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ZAYER has recently delivered the high speed Gantry milling machine, NEOS 6000 model to Audi Tooling Barcelona.

This new machine will serve as a support for the ZAYER machining center, TEBAS 6000 model, supplied in 2015. 

The TEBAS model has more than fulfilled the expectations of the demanding German car manufacturer and that has meant the access of ZAYER to Volkswagen group. 

Proof of this is the new machine TEBAS 6000 currently being installed at Audi Tooling Barcelona facilities,

as well as the next supplies of Zayer machines in Volkswagen Mexico – Puebla  (NEOS 4000) and Volkswagen Brazil (TEBAS 6000).

 

Tryout-Center de AUDI en Martorell – Cataluña

 

Main specifications NEOS 6000:

• Heidenhain TNC 640 numerical control with HR 550 FS wireless handwheel

• Longitudinal travel (X axis): 6000 mm

• Cross travel (Y axis): 4500 mm

• Vertical travel (Z axis): 1500 mm

• Table surface : 5500 x 4000 mm

• Distance between columns: 5500 mm

• Plate for automatic rotation of the heads

• 45º automatic head, 360.000 positions, 45 kW – 6000 min-1

• 35º automatic head, 360.000 positions with electrospindle 24.000 min-1

• RENISHAW RMP 600 probe for part measurement

• – Self calibration of the heads (Apps developed by ZAYER)

 

 

 

 

INTERVIEWJavier Orive QA Manager Zayer CNC Machine Tools

Metrology options for large capacity machine tools

Javier Orive

Quality Control Manager at Zayer

 

Javier Orive is the Quality Control Manager at Zayer, a company that has been developing milling machines and machining centres since the 1940s. During this interview, Orive shares his views on a number of landmarks connected to how relevant metrology has become nowadays in the machine tool sector.

 

1.- A growing demand for greater accuracy in manufacturing processes has meant that innovative alternatives had to be found in the field of metrology. This reaches out to several sectors, including machine tools, their verification and commissioning. How is Zayer addressing these new needs?

We are developing automatic running “utilities” at Zayer to check milling head geometry and adjustments.

Zayer has iCAL, an in-house smart calibration application that delivers full information on the current condition of a machine and performs self-adjustments for the kinematics and geometries of our automatic rotation header by running a sensoring programme.

2.- Zayer was one of the main stakeholders in the INTEFIX consortium featuring 30 companies and technology centres whose goal was focused on upgrading the performance of machining processes by using smart systems. What role does metrology actually play in these processes? 

Metrology is indispensable for current manufacturing processes, especially so for those in which it is difficult to control the outcome of the measurement process itself due to the variability of critical parameters or because of a lack of control of the real scene (geometry, toolings, thermal status, drift, etc.).

Integrated dimensional metrology provides manufacturing with the necessary means to get to know and control production processes better.

During the INTEFIX project, this integration has been solved via an interaction between a smart mechanism and the machine tool itself. This mechanism enables us to measure the true geometry of a work piece to accommodate machining programmes to its real shape and dimensions. This is how high accuracy machining can be guaranteed.

3.- Within the framework of the HIPERION project, Zayer’s machines have played the role of test benches to develop a volumetric verification and compensation procedures carried out in cooperation with IK4-TEKNIKER. Could you explain some of the details of this cooperation?

Our view is that the HIPERION project has been a landmark in the cooperation involving both organisations as it has allowed Zayer to acquire theoretical knowledge on the volumetric verification of machines and IK4-TEKNIKER has been able to transfer its developments to a real scenario.

Thanks to the project we were able to look into the origin of a number of deviations that occur at the tip of the machine tool when a machine shifts its entire work volume.

4.- How significant is it for Zayer to be able to cooperate with other stakeholders in this sector?

By cooperating, knowledge can be exchanged. In Zayer’s case, it has allowed us to become involved in the design of structural components. It means we can improve volumetric accuracy without having to make any corrections.

5.- The innovative character of Zayer linked to its eagerness with regard to achieving continuous improvements means that the company is permanently in touch with R&D&I processes. How much weight is attached to metrology in the machine tool sector? What sort of challenges will there be in the future?

Metrology has acquired a significant dimension in terms of heavy duty machines such as those manufactured by Zayer.

Our main aim is to guarantee the accuracy of large pieces when working in non-climatised workshop environments.

To that end, we build machines featuring mathematical algorithms that allow you to take into consideration variations that are inevitable in terms of environmental conditions.]

 

      Zayer Thera 5 Axis CNC Machine Tool  ZAYER THERA 5 FACE CNC Machining Centre

LENTUS COMPOSITES INSTALLS ‘RISING STAR’ MACHINING CENTRE

For machining pattern board, aluminium mould tools and components made from composite materials, Eynsham-based Lentus Composites has installed a Sahos Dynamic bridge-type machining centre with a 5-metre X-axis. Built in the Czech Republic by Blue Ray, the 5-axis machine was delivered and commissioned in March 2016 by sole UK agent, Asquith Butler.

Simon Odling, managing director of Lentus commented

“There are a number of high-speed machining centres on the market, mainly of European origin, that are directly applicable to production in the composites industry. We chose the Sahos Dynamic for a number of reasons. In particular, we felt that the construction of the machine when compared to its competitors was an improvement on the industry norm, providing a stiffer, more stable machining environment."
Sahos Dynamic bridge-type machining centre
“In addition, we specified direct measurement in all axes including the 5-axis head. These provide absolute feedback and minimise time-consuming maintenance and down-time associated with aligning the axes, as well as providing significantly improved positional repeatability. Having tested the market with other local machine users, we received positive feedback from other Sahos machine owners in our sector. The consensus was that this Czech manufacturer is not as well known in the UK as other brands but is a rising star in the industry.”

Lentus is in the ascendant as well. Part of Polar Technology Management Group, it is located on Polar’s 16-acre site in Eynsham that has planning permission to be developed into a large technology campus within the next few years. Lentus was established as recently as February 2014 by Polar partners Scott Roberts and Mike Dewhirst and is managed by Mr Odling and technical director Paul Lewis. Lentus was formed initially to supply composite products for superconducting magnets used in MRI scanners manufactured in the UK.

Sahos Installation at Lentus Sahos HS662

Asquith Butler has now bolstered its machine tool offering with the arrival of the new BRAY brand of machine tools. As a complement to the existing SAHOS line of high specification 3 and 5-axis CNC machining centres, the addition of the BRAY product line-up will form the core of an alignment strategy to develop and maximise market penetration in the composite, pattern making, aerospace, light alloy machining sectors.

Bray Bram M3000 Bray Milling Head

The portfolio extension for Asquith Butler is the result of Czech machine tool manufacturer SAHOS being brought under the umbrella of BRAY (Blue Ray), which is a wholly owned subsidiary of Tool Trade S.R.O, a high-tech group of companies. The synergy will also develop opportunities for the company's fibre laser cutting machines.

The re-structuring strategy of Tool Trade S.R.O presents an exciting opportunity for Asquith Butler, as the company will now offer the new products from BRAY plus a host of cosmetic and design improvements to the existing line of SAHOS CNC machining centres. The BRAY line of machines are aimed at the very high-end mould & die, pattern making, aluminium and light alloy aerospace sectors; providing the perfect complement to the existing SAHOS brand of flexible and highly productive machine tools.

Commenting upon the business alignment strategy, Asquith Butler Managing Director Mr Paul Hinchliffe says: "The arrival of the BRAY Series of machines offers some exciting new models as well as some smart new configurations for the already popular SAHOS machines. We have had some spectacular initial success with the SAHOS machines here in the UK and we are beginning to see a good machine population develop. The new BRAY machine specifications and layouts will allow Asquith Butler to further develop the market with a specification and price to suit all end-users. The BRAY brand will complement the SAHOS range and enable Asquith Butler to offer even more comprehensive machining solutions than ever before. The BRAY product lines will give us potential to target niche application and industry segments that were sometimes beyond the SAHOS brand. Such are the benefits of the BRAY machines, we are confident the popularity and population of BRAY machines grow considerably in the near future."

The SAHOS product line and now the new BRAY brand have been designed and developed to provide uncompromising levels of flexibility, innovation and productivity. With the re-alignment strategy, Asquith Butler is delighted to be extending the level of innovation and technology with product enhancements and a completely new line of machines. For further details on how to maximise your machining capabilities please contact Asquith Butler for more information.

Sahos Be Brave With Bray

Advanced Engineering 2016
ASQUITH BUTLER AT ADVANCED ENGINEERING 2016
VISIT US AT STAND N62 - BIRMINGHAM NEC
2nd & 3rd November 2016
Asquith Butler along with their manufacturing partners SAHOS/BRAY will be presenting their comprehensive High Specification 5 AXIS High Speed CNC MACHINING CENTRES

The machines are specifically designed for 5-axis machining of light materials. With their low-mass moving elements, rigid construction and wide range of spindle speed and power options, SAHOS 5-axis machining centres are ideal for producing components from light materials such as aluminium, model board, plastics including varieties reinforced with carbon fibre and glass fibre, and composites. These materials can all be machined accurately and with a high degree of efficiency.

We will be presenting the recently introduced BRAL and BRAM machines which provide improved material removal rates and increased accuracy as a result of very rigid construction. Along with representatives from ASQUITH BUTLER we will be joined by our colleagues from SAHOS/BRAY who will welcome the opportunity to discuss your High Speed 5 Axis machining needs.

BRAM FC3015 5X

BRAL FC6015 5X

VISIT us to discuss your CNC Machining Centre solutions for automotive modelling, pattern making, Aerospace machining, F1, Military and civil aircraft, competition and road vehicles, boatbuilding, wind power and renewable energy.

MUBEA MEGAFLEX HS – INNOVATIVE AEROSPACE & TRANSPORTATION MACHINING.

Mubea Systems has recently built and installed a unique long bed travelling gantry type machining centre in a major European aerospace manufacturing company.

Using Mubea’s own unique “Double” X Axis configuration the machine is capable of high speed and high precision machining of predominantly large Aluminium aerospace components.

The Double X Axis systems allows rapid positioning along the whole of the X axis travel of the main gantry structure followed by a clamping operation to secure this travelling gantry. Machining is then performed by moving a second X Axis within the fixed gantry. This allows high dynamic contouring speeds and high precision. This is because the heavy weight structure is fixed and machining is performed by a lighter assembly optimised for high speed milling.

Over the last 18 months, Asquith Butler, a long-established British machine tool manufacturer synonymous with its range of large capacity, travelling gantry (vertical) and travelling column (horizontal) machining centres, has become the exclusive UK distributor for a range of high quality machining centres from three European manufacturers, Zayer, Sahos and Mubea Systems. The agreements cover machine sales, installation, commissioning and service support. Asquith Butler is delighted with its success so far, having sold a number these cutting edge machines into the UK market.

Asquith Butler Zayer Machine Supplied to Audi Asquith Butler Zayer Machine Supplied to Batz

The Spanish firm Zayer has also been particularly successful across Europe and in its home market in the last 18 months. For example, it has sold two large 5-axis machines for toolmaking, one to Audi Tooling Barcelona and another to Batz, located near Bilbao, which manufactures stamping tools for vehicle component production. The company supplies JLR, BMW, Volvo and other famous marques.

Total Machining Solutions Ltd. recently installed a New SAHOS Dynamic FC4000 MAX 5 Axis CNC Machining Centre. The machine complements their existing two 5 Axis machines and suite of vertical spindle VMC Machines.

The machine will be used for machining a wide range of components and patterns for the aerospace, F1 and automotive industries

Sahos Dynamic FC5000 Sahos Dynamic FC5000 Asquith Butler Installation

The Customer selected the enlarged MAX HIGH version of the DYNAMIC machine which provides a machining envelope of 4000mm x 2200mm x 1095mm. This capacity is especially impressive given the relatively small footprint.

The machine is fitted with a Heidenhain iTNC530 and is as standard equipped with the Heidenhain HR520 Remote handwheel for simple work piece set up. This was further enhanced by the supply of workpiece and tool measuring probe

The machine has a 18kw, 2 Axis swivelling head with 24,000RPM and 20.9Nm of torque available.

For increased accuracy all axes were equipped with direct measurement (linear scales and high precision rotary encoders for the 2 rotating axes.)

Asquith Butler offer complete rebuilding and repair solutions for your manual and automatic universal milling heads

Butler Milling Head
BUTLER
Butler Milling Head
BUTLER
Soraluce Milling Head
SORALUCE
Milling Head Correa
CORREA

As one of the few Original Manufacturers of Manual Universal Milling Heads and Fully Automatic Milling Heads we offer a repair solution for all Asquith Butler and Butler Milling Heads as well as services to repair, rebuild and service heads from other manufacturers such as:

MACH 2016

11TH - 15TH APRIL - Stand 5395 Hall 5

Asquith Butler are exhibiting at Mach 2016. BIRMINGHAM NEC - B40 1NT

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Mach 2016

5 Axis Machining of Large Automotive ToolsOver the last 18 months, Asquith Butler, a long-established British machine tool manufacturer synonymous with its range of large capacity, travelling gantry (vertical) and travelling column (horizontal) machining centres, has become the exclusive UK distributor for a range of high quality machining centres from three European manufacturers, Zayer, Sahos and Mubea Systems. The agreements cover machine sales, installation, commissioning and service support. Asquith Butler is delighted with its success so far, having sold a number these cutting edge machines into the UK market.

The Spanish firm Zayer has also been particularly successful across Europe and in its home market in the last 18 months. For example, it has sold two large 5-axis machines for toolmaking, one to Audi Tooling Barcelona and another to Batz, located near Bilbao, which manufactures stamping tools for vehicle component production. The company supplies JLR, BMW, Volvo and other famous marques.

Paul Hinchliffe, managing director of Asquith Butler based in Brighouse, West Yorkshire, sees considerable potential for these machines in the UK, especially in the automotive sector. Here he describes Zayer’s two latest projects to provide a flavour of the manufacturer’s capabilities and strengths.