WFL at AMB Stuttgart

5-axis machining of turbine blades on a Millturn machine from WFL
5-axis machining of turbine blades on a Millturn machine from WFL

At AMB 2022, taking place at Messe Stuttgart from 13-17 September, WFL Millturn Technologies will be presenting the new M20 Millturn complete machining centre for the first time.

Alongside gear skiving technology, there is clear trend toward automation and the integration of sensors. The latest solutions from WFL range from smart software to screw programming through to intelligent tools and clamping devices. WFL claims it is the only manufacturer worldwide that concentrates exclusively on the production of multifunctional complete machining centres.

The M20-G showcased at AMB is equipped with an innovative automation solution – the intCELL. The integrated production cell is fitted on the right-hand side of the machine with the workpieces supplied on a strip accumulator.

IntCELL integrated production cell for automatic loading and unloading

With the integrated loading concept, WFL has reduced the space requirement by 50% in comparison to a conventional production cell. The M20’s integrated loading feature is designed for chuck parts with a diameter of up to 300mm and a workpiece weight of 15kg. For shaft parts, a workpiece diameter of 100mm and a workpiece length of 300mm is possible.

The turning-boring-milling unit with integrated spindle motor and a B-axis with torque motor are entirely new features. The individual toolholder with B-axis on the lower slide is another highlight. The upper and lower system can be used simultaneously, and both systems are supplied by a reliable and dynamic toolchanger from a shared magazine.

This allows even complex components to be machined with optimal efficiency, and the setup of the tool turret is no longer necessary. The tool can be moved up to 100mm below the turning centre, so drill patterns with diameters of up to 200mm can be produced on the face with a high level of precision and without turning the C-axis.

M20 Millturn

 

Universal machining solutions with the M50-G Millturn

The new M50-G Millturn generation, with greater centre distance and improved performance, will be another highlight at AMB. The optional centre distance of 6,000mm enables efficient machining of long shaft parts. When designing the M50, WFL implemented some of the features of the larger M80. The machine’s existing potential is fully utilised, particularly in terms of the increased drive power, combined with the HSK-A100 or Capto C8 tool accommodation.

Turning diameter up to 670mm is available and the M50 Millturn’s proven machine concept has also been given an attractive ergonomic finish. A separate pick-up magazine is also available for very long and/or heavy tools. Workpieces with a length of 1,600mm can be automatically inserted and changed and the standard disc magazine can be expanded to up to 200 positions.

On this machine, trade fair visitors will be able to witness a turbine blade/screw being machined live. Components such as turbine blades or plasticising screws require both dynamic and stable machining concepts. A special clamp from the manufacturer Grasch can be used to clamp rectangular raw materials easily and securely, a fundamental requirement when machining turbine blades. Technologies such as helical spiral milling and helical longitudinal milling are used to machine the blade.

Smart tools: ICOtronic and ultrasound measuring

The ICOtronic tool, which is fitted with sensors, provides information on the machining process as close as possible to the cutting edge. This should not only optimise milling processes in the future, but also increase the machines’ productivity. The demo at AMB will provide a small insight into WFL’s wide variety of development projects.

Ultrasonic measuring will also be demonstrated on the stand. The automatically loading ultrasonic measurement probe enables a fully automated measuring process. The large measurement range (1.5–30mm) offers further benefits. Ultrasonic measuring is extremely well suited to calculating the hole run-out and diameter of very deep holes.

Easy screw programming with ScrewCAM

ScrewCAM will be used at AMB to demonstrate the latest and most innovative software for programming plasticising screws with complex geometries. The geometrical functions that can be manufactured include, among others, single or multi-threaded screws, variable depths, flexible pitch adjustment, wall shaping and wall incline.

In addition, the entire NC programme will be checked for collisions and the correctness of the workpiece geometry produced, using a material removal simulation and geometrical verification against the 3D target geometry of the screw. The result is a verified NC programme with estimated machining time.

Operational data acquisition with myWFL

myWFL Cockpit is WFL’s operational data acquisition system. Machine and program states are displayed according to chronological order, productivity and technical availability. Users can view this on a web browser via the control system, either on a PC or a mobile device. This means that the user can always be well-informed about their machine productivity.

New with myWFL Cockpit is the integration of the energy usage measurement device myWFL Energy which displays the current power and energy consumption data and that of each workpiece.

Another highlight is the integrated Condition Monitoring cycle. When the cycle is running, the friction values of the axes and spindles, as well as the temperature in the milling spindle housing and the vibration or the rolling bearing condition value of the front milling spindle bearing are continuously recorded and stored on the control system.

Using Condition Monitoring Viewer, it is possible to select the data of the various Condition Monitoring runs on the control system, graphically overlay them and analyse according to time in this way. This allows for the early detection of possible malfunctions and minimises unplanned downtimes.

"The digitalisation of manufacturing systems is a key focus for WFL,” says Norbert Jungreithmayr, CEO, WFL Technologies. “The aim here is to use all available resources as well as possible and to integrate them into the manufacturing process. Sensory tools or toolholders with integrated sensors (like our ICOtronic tool), clamping force measurement during the machining process in the iJaw (Röhm) as well as various measuring and scanning technologies are extensively used by ourselves and our customers.

WFL CEO Norbert Jungreithmayr

“Projects like myWFL operational data acquisition systems or WFL iControl process monitoring are our future topics, which can be constantly extended and expanded to stay up to speed with technological developments.”

In the UK, WFL machines are sold and supported by Kyal Machine Tools.

Kyal Machine Tools
www.kyalmachinetools.co.uk

WFL
www.wfl.at

Hall 6, Stand 6A11

 

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