Ibarmia TNC 640 High end control for milling and turning operations
Ibarmia TNC 640 High end control for milling and turning operations
I definitely agree that time flies, especially in demanding environments where much good work needs to be done to stay among the elite. The two years since the last EMO Milano have passed in a flash. It seems like only yesterday, but in this time IBARMIA has done a lot of good work, which is included in this new iNews, titled: The Smart Choice.
In two years, from Milan to Hanover:
- Growth in business volume and personnel has exceeded 25%.
- New projects have been implemented in the two main global MT markets: Germany and China.
- Significant production investments have been completed in the parent company, tripling the machine assembly area.
- New machines and processes have been incorporated into the program.
- The Smart Point platform has been launched, which offers high connectivity of our equipment.
- The design lines of the machines have been updated to better convey their technology, quality, ergonomics, elegance, and simplicity.
We are a lively and dynamic company committed to offering the best solution in each case. Therefore, trusting IBARMIA is not only an elegant decision, it is a smart decision, as our new slogan for the EMO says: The Smart Choice. We would be delighted to expand on any content that has caught your attention, as our aim is to be your machine-tool reference point.
The business fabric as well as the Basque society has been dealt quite a blow after the recent financial, economic, business, and social crises. However, the solid economic structure, heavily based on industry and framed in an ecosystem of technology and innovation, has been our main shield of defense. In spite of this, because of the crisis, industry has become a smaller player in our economy and employment suffered severely.
Now, based on the data of last year and the start of the year, the conclusion we may draw is that we find ourselves in a new, and even sometimes relatively unrecognizable scenario. The economy grows, the rate of unemployment falls, business people are positive, all industrial sectors report high expectations, and, without exception, all forecasts point toward a positive future.
However, in this environment there are some companies that show exhaustion, weakness, and what is worse, face the risk of closing. Which is an affirmation of what we have been saying for many months: the crisis has opened up a new scenario in which there is no comfort zone. We must remain vigilant, and the search for competitive improvement in each company and sector will be unstoppable.
We have just adopted the new Industrialization Plan 2017-2020 which aims to tackle the immediacies and the most pressing needs of companies in difficulties, as well as the long term to strengthen the foundations of the industry of the future. A new industrial paradigm in which the Basque Country has much to learn and much to contribute.
According to the most recent data from the Basque Institute of Statistics, the weight of industry in the composition of the Gross Domestic Product is 23.9%; the objective and commitment of the Basque Government is that in 2020 the industry represents 25% of the economy of the Basque Country.
The transformation of the industry, with a growing commitment toward servitization and integral services, expands its field of performance making the boundary between industry and services more opaque, not to say non-existent when we talk about advanced services.
We are working to convert traditional production into new technologically advanced industries that offer high added-value services and evolve from a "production focus" to a "solution focus".
The Basque industry is on its way to take that qualitative leap, and the machine tool sector is one of the benchmarks in this process. A major part of the Basque Industry 4.0 strategy is focused on designing systems and methodologies that steer Basque companies towards adopting technologies of the new industry and digitalization, with spaces designed for self-diagnosis and reshaping of SMEs, for example, additive manufacturing or robotics. We have a common network from where the totality of this type of services is available, with interlinked services, and we aim to create a Digital Innovation Hub as a space where businesses can share and test their technologies in a collaborative way.
IBARMIA has an unprecedented presence both in production capacity and sales activities in the two biggest machine tool markets in the world. During this time of renovation and expansion works at the headquarters in Azkoitia, IBARMIA opened the sales branch in Eislingen/Fils, Germany, and established the Joint-Venture in Shandong, China.
SHANDONG IBARMIA, CHINA
With the new century, IBARMIA started their landing in the Asian giant. The first sales came from European companies with production plants in China. In a second stage, local private and public companies showed an interest in the IBARMIA machines, which due to their quality and affordable price won various tenders of big companies in the Energy, Aerospace, and Railway sector.
China is today the world's main producer, consumer, and importer of machine tools, and IBARMIA does not ignore that reality. This is the reason why on the last 12th of July, a Joint Venture was signed in Madrid with the company Shandong Ir a eta Heavy Industries to create Shandong IBARMIA CNC Machine Manufacturing Co., Ltd.
Shandong IBARMIA will be the first production plant outside the headquarters and will be responsible for the sales and service activity of the IBARMIA range, both the one manufactured locally and the one made at the headquarters. Initially, IBARMIA will count with a new building of 5,563 m2 for production and 951 m2 offices, and a 15,000 m2 advanced manufacturing plant is already planned for 2019. The company is based in Zhangqiu, Jinan - Shandong Province, conveniently connected to major areas such as Beijing, Tianjin, Jinan, and Qingdao. There will be an initial team of 50 people, and the local manufacture will kick off in 2018.
At IBARMIA, we strive to constantly move forward. Our objective is to innovate our products and services every year, constantly creating new proposals for our customer demands. Our mission is to offer a range of solutions according to the specific requirements of each client based on a wide range of machines and technological elements.
See below a few of our latest developments in our moving column machining centers:
1. ZVH 45/L3000 STAR
This has been one of the greatest challenges for our engineering team. Creating a special edition of machines with a configuration that covers the widest possible range of machining requirements of any workshop in any sector.
The STAR range is conceived to be manufactured in batches as a fixed configuration that should meet at least 90% of our usual machine requests.
Delivery time is another key factor: The machine must be manufactured in very short times to respond to the rapid market requirements.
With all this in mind, IBARMIA is launching the STAR machine, which we are sure will be a complete success.
Only the ones moving forward will be successful in the long term. IBARMIA machines are designed to work long hours without pause and when possible, unattended. In that line, IBARMIA went from being a simple machine supplier to providing processes where automation is key to achieving the highest productivity.
Three new automation developments are now part of our existing solutions:
2.1. Automatic change of chucks and fixtures for horizontal lathe spindles.
2.2. Pallet changer from the side of the machine: This new solution allows loading/unloading pallets from the side of the machine while the front side is clear for normal work access. An automatic side door is used by a robot that loads/unloads pallets and stores them.
2.3. New tool changing solutions: Rack type magazine with up to 400 tools of 20kg. This solution is completely adaptable in quantity and tool length depending on customer requirements.
3. ERGONOMIC DESIGNS
The ergonomics factor covers the relation between the operator and the machine, considering visual, position, and handling aspects. We have re-designed the area to integrate the command station, informative panels, and control devices, so we now have 3 different models depending on the quantity of indicators and devices to be integrated.
We considered the following points:
- Ideal position with the best vision and reach.
- Intuitive use.
- Ideal size and shape for easier use.
4. CUSTOM MACHINES: ENGINEERING AND INNOVATION TO DESIGN THE DREAM MACHINE OF OUR CUSTOMERS.
IBARMIA machines are known for their high quality and precision combined with excellent ergonomics and flexibility. Using the smart moving column architecture of high modularity, IBARMIA offers multiple solutions to most of the challenges brought by our customers.
See below 3 examples of customized machines that show the technical capacity of our engineering team to understand our customers' requirements:
4.1. ZVH58 L6000 & Ø2000 rotary table:
- Machine with Ø2000 rotary table and automatic changer of angle heads.
- Swing capacity increased from Ø1400 to Ø2400.
- Automatic storage and change of angle heads.
- Modified front to allow walking access of operators into working area.
4.2. ZVH55 L2200 MULTIPROCESS:
- Multiprocess machine with excellent ergonomics and flexibility.
- Machine with two moving elements (tailstock and steady rest) with semi-automatic positioning guided by the machine column.
4.3. AUTONOMOUS PRODUCTION CELLS:
IBARMIA offers various levels of automation, ranging from simple pallet changers and Smart loading systems to modern and complex robot installations. In this case, the images show an autonomous production cell of 4 machines ZVH45/L1600 EXTREME where the piece loading process is executed by a traveling robot.
NATURAL EVOLUTION.
A decade ago, driven by satisfied customers accustomed to dealing with the performance and production capacity of IBARMIA machines, we decided to take a strategic step and enter the market of medium and large workpieces. Leveraging the deep experience acquired with the successful Z series, we developed a solution starting from a solid base. Staying true to our principles, we are offering high-performance machines with multi-axis continuous machining capabilities for milling and turning.
The T Series covers 4 different models depending on the axis strokes and swing diameter of the working area: T12, T16, T22, and T30 for strokes ranging from 1200mm to 3000mm. Two available heads in the range, both for continuous 5-axis machining with high dynamics, work by direct transmission with a torque motor on the turning shaft, avoiding backlash issues and guaranteeing dynamics and accuracy while minimizing maintenance and repair costs in case of collision.
The combination of milling, drilling, tapping, gear milling, boring, turn/milling, and turning in a single machine offers a comprehensive solution for sectors such as Aeronautics, Automotive, Mold & Die, Railway, Valves & Pumps, Energy, and more.
AWARDED MACHINE.
The highest quality standard of the T Series is internationally recognized, evidenced by the National Prize for Innovation in advanced manufacturing technologies in 2016. The prize, judged by the AFM, evaluates aspects related to:
- Design, communication, and sustainability
- Ergonomics and Safety
- Technology and Innovation
FLEXIBLE AUTOMATION.
One of our biggest concerns is to design machines fast and flexible enough to respond to the volatile conditions of the market. The T Series combines a multi-task machine with the newest automation solutions based on handling and connectivity, perfect to support production processes with single, medium, and large batches.
BUILDING THE FUTURE,
FROM MACHINE TO PROCESS
EXCELLENCE.
In the age of accessible technology and a borderless world, IBARMIA has a very strong commitment to continuous process improvement related to our machines and installations. To achieve process excellence, we have several research areas:
Integrated Machine Capabilities:
We develop technological grinding cycles for single setup pieces of complex geometry, enhancing efficiency and precision in machining processes.
Smartization:
Our focus is on data acquisition, process monitoring, and online working. The setup of our machinery range offers a wide range of smart functions that bring the future to the present. T Series machines are equipped with black boxes for data acquisition, opening the door to data analytics and machine learning to improve machine availability and ensure a robust, complete process.
HEIDENHAIN TNC 640 AND CONNECTED MACHINING.
Tailor-Made Digitization.
Many medium-sized businesses are facing formidable challenges from digitization. The main question for them is how digital networking and software solutions can be used to analyze their own manufacturing, improve internal processes, and tailor the use of cloud solutions. Connected Machining from HEIDENHAIN offers functions for very individual networking of production, which places the TNC user at the center of digital order management through the control.
Creativity and innovative power drive the important and unique features that make a production company successful. This depends on innovative and motivated employees who put their expertise at the service of the company. No matter how deeply digitization is to penetrate into manufacturing workshops, the goal of digitization in a company has to be to make this proprietary, highly sensitive know-how available in the right places.
TNC controls from HEIDENHAIN support the shop worker with their Connected Machining package of functions for networking. The software entitled StateMonitor creates transparent processes through data acquisition and data analysis. Using the HEIDENHAIN DNC interface, the control can provide important data while the Remote Desktop Manager allows it to access data on the network. A clear, digital representation of information on the machine by the Extended Workspace is also one of the functions. All this enables flexible order management starting at a batch size of one.
The realization of uniform digital order management with Connected Machining through HEIDENHAIN TNC controls leaves the necessary leeway for individual design and connection of the network. The worker has the digital flow of information firmly in control to exploit company-specific competitive advantages in the future—regardless of whether it's on the machine tool or production planning.
C SERIES: Efficient Turning and Drilling of Large Flanges and Bearings
Machining large rings with IBARMIA: A complete range of solutions for machining large dimension rings.
Finding specific machines for niche market applications isn't easy due to low demand, making them unattractive for manufacturers to develop high-tech solutions. IBARMIA has tackled this issue by offering a complete range of solutions for machining large dimension rings, up to a diameter of 8 meters, becoming a leader in manufacturing for this niche market.
In gantry-type machines or opposing machines, IBARMIA offers integral solutions machines and fixturing devices. These solutions respect the morphology of the rings, which are much better placed in a horizontal position. This way, the part is placed on a central rotary table which indexes the exact degrees between centers of adjacent holes. The rotary tables are manufactured in-house using bearings or hydrostatic supports depending on the diameters and weights to be placed on them. In both cases, a double pinion gear system triggers the dented crown, generating the turning underneath the rotary table. The positioning accuracy is guaranteed thanks to an RCN type encoder in the turning axis of the table.
- HEADSTOCKS: DRILLING & TURNING CENTRES
Thanks to the experience of IBARMIA in manufacturing machines for big dimensions rings, we can propose several headstocks options for drilling centers as well as turning centers.
2_ MODELS BY ARCHITECTURE
Z. 1_ Portal_ Single & Dual
The Portal machines were developed to avoid that situation as the portal construction allows covering every range from the center of the rotary table to the limit of the axis at the end of the crossbar. Once again, we use a central rotary table underneath a fixed crossbar portal-type construction where we can install either one (portal single) or two (portal dual) spindle heads.
When horizontal operations are required, it is possible to use:
- VH Headstock, our latest proposal to the market.
- Bi-rotational head
- An automatic change of 900 heavy-duty angle heads
- Angular heads directly placed on the tool holder.
Since 2011, the portal range of solutions has been extended with high-performance lathes specific for this application. For workpieces over 3500mm in diameter, the L series is made of a portal structure with cast iron bodies and rotary tables on a hydrostatic support. It is usually equipped with a double RAM, although the machine can also be provided with a single RAM. Prioritizing the rigidity of the machine, we have chosen a fixed crossbar with a RAM stroke of 1200mm for workpieces up to 1050 heights. Selection of manual clamping systems with independent or self-centering jaws as well as self-centering automatic clamping devices for first clamping (raw piece) or second clamping (previously machined piece). Wide range of options for tool changing, from manual tool holders to automatic tool change using a CAPTO system. We find the top level of the range in the MULTIPROCESS series, where we add five RAMS to the high-performance lathes so we can execute operations that were impossible to do in one single machine. Apart from turning operations, the machine can also do drilling, tapping, milling, boring, and even grinding operations. The machine incorporates tool and head changes to support its versatility. Due to our extended experience in this application, IBARMIA can advise on layouts of circular piece machining plants, piece handling and transportation, centralized chip evacuation systems, making us the perfect technological partner for the companies of this industry. Our global approach to sales and service with own offices in Germany and China guarantees the proximity to our customers regardless of their location.
PORTAL SINGLE
- PSV, PSU, P5H
DRILLING CENTRES
(P5+ V, U, H heads)
PORTAL DUAL
- PDV, PDU, PDH
DRILLING CENTRES
(PD+ V, U, H heads)
- LDV, LDV_MULTIPROCESS
TURNING CENTRES /
TURNING & DRILLING
CENTRES
2. 2_ Vertical_ Single & Dual Opposing
The basic models "S," with a vertical spindle head (SV) or automatic vertical/horizontal spindle head (SVK), make the basic range at IBARMIA. Components fixed around a rotary table make an efficient drilling center. The machine is made by a transversal axis generated by the column to adjust to different diameters and a vertical axis generated by the spindle head. The SVK version with a vertical/horizontal universal spindle head is recommended for horizontal drilling works such as the hole for ball introduction and the drilling and tapping of the holes used to grease the bearing tracks.
The addition of a second column and spindle head to the previous range gives place to the "F" models. This time there are 2 spindle heads working simultaneously on the same part. The machine can be configured with 2 vertical spindles (FVV), with a vertical spindle head and a universal one (FVK) as well as 2 universal heads (FKK).
In case of having an odd number of holes or a variable distance between holes, the columns can be equipped with an intermediate saddle that generates an additional axis. It gives place to these models.
On these models and the previous one, the range of covered diameters is limited by the jig, distance between the spindle center and the guides of the vertical axis, making it impossible to reach the center of the rotary table for rings bigger than 2 meters in diameter.
3_ MAIN FEATURES
3.1_ Fixturing Devices
Customers need more than just a machine; they need a complete solution. Therefore, it is essential to solve piece fixturing issues. During 20 years of experience, 1BARMIA has developed several types of self-centering fixturing devices, manual and automatic. The flexibility and simplicity to change jaws and support positions for pieces of different diameters is something that has a clear impact on productivity, which is highly valued by our customers.
3.2_ Control & Monitoring Of Tools
1BARMIA incorporates the most advanced tool wear monitoring systems. The automatic tool magazines allow the management of twin tools and a more autonomous use of production. Ensuring the process, avoiding downtimes caused by broken tools, is crucial in this application.
3.3_ Work Area Encapsulation & Coolant Through Spindle
Using tools with hard metal inserts to drill deep holes requires coolant through the spindle for two main purposes: reducing the elevated temperatures generated in the drilling process and using the pressure to push the chips out of the inside of the hole. High-pressure (22, 40, 60, 70 bar) pumps are used for this purpose which, combined with high feed rates, push chips with great violence so it is recommended to encapsulate the entire machine to prevent chips and coolant coming out of the working area as well as reduce the machining noise.
3.4_ Automatic Chip Evacuation
Evacuating the high volume of chips generated during the machining process is a great challenge for every manufacturer, especially when it comes to big dimension machines of intense use (usually 3 shifts). With this purpose, our design avoids flat surfaces where chips could settle and favor their fall to the central channel where the paddles that turn with the rotary table push the chips to an external evacuator.
Apologies for the oversight. Here's the corrected version in English:
The ZVH45 STAR represents a significant advancement in IBARMIA's lineup, introducing a machine with a closed configuration that caters to a wide range of machining needs. Leveraging the acclaimed moving column architecture and a commitment to using only high-quality components with advanced technological features, this edition sets a new standard.
IBARMIA has a history of fruitful collaborations with renowned companies, attracting users who are typically experienced technicians with a deep understanding of machine tools. Instead of settling for off-the-shelf solutions from conventional dealers, these professionals meticulously assemble their machining setups. They carefully consider factors such as axis configuration, spindle specifications, and operational parameters, scrutinizing machine designs to identify areas for customization that align with their precise production requirements.
Given IBARMIA's focus on quality over mass marketing, potential users often sift through various brands before discovering its offerings. Renowned companies such as Thyssenkrupp, Airbus, Michelin, Liebherr, INA Schaeffler, Andritz Group, Avic, Energomash, Lufkin, Schoeller Bleckmann, SKF, and others have enhanced their production capabilities by leveraging the expertise of their mechanical engineering specialists who recognize the value of selecting the right equipment for their needs.
When approaching potential customers, IBARMIA initiates a collaborative process aimed at tailoring solutions to their exact requirements. This includes configuring the machine's workspace, specifying axis movements, selecting spindle types, and navigating through an extensive list of over 800 options to deliver a customized solution.
This operational philosophy, coupled with the cutting-edge technological features of IBARMIA machines, positions the brand as a top-tier choice among a discerning group of customers. However, not all companies in the industry have the resources or time to dedicate to extensive research and customization. Many opt for the standard configurations offered by their regular dealers.
Given the demand for shorter lead times and standardized machining processes, dealers often provide solutions that are "good enough" and readily available to meet the needs of a broad customer base. This trend was brought to IBARMIA's attention by one of its Italian machine tool dealers.
In response, IBARMIA's technical team explored a myriad of axis configurations, spindle options, and other features to develop a standardized machine that could address a wide range of machining requirements. Leveraging their expertise and award-winning design, IBARMIA conceived the ZVH45 STAR—a special edition of machines with a closed configuration.
These machines are manufactured in batches and distributed to selected showrooms worldwide for immediate delivery to end users with pressing needs, which represents a significant portion of the market. This initiative allows IBARMIA's authorized dealers and customers to enjoy the best of both worlds: high-tech machines with pre-designed configurations tailored to their needs and prompt availability, enabling them to quickly leverage the technology and achieve returns on their investment.
Don't hesitate to reach out to your local IBARMIA authorized dealer for detailed information about the STAR machine configuration. It's highly likely that this solution will meet most of your workshop machining demands with the highest accuracy, dynamics, and reliability. And of course, IBARMIA being IBARMIA, if you need that "extra touch" to make it your ideal production unit, feel free to contact us. Our technical office will be delighted to hear about your needs so we can together CREATE YOUR OWN MACHINE.
LAB-FAB-APP: THREE BUZZWORDS IN R&D NOW ALSO IN THE MACHINE TOOL INDUSTRY
During a recent conference on the future of R&D in Europe, the terms LAB-FAB-APP were mentioned as keys to innovation for the first time. The first one, LAB, underscores the importance of research for generating new knowledge. At TECNALIA, we develop manufacturing processes, model new machine concepts, and prototype new developments in our laboratories with the clear aim of offering solutions to the machine-tool sector.
The second, FAB, is ingrained in our DNA. Advanced Manufacturing is one of our main scopes of work and the heart of our country's economic activity, fostering well-being and wealth for all. We aim to collaborate with companies like IBARMIA to enhance their competitiveness, if possible, in the global arena and make Basque products and services available worldwide.
Finally, APP refers to industry digitalization and the new opportunities now available to us, as machine users and manufacturers, companies, and individuals. This involves improvements in quality, productivity, machine and tool use, etc., made possible by the integration of sensors, data analysis, and monitoring systems, among other measures.
Therefore, we welcome the presence of IBARMIA at this EMO, where the three keys "LAB-FAB-APP" have become a reality, thanks to an ongoing commitment to R&D, steadfast innovation to achieve results and generate new products and services, as well as leveraging digital technologies to the fullest.
The THR 16 MULTIPROCESS is an award-winning 5-axis universal machining center designed for turning and milling operations. IBARMIA brings this model, which received recognition for innovation and best design at the Bilbao Machine Tool Exhibition in 2016, offering a multitasking capability to machine Ø160 mm pieces. It features a powerful A-axis head with double support on the main spindle housing.
Key specifications include:
- Main spindle (HSK-100) reaching up to 12000 rpm with 74 kW.
- Working table capable of turning 3000 kg pieces at 500 rpm.
- Generous axis strokes: X: 1600 mm, Y: 1300 mm, Z: 1500 mm, enabling machining of pieces up to 1400 mm in height.
The ZVH 45/L3000 STAR EDITION is positioned as the standard machine with a premium configuration. It addresses a wide range of production requirements across various sectors, offering short delivery times. IBARMIA, renowned for manufacturing high-technology moving column machining centers, introduces this standard configuration with top-quality components stocked at prestigious machine tool showrooms worldwide.
Key features include:
- X: 3000, Y: 8000, Z: 800, B: +/-105, with an integrated rotary table of Ø800 mm.
- Main spindle operating at 12000 rpm, 27 kW, with a tool capacity of 150-40.
Lastly, the ZVH 55/L3000 MULTIPROCESS combines the power of a milling machine with the dynamics of a machining center. Notable features include the utilization of a HSK-100 spindle, distinguishing it from machines with HSK-63 spindles. Additionally, it boasts the capability to turn pieces of up to Ø1100 mm on an integrated multitasking rotary table.
The Add+Process is a technology based on laser metal deposition, aimed at manufacturing, coating, and repairing parts using metallic powder as raw material and a laser beam as a heat source. Additive manufacturing and 3D printing are realities that are drastically changing processes in various fields and sectors. The machining process of pieces obtained by additive methods has only been approached by a few world-leading companies so far.
In the Add+Process, the substrate material is melted with the laser beam, creating a melt pool where metallic powder is injected in a locally controlled atmosphere by an inert gas. The LMD head is moved along a tool path to create the final geometry layer by layer. The result is an extremely strong union between the substrate and the deposited material, achieving structures with similar or even better properties than the base material.
1. OUR MACHINERY RANGE, THE BASIS OF A NEW GENERATION OF MACHINING CENTRES:
The machining centers of IBARMIA offer the manufacturing of complex geometry and large volume pieces, significantly reducing lead time thanks to the multiprocess concept (milling and turning in the same machine). These machining centers improve the quality of the final piece and reduce the initial investment cost by requiring fewer machines as well as less space, eliminating the transit of parts between different machines and simplifying industrial management.
2. THE HYBRID MACHINE, THE TRANSFORMATION THAT WILL MULTIPLY YOUR PRODUCTION CAPACITY:
The evolution of IBARMIA's machining center into a hybrid machine involves the integration of Additive Manufacturing based on Laser Metal Deposition (LMD) technology. This integration provides high versatility to produce parts with complex geometries and to combine different materials in the same part. The automatic change of the LMD head allows an easy switch between additive and subtractive processes. Thus, parts produced by LMD can be finished in the same setup, obtaining the accuracy and precision of machining processes in additively manufactured parts.
3. LATEST TECHNOLOGY ON ADVANCED MANUFACTURING
Our Add+Process technology is focused on manufacturing, coating, and repairing parts using metallic powder as a raw material and a laser beam as a heat source. The substrate material is melted with the laser beam, creating a melt pool where the metallic powder is injected in a locally controlled atmosphere by an inert gas. The LMD head is moved along a tool path to create the final geometry layer by layer. The result is an extremely strong union between the substrate and the deposited material achieving structures with similar or even better properties than the base material. The laser beam concentrates the energy in a spot of 1-3 mm, thus, allowing the production of high-accurate and complex parts.
4. LASER BASED MANUFACTURING PROCESSES
- Laser Metal Deposition (LMD):
Manufacturing of 3D features, repairs, and coatings to improve the properties of the piece allowing a combination of different materials in the same piece.
- Laser Heat Treating:
Using a laser beam as a heat source to improve the surface properties of metallic parts by locally changing their microstructure through controlled heating and cooling cycles.
- Laser Polishing:
A process where a thin metal surface layer is melted with surface tension, leading to material flow from peaks to valleys, thus, smoothing the surface roughness.
- Laser Marking:
Leaving marks on an object, including engraving, induced by the typical physical effect of inducing a color change within the material.
5. LASER BASED MANUFACTURING APPLICATIONS
- Coating:
Adding functional coatings to specific areas of parts to improve their mechanical properties, thus, increasing the lifecycle of the final product.
- Repairing:
Using a combination of machining and LMD processes to repair damaged parts, first by restructuring the damaged area through machining, then by adding new material through LMD, and finally, by finishing to achieve the required geometrical accuracy.
- Feature Adding:
Adding features with specific characteristics (complex geometry, different material, etc.) to parts previously manufactured by other manufacturing processes instead of producing the whole part.
- 3D Parts Manufacturing:
Using the LMD process to produce a three-dimensional object layer by layer, creating a three-dimensional object.
6. ADD+PROCESS TECHNOLOGY MAIN TECHNICAL DETAILS
- 3 kW LASER POWER: The Add+Process technology utilizes a laser with 3 kW of power to provide the energy required for the metal deposition process.
- PRECITEC YC52 CLADDING HEAD: This cladding head from PRECITEC is specifically designed for laser metal deposition applications, ensuring precise control and efficient operation.
- POWDER FEEDER: A powder feeder is integrated into the system to deliver metallic powder to the melt pool created by the laser beam during the deposition process.
- AUTOMATIC TOOL CHANGER: The machine is equipped with an automatic tool changer, allowing for seamless switching between the LMD head and other machining tools, enhancing flexibility and efficiency.
- VARIABLE SPOT: The laser head offers the capability to vary the spot size, enabling the optimization of productivity or the creation of fine geometries as needed for different applications.
7. MATERIAL DATABASE
- Nickel Based Alloys: These alloys offer high mechanical properties at elevated temperatures and are suitable for service in extreme environments subjected to pressure and heat.
- Cobalt Based Alloys: Known for their high wear and cavitation resistance at high temperatures, cobalt-based alloys are often used in coating operations to enhance the mechanical properties of surfaces.
- Iron Based Alloys: Iron-based alloys provide high mechanical properties, including abrasion resistance up to 500°C. They are commonly used in coating operations and can be further improved with surface heat treatment.
- Stainless Steel: Stainless steel contains a minimum of 10.5% chromium content by mass, offering excellent corrosion resistance and good strength. It finds widespread use across various sectors due to its versatile properties.
IBARMIA introduces a new cloud infrastructure platform named SMART POINT, designed to be open to other platforms and hosting smart applications. This customer-focused solution provides access to reliable and valuable services aimed at increasing productivity through enhanced production control, precision, programming, machine self-learning, and maintenance.
WHAT?
SMART POINT is a cloud infrastructure and Software as a Service (SaaS) platform that offers access to reliable and valuable services. It is compatible with other platforms such as Predix, MindSphere, or Heidenhain. Additionally, it provides the opportunity to host applications for third-party companies within IBARMIA's value network, including tool manufacturers, machine component manufacturers, CAD-CAM providers, and other machining enabling technology suppliers. This platform serves as the digital medium for apps incorporating various functionalities that enable Smart Machine Performance and Smart Machine Use.
WHAT FOR?
The SMART POINT platform from IBARMIA offers customer-focused services and solutions, contributing to significant benefits for machine users. These benefits include increased productivity through enhanced production control and process optimization, guaranteed precision achieved through intelligent real-time machine tuning based on online conditions, easy definition of high-performance machining processes through technical suggestions, simple programming cycles, and machine self-learning capabilities. Additionally, maintenance optimization enables prevention and prediction of issues.
HOW?
Smart Machine Behavior applications make autotuning decisions by comparing the real state of the machine with data from a sensitive machine system (digital twin) and historic performance data. Examples of real-time intelligent autotuning capabilities include autotuning and compensation for thermal deformations or axis dynamics based on part weight or morphology. For Smart Machine Use, easy interaction with the machine and definition of complex processes are crucial. For instance, providing a selective and easy-to-configure view of the process executed in real-time and historically facilitates optimal analysis and self-learning of machining processes.
WHY?
SMART POINT provides transparency into the status of machines and processes, facilitating more effective and intelligent decision-making. By making machine and process status transparent, SMART POINT enables users to make informed decisions more easily.
SMART MACHINE PERFORMANCE_
ALL THE APPs
1_ LUBRICATION ON DEMAND
This intelligent and sensorized equipment is aimed at adjusting the lubrication requirement in ballscrews according to the variable operational conditions in terms of loads, temperatures, velocities, etc. The objective of this adaptive lubrication is to minimize the friction torque in these ballscrews as a means of increasing their efficiency and, above all, their lifetime. This on-demand lubrication system has the following characteristics:
• Integration of a simulation model for calculating, in ballscrews, reference temperature and friction torque values for specific load, temperature, and velocity conditions.
• Automatic detection of abnormal deviations among values measured in ballscrews and calculated reference values.
• Automatic adjustment of lubrication to minimize any deviation detected among reference values and measured values out of the working area as well as reduce the machining noise.
2_ MACHINE THERMAL COMPENSATION
Thermal induced errors are the most significant errors on machine tools; the thermal error compensation is designed to compensate for thermal drift of the Tool Center Point (TCP) due to thermoelastic deformation of the machine. The effect of some particular heat sources on the drift of the TCP has been characterized very accurately, regarding the temperature of the heat source and TCP position; therefore, it is possible to compensate for this drift by means of some temperature sensors distributed on the machine. The thermal error compensation has the following features:
• Based on temperature measurement on many points on the machine.
• Static and position-dependent machine error compensation.
• Compensation for 3-axis machines.
3_ ELECTROSPINDLE THERMAL COMPENSATION
The compensation of thermal drift of the main spindle is designed to compensate for thermal drift of the Tool Center Point (TCP) due to thermoelastic deformation of the main spindle. There are two sensor kind solutions, on one hand direct measurement of the main spindle drift which is carried out by non-contact sensors; on the other hand, thermal drift is estimated by the measurement of main spindle bearing temperature. The compensation of thermal drift of the main spindle has the following features:
• Direct and indirect measurement of thermal drift of the main spindle.
• Available for various spindle references.
4_ MACHINE COOLING ON DEMAND
The cooling systems are one of the main electric power consuming systems on the machine tool, it is normally sized to the maximum flow consumption and the maximum heat dissipation whereas this power is not required all the time on the machine. The Demand Operated Cooling System (DOCS) adjusts the pressure and the flow of the refrigeration of the gas circuit to the flow and pressure of the coolant circuit. This way, the cooling of the machine is steadier and less prone to thermal micro-oscillations of the TCP. The features of the DOCS are the following:
• A frequency converter for fan and pump motors.
• Flow and pressure sensor for both circuits.
• Controller of the coolant system adapted to the machine tool.
• Steadier cooling less prone to thermal micro-oscillations of the TCP.
5_ ELECTROSPINDLE PRELOAD CONTROL
This equipment is aimed at adjusting, by means of an appropriate actuator, the preload of electrospindle bearings according to their specific load and velocity values. The idea behind this adjustable preload is to reduce the preload in non-demanding operations and increase it in demanding ones as a means for maximizing the stiffness and accuracy values when required, while at the same time maximizing the lifetime of these electrospindle bearings. The main characteristics of this equipment are the following:
• Integrated force monitoring capabilities for detecting the requirement level for electrospindle bearings.
• Automatic spindle bearing adjustment according to the type and level of forces detected by the integrated force sensors.
6_ AXIS AUTOTUNING CYCLE
This application tunes in an automatic manner the gain values of position and velocity control loops of moving axes in machine tools. This automatic tuning procedure is aimed at maximizing the position loop bandwidth for the case of variable moving masses, especially for the case of variables masses placed on rotary and mobile tables. This application has the following features:
• Automatic measurement of axis inertia for every notable change in the mass on moving tables.
• Automatic calculation of natural frequencies and inertia ratios by means of motor consumption signals.
• Automatic adjustment of velocity and position control gains for maximized position loop bandwidth according to the specific values of mass, inertia ratios, and natural frequencies in the feed drive.
7_ MACHINE SPINDLE PROTECTION
This smart equipment integrating vibration sensors and monitoring tools has been designed to detect at a very early stage abnormal situations and disturbances that may affect the lifetime of main spindles, especially imbalanced tools and collisions among spindles and machined parts. This equipment will also take decisions for minimizing the effects of those disturbances and will also monitor the condition of spindle bearings in a continuous manner. This protection equipment has the following characteristics:
• Monitoring of spindle imbalance during idling conditions and automatic warning for the case of imbalance values that are above predefined values at specific balance grades.
• Automatic stop of spindle feed axis for the case of abnormal vibrations above security threshold values.
• Continuous diagnostic of the state of spindle bearings for preventive maintenance purposes.
8_ RESIDUAL UNBALANCE CHECK FOR ROTATING AXIS
Unbalance reduces the lifetime of the bearings and other components, produces noise and may be a safety risk; the Rotatory Axes Unbalance Compensation (RAUC) enlarges the life and the safety of your machine. Accelerometers located on the axis detect static, coupled, and dynamic unbalance and fires an alarm that stops the spinning of the axis. RAUC detects the causes of the unbalance among clearance on the bearings, bending on the shaft, and uneven mass distribution; for the latter on rotary tables, it proposes the location and weight of balancing masses. The RAUC features are the following:
• Static, coupled, and dynamic unbalance detection.
• Clearance of bearing, shaft bending, and uneven mass distribution detection.
• Balancing masses weight and location suggestion for rotary tables.
9_ STATUS MONITORING
Machine's current state can be viewed in real-time using a web application using any internet device. Deviations from production plan can instantaneously detect and notifications regarding production events can be received.
10_ CHIP BREAK FUNCTION
Long chips are needed to be removed from the machine manually, causing long machine
SMART MACHINE USE
ALL THE APPs
1_ B AXIS FIT IN
High workpieces often pose problems during internal machining due to the difficulties in introducing the tools into the cavities. The B axis fit-in cycle enables simultaneous movement of the table in X and Y with the long tool, allowing safe machining.
• Synchronized movement of the tool and table to maximize machine efficiency.
2_ GEAR HOBBING CYCLES
The gear hobbing cycle assists machine operators in programming gear hobbing strategies quickly and easily. An interface gathers basic geometrical features of the gear and generates CNC code automatically, significantly reducing programming time.
• Operator-friendly cycle through dialog programming.
3_ TECHNOLOGICAL CALCULATOR
The Machining Technological Calculator is a user-friendly tool for estimating cutting conditions, net metal-cutting power demand, material removal rates, cutting forces, and spindle torques for various machining applications.
• Input fields for various machining parameters.
• Provides cutting conditions and estimated power demand, forces, and torque.
4_ ADD+PROCESS TECHNOLOGICAL CALCULATOR
Designed for design engineers, manufacturing engineers, and machine operators, this calculator supports the use of AM technology for producing metallic parts. It provides a database of process parameters for different material feedstocks and calculates productivity, powder efficiency, and material deposition rates.
• Includes materials like AISI 316, Hastelloy X, and Inconel 718 for 3D part manufacturing.
• Provides layer thickness and distance between adjacent clads for toolpath programming.
5_ BEST FIT PART ALIGNMENT
The centering assistant for variable over-material parts streamlines the parts setup and reduces machining time. It calculates the part center position/s automatically and optimizes machining strategy.
• Calculates part center position/s automatically.
• Optimizes machining strategy to reduce air cut trajectories.
6_ CNC AUTOTUNING CYCLE
Auto-tuned Linear Tables (ALT) automatically detect axis inertia and set up optimal performance parameter sets, reducing vibrations, response time, and overshoots for better machine accuracy.
• Automatic inertia detection.
• Automatic setup of tuning parameters.
• Minimizes human errors in specifying inertia.
7_ MACHINE HISTORIAN
Critical signals, fired alarms, and key performance indicators are securely saved on the cloud for querying when needed, aiding operators and CAM engineers in boosting machine performance and workpiece quality.
8_ REPORTING & NOTIFICATIONS
Periodic reports and notifications keep users updated on production events, machine performance, and component health.
9_ 3D MONITORING
The toolpath can be visualized in 3D, allowing key process signals to be projected onto the reconstructed toolpath for problem resolution or optimization of machining.
