Customers want 'all inclusive' package with maximum flexibility

As showed in the last edition of the Metav with the manufacture of artificial joints of knee, hip and all kinds of implants, it is obvious that a combination of turning and milling in a single machine is a big step forward for the expansion of the market of medical technology. The machine tool control systems, and the generation of CNC data, are becoming increasingly complex and therefore the use of a harmonized software is helpful for planning process engineer. Manufacturers are offering tools well configured, designed to meet the sophisticated requirements of machining of biocompatible materials. In addition, the increasing demand for energy involves the use of still major components in the water and energy technology, so the machining precision of large pieces has increasing importance.

For complete machining of medium-sized components, could be seen in the Metav a 5-axis machining center. This Centre, Heller Maschinenfabrik GmbH, is able to accommodate pieces of work from up to 1,400 pounds. The distance of displacement in the X axis and and 800 millimeters and direction of the z-axis of 1,000 mm, with a rotating head specific for heavy machining with HPC criteria allow machining parts of the sector of aviation or processes of manufacture and moulding toolswith times reduced. A feature incorporated into the monitoring system for the anti-collision control, including in the form of not machined piece, offers support for the simultaneous machining of 5-axis without friction. If the tool breaks or collides during the process of machining with a 5-axis tool setting, the system of the machine control offers certain strategies to remove the tool.

Another manufacturer,-Metrom Mechatronische Maschinen GmbH - account with a machining center for 5-axis which implements the movements of the machine and the head, using parallel kinematics. Using five cranks can achieve angles of rotation of more than 90 °. The ball spindles allow a speed of 45 meters per minute and a maximum acceleration of 10 metres per second squared in fast mode. The 'gantry' construction provides a modified variant for machining considerable work pieces with a weight up to 7 tons; There is also a mobile Variant that can be used for machining work pieces of fixed, for example, for repairs.

The units of drilling and turning with scrollable column layout allow the machining of large structures, as well as parts of connection of facilities of water and energy supply. The Italian automaker Pama, S.p.A has a system of production to work pieces of medium size, with a tiny hole size of hydrostatic Assembly achieved speeds up to 30 meters per minute. The incorrect alignment of the spindle of drilling caused by factors related to heat or elasticity can be offset with the position fixes in real time by the control system.

For machining work pieces with controlled 5-axis tool orientation at the same time, it is essential to use a harmonised CAD-CAM software, to take advantage of all the capacity of the machine tool. Available software packages provide for the generation of CNC, not only the interface CAD data, but also an option for the reconstruction of the surface and the scanned data processing. If the characteristic elements are being used in the model of CAD data in the design stage, these can be detected by the CAM software, can be selected as sets CNC adapted and incorporated into the CNC program. While, there are also software packages updates for machine tool with more than one spindle of machining, process combinations, as turning rotation, laser cutting or turning deburring of components made of fiber reinforced plastics. Evidence of this is technology Tebis AG, and Missler Software.

For the manufacture of medical products, whose surfaces of friction and contact are complex and free form with a high quality of finishing, Schütte-Schleiftechnik GmbH has a machine of turning 5-axis with linear drives. The machine also offers an option to tighten unity of milling of tape and the tools of crimped. Asymmetric moulds can be premecanizados cheaply made the knurling with a solid ball of hard metal or tools for turning, and then move on to the final finish. A charger crawler to 170 semi-finished products can provide and download the workspace of the machine.

To make specifically different nuts in symmetrical components in rotation in the surgical and medical, categories such as the bones screws, Leistritz Produktionstechnik GmbH offers a rotating Capper machine: the pretorneadas not machined parts of different lengths are measured by a photocell after aligning food using an oscillating conveyor. The CNC program changes depending on the length of the screw machining, so it can occur bone screws with a length from 10 to 150 mm, in any desired sequence. The diameter varies from 2 to 15 mm. Rotating screw units stand out in the different depths of cut. In addition, the position of the tool in relation to the axis of rotation of the workpiece is eccentric, and adjusts to accommodate the involved nut. Small forces of process and comma-shaped chips are conducive for machining of stainless steel and alloys of titanium, with a high level of dependence on the process. This allows the production of damage-free components.

Tools with roots of diamond and boron nitrate provide various options to reduce the time of the main machining process. To allow the incorporation of rompevirutas and slots to remove shavings, DMG Sauer GmbH has a system of machining by laser integrated in a machining center. To cut the shape of the tool from diamond or boron nitrate spaces you can use fiber, vanadato or an alternative laser ranging from picoseconds, creating slots for chips and generating defined angles. The laser of PS, thanks to its high-speed pulsation, promises a thermal bottom-loading in the marginal areas of the component in question.

Small work pieces and filigree structures require adequately modified tools. For the cromo-cobalto or titanium-based materials, were presented at the Metav microherramientas ultra grain thin and prepared in areas of edge and ultra thin hard metal to suit specific application. One of the manufacturers presented a tool to make micro-perforaciones with a diameter of 50 µm. SPPW Spanabhebende Präzisionswerkzeuge GmbH also showed other tools to make small parts, such as, for example, to move forward or backward in the process of excavation or Burr.

To handle material of greater force that are difficult to machine, such as titanium alloys or nickel materials, lubrication of high pressure cooling systems offer advantages in terms of time of tool useful and monitoring of dwarfs. During the process of turning, the game of coolant lubricant is directed on the side of the tool as close as possible to the desired point, using coolant lubrication of high pressure spray through fixed power nozzles in the subject of inclusion support clawThus cooling and lubrication of the surface of the tool. In addition, Iscar Germany GmbH has optimized food in the part of the face rotating nozzles for food that can be adjusted to the process in question with regard to position.

For deep drilling in difficult to machine steel materials, Präzisionsbohrtechnik GmbH offers deep punches only edge and solid hard metal tools. In comparison with the punches tools deep edge only conventional, the use of a construction of hard metal-based tool offers a superior tool rigidity and a reduction of the trend of the torque. In comparison with the punches tools deep rifling helical, they can achieve higher feed speeds up f = 0.18 mm m, depending on the material involved. For higher drilling diameters of 15 to 30 millimetres, was presented a tool drill deep only edge with indexable replaceable and strips Guide. To adjust the material that is being machined, they can change the pairing of material from court and strip guides.

Practical metrological equipment uses the full potential of the production system, while it ensures the quality of the product. Qass GmbH has a system of measurement of noise generated by structures, which consisted of a sensor emissions acoustic (AE sensor), a filter unit and a PC monitoring and evaluation. The AE sensor, covered by a steel jacket, enables the analysis of processes of high frequency. In a machining operation, for example, the State of the edge of the tool, cutter or rounded, be evaluated with the process. When bind components by welding or in process of forming, the system can be used to detect cracks, for example, when the axes are stretching. The pressure wave which takes place when you create the rupture occurs metrológicamente. According to the manufacturer, the noise caused by the production process normally go unnoticed, since the condition monitoring is carried out in frequency between 40 kHz and 100 MHz.

Optosurf GmbH has 100% of the quality of the parts of another system for monitoring operates using processes with a slight mismatch. The LED light source emits monochromatic light to the surface. Acquiring and cualificando light of mismatch distribution, can detect deviations of form as the circularity and ripples or defects of surface in form of micro-roturas. The distance-dependent process operates with a speed of 2 Hz scanning. It is suitable for reflective surfaces and has been standardized by VDA (German Association of the automobile industry). The process is being used for the monitoring of the quality of work pieces during the production of zippers, the tamping of the crankshaft and polishing processes.