With the slogan “THE CUTTING EDGE – Solutions for top-quality performance” the KOMET GROUP showcased more than 1000 new products for efficient machining at the EMO Milano 2015. “Achieving a competitive advantage by using cutting-edge technology is the promise we are making to our customers,” is how Dr. Christof Bönsch, Managing Director of the KOMET GROUP, describes the meaning behind this year’s trade fair slogan. “Customer focus and process optimisation are our primary concerns,” Dr. Bönsch goes on to explain, “because increasing performance, productivity and efficiency for our customers is – for us – the principle driving force behind the development of new products.”

Complete product portfolio In addition to the familiar tool portfolio for high-precision drilling, reaming and threading, the KOMET GROUP in particular, be presented at the EMO 2015 an extensive new range of high-performance milling cutters, thereby emphasising once again its leading position in the area of technology and innovation. In addition to the already successful KOMET^® Quatron hi.feed, KOMET^® hi.aeQ and KOMET^® hi.apQ range of milling cutters, six further indexable insert milling cutter systems are now also included in their ex-stock range. KOMET has also extended its leading position in bore machining as a result of a consistent further development of its product range.

Technology precursor in Industry 4.0 With the ToolScope system, the subsidiary KOMET^® BRINKHAUS provides an efficient, high-end technology in the area of machine and process monitoring. With the new firmware version 10 and its user-friendly applications, the assistance system for machining production now marks a milestone in Industry 4.0.

Investment in innovation

Management at KOMET is extremely pleased with the business transactions and growth in turnover achieved in the current year. Dynamic growth is particularly evident at the European subsidiaries. “Growth in the first half of the year was above 10%,” says Matthias Heinz, Managing Director of the KOMET GROUP, “and we expect to see a continuation of this extremely positive trend for the second half of the year.” The focus of investments, which are being maintained at a continuously high level, is centred on the area of innovation. “We invest around 8% of turnover in development,” Heinz goes on to explain. In the current business year, our main interest has been primarily the expansion of our own carbide production.

The VARDEX line of original and innovative Gear Milling tools are used around the globe in a wide range of Gear, Spline and Rack manufacturing applications. To meet a growing market demand and expedite the ordering process, VARGUS is pleased to add a Standard Line for Gear Milling Inserts. To date these highly accurate and cost-effective tools were available only in tailor-made configurations according to specifications provided by the customer.

At EMO Milano 2015 VARGUS introduced a new set of standard yet versatile Gear Milling inserts for gear applications that are kept in stock and thus cut down considerably on delivery times.

VARGUS offers standard gear inserts for DIN 3972 Basic Profile I, which are available in the following Modules: 1.0, 1.5, 2.0, 2.5. The available insert sizes are IC 3/8″U, IC 1/2″U, IC 5/8″U.

VARGUS is also expanding its Gear Milling line with tailor-made solid carbide tools whose small cutting diameters, ranging from 5.9-19.9 mm (.17”-.75”), make them ideal for applications that require cutting close to the shoulder. These multi-fluted tools support high RPMs and fast feed for exceptionally rapid machining. Their solid carbide construction guarantees high accuracy.

All the new standard inserts described above are fully compatible with VARDEX’s Shell Mill, End Mill and Disc Mill toolholders.

VARGUS is also pleased to announce the addition of two new Shell Mill toolholders to its gear-milling solution: one for insert size IC 1/2”U and the other for IC 5/8”U. The smaller cutting diameters of these toolholders are well-suited for applications where the geometry of the component to be milled places constraints on the gearmilling tool diameter. VARGUS continues to expand and develop its leading Gear Milling line and provide customers innovative solutions for gear, rack and spline applications.

Nicolás Correa is entering the market of multi-tasking mill-turn machines and introduced its Correa VH-PLUS MG-T range of machines during EMO 2015.

A bed-type milling machine, T-structure and rotary table integrated on the longitudinal axis. An extremely robust machine that enables high performance machining of all types of materials.

The T-architecture and thermo-symmetrical construction (vertical carriage centred on column) offers the customer tremendous flexibility and positioning accuracy, even in adverse environmental conditions.

The machine has a hydraulic locking system on the X axis to ensure smooth high-performance turning. There are two options of turning systems: 

Accessory for turning: It is an accessory manually attachable to the milling head with a Capto C8 coupling. Designed for processes where 80-85% is milling work and a simple economical solution is required. 

Turning head: A turning head that is automatically guided with a C8 automatic coupling. Designed for processes where 65% is milling work but a totally automated mill-turn solution is sought. 

At EMO 2015 in Milan, Haas Automation chose to highlight the many, productivity-enhancing innovations that go towards making Haas CNC machine tools the best value, most reliable machines in the world, with the lowest cost of ownership and, therefore, the lowest cost per part produced.

Visitors to the Haas Automation booth were able to join a multi-stop tour of the company’s CNC vertical machining centres, turning centres and 5-axis machines, to see and learn first-hand the difference made by Haas innovations in software and control, automation, part and tool cooling, probing and setting-up, live tooling and high-speed machining.

“This was a fantastic event for Haas,” says Mr. Jens Thing, managing director of Haas Automation Europe. “It was our biggest trade show investment to date and it yielded far greater than expected returns.”

Mr. Thing points out that this dramatic result is a clear indication that the company’s collaboration with Milan-based machine tool group Celada, operating the official Haas Factory Outlet (HFO) for Italy, also has the potential to exceed expectations.

“We joined forces with Celada a little over two years ago,” he says. “In that short time, the company and its people have invested significant capital and enormous energy in creating what will undoubtedly prove to be one of the best HFOs in the world.

“It’s still relatively early days, so the results at Milan just go to show how committed the Haas and Celada teams both are, and how well we work together. I’d like to thank everyone who contributed on our booth at EMO – we had operators and sales engineers from all over Europe, but my biggest thanks go to the Haas Automation team and the Celada team. ”

During the show, journalists and Haas customers had the opportunity to meet Mr. Bob Murray, general manager of Haas Automation Inc., who was visiting from the company’s factory in Southern California.

As always, Mr. Murray shared plans for future Haas products, and his thoughts about opportunities and challenges in Europe and the rest of the world.

“We never stop innovating and designing new machines,” he said. “That’s really one of the keys to our continued success. We have a new CNC currently in development – a next-generation, more powerful control that will build on the current system and still be very familiar to Haas customers around the world.”

There are also new versions of the UMC750 currently in development. “This machine has proved to be very popular in Europe,” says Mr. Murray, “so we plan to build it in different configurations. Also, we have CNC gantry machines nearing launch and, of course, we already have available the ST-15 and ST-35 CNC tuning centres, which offer robust, big-bore capability and more powerful spindles, in machines with smaller footprints. We find more and more that our customers need capable machines with generous travels but small physical dimensions.”

As for challenges in the European and global economies, Mr. Murray openly discusses Haas’ strategies for maintaining growth. “We have great potential for increasing our market share,” he says, “especially amongst the small to medium, privately owned machine shops. We have a large range of CNC machine tools, all of which are built in volume, which means we can supply existing and new customers with exactly the capabilities they need at the right price and with excellent back up and support from the HFO network.” All Haas prices – machines and spares, are available on-line, so customers know exactly what they can expect to pay.

“As our customers grow, we can continue to supply the reliable, productive machines they need. It doesn’t matter where a customer is based, we can support them, help them do business and, of course, make money.” It’s a strategy that has worked very well in the USA, where in some market niches, Haas enjoys 50% market share.

“These are great results at EMO 2015 in Italy,” concludes Mr. Murray. “It goes to show, customers around the world all want the same things, wherever they are: high levels of service and support, and reliable products. Italian companies are very demanding and I’m happy to say, our machines and our service make sense to them.”

OPEN MIND Technologies AG draws a positive conclusion from this year’s EMO MILANO metalworking trade fair. In addition to the numerous lively discussions taking place at the OPEN MIND booth that often revolved around very specific manufacturing challenges, the main focus of the company’s presence at the trade fair was on introducing its upcoming hyperMILL MAXX Machining performance package. The solution features three special optional modules for highly efficient rouging, finishing and drilling. These strategies will be available in the new hyperMILL 2016.1 release.

OPEN MIND’s presentation at the trade fair devoted special attention to a specific finishing strategy from the new hyperMILL MAXX Machining performance package: ‘Tangent plane machining’ makes it possible to achieve machining time savings of up to 90 per cent. Using conical barrel tools allows for larger path distances for the same theoretical scallop height. The OPEN MIND machining strategy takes advantage of the extremely large radius of the barrel shape, which allows for optimal inclination to the faces. This makes it possible to achieve considerably shorter machining times and a high level of surface quality.

EMO MILANO 2015, one of the most lively industrial exhibitions, was held at prestigious exhibition centre of Fieramilano – Milan, Italy from 5th – 10th October this year. The Manufacturing Industry across the world witnessed grand participation of more than 500 leading companies of Italy, followed by companies from Germany & Taiwan.

Live demo of Tool Preset & Measuring management system given by Speroni SpA was the special attraction of event. Speroni, Italy’s one of the most premium brands, offering vast range of products and solutions in the field of Tool Preset, Measurement Management & Quality Inspection of the Manufacturing Process amazed the visitors by displaying most astonishing range of tool measuring system. Speroni’s vast display varied from Tiny tool dia. 20 microns to a giant size tool dia. 500 weighing 500 Kg. with top class precision throughout the range was one of the highlights of the show.  The company also offered Tool Management (TM) interface with partners with vending machine Supply point , CAM interface Edge Cam.   Live display of total integrated solution was another attraction that mesmerised the audience.

This phenomenal event witnessed significant footfall of Indian manufacturers and Industry experts, who came in for pleasant surprise to see Speroni’s performance at the show. Most of them expressed desire to adopt to the world-class technology offered by Speroni.

EMO MILANO 2015 event was deemed part of the Industrial Policy of Italian Ministry of Economic Development, who carried out several initiatives in cooperation with Ice-Agenzia. The show involved display of amazing product mix of advanced machine tools, precision tooling system, manufacturing & Process Automation and Metrology & Quality Control Systems, Quality Assurance software and many other process sophistication techniques.

Grind Master, India’s leading grinding machine manufacturer is showcasing its advanced Superfinishing Technology – NANOFINISH Products at EMO Milano 2015 at Milan, Italy.

Grind Master is a pioneer and leader in metal finishing technology. Grind Master “NANOFINISH” range of machines are used to generate Engineered Finishes on Automotive Powertrain and Engine components are trusted by leading automotive OEMs around the world, including SGM, Great Wall, Tata, Toyota and Renault Nissan. Over the past few years Grind Master has been successful in innovating success in an area dominated by German and Japanese machine builders. Competing with the best in the field, Grind Master offers state of the art technology

Grind Master exports NANOFINISH range of machines to China, USA, UK and South America. With a Representative Office in China, Grind Master has a very strong presence in the world’s largest Automotive market. In future it is planned to increase reach in the markets in the Americas and Europe.

At the stand F16 in Hall 11, Hexagon Metrology is demonstrating the latest version of its Measurement Software 3D Form Inspect live on a Mikron HSM 200.

m&h Radio-wave Touch Probe RWP20.50

m&h RWP20.50 radio-wave touch probes are available in two different frequency ranges. As a technology pioneer, m&h long ago introduced the first reliably functioning probe with radio-wave transmission of the measurement signals onto the market. The industrial frequency band of 433 MHz is still used today for reliable transmission of time-critical signals. The new radio-wave touch probe is still compatible with existing equipment in the available 433 MHz version.  Alternatively to this, the new m&h RWP20.50 radio-wave touch probe is also available with a new radio transmission technology in the frequency range of  2.4 – 2.4835 GHz.

m&h Radio-wave Receiver RWR95.50

The compact radio-wave receiver RWR95.50 communicates with m&h radio-wave touch probes in the 2.4 GHz range and can be easily mounted in the machine room. With AFS (Automatic Frequency Select) technology, the frequency ranges of this radio band are continually scanned and partial frequencies are automatically selected which are free of interfering signals. This not only ensures the system‘s own transmission to be fast and trouble-free, but also prevents interference form WLAN systems or other radio sources. The spread spectrum transmission and a multiple transfer of the records ensure transmission reliability and a fast and trouble-free measurement process.

PC-DMIS NC Gage V2.4

New also for machining centres with swiveling heads. PC-DMIS NC Gage sets the new standard for measuring on the machine tool. Developed for easy, quick and safe application of touch probes without requiring the operator to have programming skills or special knowledge of measuring technology. See for yourself at our stand – live demonstration on the tablet PC.

Edgecam supports m&h touch probes

Measuring cycles no longer necessary. Fast and simple programming. Users can measure workpieces and simulate the probe movements with six individual measuring cycles. Each cycle has been enhanced with eight new functions, giving a wider choice of inspection data.

m&h Inprocess Messtechnik
m&h probes are used to measure parts on milling machines, machining centres, lathes, turning-milling centres, grinding machines, special machines and robots. For small batches or medium to mass series production, parts can be aligned and their geometries checked while still in the machine.
Probes make everyday work easier, reduce manufacturing times and costs, and open up the full possibilities of modern machines.

LMT Tools group, leading cutting tool manufacturer, is presenting in Milan tool innovations for more productivity. Faster, more efficient, more flexible – the requirements with regard to the machining of modern industrial materials are diverse. Numerous solutions that can effectively boost the performance of existing production processes will be presented in hall 10, stand D12/E11. This applies to high-performance milling, threading and rolling in the same way as to gear cutting, drilling, reaming and turning.

The SpeedCore hobs are now even more powerful

The LMT Fette SpeedCore hob has established itself as a specialized high-performance production tool for toothed wheels – for example in vehicle transmission systems. By integrating an innovative cutting material that uses so-called intermetallic phases, the hot hardness of the SpeedCore is significantly higher than that of PM-HSS substrates. The outstanding performance of these tools has now also been transferred to larger tooth systems. As a result of this development, hobs are now available up to module size 20 (diameter 250 mm) (lead image), which are used, for example, in transmission systems for commercial vehicles, heavy machinery engineering and wind turbines. In addition, a higher evolutionary stage of the previous coating Nanosphere 2.0 was achieved to increase the temperature resistance once again. With the new coating, called “HT” (high temperature), the distance between the SpeedCore hob and the carbide is reduced even more with regard to its machinability properties.

HT” (high temperature), the distance between the SpeedCore hob and the carbide is reduced even more with regard to its machinability properties.

Thread rolling – now even faster

Thread rolling systems are part of the important core competencies of the LMT Tools group. The proven user benefits of thread rolling compared to thread cutting are extremely short production times combined with highest thread stability, constant dimensional accuracy and excellent surface quality. Very recently LMT Fette launched the brand new and very user-friendly axial rolling head EVOline. The next development step follows already: The coolant-operated closing device that shifts the entire process time required for closing the rolling head to the ancillary time of the machine (image 2).

The closing operation by means of coolant (or compressed air) with a working pressure between 8 and 16 bar can be integrated into the machine program with a simple function. Easy, safe and fast.

Highest copy milling quality

The requirements with regard to finishing in die and mold manufacturing are process reliability, good surface quality and an extended tool life at high cutting speeds. The new copy milling cutter HSCline SuperFinish2 by LMT Fette (image 3) sets new standards in exactly these areas, especially in the finishing of hardened steel between 56 – 65 HRC . Due to its high-precision cutting edge geometry with an optimized cutting edge preparation, significant tool life improvements can also be realized. The tools featuring a multilayer PVD high-performance coating ensure a maximum of process reliability. However, if the focus is not only on a long service life but also on higher speed, the processing time can also be reduced without much effort by applying the strategy for reduced processing time. These new tools have two cutting blades and are available in a short and long version for diameters of 4 – 12 mm. The precise radius tolerance of the cutting blade is in the range of +/- 5 µm.

Highest machining volume with small indexable inserts

The difference to high-speed cutting (HSC), which exhibits an excellent surface quality, particularly in finish machining, is that in high feed-rate cutting the focus is on a short processing time during roughing. A brand new addition is the MultiEdge 2Feed mini by LMT Fette (image 4). The new insert milling cutter is used for roughing small and medium components. The positive high feed geometry of the small cutting inserts permits a maximum material removal rate even in weaker machining centers. But when this tool runs at full throttle, feed rates of 14 m/min are not unusual, for instance, for the machining of tool steel with a tensile strength of 1000 N/mm2. And the cutter has 9 cutting edges on a tool diameter of 80 mm. The cutting inserts are now also available with a theoretical corner radius of 2 mm and the carrier bodies as a face cutter and a screw-on milling cutter.

The new milling strategy significantly reduces manufacturing costs

Trochoidal milling requires rethinking of milling and opens up new performance dimensions. The result is higher removal rates at lower cutting forces. This also facilitates the optimized machining of hardened and high-strength material with reduced machining times. LMT Tools follows this strategy and for example reduced the machining time by 70% compared to conventional milling strategies while at the same time tripling service life with the VHM milling cutter DHC HARDLINE (image 5). During trochoidal milling, the feed motion of the tool is not linear but curved. This causes the wrap angle, chip load and radial depth of the cut to change constantly. In contrast to conventional milling, the mean chip thickness hm remains constant. The prerequisite, however, is a powerful CAM software and a dynamic and fast machine control.

The specialist for threading stainless steels

The new INOX tap by LMT Fette was developed especially for machining stainless steels (image 6). These difficult materials do not pose a problem. The positive torsion characteristics of the HSS-E cutting material, its special geometry and the low-friction, multilayer sliding layer based on TiAlN and WC/C ensure maximum process reliability with excellent chip flow and minimal lubrication. This also sums up the main benefit for the user: It’s reliable and reproducible application guarantees high profitability. In order to improve the quality and process reliability, pre-drilling with the X-Speed INOX drill system is recommended. The new INOX tap is available in the versions Markant for through-hole threads and Rasant for blind-hole threads in metric, metric fine, UNC, and UNF sizes.

The new and user-friendly tap catalog shows the outstanding variety of tools for threading and drilling offered by LMT Tools. At the heart of the new catalog is the LMT Guide, which guides the user to the ideal tap in four easy steps.

Renishaw, the global engineering technologies company, is announcing more new products that will be demonstrated on hall 5, stand D15 at theEMO Milano exhibition taking place in Italy, from 5th – 10th October. These include a new vision measurement probe (RVP) for use with the REVO® 5-axis measurement system, a new improved version of the REVO measuring head and a new free software suite for Renishaw calibration systems.

These new metrology products will be demonstrated alongside other significant products already announced, including new software for theEquator flexible gauge which allows users to create simple gauging routines in minutes, new MODUS 2 metrology software suite which simplifies the programming of co-ordinate measuring machines (CMMs), a new ‘pay-as-you-go’ machine tool probe system and a simple single-axis tool setter.

New non-contact vision probe for the REVO multi-sensor system

Renishaw is pleased to announce the launch of a new vision measurement probe (RVP) for use with the REVO 5-axis measurement system on co-ordinate measuring machines (CMMs). RVP increases the multi-sensor capability of REVO by adding non-contact inspection to the exisiting touch-trigger, high-speed tactile scanning and surface finish measurement capability of the system.

For certain applications, non-contact inspection provides clear advantages over traditional tactile probing techniques. Thin sheet metal parts or components with large numbers of holes as small as 0.5 mm, and parts which are not suited to tactile measurement, can be fully inspected with the RVP system. RVP also gives exceptional improvements in throughput and CMM capability by utilising the 5-axis motion and infinite positioning provided by the REVO head.

New version of the REVO multi-sensor 5-axis measurement system

EMO Milano 2015 also sees the launch of REVO-2, a new improved version of the revolutionary multi-sensor 5-axis measuring head for use on co-ordinate measuring machines (CMMs). REVO-2 and its new CMM controller UCC S5, build upon the successful REVO multi-sensor system with enhanced power and communications capability to carry the latest REVO sensors such as the RVP vision measurement probe. The head also has an increased range of movement in the negative A-axis which can improve part access and reduce the complexity of stylus set-ups.

REVO-2 incorporates Renishaw’s own ATOM optical incremental encoder system that uniquely combines miniaturisation with ruggedness and exceptional metrology performance. ATOM is the world’s smallest readhead using filtering optics. It offers speeds up to 20 m/s (29,000 RPM on a 17 mm disc) and resolutions to 1 nm (0.004 arc second on a 108 mm disc) with a range of linear and rotary (angle) scales available in stainless steel and glass.

New CARTO software solution for calibration systems

Renishaw is also launching a new free software suite for Renishaw calibration systems at EMO Milano 2015. The suite includes Capture and Explore, which provide data capture and analysis for the XL-80 laser interferometer system. CARTO release 1.1 supports linear, angular and straightness measurement with a choice of keypress, position and remote (TPin) triggering. CARTO features a new database system which automatically stores and organises data for the user, simplifying operation and allowing users to quickly and easily compare data with historical results.

The intuitive CARTO user interface allows new users to begin capturing and analysing data quickly, without the need for training or reading lengthy manuals. The capacity for customisation throughout the suite means that both Capture and Explore can be tailored to suit an individual user’s requirements.