hp tooling 2020 #1

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cover story that may have been instigated by the grinding process, such as the wheel pores stay open to accommodate grinding oil and can remove the chips that have been gener - ated during the high material removal rates. Diamond is the ideal material for dressing tools, as it is much harder than the aluminum oxide of the threaded grinding wheels employed in the process. Only rotary dressing rolls can match the high requirements regarding geometry, service life, and efficiency during the dressing process. Illustration 6 shows a multistart, reverse-plated diamond dresser. Additionally, this dresser features an RFID chip that can communicate with the machine. frequent part changeover is required. This system reduces set-up times and increases productivity, translating into economic use of the continuous gear-grinding machine for small or large batch production. As described for the diamond dressing tools, the fixturing also can be fitted with RFID chips, and the resulting system “machine tool - fixturing - grinding wheel - dressing tool” makes for a grinding process perfectly adapted to the highest quality requirement both in accuracy and in short cycle times. The RFID option allows the tracking of the number of fixturing operations, the monitoring of maximum and minimum clamping pressures, and the integration of preventive maintenance. Furthermore, for a known part, the part data stored in the clamping tool can assist the machine tool in moving automatically into the correct set-up positions. 6-Diamond dressing tool with RFID ring 7-Clamping arbor with integrated RFID-chip Radio Frequency Identification (RFID) built into dressing tools serves, among other things, to generate and utilize usage data. The number of potentially remaining dressing cycles is stored in the dressing tool and can be read and accounted for by the machine. This offers the end-users an overview of the potential remaining dressing life, allowing stock management and determining when new tooling should be ordered. Furthermore, the RFID chip also stores all the geometrical data of the dressing tool, which is directly read by the machine. For these reasons, input data errors are eradicated. Additionally, the end-users can choose from further options such as connections to internal and external tooling databases. Work Holding Precision gear grinding results depend on fixturing of equal high precision, which only hydraulic expansion can deliver with a repeatability of ≤ 3 micrometers. To maintain control over the whole gear-grinding process, Reishauer decided to make its own fixturing. The clamping tools are tailor-made to specific parts. The hydraulic expansion mandrels can be coupled to quick-change bases if a Made in Switzerland The high degree of in-house manufacturing or vertical integration is the foundation of the Reishauer performance portfolio. All core components are developed in-house and manufactured in Switzerland. In this way, the continuous generating process holds its leading-edge as the superior hard-finishing method for making gears. author: Walter Graf, Marketing Manager Reishauer AG, Switzerland. GrindTec 2020, hall 3, booth 3017 further information: www.reishauer.com 8 no. 1, 2020, March

materials & tools Pushing forward boundaries of additive manufacturing with new metal powders and components Sandvik and BEAMIT joined forces at Formnext 2019 in Frankfurt to showcase the strength of the two companies’ combined offering in metal powder and additive manufacturing. Together the companies have leading capabilities across the whole additive manufacturing value chain, from metal powders to finished components. Earlier in 2019, Sandvik acquired a significant stake in BEAMIT - a leading European additive manufacturing (AM) service provider. The joint Sandvik-BEAMIT booth at Formnext featured several industrial additive customer use-cases in a wide range of materials, produced via different additive processes - along with Sandvik’s wide range of Osprey ® metal powders, now also including nickel-based superalloys and titanium. These high-grade powders can be used to produce light, but extremely durable components, with some incredible internal geometries that maximize their performance characteristics, making them suitable for use in demanding industries such as aerospace, automotive and energy. With these additions to the material program, Sandvik now offers one of the widest alloy programs on the market for additive manufacturing. In addition, the company’s additive machine park includes all relevant additive manufacturing processes for metals - meaning that Sandvik can tailor the powder to any printing process. High-profile 3D-printed components The Sandvik-BEAMIT booth featured some high-profile 3D-printed components which underline the tremendous pace of technological advancement in the additive manufacturing sector. These include the world’s first 3D-printed diamond composite. This super-hard material is produced using an advanced proprietary Sandvik-process, printing in a slurry consisting of diamond powder and polymer, using a method called stereolithography, where complex parts are produced, layer by layer, using ultraviolet light. A tailor-made, post-processing method then makes it possible to achieve the exact properties of the super-hard diamond composite. “Until now, the production of super-hard diamond materials has only allowed for a few simple geometric configurations to be formed. But the new process means it is now possible to 3D-print diamond composites into almost any shape, which can revolutionize the way industries use the hardest natural material on the planet”, says Mikael Schuisky, VP and head of R&D and operations, Sandvik Additive Manufacturing. Another innovation on display at Formnext 2019 was the world’s first 3D-printed, smash-proof guitar (in titanium, of course), tested by rock legend Yngwie Malmsteen, and produced earlier this year as a means of showcasing the highly precise and amazing durable nature of the additive manufacturing process - and the strength of titanium. Revolutionizing milling cutter in titanium and 3D-printed parts in super duplex Another innovation on display from Sandvik is the 3Dprinted lightweight CoroMill ® 390 titanium milling cutter, which is produced through additive manufacturing, reducing its weight by 80 % and increasing its productivity by up to 200 %. Sandvik has also produced 3D-printed parts in super duplex steel Osprey ® 2507-AM, with hardness and corrosion resistance properties that make them ideal for the harsh conditions encountered in the offshore and marine industries. Yngwie Malmsteen testing the 3D-print smash-proof titanium guitar information: www.additive.sandvik no. 1, 2020, March 9