MTW NOVEMBER 2021

TECH INNOVATION



Complete machining of



truck camshafts proves its worth































Effective complete machining of DAF camshafts for commercial vehicles is based on the sophisticated interplay
between highperformance linear motors, ultra-precise in-process measuring systems and easily accessible
components. The Dutch truck manufacturer is extending its camshaft machining operations by adding the
modular concept on the new platform 6.

omfortable furnishings, long maintenance intervals and
excellent driving dynamics are the reasons for purchasing
Creliable DAF trucks. DAF praises its customers with the
highest level of efficiency, maximum driving comfort and a high
residual value.
The precisely machined camshafts ensure that the engines
of commercial vehicles function faultlessly and constantly
for a high mileage. With the JUCAM 6L, these are machined
efficiently and ultra precisely in a single clamping set-up. “The
camshafts are used in the six-cylinder diesel engine series of XF A matter of pure form
and CF models”, explains Wannes Bloemen, Senior Production The JUCAM machines impress with precise grinding results
Engineer, from DAF in Eindhoven, the Netherlands. in a single clamping set-up. (Source: JUNKER)
JUNKER‘s non-cylindrical grinding machine, JUCAM, provides
Shortest cycle times ensure greater efficiency process reliability by machining in a single clamping set-up.
Two wheelheads with four grinding spindles were installed Mr. Bloemen explains: “Halving the cycle times while complying
in the grinding machine. The camshaft is clamped between with the tolerances is an optimum result.:
centers, an integrated driver and a retractable jaw chuck. The
ultra-precise in-process measuring systems ensure perfect Halving the cycle times while complying
radial and longitudinal positioning. First the bearings are with the tolerances is an optimum result
machined, followed by the pump cams and inlet and outlet
cams. An additional step to deburr the elements is not required. Top speeds are achieved especially with the installed linear




46 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com



TECH INNOVATION























JUCAM non-cylindrical grinding machine Video: Cylindrical and non-cylindrical grinding of DAF
With the new JUCAM 6L platform, the truck camshafts are truck camshaft
machined efficiently and ultra precisely in a single clamping Maximum quality and the greatest process stability during
set-up. (Source: JUNKER) cylindrical and non-cylindrical grinding with the new
platform 6. The JUCAM 6L grinding machine from JUNKER
ensures efficient six-cylinder truck camshaft machining.
motors and the proven hydrostatic guides, as well as a reliable #DAF #grinding #truckcamshaft (Source: JUNKER)
coolant system. The complete machining does away with the
need for repeated loading and unloading. Within a defined operation. The high-speed grinding machine is loaded by a
spectrum of workpieces, the grinding machine can be easily set- robot and unloaded by a gantry loader.
up without mechanical retooling.
Reliable, long-established partnership
Complete machining ensures process stability Mr. Bloemen affirms that they have implemented several
Maximum quality while adhering to all tolerance specifications projects together: “JUNKER is a reliable partner with a very
and the greatest process stability result in efficient truck good technical understanding who achieves its objectives at
camshaft machining. Mr. Bloemen confirms: “The modular every stage in the project.” With a young, open-minded team,
and ergonomic design of the grinding machine and therefore the truck manufacturer has been working with JUNKER for over
the accessibility to the components are very important to us. 20 years and implements its projects using a constructive and
For example the modular units for the hydraulic and coolant targeted approach.
system. The associated flexibility and ease of maintenance
were pivotal in DAF‘s decision to purchase.“ The installed in- JUNKER is a reliable partner with a very good technical
process measuring systems ensure a precise profile contour on understanding who achieves its objectives at every stage in
the cylindrical and non-cylindrical elements alike. These allow the project.
the data to be incorporated into the grinding process in real
time. Even the smallest deviations are corrected immediately. For more information,
The JUCAM machine runs fully automatically in continuous Website: www.junker-group.de

















Constantly stable grinding processes during truck camshaft machining for DAF commercial vehicles
Perfect grinding results with the JUCAM grinding machine from JUNKER. DAF relies on the complete machining of the six-
cylinder truck camshaft with outstanding grinding results and a constantly stable grinding process. (Source: JUNKER)




48 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com



TECH INNOVATION




Reduced hardware & engineering costs through new generation of safety controllers

TwinSAFE: consistently modular,


scalable & distributed safety applications




With its focus on increased modularity and scalability, the new generation of Beckhoff safety controllers allows
optimum adaptation to the specific safety requirements of individual machine concepts. The ability to distribute
the intelligence of an entire safety application across multiple TwinSAFE Logic-capable I/O modules enables the
flexible implementation of increasingly modular architectures that can be adapted to given system requirements
even more effectively than before.

ith the new safety controllers based on the
EL6910 TwinSAFE Logic, it is possible to adapt
Wthe TwinSAFE system even more specifically to
the individual requirements of a machine concept as well as to a
broader spectrum of safety applications. The new I/O components
include:
• TwinSAFE EtherCAT Terminal EL1918: digital terminal with
eight safe inputs
• TwinSAFE EtherCAT Terminal EL2911: safe potential supply
terminal with four safe inputs and one safe output
• TwinSAFE EtherCAT Box EP1957-0022: IP 67-protected
digital combi module with eight safe inputs & four safe outputs.

More options for distributed safety applications With the new TwinSAFE controllers, distributed safety
applications can be implemented more efficiently, i.e. with
Just like the TwinSAFE Logic-capable I/O and motion products minimum engineering and cost requirements.
that are already available, the three new I/O modules can be used
as controllers for the direct execution of customer-specific safety more convenient. It also ensures minimum validation effort, which
projects. A special feature is their communication capability, in turn further reduces the development costs.
because like a dedicated controller, the safety project to be
executed on the corresponding I/O component can establish More efficiency through customizing
direct communication relationships with other safety-relevant Safety projects can be modularly designed in TwinCAT as usual.
devices and preprocess the data internally. This makes it possible However, with the new customizing function, the operating
to implement highly granular machine modules with distributed modes “temporary deactivation”, “permanent deactivation” and
safety applications. The central safety controller, if it exists in “passivation” can now be configured for each of these modules.
the application scenario, only needs to process the data that has With the corresponding configuration of replacement values for
already been accumulated. the interfaces between the different modules, users can thus
implement highly complex, modular and scalable architectures
The consistent hardware & software modularity while reducing their development costs. For example, a single
of the safety project can be used for an entire family of machines
TwinSAFE system simplifies the implementation of even very by simply deactivating any modules that
complex safety applications, and the combination of I/O and may not be needed according to the given
TwinSAFE control functionalities in a single I/O component makes requirements.
it easier to distribute safety tasks across individual machine
modules. It also reduces hardware costs. In terms of engineering, For more information,
the customizing function speeds up the process and makes it Email: [email protected]




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INDIA’S LEADING MONTHLY MAGAZINE

ON MACHINE TOOLS &


ALLIED INDUSTRY





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the industry




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opportunity contact:

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TECH INNOVATION





























How to Prevent



Deformed Parts



During ALUMINUM



MACHINING









Emily Newton is the Editor-in-Chief of Revolutionized. She has over four years experience
covering the industrial sector.

eformed parts can be a costly will have a major impact on cutting more brittle than other material options,
waste of both material and time. force and heat, which can cause the its hardness means it stays sharper for
DPreventing deformations during deformation of aluminum. longer. The softness of aluminum also
machining is critical, but many materials — Typically, it’s best to avoid general- means that carbide’s brittleness likely
like aluminum, with its low hardness and purpose tools when working with won’t be an issue while machining.
high thermal expansion coefficient — are aluminum. These tools may work, but their Aluminum’s softness also makes
more prone to deforming than others. characteristics typically make them a bad coatings important. Aluminum chips can
Simple changes to machining equipment fit for machining aluminum. easily clog the flutes of your end mills,
and practices can help machinists prevent Material, flute count, and helix angle of especially when your cuts are particularly
the deformation of aluminum, aluminum your tool will all significantly affect tool deep. Coatings keep chips moving, helping
alloys, and similar materials. performance while machining aluminum. you to avoid some of the “stickiness” that
aluminum chips can have.
1. Select Tooling to Minimize Heat Material
and Maximize Chip Evacuation Coated carbide end mills are essential for Flute Count
The tool used for machining the aluminum working with aluminum. While carbide is Most experienced metalworkers will




54 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com



TECH INNOVATION





recommend end mills with two or three will help minimize heat and deformation. traditional one-side machining, is one
flutes. Three flutes will provide a balance Regularly inspecting tools for wear will way to reduce deformation produced by
of tool strength and chip clearance. Two prevent dull or worn tools from being residual stresses during the machining
fluted end mills will be slightly weaker but used. process, especially when working with
provide slightly more clearance. Anything If chip evacuation is a concern, using thin-walled parts or light alloys. With
with more than three flutes will provide an endmill with a chip breaker design symmetrical machining, a part is attacked
additional strength you don’t need while may help. These end mills feature a from multiple sides or angles, rather than
also limiting chip evacuation. profile with notches that improve chip just one face.
For the most part, the choice between evacuation. For example, imagine milling an
two and three flutes will come down to aluminum plate to a desired thickness.
personal preference and the tooling you 2. Choose Materials and Pre-Heat Milling exclusively one side of the plate
have on hand. So long as you don’t use to Minimize Deformation Risk will concentrate heat, increasing the risk
an end mill with four or more flutes, the The choice of material can influence of thermal deformation. Milling both sides
end mill should work well. deformation during machining. While to reach the desired plate thickness will
heat treating is traditionally done after spread this heat out.
Helix Angle rough machining and before finishing This process change is not complex,
Helix angle choice will help to minimize machining, choosing an aluminum alloy but it can make it much easier to manage
chatter while improving material that has been pre-heat-treated for the heat that is generated by processing
removal speed. Typically, machinists strength and ductility can help prevent a part.
will recommend angles of 35, 40, or 45 deformation. Vibration and cryogenic
degrees for machining aluminum. 35- and treatments to eliminate internal stress Running Parameters
40-degree angled tools will work well for may be an option. Choice of cutting parameters can also
roughing. A tool with a 45-degree helix The use of salvaged components that affect how easy aluminum is to work with
angle will work better for finishing. have been pre-treated may reduce risks and how likely the material is to deform.
The lower angle helps to keep the of deformation. Using the components Commonly recommended surface
tool — and the aluminum — cooler could also mean significant savings. Some footages for aluminum typically fall
than it would be otherwise. The faster machinists say it’s possible to save as around 400 to 1,000 SFM. Wrought
processing that a wider angle enables much as 60% on material costs by using aluminum alloys may require a higher
will also help with the thermal regulation salvaged components and materials. surface footage than cast aluminum,
of both the end mill and the part being In some areas, the material choice will possibly between 800 and 1,500 SFM.
milled. While the angle will result in a not have an impact, however. The thermal You can use this formula to calculate tool
rougher surface finish, you’re likely going coefficient of aluminum can vary between RPM from your chosen SFM:
to return with another tool for a finishing alloys, but only somewhat — meaning RPM = SFM ÷ tool diameter (in inches)
pass — meaning it shouldn’t be a major heat will always be a challenge when × 3.82
issue. working with aluminum, no matter the
A 45-degree helix angle is better for alloy or material source. Machining Strategies That Can
finishing as it produces smoother cuts. Prevent Aluminum Deformation
While a tool with this angle will produce 3. Make Process Changes to Aluminum can deform easily during
more heat, it should be less of a problem Minimize Deformation machining due to its softness and high
when making the light cuts you need to Your approach and strategy for organizing thermal coefficient. Working carefully
finish a part. the machining process can also have a with the right tools can help you minimize
Higher angles could be possible if the major impact on part deformation. Along the risk of deformation.
45-degree angle tool does not produce with strategies that improve the efficiency Tools with the right material, flute
the desired finish. However, higher helix of your machining, these strategies can count, and helix angle can encourage chip
angles will produce more heat, which will help you better manage aluminum’s evacuation and more effectively manage
make deformation more likely. thermal properties and softness. heat. The right process changes can also
help you to distribute thermal energy and
Other Considerations Symmetrical Machining balance efficient machining with effective
Keeping your tools as sharp as possible Symmetric machining, rather than heat management.




56 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com



TECH INNOVATION























How


VERTICAL MILLING


MACHINES Lead to


Improved and Diverse


Machined Parts?







illing is the process by which Types of Vertical Milling Machines
material is removed from a Vertical machines are of two types-
Mstationary workpiece using turret milling machines and bed milling
a rotary cutting tool. This machining machines.
process is used to cut a wide variety
of materials such as metal, wood, and Turret Milling Machines
even plastics. Each type of CNC milling A turret milling machine comes with a
machine comes with its own unique vertical spindle that remains fixed while
features and applications. Vertical Milling the bed portion of the machine moves
machines, for example, are distinguished horizontally and vertically. Turret milling
from other types of milling machines by machines are more effective for use on
the positioning of the spindle axis, which small parts.
is vertical and moves in an up and down
motion. Bed Milling Machines
Vertical Milling machines contain On the other hand, the Bed Milling One of the most commonly touted benefits
cylindrical cutters and use automated machine only allows for horizontal of using vertical milling machines is that
processes that result in more accurate cuts movement and is more effective for use on they are much less pricy compared to
made to precise custom specifications. bigger workpieces. horizontal milling machines. The machines,
Read on as we discuss the types of in general, are also more easily available.
Vertical milling machines and their benefits Advantages of Vertical Milling The smaller investment results in a lower
over horizontal milling machines in greater Machines cost of operation and maintenance, which
detail. Low Cost is then further passed on to consumers in




58 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com



TECH INNOVATION





lower machining costs. Use and Applications of Vertical useful in the F and B industry, for example,
Milling Machines for producing cans and tabs and even
Highly Efficient Vertical CNC machined parts have many containers.
Vertical milling machines provide a high different applications and are used in
level of cutting efficiency as the machine many diverse industries. In particular, Aerospace:
bed is a whole. vertical milling machines are used in The aerospace industry also favors parts
industries where there is a requirement produced by Vertical CNC machining
Precision for a high rate of precision, accuracy, as the five-axis capabilities allow these
The way the CNC vertical milling and large-scale projects. Some of their machines to cut materials like Inconel
machines are designed and operated applications are detailed below: commonly used aerospace products.
allows for more precise cuts and fewer Vertically milled machined products are
incidences of human error. The computer- Military: used engine and steering equipment and
controlled cutting process ensures the Military industry is subject to a variety even onboard accessories.
highest levels of accuracy compared to of strict standards relating to the design
manual machines. The long and thin tools and build of parts. As a result, machined Final Takeaway
used in vertical milling machines also components produced by Vertical milling Vertical CNC milling machines offer
contribute to the nature and accuracy of machines are particularly desirable. The users a high degree of customization
cuts. high degree of precision offered by these and allow them to manufacture solutions
machines ensures the parts always meet with precise requirements. The result
Easy to Use industry specifications. is machined components that are
Vertical milling machines use CNC controls innovative, functional, and extremely
that make the machines extremely easy to Curved Parts: cost-effective.
use without special fixtures. It is difficult to produce curved parts like
cams and propellers with a high degree of About the Author:
Attention to Detail precision using usual machining methods.
Vertical milling machines increase users’ However, with the multi-axis Vertical CNC
visibility due to their orientation, making milling machines, these can be produced
them especially useful in slower projects easily and quickly.
that require particular attention to detail.
Electronics:
Higher Accuracy Vertical CNC machines find great use in
Vertical milling machines provide for the electronics industry to produce parts
higher accuracy compared to their of computer motherboards and intricate
horizontal counterparts. They are also hardware such as panels, hardware, and
especially useful for performing plunge numbers.
cuts and drilling on the workpiece.
Irregularly Shaped Parts:
Diversity Vertical Milling machines are useful for Vincent Hua is the Marketing
Vertical milling machines provide for more producing irregular parts in shapes such as Manager at TSINFA. He is
project flexibility and diversity, allowing brackets or bases. As these components passionate about helping people
users to work with a wide variety of have complex designs, it is difficult to understand high-end and complex
shapes and size configurations. This produce them with other manufacturing manufacturing processes. Besides
ability also gives Vertical milling machines methods. Vertical Milling machines with
a significant advantage over horizontal automatic machining capabilities are useful writing and contributing his
milling machines. The advanced CNC to produce these highly complex designs insights, Vincent is very keen on
milling technology has allowed vertical with ease. technological innovation that helps
milling machines to perform more build highly precise and stable
advanced functions than traditional metal Food and Beverage Industry: CNC Machinery.
cutting. The design of vertical milling machines is




60 MACHINE TOOLS WORLD NOVEMBER 2021 www.mtwmag.com



PRODUCT SHOWCASE




Compact time of flight sensor for

Industry 4.0 applications


For the first time, ifm integrated their photoelectric PMD sensors (on-
chip time of flight measure) into a compact M18 design, developing a
sensor perfectly suited for Industry 4.0.
The PMD OGD Cube precisely measures on to the next processing step (in-
the distance to the object via laser light and line quality checks).
time of flight technology. Depending on the The sensor has an IO-Link
version, the range is 300 or 500 mm for interface that not only transfers
the OGD Precision and 1500 mm for the the measured value but makes
OGD Long Range. Thanks to the small light it possible to remotely set all
spot diameter, the sensor can not only be parameters. The sensor cam be
used to detect big objects, it is also suitable individually adapted to different workpieces
for error-proofing applications, particularly or manufacturing situations. It is perfectly For Product Enquiry Contact
in assembly automation. It offers enough suited for Industry 4.0. ifm electronic India Pvt. Ltd.
precision and resolution to check for example This makes the PMD OGD Cube an Plot No. P-39/1, MIDC Gokul
Shirgaon, Kolhapur - 416234
the depth of bore holes or the installation of extremely compact and user-friendly Website: www.ifm.com
very small parts before the workpiece moves problem solver for numerous applications. Phone: + 91 231 2672770
E-mail: [email protected]




Poly Cotton Knitted Seamless



Features & Benefits
Poly Cotton Knitted Gloves are mainly
made from mixed fibers or recycled
materials to make it more cost
effective. But the wearing comfort &
features are same as 100% Cotton.
These gloves are more popular in
Shell Colours like Natural, Black, Navy
Blue, Grey & white. The color options
are also be developed/ available for
bulk orders. There are various weight
options available.

Application:
• General Purpose/ Maintenance
For Product Enquiry Contact • Shipping & receiving
Marvel Gloves Industries • Warehousing
[email protected] • Assembly
www.marvelgloves.com • Packaging & Stacking








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18
09
07 19 08 20 JAN 2022
VENUE : AUTO CLUSTER EXHIBITION CENTER, CHINCHWAD
PUNE

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