess to transport via the Port of Tianjin and Binhai International Airport as well as the new Beijing Daxing International Airport that is now under construction.

As the Tianjin region has boomed, REFULL Tianke has grown—and along with it, the company’s GF Machining Solutions machine fleet has grown.

REFULL Tianke dependson best-in-class machinesEven before North China’s Tianjin REFULL Tianke Mold & Die Co., Ltd, got up and running in 2006, GF Machining Solutions was its first choice for EDM technology. Today, as a full-service partner to globally known brands, the company still counts on GF Machining Solutions for best-in-class machine tools.

« Our GF Machining Solutions machine tools and Automation deliver the stable performance and high precision we need to quickly meet our customers’ changing needs. »Lizheng Wang, General Manager, REFULL Tianke

Tianjin REFULL Tianke Mold & Die

GF Machining Solutions Results Today 0912 Asia

“First, we worked as a job shop for big mold factories. After three years, we had our own research team. That means we can both design and manufacture molds, especially precision molds for ICT and automotive,” Wang explained. “Also important to our success is our ability to provide our custom-ers with a full-service solution be-yond just mold manufacturing. We have the world’s best machines to ensure our productivity. Many of our customers come to us to see our machines.”

Overcoming challenges, staying ahead of change

REFULL Tianke’s GF Machining Solutions fleet includes 17 ma-chines, including AgieCharmilles die-sinking and wire-cutting EDM and high-speed, high-perfor-

mance and high-efficiency Mikron Milling machines. In addition, System 3R Automation is part of the company’s success.

“Our two FO 350 SP die-sinking EDM machines are connected by System 3R’s flexible WorkMaster modular Automation system, which serves both machines in one production cell,” Wang said. “Thanks to System 3R Automa-tion, we could reduce our work-force by half and increase our productivity by 20 percent—and this cell can work 24 hours a day, seven days a week.”

GF Machining Solutions helps the company stay ahead of its chal-lenges.

“Speed is one of the technical challenges we face as a supplier,

because the requirements of our customers are changing so quickly and that drives changes in the products,” he said. “Our GF Machining Solutions machine tools and Automation deliver the stable performance and high pre-cision we need to quickly meet our customers’ changing needs.”

REFULL Tianke has a bold vision for its future:

“We want to provide customers with a one-station solution: from an idea, to an industrial design, all the way through to a finished end product,” he said—and GF Machining Solutions will be there every step of the way.

www.tjrefull.com

The REFULL Tianke building in Tianjin, China

REFULL Tianke’s first GF Machining Solutions

machine, an FO 23 UP, machines a mold.

REFULL Tianke employee using the Mikron

HSM 500 to work on an electrode for a mold.

Thanks to System 3R Automation, REFULL Tianke could reduce its workforce

by half and increase its productivity by 20 percent.

REFULL Tianke’s CUT 20 P is one of 17

GF Machining Solutions machines used at

REFULL Tianke.

REFULL Tianke produces molds

for mobile phones.

REFULL Tianke can produce

molds for the medtech segment.

Tianjin REFULL Tianke Mold & Die Co., Ltd.

Huayuan Zone Jinghai District

TianJin, PRC 301636


1 AgieCharmilles CUT 20 P

1 AgieCharmilles CUT 30 P

5 AgieCharmilles FO 23 UP

1 AgieCharmilles FORM 20

2 FO 350 SP

1 Mikron HPM 600 HD

2 Mikron HSM 500

2 Mikron HEM 800

2 Mikron HEM 1200


« We try to go to every race with better solutions than we took to the previous race. Our nearly 20-year technical partnership with GF Machining Solutions helps us do that. »Luca Mazzocco, Head of Partner Management, Lotus F1 Team

Using ‘best technologies’ sharpens Lotus F1 Team’s competitive edgeIn a sport where every fraction of a second counts, the tiniest competitive edge can make the difference in the machine shop as well as on the race track. That’s why GF Machining Solutions is the team’s longest-standing technical partner.

Lotus F1 Team

In F1 racing, the highest expression of technology in motorsport, Lotus F1 Team uses innovation and tech-nology to gain every possible com-petitive advantage; this applies to the machine tools used to produce more than 50,000 components per year. Luca Mazzocco, Head of Part-ner Management, explained how GF Machining Solutions machine tools come into contact with many of those components.

“All metal parts are produced with GF Machining Solutions products. The great majority of these compo-nents are milled and 10 percent go on to be machined with wire-cutting or die-sinking EDM,” he explained. “And we try to do all of the machin-ing in just one setup or operation.”

Counting on best technologies

Lotus F1 Team’s mission is to compete at the top of the Formula One World Championship, and that means outsmarting competi-tors with larger budgets and gain-ing small advantages in as many areas as possible.

“Every hundredth of a second is important to us and when you ap-proach the delicate business of designing an F1 car, it’s absolutely essential to be able to count on the best technologies available,” Mazzocco said. “We try to go to ev-ery race with better solutions than we took to the previous race. Our nearly 20-year technical partner-

ship with GF Machining Solutions helps us do that.”

The team’s GF Machining Solu-tions machine tools perfectly ac-commodate those extremely short innovation cycles.

“In Formula One, the innovation cycle is relentless. That means our engineers are constantly coming up with solutions to make our car more competitive and our production team has to cope with that,” he said. “Our Mikron Milling machines and AgieCharmilles EDM machines allow the flow of ideas to very quickly become reality—with ab-solutely no compromise in preci-sion or reliability.”

Such an agile team requires technical partnerships that are responsive and versatile and since 1997 GF Machining Solutions has been there for Lotus F1 Team, providing not only state-of-the-art machining technologies, but valuable application and process expertise, training, and Customer Services.

“This technical partnership gives our team the solid and reli-able manufacturing platform we need to achieve the ambitious goals we have set for ourselves,” Mazzocco noted.

Partnership got a strong start

An example of how Lotus F1 Team got its first taste of GF Machining Solutions with EDM is the revolu-tionary redesign of the front and rear uprights in the late nineties.

“Before EDM, it had been made of steel that was cut, bent and skill-fully welded by hand,” he said. “By using wire and spark erosion, we were able to make it out of tita-nium, which in turn made it faster to manufacture, lighter, and with a longer life expectancy.”

In 2012, when the team was looking to upgrade its Milling op-erations, GF Machining Solutions’


www.lotusf1team.com

Since 1997, Lotus F1 Team has relied on GF Machining Solutions as a technical partner.

Mikron machining centers were an obvious choice.

“We chose these machines due to the overall good experience we’ve had with AgieCharmilles EDM products and the reliability and support we have experienced,” Mazzocco stated.

Just before the 2014 racing sea-son, the team took delivery of six Mikron HPM 450U Milling centers with integrated Automation and pallet and tool changers. They’re used to machine the manifold for the team’s gearbox control sys-tem, uprights, the steering rack,

and the many inserts in the car’s composite chassis.

“The compactness of the HPM 450U machines is very good. Because of their slight L shape, one operator can control two ma-chines, giving us more productivity per square meter of floor space,” he said. “Technical Partnerships are one of Lotus F1 Team’s stron-gest points and GF Machining Solutions has made a strong con-tribution to what we are and to the successes we have shared.”

« Our Mikron Milling machines and AgieCharmilles EDM machines allow the flow of ideas to very quickly become reality—with absolutely no compromise in precision or reliability. »Luca Mazzocco, Head of Partner Management, Lotus F1 Team

Lotus F1 Team’s fleet of GF Machining Solutions machines

All metal parts created by Lotus F1

Team are produced with GF Machining

Solutions products.

Lotus F1 Team aerodynamicist

Lotus F1 Team

Whiteways Technical Centre

Enstone, Oxfordshire

OX7 4EE United Kingdom

Contact

Luca Mazzocco,

Head of Partner Management

[email protected]


6 x HPM 450U

1 x HPM 600U HD

3 x CUT 300

1 x CUT 200

1 x FORM 200

Romain Grosjean (FRA) Lotus F1 E23.Monaco Grand Prix, May 21, 2015.Monte Carlo, Monaco.


MILL S 400 (U)

HSM 200 (U) LP

HPM 800 U

CUT 200 mS CUT 300 mS CUT E 350 CUT E 600CUT 200 Sp CUT 300 Sp CUT 400 Sp

Whether you’re a mold and die maker in need of effective cut-ting of short runs or a producer of highly precise parts, stamping dies or plastic injection molds, GF Machining Solutions has the answer.

CUT 200/300 mS and CUT 200/300/400 Sp

Performance and versatility to meet the highest demands are en-gineered into the CUT 200/300 mS and CUT 200/300/400 Sp. Designed and made in Switzerland, these

machines are built for long-lasting precision that remains unchanged even after years of use.

Thanks to their built-in EXPERT modules, these machines deliver perfect accuracy and surface fin-ish, impeccable control of the finest details regardless of the contour or machined height of your workpiece, a reliable and maintenance-free threading sys-tem, superior stability thanks to the QUADRAX design, and the ability to expertly machine even heavy workpieces.

At the same time, you experience greater safety in operation with In-tegrated Collision Protection (ICP), faster data processing, and energy savings, thanks to the state-of-the-art numerical controls.

CUT E 350/600 boosts productivity

Accurate cutting of complex shapes and effective cutting on short runs are a snap with the CUT E 350/600 machines, thanks to onboard collision protection, new built-in machining strategies

and flexible job management, within a new, easy-to-use human-machine interface (HMI).

ICP eliminates costly collision-related downtime and protects your machine and workpieces, so your machine operators can work with confidence. In parallel, complex parts are easily executed, thanks to the AC CUT HMI and the POWER-EXPERT module that op-timizes cutting parameters to the workpiece height and shape.

High cutting performance is made easy but the machines’ ability to automatically select optimal cut-ting technologies based on the machining path. With the onboard corner strategy, sharp angles are easily achieved with perfect quality on details.

GF Machining Solutions’ AgieCharmilles CUT E 350/600, CUT 200/300 mS and CUT 200/300/400 Sp wire-cutting EDM products satisfy a wide variety of customer needs.

Performance, versatility are hallmarksof these wire-cutting EDM solutions

MILL S 400 (U)

The latest generation of Mikron’s high-speed Milling portfolio, the MILL S 400 (U) is the ideal solu-tion for producing precise molds requiring long machining, thanks to its active thermally stabilizable body and increased accuracy.

In addition, Mikron’s solution re-mains the fastest solution on the market, thanks to its Operator Support System (OSS Extreme): This module allows up to 24 per-cent faster machining compared to the machine’s predeces-sor — without compromising qual-ity. The MILL S 400 (U) is a game changer in terms of productivity and investment strategy because the next step is Automation, rather than an additional machine: This is tangible proof of GF’s commit-ment to deliver complete solutions for its customers.

HSM 200 (U) LP

The most compact and precise machine in Mikron’s HSM portfo-lio, the HSM 200 (U) LP can ma-chine parts within up to 1 micron at unbeaten speed compared to the competition.

The HSM 200 (U) LP is the optimal solution for applications such as precision tools for carbide cutting tools manufacturing, and micro molds for electronics, automotive and medtech.

HPM 800 U

Manufacturing of heavy molds is easy thanks to the HPM 800 U’s high dynamic tilt table and high speed Spindle. A dedicated tire mold package is to be highlighted, including dedicated accessories and software tuning to help you achieve best-in-class tire mold quality and unbeatable productivity.

And if your applications deal with synthetic materials (Ureol, large graphite electrodes, aerospace composite parts) challenging your chip management system, the HPM 800 U offers you a unique extraction system integrated into the machine: another example of our application expertise.

Your productivity and precision are designed into the Mikron MILL S 400 (U), Mikron HSM 200 (U) LP, and Mikron HPM 800 U, so you can work with full confidence.

These Milling solutions deliverthe productivity and precision you need

GF Machining Solutions Results Today 0916 News, GF Machining Solutions

Infinitely repeatable high perfor-mance and quality are the hall-marks of the LASER 400 family of Laser texturing machines: the three-axis LASER P 400 and five-axis LASER P 400 U with brushless motor, launched in October 2015. The machine range concentrates versatility, highly accurate perfor-mance and repeatable results.

Whether your application requires engraving, surface texturing or structuring, the LASER 400 range is the answer. The range’s fully digitized texturing process makes it easy to texture, engrave and add functional texture to parts, molds

and dies. From design to the fin-ished, error-free workpiece, the digital process takes the guess-work out of texturing, engraving, labeling and marking even com-plex 3D parts.

Dual Laser head

The modular concept of the LASER 400 range includes a pat-ented, all-in-one dual Laser head that can combine two Laser sourc-es for texturing and engraving the same surface with just one setup.

In addition to a fiber nanosecond Laser, a femtosecond pulsed Laser

is available; with femto inside, you get burr-free texturing, extend the range of materials that can be used and open new application fields.

Compact, flexible, easy to Automate

The compact machines in the LASER 400 line can easily be transported by elevator and inte-grated into an existing production line. Texturing efficiency and flexi-bility are boosted by the machines’ small footprint, ensuring more productivity per square meter. The machines have a generous working area with easy access and process monitoring via two large sliding doors.

The LASER 400 machines are Automation ready, so increasing unattended night and weekend running time is a snap. A System 3R pallet changer can be added to boost efficiency and flexibility, and is especially useful for parts with shorter machining times.

The motor Spindle is a central component that runs up to 7,000 or more operating hours per year. So that its accuracy is ensured, its high performance is always on hand and its availability is ensured, professional servicing and preventive maintenance are essential. In the event of Spindle failure, an important aspect in ad-dition to costs is the time required until the machine tool can be used in production again.

With a Step-Tec maintenance and repair portfolio tailored to customer needs, GF Machining Solutions offers a dependable solution for every customer. The portfolio ranges from on-site visits for Spindle diagnostics and minor repairs (SOR) and factory repairs (SFR) to a refined, world-wide Spindle exchange concept (SEP). Engineers specialized in Spindles and the exclusive usage of original Step-Tec spare parts secure the quality of your portfolio and guarantee an optimal price-performance benefit.

On-site Spindle service, so that you know the situation on your Spindle. The preventive Spindle diagnostics provide you with in-sight into your Spindle. In this way Spindle maintenance, repair or exchange can be planned.

SOR: competent repairs on the installed Spindle. With Spindle On-site Repair GF Machining Solutions offers a quick solution for straightforward repairs on the installed Spindle. The repair can be made either by one of our engineers or you can undertake it yourself.

SFR: factory repairs optimized for the customer. Factory over-haul at Step-Tec is appropriate as the Spindle ages or in case of damage that cannot be rectified

on-site. With the Spindle Factory Repair concept it is possible to de-fine a tailored repair that takes into account the condition of the Spindle and your requirements.

SEP: If the situation is urgent, time is money. Is machine avail-ability the most important argu-ment in your organization? Then the Spindle Exchange Program is the right solution for you. Your defective Spindle will be replaced with a fully factory overhauled Step-Tec Spindle within 24 hours.

The replacement Spindle will be quoted at a fixed price and will have the same warranty conditions as a new Spindle, independent of the condition of the defective Spindle. Warehouse locations in the United States, Switzerland and China en-sure the worldwide availability of the exchange Spindles.

GF Machining Solutions’ compact, versatile and highly accurate new LASER 400 range of three- and five-axis Laser texturing solutions represent the future of texturing—today.

Step-Tec Spindles from GF Machining Solutions stand for quality and guarantee the highest performance and reliability; they are the heart of your machine tool.

LASER 400 range delivers versatilityfor easy engraving, texturing, structuring

Step-Tec Spindle repair and maintenance

SORSpindle Onsite Repair

Customer

24 hours

Spare part from stock Step-Tec or machine

tool manufacturer

SFRSpindle Factory Repair

Customer

10 days


Customer

24 hours

SEP Stock


ESNExchange Spindle New

Customer

Spindle available within minutes

Spindle stored in customer’s stock

Spindle Service Solutions

SEPSpindle Exchange Program


In aerospace alone, original equip-ment manufacturers (OEMs) and their value chains face immense challenges to stay on course to meet the increased need for new aircraft due to increased global travel demand and the fleet replacements spurred by ambi-

tious international emissions re-duction targets.

Just a quick look at current market outlooks from Boeing and Airbus un-derscores the constrained capacity scenario faced by the aerospace value chain: between 31,358 and

36,770 new commercial aircraft with a market value of $ 4.6 trillion to $ 5.2 trillion through 2033. Liechti Engineering’s airfoil machining systems play a key role in helping aircraft engine, turbine and turbine component manufacturers keep pace and maintain consistently high productivity and superb qual-ity, integrity and accuracy in their machining operations.

Thanks to reduced machining times enabled by specific pro-file machining technology and specialized CAD/CAM software pioneered by Liechti Engineering, turbine manufacturers achieve productivity gains of more than 30 percent. That high performance is based on Liechti’s engineering competence for full five- and six-axis ultra-dynamic machining in titanium, Inconel, titanium alumi-nide and high-alloy steels.

With a history going back to 1865, Liechti for the past three decades

has specialized in single- and multi-spindle Milling machines for high-speed cutting of complex curved surfaces. With that expertise and a vision of being the performance-leading solution provider in airfoil machining and being a dependable partner during evaluation, start-up

and production, it’s no surprise that Liechti today is a partner to global aerospace luminaries, including General Electric, Pratt & Whitney, and Safran-Snecma.

For more information, please visit www.liechti.com.

GF Machining Solutions’ Liechti Engineering helps its aerospace and power generation customers achieve productivity gains of more than 30 percent, thanks to reduced machining times.

Liechti Engineering: the world leaderin airfoil machining solutions

With these new solutions, System 3R is now a complete Fanuc inte-grator of five models based on the already successful Transformer modular Automation concept.

All existing system accessories, such as shelf and rotary maga-zines, load stations, drain station and clean station, can be integrat-ed into the new Fanuc solutions. In addition, all existing machine processors can be used to com-

municate with machines from a multitude of manufacturers.

Due to the increased weight ca-pacity of up to 700 kg, new maga-zines and a new rotating load station have been added to the program. The new LFT magazines easily handle the increased weight and dimensions of the pallets/workpieces. The new rotating load station makes it easier for an op-erator to mount a part onto a fix-

ture/pallet directly at the load sta-tion; this is especially important in precision parts production where the pallets are usually stored in the magazine inside the Automa-tion cell, and the operator needs easy access to fixation screws and supports on the fixtures.

New software features have also been implemented into the Work-ShopManager to support the new Fanuc solutions. Included is a new load station human-machine interface (HMI) making it easier to identify and command what parts

need to be loaded and unloaded. This feature also better handles refixturing of a part on the same pallet or refixturing of a part to a different pallet for a subsequent operation. The last features are especially suited for five-axis milling operations where parts need refixturing before being ma-chined complete.

Finally, bar code scanning has been introduced into some of the WorkShopManager modules, al-lowing the operator to keep track of a part even when it is not on a pallet inside the Automation cell. This enables users to follow the entire manufacturing process of a part by scanning a bar code.

The distinct needs of precision parts producers are at the heart of System 3R’s new Automation solutions using Fanuc six-axis industrial robots.

New System 3R solutions with Fanuc robotsmeet precision parts producers’ needs

System 3R Fanuc Automation solution T6-700 with an indexing load station and

LFT magazines for workpieces weighing up to 700 kg

Liechti Engineering: productivity gains of more than 30 percent

in blisk and blade machining

Liechti Turbomill g

System 3R Fanuc Linear Automation solution

T6L-360 with four indexing load stations and LFT

magazines for workpieces weighing up to 360 kg

GF Machining Solutions Results Today 0918 News, GF Machining Solutions


rConnect

Closer linkfor you

As manufacturing undergoes a digital transformation accelerated by expanding technologies includ-ing cyber-physical systems, the Internet of Things and the Inter-net of Services, opportunities are

arising for businesses to increase their competitiveness by ensur-ing maximum machine uptime. That’s the point of GF Machining Solutions Customer Services’ new rConnect technology.

The first phase of rConnect is Live Remote Assistance (LRA), allow-ing customer-authorized remote assistance and therefore connects the customer with the local diag-nostics center and the GF Machin-ing Solutions plants in real time. LRA allows Customer Services to inspect a machine tool remotely with diagnostics performed by a GF Machining Solutions techni-cian or the customer. Any result-ing maintenance is performed on site by a service engineer.

Clear customer benefits with LRA

The customer benefits of LRA are clear: faster diagnoses and inter-ventions when machine issues arise, significantly less machine

downtime and, consequently, higher continuous productiv-ity. With LRA, information can be shared between the customer and GF Machining Solutions via audio, video, chat, whiteboard, file transfer, screen sharing, and sys-tem access. All interactions are logged, and a record is created.

Behind rConnect and LRA is an instant virtual private network al-lowing highly secure access to the machine and certified with TÜViT Trusted Product Certificate. By 2016, all machines leaving GF Machining Solutions’ factory will be rConnect enabled, setting the stage for future rConnect modules.

The best value delivered by LRA and rConnect is direct result of

GF Machining Solutions’ commit-ment to customers and its long Industry 4.0 partnerships with leading European research insti-tutes including the University of Birmingham (UK), the University of Geneva (CH), the Swiss Federal Technical Institute in Zurich, RWTH Aachen University (DE), and the Fraunhofer Institute (DE).

GF Machining Solutions is advancing the Industry 4.0 vision of the smart factory of the future with the launch of the machine tool industry’s most in-depth remote machine tool analysis.

Customer Services’ rConnecttakes your operation into the future

ImprintPublished byGF Machining Solutions Management SALaetitia Saint-Pierre, Head of Communications

© 2015 – GF Machining Solutions Management SA. Illustrations and specifications do not necessarily apply to products and services offered in each local market. Technical specifications are subject to change without prior notice. All other trademarks are the property of their respective owners.

Rue du Pré-de-la-Fontaine 8CH-1217 Meyrin 1, Genevawww.gfms.com

Editors in chiefElke Magnin, Melody Corrieri

Contributing EditorCedric Arnaud

Art direction and layout David Hirsbrunner

Translations and editingIFA-TRADUCTO GmbHKarsten U. Timmerdelicatext

Image creditsMarinus van Breugel, Ryan Davis Photography, projektelf, Edvard Krikourian, Vested, Lotus F1 Team, Shirley Dai, Lorenzo Teritti. Other images: GF Machining Solutions

Print Nastro & Nastro Srl

Print runEnglish, German, French, Italian 11,500 copies

System 3R’s Vibration Damped Palletization (VDP) improves workpiece surface quality, extends tool and spindle life, and provides shorter lead times.

VDP feature improves stability,paves way to desired surface quality

With conventional milling chucks, workpiece surface quality can be compromised by vibrations caused by dynamic forces generated by the action and rotation of the cutting tool. To prevent instability and af-ford the desired workpiece surface quality, restrictions must be im-posed on the rotational speed and feed rate of the cutting tool. System 3R’s VDP technology is a solution that limits such restrictions.

VDP is the result of intensive re-search into the dynamics of chuck systems. By reducing vibration of the workpiece and a consider-able proportion of the vibration of the cutting tool, the VDP tech-nology improves the dynamics of the entire metal cutting process. That means that machine tools can be operated at higher speeds with greater accuracy and at the same time with less wear. Greater

accuracy means fewer rejected workpieces. Furthermore, work-pieces can usually be produced in a single operation within strict dimensional tolerances and with a surface quality in the micrometer range—a millionth of a meter.

VDP reduces cutting forces by up to 25 percent, resulting in reduc-tion of both power consumption and tool wear. At the same time, VDP lengthens tool wear by up to 30 percent to reduce your tool costs and broadens your scope for machining difficult materials and complex shapes.

Machine spindle life is appreciably lengthened by VDP. Less vibration in the machine spindle has been shown to extend spindle life by at least 30 percent.

Furthermore, by allowing machin-ing with higher cutting data, you better utilize your existing machine

capacity, increasing capacity by as much as 30 percent and shorten-ing lead times. You also experience less noise during machining.

All System 3R VDP products are completely compatible with cor-responding System 3R tooling systems: Dynafix, MacroMagnum, and Macro.

Dynafix MacroMagnum

WITHWITHOUT

Macro


AgieCharmillesMikronLiechtiStep-TecSystem 3R


With challenges coming at you from all sides in today’s highly competitive, global manufacturing environment, GF Machining Solutions thinks ahead of the game on your behalf. With our broad portfolio of complementary machining technologies and Customer Services, we are constantly innovating to deliver optimal machining solutions perfectly adapted to your distinct manufacturing needs.

www.gfms.com

Machining Solutions – for You

results today - gf machining solutions · 2020-06-12 · solutions’ customer magazine, results...

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