Inspiration through Innovation - Demonstrations 2018

Mazak Nexus: Oil & Gas Sector, Stainless Steel Shaft Coupling	Technical Partners: • Machine tool builder: Mazak • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Vero/Edgecam • Metrology: Alicona • Collant saver system: Wogaard Using 316 stainless steel, a common material in the oil & gas industry due to its molybdenum content for increased corrosion resistance and improved resistance to pitting, this machining demonstration highlighs the stratergies used to achieve an excellent surface finish to help improve component performance.
DMG Mori CTX: Oil and Gas Sector, Flange	Technical Partners: • Machine tool builder: DMG Mori • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Edgecam • Metrology: Renishaw • Workholding: Leader Chuck The actuator being machined on the DMG Mori CTX has gone through a process improvement programme, as the customer wanted to improve the existing process to achieve a significant reduction in the cycle time and production costs. To do this required re-engineering of the total machining process. By combining the resources of a number ot Technical Partners, it was possible to reduce the part cycle time by 43% and reduce production costs by 32%. This machining demonstration showcases the optimised process and highlights the problems encountered and how they were overcome. Further insights into process improvements can be gained by attending the seminar 'Designing and Delivering Turnkey and Process Improvement Solutions' that takes place on Wednesday 10th October.
DMG Mori SVD 503: Automotive Sector, Automotive Rib	Technical Partners: • Machine tool builder: DMG Mori • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Autodesk • Workholding: MicroLoc An automotive ribbed gearbox bearing housing is located between the gearbox and drive shaft. To keep the strength-to-weight ratio as low as possible, rib sections are often designed with several pockets. Pocketing creates many challenges when machining, especially maintaining a constant and optimum feed rate when machining deep pocket radii. This machining demonstration illustrates the advantages of vortex (dynamic) milling. Two components will be machining in the demonstration, one using standard pocket milling stratergies and the second using vortex milling. Surface finish, tool life and cutting forces will be compared, contrasted and discussed during the event.
Hermle (1): Aerospace Sector, Blisk Aero Blade	Technical Partners: • Machine tool builder: Hermle/Kingsbury • Cutting Tools: Seco Tools & Nikken • Metalworking Fluid: Houghton • CAD/CAM: Vero/WorkNC • Workholding: Thame Workholding Traditionally, jet engine compressor fan disks are produced with a single disk and multiple blades. The development of multi-axis machine tools with sophisticated CNC controls combined with the latest programming stratergies now enables the manufacture of blisks - components where the disk and blades are intrinsically machined in one piece. Manufactured from either titanium or nickel-based superalloys, aerospace blicks present a number of machining challenges due, to a large extent, the nature of the material machined and a blick's complex machine profile. This demonstration will highlight the latest roughing stratergies that optimise part cycle time. On the side wall profile of the blisk, a new finishing technique called 'lens milling' will be employed. Lens milling delivers significantly improved surface finish results over those achieved by adopting a typical scanning finishing strategy.
Hermle (2): Aerospace Sector, Fuel Connector A350	Technical Partners: • Machine tool builder: Hermle/Kingsbury • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Tebis • Metrology: Bowers Due to the complex form of aircraft fuel connectors, they are often machined in two seperate and distinct operations and set ups. This is not ideal from both a productivity perspective or for meeting the exacting quality requirements for achieving aerospace compliance. The challend (and the solution) in this machining demonstration will be to machine the complete fuel nozzle in one operation. This will be achieved by optimising all aspects of the machining process and all the technologies involved to enable the component to be machined, to completion, in just one operation.
Hermle (3): Aerospace Sector, Annulus Filler Hook Section	Technical Partners: • Machine tool builder: Hermle/Kingsbury • Cutting Tools: Seco Tools • Metalworking Fluid: Blaser (Jemtech) • CAD/CAM: OpenMind • Workholding: Roemheld A key component in an aerospace blisk in the annulus filler - a component that is attached to the blick hub between each of the blades. Its primary function is to seperate the blades and, by doing so, resist the significant radial forces( as well as directing an axial airflow surface) for air being drawn through the engine. The complex geometry of an annulus filler and the requriement to be manufactured from a solid billet create several manufacturing challenges. A significant and unacceptable issue in the machining processs can be excessive surface vibration which occurs when machining deep pockets with tools and long overhangs. In this demonstration optimised roughing and finishing machining stratergies will be employed with a specific emphasis on 'barrel milling' techniques utilising custom Jabro solid carbide convex profile milling cutters.
Hermle (4): Medical Sector, Femoral & Tibal Tray	Technical Partners: • Machine tool builder: Hermle/Kingsbury • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Majenta PLM • Workholding: Craftsman, Brown and Holmes & Laserline (3D Printing) Global demand for knee and hip replacement parts is increasing, with worldwide sales, last year, exceeding £9 billion. Femoral and tibial tray components are commonly produced in cobalt chrome (Co-Cr) and titanium. These biocompatible materials are stong and hard, and exhibit high stiffness and abrasiveness when being machines. Machining challenges facing component manufacturers are many and varied, including producing parts with a superior and consistent surface finish that is also burr-free (to minimise the need for secondary polishing operations). Machining processes also need to be secure, optimise productivity and ensure high tool life. To deliver these requirements Seco ha produced a range of material-specific cutting tools which, in combination with optimised machining stratergies, help manufacturers machine high-precision orthopaedic component. In this machining demonstration complete process for machining femoral and tibial components will be showcased.
GROB 550T: Aerospace and Oil & Gas, Drive Actuator	Technical Partners: • Machine tool builder: GROB • Cutting Tools: Seco Tools • CAD/CAM: OpenMind The component has been designed specifically for this year`s ITI event with the aim of showcasing unique machining strategies that may not have ever been seen before. The stainless-steel component has many features that are evident in the Aerospace and Oil & Gas sectors. Our aim is to use several unique processes to show that there is always more than one way to machine a feature. These include: 3-axis simultaneous turning which improves the flexibility and efficiency of a tool and reduces the need for intermediate extensions. Dynamic milling utilising the full flute length of a cutter to reduce cycle times and improve tool life. On machine broaching, means the part can come off complete in 1 operation, illuminating the need for an additional operation or the purchase of an expensive right-angled head. This is a truly collaborative demonstration with Open-Mind, Grob and Seco all working together to showcase each other’s abilities!
Willemin-Macadel 508MT2: Medical Sector, Stent Holder	• Machine tool builder: Willeming Macodel with Fanuc • Cutting Tools: Seco Tools A stent holder is key element to a collet system that is used to hold delicate medical stents securely and without causing any deformation. Utilising the Willeming-Macodel 508MT2 machine's multiple driven spindles, the stent holder is machines from solid (bar) to completion in one set up. The machining demonstration will show this small and intricate stainless steel stent holder (the complete part measures a diameter of 4mm by 8mm long) being machined without manual intervention. Additional automation technolcoy will also be demonstrated via the use of a bar feeder and the integration of a Fanuc robot for loading/unloading operations.
Matsuura MX-520 PC4: Aerospace Sector, Rotor Crank	• Machine tool builder: Matsuura• Cutting Tools: Seco Tools • Metalworking Fluid: Blaser (Jemtech) • CAD/CAM: Vero/Edgecam • Metrology: Renishaw • Workholding: Craftsman Made from aluminium, this complex 'scaled' helicopter rotor cover has been produced by optimising the 5-axis machining capabilities of a Matsuura MX-520 PC4 machining centre - a machine with integrated automic pallet change capability. The demonstration also features a bespoke fixturing plate from Craftsman Tool, solid carbide cutters and Feedmax drills from Seco Tools, Blaser B-Cool 755 metalworking fluid from Jemtech and machine programming stratergies developed using Edgecam CAD/CAM software.

Romi D800V5: Aerospace Sector, SS Aerospace Bracket	• Machine tool builder: Romi • Cutting Tools: Seco Tools • Metalworking Fluid: Blaser (Jemtech) • CAD/CAM: SolidCam • Workholding: Schunk The UK debut of the Romi D800 version 5, provides the ideal machine tool platform to demonstrate the machining of a stainless steel aerospace bracket. As with most aerospace components, material microstructure integrity, machined surface finish and accuracy are of paramount importance. To meet these exacting requirements, SolidCAM tool path strategies were employed to help optimise productivity and Schunk rigid workholding and fixturing equipment to hold the component securely, without deformation, was also used. Cutting tools from Seco designed to achieve the exacting surface finishes and surface integrity required, and a high-performance Blaser metalworking fluid from Jemtech that enhances tool life and chip evacuation were also specified. By bringing these Technical Partners and their respective technologies together in a collaborative environment, the machining of this stainless steel aerospace bracket has been optimised.
Doosan NHP 5000: Automotive Sector, Differential Casing & Suspension Upright	• Machine tool builder: Doosan (Mills) • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Autodesk • Metrology: Renishaw •Workholding: Brown & Holmes Commonly referred to in the automotive industry as a steering knuckle, this component is the focal point in a car's front axle and connects the wheel to the suspension and steering. To machine this critical component, a rigidly-designed and built high-performance Doosan NHP 500 horizontal maching centre will be demonstrated combined with Autodesk CAM machining stratergies, Seco Tools' Aeromaster and Jabro solid carbide tooling, Houghton Hocut 4940 high-lubricity metalworking fluid, adjustable and rigid work-holding from Brown & Holmes, and high--precision measurign equipment from Renishaw. The demonstraiton willl focus on process time reduciton and compoent accuracy improvement.
Heller HG3500: Aerospace Sector, Ti Rib	• Machine tool builder: Heller • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Jaivel in conjunction with Autodesk •Workholding: Schunk In order to maximise metal removal rates when machining titanium, the latest innovative technology solutions from the collaborative Technical Partners are used to machine the aerospace rib component from solid on the Heller HF 3500 machining centre. In addition to high-accuracy drilled and milled features on the component achieved by using advanced holemaking and face milling cutting tools, machining operations also included the use of tools with long overhangs. The demonstration will highlights how the performance of these tools can be optimised to deliver high material removal rates and, as a consequence, reduce part cycle times and improve productivity.
Mazak I400: Oil & Gas Sector, Duplex Gear Valve	• Machine tool builder: Mazak • Cutting Tools: Seco Tools • Metalworking Fluid: Houghton • CAD/CAM: Edgecam • Metrology: Renishaw •Workholding: Hainbuch Duplex stainless steels are commonly used in the oil and gas industry due to their twin-phase austenitic and ferritic microstructure that gives the material a strength and toughness that is twice that of regular stainless steels. While these properties are attractive for component designers, they create a unique set of challenges and difficulties during machining operations. Working closely with our technical partners, this machining demonstration focuses on machining strategies based around the Mazak I400 5-axis machining centre to maximise tool life and productivity. Using rigid Hainbuch workholding and Edgecam waveform cycles, new machining strategies were developed to overcome the issues. Coupled with Seco MDT grooving systems and Jabro solid carbide round shanks tools, metal removal rates were significantly increased without comprising tool life.
Fanuc Robodrill: Automation	• Machine tool builder: Fanuc • Cutting Tools: Seco Tools • CAD/CAM: OpenMind •Workholding: Hainbuch • Metrology: Renishaw At this year’s event, Fanuc have partnered with Open Mind, Seco Tools and Renishaw to showcase their latest small footprint Robodril a-DiB machining centre integrated with a Fanuc robot to create an automated manufacturing cell. By incorporating a Renishaw Equator gauging system into the cell - machined components are measured/inspected on the shop floor and in-process meaning that production is not disrupted.
CNC Robotics	Strength and weight are important requirements in the manufacture of Polo riding helmets. The first helps ensure rider safety - the second rider comfort. To achieve both requirements helmets are manufactured using a honeycomb core sandwiched between two carbon fibre shells. A final part of the finishing process involves the inner and outer shells being trimmed and the required apertures being machined. Due to the size and complexity of the helmet, and the need for a fast and reliable machining process, a CNC robotic multi-cube robot cell coupled with a Kuka KR10 Agilus robot has been created for this demonstration. By working in partnership with Tebis and Seco Tools, CNC Robotics have optimised part cycle times, consistency and trim quality.

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