9B971d01

Mikron delivered an HSM 400 Uequipped with motor spindle with 42,000 rpm to E.S. Tooling inBelgium. It is the 1,000th machinewith a spindle from this powerclass, a world record in the areaof chip removal.

Jens Thing

For years, Mikron machineswith motor spindles have won pop-ularity by virtue of their high reli-ability. When integrated in a com-plete machine system, they enablecost-efficient production. The mo-tor spindle has become the stan-dard today for high performanceand high speed milling machinesdue to a range of user benefits.These advantages include:- High power density (high

torques and speeds using lit-tle space), which, with goodaccessibility to the workpiece,permits high performance

and high speed milling. - Quiet running and concentric-

ity precision which enables good surface qualityand precision.

Large selection of motor spindlesThe selection of Mikron motor

spindles ranges from 12,000 rpm

to 54,000 rpm, to tool holders suchas HSK 32 E, HSK 40 E, HSK 50 E,HSK A 63, ISO 40 and torques up to200 Nm. The maximum number ofmotor spindles will be removed inthe range of 12,000 to 24,000 rpm,whereby those with HSK A 63 in-terface will be preferred. Togetherwith numerous users of its ma-chining centers, Mikron, has overmany years, consolidated highspeed machining in mold makingand in the production of high-qual-ity parts. Therefore, the motor spin-dle with 42000 rpm and HSK 40 Einterface has proved to be a goodchoice. Mikron is, thus, in the po-sition to celebrate this record of1,000 machines with 42,000 rpm inindustrialized application. Mikronexpresses its gratitude to the usersof its machining centers for theircontinued trust in this technology.A spindle, which is delivered 1,000times in the 42,000 rpm powerclass, must be distinguished as a

reliable product owing to produc-tion and assembly safety. For years,Mikron machines have beenequipped with spindles made byStep-Tec. Like other spindles too,even the spindle with 42,000 rpmwas developed further and with in-tegration into a complete machinesystem, comes with the smart ma-

chine Module APS (AdvancedProcess System), ITC (IntelligentThermal Control) and SPS (Spin-dle Protection System) developedby Mikron.

The smart machine moduleAs a system, APS is in the po-

sition to continuously demonstratethe vibration arising during themilling process and to visualize itfor the user. With new access to themilling process, the productionprocess can be optimized with apositive influence on surface qual-ity, workpiece precision, tool en-durance and spindle service life.

Mikron delivers APS as stan-dard with all machines which are equipped with Step-Tec motorspindles.

ITC is an automatic compensa-tion of ensuing thermal changes inthe Z-axis, which ensures that themachine precision remains in alower tolerance range over time.

SPS constantly monitors thecurrent status of the motor spindle and in case of deviationfrom the normal status, can stopprocessing and thus prevent or reduce possible damage to the motor spindle.

The Smart Machine has otherinteresting modules which Mikronwould be happy to present at anytime. Our distributors in variouscountries are happy to provide information.

Good service is a mustMotor spindles in general, and

even high capacity motor spindlessuch as the spindles with 42,000rpm by Step-Tec, cannot assertthemselves on the market withtheir excellent technology alone. Inthe event of failure due to wear orother influences, the user needsreliable and quick spare parts. Overthe years Mikron has developed alogistics system which ensureshigh reliability and enables quick

delivery worldwide. Thus, users of Mikron machining centers haveshorter downtimes during possi-ble failures.

E.S. Tooling gets the 1,000thMikron machine

E.S. Tooling a Belgium compa-ny relies on Mikron machines andservices. The company was found-ed in 1996 by the current CEO, ErikSchildermans. E.S. Tooling flour-ished within a few years. Today, itmanufactures molds and tools forthe automobile industry and evenparts for the medical and optics in-dustry. The deciding factor for ac-quiring a Mikron HSM 400 U wasthat this machining center allows5-axis milling simultaneously, andtherefore fully automated opera-tion is possible. Also it’s importantnot to forget that Mikron machineshave first class ergonomics. Thenew HSM 400 U for E.S. Tooling is naturally equipped with a highperformance motor spindle with42,000 rpm. It will be integrated ina production cell which consists ofa handling system and anotherHSM 600 U. The target is to oper-ate the plant in 3 shifts 7 days a week.

Mikron wishes E.S. Tooling con-tinued great success.

Page 2-3: Precision golf clubwith the UCP 1350

Page 10: UCP 600 Vario sets anew standard

Page 4-6: Swiss precision forthe aviation industry

Page 16: Camel races withjockeys from Switzerland

Page 13: Prototype productionusing a Mikron XSM 600U

Specialist journal from MikronAgie Charmilles AG

for the Milling Technology

Issue 15

Mikron celebrates delivery of its 1,000thmachine with 42,000 rpm

www.mikron-ac.com

Selling price:Euro 3,00CHF 4,50US $ 3,00

2 Universal machining HSM today Nr. 15

The KRAMSKI Group is an inde-pendent family concern based inPforzheim, Germany. In 1978,Wiestaw Kramski, together witha partner, founded KRAMSKIGmbH as a production unit for themanufacture of precision tools.

Gordana Uzelac

Today, the company designsand manufactures punching dieswith which stamped metal partsare manufactured for electrical engineering. The medium-sizedproprietary company is among the best in its field worldwide. With over 350 employees at three production locations in Germany,

North America and Sri Lanka,KRAMSKI has been a reliable part-ner for 27 years. In 1999, the com-pany acquired a factory built according to the latest standardsin Pforzheim, in the industrial beltof Wilferdinger Höhe, HeilbronnerStrasse 10. The key technologiesdeveloped by KRAMSKI, such asrivet insertion of Ag and Ag Sn Owires in the punching die, punch-es of roll-bent parts, use of ceramic, integration of weldingtechnology, measuring technologyand assembly in the tool at highspeeds resulted in the companytaking a pole position in its field.Wiestaw Kramski, a golf player atheart and company leader with

foresight comments on how theyreached the top position: “This suc-cess is attributed to our worldwideapproved and popular high per-formance punching and precisiontools as well as to the capability ofapplying our skills profitably, ori-ented towards requirements andthe market. Today, we manufacturepunching dies, plastic parts, andcompound parts as well as sub-assemblies and samples for allfields and industries with a consis-tent zero-error philosophy. Thetools designed and manufactured

by us are the guarantee for highparts’ volumes, low follow-up costsand maximum productivity.

From tool-maker to golfer How does an entrepreneur from

the tool and mold-making indus-try design his own golf putter? What was the background? What was the personal motivation?So many questions that cannot beanswered easily in one sentence.So we asked W. Kramski to clarify.“In 1987 when the first golf courseopened in Pforzheim, I seized theopportunity and started playinggolf. The first putter I bought wasan old second-hand putter. I likedthe grip and feel. Since then, I’veplayed with many different kinds ofputters. As if in a cycle, I added anew putter to my collection everyyear. Whether in Singapore, Dubai,Japan or Portugal I could neverwalk past a professional shop. SoI tested all kinds and brands of put-ters. I was not satisfied with any ofthem putters. This didn’t improveeven when I started wearing bifo-cals. On the contrary. The glasseswere finally the real reason why Idecided to get intensively involvedwith putters. That is how the ideawas born”. The HPP putter collection is atrendsetter in functionality, preci-sion and harmony. W. Kramski invested almost three years to

Dear Readers,

For months, Mikron has regis-tered an above average numberof new orders. Obviously, we aredelighted. We owe this successto all those who have trusted usand have been satisfied with thequality of our machining centers.Due to the high load, we are ex-panding our production unit andare hence looking for additionalpersonnel. By doing so, we wouldlike to improve our current delivery situation significantly.Companies for chip removal intool and mold making as well as in production are running to capacity worldwide. A geograph-ical shift can be seen for variouschip removal tasks, which is how-ever not rigid, but rather alwayskeeps pace with new productiontechnologies and concepts. Thus, Mikron presented sevennew machines and further de-velopments at the EMO 05 inHanover. These innovations arein line with the Mikron philoso-phy and represent high qualitymachine construction. We haveplaced special emphasis on theintegrated and optional automat-ic feature. Thereby, it is alwaysensured that the best possibleaccess to the work area is pro-vided. More modules will beadded to the area of “smart ma-chines”. Consequently, we willoffer our customers more com-fort, safety and technology feed-back. Our field representativeswill be happy to offer personalconsultation. For more detailed information on Mikron products, please contact our distributors or visitwww.mikron-ac.com. We strive to improve your suc-cess with our commitment.

Editorial

Jens ThingBrand Manager Mikron

Precision golf club with aUCP 1350 by MikronFor more than 25 years, KRAMSKI has stood for quality, innovation and precision. It is the provider and high-end solutions partner for complicated and sophisticatedstamping and injection molding products

3Universal machiningHSM today Nr. 15

design the ideal putter. In fact, with the HPP product line, he has successfully introduced an extraordinary putter range, withwhich pros, amateurs and even spectacle-wearers experi-ence sensational putts!

Development and productionWith his wealth of experience

in tool-making and injection mold-ing, by applying the most modern3D computer technology, and withthe help of high tech processingmachines, such as the Mikron UCP1350, the putter development gota steady boost. Under strict obser-vance of the “Rules of Golf” as wellas through regular consultationswith Club Pros and Golf Friendswith single-digit handicap and 30months of development time, theHPP 330 was finally created. In all,ten development stages were re-quired to present the HPP putterline in its perfected form.

High quality materials with per-fect processing

Whether made of metal or plas-tic, the products and the high per-formance precision tools from thehouse of KRAMSKI are inimitablein the literal sense, as we alwayswork in compliance with the com-pany philosophy: Ideas realisedwith perfection. And this principlewas naturally also the force behindthe design and manufacture of theHigh Precision Putter line. TheKRAMSKI High-Precision Puttersare processed on a UCP 1350 highspeed Mikron milling machine.Milled precisely from extremelyhigh grade materials, three-dimensional and individually. Finally, the putters are hand-polished for the final finish, untilthe conical shape is created withthe harmonious striking geometry.The putter design is discreet. Theshape and line of the High-Preci-sion Putter collection (HPP) is extremely geometric. These arepurists in the true sense, whichmust be especially emphasised inview of the predominantly futuris-tic design of putters today.

Putter already in the top classWithin only one year, W. Kram-

ski succeeded in pushing forwardhis putter to the top class in theworld. Some of the best players already have this putter in their golfbags, others are in the process oftesting it. It is popular even withnew players. Sean Einhaus, thecurrent best German young player– three times German Master 2004and winner of the current GermanMasters title 2005 in the age groupof 16 years, plays with the HPP 325and is impressed.

A quick look at the statisticsshows that golf as a sport offersenormous economic potential.Thus, in 2004 in America over 27 million golf tournaments were

organised. In Germany, there are already about 500,000. So, W. Kramski assumes that in abouttwo or three years, he will producebetween 25,000 to 30,000 puttersper year.

The charismatic businessman,W. Kramski, knows how to inspireothers with his ideas, visions andhis courage to set new trends. Inthe last 27 years, he has won

many awards and accolades for his excellent entrepreneurial de-velopment. KRAMSKI, the com-pany is seen as a partner of all companies. With its solutions, itsupports over 300 companies from20 industries in Europe, overseasand Asia. Day by day it helps itscustomers to manufacture precise,process-oriented and, above all,profitable products.

www.mikron-ac.com

Putter HPP 325, ground view

Kramski Milling Shop Manager, Alexander Dukart, during putter manufacture on the Mikron UCP 1350

Professional golfer Scott Drum-mond (right), just 36 hours be-fore start of his game, decides toplay with the newly testedKramski Putter HPP 330 andreached a sensational 7th placeat the Volvo Masters in Valderra-ma 2004, a prize money of€103,125 and qualification onthe US PGA Tour. Michael Torres (left) – responsi-ble for Marketing and Sales atKramski – accompanies profes-sional players on the tour.


5.33pm Christmas Eve...When many UK companies werepreparing to close down for theholiday break and British workerswere either making a beeline tothe local pub or frantically doingsome last minute Christmas shop-ping or even just collapsing infront of the TV – a Mikron VCP 1350high-performance milling ma-chine was being delivered to BAESystems’ facility in Samlesbury.

Ged Scully

The arrival of the new machine,due for installation at the com-pany’s High Technology Tooling Facility (HTTF), had been eagerlyanticipated by everybody at BEASystems involved in the planningand procurement process – start-ed just 3 months previously! A similar adrenalin rush was also being collectively felt amongst stafffrom Agie Charmilles - as this machine was the first Mikron machining center to be installed atBAE Systems and was the culmi-nation of many months hard workand intensive planning.

With a requirement that theMikron VCP 1350 be fully opera-tional by Week 8 in order to startproduction on wing and fuselagetooling for state-of-the-art jet air-craft ... it was vital that a strong,highly-focused and proactive part-

nership was created between the two companies so that the time critical deadlines could beachieved.

Target reached in time Due to the commitment and

dedication of the project teamsfrom BAE Systems and AgieCharmilles the Mikron machinewas installed, commissioned andready for action by the Week 8 deadline.

Phil Green, Facilities Engineerat BAE Systems, the man respon-sible for ensuring that the projectwent to plan, gives us his view.

Volumetric accuracy is essential‘We knew that the Mikron VCP

1350 was an excellent machine andwould suit our requirements per-fectly. We were, and still are, par-ticularly impressed with its accu-racy and versatility.

‘The tools we require are intri-cate. Volumetric accuracy, evenwhen machining large workpieceswith complex geometries and, irrespective of the materials beingmachined (aluminium, titanium,tool steels etc.) – is essential. Weare often working to extremely tighttolerances and that’s why we needmachine tools that guarantee highaccuracy. Such precision is vital inthe manufacture of the jet aircraft’souter shape to ensure that its low

observability (stealth) characteris-tics are maintained.

‘But in addition to the technol-ogy it’s equally important that wehave suppliers and partners thathave the necessary project man-agement skills and people who can deliver.

The culmination of many monthshard work and intensive planning

‘With the tight deadlines we

work to – teamwork and commu-nication are vital. Our team com-posed of specialists from Opera-tions and Engineering workedclosely with the Agie Charmilles’team ... and the results were im-pressive.

‘The whole process, from startto finish, ran smoothly. Good com-munication meant that everyoneinvolved was kept up to speed withthe latest developments – andeveryone knew what was expectedfrom them ... and each other.

‘The effort of all concernedmeant that we achieved scheduleadherence and costs to budget in3 months! Usually a process of thiscomplexity and magnitude wouldtake 12 months to complete.’

Although the Mikron machineis the first to be installed at BAESystems – Agie Charmilles tech-nology is widely used across theaerospace sector.

Tony Steels, managing director ofAgie Charmilles, gives us his view.The installation at BAE Systems isgreat news for Agie Charmilles. ‘We knew that when we embarkedon this project that the competitionwould be fierce. And we were right.‘However, we knew that we had thebest product (VCP 1350) for BAESystems requirements and wewere right with that assessmenttoo ... because the Mikron VCP 1350is an incredibly versatile and accu-rate machine.‘We were also confident about our

project management and the ability to hit the Week 8 deadline.The experience and knowledge of our staff coupled with the ex-pertise of BAE Systems’ projectteam dovetailed perfectly. The result achieved are down to thepartnership approach adopted. It’sa case of great teamwork deliver-ing great results.’

www.mikron-ac.com

Mikron...on time...on

budget

BAE Systems install a Mikron VCP 1350 at its Samlesbury facility to make wing and fuselage tools for state-of-the-art jet aircraft

BEA System also produces parts for the airbus. Here the A 380 at the landing after itsmaiden flight in April 2005


The aerospace engine manufac-turer MTU Aero Engines has cho-sen UCP 1150, five-axis machinesmade by the Swiss companyMikron for machining turbine andcompressor disks.

Christoph Manegold

MTU’s prerequisite was the in-clusion of a Sinumerik 840D. Thiscontrol has been available for ashort time as an option for this machine series. The Siemens con-trol was successfully installed incooperation with Siemens Chem-nitz. Excellent results are beingachieved with the Mikron UCP 1150in this configuration.

With approximately 5000 em-ployees, MTU Aero Engines in Munich is the company’s head-quarters and its largest location. A sizeable number of airliners feature engines equipped withcomponents from MTU.

The Airbus A 380, the largestpassenger aircraft in the world,was recently introduced to the pub-lic in Toulouse, France and will be

propelled with engine componentsfrom MTU.

One important part of turbo en-gines for airliners include the in-dividual rotor disks in the low pres-sure and high pressure section.These rotor disks have radial slotsinto the individual turbine bladesare inserted and secured. The ro-tor disks are made of extremelyhigh temperature, ductile steelswith over 50 percent nickel content.

Milling machines that must ful-fill the highest technological de-mands are required to machinethese disks. Absolute process con-trol during machining is impera-tive with theses components, aseven the slightest uncontrolledstructural changes in the materialcan detrimentally affect operatingsafety in the air.

Machining these components,which are subjected to extremelyhigh temperatures and pressuresduring operation, requires a highlevel of technological know-howand first-class machine tool equip-ment that optimally meets the re-quirements for turbine production.

The search for the ideal millingmachine...

Consequently, MTU left noth-ing to chance in procuring newmilling machines with which to machine the turbine disks. MTUconducted a lengthy selectionprocess. A series of machines ofwell-known manufacturers wasselected and intensely tested as tostability, accuracy and surface fin-ish. During test machining of a tur-bine wheel, a clear favorite wassoon established – Mikron, a com-pany which is headquartered inNidau, Switzerland.

The five-axis milling machineMikron UCP 1150 proved to be avery stable machine capable of veryquickly and accurately milling theturbine materials, which are ex-tremely difficult to machine. TheUCP 1150 is equipped with a mo-tor spindle that can be swiveledover 135 degrees. Together with the directly driven round table thatcan be clamped hydraulically, itachieves the optimum machiningflexibility on five axes with a levelof rigidity equal to that of a 3-axismachine. The tool magazine

features 46 tool locations with op-timum clamp-toclamp time.

... but with Sinumerik 840Dplease

While MTUfound the Mikronmachine to be an ideal solution in terms of rigidityand kinematicalperformance, therewas still a chal-lenge regardingthe control: theMikron machinewas not as yetequipped with a

Sinumerik control. Thanks to itspositive experience with Sinumerikcontrols, MTU Munich standardizedon them and tailored its machin-ing programs accordingly.

Now there was a challenge fortechnicians on both sides. Jointmeetings were held to discuss howto proceed together. They weresoon in agreement that installationof a Sinumerik 840D into the five-axis machine UCP 1150 couldbegin.

Good “combination” in ChemnitzI was an excellent situation that

the Mikron machine series UCP1150 and 1350 are built in a Mikronpartnership plant in Chemnitz.Siemens was already delivering thecontrol cabinets for the Mikron machines from its company WKC(plant for combination technology),which is also located in Chemnitz.Therefore it was not difficult to expand the cooperation to includecontrols.

After the machine for MTU AeroEngines was set up in Chemnitz, itwas taken to the Siemens labora-tory in Chemnitz for several weeks,where the necessary adaptationand parameterization of the ma-chine to the Sinumerik 840D toolplace. Work proceeded with speedand expertise. “During commis-sioning, only a very few readjust-ments were left to make, “summa-rized Stefan Fahrni, ProductManager at Mikron.

Customized production for MTUFor MTU, the Mikron UCP 1150

was equipped with a number ofnon-standard options that are required for machining highly critical turbine and compressordisks. These include continuousprocess monitoring, e.g., of spin-dle speed, pressure of the coolinglubricant and quantity of the cool-ing lubricant.

For the cutting process at MTU,special oil is employed that requires installation of an oil fumeextractor with a spark detector system and explosion flaps. Thisavoids the risk of explosion for themost part and, in an extreme case,pressures that develop are drawnoff to the outside.

Each work piece is calibratedwith an infrared sensor becausethe MTU pursues a zero-error policy with a 100 percent qualitycontrol.

Sinumerik, now as an optionFour machines have been

delivered to MTU already and theyhave performed with excellence.Further machines are planned.

Thanks to MTU’s positive expe-rience with the machines, Mikronnow expects to sell the five-axismachine UCP 1150 and the some-what larger UCP 1350 in largerquantities, also with the Sinumerik840D control.

www.mikron-ac.com

When machining engine parts, MTU relies on Mikron machineswith Sinumerik 840D


In January 1996 Pedro L. Díezfounded his own company with thename Electrohilo S.L. Before that,he worked with different compa-nies in the area of blanking andpunching dies.

Ferran Santandreu

Electrohilo S.L. began as a sup-plier in metal processing and con-centrated on blanking and punch-ing dies with the help of wire electroerosion. This was because PedroL. Diez knew a lot about this indus-try. With the purchase of a wire ma-chine, Charmilles Robofil 310, hestarted the adventure with his owncompany. In 1997, he expanded thecompany to the aviation sector. Un-til today, Electrohilo S.L. has beenactive in both industries. When thecompany was first set up, therewere only two employees; today it employs over 11 workers. TwoMikron machines, six Charmillesmachines and two Act Spark ma-chines are part of the machinepark.

In January 2004, Diez onceagain proved his trust in the Agie Charmilles Group by buyingthe Mikron VCE 800 Pro. The VCE 800 Pro helps in processingblade carriers in low pressure tur-bines in different engines. Due to the high satisfaction with the

surface grinding results and theprecision during rough grindingand finishing, the managing direc-tor decided to acquire anotherMikron machine.

With the purchase of the VCE600 Pro, Electrohilo S.L. could ex-pand its customer base to the avi-ation sector. With the production ofhundreds of workpieces using theMikron machining centers, a step-wise optimization of the manufac-turing methods was achieved. Already during the first year, thecompany has succeeded in achiev-ing excellent productivity in thearea machining.

One of the most important requirements for business in theaviation sector is meeting the requirements of large manufac-turers. For this reason, companiesactive in this industry must show avariety of certificates. Electrohilowas awarded the quality certificateISO 9001-2000 and the aviation cer-tificate EN 9100-2003. It also com-plies with the environmental direc-tives of the European Union. Thecompany is in a constant processof optimization. For this reason, italso applied for the NADCAP cer-tificate for large engine manufac-turers, including Rolls Royce, Gen-eral Electric, Honeywell etc. Theclose association with aviationprojects of Rolls Royce and Airbus

(A 380 and TP 400) shows that Elec-trohilo is a powerful company inthe aviation industry. In the fore-seeable future, Diez is already con-sidering the purchase of a machinethat will also meet requirementsfor precision and finishing of sur-faces during the processing ofworkpieces with larger dimen-sions. Without doubt, this is theMikron VCE 1600 Pro which is de-signed for traverse paths of 1600 x900 x 875 mm.

At present, Electrohilo S.L. isexperiencing a continuous up-swing. In its workshop, the com-pany exclusively uses machinesfrom the Agie Charmilles Group,which also include Mikron and Act Spark.

Electrohilo S.L. – A company in

constant upswing!Electrohilo S.L uses a Mikron VCE 800 Pro

especially in component manufacture for the aviation industry

www.mikron-ac.com

7High-speed machiningHSM today Nr. 15

The mold designer, Shin YoungPrecision Co. Ltd. from South Korea, offers highest precisionand high performance within ashort delivery turnaround andwithout subsequent machiningwith Mikron HSM and XSM machines

Hocheorl Seong

Shinyoung Precision Co., Ltd.,the mold designers, was estab-lished in 1993. Over the last 12years, the company continued itsgrowth in mold and injection moldmaking for components for beep-ers and telecommunication de-vices. In 1998, Motorola pickedShinyoung Precision as supplier forits cellular phone network. Shiny-oung Precision used this opportu-nity to customize its mold makingand the plastic injection mold mak-ing to state-of-the art and to be-come a “top company”. In May 1999,Shinyoung Precision was listed onthe stock market for the first time.With its constant technical innova-tions, automation and standardi-zation of the work process, its pro-ductivity grew steadily. Even thedelivery system was improved andthe shorter delivery periods im-pressed customers.

Production round the clock – without shifts

Under the slogan “1105”,Shinyoung Precision had devised astrategy that was to help achievethe following ambitious goals: - only few days (less than 9

days) must be needed formanufacturing a mold

- the machining time for an injection mold must be lessthan 9 seconds

- no more finishing work mustbe required

- everything must be completedby the year 2005.

With a view to success, theShinyoung Precision MachinesManagement decided to purchasemachines from Mikron. In the past,Shinyoung Precision had used con-ventional milling machines withspindles from 6000 to 12000 rpmfor manufacturing molds. But whenthe company had to work with theSlogan “1105” to achieve the tar-get innovations, the old machineshad to be replaced with new ones.Machines enabling the use of

spindles with over 40,000 rpm wererequired. This was the only way tomeet the set targets.

In April 2002, Shinyoung Preci-sion engineers visited the "Inter-national Machine Tool Show 2002"in Busan. There, for the first time,they saw Mikron machines andwere impressed. During subse-quent meetings with Otra Co Ltd.,representative of Mikron in SouthKorea, the Shinyoung PrecisionPresident, Chang-Seok Shin, ob-served how, who and for what theMikron machines could be used.He observed that many tool andmold makers were using machinesfrom the Mikron VCP Series formilling, and were successful too.However, the Management decid-ed on a Mikron HSM 400 with au-tomatic pallet changer. Unfortu-nately, at that time machines withautomatic pallet changers were notimmediately available on the Ko-rean market, and Shinyoung Pre-cision had to be patient. The com-pany wanted to kill two birds with

one stone: on the one hand, a pre-cise machining of workpieces and,on the other, the possibility of au-tomation. However, it was not easyto wait until August, when this ma-chine would be available on the Ko-rean market. Shinyoung Precisioncompetitors working abroad werealready very successful with theMikron machines and Chang-SeokShin was afraid of missing the boat.However, his personal wish couldnot sway the management deci-sion, as it was his company policyto avoid night shifts for employees,but still produce 24 hours, roundthe clock.

First experiences with the HSM 400

By August 2002 things were inplace. The HSM 400 was installedat the Shinyoung Precision produc-tion premises. They could finallytake the first steps in the directionof high speed milling. After a shorttraining period, machining timescould be significantly reduced with

the HSM 400 as opposed to the conventional milling machines.Even the surface quality of work-pieces was significantly better. No more finishing work was re-quired. Instead of the spindle usedbefore with 12000 rpm, a highspeed spindle with 42,000 rpm wasnow used. At the same time, eventhe tool selection could be in-creased by around 0.3 mm spher-ical cutters. All of the afore-men-tioned factors contributed towardsreducing the total machining timefor a complete set of molds from25 to 13 days. The Mikron highspeed centers are distinctly fasterthan the cavity sinking EDM-machines used in the past. Theseentirely positive experiences en-couraged Shinyoung Precision toscrap all conventional milling ma-chines. In March 2003, the compa-ny purchased two more MikronHSM 400 machines.

The machine park expanded bytwo HSM 400U and two XSM 400Umachines

If we observe the market situ-ation for mobile phones, it is ap-parent that the lifetime of modelsis very short indeed. Naturally, thisis a favourable situation for a moldmaker such as Shinyoung Preci-sion, as there is a constant demandfor new models. However, on theother hand, customers are contin-uously demanding better surfaceand higher precision of molds andobviously with shorter delivery periods. This is only possible with5-axis machining centers.

Because of the good experi-ences with Mikron, on recommen-dation from Otra, Shinyoung Pre-cision purchased two HSM 400U

machines to meet market de-mands. After moving to new andlarger company premises, the ma-chine park was once again expand-ed, this time with two Mikron XSM400U. Both machines are equippedwith spindles with 54,000 rpm.

With the help of Mikron, Shiny-oung Precision became more and more successful. Now there is no longer any doubt that it will achieve its goals by the end of 2005. In the meanwhile, the com-pany has three Mikron HSM 400,two HSM 400U and 2 XSM 400U machining centers.

www.mikron-ac.com

Shinyoung Precision Co., Ltd.,the HSM 400, HSM 400U and

XSM 400U by Mikron. A successstory from South Korea

HPM 1850Ufor large parts


Perpetual positive results in pro-duction and the sale of machiningcenters are based on constantmarket observation and consider-ation of customer requirements.This results in innovative devel-opments, which set new standardsfor the entire market. Followingfashionable trends alone does notalways guarantee long-term suc-cess, but trend-setting design ofunique series does.

Mikron is known for its spirit ofinnovation, and in recent years has

defined many trends in the area ofstandard, high speed and high per-formance machining centers. De-velopments for the automated tooland workpiece changeover are par-ticularly pioneering. The huge mar-ket acceptance of the UCP 600 Varioclearly shows that in the first place,the customers’ demand is not forreliable and powerful individualcomponents, but rather for an ef-ficient, economical system, whichis complete in itself, and which can also react to inputs from out-side the system (external robots,clamping devices from different

manufacturers etc.). All require-ments of a modern machining cen-tre which contributes to the sus-tained success of a company.

The UCP 600 base machine together with the pallet changerand the new large tool changer isunique and extremely attractive forcustomers. In the past, the MikronHSM series has already shown thatthe automation approach makessense especially for high speedmachining centers. Now, even theVario gets more potential with theautomation of the tool changeover

Sustained success requires trend-settingconcepts. The UCP 600 Vario, together

with the pallet changer and the new toolchanger is one of a kind

UCP 600 Vario setsnew standards

All necessary components for a successful production are located over the smallest installation area

Top: Roughing the head part with a milling head and internal coolantfeed (IKZ)

The operator always has optimum access to the workpiece

Processing in the shaft area with a roughing mill

5-axis simultaneous machining of the teeth

Finished part before separation

Urs Hänni


process and with the 120, 170 or220 times tool changer. Price/performance is optimum in this combination and a machine with

such a configuration is, as alreadyproved, very cost-efficient.

The UCP 600 Vario is suitablefor an extremely versatile range of

applications. This includes cus-tomers who want to produce highquality parts in 5-side processing,like production companies, who

will have to manufacture medium-sized series and various parts in 5-side processing more economi-cally in the future. It is especially

customers in market regions withhigh salary costs who recognise thebusiness advantage of an UCP 600Vario with automation.

With new options, the UCP 600Vario does more justice to its claimto universality. A powerful vacuumunit for dust particles turns theUCP 600 Vario into a machiningcenter which is suitable for versa-tile processing of different metalsand also for occasional milling ofgraphite electrodes.

The new HSM 300 GraphiteMasteris the optimal machine for millingdusty materials. Together with the Heidenhain iTNC530 controlsystem, the machine correspondsto the latest technological fea-tures and replaces the previousHSM 300.

The HSM 300 GraphiteMaster is especially suitable for machininggraphite electrodes for tool andmold making as well as for the manufacture of electrodesmade of copper, for highly precise molds, stamps and matrixes.Mikron supports tool and moldmanufacturers with the HSM 300GraphiteMaster in order to coverthe rapidly growing graphite elec-trode market.

The BaseThe HSM 300 GraphiteMaster over-head version has a polymer con-crete base. This ensures bestdamping properties and maximumstability. Linear jigs and highly accurate drive stems ensure precise positioning and high rigid-ity on axis acceleration XYZ of up to 17 m/s2 (1.7G). The digitaldrive technology is also a guaran-tor for best machine dynamicswhen undertaking complex 3D machining. The user friendly and sound-absorbing cabin with ample access

to the machining room completesthe concept. The latest Heidenhaincontrol generation is used. iTNC530 imparts the necessary controlspeed to the machine to meet therequirements of very complexarithmetical problems.

Effective suction systemTo ensure clean and efficient ma-chining of graphite electrodes, apowerful extraction system includ-ing extraction frame, is included inthe standard scope of delivery. Spe-cial attention was paid to the airsupply to the machining area. With-in a few minutes, the extractionframe which is mounted on the ma-chining table can be easily removedand installed again. The automatictool changer is protected againstany form of contamination in thebest possible way. In other versionsof the HSM 300, the extraction sys-tem can also handle metal chips.

Tool changerA suitably large tool changer is ofgreat importance for the intendedarea of application of the HSM 300GraphiteMaster. Here, an 18x toolchanger (pick-up system) is ma-chine standard. A 27x tool chang-er is offered as an optional up-grade. This quantity of toolsenables proper selection of cuttingtools in the magazine and conse-quently simplifies handling.

The spindleThe ceramic hybrid suspension of the heavy duty spindle permitsspeeds of up to 30,000 rpm. TheHSK 40-tool holding fixture withoptimum concentricity allows pre-cise smoothing with the smallestcutting tools of up to 0.2 mm diameter, as well as roughing withtools having a maximum diameterof 13 mm. It is designed for stability and longlife. Thanks to lifetime lubrication,there are no oil drips from the spindle head which is a very im-portant issue when manufacturinggraphite electrodes.

Cooling / lubricationTo economically mill hard materi-als, the HSM 300 GraphiteMasteris equipped with a programmable(via NC programme) minimum oillubrication system. This lubrica-tion system is outstanding espe-cially due to its low consumptionof lubricants. At the same time, the maintenance and disposal ofpossible cooling emulsions is notrequired.

Technical specifications:

Traverse paths:X 380 mm, Y 390 mm, Z 255 mmSpindle characteristics:Speed range 5,000 – 30,000 rpm,

spindle power rating 6`kW at 100%duty ratioTool changer:Standard 18-tool capacity HSK 40(optional 27-tool capacity HSK 40)Machine base:Overhead version made from con-crete polymer, machine weight2900 kgDrives:Digital drive technology, linear jigsfree from play

Graphite dust extraction:Well thought-out extraction systembuilt in the machine which is highly effectiveControl unit:Heidenhain iTNC 530Operator console:With an ergonomically arrangedmembrane keyboard and 15" flatscreen.

www.mikron-ac.com

www.mikron-ac.com

HSM 300The new optimal solution for dusty materials

The robot interface enables combining the Vario with external robotsPowerful graphite suction: For occasional production of graphite electrodes


VCE Pro-X machines qualify them-selves through faster feeds of upto 36 m/min and through new pow-erful motor spindles with up to16,000 rpm at an 14.75 KW rating(40% duty ratio). Excellent valuefor money makes them particu-larly interesting.

Stefan Fahrni

The HSM and HPM milling tech-nologies are more cutting edgethan ever. Continuous developmentand increasing simplification overthe last decade has made these

technologies advance to enjoy anincreasing market share. Thistrend is unbroken. HSM and HPMtechnologies have continued to increase the pressure on conven-tional milling techniques. In orderto make them integrate into theHSM and HPM areas, Mikron hasdeveloped the new VCE Pro-X machines.

An important feature of HSMmachining is the high feed ratesand spindle speeds. On the newVCE Pro-X a great deal of attentionwas devoted to these technical "pillars". The performance of the

feed drives has been increased dramatically and allows feed ratesof up to 36 m/min at the same timeas an increase in acceleration. Allaxes are equipped with a linearmeasuring scale.

A particular highlight of the VCE Pro-X is the elaborately devel-oped and carefully produced Inlinemotor spindle which is manufac-tured by the company Step-Tec inSwitzerland. These spindles reachspeeds of up to 16,000 rpm at a14.75 kW rating (40% duty ratio).

To date, milling spindles havefrequently been driven either by a

gearbox or a belt or motor spindleshave been used. Gearbox spindlesare used for speeds of up to 10,000min-1 and high torque - belt spin-dles are used in areas of applica-tion with speeds up to approx.14,000 rpm.

The non plus ultra of the spin-dle drive is the motor spindle. Withspeeds from 12,000 to 60,000 rpmit covers the largest applicationarea and at the same time achievesa high torque. As a new feature, Inline motor spindles are beingused in VCE Pro-X standard ma-chining centers. On the basis of our consistent implementation of the technical pillars (high spindle speed and high feeds), theVCE Pro-X line is universally usedon shop floors.

These machines make it possi-ble to achieve considerably short-er machining times and therefore,larger order sizes. Even difficultjobs, such as the production of thinwalled workpieces, are now eveneasier. A further feature of greaterspindle performance is the protec-tion of the milling tools and there-fore longer life. With fast feed rates,individual parts such as perforat-ed plates, which include a largenumber of travel times, can be machined more economically.

Of course it is also possible tocarry out conventional machiningwith the VCE Pro-X. With a spindletorque of 94 Nm (40% duty load) itis possible to carry out large swarfvolumes such as in the manufac-ture of molds and in the aviationindustry but also those arising ingeneral mechanical machining,without further ado.

In this market segment, theMikron VCE Pro-X line offers un-beatable advantages.

The Mikron VCE Pro-X Line ma-chines are extensively equippedas standard with: • Actively cooled Step-Tec work

spindle• Cooling through the ICS tool• Glass measuring rods on all

axes• Heidenhain Control Unit

• Cleaning jets in the work-space

Options• 4th axis• Laser tool measurement• Programmable coolant jet• Bandpass filterand more

www.mikron-ac.com

The new VCE Pro-XLine from Mikron

Mikron presents the VCE 800 Pro-X and VCE 1000 Pro-X which are further developments

of the proven VCE Pro machining centers.

HSMtodayTM

Specialist journal from Mikron

Mikron Agie Charmilles AG Ipsachstrasse 16, CH-2560 Nidau Tel. +41 32 366 11 11, Fax +41 32 366 11 66,E-Mail: [email protected]

Brand Manager: Jens Thing

Managing and Design Editor: Jürgen Maurer

Photo adaptation: Vik Furer

Circulation: 45’000

Published in German, French, English, Italian, Polish, Spanish and Chinese

Photos: Cliff Design&Development, EADS, Electrohilo, E.S. Tooling, Kramski, Mandatec, Mikron, MTU, Shinyoung, Step-Tec

Print: Stämpfli AG, CH-3001 Bern

Issue 15, November 2005

© Mikron Agie Charmilles AG 2005

Impressum

www.mikron-ac.com

Agie Charmilles Group


Cliff Design & Development, aSwedish company, set itself thegoal of making its customers pro-totypes within 24 hours and deliv-ering the parts within the sametime-scale.

Fredrik Gedda, Martin Brun

Cliff Design & Development isone of Sweden's top component development and design compa-nies. With their skilled staff andtechnical setup, they specialise inproduct development, industrialdesign, producing prototypes andcreating 3D illustrations and visualisations. They aim to support all companies, however large, in their development and designprocesses, and thus improve theircompetitive edge. Cliff’s clients in-clude well-known companies suchas Volvo, Saab, Volvo Car Corpora-tion, Siemens-Elema, Orrefors,Kinnarps, BT and Stiga.

The company's objective is toget to know and understand theirclient's market so that they can implement the client's vision more accurately and efficiently.They employ their expertise to im-prove the form and function of finished components so that theclient will gain a competitive advantage in the marketplace.

Cliff also aims to become themost advanced and successfulproduct development and virtualsolutions supplier in Northern Europe. To achieve these aims,

however, they need to change theirwork procedures within the boundsof their corporate philosophy.

This means that they have to alter not only their working meth-ods but also their machinery base.So they are investing in new soft-ware and hardware. For producingprototypes, Cliff already owns oneof the fastest machines in Sweden– a Mikron XSM 600U. Time sav-ings and standardisation helpedmassively reduce production costs,with no negative impact on thequality required by clients in termsof surface finish and dimensionalaccuracy.

The new concept is called Speed 24

Cliff set up a new team toachieve this goal. Managing Director Patrik Sjöstrand ex-plained, "We created what was almost another 'company' withinthe company. It consisted of a team leader, machine operators,CAD/CAM specialists and modelbuilders. Working hours are flexi-ble, but the team has to be on per-manent standby to tackle new jobs.The clock begins to tick once theorder is confirmed. Before westarted using the XSM 600U it wassometimes difficult to meet cus-tomer’s deadlines. But the Mikronmachine has eliminated that prob-lem completely." The company iscurrently pushing ahead with automation. This means that the 7-pallet pallet changer andMikron's 'smart machine' modules

are due to be integrated into thework process.

For any company involved inprototype production, the compo-nents' surface finish is crucial. Cliffis no different. Mats Carlsson, oneof their operators, told us, "We doour machining on the XSM 600U.The thermally stable 36,000 rpmspindle and the 'smart machine'modules with the laser measuringsystem enable us to achieve accu-rate form on every job. Cliff havealso begun to use the XSM 660U tomachine aluminium componentsand even glass. First the operatorswent on a programming course at the local Mikron dealership, TL MaskinPartner, to ensure theyhad a first-class grounding. Theythen learned how to use the HSMmilling technology on a course at the manufacturer's own HSMskill centre.

"We have gone a long way to-wards achieving our objectivessimply by purchasing the XSM600U", says Christian Wadell,Cliff's corporate planning and pur-chasing manager. "The expert ad-vice we got from Fredrik Gedda, theSales Manager at TLMaskinPart-ner, had a major influence on ourdecision to purchase, while our visit to the top HSM machine manufacturer, Mikron, completelyconvinced both Boris Uvalic andme. Fredrik Gedda saw from thevery beginning that the XSM 600Uis the best machine for our re-quirements.”

Prototype productionusing a

Mikron XSM 600U

Machine type XSM 600U

Work range: X: 800 mm B: + 30° / -110°Y: 600 mm C: 360°Z: 500 mm

Working spindle: 54´000 min-1, 42´000 min-1

Feed drives X, Y, Z: 80 m/min B, C: 200 min-1, 360 min-1

Acceleration X, Y, Z: 25 m/s2 B, C: 30 rad/s2, 125 rad/s2

Control: Mikron Cyclone Expert / Heidenhain iTNC 530, 2 processors

smart machine moduls: APS, APS extented, OSS, ITC-5X, RNS

14 High-speed machining HSM today Nr. 15

For more than 10 years, Step-Techas been designing, manufactur-ing and selling motor spindles forleading manufacturers of machin-ing centers. The company hasbeen based in Luterbach since2000, very close to Solothurn,Switzerland.

Jürgen Maurer

The Step-Tec specialty is fast,high performance spindles with in-tegrated motors. Workpieces ma-chined with it boast of excellentsurfaces and only require finishingin special cases. Machining timesare distinctly reduced together withthe corresponding machining cen-ters. The Step-Tec spindles areused largely for milling and drillingapplications in tool and mold mak-ing as well as for production. In-ternational companies like Grob,Emag and numerous suppliers forthe aviation and space industry aresome of its customers. Close co-operation with research institutes,know-how coupled with high inno-vation potential and, naturally,close cooperation with its cus-tomers and its interesting applica-tions explain Step-Tec’s passion fordesign, production and customerservice. The requirements for spin-dles vary greatly. Thanks to Step-Tec’s vast experience, the most im-portant prerequisites are known.Close cooperation with machinemanufacturers enables Step-Tec to be involved as early as in

the design stage of new machine generations. Hence, the spindleson prototype machines can be sub-ject to higher loads in several ways.The spindles are, therefore, sub-ject to continuous operation phas-es, before being launched onto the market. With this cooperation,Step-Tec knows in advance if thereis something new in tools, materi-als and processes. Thus, the spin-dles can be adapted accordinglyand therefore increase customerbenefits.

Advantages of Step-Tec spindles: Step-Tec spindles guarantee

extremely high chip volume, pre-cision and optimum surfaces. Theusage time of tools, processing ma-chines and spindles, as well as operational safety, are increased.Good machining results are ob-tained even with thin and long tools.These advantages are achievedthrough the synergy of many spe-cial design features of Step-Tecspindles:- Motors with a large bore hole

on the rotor are design pre-requisites for high rigidity.

- Hybrid bearings (rings madeof steel, balls made of ceram-ic) and specially designed lubrication systems enablelow-vibration operation athigh speeds.

- The special spindle structurefor minimum axial dislocationof the spindle shaft.

- The integrated sensor mecha-

nism with temperature andlength measurement, vibra-tion analysis and permanentrecording of operating data.

Over 2 million tool changes! Production spindles, and their

clamping systems, are exposed to

an extremelyhigh number of toolchanges. The follow-ing example gives an ideaof what wear and load thematerial must endure:- 5 tool changes per minute- produces 300 tool changes

per hour- computed running time of

spindles 7, 000 hours- total results 2.1 million tool

changesAdded to this are release time cycles of 200 ms and highly chang-ing speeds. The demands on ma-terials and the entire clamping sys-tem are thus comparable with aformula 1 engine.

New products for more productivity

Gerhard Zuber, Manager ofSales, Service and Marketing atStep-Tec spoke to us in an inter-view.

Mr. Zuber, what design trends canwe expect?

“Machine tools define thetrends in spindle engineering. A

constant concern in the marketfor many years has been

achieving high pro

ductivity. Tool manufacturers try toreach that goal. So, more chip pro-duction, but with high precision,given that precise machining saves

on expensive finishing work. Thus,we too must adapt our spindles accordingly”.

What main points will Step-Tec fo-cus on when designing spindles?

“First, a more consistent orien-tation to a modular structure. A lotwill change in the spindle interior.For example, we are consideringwater bearings. For very highspeeds, i.e. for more than 60,000rpm, magnet bearings will proba-bly be the future. Memory metalscan take over the initial tension regulation”.

Can one reckonwith more innova-

tive designs?“Possibly, with an active vibra-

tion damping through the magnet-ic field of the motor coil. Special

High speed spindles The passion of Step-Tec

Step-Tec delivers the bestspindles in the world for high machining performance,high power density and out-standing quality


Mikron has combined differentmodules (software and hardware)under the term “smart machine”.Each module has a special func-tion to optimize the millingprocess.

Mikron Advanced Process System (APS)

The APS module is a monitor-ing system which opens up new op-portunities for the user to observeand control the milling process.This system was especially de-signed for high performance andhigh speed machining. However,also be used for other milling work.With the help of an accelerationsensor integrated in the spindle,vibrations during the millingprocess are recorded and displayedto the operator on the console.Through this, it is possible to inter-vene in the process to optimize it.

Remote Notification System (RNS)A new era of communication

and flexibility is obtained with this module. Thus, it is now possi-ble to obtain information about the operation status of the Mikronmachining centre as well as the

milling process regardless of thelocation.

The operator can receive infor-mation about the operating statusor program status of the machinevia SMS to a mobile phone. Conse-quently, the operator can work extensively and flexibly because astandby facility is easily achievedwith this module.

Operator Support System OSSOSS is the first unique intelli-

gent Operator Support Systemused worldwide. Using the work-piece, it optimizes the machining

process in accordance with thequality and specifications. The tar-get variables for speed, precisionand surface quality as well as work-piece weight and machining com-plexity can be set and modified atany time with the user-friendly in-terface. Maximum utilization of theMikron machine is guaranteed withthis process-oriented work.

Intelligent Thermal Control (ITC)With the ITC, the machine op-

erator no longer needs to wait for thermal equilibrium of the machine. It can concentrate fullyon the workpiece-specific re-

quirements. The Mikron machine already has the “thermal processknowledge”, as well as the 5-axis machining centers of course(ITC-5ax).

Benefits of the different “smartmachine” modules:• Higher precision at shorter

machining times• Increase in workpiece surface

quality as well as accuracy ofshape

• Detection of critical machin-ing strategies

• Improvement of process safety

• Reducing the use of the machine by increasing theservice life of the machine

• Increasing the availability• Increased operation comfort

even in automatic mode• Essential increase in reliabili-

ty during unmanned operation• Economical overall approach

improves through optimiza-tion in all process areas.The "smart machine" modules

can be used on all Mikron machines

with current Heidenhain controls.Some of the modules already formpart of the standard configurationof machines. Others are availableas an option. Each “smart ma-chine” module fulfils a specificfunction. Like a modular system,the user can choose the modulesthat he finds most suitable for im-proving the milling process. Thus,workpieces can be manufacturedprecisely and according to theprocess, reliability is increasedduring unmanned operation, theservice life of machines is extend-ed and the production costs are re-duced significantly.

Since "smart machine” is amodular system and new modulesare constantly designed, the current combinations, Mikron machine and module, can beviewed on the Mikron website atwww.mikron-ac.com.

smart machine makes the milling process simpler and easier for the operator to controlsmart machine

alloys can produce improved con-trol of radial and axial dislocations,e.g. by deriving the ensuing loadsfrom the dislocations. Even newconcepts in clamping tools willshow us the future, likewise the re-placement of steel disk springs,e.g. with carbon fiber. Contactlesssensors and active cooling of therotating shaft will be other designtrends”.

Step-Tec’s philosophy Step-Tec AG designs and man-

ufactures spindles according tomarket requirements. Whethertool-making, production or aero-space, owing to the close cooper-ation with universities, research in-stitutes and customers, as well asthe immense motor spindle know-how and the ideal utilization of theinnovation potential, Step-Tec is inthe position to meet special cus-

tomer demands with relation tohigh torques, compact systems andmain spindle drives and B-axes,which correspond to the requiredprocess safety. The high diversifi-cation and increasingly shorter de-livery times demand both defineddesign standards and reliable cal-culation methods and prognosiswith regard to statistic and dynam-ic properties.

Using the most modern work-ing tools, Step-Tec transforms thedigital product into reality. Calcu-lations and simulations are carriedout on the same CAD model, whichis later used in production for pro-gramming with the help of CAM.Only by applying this uniformprocess can it be ensured that quality is complied with, in theglobal sense.

www.mikron-ac.com

The Step-Tec spindles are used largely for milling and drilling applications in tool and moldmaking as well as for production. International companies like Grob, Emag and numerous suppliers for the aviation and space industry are some of its customers.

www.mikron-ac.com

16 High-speed machining HSM today Nr. 15

Whether robots for camel races orfor clock manufacture, parts formachine tools or chip conveyors,Mandatec in Biel, Switzerland hasgrown from an average parts man-ufacturer to a highly efficient busi-ness in component manufacture.

Jürgen Maurer

Lorze-AG - Mandatec wasfounded in 1985. Today, it employsapprox. 70 people. Naturally, thecompany also has its own trainingdepartment. Orders for Mandateccome from the most varied indus-tries, e.g. from semi-conductor industry, machine tool manufac-ture, medicine industry, clock industry etc.

Production is carried out roundthe clock, with two fully auto-mated shifts. Continuous shorterproduction development times orthe aim of processing repeated

orders (same workpieces) within 24 to 48 hours, has induced Mandatec to rethink the entire pro-duction process and to make fun-damental changes. A uniformclamping system by Erowa (MTS)was introduced. It can be used onall machine sizes and can clampnot only pallets, but also individualchucks, precise and stable.

While all machines areequipped with the MTS, Mandatecstarted converting the existingclamping tools to MTS even for the complete production. Moreover,some machines, including a MikronHSM 600U ProdMod, were equippedwith loading and unloading robots.Mandatec could achieve its ambi-tious goals. Thus, process safetywas improved, production process-es and clampings were standard-ized, batch sizes were reduced, 80% of all workpieces are manu-factured in only two clampings,

the machine running times are extended and the working hoursflexibly organized.

Robots for QatarAt present, Mandatec has re-

ceived a very special order. It ismanufacturing robots for use ascamel jockeys in Qatar. Normally,in traditional camel races, youngboys handle the camels. But as thishas resulted in constant criticismfrom human rights organizations,the Sheiks of Qatar had to look foralternatives. They chose the Swisscompany, K-Team Project & Ser-vices from Yverdon-les-Bains andhired them for the development.After successful tests in Qatar, theMandatec robots are now producedin Biel, Switzerland.

The HSM 600U ProdModSome components for the robot

jockeys will be milled on a Mikron

HSM 600U ProdMod. The new se-ries of ProdMod machines originat-ed from the HSM series, which even today, is the standard for highspeed machining. The results include high speed machining cen-ters with best dynamics for eco-nomical machining of exacting pre-cision parts for medium to largebatches. The HSM ProdMod ma-chines are especially designed forproduction. They are equipped withhighly dynamic direct drives for theB and C axis. With a pallet chang-er system and an automated toolchanger, machines from the Prod-Mod series are especially good forautomatic production.

The powerful motor spindles, indifferent versions for differentspeeds and torque ranges, have also contributed to the success ofthis machine series. Now spindleswith HSK-A63 tool holder and in-ternal coolant feed are available on the new HSM ProdMod. This ad-dition to the existing range of spindles allows for the use of larger and subsequently evenlonger tools. With this, Mikron clos-es a gap in the present range ofHSM machines. At the same time,it addresses a new application seg-ment, the production of mediumand larger series.

Tool changer was crucial for Mandatec

Some criteria were particular-ly important for Mandatec in the selection of machines, e.g. 5-axismachining, automation or even access to a large number of tools.Even the ProdMod versions ofMikron machines can be adaptedto individual requirements and are

equipped with a modular toolchanger system. 120, 170 or 220memory spaces can be selected.The separation of the pickup mech-anism and delivery handling resultin short changing cycles. Thanks to the "Double-Tool-Handling",changing cycles of less than 3 sec-onds area achieved, the chip to chiptime is about 5 seconds. Even thepickup time in the modular Mikronchanger system is less than 10 sec-onds. Hence, even tools with veryshort usage times (e.g. drilling,countersinking, tapping) can beused economically on the next toolwithout waiting.

Parts manufactured with theMikron HSM 600U ProdMod nolonger need to be machined man-ually. Similarly, this results in op-timum safety during reproduction.Together with Mikron and Erowa,Mandatec has achieved its goal of maximum flexibility. Subse-quently, the company only produceswhat the relevant customer needsat present, even small quantities.Expensive storage is omitted.

As system manufacturer forcomplex sub-assemblies and devices, today, Lorze AG - Mandatecis the leading company in Switzerland.

www.mikron-ac.com

Robots as camel jockeysmade in Switzerland

Together with a Mikron HSM 600U ProdModand the Erowa MTS clamping system,

Lorze AG - Mandatec performs the shortestreaction and delivery times with simultane-

ously long machine running times

The HSM 600U ProdMod also makes big chips A specialty of Mandatec is the treatment of cubic parts

9B971d01

Documents

production of high

rpm powerclass

spindle service life

motor spindle

motor spindle

workpiece precision

high reliability

mustmotor spindles