The European machine tool manufacturer, specialising in milling, boring and turning, showcased its high value added technological proposal at its 6th Technology Days, which are also marking the 25th anniversary of the BIMATEC SORALUCE Centre of Excellence in Limburg.

With a total of over 800 European, American and Asian customers in attendance, SORALUCE showcased its latest innovations and developments, under real machining conditions, by means of a Technology Tour where nine milling, boring and multipurpose machines were on display. During the tour, the capacities of each machine were illustrated with live demonstrations, which included impressive examples such as the use of the DAS technology that has recently been recognised as the Quality Innovation of the Year and taken the Best of Industry Award, along with the innovative DAS for tooling.

The tour also included demonstrations of other technologies applied to SORALUCE machines, aimed at improving productivity, precision and multipurpose, such as the dynamic CNC Ram Balance system (patented) and the Modular Quill system (patented), which interchanges the modular quill spindle with the machine’s other heads totally automatically, which allows for different quill spindles with different diameters and lengths. The SORALUCE DHC new dynamic head calibration or the ADAPTIVE CONTROL feed adjustment system were in the spotlight on the tour.

Furthermore, SORALUCE also showcased its latest development in automation systems to improve productivity and unattended machining, the multitasking solutions for large parts, gantry technology and the new SORALUCE H100 and H200T heads for 5-axis machining and multitasking operations.

SORALUCE unveiled the full range of the new generation of milling, boring and multipurpose machines

The new generation is the expression of the SORALUCE values: reliability, accuracy and competitiveness. Within these concepts, the customers find huge improvements in maintenance, ergonomics, high dynamics and the safety of the working environment.

The new SORALUCE generation is based on a comprehensive review of the machine from the perspective of the user, focusing on making the functioning more efficient and developing a Total Machine concept. This concept not only takes into account the machine, but also the entire work area. All the interactions of the operator with the different elements of the machine are analysed for an optimum application. The evolution in the design has made the machine easier to operate and maintain, with a safer and more ergonomic working environment for the operator. SORALUCE was recently awarded the Red Dot 2016 award for this innovative design.

SORALUCE is a step ahead with its SMART MACHINES

The SORALUCE Smart Machines had a prominent position in the demonstrations that took place in the Technology Days 2016. These milling and boring machines include technological elements within the Industry 4.0 concept, which become a reality in a comprehensive monitoring package based on “cloud computing”.

They include features such as the displaying of the machine status in real time with relevant information on the situation of the machining tooling in progress and the sending of emails in the case of a shutdown; the generation of reports on sensitive issues for the user such as production or process, such as energy consumption or the performance of the machining cycles; and the diagnosis of key warning signs for the maintenance of the facilities. This is all carried out by means of secure connections using a PC or any mobile appliance (smartphone, tablet) with simple web access to Internet.

25 years leading the German market

A quarter of a century has already passed since the setting up of BIMATEC SORALUCE, a commercial-technological venture that is celebrating its 25th anniversary with the satisfaction of having turn into reality the dream of progress that inspired its founders: to turn the German market into leaders and to offer groundbreaking solutions to its customers.

BIMATEC SORALUCE was established in 1991 with the mission of introducing the SORALUCE product and brand in Europe. The union meant that strength and commitment that united SORALUCE with its German partners, Walter Markuske and Fred Bisgwa, was a real long-term commitment that has proven to be a total success.

SORALUCE initially marketed its machines in Germany under the “Soramill” brand, an initial step in the progressive evolution of a range that has been steadily consolidated and it now leads the milling and boring machine sector on the German market, with more than 1,000 machines installed among benchmark customers. This endorsement has allowed the company to expand across the continental frontiers, so that BIMATEC SORALUCE is the SORALUCE Centre of Excellence, which is fundamental in the world positioning strategy and which is already firmly established in 45 countries.

After its successful implementation in Germany, SORALUCE has already overcome its “outsider” status, of a mere supplier of machinery, and has taken a step further to becoming a real market driver, an active technological player that develops new and increasingly more efficient applications, contributes value added to products and services, and from its leadership position, its guides its customers along the path of innovation. In this regard, the creation of the BIMATEC SORALUCE Centre of Excellence at its Limburg offices has been crucial. It is a fundamental platform to continue to offering ground-breaking solutions on the international markets. This centre was refurbished and expanded in 2012, coinciding with SORALUCE’s 50th anniversary and it was fitted out with 2,500 m2 of showroom and 1,200 m2 of office space, which includes the Technical Assistance Service Department, Training rooms, Project Management Department and Technology Department.

BIMATEC SORALUCE is now experiencing a boom and aspiring to continue to lead the milling and boring sector during the coming 25 years, while continue to be faithful to the precepts that made its successful possible: mutual trust, the will to succeed, joint effort and a clear customer orientation.

Knowledge is the raw material of the future and SORALUCE wishes to share it

The Technology Days 2016 were also the chosen scenario for the global launch of the SORALUCE Academy. SORALUCE is committed to fostering the knowledge and learning of its customers, associates, distributors, suppliers and employees through the SORALUCE Academy.

SORALUCE Academy is a place where customers can contact experts in different areas to share, learn and implement solutions and projects. SORALUCE provides the means for our customers to consolidate their knowledge by means of a series of standalone seminars, workshops and master classes, specific for each industry and with the emphasis on the practical aspects.

To turn this training proposal into reality, SORALUCE has the necessary facilities, rooms for seminars, a heads laboratory, an R&D&I department and a research centre, along with rooms for seminars and testing teams at the Centre of Excellence in Limburg, Germany. SORALUCE organises this type of technological activities internationally with an annual programme where it shares knowledge and skills with the customers, by developing higher levels of know-how and use of the equipment (machines, tools, processes, etc.) that allow the customers to recognise the return on their equipment, enabling the customers to optimise the performance of their products or develop new machining solutions, with new technological developments, peripherals, etc., and improving the quality and scope of customer relations.

A first-rate service and the new monitoring tools are a reality with which we are working every day at SORALUCE

The Technology Days 2016 provided a perfect set of opportunities for the SORALUCE customers. Live technological demonstrations, a good number of workshops every day, the 25th anniversary celebrations and a comprehensive display of its service capacity illustrated in different case studies set out in detail. SORALUCE tailors its work to the needs of each customer. It’s Services and Solutions Department develops comprehensive special project, by working closely with our R&D&I equipment and our research and development centre.

Xabier Mendizabal, SORALUCE’s R&D director, pointed out: “The market is constantly evolving and the requirements of the customers are increasingly more demanding. At SORALUCE, we are constantly striving to develop new solutions such as multitasking machines, automated systems, solutions for large components, technologies to improve productivity and the accuracy of our milling, boring and turning range, such as the prize-winning DAS system, which is complemented with the new development for tooling.”

“Ahead of its time” is this year’s slogan for the SORALUCE Technology Days and it perfectly summarises the set of technology on show at the BIMATEC SORALUCE Centre of Excellence throughout the week.

SORALUCE, a proven track record

The European brand has a proven track record. A clear example of this are its more than 2,500 machines sold, nearly half of them in Germany, a very demanding market where, as has been seen down through the years, 80% of customers have placed their trust in its products. This year, SORALUCE is marking 25 years leadership on the German market and 15 years as the benchmark in technology on the Italian market.

SORALUCE is part of the DANOBATGROUP, the machine-tool division of the MONDRAGON Corporation, one of Europe’s most important business groups. With nearly twenty first-rate manufacturing plants in Spain, Germany, the United Kingdom and the USA, it also has its own R&D centre where 120 engineers and 24 PhDs work. DANOBATGROUP meets the needs of its customers with one of the most competitive and comprehensive multi-technological ranges on the market. With a workforce of 1,300 people, it posted a turnover of around EUR 269 million in 2015, which has led to its high level of investment in R&D&I, which accounts for 8% of its turnovers.

Danobat has been developing two highly versatile grinding machines for Grupos Diferenciales. These grinders will make it possible to turn, grind and measure large parts using a high-efficiency process that ensures the utmost quality.

The challenge

Grupos Diferenciales, which specialises in producing high-tech gears for mechanical transmissions used in sectors such as the automotive industry, maritime transport, railway and aeronautics, performs technologically advanced tasks while providing high added value, using difficult to machine materials with close tolerances.

In its ongoing search for new technological solutions to increase its efficiency and competitiveness, there was a need to find a flexible, adaptable solution that could be highly customised, making it possible to finish the parts in a single set-up.

After evaluating different solutions existing in the market, Grupos Diferenciales decided to entrust DANOBAT with the development of two new edquipments that will allow it to produce large parts that are consistently compliant with stringent quality standards.

The main goal of the company, with high quality and short lead production times, was to have a cutting-edge equipment that would allow it to manufacture larger components so as to expand its customer portfolio.The main challenge consisted of producing optimum quality parts in a standardised manner.

The solution

The team of mechatronics engineers at DANOBAT designed and developed both horizontal and vertical grinders for Grupos Diferenciales. They are highly versatile and capable of turning, measuring and grinding parts of different sizes. The equipment has enhanced the tolerance and roughness of machined parts.

The equipment

The VG-1000/700 vertical grinder is equipped with a multi-position head for hard turning and grinding of parts, as well as a measuring arm that makes it possible to verify whether the manufactured components meet the standards and provide optimal quality.

This grinding machine has a high stiffness and was designed bearing in mind stability and vibration elimination requirements in hard turning processes.

The measuring tool integrated in the machine is able to measure internal and external diameters, faces and cones, with repeatability of less than 1 micron, thereby ensuring the dimensional geometry of the parts in less than 5 microns.

DANOBAT’s experts designed this highly-customised machine so that it could be adaptable to the already existing clamping tools. Therefore, the system has a main magnetic clamping system intended for manufacturing medium to large-sized diameters and a self-centring jaw chuck for batches of smaller parts.

One of the needs to be addressed by Grupos Diferenciales was the versatility and flexibility of the equipment. This is why DANOBAT included an automatic tool changer in the grinder that makes it possible to select the most appropriate tool for each type of part to be manufactured on each occasion.

To complete the tasks commissioned, DANOBAT also developed a horizontal grinder, the HG-72-2000-B12, capable of machining parts with a length of up to 2,000 mm, a diameter of 640 mm and a weight of 1.5 tonnes.

One of its main features is that it is equipped with a head that includes three grinding wheels, making it possible to machine external diameters, faces and threads. This head, which rotates around its vertical axis and reaches every point on the part, is powered by a 45 kW motor that reaches peripheral speeds of up to 45 m/s, with grinding wheels that have a maximum diameter of 610 mm.

Thanks to these features, the device is able to respond to all grinding needs, including parts with Ra 0.1, in a single set-up and with guaranteed geometric quality.

The inclusion of the DANOBAT MDM-300 multi-diameter measuring device, which runs in parallel with the machining process, is advantageous since it prevents subsequent measurements and enables single-stage grinding. This will ensure that the part meets all the requirements established in the design.

The DANOBAT MDM has a repeatability of ± 1.5 microns, makes it possible to measure a wide range of diameters and once the grinding process has ended but before removing the part, post-process verification may be performed.

Moreover, the machine includes a filtration unit making it possible to filter up to 15 microns. This contributes significantly to the quality of the end product, improves roughness and allows for enhanced finishing.

Thanks to the tools that have been developed, this horizontal grinding machine also enables to clamp down all parts while ensuring that they may be ground with one single clamp.

DANOBAT will showcase on hall 22A stand 601 of INNOTRAS 2016 tradefair its latest developments on railways maintenance depot equipment, exhibiting preventive and corrective solutions for a wide range of vehicles, such as high-speed trains, locomotives, commuter trains, trams and metros.

DANOBAT will also display on the stand a complete solution for the maintenance of components for rolling stock. This new solution consists of a measuring unit of train wheels, wheelset optimisation software and a new range of underfloor wheel lathes. The new development is especially geared to increasing the life-span of wheelsets by some 25% and cutting maintenance costs.

The stand will also include a virtual-reality area where visitors can experience a fully automated solution developed and implemented by DANOBAT for integral maintenance and repair of mining wagons.

Innotrans is the leading international trade fair in transport engineering industry which is held every two years in Berlin. A large number of reference projects and over 220 companies aimed at transport technology make this fair a must for every professional of the sector. Because of this, Innotrans has become an international showcase for railway technology.

DANOBATGROUP was awarded the Prize for Innovation in the discipline integration of Industry 4.0 concepts in advanced manufacturing systems at the BIEMH 2016 trade fair.

The group presented the following developments in the digital field under this 4.0 concept:

HMI – Human-machine interface, to improve the interrelationship man machine, through an environment that simplifies machine operation, includes support for programming and specialised machining cycles, facilitates the maintenance reducing down-times, and provides information on how to reduce power consumption.

Data system, a set of services based on machine monitoring and Big Data to analyse the machining process and machine behaviour. A tablet or mobile phone can be used to check the status of the machine and, if necessary, optimise the process or anticipate possible failures.

Intelligent components, devices integrated in the machine that, based on the information received from multiple sensors, act to improve the performance and precision of machines, optimise the process times, increase the lifespan of tools, etc.

Control system, a computer application for full management of production lines. This system is independent of the manufacturer of the equipment, and can be fitted on different types of machines; all information necessary to perform the given task is managed by the system: CNC programs, tools and tooling, etc. It can be included in other data management programs used on-site such as PLM, MES, ERP, etc.

The innovations were valued by a jury of 11 people representing Beaz, Bic Berrilan, Cdti Eide, Ergogroup, IHOBE, Mondragon Unibertsitatea , Osalan, SPRI, Tecnun-Universidad of Navarra and the University of the Basque Country (UPV/EHU).

The DANOBAT LG-1000 grinding machine is the largest model in its range. This is an external and internal horizontal grinding machine, capable of grinding parts within a maximum between-centres distance of 1000 mm. Parts such as cams or eccentric diameters can also be machined on this grinding machine.

The LG range has been developed for the manufacture of highly complex parts such as cutting tools, hydraulic precision components and automotive parts.

Its natural granite bed ensures great thermal stability. The cooled electro-spindles on the wheel head produce a maximum peripheral wheel speed of 120 m/s that covers the range necessary for grinding with conventional abrasives (45-60 m/s) or super-abrasives (20 – 120 m/s) with maximum torque. The axes are driven by means of CNC-controlled linear motors using glass scales for position control.

The grinding machine presented at the BIEMH is equipped with a CNC-controlled follow-up steady rest. This system guarantees an optimal roundness even for very slender parts.

Thanks to the B-axle multi-wheel configuration, both grinding with conventional abrasive wheels and with high speed grinding wheels is possible. The wide variety of wheel head set-ups provides the perfect solution for any process required by the client.

Requirements of completely automated manufacturing processes are fulfilled with customised automatic loading systems developed by DANOBAT, such as an integrated gantry or robot solutions.

Lymington Precision Engineers has gained a reputation over its 30 year history of being a ‘can do’ organisation, growing to a £50 million turnover business on the back of targeted investment in people and manufacturing technology. Now under the wings of the Senior PLC as a member of its Flexonics Division, LPE is continuing to invest and diversify as well as increasing the capacity for existing customers within the Oil & Gas, Telecommunications, Aerospace and Defence, Land and Sea Systems, Nuclear and Marine industries.

In the past 12 months LPE, which is accredited to ISO 14001 and 18001 and is working towards AS9100, opened a second manufacturing location, this additional 30,000 ft2 facility takes total floorspace to 121,000 ft2 and enhances the company’s ability to project manage large, low-volume components on machines with up to 4 m capacity as well as higher volume work on its two flexible machining systems. All of its work tends to be high-tech, high-added value, working with difficult to machine materials to tight tolerances. Within the new facility is a purpose-built, temperature-controlled, environment for its latest machine tool investment, a Danobat HG-72-3000-B11, a universal heavy-duty grinding machine. This 3000mm between centre machine is capable of grinding diameters up to 640 mm weighing up to 1.5 tonnes and, the integrated torque motor on the CNC-controlled B-axis allows the machine to carry out a wide range of grinding functions, including external and internal grinding, thread grinding. The machine’s wheelhead is powered by a 45kW motor that generates peripheral speeds of up to 45 m/min on the machine at LPE, with a maximum wheel diameter of 610 mm.

The new Danobat machine was purchased to support a long-term commitment by a longstanding customer, which will be part of a 10-year project for LPE. While this work takes priority the additional capacity created will allow new work, that couldn’t previously be ground, to be won. “The Danobat HG-72-3000-B11 is probably the largest capacity universal CNC grinder available for sub-contract work in the UK and having it should open up a number of opportunities for us. It is also a very accurate machine that will allow us to grind very large components, many with thin wall sections, to tolerances of 0.01mm,” says Nathan Davies, New Product Development Manager, Lymington Precision Engineers.

While LPE already had a wide range of grinders at its disposal, this is the first Danobat machine that it has purchased, and initially Nathan Davies was looking at ‘sticking with what he knew’. However, a visit to the Danobat factory quickly convinced him that it was time for a change. “We gave our existing supplier and Danobat three challenging parts to look at, and while the former would only talk about additional cost involved, Danobat simply got on with developing the process, they provided additional cycles for internal thread grinding including probing cycles and they committed to working closely with us throughout the project. Some of the parts have bores up to 1.1metres deep with wall thicknesses down to 2 mm, we are now able to grind these to tolerances of 0.02 concentricity and 0.01 on diameter to surface finishes of 0.4Ra. Danobat took on responsibility from start to finish and offered solutions to problems, not simply fixed ideas. This gave us the confidence that we had chosen the right supplier as we could blend our knowledge of the parts with their experience in grinding.”

The detailed planning by LPE ensured that the machine arrived and was installed without issues and virtually every contingency has been accounted for, with LPE specifying a wide selection of work steadies and ancillary equipment with the machine. To cover all internal grinding applications LPE ordered five spindles, with one having the shaft manufactured from carbon fibre, due to the extreme diameter to length ratio. Also fitted to the Danobat HG-72-3000-B11 grinder is an MDM Danobat Absolute Measuring Unit. This is designed for in-process gauging and enables LPE to measure a wide variety of diameters whether they are solid or intermittent surfaces. Once the grinding cycle is complete, before removing the part from between centres, it can then check, post-process, for diameter, faces and geometry within the complete mechanical working range of the machine.

Typical of the partnership that developed between LPE and Danobat were specific machine modifications that were made, such as the dual coolant system that allows LPE to quickly switch from the ‘clean’ coolant required for its long-term customer’s work to regular coolant for general work. Also, the machine’s internal covers are all manufactured from stainless steel, again to prevent contamination of parts. Service support was also a vital element in the decision making process and the fact that Danobat has UK-based service engineers who can be called on at any time was further reassurance for Nathan Davies.

“Working with Danobat has been an unexpected bonus, they are a company that is open to challenges and their engineers were willing to change and develop ideas in partnership with us. And, while the price of the machine was important, we presented them with lots of ‘what if’ scenarios Danobat took them all in their stride, gave us a fixed price for the machine, including software support in terms of writing new grinding cycles if we need them during the first 12 months. We added to the pressure further by not being able to fully divulge many of the part details in the early stages due to confidentiality clauses and when our customer put pressure on us to commence manufacturing Danobat pulled delivery of the machine forward by two months. The result of the close working relationship between LPE and Danobat means that we have achieved something quite special in terms of grinding capability,” says Nathan Davies.

The international company Tubos Reunidos has its new facility ready with DANOBAT  machines for the manufacture of threaded pipes and hoses. The project is the result of the joint venture of Tubos Reunidos and Marubeni; the premises total some 31,500 square meters with, amongst others, a workshop where theDANOBAT machines manufacture the threaded pipes.

The new production line will manufacture highly technological pipes, specifically threaded pipes for drilling and production of oil and gas wells. DANOBAT machines finish off the pipes with patented PREMIUM threads, that provide superior performance compared to standard threads. “They are perfectly suited for work on sites at 4,000 or 5,000 meters depth”, explains Carlos San Martín, director of technology and development of Tubos Reunidos Industrial.

Among other facilities, the line will have several horizontal DANOBAT TTB lathes for machining of pipes. One of the most important features of this machine is the rigidity, high production and extraordinary chip removal capacities during turning and threading operations. In addition, it is provided with load-unload systems, positioning channels and solutions with specific tools for turning pipes. To top it all off, the line will be equipped with DANOBAT band saws to cut the pipes, thus offering a high value-added comprehensive solution to Tubos Reunidos.

In the new factory, DANOBAT machinery will also produce the necessary special couplings to join the pipes in the well: the couplings. The company will have sophisticated DANOBAT lathes to machine the couplings, in addition to a robotised load-unload system thus obtaining a near fully automated production system with minimum operator intervention.

The Oil & Gas sector has always been a highly demanding industrial market. The shortage of available energy resources, increased activity in deep waters, high pressures, low temperatures, extreme conditions, etc,  in addition to the absolute need for high productivity and  reliability make it a challenging industry in a complex world.

DANOBATGROUP has a business area specialized in turnkey solutions for the Oil & Gas industry. The company has been working together with the world’s leading manufacturers such as Aker Solutions, Cameron, Metso, Mogas, NOV, Tenaris, Tpco and Vallourec among others, providing high value-added solutions in the manufacture of parts such as pipes, couplings, high pressure valves, ball valve seats, balls for ball valves, and more. In this occasion DANOBAT comes up with a solution for the machining of balls for ball valves: the DANOBAT BGM mahine. The BGM is able to machine diameters up to 2100 mm and materials with a complex machinability such as stainless steel, duplex and superduplex HVOF. Its long-standing experience in the field of grinding technology is materialised in this product family. Machining is performed with a segmented grinding wheel and the power spindle ranges from 25 to 85kW.

DANOBAT BGM machines govern the force exerted on the   ball during the machining process, thus guaranteeing the surface finish requirements set by the client. Also, centering of the workpiece is performed by controlling the two axes to adjust the height of the wheel spindle to the horizontal work spindle axis. Furthermore, during the machining process, measuring can be done before and after grinding with the purpose of obtaining a more controlled result. The operator can monitor and make adjustments to the entire process through the graphic 12″ NC panel with CNC or PLC technology and specific software for grinding balls of ball valves.

The bed is also designed and optimised to achieve the best results, facilitating the removal of residues produced during the grinding process so as not to damage the workpiece or the machine components. Even so, both the linear axis and the spindles are protected against residues with pressurised metal bellows to ensure the durability of the BGM. These machines offer several possibilities for customisation to suit the needs of each customer and each process. Optional equipment includes, among others, turning capability, diamond dressing and automatic tool changes. These configuration modules facilitate several automation processes and as a result enhance the productivity of the machine.

However, DANOBAT solutions for this specific sector do not end here. Apart from the earlier mentioned system, the company offers a comprehensive solution for machining the ring of the valve seat of between 100 to 1700 mm, and its manufacturing plant in Germany, DANOBAT-OVERBECK, manufactures machines  such as the IRD model which has been conceived to grind smaller valve balls.

DANOBATGROUP India will be exhibiting its latest developments and technologies of its two product brands, DANOBAT and SORALUCE in Hall4, stand B-110 at the 17th Indian Metal-cutting Machine Tool Exhibition – IMTEX 2015.

DANOBATGROUP will showcase the SORALUCE FP-6000 milling boring machine which has a 6000 mm longitudinal travese, 3200 mm vertical traverse and 1500 mm cross traverse and is equipped with an orthogonal head, indexable at 1ºx1º, with 37 kW, 4000 rpm motor and a 20-position tool magazine. Apart from the machine, a model of SORALUCE VTC 6000 vertical turning centre and a model of a complete turnkey line which is now being developed by the group for Indian railways will be also showcased. This line accomplishes a full automatic axle, wheels, wheelset machining, assembly and inspection line. Besides, grinded part applications and soltutions for the most demanding industries such as oil&gas, earospace, energy, general engineering or capital goods among others will be also showcased.

SORALUCE is celebrating TECHNOLOGY DAYS 2014 from the 12th to 15th November. This year, the event will take place at BIMATEC SORALUCE GmbH, its Technology Center in Limburg (Germany).

The TECHNOLOGY DAYS 2014 will consist of showing to its customers’ technology behind the machines and new developments applied to milling, boring and turning machines. These developments will be showcased in real machining conditions by the best specialists in these technologies.

At the edge of a new Industry 4.0, in a market increasingly global and competitive, more automated and able to manufacture high added value and tailored products, SORALUCE is committed with these new challenges in order to provide new solutions.

SORALUCE will show live demonstration on different technologies such as Dynamics Active Stabilizer DAS (World First presentation will be done during Technology Days), Spindle Speed Variation SSV, Adaptive Control,… developments by SORALUCE oriented to achieve higher productivity, quality improvements and cost savings.

During the evet, three new milling-turning heads will be presented to the market as well.

Different machining trials will be showcased: milling gym khana, big components machining trials, gear milling, turning trials, etc. displaying high performance milling-boring-turning solutions for the most demanding manufacturing sector, offering much more than machine tool. Intelligent solutions from a brand committed to accompany its customers along their requirements.