Smart machining is here!
14th Jun 2021 | In News | By Mike Richardson
In a Q&A session, Aerospace Manufacturing hears from WFL Millturn Technologies managing director of sales, technologies and customer services, Günther Mayr and how the company’s CNC machining centres play a vital role in the daily take-offs and landings made by today’s modern aircraft.
WFL says it has developed its most technologically advanced MILLTURN yet that will meet the demands of customers for fully-automated complete machining solutions. All set to make its world premiere at EMO Milan this October. The M20 MILLTURN is positioned at customer segments looking for a compact and powerful complete machining solution to offer special technologies and features in addition to existing WFL machines.
Decades of expertise have gone into the development of the completely new M20 machine in both the design and technology. Special features include the high stability of the machine, as well as the integrated motor spindle concept for demanding machining technologies. The M20 is designed for integration of automation to enable a multitude of component types to be easily manipulated within the machining cell.
Q) Please provide the latest news on your M20 MILLTURN?
When developing the M20, the objective was to introduce a compact and rigid machine designed for long-term accuracy with a focus on complete machining. The machine frame is made from spheroidal graphite, which is extremely strong and guarantees excellent damping characteristics. Thanks to its construction, which incorporates vibration-absorbent cast components that offer optimum rigidity, even the heavy cuts during machining are undertaken without vibration.
We also offer new solutions centred around Industry 4.0 and digitisation - starting with an updated version of CrashGuard Studio, the completely new process monitoring WFL iControl and further developments in sensor technology in tools. The new iControl process control software protects the MILLTURN, even during autonomous production throughout the night. Depending on the machine’s equipment, up to 16 freely configurable process signals are continuously monitored. The new design contains more complex and intelligent monitoring options, offering comprehensive safety during production. Multi-stage monitoring logics are used, which respond if the collision limit or adaptive process limit is exceeded or if there are significant, rapid changes in force.
Q) What aspects of your latest machining centres are your customers most happy with?
Our customers enjoy tailor-made solutions and our objective is to evolve from a solution provider into a system provider. Complete machining is subject to greater demands, which is why we’re always striving to integrate a wide range of technologies, measuring tasks, finish machining operations, gear teeth and much more into our MILLTURN complete machining centres, all to suit our customers’ needs. Right from the start, our motto has been “clamp once – machine complete”. This remains our goal.
Machining operations are increasing in complexity, so we’re ramping up our technological processes. However, we focus on more than just the machining operation itself; we cover the entire process. This means defining the machining process, workpiece programming, simulation, production and finally, support throughout the entire service life of a machine. We want to play our part in maximising productivity.
Q) What are your aerospace customers’ machine tools used mainly for?
Landing gear, turbine shafts, fuel pump housings and other aerospace components require specially adapted technological solutions. Our objective is to ensure that machining is economical. Therefore, the advantages of complete machining are particularly illustrated in this sector. Thanks to the broad technological spectrum of the multifunctional turning-boring-milling centres and decades of experience, our customers can rely on the highest levels of productivity.
Our ambition is to remove as much complexity as possible and to guide the customers in a step-by-step approach. We get to solve some of the most challenging manufacturing tasks and the projects often involve a number of digital solutions as well as automation. Our offer is highly flexible and based on very comprehensive internal solutions.
Q) What kinds of productivity benefits do your customers enjoy from the implementation of your CNC machine tools?
Heavy-duty cutting of exotic alloys can place huge requirements on a CNC machining centre when manufacturing large aerospace components. WFL’s competence allows manufacturers to produce parts that other machining centres can’t handle.
Aerospace demands maximum precision and reliable machining of complex geometries. WFL’s modular system minimises distances between the workpiece, tool, and slide rails while giving the widest possible guideway distances. This creates stable conditions and geometries and ensures machining is flexible, accurate, and economical.
The goal is to clamp the workpiece once and machine it completely. Tools can be stored and kept ready in the tool magazine, minimising clamping times while significantly improving positional accuracy – important because six-sided, deep-hole machining can only be performed during one clamping, two at the most. Setup times fall sharply, and any finishing work can be performed immediately.
Hard-to-cut material, such as titanium, requires expertise. We provide turnkey solutions that include production strategy, tool selection, and cooling in addition to the machine. MILLTURNs can be adapted precisely to customer requirements – such as the emergency retraction to remove the tool from the workpiece immediately if a power outage occurs to prevent workpiece damage.
Our wide range of technology expertise includes internal machining and feed-out tools: deep drilling, boring, bottle boring, and facing heads. All benefits of complete machining for aerospace work are exploited, setting new standards in value and precision.
Machining large, heavy, complex workpieces poses significant challenges for in-process probing. MILLTURN’s touch probing complete measurement system can evaluate surface roughness or run-out roundness. After surface turning or milling, the scanning probe measures the feature and feeds the information to the machine tool’s control for automatic correction before the final cut. This assures the finished part corresponds with dimensional requirements.
Q) What do you feel are the most important assets of a company?
At WFL, we act according to the motto “best in complete machining” and continue to offer our customers the most efficient manufacturing solutions, high-quality machines and the highest quality of service.
We intend to support our customers with outstanding products from machines to software and from production solutions to customer services. We want to have a stronger presence in the markets, establish additional branches and look after national regions. We want to use the latest technology, not just in its machines but also in its processes and service support. The expansion of the sales and service network (with 24/7) in the markets is a key strategic goal.
To sum up, we believe in a combination of a defined strategy, the commitment of our employees, our experience, technology etc. to play a leading role in the global business market.
Q) What differentiates your company from the competition?
We are the technology leader in the field of metalcutting production machinery. The combination of different machining technologies, such as turning, milling, drilling or grinding in one machine tool is known as complete machining. ‘Clamp once – machine complete’ is applicable for parts that were previously manufactured in several process steps on various different machines.
Complete machining is about maximum quality, maximum flexibility, highest degree of utilisation, short lead-times and highest level of productivity. Complex machining components are manufactured to the narrowest tolerances and with minimal clamping. In-process measurements guarantee and maintain existing levels of precision and stability. Shortened setup times and a reduction in clamping devices and special tools increase flexibility in terms of machining options. This allows for an efficient manufacturing process and technological optimisation. Several important factors come into play in achieving an increase in the degree of utilisation. Minimal clamping and few internal transport movements increase the efficiency of the production process significantly. Lead-times are minimised due to short wait and handling times. The combination of maximum quality, maximum flexibility, maximum utilisation and short lead-times results in the highest possible level of productivity.
Q) What particular aspect has helped your company get through the pandemic?
Such a crisis can only be overcome with combined strength and personal commitment from each individual. Practically – being regarded by our customers as the technical leader – we are less influenced as most machine tool companies like the big producers of standard machines, because we have many customers who see us as a product and technology development partner. With our business model we are involved in R&D and prototyping of turbine parts for example in the aerospace industry.
Despite the difficult times, we generated many innovations and further developments in the course of 2020. Throughout the year, despite the constant presence of Covid, our MILLTURNs were shipped worldwide, assembled in the respective countries and put into operation. In summary, it can be stated that we got through the crisis well. We owe this above all to the special commitment of all employees at home and abroad during this difficult phase.
Q) Are there any positives in general to come out of all this?
In our experience, it’s crucial to innovate. High-speed or high-precision machining, composite materials, functional expansion and improvement, increased performance, pleasant operation, automation with highest automated night shifts or into the weekend, expansion of the functional software, energy saving, environmental protection and many other aspects will be focused on.
Q) What kind of industry landscape will we be faced with when everything gets back to normal?
Building complete machining centres for various well-known customers in the aviation, engineering and plastics machinery industries represents the most important branches for us. Increasingly more hard to machine materials are becoming prevalent in the aerospace sector. The most important requirement our products must satisfy is absolute process reliability.
Complex geometries and difficult materials are also features of the key components for injection moulding machines. Time-saving programming solutions combined with precise milling enable highly efficient production of screw shapes on a MILLTURN. In addition, sophisticated deep hole drilling solutions give our machines a decisive advantage in comparison with conventional production methods.
The manufacturing of key components for high-tech engineering is in a class of its own – the highest level of productivity for roughing and finishing without grinding whilst maintaining the narrowest of tolerances, together with integrated workpiece measurement are among the requirements. Alongside technological factors, process-safe manufacturing and a high level of flexibility of the machine design also play a very important role. Our MILLTURNs master these challenges with ease.
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