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2 OREGON MANUFACTURERS SUMMITT How to stay ahead in a competitive world with MILLTURN Technology Speaker: Regional Manager, WFL-USA, Josh Yarrington Monday, March 13 th, 2017 Page 2

A PIONEER IN COMPLETE MACHINING 1948: Beginning of machine tool production VOEST-ALPINE 1982: Design of

Crankshafts 1990 MILESTONE: Rockwell International, MILLTURN with auto loading, auto tool change 120

MILLTURN 2011: M80 MILLTURN 2009: M150 MILLTURN 2005: The M35 MILLTURN 2002: M40 MILLTURN 1998:

3 A PIONEER IN COMPLETE MACHINING 1948: Beginning of machine tool production VOEST-ALPINE 1982: Design of the world s first complete machining center MILLTURN WNC 1986: First MILLTURN sold to USA GM Detroit, R&D Crankshafts 1990 MILESTONE: Rockwell International, MILLTURN with auto loading, auto tool change 120 tools, auto chuck change, auto probing 2016: M200 MILLTURN / 6000mm 2015: Integrated Laser Unit 1992: M30 MILLTURN 2011: M80 MILLTURN 2009: M150 MILLTURN 2005: The M35 MILLTURN 2002: M40 MILLTURN 1998: Presentation of the M65, following the M100, M60 and M : Partial privatization of VOEST-ALPINE WFL founded Page 3

4 MILLTURN ADVANTAGES Page 4

5 COMPLETE MACHINING CONCEPT Work preparation Several machines one product Programming Turning Boring Milling Production Boring Turning Rejects Milling Measuring Page 5

6 COMPLETE MACHINING CONCEPT MILLTURN complete machining Turning, boring, milling, measuring Turning, boring, milling, measuring Page 6

7 Costs per part ($) MACHINING COSTS ACCORDING TO LOT SIZE MILLTURN Conventional machines > parts? Number of parts Page 7

8 WFL IN THE LEAD MILLTURN complete machining results in highest PRODUCTIVITY highest QUALITY highest FLEXIBILITY highest UTILIZATION RATE short LEAD TIME Extremely precise and solid Short set-up times One operator for several machines A minimum of set-ups machine design Less clamping devices and special Less staff for internal processes Short idle periods In-process measuring tools No more organizational standstills Short handling times Extremely close tolerances Efficient change of the production High machine utilization Less internal transport A minimum of clampings process No intermediate raw part storages (no clamping errors) Efficient technology optimization Page 8

9 AXIS SCHEME Machine configuration with tailstock and steady rest Machine configuration with turret and counter spindle Page 9

10 MACHINE CONCEPTS Page 10

11 TRAVELLING COLUMN CONCEPT Large distances between tool and guideways in this design VIBRATIONS Changing distance between tool tip and Z- and Y-axis guideways at varying diameters ACCURACY / VIBRATIONS Main cutting force runs parallel to the Z-guideways, therefore high torque development VIBRATIONS Narrow tailstock and steady rest guideways caused by forced, low machine bed height (X-slide stroke is below turning center) high static triangle VIBRATIONS / ACCURACY Page 11

12 CENTER OF GRAVITY CONCEPT Machine bed execution with a neck in the middle ACCURACY Left headstock with open frame on front side ACCURACY Cavity for the bottom turret X-axis stroke, jamming chips Y-axis guideways adjusted by a wedge strip Stick slip effect by conventional guideways Heat sensitive because of B-motor in column Page 12

13 CROSS SLIDE CONCEPT main cutting force free chip fall into chip conveyor static triangle upper tooling system static triangle tailstock, steady rest and lower tooling system Page 13

14 CROSS SLIDE CONCEPT WFL Cross Slide Concept allows shortest distances to the bed guideways (see ill. 1) HIGH STABILITY minimum change of the distances at diameter changes ACCURACY minimum change of the occurring torque at diameter changes ACCURACY main cutting force in turning mode led straight into the bed guide ways (see ill. 2) LESS VIBRATIONS from M60 upwards clamping of the Y-axis slide in turning mode to the column to protect the Y-axis spindle and bearing from the main cutting forces (particularly at interrupted cuts) SERVICE COSTS SAVING Page 14

15 MILLING SPINDLE CONCEPT Preloaded double slant ball bearings in the front of the spindle and single slant ball bearings in the rear guarantee highest rigidity and high precision in concentricity and run out (even at cold start no warm up required) AVAILIBILITY Thermal separation of motor and spindle, motor spindles reach over 120 C High torque for machining of difficult materials Oil mist lubrication for bevel gear and bearings Cooling of the entire B-axis head provides minimum temperature increase of the spindle and an optimal temperature stabilization Page 15

16 MILLING SPINDLE CONCEPT Hirth coupling at the spindle end and a form closed connection in the front result in an ideal stability for using long turning tools Double sided spindle clamping saves the spindle bearings from damage due to collisions and heavy tool breakage In case necessary the exchange of the spindle is simple and relatively inexpensive (with motor spindles in most cases the entire spindle unit has to be exchanged) Page 16

17 CONVENTIONAL MOTOR SPINDLE Spindle clamping Bearing situation of a motor spindle respectively of conventional spindles Temperature increase in spindle Page 17

18 ADVANTAGE: GEAR DRIVEN SPINDLE Oil mist lubrication Cooling B-axis head Page 18

19 SOFTWARE SOLUTIONS Page 19

SOFTWARE SOLUTIONS Millturn PRO CrashGuard Studio CrashGuard

Studio Efficient processing of NC programs 3D simulation

programs Workpiece geometry storable and reusable after every

Prevents collisions of machine components in the manual and

20 SOFTWARE SOLUTIONS Millturn PRO CrashGuard Studio CrashGuard Graphically interactive program editor Part of CrashGuard Studio Efficient processing of NC programs 3D simulation software on the PC For verification and optimization of NC programs Workpiece geometry storable and reusable after every simulated clamping Software for real-time collision prevention Prevents collisions of machine components in the manual and automatic mode Integrated into the interpolator of the machine control (NC core) Page 20

WFL CYCLES (extract) Gear cutting cycles Crankshaft cycles

(Gear hobbing) Flanx-Spline (Gear shaping) Flanx-LM (milling

Cranx-Advanced Cranx-Plus Deburring of centric bores and

inlets Calibrating probe Two-point difference check

21 WFL CYCLES (extract) Gear cutting cycles Crankshaft cycles Cycles for deburring and rounding Measuring cycles Flanx-Hob (Gear hobbing) Flanx-Spline (Gear shaping) Flanx-LM (milling of large gears as single components) Cranx-Basic Cranx-Advanced Cranx-Plus Deburring of centric bores and slots Deburring of inclined bores Rounding of oil hole inlets Calibrating probe Two-point difference check Calculation cycle Entry in measuring point compensation memory Entry in zero offset Page 21

22 TECHNOLOGIES Page 22

23 TECHNOLOGIES Turning Drilling Milling Gear cutting Milling Gear hobbing Measuring Boring bar ID machining Contour boring bar ID machining Page 23

TECHNOLOGY GRINDING Highlights: Automatic exchangeable attachment for grinding (for OD and ID) Corundum and CBN (cubic boron nitride) grinding wheels Step-by-step grinding to final diameter Including

24 TECHNOLOGY GRINDING Highlights: Automatic exchangeable attachment for grinding (for OD and ID) Corundum and CBN (cubic boron nitride) grinding wheels Step-by-step grinding to final diameter Including manual diameter measuring and semi-automatic roundness and run-out measuring Machine optimised for grinding operations (pumps, filter system, chip conveyor, seals, scrappers,...) Advantages: For highest surface requirements For close tolerances using repeatedly measuring, correcting and grinding Grinding and dressing machining cycles (automatic dressing of grinding wheel inside working area) Page 24

25 Cutting depth 2 Cutting depth 1 TECHNOLOGY UHPC Highlights: Ultra-High Pressure Coolant (UHPC) for turning operations Coolant pressure up to 350 bar (5076 psi) Increased process reliability due to controlled chip breaking Prolonged cutting edge life of tool cutting material Higher cutting parameters (shorter machining time) 10 bar 80 bar 300 bar Page 25

TECHNOLOGY INTEGRATED LASER UNIT Highlights: Integrated laser unit for the application of laser technologies inside the working area (hardening, welding, cladding) Laser head at

26 TECHNOLOGY INTEGRATED LASER UNIT Highlights: Integrated laser unit for the application of laser technologies inside the working area (hardening, welding, cladding) Laser head at turning-boring-milling unit Automatic exchangeable laser optics for laser head Laser supply unit: Diode laser generator (high-performance laser, up to 40 kw) Field bus interface Dust protection system and anti-humidity device Water/air cooler, optics cooler Machine modification: Media supply inside working area Deposit station for laser head Protection windows Interface and software for laser Powder feeder, inert gas Page 26

TECHNOLOGY LASER HARDENING Highlights: Diode laser with highest efficiency Laser head with high-performance hardening optics at the turning-boring-milling unit Automatic exchangeable hardening optics

27 TECHNOLOGY LASER HARDENING Highlights: Diode laser with highest efficiency Laser head with high-performance hardening optics at the turning-boring-milling unit Automatic exchangeable hardening optics Ratio pyrometer for temperature measuring and power control Visible adjusting laser included Application of laser hardening: Gear tooth flanks Bearing areas Contact areas Advantages of laser hardening in a MILLTURN: Hardening process directly inside machine High hardening depths (depending on material) Minimum distortion due to local heating Fast processing Page 27

TECHNOLOGY LASER CLADDING Highlights: Diode laser with highest efficiency Laser head with high-performance cladding optics at the turningboring-milling unit With coaxial powder nozzle (powder feed

28 TECHNOLOGY LASER CLADDING Highlights: Diode laser with highest efficiency Laser head with high-performance cladding optics at the turningboring-milling unit With coaxial powder nozzle (powder feed via inert gas) Automatic exchangeable cladding optics (including media supply) Application of laser cladding: Building of wear-protection layers Repair of wear areas Wide material spectrum possible Advantages of laser cladding in a MILLTURN: High build-up rate Minimum distortion Highest utilization of powder User-defined layer thickness (multi-layer) Page 28

Stress [MPa] TECHNOLOGY MACHINE HAMMER PEENING Highlights: Machine hammer peening with directly accommodated pneumatic tool Automatic exchangeable tool Patented WFL solution for multi-tasking

surface roughness Creation of inherent compressive stress Increase in surface hardness Test results of machine hammer peening: Example: Inherent compressive stress Critical workpiece area

29 Stress [MPa] TECHNOLOGY MACHINE HAMMER PEENING Highlights: Machine hammer peening with directly accommodated pneumatic tool Automatic exchangeable tool Patented WFL solution for multi-tasking machines Application of machine hammer peening: For critical workpiece areas Surface improvement after machining operations (milling, turning) Advantages of machine hammer peening: Improved surface roughness Creation of inherent compressive stress Increase in surface hardness Test results of machine hammer peening: Example: Inherent compressive stress Critical workpiece area Example: Surface roughness Milled surface: After machine Ra=1.185 hammer peening: Ra=0.186 Mean roughness index Ra [μm] Example turning Example milling Before After Page 29 Depth [µm]

TECHNOLOGY B-AXIS TURNING First and intermediate stage machining: Last stage machining: - Constant DOC causes notch wear - High risk of tool breakage + Ramping solves wear problem - Sufficient stock

30 TECHNOLOGY B-AXIS TURNING First and intermediate stage machining: Last stage machining: - Constant DOC causes notch wear - High risk of tool breakage + Ramping solves wear problem - Sufficient stock required - Large radius in corner required - More cuts required + B-axis turning solves problem + Even with little stock + Just one cut Contact point of insert without B-axis turning: - Just one single spot - Poor tool life - Higher risk of scrap Contact zone of insert with B-axis turning: + Wide area + Increased tool life + Less risk + Reduced tool costs Page 30

31 TECHNOLOGY CONTOUR BORING Challenges of contour boring: Reliable machining process of complex geometries inside workpiece Centric and eccentric contour boring Radial feed out of insert carriers on tool head Contour boring or special machining transverse/inclined to workpiece axis Chip removal Page 31

TECHNOLOGY CONTOUR BORING 4 1 1 2 3 Facing head Rotating Radial feed out via U-axis Page 32 1 CNC special contour boring bar Rotating Radial feed out via U-axis Seat pocket tool 2 3 4

32 TECHNOLOGY CONTOUR BORING Facing head Rotating Radial feed out via U-axis Page 32 1 CNC special contour boring bar Rotating Radial feed out via U-axis Seat pocket tool CNC special contour boring bar Non-rotating Radial feed out via milling spindle Bottle boring tool Angular head Driven tool (via milling spindle) For ID machining (milling, deburring, )

33 TECHNOLOGY BOTTLE BORING METHODS Methods for bottle boring: Sulfur machining process (early method) Conventional bottle boring process Bottle boring process with self-supporting paddles Conventional bottle boring process: Rough- and finish-machining in segments, several contour steps remain Bottle boring process with self-supporting paddles: Rough machining in segments, leaving stock for finish machining Bottle boring process with self-supporting paddles: Finish machining in continuous cut no steps in final contour Page 33

TECHNOLOGY BOTTLE BORING METHODS Bottle boring tool with self-supporting paddles: Bottle boring tool for turning of centric ID contours (non-rotating tool) CNC-controlled feed out of turning insert

(coolant flow through tool) Automatic docking of coolant supply to bottle boring tool Automatic tool change expanding insert chamber bore tool head expanding paddles special actuation tube coolant

34 TECHNOLOGY BOTTLE BORING METHODS Bottle boring tool with self-supporting paddles: Bottle boring tool for turning of centric ID contours (non-rotating tool) CNC-controlled feed out of turning insert on tool head Hydraulically actuated feed out of paddles on tool head Rigid, fixed pilot for rough machining Hydraulically actuated paddles for finish machining Coolant supply of up to 800 l/min (coolant flow through tool) Automatic docking of coolant supply to bottle boring tool Automatic tool change expanding insert chamber bore tool head expanding paddles special actuation tube coolant outlets coolant infeed paddle actuation device hydraulic infeeds WFL drive box Advantages: No steps in the ID contour after finish machining compared to conventional bottle boring (due to self-supporting paddles) Re-machining of finished chamber is possible Expanding insert on tool head Expanding paddles on tool head Page 34

TECHNOLOGY ID TURNING WFL advantages at ID turning with Sandvik Silent Tools Use of long vibration free boring bars Reliable and hands free machining High chip removal rate at rough machining Highest

35 TECHNOLOGY ID TURNING WFL advantages at ID turning with Sandvik Silent Tools Use of long vibration free boring bars Reliable and hands free machining High chip removal rate at rough machining Highest surface quality and accuracy at finish machining Coolant through the tool, high pressure up to 2100 psi for long tool life, smaller chips Use of boring bar in angular B-axis position, holding torque up to lbsft ID turning Page 35

36 TECHNOLOGY ID TURNING Directly accommodated Max. Length = 10 x diameter (up to 900 mm) 1 Accommodated through prismatic tool accommodation Max. Length = 16 x diameter WFL system boring bar Accommodated through prismatic tool accommodation 3 Boring bar slide Extendible boring bar Length of boring bar up to 3 m Page 36

TECHNOLOGY ID TURNING: CARRIER SYSTEMS Standard

standard tool accommodation Automatic tool change

37 TECHNOLOGY ID TURNING: CARRIER SYSTEMS Standard tools (HSK, Capto, ) on boring bars WFL system boring bar (L=550 mm) with standard tool accommodation Boring bar on boring bar slide with standard tool accommodation Automatic tool change of cutting heads on the boring bar from standard tool magazine Page 37

PRODUCT AND TECHNOLOGY SUPPORT Are you facing a seemingly

one of our technology experts to develop an efficient solution to

38 PRODUCT AND TECHNOLOGY SUPPORT Are you facing a seemingly insurmountable challenge in terms of production technology or other technology? We can offer you our expertise in the form of on-site support from one of our technology experts to develop an efficient solution to your problem. Production & technology support Feasibility studies Production support Workpiece and processing time optimisation Page 38

39 PRODUCT AND TECHNOLOGY SUPPORT Feasibility studies You want to enhance your range of produced parts, but have unanswered questions regarding the feasibility of this? If you have questions about the feasibility of a new workpiece and any necessary machine modifications, consult our experienced technicians. Our decades of experience will help you save time and money. Production support For specific production support, our experienced technology specialists will help you in all aspects of optimising your production workflow over a defined period. Support may also be provided on-site with your MILLTURN. This is particularly recommended when starting new complete processing or when changing your range of produced parts. Production support includes, for example, detailed tool development, programmer support or the introduction of new workpieces. Workpiece and processing time optimisation Not happy with your current production results? A technician will be available onsite to ensure optimal processing times, production workflows (throughput times) and optimal workpiece quality. The objective is to achieve a perfect production solution. Page 39

40 WORKING TOGETHER WFL Millturn working with clients and tech centers Oregon Manufacturing Innovation Center (OMIC) WFL M80 Millturn Testing and machining platform University / Students Corporate partners Page 40

41 COST EFFECTIVENESS Page 41

42 EFFICIENCY EXAMPLE 105 JET inspection, ENGINE run out check SHAFT 0,25 existing process operation description set up time run time 5 issue material 0,50 10 face and turn steady band flange end 1,00 0,25 15 face and turn steady band small end 1,00 0,50 20 wash, clean, dry 0,25 25 paint for sulphur 0,25 30 fill part with sulphur 0,25 35 first roughing cut ID 2,00 0,75 40 wash, clean, dry 0,25 45 paint for sulphur 0,25 50 fill part with sulphur 0,25 55 second roughing cut ID 1,50 0,75 60 wash, clean, dry 0,25 65 paint for sulphur 0,25 70 fill part with sulphur 0,25 75 third roughing cut ID 1,50 0,75 80 wash, clean, dry 0,25 85 paint for sulphur 0,25 90 fill part with sulphur 0,25 95 finish cut ID 1,50 1, wash, clean, dry 0, inspection, run out check 0, machine tool bands concentric with ID 0,50 1, finsh ID profile small end 2,00 1, finish OD profile 3,00 4, finish OD & ID profile flange end 2,50 2, finish flange holes at end face 4,00 5, deep hole drill 6 angled holes 1,00 1, deburr 2, polish and blend ID 1, wash, clean, dry 0, inspection 0, pack an shipo to heat treat 0, check hardness 0, finish machine flange 0,50 0, finish machine flange holes 3,00 3, finish countersink 6 holes 0,50 0, machine slots and rough spline 3,00 3, grind OD at small end 1,00 0, grind OD at flange end 1,00 0, grind spline 1,50 1, grind ID small end 0,50 0,25 Page wash, clean, dry 0,25 85 paint for sulphur 0,25 90 fill part with sulphur 0,25 95 finish cut ID 1,50 1, wash, clean, dry 0, machine tool bands concentric with ID 0,50 1, finsh ID profile small end 2,00 1, finish OD profile 3,00 4, finish OD & ID profile flange end 2,50 2, finish flange holes at end face 4,00 5, deep hole drill 6 angled holes 1,00 1, deburr 2, polish and blend ID 1, wash, clean, dry 0, inspection 0, pack an shipo to heat treat 0, check hardness 0, finish machine flange 0,50 0, finish machine flange holes 3,00 3, finish countersink 6 holes 0,50 0, machine slots and rough spline 3,00 3, grind OD at small end 1,00 0, grind OD at flange end 1,00 0, grind spline 1,50 1, grind ID small end 0,50 0, grind ID flange end 0,50 0, mark part 0,25 0, turn thread M104x1,2 2,00 0, turn thread M90x1,5 2,00 1, machine slots at small end 2,00 1, deburr 2, check unbalance 1,00 2, remove material to correct unbalance 0,50 1, wash, clean, dry 0, % inspection 1, pack and ship part for shot peen 0, shot peen 270 inspect per standard 0, pack and ship to assy 0,25

43 EFFICIENCY EXAMPLE JET ENGINE SHAFT existing process operation set up time run time 5 0, , , , , , , , , , ,5 0, , , , ,5 0, , , , ,5 1, , , ,5 1, , , ,5 2, , , , , , , , , ,5 0, , ,5 0, , ,00 0, ,00 0, ,50 1,00 Page 43 Millturn open process operation set up time run time Millturn 5 open 0,50 process operation 20 set up 0,3time run 4,50 time ,50 0,3 1, ,3 4, ,3 1, ,3 5, ,3 5, ,3 3, ,3 3, , , ,25 1, , , ,3 3,50 0, , ,3 3, ,3 2, ,3 2, ,50 0, ,50 0, , , ,5 1, , , ,5 1, , , ,5 2, , , , , , , , , ,5 0, , ,5 0, , ,00 0, ,00 0, ,50 1, ,50 0, ,50 0, ,25 0, , , , , ,00 2, ,50 1, , , , , , ,3 5, ,3 3, , , , , , ,3 3, ,3 2, ,50 0, ,50 0, , ,00 2, ,50 1, , , , , ,25

44 EFFICIENCY EXAMPLE JET ENGINE SHAFT total operations machining operations manual operations grinding operations set-up time machining time manual time total time Page 44

45 EFFICIENCY EXAMPLE VALVE BLOCK Production Several machines for single product MILLTURN complete machining Turning, boring, milling, measuring Boring Turning Rejects Milling Measuring Page 45

COST EFFECTIVENESS Turn-key solutions with each

and tool selection Programming/simulation Production

process parameters Training (programmer, operator,

46 COST EFFECTIVENESS Turn-key solutions with each MILLTURN: Machining sequence Time study Tool layout and tool selection Programming/simulation Production of component Probing and closed loop correction of process parameters Training (programmer, operator, service) Production support for start-up period or new products Page 46

47 APPLICATIONS Page 47

48 ENERGY OIL AND GAS AEROSPACE APPLICATIONS Page 48

49 HYDRAULICS & PNEUMATICS CRANKSHAFTS ENGINEERING APPLICATIONS Page 49

50 PLASTICS AUTOMOTIVE PRINT APPLICATIONS Page 50

KTM-16/20 TECHNICAL DATA

KTM-16/20 TECHNICAL DATA TECHNICAL DATA Table Diameter : 1,600mm Max. Turning Diameter : 2,000mm Max. Turning Height : 1,750mm Table Indexing Degree : 0.001mm CNC Controller : FANUC 18i-TB ** Bed The bed has symmetrical structure