Maintaining the wall thickness of pump bodies and reducing the part setting time for manufacturing steering worm shafts is an important task for SuMax Enterprises Pvt Ltd, situated in Pune, India.It was made easy following installation of a Renishaw Primo system with Primo Radio Part Setter and Primo Radio 3D Tool Setter which has helped the company reduce part set-up time by 90% and eliminate scrap (previously 12%) caused by machining.

SuMax Enterprises was established in 1979 to facilitate additional capacity to manufacture different products for its parent company, Vijay Engineering, a manufacturer of tooling systems and high-precision parts.

Initially using conventional lathes and milling machines, SuMax supplied tooling, fixtures and gauges for checking components which directly contributed to Vijay’s product development cycle. In 1998, as a result of customer demand, SuMax started manufacturing components for tractor manufacturer John Deere. Today, SuMax has 65 machines, of which 35 are CNC machines used to produce high precision parts for automotive, machine tool and other industries. The company has the capacity to manufacture 100,000 components per month.

Primo is worth recommending to other SMEs as it is worry-free probing because of the warranty available and the credit token system. It helped us in reducing our part setting time and scrap on our components. The manufacturing sector will definitely benefit with this product.        SuMax Enterprise (India)

The big partnership
SuMax has always been considered a premium supplier of quality components focussing only on the manufacture of precision parts where a machining accuracy of ±10 microns is required. Manufacturing capabilities include turning, milling, broaching, cylindrical grinding and surface grinding. Inspection is carried out using a co-ordinate measuring machine (CMM).

“During evaluation of a CNC machine, a trial on one of our critical components was conducted at a machine tool supplier’s facility and there for the first time we saw part setting being done using one of the Renishaw probes. We found it very useful and were convinced to adopt this technology while manufacturing our parts,” said Managing Director of SuMax Enterprises, Mr Rajesh Suttatti.

Renishaw engineers advised which probe would be suitable for SuMax based on the application requirement. Using a Primo system has helped SuMax to increase machine utilisation time, eliminate scrap and reduce the time consuming tool setting process.

SuMax was attracted to the Primo system’s ‘pay-as-you-probe’ concept with a low initial investment and a unique credit token system. Moreover, the Primo Total Protect cover provides complete peace of mind and safeguards the Primo system against any accidental damage by providing a comprehensive warranty.

Worry-free probing
The Primo system is available at an affordable price and aimed at providing a fast return on investment.
Consisting of a Radio Part Setter and a Radio 3D Tool Setter, the system enables automated on-machine part setting, part inspection and tool setting. It helps to eliminate manual setting errors, improves accuracy and part conformance, and reduces non productive time and scrap. All of which increase productivity, improve quality and increase profits. The system is easy to use, simple to install and represents a low initial financial outlay. Its exclusive, enhanced warranty offers users complete peace of mind.

The innovative Primo Credit Token system offers users the flexibility to ‘pay-as-you-probe’. Its 6-month renewable tokens allow unlimited use of the Radio Part Setter and the Radio 3D Tool Setter within this period of time. The credit tokens are also available as an upgrade to enable unrestricted continuous use.

A Primo system was installed at SuMax in just one hour and as the system is so easy to use, it took the company only 15 minutes to get started. With the Primo training kit and pocket guide, it is very easy to learn and implement the system.

A key benefit is the elimination of the need for extensive G-code knowledge. The system is supplied with GoProbe, an innovative ‘all-in-one’ software package that simplifies part setting, tool setting and calibration. Simple, single-line commands are used instead of multiple lines of code which further eliminates the need for any special training.

Tangible returns
The Primo system was installed on a machine used for the precision machining of pump body castings and steering worm shafts.

In the case of the pump body casting, establishing a datum edge accurately to avoid wall thickness variation was critical. Previously the rejection rate due to variations in wall thickness had been 12%. Using the Primo system provided an automated part setting capability that was accurate and reliable, completely eliminating rejections of
this kind.

While machining the steering worm shaft, the dimension from the edge of the groove to the centre of the thread has a tolerance of ±0.1 mm. The start point of the thread in relation to the groove and orientation of the slot is critical. After threading is completed on the CNC lathe, the operator uses a rotary table to position the shaft prior to milling the slot on a vertical machining centre (VMC).

This part setting used to take 15 to 20 minutes whereas the actual machining time was five minutes. By establishing the orientation automatically, the Primo system eliminated a complex manual setting operation and reduced setting time to just two minutes.

For both of these applications, inspection following the machining process indicates that process variation has been eliminated – a major advantage of the Primo system.

“Without the probe the operator has to find edges and calculate the mean value to come to the centre. It is a process in itself and is a job which can be done by an experienced person only. If it has to be done with a trainee or inexperienced person, then there is no alternative to Primo. He has to just call a code to find out the width of the part so as to come to the centre. It is a very simple process which any operator could pick up within 10 minutes,” said Mr Suttatti.

At the Diemould exhibition taking place at Bangalore International Exhibition Centre, Bangalore, India, from 6-9 April, Renishaw (hall 2A stand B38) will highlight a range of process control solutions that help tackle the increasing drive to lean manufacturing, from new technologies for pre-process machine calibration, to on-line and off-line post-process measurement. There will also be a significant focus on the company’s additive manufacturing (3D printing) systems with the new PlusPac upgrade for its AM250 additive manufacturing machine.

The company will have active demonstrations of its Equator gauging system along with various machine tool software’s catering to Diemould industry.

Renishaw is the UK’s only manufacturer of a machine that ‘prints’ metal parts and visitors to the Renishaw stand will be able to see applications that demonstrate the capabilities of the company’s additive manufacturing technology and Strain gauge high-accuracy machine tool touch probes – Unparalleled accuracy and repeatability make this technology the best choice for complex multi-axis work and machine calibration .

RENGAGE technology
RENGAGE technology delivers true three dimensional (3D) measurement performance and submicron repeatability. So for exceptional performance, reliability and durability, why choose anything less? Conventional probes continue to fulfil a valuable role, which is why Renishaw maintains its position as market leader in the design, manufacture and support of these products.

However, for numerous applications, the significant performance benefits offered by RENGAGE technology provide users with a competitive advantage, for both now and the future.

RENGAGE technology is available with radio transmission in the RMP600; with optical transmission in the ultra-compact OMP400 and compact OMP600; and in the miniature MP250, offering an unmatched combination of size and accuracy.

The Primo system – opening up the world of precision manufacturing
At Diemould Renishaw is highlighting the Primo system: an entry‑level machine tool probing system that opens up the world of precision manufacturing to all types of manufacturing operation.

A genuine breakthrough business model, the Primo system makes it easy for manufacturers to take their first steps towards higher-value manufacturing by automating their operations and achieving repeatable processes.

Renishaw fixtures: the new single source for metrology fixturing
Following the acquisition of R&R Sales LLC in 2012, Renishaw has developed an extensive new range of modular fixturing designed specifically for co-ordinate measuring machines (CMMs), vision systems and its Equator gauging system. Visitors to Diemould 2016 will see that the new range offers a wide choice of base plates and components available in M4, M6 and M8 thread sizes, and can be utilised for measurement applications across multiple industries, such as aerospace, automotive and medical.

Automated gauging and process monitoring software for the Equator gauge
Renishaw Equator, a lightweight, fast and highly repeatable gauge, will be demonstrated in an automated cell. Equator’s innovative flexible gauging technology is based on the comparison of production parts to a reference master part, which can greatly increase throughput and reduce scrap rates at a fraction of the cost of an equivalent custom gauging system. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines.

A new process monitoring window has also been added to the shop-floor user interface for the Equator gauging system. This instantly displays measurement results of inspected features to the operator on a bar-graph display. It also shows the history of measurement on each feature so that process trends can be seen. The system’s re-mastering process can now be managed based on temperature limits, number of parts or time since last master.

Enhancements in metal 3D printing
Visitors to Diemould will also see a new range of additive manufacturing technologies. Renishaw’s laser melting systems utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a high-powered fibre laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100 microns.

The AM250, Renishaw’s first additive manufacturing machine is now available with PlusPac – an add-on kit which transforms the machine to meet the demand for cleaner process environments, improved surface finish and precision. PlusPac includes new Optical Control Software (OCS), a gas knife lens window protection system, and a high capacity filtration system. These updates give the user tighter control over the build process, enabling users to create even better components.

Global engineering technologies company Renishaw has launched the Primo LTS (length tool setter). The Primo LTS is a single-axis tool setter which allows users to set tool length, check for breakage, and compensate for thermal growth on a CNC machining centre.

The Primo LTS eliminates the need for time-consuming, error-prone manual tool length setting which can lead to scrap, rework, and reduced productivity and profit levels.

Automated on-machine tool length setting with Primo LTS is up to ten times faster than manual methods, resulting in immediate and significant cost savings. It is suitable for use on small to large CNC machining centres and helps guarantee “right first time” parts, reducing waste and increasing profits.

During a machining process, dimensional accuracy is dependent on a number of variables, including tool length and tool breakage. The Primo LTS monitors these variables automatically, enabling users to compensate for variations which may occur and benefitting the overall machining process.

The Primo LTS is a hard-wired product featuring a fully integrated interface for straightforward electrical connection: the hardware can be bolted onto the machine table and is immediately operational, with no additional set-up required. The Primo LTS is designed to operate in the harshest of machining environments, so it is resistant to swarf or coolant ingress and prevents false triggers caused by shocks or vibration. An integrated air blast provides effective swarf removal when necessary.

Easy to install and use, Primo LTS provides an accessible solution for increasing the productivity and profitability of a machine tool.

Affordable ‘pay-as-you-go’ machine tool probe system brings high-end manufacturing within reach of every company.

Renishaw, a market leading engineering technologies company, introduces the Renishaw Primo system at CIMT 2015, Beijing, China. This market development opens up high-value manufacturing to companies of all sizes. Machine tool probes are the foundation of precision manufacturing. Now, through a combination of minimal upfront costs, a free, comprehensive training package, and immediate parts replacement in a unique ‘pay-as-you-go’ model, the Renishaw Primo system represents a significant step forward in the way that machine tool probes can be introduced.

In factories across the globe, demand is growing for higher precision in manufacturing to ever greater tolerances – many manufacturers work to tolerances of less than 100 microns (the width of a human hair). Machine tool probes play a vital role in enabling manufacturing companies to meet these exacting specifications at each stage of the machining process: before, during and after cutting. Jean-Marc Meffre, President – Far East, Renishaw, said: “Amid rising wages, skills shortages and fierce global competition, the move to high-value manufacturing has become an economic imperative for many companies and countries. Precision measurement and machine tool probes are key to achieving the level of quality required to compete.”

Mr Meffre continued: “Our research showed that customer concerns, including investment cost, ease of-use and durability, have held some companies back from using probes. Our response is the Renishaw Primo system, a truly innovative approach that addresses each of these concerns. With a low initial cost, free training kit and immediate parts replacement, the Primo system now enables every manufacturer in Asia to grasp the opportunities of high-value manufacturing.

The latest pioneering initiative from Renishaw and a first for the industry, the Primo system offers users all of the advantages of automated setting at a very affordable price. The twin-probe system comprises the Primo Radio Part Setter, Primo Radio 3D Tool Setter and Primo Interface. The Primo Radio Part Setter accurately locates a workpiece prior to machining and the Primo Radio 3D Tool Setter measures the length and diameter of cutting tools. The Primo system has three additional key elements: Renishaw Primo Credit Token, Primo Total Protect and GoProbe software.

Renishaw Primo Credit Tokens enable the ‘pay-as-you-go’ solution which makes the Primo system unique and ensures an affordable initial investment, attractive overall purchase price and fast payback. Users buy a six-month credit token which enables unlimited use of the Primo machine tool probe system during that period. Once the credit expires, users can simply purchase an additional credit token to extend system usage by another six months. New credit can be inserted at any time and will be added to the remaining credit. An upgrade credit token is also available to provide unrestricted continuous use.

Registration of a valid credit token activates Primo Total Protect, which provides cover against accidental probe damage. If any hardware element of the system is damaged, Renishaw will replace it free of charge. Primo Total Protect provides the same level of coverage experienced by long-term contracted customers of more sophisticated systems. Finally, the GoProbe software and supporting training kit makes these already easy-to-use machine tool probes even simpler. A comprehensive self-study package with a range of training tools and modules guides users through everything they need to get the most out of the Renishaw Primo system.