Archive for January, 2008

INDIANAPOLIS, IN , Jan 22, 2008 – In 2008, OFCDesk will begin the first U.S. rollout of their IDC (interior design CAD) software product. In accordance, the company has announced dates for product demonstrations to be held in Indianapolis, Chicago, and Cincinnati. The demonstration in Indianapolis, IN will take place on January 31. The second tour date is scheduled for February 19, in Chicago, IL. The software will then be introduced in Cincinnati, OH on March, 20. Professionals in the interior design and architecture industries are invited to attend free of charge. For additional details on each event, visit www.ofcdesk.com/events.

OFCDesk IDC is the first CAD software focused exclusively on commercial interior design. “It was important for us to provide an industry specific tool set for this growing profession,” commented OFCDesk Chief Software Architect Mauricio Ritzman. “The interiors industry has long been awaiting a software package unique to their needs.” IDC includes a built-in content creator and customizable library. The software is based on the AutoCAD platform and features an easy-to-use interface with industry specific tools and terminology.

The three month road show marks the introduction of OFCDesk’s IDC software to the US market. For professionals unable to attend, a demonstration webcast is also available. Future product demonstrations will be scheduled for the East and West coast regions during the second and third quarters of 2008.

For more information about product demonstration dates or for registration information please visit www.ofcdesk.com/indyevent.

About OFCDesk, LLC

OFCDesk, LLC has been developing specialized CAD solutions for the interior design industries for over fifteen years and continues to deliver a wide range of solutions and custom development services. In July, 2005 the Brazil-based company launched its first U.S.A. operations in Chicago, IL. To learn more, visit www.ofcdesk.com.

U.S. CAD™ Chosen by David Evans and Associates as Official Autodesk® Reseller and Civil 3D Implementation Consultant

Major engineering firm taps U.S. CAD to speed transition to new civil engineering software standard.

Costa Mesa, CA (PRWEB) January 22, 2008 — U.S. CAD, Inc. (formerly L.A. CAD), the Western U.S.’s largest provider of computer-aided design (CAD) consulting, training and support services, and its largest Autodesk® solutions reseller, today announced it has been chosen by engineering firm David Evans and Associates, Inc. (DEA) as its official Autodesk reseller and Civil 3D implementation consultant. The multi-year contract puts DEA at the forefront of engineering firms transitioning to the new industry standard in civil engineering software, with U.S. CAD advancing the effort.

"We are very excited about our agreement with DEA, which enables us provide them the latest Autodesk solutions, as well as our advanced training and support services — all aimed at helping DEA and its customers be even more successful," said U.S. CAD CEO Danny Counts. "This agreement exemplifies our U.S. CAD strategy to expand our technical capabilities and reach, while maintaining our core focus on delivering superior technical solutions and customer service."

"Over the past two years, DEA has been embracing and leveraging the new Autodesk Civil 3D technology through a large scale, phased approach," said J.C. Davis, DEA corporate information systems and Civil 3D project manager. "U.S. CAD has the resources and expertise to handle the ongoing administration and management of this project, as well as the ability to meet our other ongoing Autodesk product, training and support needs. It’s a good match."

With offices in Arizona, California, Colorado, Idaho, New York, Oregon and Washington, DEA is ahead of most other large engineering firms in implementing the new Civil 3D standard, which for many large-scale applications is the next-generation to Autodesk’s workhorse Land Desktop software. "Civil 3D is far more than a new civil engineering software application; it’s a fundamental advance in the field — a new way of completing projects faster, more efficiently and with greater design consistency than previously possible," said Davis. He added that DEA’s time savings on production plan development thus far using Civil 3D has approached 30 percent, with greater savings anticipated with through product familiarity and U.S. CAD’s support.

"With its ability to dynamically connect design and documentation, enabling design development to occur simultaneously with data collection, Civil 3D requires an organizational commitment to workflow change that many firms aren’t yet able to approach," said Melanie Santer, U.S. CAD applications engineer, who specializes in Civil 3D training, installation, support and implementation. "This is where DEA’s forward-thinking and U.S. CAD’s Autodesk and Civil 3D expertise make the perfect pairing. The end result will be time and cost savings for DEA and its customers."

About David Evans and Associates

Since its founding in 1976 in Portland, Ore., DEA has become a recognized leader for progressive and sustainable design and management solutions for complex transportation, land development, energy, and water resources projects nationwide. DEA’s multi-disciplinary teams partner with clients to tailor solutions to meet the unique needs of each project. The firm has over 20 offices in seven states and employs more than 1,000 people firmwide. Its staff includes professional engineers, surveyors, planners, landscape architects, and natural resources scientists. DEA is an employee-owned corporation and consistently ranks among ENR’s Top 100 Pure Design firms in the U.S. DEA and its staff are committed to improving the quality of life, while demonstrating stewardship of the built and natural environments. For more information, visit www.deainc.com/default.aspx.

About U.S. CAD

Based in Costa Mesa, Calif., U.S. CAD, Inc. is a major provider of computer-aided design (CAD) consulting, training and support services, and Autodesk software solutions. Specializing in the civil, mechanical and architectural design, building-engineering and geospatial industries, the company provides technical expertise and customized training to deliver superior customer solutions. Customers value U.S. CAD’s quality instruction from Autodesk Approved Instructors, and its flexible training options, including modular mobile training labs. With Autodesk Authorized Training Centers at its Costa Mesa, Los Angeles, San Diego and Honolulu, Hawaii locations, U.S. CAD has become the Autodesk provider of choice for many of the West’s leading CAD-related companies. For more information, visit www.uscad.com.

U.S. CAD and L.A. CAD are trademarks of U.S. CAD, Inc.

Tuesday, January 22, 2008:  SYCODE, a developer of software solutions for computer aided design (CAD) industry, has launched seven CAD file import and export add-ins for Inventor. The Inventor model is a 3D digital prototype that enables users to validate design and engineering data as they work, minimise the need for physical prototypes and reduce costly engineering changes discovered after the design is sent to manufacturing.

The import add-ins are as follows: STL Import for Inventor — Stereolithography STL file import add-in; 3DS Import for Inventor — 3D Studio 3DS file import add-in; 3DM Import for Inventor – Rhinoceros/OpenNURBS 3DM file import add-in; and OBJ Import for Inventor — Wavefront OBJ file import add-in.

The export add-ins are as follows: 3DS Export for Inventor — 3D Studio 3DS file export add-in; 3DM Export for Inventor — Rhinoceros/OpenNURBS 3DM file export add-in; and OBJ Export for Inventor — Wavefront file export add-in.

"Autodesk Inventor is being widely used the world over for 3D solid modelling,” stated Deelip Menezes, owner, SYCODE. “These seven CAD data exchange add-ins are our contribution towards helping Inventor fit into the 3D design workflows of Autodesk customers. With the launch of these add-ins, SYCODE now offers more than 100 products (standalone and plug-ins), 101 to be precise.”

The add-ins are priced at €195 each and are available as fully functional 10 day/run trials.

Having acquired a large capacity VMC, and oil and gas industry components supplier can now cost-effectively machine 2.5m long workpieces in one set-up

Nexus Precision Engineering has acquired a large capacity Hartford Sumo vertical machining centre (VMC) from Ward CNC to cost-effectively machine 2.5m long workpieces in a single set-up. The 3m bed capacity VMC features an integrated fourth axis and right-angle machining head, as well as 60-tool auto toolchanger.

Project manager at Nexus’ Broxburn (Edinburgh) site, Paul Rafferty, said: ‘The whole concept of Nexus’ operation has been to identify niche requirements then source machines to satisfy them.

And the deal with Ward CNC of Sheffield was no different – we saw an opportunity and we invested appropriately in a machine that was fit for purpose’.

Nexus employs 40 to manufacture a wide range of components – including undertaking a certain amount of assembly – to satisfy a ‘blue chip’ customer base in the UK and Singapore.

Nexus supplies a variety of workpieces for oil and gas work, and in particular, downhole tooling to companies such as Baker Hughes ProductionQuest, FMC and Schlumberger with The Hartford Sumo was purchased primarily to satisfy the need for the one-hit machining of downhole gauge carriers for Baker Hughes ProductionQuest.

Required in batches of two-/12-off, currently on average 15/month are being supplied.

Made from 4140 or 420 stainless steel, these are received by Nexus as offset bored and honed ‘blanks’ in a variety of sizes from 100mm to 150mm diameter and from 1800 mm to 2.5m long.

Once the journals are turned (within the dedicated cell built around the Hartford machining centre and a lathe ) each carrier enters the Hartford Sumo for a series of milling and drilling routines.

Routines include component-length slot production, to tolerances of +/-0.05mm using bull nose cutters.

Nexus then completes premium (licensed) threading before pressure testing.

‘The key to the success of the Hartford Sumo, apart from its extra long bed capacity, is the integrated fourth axis and right-angle head,’ said Rafferty.

‘These features enable all prime machining operations to be performed in a single loading – there’s no second operations and therefore no inter-operation handling to extend lead times and overall costs.

The machine is the ideal solution’.

He continued: ‘When the opportunity came along to machine these parts, we obviously looked at other machines but quickly decided on the Ward CNC solution because of the capability it offered and the fact that it was a tremendous value-for-money package.

It was also supplied with Fanuc-based CNC, which offered a degree of uniformity across the shopfloor’.

* Open-fronted design VMC – of open-fronted design, the construction of the Sumo 3100 AG VMC is based around a cast iron frame with hardened and ground box slideways.

It has a table of 3100 by 1050mm able to accommodate 4,000kg workpieces, and X, Y and Z travels are 3050mm by 1016mm by 1070mm.

As standard, the 18.5/25kW spindle produces speeds of 50 to 6,000 (optionally 8,000) rev/min (pulley-style – 40 to 4,000/6,000 rev/min geared).

The BT 50 taper machine is supplied with a 20- (optional 32- or 40-) tool automatic toolchanger.

* Reduced programming times – running the Sumo ‘around the clock’ on a two-shift basis, product manager Mark McLellan said the Hartrol-Fanuc AI100/0iMC programming package is especially useful.

The Hartrol advanced functionality programming routines consist of a series of easy-to-use cycles designed to simplify and speed up programming times and therefore reduce downtime along with other useful setting and maintenance functions for ease of operator use.

These routines include, for example, the following.

* workpiece datum setting using edge setter.

* Manual tool setting using calibrated setting block.

* Tool magazine tracking (for arm-type ATC).

* Tool logging.

* Spindle load monitor.

* Full M Code listings.

* Comprehensive set of special canned cycles.

The Hartford Sumo is also allowing ISO 9001:2000 accredited Nexus to gain additional cycle time reductions by the use of new tooling, said Ward to manufacturingtalk.com.

The VMC also has the ability to run existing tooling at faster speeds.

McLellan said: ‘For example, we can now utilise carbide inserted FMR (fast metal removal) face mills of 50-63mm diameter at 3,000 rev/min spindle speeds compared to 1,000 revs/min, and at feed rates of 3000mm/min compared to 500mm/min.

This is making a massive contribution to shorter cycle times.’ Rafferty concluded: ‘Like all our investments, the new machine was justified on the basis of volume of orders, and the buoyancy of the market in terms of future projected loading.

We partner our customers in the true sense of the word – beginning with dedicated key project/account managers to offer a personal service with a single point of contact.

On this basis we are able to make calculated decisions regarding all machine installations, which have totalled around GBP 2 million during the past three years’.

With annual turnover forecast to reach GBP 6 million during the next four years, it is clear that since the company was established in 1997 Nexus continues to build a successful business in the oil and gas industry.

Ward CNc said that there’s also no doubt that investment in the appropriate machining technology is central to that success.

High-pressure, hydraulically balanced, coolant pumps for machine tools reduce maintenance costs because there are no packings, cups, or seals, said the manufacturer

High-pressure MP-B series coolant pumps use a Hydra-Cell diaphragm pump. This patented, hydraulically balanced design reduces maintenance costs because there are no packings, cups, or seals. This rugged, fixed or variable volume pump is built to handle the abrasive particles found in machine tool coolant that can wear out conventional centrifugal, screw, or piston pumps.

* Lathes and milling machines – In lathe and milling machine applications, this pump effectively removes chips from even deep and blind holes and reduces ‘cyclic cooling’ in milling applications, said Monster Swiss to manufacturingtalk.com.

Cyclic cooling occurs when steam is produced and creates a boundary layer, which interferes with coolant effectively reaching the tool/workpiece interface.

In grinding, the MP-B’s high-pressure (1,000 lb/in2) keeps the wheels free of swarf build-up and optimally cooled, again by breaking the boundary layer created by the wheels high speed, and giving the successful result of increased wheel life and metal removal rates.

* Positive displacement – the MP-B’s positive displacement design allows users to adjust the flow rate by changing the speed of the pump shaft.

This is a helpful feature when using tools with different coolant flow requirements.

The unit is portable on sturdy locking castors, so that operators can easily move it when necessary, even with the 50-gallon reservoir filled.

MP-B pumps have electrical components manufactured by Sprecher + Schuh, a Swiss company, and are certified to the highest standards including UL, CSA, and CE.

All of the machine components, including twin filters, are housed conveniently and neatly inside the cabinet assembly.

hyperMILL® receives ‘Certified Gold Product’ award from SolidWorks

Für den Inhalt der folgenden Meldung ist nicht die Verivox GmbH sondern der Autor Open Mind Technologies AG verantwortlich.

(pressebox) Wessling, 15.01.2008 – The new hyperMILL® V9.7 from OPEN MIND offers CAD integration with SolidWorks®. SolidWorks Corporation, developer of the popular Solidworks CAD product has certified the integration of OPEN MIND’s complete solution and has designated hyperMILL® as a ‘Certified Gold Product’. This is SolidWorks’ highest award based on outstanding integration, quality and interoperability.

To receive the ‘Certified Gold Product’ award, the partner product must go through a multilevel certification process. The requirements include full integration of the software user interface within SolidWorks® and associative database linking of the geometric data of SolidWorks®. In addition, SolidWorks® reference customers must be able to use the software product effectively. In-house product tests are also conducted at SolidWorks to determine whether its high requirements are fulfilled. OPEN MIND Technologies released hyperMILL® V9.7, including the SolidWorks® integration in October 2007. And now hyperMILL® has successfully completed and passed the certification process.

Integrated process chains for CAD users

"Our CAD-integrated CAM solution hyperMILL® has the advantage of allowing SolidWorks® users to implement integrated process chains on their existing user interface," explains Frank Eckstein, responsible for hyperMILL® in SolidWorks® in the Application Technology division at OPEN MIND. "In our software solution, the CAD and CAM systems both access the same database. A uniform data model is used for the entire process. This helps ensure transparency and accuracy in the production process and prevents errors."

Additional information is available upon request or from our website at www.openmind-tech.com.

OPEN MIND Technologies AG is a leading developer of CAD/CAM software and postprocessors for designing and manufacturing complex moulds and parts. OPEN MIND offers an extensive range of products, from 2D feature-oriented solutions for milling standard parts through to software for 5-axis simultaneous machining.

With their hyperMILL® software, which is used in the automotive, tool and mould manufacturing, mechanical engineering and aerospace industries, OPEN MIND Technologies AG is represented in all the important markets in Asia, Europe and North America.

OPEN MIND Technologies AG is a Men and Machine company (www.mum.de).

Maximizing the benefits of multi-tasking starts with a CAM software strategy that can leverage the sophistication of the machine tool.

Friday, February 01, 2008
By  John Teresko

Start with the understanding that maximizing the benefits of multi-tasking machines requires a computer-aided manufacturing (CAM) approach that takes full advantage of the machine tool’s capabilities.

Keep in mind that operations will vary from basic turning operations to complex 5-axis simultaneous milling, says mill/turn manager Olivier Thenoz of CAM specialist DP Technology Corp., Camarillo, Calif. His advice: Be as serious about the CAM software as you are with the selection of the multi-tasking equipment.

In DP’s ESPRIT software, the operation manager handles any kind of milling (up to 5-axis simultaneously) and turning operations (including pinch strategies) in the same time and with several heads/turrets. He says the CAM system must also offer support for all the optional components and the special devices of the machines. Examples: steady rests, tall stocks, part catchers, devices for the transfer of the part, special milling heads, boring devices and special tool holders.

"One of our customers cuts crankshafts with two opposite milling tools that cut simultaneously while both spindles are holding the part," he says (refer to the graphic). "The programming requires a powerful CAM system, but the time saved with this process is important."

Thenoz emphasizes his basic premise: "Multi-tasking machines are very complex and challenging to program manually." He says a good CAM system is the best way for mastering "the beast" and therefore the programmer can use the machine to its full potential. "We’re very successful programming high-end multi-tasking machines."

The multi-tasking world is rapidly evolving, Thenoz points out. "From the first single spindle, single turret mill-turn machines, many things have changed." He says machine tool manufacturers are offering multi-head and multi-spindle configurations. There are many variations of B-axis kinematics: B-axis head, index turret mounted on a B-axis tilting spindle or a B-axis on a Swiss-type lathe.

As a producer of multi-axis machining software, DP Technologies fully utilizes and supports the capabilities of the latest machine tool technology. "In order to support the latest technologies, we’re working in partnership with tooling companies," Thenoz notes.

"A primary challenge is to provide CAM systems that are easy to operate — despite the rapidly increasing complexity of the machine tools." His point: "We want the programmer to focus on the machining and not on understanding the software complexities." Automation is another DP Technology focus. "We try to offer automation for any repetitive tasks — a goal that evolves with user practice, and is intended to improve not only productivity, but quality and consistency."

CAM software for multi-tasking — such as DP’s ESPRIT software — bears conceptual similarities with software for conventional machines, notes Thenoz. "For example, someone who knows how to program a drilling operation for a vertical milling machine in ESPRIT is able to program the same operation for high-end multi-tasking machines. Regardless of the machine, individual operating definition is very similar, he adds. "The difference is in much higher requirements for process management, simulation and NC code for multi-tasking machines."

He says the programmer needs to balance the operations on the various turrets and spindles in order to reduce dead time and maximize productivity. "Simulation has to closely match the complex kinematics of the machine in order to prevent any collision. Then the NC program has to accurately reflect the calculated tool path."

Thenoz describes simulation and post-processors as two critical features for multi-tasking. "Simulation has to be accurate with full collision detection and a good representation of the machine and the cutting environment — tools, fixtures, holders. Previously, a lot of time was required to verify the NC program."

ESPRIT 2008 (announced last August) introduces a new continuous B-axis cycle that reduces the number of cutting tools required, the number of tool changes and results in a smooth, stepless surface, adds Thenoz. He says the new B-axis contouring cycle is designed specifically to achieve higher performance levels from multi-tasking machines by fully utilizing the rotational capabilities of the B-axis. While traditional lathe contouring cycles rotate the B-axis once at the start of the cut, the ESPRIT B-axis contouring cycle allows for dynamic, continuous rotation throughout the cut.

The tool follows inner and outer contours without stopping for tool changes, emphasizes Thenoz. That allows a single tool to reach areas that would otherwise be inaccessible due to the tool’s geometry. Using the new B-axis finishing cycle to reduce both the number of cutting tools and the required tool changes ultimately results in a significant savings in time and money, says Thenoz. "If you’re using one tool instead of three you could save as much as 20 seconds," says Thenoz. "If you multiply that by the number of parts you’re producing, the results can be very interesting." That’s in addition to the smooth, stepless surface.

EDM and milling machine tool builder, GF AgieCharmilles, recorded a 20% growth in UK sales during 2007, including a growth in 5-axis milling machine deliveries

GF AgieCharmilles, builder of EDM and CNC milling machines recorded 2007 UK sales figures of 20% growth, when compared with 2006, and a dramatic increase in total units sold – 170 units. Commenting on the sales figures, managing director of the UK operation, Steve Sylvester, said: ‘We have had a good year.

EDM and milling machine tool sales have increased substantially and our Customer Services Business (i e, consumables and after-sales services including wear and spare parts, preventative maintenance, training, etc), has also experienced double digit growth too’.

Particularly important has been the growth in sales of its 5-axis milling machines.

Sylvester commented: ‘Demand for our standard; high-performance and high-speed 5-axis milling machines has never been higher.

We have a 5-axis machine tool range that is second to none – and this is reflected in our sales figures.

Our 5-axis machine tool provision means that customers can source the optimum machining solution direct from us – and an increasing number of precision manufacturers are doing just that’.

Also worth mentioning has been the impressive sales of the company’s Cut 20/30 wire edm machines.

Only launched at EMO in September 2007 – sales of the Cut 20/30 machines have ‘gone through the roof’ – and demand shows no sign of abating.

Sylvester concluded: ‘With a company Open House already organised – 6 and 7 February 08 – and MACH 08 in April following hard on its heels, plus a number of innovative sales and marketing campaigns we’ve introduced and that are now being implemented for our EDM, milling and customer services business – we have everything in place to top last year’s performance.’

SolidCAM to Exhibit its latest version at SolidWorks World 2008

2008-01-18 17:36:29 -

January 18, 2008 – SolidCAM, the leading and fast growing supplier of integrated CAM software solutions for the manufacturing industry, today announced it will exhibit at SolidWorks World 2008, one of the world’s largest annual 3D CAD events. This in-ternational user conference and exposition takes place in the San Diego, CA, Conven-tion Center January 20 – 23, 2008.

SolidCAM will demonstrate the new version SolidCAM2008 R12, which is Gold-certified for SolidWorks®2008 at Booth # 632. The single-window user interface and the full as-sociativity between the CAD model and NC tool path guarantee a short learning curve and an efficient data flow from the 3D design model to the machined part. The new version provides a complete manufacturing solution with enhanced user friendliness, more automation features and additional CAM functions. SolidCAM2008 R12 supplies improvements for all Milling applications, including interactive and automated 2.5D Mill-ing, High-Speed Machining, Indexial and Simultaneous 5-axis Machining. Also, users will benefit from new features for the Mill-Turn, which includes support up to 5-axes (XYZCB) and back spindle operations.

SolidCAM is also presenting at the Certified Partner Theater on Tuesday, Jan 22nd at 4 p.m. Mr. Bede Kortegast, SolidCAM’s VP of sales for North America, will demonstrate the latest innovations in SolidCAM2008 R12.
Today, SolidWorks and SolidCAM look back to a successful 5-year partnership, which started in the year 2003 with the Gold certification and the Bundle agreement. Emil Somekh, founder and Managing Director of SolidCAM, states: ‘As a Gold-certified part-ner of SolidWorks, we have always been committed to single-window integration and full associativity with SolidWorks – in our view the best solution to streamline the entire manufacturing process which results in reduced costs and shorter lead times.- He continues: ‘In the past 5 years, we succeeded together with SolidWorks to win several thousand new customers, which benefited from the combined solution Solid-Works+SolidCAM. In the next years, we will continue to strengthen our leadership in In-tegrated CAM.-

About SolidCAM

Founded in 1984 by its Managing director Dr. Emil Somekh, SolidCAM provides manu-facturing customers with a full suite of CAM software modules for 2.5D and 3D Milling, High-Speed Machining, Multi-sided Indexial 4/5 axes Milling, Simultaneous 5 axes Mill-ing, Turning, Turn-Mill up to 5-axes and WireEDM. SolidCAM has the Certified Gold-product status from SolidWorks and provides seamless, single-window integration and full associativity to the SolidWorks design model including parts, assemblies and con-figurations. SolidCAM has today more than 12,000 seats installed. SolidCAM is sold by a worldwide reseller network in 46 countries. SolidCAM is used in the mechanical manufacturing, electronics, medical, consumer products, machine design, automotive and aerospace industries, in mold, tool and die and rapid prototyping shops. SolidCAM has been on a very rapid growth path since it implemented the SolidWorks integration strategy with high annual growth rates of more than 30%. For the latest information, visit the company’s website www.solidcam.com

For more information about SolidCAM visit:
www.solidcam.com

Press Contact
Rachael Dalton-Taggart
Strategic Reach PR
Tel: (303) 487-7406
Email: Rachael@strategicreachpr.com

Milling machine for Tough Applications

Automotive parts subject to high loads, such as drive shafts, gear wheels, and cardan joints, are formed using special tools. Besides having to meet increasingly demanding quality requirements, component manufacturers have to pay particular attention to the cost of the manufacturing process as a whole.

Eleven partners working together in the European Union (EU) project, HardPrecision, have developed a five-axis milling machine for high-precision hard machining. The results were presented at the Euromold 2007 fair, which took place in Frankfurt, Germany.

"Automotive parts, for instance, and the cold-working tools used to shape them, are expected to last for increasingly longer. For this reason, they are made out of extremely hard, high-strength materials, but this also means that they are more difficult to machine.

It is a major challenge for the European tooling and mould-making industry, because the parts have to be manufactured to a high standard of quality, without driving up costs,“ says Kristian Amtz, of the Fraunhofer Institute for Production Technology, in Aaachen.

In current practice, the process chain in tooling and mould-making involves milling, hardening, surface treatment by spark erosion and, often, final finishing by hand. In the EU’s HardPrecision project, the Fraunhofer specialists teamed up with ten European partners to develop an improved machine for high-precision, five-axis hard milling.

The industrial partners included component manufacturers, such as Hemtech Machine Tools, of the Netherlands, System 3R AB, of Sweden, and Walter Dittel, of Germany, and also end-users, such as Hirschvogle Umformtechnik, Moldit SA, of Portugal, and Norma, of the Netherlands.

On the scientific side, the Fraunhofer researchers were supported by the Research Centre for Manufacturing Technology, at the University of Prague, in the Czech Republic.

"One of the chief objectives was to reduce the process cycle for the tools,“ Amtz explains.

To do so, the researchers undertook a detailed study of the whole milling process – starting with Cam and NC technologies, and continuing with machine tools and tool coatings through to process monitoring.

"In HardPrecision, we took a broad view of the whole process chain. Our partners told us which materials they intended to work with in future. These comprised mainly conventional and powder-metallurgical cold-work and high-speed steels,“ Amtz relates.

To optimise the entire seqsuence of proces steps, the scientists defined a number of separate work packages. This meant, for instance, having to reconfigure the process technology, given that one of the key questions addressed by the project was: What is the most cost-effective way of obtaining the necessary tool geometry?

"The modern trend in manufacturing is to use a single forming process to produce increasingly complex shapes, for instance, highly loaded steering system componets. As a conequence, toolmakers are also having to deal with highly complex shapes. This, in turn, increases the complexity of the necessary machining tools and the design of the individual milling paths," says Amtz.

The solution found by the researchers was to adapt the machine to the new requirements by developing an optimised prototype with all-hydrostatic bearings. The improvements they implemented included the integration of lightweight structures and optimising the coordination between the machine and the control system.