Tag Archives: workpiece

Allgemein

Gentle finishing of extremely hard surfaces

Overlapping rotational work piece movement is the basis for even, all-around surface finishes

Gentle finishing of extremely hard surfaces

The spindles allow the processing of batches of up to 18 work pieces. For this photo different work

At this year“s IMTS Walther Trowal is introducing the new drag finisher M-TMD 6M for treating high-value components that require a first-class surface quality. The new drag machines will place a mirror polish on the hardest materials – even on ceramic components. With these machines the costs for polishing can be reduced to a fraction of the costs for manual surface grinding and polishing. But even more important: They ensure absolutely repeatable, high-quality finishing results within an extremely narrow tolerance band.

Walther Trowal developed these new machines specifically for treating high-value components requiring extremely careful handling for the complete finishing process. For example, they are utilized for finishing the surface of turbine blades, impellers for turbo chargers, precision components for pumps and compressors as well as for orthopedic implants.

The new drag machines of the M-series have a carousel with multiple rotating workstations. In turn each workstation is equipped with spindle heads containing several spindle drives onto which the work pieces are attached with special fixtures. In addition, these machines also contain a stationary work bowl filled with grinding or polishing media. As the work pieces are „dragged“ through the stationary media mass, the simultaneous rotational work piece movement by carousel, workstations and spindles creates different overlapping patterns, which ensure an even and intensive coverage of the complete work piece surface.

Christoph Cruse, director of sales at Walther Trowal, foresees a big demand for these machines at some of his customers who produce delicate, high-value components. He explains: „With our new machines we want to assist the manufacturers of work pieces that must receive the best possible surface finish, and where even the slightest surface flaw or scratch might cause them to be scrapped. Furthermore, we target parts where deviations from the dimensional specifications of a few thousands mm can be a detrimental. The M-TMD drag finishers with their perfect surface coverage open brand-new possibilities for finishing such work pieces.“

Die M-TMD 4 drag finisher is equipped with four work stations and can process 12 parts in one single batch; the M-TMD 6 – with six work stations allows batch sizes of up to 18 pieces.

At this year“s IMTS Walther Trowal also displays a range of mass finishing equipment including rotary vibrators, the MV multi vib vibrators and a high-energy centrifugal disk finishing machine.

One drag finishing success story:
Polishing of the extremely wear resistant ceramic coating on orthopedic implants

One example for the successful use of the new drag finishers is a process, specifically developed by Walther Trowal, for polishing of knee femorals made from a chromium-nickel alloy, which are covered with a ceramic coating applied with a special vapor deposit method. To date these parts had to be finished manually in time consuming multiple steps with the risk of high quality fluctuations.

After a pre-grinding step the ceramic coating is polished in the new M-TMD drag finisher with a polishing medium specifically developed for this application. The result: Although the ceramic coating is extremely hard, the drag finisher produces a very smooth, shiny and highly wear resistant finish from the initially rough surface condition. The new coating extends the fatigue life of the implants from to date about 20 up to 30 years!

In developing this process Walther Trowal took an entirely new approach. Instead of using relatively soft polishing materials the company is adding an extremely hard substance to the polishing medium, namely diamond powder.

Christoph Cruse explains the advantages of the new process as follows: „Soft materials can be polished relatively easily. But the manual polishing of extremely hard coatings has been extremely difficult, especially because an even surface finish is essential for the functionality of the component. In the case of vapor deposit coating, with a layer thickness of just a few microns, it is essential not to remove too much of the coating material from the part surface. With the M-TMD drag finishing technology and the new polishing media we have resolved this difficulty: The finish is absolutely even on the entire surface area of the implants.“

Walther Trowal at the IMTS 2018
September 10 – 15, 2018, Chicago, IL, USA
North Building, Level 3, Booth 236609

The technical details

In standard drag finishers the work pieces are directly mounted to the workstations and „dragged“ through the stationary media bed producing an extremely high processing intensity. This method is more than adequate for most work pieces and produces excellent finishing results.

The new M-TMD systems allow one additional rotational movement, namely that of the spindles mounted to the workstations. The multi-spindle heads on the workstations can be also be angled allowing the adaptation of the media coverage on the work piece surface to different work piece geometries.

All process steps, from cut-down, over surface smoothing to the final polishing, take place in the same machine, without having to remove the work pieces from the spindles.

The new drag finishers are suitable for dry as well as wet processing. In wet processes for cut-down, surface smoothing and, occasionally, for polishing, special finishing compounds are used. For the targeted edge radiusing within a tolerance range of a few thousands mm, like for example for tungsten carbide drill bits or milling tools, dry grinding media are utilized. Dry processing is also used for high gloss polishing with special pastes and polishing media.

Facts about Walther Trowal

For 85 years Walther Trowal has been a pioneer and market leader in various surface treatment technologies. The company offers modular and custom engineered solutions for a wide range of surface treatment problems.

Initially only making vibratory finishing equipment, over the years Walther Trowal has continuously broadened its product range and today offers a wide portfolio of equipment and services for improving all kinds of surfaces, e.g. mass finishing, part cleaning, shot blasting and drying of a wide spectrum of work pieces, last but not least, the coating of mass produced small parts.

Walther Trowal offers not only various types of equipment but complete surface treatment systems: By linking the various equipment modules and automating the complete process, we are able to precisely adapt our process technologies to the technical requirements of our customers. This also includes various types of peripheral equipment and process water cleaning and recycling systems. Of course, we also offer comprehensive pre- and after-sale service like sample processing in one of our demonstration labs and global repair and maintenance service.

Walther Trowal serves many customers in many industries around the world. For example, in the automotive and aerospace industry, medical engineering and wind power generation.

Walther Trowal in America

The recently opened „Tech & Training Centre“ of the Walther Trowal LLC in Grand Rapids, Michigan has, among other equipment, a test lab for the „Trowal Coating“ technology allowing interested customers informing themselves about the most suitable coating method for their work pieces.

Trowal has also extended its presence in Latin America by recently opening a sales office in Mexico, which is, of course, using the knowhow and resources of the Grand Rapids facility.

Company-Contact
Walther Trowal GmbH & Co.KG
Georg Harnau
Rheinische Str. 35-37
42781 Haan, Germany
Phone: +49 2129.571-0
Fax: +49 2129.571-225
E-Mail: info@walther-trowal.de
Url: http://www.walther-trowal.de

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Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen, Germany
Phone: +49.241.89468-24
Fax: +49.241.89468-44
E-Mail: reinhardt@vip-kommunikation.de
Url: http://www.vip-kommunikation.de

Allgemein

Two-point measurement reduces non-productive times

Quality control integrated into the production process makes time-consuming manual measurements superfluous.

Two-point measurement reduces non-productive times

The two opposing probes detect the diameter of the rotating part with high precision.

At EMO, GEORG will be presenting the integrated two-point measurement system for horizontal machining centers of its ultraturn MC series. These machines process workpieces weighing 10 tons and more and with diameters of 1,000 mm upwards. No other manufacturer in the world combines machining and measuring in a single unit of such size.

With the two-point measurement, GEORG has for the first time integrated quality control directly into the manufacturing process: ultraturn MC is worldwide the first series of machining centers for large turned parts in which the diameters of the workpiece are not measured with just one probe, as has been common practice so far. Instead, GEORG uses a travelling two-point measuring system attached to the frame, which automatically measures the workpieces directly in the machine with two opposing probes. This technique ensures high precision and high reproducibility.

ultraturn MC machines are used among other things for the complete machining of turbine and generator rotors as well as crankshafts.

While a measuring team would need several hours to manually measure the diameters or the axial run-out of workpieces on the machine, the measurement with the integrated two-point system is completed after just a few minutes. By integrating this function into the machine, GEORG is a worldwide pioneer.

The two-point measuring system which GEORG is demonstrating at the trade fair on a machining center of the ultraturn MC series is also applicable to the company“s classic lathe series for roll and turbine rotor machining. Furthermore the system can be retrofitted to existing lathes – to those made by GEORG or other manufacturers. Just recently, GEORG has successfully retrofitted a two-point measuring system to a lathe in operation for several years at Siemens in Mülheim/Germany.

Jan Ebener, sales manager for machine tools at GEORG, explains the great economic benefits of the integrated measurement: „Experience gained from the operation of the first systems using our two-point measurement technique shows that not only the dimensional precision of the workpieces is increased but that also the overall machining times are markedly reduced. This is because the new measurement technique drastically reduces non-productive times.“

Like the large machines of the ultraturn MC type, designed to machine parts of up to 250 t weight, also the smaller ones are based on the classic GEORG concept: robust cast construction – instead of the frequently common welded construction – and hydrostatically guided axles. The result: high precision in machining, low maintenance and long lifetime.

Heinrich GEORG at EMO 2017 in Hanover, Germany
18 – 23 September 2017
Hall 26, stand B12

About Heinrich Georg Maschinenfabrik

GEORG is a business partner worldwide well-reputed for reliable and powerful high-tech mechanical engineering solutions. The company“s cutting-edge finishing lines and machine tools as well as production lines, machines and equipment for the transformer industry are in operation in numerous renowned companies around the world.

The family business, now in its third generation, supplies a wide range of products to most diverse markets and customer segments. The divisions GEORG finishing lines, GEORG transformer lines and GEORG machine tools are supported by the company“s own manufacturing facilities at the headquarters in Kreuztal, Germany. The GEORG corporate services division completes the portfolio with a wide range of value adding services. The company maintains a worldwide network of sales and service branches to be within easy reach for its international customers.

GEORG machine tools

The GEORG machine tools division develops and manufactures advanced value-adding machine tools for turning, drilling, milling and grinding in close cooperation with its customers and optimally tailored to their individual requirements.

Company-Contact
Heinrich Georg GmbH Maschinenfabrik
Thomas Kleb
Langenauer Straße 12
57223 Kreuztal / Germany
Phone: +49.2732.779-539
Fax: +49.2732.779-39171
E-Mail: thomas.kleb@georg.com
Url: http://www.georg.com

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VIP-Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen / Germany
Phone: +49.241.89468-24
Fax: +49.241.89468-44
E-Mail: reinhardt@vip-kommunikation.de
Url: http://www.vip-kommunikation.de

Allgemein

Heinrich Georg Maschinenfabrik: New machining centers save 40 percent of machining time

3D virtual tour of the new machine at „GEORG-Cinema“ at our booth.

Heinrich Georg Maschinenfabrik: New machining centers save 40 percent of machining time

The horizontal machining center Siemens AG machined workpieces with a weight up to 180 tons

At AMB GEORG presents the horizontal machining centers of the series ultraturn MC, which processes workpieces up to 250 tons and 4,000 mm diameter. With the successful commissioning of the first machine at Siemens AG in Berlin and installation of two additional machines GEORG is the world’s only manufacturer of machining centers of this size which implements the concept of working and measuring on the same machine.

At this year’s AMB GEORG presents the new horizontal machining centers of the series ultraturn MC in virtual reality: In the „GEORG-Cinema“ visitors will be equipped with 3D glasses which allow them to experience a machine longitude up to 30 m within one`s reach.

GEORG has developed the new machining centers for complete machining of complex workpieces up to 250 t weight and 4,000 mm diameter. They are used among others for the production of turbine and generator rotors as well as for compressors.

Recently, Siemens AG has granted acceptance for the new machining center at the Berlin plant. It is the world’s only machining center for workpieces with a weight up to 180 t where machining and measuring is implemented in the same machine. It processes workpieces with a diameter of up to 4,000 mm and a workpiece length up to 10,000 mm. Siemens already owns about 20 GEORG machines worldwide.

The experience gained from the operation of the installation of the new series shows that in addition to the significant increase in the workpiece precision it results in dramatic time savings in the machining of approximately 40 percent partly because it shortens non-productive times drastically. A machine of the new generation replaces several others in manufacturing who have previously bound not only personnel for manufacturing and maintenance, but also space and capital. It also simplifies the production planning significantly, since only one machining center performs all operations.

Georg has already delivered two other ultraturn MC machining centers which will soon go into operation. The machine GEORG currently assembled at Doosan Skoda in Pilsen / Czech Republic is designed for a workpiece weight up to 140 t with a diameter of up to 3,500 mm and a maximum workpiece length of 12,000 mm.

Jan Ebener, head of sales at GEORG´s machine tool division explains why his customer has opted for the ultraturn MC: „We are the only supplier worldwide who combined turning milling and grinding on one machine for workpieces with truly gigantic dimensions in a conclusively concept. And as in the order from Siemens only we could realize the workpiece measurement on the same machine. “

GEORG currently mounted another ultraturn MC at Iskra Turbogaz in Perm / Russia. In future workpieces with a weight up to 25 tons a diameter up to 2,500 mm and a workpiece length of up to 7,000 mm will be manufactured. They required, among others for compressors and pumps for the oil and gas extraction industry. For internal machining of these components the machine features scores like the combined turning and milling as well as the editing of complex contours which does not run parallel to the workpiece central axis. GEORG delivered all three machines according to customer requirements as complete solutions including peripheral systems.

Background: Measurement without setup changing

During machining of workpieces of that magnitude in different machines were previously set four to eight hours per machine for the change between the processing steps which has often accumulated weeks and months for complex workpieces.

The novelty is that GEORG has now integrated the quality control into the production. The ultraturn MC is the world’s first machining center which uses for the diameter measuring not only a single touch probe – as always usual. Placed at the milling tower the moveable two-point workpiece measurement system works – like a big micrometer screw – with two probes and measures the workpieces directly in the machine with high precision.

While the measuring diameters or axial run-out for workpieces of up to 2,000 mm with measuring machines may take several hours to complete the integrated system requires only a few minutes. With this feature Georg is a pioneer worldwide. In addition, the measurement is automatic and no employees of other departments must be called in to help.

Heinrich Georg at AMB 2016 in Stuttgart
13th until 17th of September 2016:
Hall 9 / booth D51

www.georg.com

Firmenkontakt
Heinrich Georg GmbH Maschinenfabrik
Jan Ebener
Langenauer Straße 12
57223 Kreuztal / Germany
+49. 2732 779-306
+49. 2732 779-316
wzm@georg.com
www.georg.com

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen / Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Maschinenbau

Heinrich Georg Maschinenfabrik delivers the fourth Roll Lathe to Trinec

Rough and Finish Machining of Profile Rolls in the Steel Industry

Heinrich Georg Maschinenfabrik delivers the fourth Roll Lathe to Trinec

Already in use in Trinec: A GEORG Roll Lathe Type ultraturn 1500 R for profile rolls.

Last December, Heinrich Georg GmbH Maschinenfabrik received an order for the delivery of a roll lathe for up to 10 t of workpiece weight from Czech company Strojirny a Stavby Trinec, a.s. This is already the fourth machine ordered in Kreuztal by the subsidiary of Trinecke zelezárny a.s. since 1996.

The new Roll Lathe Type GEORG ultraturn 900 R will be used for new machining and finishing of profile rolls, by means of which Trinecke zelezárny mainly produces round profiles, flat sections, angle profiles as well as reinforcing steel for the construction industry.

The machine is designed for rolls with a diameter of up to 900 mm and a weight of up to 10 t and a center width of 2.500 mm. The tool holder in slide design with one tool slide ensures a safe transmission of highest cutting forces.

Already in 1996 and 2003 GEORG delivered two machines for workpiece weights of up to 40 t, in 2004 another machine for rolls up to 10 t. The new machine completes the roll workshop equipment, having four GEORG machines in operation in the future. The production capacity expansion makes this investment necessary. All four machines are fully hydrostatic guided, a concept which GEORG generally applies for all its roll lathes. The biggest machines of the ultraturn range can handle workpieces with weights of up to 300 t and more. The machine enables heavy roughing with high cutting parameters as well as finishing with highest demands on accuracies. In this way, the customer additionally saves time for workpieces setup.

In contrast to more simple linear-guided or slide guided machines there are almost no running costs for loss lubrication or guiding elements exchange as it is the case for hydrostatic guided machines. Furthermore, based on the design principle, these machines achieve the same accuracy as new machines, even after heavy use in a roll shop for decades. By receiving this order, Jan Ebener, Head of Sales for GEORG´s Machine Tool Division, believes the concept of hydrostatic guided machines to be proven:

„Besides the quality of our machines, our customers obviously also appreciate their efficiency. Thus, we have succeeded against strong domestic and foreign competitors. Lathes equipped with the hydrostatic and wear-free guideways are more expensive to purchase, but more efficient and economically over the years and decades.“

GEORG will deliver the machine in autumn 2016.

Background:

GEORG- Roll Lathes cost advantages

The extremely robust construction of the GEORG Roll Lathes reflects its advantages after only a few years of operation time: In comparison to lighter or not fully hydrostatic machines, they generate much lower costs for the operating time duration. The lifecycle costs are reduced by high maintainability and low operating costs as well as by using wearfree hydrostatic guideways or high availability of stable and proven components. Due to wide machine beds and overall more stable machine, the maintenance intervals are extended and thus lead to much lower operating costs. Shorter machining times increase the productivity and hence reduce the unit prices.

www.georg.com

Firmenkontakt
Heinrich Georg GmbH Maschinenfabrik
Machine Tool Division
Langenauer Straße 12
57223 Kreuztal / Germany
+49. 2732 779-306
+49. 2732 779-316
wzm@georg.com
www.georg.com

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Dennewartstraße 25-27
52068 Aachen / Germany
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Allgemein

Heinrich Georg Maschinenfabrik reduces manufacturing time of large and complex workpieces by weeks

New Horizontal Machining Center for workpieces of 12 up to 250 tons of weight

Heinrich Georg Maschinenfabrik reduces manufacturing time of large and complex workpieces by weeks

The ultraturn MC is installed deep in the ground

On a customer day, GEORG introduced the new Machining Center „ultraturn MC“ to manufacturing experts. More than 80 specialists of large part manufacturers came to Kreuztal to witness the premier of the new machine, which is able to handle workpieces from 12 up to 250 tons. The ultraturn MC offers plenty of innovations, which combine highest precision during the machining process with optimum productivity and flexibility. For such large-size parts, the machine reduces the manufacturing time by up to 40 per cent. The integrated 2-point-workpiece measuring system as well as the complete machine enclosure set new standards.

GEORG has developed the new Horizontal Machining Center ultraturn MC for complete machining of workpieces with diameters of 1.100 up to 4.000 mm and almost any length. The center width of the system introduced during the customer day is 10.000 mm. The machine will soon be delivered to its German customer, two more Machining Centers have been ordered by companies in Russia and the Czech Republic.

The ultraturn MC is designed for the machining of complex, heavy workpieces, e.g. for heavy forged parts, rolls, turbines, motor and generator shafts as well as for compressors or pumps for the oil and gas industry. Internal machining of components, such as turning-milling machining or processing of complex inside contours, which are not parallel to the workpiece center line is one of the main characteristics.

New in this range: One machine replaces several others

The ultraturn MC saves a lot of production time since the complete machining, e.g. turning, drilling, milling or grinding and also the measuring is carried out on the same machine. There are no more time-consuming transports between different machines necessary so far as well as associated waiting and set-up times.

By implementing different work steps on one machine, the ultraturn MC not only reduces the production time but also the transport risks of the complex and expensive workpieces. The result: significantly increased and ensured quality of the finished workpieces as well as optimized production planning and scheduling.

Highest productivity with short downtimes and set-up times is the main focus of the new concept. All tool changing processes are carried out automatically, which is a novelty for machines of this size. The tools are stored in the so called tool arena and changed via a six-axis robot which is moving together with the machining unit. This results in minimum access and processing times. Also, the attachment heads in the pick-up magazine are changed automatically and within shortest time.

The machine achieves highest precision due to the 2.000 mm wide machine beds, the hydrostatic guideways of all linear axes and backlash-free NC-controlled drives.

GEORG offers the ultraturn MC in several versions with center widths up to 25.000 mm. The machine presented during the customer day has a center width of 10.000 mm. On the carriage side in S1-operation, the center achieves a milling performance of up to 94 kW and a torque of max. 7.000 Nm directly at the spindle. The carriage is equipped with a hydrostatic guided RAM with a cross section of 700 x 550 mm and a travel distance of 1.600 mm.

New: Machining and measuring without reclamping

With the ultraturn MC GEORG includes the quality control in the production process which is new in the area of large parts machining. The ultraturn MC is the first machining center worldwide, which is not only using a single probe. The moving 2-point workpiece measuring system installed at the milling tower acts like a big micrometer gauge with two probes and measures the workpieces directly at the machine with highest precision. While the measuring of large diameters up to 2.000 mm in measuring machines takes several hours, the integrated GEORG system requires only a few minutes.

New: Complete housing

Also the complete machine enclosure with integrated oil mist removal system is new for exceptionally big machining centers: Nearly no oil mist will exhaust into the shop. Furthermore, the ultraturn MC requires very little space because the enclosure covers the workpiece and the machine itself very tight. The complete machine is mounted deep in the ground so that all components are accessible without steps.

www.georg.com

Firmenkontakt
Heinrich Georg GmbH Maschinenfabrik
Dr.-Ing. Wieland H. Klein
Langenauer Straße 12
57223 Kreuztal / Germany
+49. 2732 779-306
+49. 2732 779-316
wzm@georg.com
www.georg.com

Pressekontakt
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen
+49.241.89468-24
+49.241.89468-44
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de