The Magazine for Production Engineers JUNE 2011
SPONSORED BY
Fi v e- A x i s SupplementMACHINING – TOOLING – WORKHOLDING
CADCAM– INSPECTION
www.machinery.co.uk
5 coveraxis.qxp:Layout 1 25/5/11 14:04 Page 1
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P002_MCSP_JUN11 23/5/11 07:08 Page 1
3
INTRODUCTION/CONTENTS
FIVE-AXIS SUPPLEMENT
www.machinery.co.uk • June 2011
Five-axis technology development and
uptake continue apace.
In our first feature, which concentrates on
machine tool technology in action, the
University of Warwick is pushing boundaries
in 5-axis machining, marrying it with CO2
cooling to allow the cutting of materials such
as titanium.
Elewhere, in the CADCAM area,
GibbsCAM, for example, has some new
developments to talk about, while in the
tooling and workholding field, reduced
setting times keep 5-axis spindles running
longer, we report.
Finally, we highlight how 5-axis machined
parts can be measured effectively.■■
The power of five
CGTech 01273 773538
CMS 0115 977 0055
DMG 01582 570661
Dormer Tools 0870 8504466
Delcam 0121 766 5544
Faro 02476 217690
GF AgieCharmilles 02476 538666
Haas Automation 01603 760539
Hardinge 01162 869900
Heller Machine Tools 0121 275 3300
Hexagon Metrology 0870 446 2667
Hilcliff Tools 01483 266780
Hurco 01494 442222
Leader Chuck Systems 0121 771 4843
Mills CNC 01926 736736
Mori Seiki 0844 800 7647
NCG CAM 01223 863911
Nikon Metrology 01332 811349
Open Mind Technologies 01869 290003
Phase Vision 01509 839000
REM Systems 01452 314100
Renishaw 01453 524524
Sandvik Coromant www.sandvik.coromant.com
Schunk-Intec 01908 611127
Sescoi 0844 561 7014
SolidWorks 01223 346900
System 3R 02476 538653
Tech CADCAM 01284 754781
Vero 01242 542040
WNT 0800 073 2073
Yamazaki Mazak 01905 755755
Editor: Andrew Allcock – Contributing Editor: Steed Webzell – Art Editor: Neil Young – Sales Director: Joe Opitz – Sales Manager: Laura Cunningham
Account Manager: Stuart Tarrant – Publishing Assistant: Lyn Evola – Circulation Manager: Chris Jones – Production: Heather Upton – Publisher: Peter Knutton
A Machinery supplement: © 2011 Findlay Media, Hawley Mill, Hawley Road, Kent DA2 7TJ – 01322 221144. Email: [email protected] ISSN: 1753-0482
Origination: CTT (Camden Town Typesetters), Walthamstow, London E17 6BU – Printed by Wyndeham Heron, Heybridge, Maldon, Essex CM9 4NW
Supplier index
Contents
04 – Machining
11 – CADCAM
17 – Tooling/workholding
21 – Inspection
You can find further contact details and related editorial for many of the included
companies, together with more product news, at: www.machinery.co.uk
SPONSORED BY
5axis_Intro_cont.qxp:Machinery 25/5/11 15:27 Page 3
Foundry Road, Stamford, Lincs. PE9 2PP
Tel: 01780 765965Fax: 01780 765877
e-mail: offi [email protected]
The E Series Concept
Combines conventional, manual
data input and CNC versatility
within one machine and control
system
E30/E40/E50/E60/E70
Innovative Performance
E90/110/120/150/175
Oil and gas industries
• Robust design for precision
and stablility
• Multiple tooling turret options
• Large spindle bores upto
580 mm diameter
• Automated cycles fast and
simple communication
between man and machine
Apprentice, vocational training
• Machining of
simple/complex components
Injecting 5-axis machining into the mindset
of future generations of production
engineers begins at education level, and
more and more learning establishments are
investing in this innovative technology to
attract students keen to adorn themselves
with a broad understanding of complex
machining.
For instance, postgraduates studying for
doctoral research degrees in manufacturing
at the University of Warwick will soon have
access to the facility’s fourth 5-axis model,
following the decision by one of the
university’s academic departments, WMG,
to install a DMU65 monoBLOCK from
long-standing technical partner DMG
(01582 570661).
The new machine will be the first in the
UK from this German manufacturer to be
fitted with CO2 cooling. The continuous
stream of refrigerated gas can be used in
place of the more usual fluid coolant to flood
the machining area at the point where the
cutting tool meets the workpiece.
“The advantages of the technology when
machining titanium and exotic alloys include
less contamination of the workpiece, better
surface finish, longer tool life and the ability
to use elevated cutting feed rates for higher
productivity,” says Roger Bull, technical and
facilities officer at WMG. “It is said that
cryogenic CO2 cooling also allows PCD tools
to machine ferrous metals, which is not
normally possible, due to the high affinity of
carbon with iron.”
MICRO-ANALYSIS STUDIES
Research carried out at Warwick, which will
include micro-analysis to study comparative
surface grain structures of the tool, chip and
component, with and without CO2 cooling,
will be of mutual benefit to both WMG and
machine tool supplier DMG.
“Our priority has been on 5-axis machining
capability for some time, in order to make
the components our students were
designing on ever more powerful CAD
systems,” says Mr Bull.
Graduated students will take these skills
out into industry, where increasing numbers
of manufacturers are installing 5-axis
machining technology to embrace a growing
culture of low volume, high complexity
component orders. A good example can be
seen at Rotherham-based subcontractor,
Cutting & Wear Resistant Developments,
which has reduced cycle times by as much
as 50% on selected parts with its recently
installed Doosan 5-axis machining centre
from Mills CNC (01926 736736).
The machine, a VC630 5AX, is being used
to machine complex parts for the oil and gas
sector, typically down-hole tool technology in
batches up to 15-off.
“In the past, we were relying on our older
3-axis machines to produce these parts, but
we could see that ‘one-hit’ machining was
4 June 2011 • www.machinery.co.uk
Access all areasThe benefit of motion in five axes continues to appeal to an ever wider
plethora of manufacturers, all seeking competitive gain when machining
complex parts. Steed Webzell reports
BAW opted for Hurco technology to support full
5-axis machining capability
5axis_machining application.qxp:Machinery 25/5/11 15:40 Page 4
the way to go. Reducing both cycle times
and the number of job set-ups required to
manufacture the components were obvious
advantages,” says workshop manager John
Kennedy.
“Mills recommended their Doosan VC630
5AX, 5-axis model. We liked the machine’s
ability to perform high accuracy 5-face
machining (3+2 positional 5-axis machining),
and the potential for us to move into full 5-
axis simultaneous machining in the future.”
Another progressive subcontractor to
invest in the latest 5-axis technology is
Swansea-based BAW Precision Engineering,
which emerged from the global downturn
under new ownership in July 2010. The
management team has installed a culture
of employee training and lean manufacturing,
supported by investment – the company’s
latest asset is a new VMX30U 5-axis
machining centre from High Wycombe-based
Hurco (01494 442222).
“Despite already having 3+2 axis set-ups
on our existing machines, we acknowledged
that we needed full simultaneous 5-axis
capability to drive the company forward,”
explains operations manager Andrew
Hoseasons. “We have identified a need in
the marketplace and the new Hurco will be
our first step to filling this gap.”
IMMEDIATE IMPACT
Richard Gunn, group engineering
development manager of RG Tooling, BAW’s
development arm, is keen to highlight the
immediate impact of the Hurco VMX30U,
with its integrated trunnion table.
“At present, we are machining toolholders
for sister company Eurogrind, a manufacturer
of standard and bespoke milling and turning
toolholders,” he says. “Previously, our square
shank toolholders underwent three individual
set-ups that took 10 minutes each. Added to
the set-up times were three machining
cycles of 15 minutes each, resulting in a
complete part time of 75 minutes per
toolholder. Now, the new VMX30U only
requires one 10 minute set-up and one 15
minute machining cycle.”
To put the saving in perspective, BAW
machines the toolholders in batches from 10
to 30, with an annual production exceeding
500 units.
One of the niche markets BAW is
targeting is the oil and gas/hydraulic valve
sector. The company set this strategy in
motion when specifying the VMX30U: the
trunnion table, with a 420 mm face plate,
accommodates a diverse range of chucks
and is suited to producing complex valve
components.
Also with an interest in this industry is
Gateshead-based subcontractor NTG
Precision Engineers. Its decision to switch
focus around five years ago to supplying
precision-engineered components to sectors
such as power generation, and oil and gas,
has proven very successful. The move has
certainly allowed the company to continue its
planned programme of investment, the latest
addition to which is a travelling column VTC
800-20 SR, a large capacity 5-axis
simultaneous machining centre supplied by
Yamazaki Mazak (01905 755755). The new
machine supports its existing Mazak Integrex
300-IV ST, a twin-spindle multi-tasking
machine, capable of simultaneous 5-axis
turning and milling.
BIG STEP FORWARD
“We were initially looking at a larger vertical
3-axis machine, but that wouldn’t have given
us the step-change in technology we were
seeking,” says works director Charlie Sampy.
“We eventually decided on the Mazak VTC,
which was another big step for us, in terms
of initial investment, but again we were
5
MACHINING
www.machinery.co.uk • June 2011
FIVE-AXIS SUPPLEMENT
DMG 5-axis machining + CO2 at WMG
5axis_machining application.qxp:Machinery 25/5/11 15:40 Page 5
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HORIZONTAL /
VERTICAL LATHES
FOR ULTRA
PRECISION
TECHNOLOGY
Foundry Road, Stamford, Lincolnshire PE9 2PP
Tel No. 01780765965; Fax No. 01780765877
e-mail: [email protected]
www.kyalmachinetools.co.uk
careful and initially only targeted work from
our existing customer base.
“The key for us has been to tool up with
new technology, but then use the savings
generated by the technology to hold our
prices,” he continues. “In effect, we’ve used
technology to absorb and deliver cost-down
initiatives, while enhancing our profitability
going forward. At a time when inflation is
driving up transport costs, materials and
wages, this is a significant selling point
for us.”
The one potential constraint on growth is
the shortage of trained engineers in the
northeast, but Mr Sampy is confident he can
overcome this.
“We are employing two new apprentices
in the summer and we want them both to be
CNC people. But the beauty of Mazak multi-
tasking technology is that it reduces the
reliance on having to find and persuade
highly trained operators to join you.”
OEMs are also taking to 5-axis machining
in their numbers, as demonstrated by
Daventry-based Hi-Force, a manufacturer of
high pressure hydraulic bolting and lifting
products, which has implemented a strategy
to move away from subcontract suppliers.
“The aims were to increase efficiency,
reduce costs and shorten delivery times,”
says Kevin Brown, the company’s managing
director. “The crucial change has been for us
to get ahead of demand from our customers,
despite the 32% growth in our turnover
during 2010. As a result we have invested
around £2 million in manufacturing and
machining over the past two years.”
ONE-HIT INVESTMENT
Among the recent acquisitions is an
NMV5000 DCG 5-axis machining centre from
Mori Seiki (0844 800 7647), which was
purchased to manufacture Hi-Force’s range of
10 torque wrenches – these vary in size and
capacity from 1,700 up to 48,000 Nm of
torque output. The 5-axis capability of the
machine enables the component parts to be
completed in one hit. Furthermore, Mori Seiki
has been providing an ongoing programme of
training and optimisation to enable the
company to produce the complete range of
wrenches and to swap between them
rapidly, as requirements change.
Takers for 5-axis machines are coming
from a diverse range of sources and one
recent trend has seen a string of cutting tool
specialists invest in new models. Among
them is Alcester-based Seco Tools (01789
764341), which has installed a new HPM
600U 5-axis machining centre from GF
AgieCharmilles (02476 538666). The machine
will fulfil a variety of functions, such as: in-
house product and applications training for
staff; undertaking individual customer
projects; and company-organised and
sponsored promotional and educational
events.
“Precision manufacturers machining
complex parts for the aerospace, medical,
oil/gas, power generation and motorsport
sectors are increasingly using and relying on
5-axis machine tool technology to increase
their productivity and improve their
performance,” says Mike Fleming, marketing
and technical manager at Seco. “Many of
these manufacturers are Seco customers.
They use our cutting tools and associated
products, but until now we couldn’t easily
demonstrate or provide customers and
prospects with all the evidence they needed
about our 5-axis technology.”
This strategy is mirrored at another cutting
tool supplier, Halesowen-based Sandvik
Coromant (0121 504 5400), where a new 5-
axis model has strengthened the company’s
prismatic metalcutting capability. The new
DMU50eco from DMG will assist in
demonstrating the latest grades and
geometries of Sandvik Coromant tooling to
customers and will also help in the
development of new milling processes
targeted at specific industries, notably the
aerospace and medical sectors.
One early demonstration has seen ‘rolling-
in’ milling on a 316 stainless steel block,
using a 50 mm diameter face mill and 20 mm
diameter end mill. Trochoidal climb milling,
morph milling (especially of airframe
structures), slice milling and rolling-in
strategies are current areas of focus, in order
to maximise cutter life.
7
MACHINING
FIVE-AXIS SUPPLEMENT
GF AgieCharmilles technology at Seco Tools
www.machinery.co.uk • June 2011
5axis_machining application.qxp:Machinery 25/5/11 15:42 Page 7
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P008_MCSP_JUN11 23/5/11 07:09 Page 1
Made in Switzerland
Foundry Road, Stamford, Lincs. PE9 2PP
Tel: 01780 765965Fax: 01780 765877
e-mail: offi [email protected]
The opinion of experts,
the machine operators is
unparalleled and drives the
continued development and
demand for machines like the
milling and drilling machine
Picomax 54 with CNC control
and manual hand wheels.
• Machining of simple parts, for
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Sheffield-based Dormer Tools (0870
8504466) is also keen to shout about its
latest acquisition – an FT 4000 5-axis
horizontal machining centre from Heller
Machine Tools (0121 275 3300). The new
machine’s spindle power and high torque
characteristics make it suited to Dormer’s
milling, tapping and drilling demonstrations.
The FT 4000 5-axis will also be used in
Dormer’s customer surgeries – component-
specific demonstrations that help prove the
efficiency of the company’s tools and to
provide optimum advice regarding speeds
and feeds.
REELING IN THE BENEFIT
Of course, 5-axis machining is a growing
trend in almost all Western markets,
including the USA, as demonstrated by Ross
Reels, a Colorado-based fly-fishing reel
manufacturer that has scored enormous
success with its fully machined fly reel,
which is saltwater approved and durable
enough to last a lifetime.
“People thought the owner [Ross Hauck]
was crazy when he launched the business,”
says the company’s plant manager, Larry
Donaldson. “Ross was trying to sell a reel
that cost $150 – probably six times what the
simple stamped and die-cast models of the
day were going for. But, surprisingly to many,
the good-looking product caught on. We now
machine around 27,000 kg of aluminium into
fly reels every year.”
The sport’s demanding customers want
the most satisfying equipment they can get.
High end reels must delight the senses –
they have to look perfect, feel perfect and
sound perfect. And, above all, they must
perform perfectly, every time. While the reels
contain as many as 25 parts, the assemblies
boil down to two basic components: a
stationary frame that attaches to the fly rod,
and a rotating spool that snaps into the
frame. “The frames are the most difficult
parts we make,” says Mr Donaldson.
“They begin as 75-115 mm diameter by 38
mm thick ‘pucks’ of 6061-T6-G aluminium bar
stock. They’re mounted on 5-axis trunnion
tables in one of two VF-2SS Super-Speed
vertical machining centres, supplied by Haas
[01603 760539]. By the time they’re finished,
most of the original material has been milled
away: the billet weighs 1.8 kg going in and
the part that emerges weighs just 0.2 kg.
“Spools also start as aluminium billets,”
he continues, “but they’re initially shaped
and faced on lathes, then transferred to the
mills for the final operations that sculpt their
decorative cut-outs. We machine to
reasonably tight tolerances and really fine
finishes. Standard dimensions are held to
0.05-0.075 mm.”
Ross Reels has now specialised in Haas
technology, with around 14 machines
currently on site.
“For years, we used Japanese horizontal
machining centres to do the frames,”
explains Mr Donaldson. “We figured
horizontals were the best machines to give
us the high productivity and fine finish we
wanted. But, as production expanded, it
became a nightmare to keep the complicated
machines running; they were a well-known
brand, but they were down 50% of the time.
It got to the point where I needed a full-time
maintenance man to keep four machines
going,” he underlines.
By upgrading Ross Reel’s Haas VF-2SS
machines to 5-axis capability, and loaning the
company a Haas TR-160 trunnion table to
develop and test the process, the solution
showed itself.
“The new process saves us 30-50% cycle
time over the old way, and I was able to get
rid of the four big horizontals. We now see
much greater productivity from just two Haas
VF-2SS machines,” says Mr Donaldson.■■
9
MACHINING
FIVE-AXIS SUPPLEMENT
www.machinery.co.uk • June 2011
Ross Reels upgraded its 3-axis Haas machines to 5-axis
5axis_machining application.qxp:Machinery 25/5/11 15:43 Page 9
June 2011 • www.machinery.co.uk
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P010_MCSP_JUN11 23/5/11 10:17 Page 10
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e-mail: [email protected]
11
CADCAM
FIVE-AXIS SUPPLEMENT
Softly does itSteed Webzell reviews the current market for 5-axis machining software,
discovering that uptake is more than matching the rate of product
development
Effective CAM software for 5-axis
machining is still relatively young
technology. In the early days, there were
concerns: the tool angle relative to the
selected reference point or surface for the
entire machining area could not be changed,
which made it difficult to avoid collisions; and
rest machining necessitated breaking the job
into several machining steps, significantly
increasing programming time.
One of the biggest stumbling blocks was
complexity of programming. Here, Open
Mind Technologies (01869 290003) says that,
to make program creation as easy as
possible, its hyperMill CAM offers a uniform
interface concept, from turning to 2D and 3D
machining, through to 5-axis simultaneous
machining. This is important, because there
are very few workpieces that require only
one type of machining (2D/3D/5-axis) – the
broad spectrum of strategies grants
flexibility, allowing the user to program many
parts with one type of software.
hyperMill exploits the performance range
of each machine tool and considers
kinematic particularities. Compared to 3-axis
milling, the tool reference point and the
movements of the machine’s linear axes are
different during 5-axis simultaneous
machining, as motion of the rotary and tilting
axes result in ‘compensation’ movements in
the linear axes. The software also enables
users to control the rotation axes
independently of one another, as well as
machining with automatically indexed axes.
And it is benefits such as these that led
Northampton-based GE Precision
Engineering (GEPE) to invest in hyperMill.
www.machinery.co.uk • June 2011
Gibbs upgrades 5-axis routines
Gibbs and Associates, developer of GibbsCAM software, says there are many improvements
within GibbsCAM 2011, including several additions and enhancements to 5-axis machining
routines. For instance, there is a new routine for 5-axis hole-making operations, aided by
enhancements to GibbsCAM’s automatic feature recognition, hole manager and hole wizard,
which makes programming 5-axis drill cycles much easier and more efficient.
Also, a new ‘Operation Modifier’ allows converting 2.5 and 3-axis toolpaths for machining in
five axes, which enables use of shorter tools to achieve smoother toolpaths at certain surface
intersections and other geometric conditions. There is also a new 5-axis trimming (wire-frame)
strategy and new support for 5-axis milling on turning machines (using B-axis functionality).
GibbsCAM 2011 is offered in the UK via Tech CADCAM (01284 754781).
Open Mind supports GE Precision’s 5-axis efforts
5axis_cadcam.qxp:Machinery 25/5/11 15:55 Page 11
P012_MCSP_JUN11 23/5/11 07:27 Page 1
In its four years of trading, the company
has invested in several 5-axis machining
centres, including a DMU50 from DMG
(01582 570661), a Mikron UCP600 from GF
AgieCharmilles (02476 538666) and an XR60-
5AX from Hardinge (01162 869900).
However, according to the company’s
managing director, Garry Edwards, the most
important purchase for the 17-employee
business has been hyperMill CAM software,
he affirms.
The selection of hyperMILL occurred
when GEPE was awarded a contract with a
Formula One engine manufacturer to
produce cam covers from solid billets. Mr
Edwards was given a demonstration of
hyperMill at the team, and immediately
realised how easy it was to produce complex
shapes and forms.
“The demo really opened my eyes to the
capabilities of hyperMill, but, most
importantly, how easy it was to program
complex 5-axis forms.
“hyperMILL offers shorter program
lengths, with less code, by condensing
outputs, such as incorporating radii into G2
and G3 codes. It was streets ahead of
anything I had used previously, so the
decision was made immediately,” he says.
The first seat of hyperMill arrived in April
2009, with additional seats following in June
2009 and September 2010.
“Programming times have fallen by
anything from 30 to 60% and, when our
average programming time is approximately
16 hours, it shows how invaluable hyperMill
has become,” says Mr Edwards. “As well as
prototype work, we now have a production
cell machining 40 sets of Norton crankcases
and cylinder heads per week. With its port
machining strategy, hyperMill makes port and
exhaust machining simple.”
Another CAM software specialist,
Delcam, says it, too, has achieved recent
5-axis success at Manchester-based
aerospace subcontractor LSNW (Lofting
Services North West). Here, director Richard
Fielding claims that his company has “no
interest” in simple, high volume jobs,
preferring to take on more demanding work
where other subcontractors would struggle
to compete.
LSNW has invested in Delcam’s
PowerMill, PowerShape CAD and
PowerInspect software suites, plus Delcam
Exchange to read in CATIA models. The latest
and biggest machine tool purchase is a 5 m,
5-axis model. The post-processers for this
machine were written by Delcam engineers,
who liaised closely with the designers of the
5-axis head from ISA, based in Milan.
Further north, at German toolmaker
Formenbau Kellermann, lead times have
been reduced by more than 20% after
investing in VISI from Vero Software (01242
542040), along with a palletised production
process with a zero-point clamping system.
“Pricing pressure, competition from
emerging countries and the trend towards
ever shorter project terms are challenges that
force toolmakers to rethink the traditional
form of single item production,” explains
managing director, Sabine Kellermann. “In
toolmaking, flexibility and the use of the
latest technology is a must.”
The company’s milling department is
equipped with two HPM 1350U and HPM
1850U 5-axis milling centres from GF
AgieCharmilles. One VISI function that is
used intensively at Kellermann is the ability
13
CADCAM
5-AXIS SUPPLEMENT
www.machinery.co.uk • June 2011
• CNC-Machining Centres
• Mill/Turn Centres
• Gantry Machines
Foundry Road, Stamford, Lincolnshire PE9 2PP
Tel No. 01780765965; Fax No. 01780765877
e-mail: [email protected]
www.kyalmachinetools.co.uk
Made In Germany
Consistently customer orientated
LSNW has no interest in simple, high volume jobs, and is using Delcam software to support its ambition
5axis_cadcam.qxp:Machinery 25/5/11 15:56 Page 13
P014_MCSP_JUN11 23/5/11 07:27 Page 1
Foundry Road, Stamford, Lincs. PE9 2PP
Tel: 01780 765965Fax: 01780 765877
e-mail: [email protected]
Combined cleaning... (solvent and
aqeous media)
...then
V A I O C SVacuum Assisted Inorganic Organic Cleaning System
Problem
• Continual growing demands in cleanness.
• Parts with organic (oil, grease) and inorganic (emulsion, abrasion) dirt.
• High operation expenses while running two cleaning machines (solvent and aqueous media).
Solution
• With the unique system “VAICOS” it is possible for the first time to apply different cleaning media in one insulation.
No expensive and large-scale recharging
to automatically convert 3-axis to 5-axis
continuous toolpaths. “This enables us to
reduce expenditure on programming time
and still benefit from the advantages of 5-
axis machining,” explains Ms Kellerman.
“For example, the Mikron HPM 1350U
allows for an approach angle from +16° to -
120°, whereby the distance between spindle
and table is only 30 mm. This approach is
applicable for most geometries, and we
benefit from better surface finish through the
use of shorter, more rigid tooling and
reduced vibration.
“The consolidation of high end software
and high end machinery has reduced our lead
times by more than 20%,” she states.
“Those who stand still have no chance in
toolmaking over the long term. Technology
has reduced our costs now and will continue
to do so in the future.”
Another mould tool maker, this time
based on the other side of the Atlantic,
agrees with these sentiments. Ohio, USA-
based Prospect Mold is using WorkNC CAM
software from Sescoi (0844 561 7014) to
optimise 5-axis machine utilisation.
Mould designs are created in I-DEAS NX,
and subsequently every element of the tool
including core and cavity blocks, lifters and
slides, is exported to WorkNC-CAD on the
shop floor.
“The machine operators can turn off
layers to remove water lines, for example,
and do a little bit of surfacing to block ejector
pin holes or fill gaps in the model,” says Mark
Gruic, the company’s data co-ordinator.
“WorkNC CAD does everything we need, is
easy to use, and is completely integrated
with the WorkNC CAM software.”
The company’s 16 operators use the
dedicated 5-axis CNC commands in WorkNC
software for cutting parts such as turbine
blade dies on its seven 5-axis CNC machines.
“We work two shifts, preparing most of
the WorkNC CNC programs during the day
and batch process long calculations
overnight,” says Mr Gruic. “We merge
multiple programs, so that the machines can
run unattended for up to seven hours
overnight or at weekends. WorkNC is
absolutely reliable, enabling us to operate
unmanned with confidence.”
The intelligence in WorkNC’s toolpaths
and its graphical editing are particularly
appreciated by Prospect Mold.
“The amount of time the tool is out of the
material is really low and it stays cutting in
one area at a time, maximising machine
efficiency. We monitor our machine utilisation
levels and we consistently spend 80% of our
time cutting metal. Furthermore, the
flexibility of the toolpath editing is something
which you don’t get with other CNC software
– if you want to change or remove a path,
you can do it very quickly.”
Uptime and reduced cycles are two of the
most important factors for manufacturers
looking for a new CAM package, and it was
with these issues in mind that Halesowen-
based Somers Forge selected NCG CAM
(01223 863911) for shop-floor programming
compatible with SolidWorks (01223 346900)
and the company’s machining centres.
Since introducing CNC machines with
NCG CAM, Somers Forge has had some jobs
reduced from 300 hours to just under 30
hours. The software also allows drilling and
milling on the same machine tool and
eliminates further operations on parts by
using the 3+2 strategy.
Furthermore, when drilling using 3+2,
operators do not need to worry about the
angle of the hole, as NCG says the system
always finds the correct place. ■■
15
CADCAM
FIVE-AXIS SUPPLEMENT
www.machinery.co.uk • June 2011
Collision checking
CGTech is now shipping Vericut 7.1 CNC machine simulation and optimisation software. Vericut
7.1 features significant enhancements to reduce the time required for manufacturing engineers
to easily develop, analyse, inspect and document the CNC programming and machining
process.
Among the many enhancements, the latest version sees a new feature added for Vericut
collision checking – it is now possible to stop the simulation at an ‘exact’ collision point
between the machine components. While simulating an NC block with the ‘stop at collision’ box
checked, Vericut will stop in mid-motion at each collision point. Clicking the ‘step’ button
continues simulation to the next collision point – or to the end of the motion, if no other
collisions exist.
5axis_cadcam.qxp:Machinery 25/5/11 15:57 Page 15
‘Challenge Dormer’ aims to help businesses save significant
amounts of money and time by offering cost-effective
machining solutions.
To launch the campaign, Dormer is staging open days, on July 5
and 6, where businesses from around the country can visit the
company’s fully serviced productivity centre, located within its UK
headquarters at the Advanced Manufacturing Park (AMP) in South
Yorkshire.
All of Dormer’s partners will
be in attendance at the open
days, including Heller Machine
Tools, Kelch, Open Mind,
Delcam, System3R and
Hexagon Metrology.
Visitors will be able to view
demonstrations of the
machining capabilities of
Dormer’s productivity centre,
including the recently
installed Heller 5-axis FT
4000.
Dormer’s partnership
with fellow global leaders in
the engineering sector is a
further indication of its focus
on milling and threading, in
addition to the company’s
market-leading drilling
products.
Dormer is already gaining
national recognition with
aerospace and automotive companies from around the world for
offering customer-specific solutions, using the new machining
centre to improve manufacturing and process efficiency.
Budding engineers have also benefited from the workshop,
with students from JCB Academy visiting Dormer to build their
knowledge of the machinery and technology being used.
John O’Donoghue, general manager at Dormer Tools, said:
“Dormer’s significant investment in R&D means that our cutting
tools are designed to last longer and work more efficiently,
providing our customers with cost-effective solutions that give
value for money.
“Coupled with the fact that we now have a fully operational
workshop with state-of-the-art machines from a host of leading
organisations, this makes our productivity centre a unique location
in the UK.
“We are confident that with our expertise, and that of all our
partners, we will be able to meet the needs of any application, and
provide our customers with considerable savings – both financially
and in terms of reducing machining hours.
“We encourage companies across the UK to come forward and
put us to the test!”
To attend the Dormer Tools open days on July 5 and 6, between
10am and 7:30pm, in South Yorkshire, or take part in Challenge
Dormer, call 0870 850 4466. Further information at
www.dormertools.com.
June 2011 • www.machinery.co.uk
Challenge Dormer at national open daysEngineering and manufacturing firms across the country are being invited to put Dormer Tools to the test
16
Advertisement feature
Dormer Tools UK has launched its own Youtube channel to
showcase the company’s productivity centre in South
Yorkshire.
The channel’s latest video showcases Dormer’s
partnership with Heller Machine Tools and the installation of
the new FT4000 5-axis machine.
To watch the video, visit Dormer Tools’ YouTube channel
at www.youtube.co.uk/dormertoolsuk.
You can also follow Dormer’s
Productivity Centre on Twitter –
@DormerPRDcntrUK – and download
the new iPhone App – ‘Dormer Tools
Threadsize Calculator’. This calculates
the drill diameter required to support
precise thread creation.
John O’Donoghue, general manager
at Dormer Tools (right) with Geoff
Lloyd, managing director of Heller
Machine Tools.
P016_Dormer.qxp:Machinery 26/5/11 10:28 Page 16
17
TOOLING AND WORKHOLDING
FIVE-AXIS SUPPLEMENT
Well held; well cutWhile 5-axis machining centres grab most column inches, tooling and
workholding requirements are sometimes overlooked. Steed Webzell seeks
to even things up
The optimisation of 5-axis machining
means achieving the correct dynamic
between machine, cutting tool and fixture.
For components that are characterised or
dominated by curves and contours that
require movement in all five axes
simultaneously, only selection of the right
workholding and tooling (with a suitable
constant engagement) will achieve
efficient machining.
Or so says Sandvik Coromant (0121
504 5400), which insists much of the
success of 5-axis machining is in the
preparation. For instance, the way the
cutter is presented to the component
surface is a primary consideration, and
for this reason the lead and tilt angles
should be established as part of the set-
up, using CAM software; not only the
entering angle of the cutting edges, but
also cutter engagement and clearance.
THE RIGHT ANGLE
The lead angle is measured between the
centreline of the tool and the perpendicular
normal to workpiece surface at the point of
tool contact in the direction of feed. In many
cases, this is kept constant, according to
recommendations for the tool, but can be
varied through programming, if the CAM is
capable. Through a locked lead angle, the
cutter is inclined at a predetermined angle
throughout the feed direction, in relation to
the part surface. The angle is established
with reference to the smallest internal radius
on the surface and the effective cutter
diameter, says Sandvik Coromant.
The tilt angle of the cutter is established
in the plane which is perpendicular to the
direction of feed and therefore to the lead
angle; measured between centreline of
cutter and the normal to the surface at the
point of cut. A constant lead angle is
necessary for generating curved and
concave surfaces and, although point milling
consumes more cutting time and tool life,
it’s a secure method to use. Three-
dimensional surfaces are generated by
successive levels of cutters, passes by the
tool engaged with the workpiece at a point
on its corner radius, which varies along the
radius, according to the surface.
According to Sandvik Coromant, flank
milling is more effective in that it has a
shorter cutting time than point milling, but is
more limited in certain respects. For
instance, it is most suitable for semi-finishing
and finishing operations, but only on single
curved or convex surfaces.
Tool selection for 5-axis machining
depends partly on whether point or flank
milling is applied. Flank milling requires tools
with adequately long radial cutting edges,
such solid carbide end mills or exchangeable
head cutters. These can be either straight or
conical and have various corner radii.
www.machinery.co.uk • June 2011
Sandvik offers guidance on best practice
5axis_toolingand work.qxp:Machinery 25/5/11 16:12 Page 17
Foundry Road, Stamford, Lincs. PE9 2PP
Tel: 01780 765965Fax: 01780 765877
e-mail: offi [email protected]
The E Series Concept
Combines conventional, manual
data input and CNC versatility
within one machine and control
system
E30/E40/E50/E60/E70
Innovative Performance
E90/110/120/150/175
Oil and gas industries
• Robust design for precision
and stablility
• Multiple tooling turret options
• Large spindle bores upto
580 mm diameter
• Automated cycles fast and
simple communication
between man and machine
Apprentice, vocational training
• Machining of
simple/complex components
For point milling, there are a number of
tool choices, depending upon the component
features and finish requirements. Generally,
for larger, open surfaces, toroid or bull-nose
type milling cutters are preferred. For
cavities, ball nose cutters are often the best
choice, with conical tools for long overhangs,
where also modular tooling can be provided
and offer reduction adaptors for maximum
stability when tool reach is necessary.
Moving up the shank, away from the
cutting zone, toolholding plays a vital
facilitating role, as the Advanced Engineering
Division of Finecut can testify, following its
researching of options subsequent to the
acquisition of a new 5-axis machining centre
for its mould and die machining operation.
BALANCED APPROACH
Finecut acknowledged that machining at up
to 25,000 rpm demanded balanced, rigid and
robust tooling solutions. CADCAM manager
Danny Welsh reviewed that marketplace and
opted for a Schunk toolholding system.
“Only heatshrink systems could match the
guaranteed 3 micron balanced accuracy of
the Schunk Tribos system,” he says. “This
accuracy is exceptional, considering our
previous collet chucks could only deliver
accuracy of 10-20 micron. However,
heatshrink systems take a long time to reach
the temperatures needed to clamp and
unclamp the cutting tools, whereas the Tribos
can clamp and release a cutting tool
instantly.”
To clamp the cutting tools in the Tribos
holders, the Lancing, Sussex-based company
acquired a Schunk SVP2 pump system for
clamping and unclamping tools, with
corresponding SRE rings to hold the Tribos
holders during clamping.
The SVP pump places a high level of force
on the Tribos S toolholders to create the
elastic deformation necessary.
“The Schunk system arrived within a
matter of weeks of the company acquiring
the 5-axis machining centre,” says Mr Welsh.
“Despite this relatively short period, we
instantly witnessed surface finish
improvements, credit to the 3 micron
accuracy and the improved clamping rigidity.”
Since acquiring the Tribos S system, the
company’s workload has evolved to include
deep cavity mould machining. To facilitate
this shift in strategy, Schunk again provided
the solution, in the form of its Tribos SVL
18 June 2011 • www.machinery.co.uk
B-axis turn-milling
HSK-T is a new derivative of the HSK quick-change spindle interface that is totally compatible
with multi-tasking, turn-milling applications. The key factor with HSK-T is its ability to guarantee
the centre height of a turning tool when being used in a rotating spindle, such as the B-axis found
on many multi-tasking machine tools, with insert position guaranteed to ±0.11 mm on an HSK-T100
toolholder. According to supplier WNT (0800 073 2073), HSK-T provides a new ISO standard in
toolholding for turning applications on multi-tasking machine tools.
“Users of multi-tasking machine tools have been severely limited in their choice of spindle
interface, due to HSK not being available for turning applications. Now, with the arrival of HSK-T,
we are providing customers with a choice of spindle interface that is compatible with existing
HSK spindles they may have on their machining centres, thus creating a more cost-effective
solution,” says WNT’s managing director, Tony Pennington.
Schunk’s Tribos system helps out at Finecut
5axis_toolingand work.qxp:Machinery 25/5/11 16:13 Page 18
toolholder extensions, which can be clamped
inside the existing Tribos S toolholders to
enable operators to machine complex forms
inside deep cavities.
With most 5-axis machining in the UK
centring on short batch production, the need
for quick changeover is paramount,
particularly with regard to workholding
technology.
One company meeting this challenge is
Leydon Transmissions of Liversedge, a maker
of power couplings and braking systems for
the yellow goods sector, as well as a provider
of subcontract machining services.
The company’s new managing director,
Mike Robinson, joined in January 2010 and
immediately set about implementing a
programme of investment, starting with a
new £200,000 Doosan 5-axis machine tool
from Mills CNC (01926 736736). He then set
about the process of maximising spindle run
time and minimising set-ups.
“From stopping one job to cutting the
next, our vision is 20 minutes maximum for
any part, including loading any tools required,
workholding and downloading the NC
program. It’s an aggressive target, but an
achievable one, once everything is in place.
QUICK-CHANGE ARTIST
A Hainbuch MS Dock and Mando segmented
mandrel from Leader Chuck Systems (0121
771 4843) addresses the quick-change
workholding demands at Leydon. For a
certain set of quality-critical components, the
company has to locate on the bore of the
parts.
“Starting with round bar stock, we bore a
hole in the middle and then mill it square,
before cross-feed holes are drilled. So, we
have a decent size bore to locate and hold
on, which also acts as the datum,” says
Mr Robinson.
Using the 5-axis Doosan, in combination
with the Leader workholding solution, has
allowed the company to replace what were
six sequential machining operations with just
two – only the back face is accessed after
the cycle has been completed.
“The Leader product is well suited to the
quick changeover ideology: a full mandrel
change only takes three to four minutes.”
Helping to enhance both accuracy and
efficiency even further is palletisation, and
illustrating this point is Northamptonshire-
based Salcey Precision Engineering, a
motorsport component machining specialist
that works regularly to tolerances of +5
micron, with the aid of palletisation from
System 3R (02476 538653).
“System 3R MacroMagnum pallets suit
our requirements perfectly, with up to 18
pallets (each 156 mm diameter) able to be
located on the table of our four Mikron
HSM400 5-axis machines,” says the
company’s managing director, Richard Alcock.
“This gives us the ability to ‘mix and match’
machined parts, together with unmanned
operation – especially as our existing vices
and tombstones can also be accommodated.
“Taking any part off the machine and
measuring it with our CMM is also easily
facilitated. Using our own interface fixed to
the System 3R pallets ensures that positional
accuracy is maintained at all times,” the
managing director adds. ■■
19
TOOLING AND WORKHOLDING
www.machinery.co.uk • June 2011
Modular workholding
Triag Precision Tools says that its range of
modular workholding systems brings
particular benefits to 5-axis machining
operations. For instance, the lower base
rails on Triag products serve both as a
mechanical zero-point clamping system, as
well as a vice. Here, all the tension acts at
the workpiece, keeping it rigid – whether
small, long or large – and at the same time
providing high levels of accessibility.
The Triag range offers over 50 different
clamping modules. As well as the raw
‘base’ modules, there are self-centring,
three-jaw chuck, collet chuck and vacuum
clamping modules, to name but a few – and
the interface is always the same.
The range is available in the UK from
REM Systems (01452 314100) and Hilcliff
Tools (01483 266780).
FIVE-AXIS SUPPLEMENT
WNT’s HSK-T interface for mill-turn machines
5axis_toolingand work.qxp:Machinery 25/5/11 16:13 Page 19
June 2011 • www.machinery.co.uk
TRIAG precision toolsAussergrütstrasse 2CH-6319 AllenwindenTel. (d+e) +41 (0) 41 727 27 27Tel. (f) +41 (0) 41 727 27 96Fax +41 (0) 41 727 27 99E-Mail: [email protected]
Threading tools
Rem Systems Ltd.Hillcliff Tools Ltd.www.remsystems.co.ukwww.hillcliff-tools.com
tripoxyMINERAL
Epoxy mineral tombstones
powerCLAMP
microCLAMP
aptoCLAMP
mivaCLAMP
oppSystem
triGEL
BAR BY BAR
modular workholding systems
www.amdale.co.uk
22 years of excellence in:
5 Axis CNC Machining
EDM Wire Erosion
CNC Turning
Laser Etching
Units 6/7 Culverin Square
Limberline Road
Portsmouth PO3 5BU
Tel: +44 (0)2392 660726
Fax: +44 (0)2392 655177Quality. Reliability. Customer Service.
Cert No. FM25674
20
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UALITY
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SUPPLIERS
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The UK Leaders in mobile ON-SITE Calibration with 30 years experience -
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To arrange a visit to discuss your specific requirements, provide a quotation or price list please contact:
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On-site service reaches 30 years
P020_MCSP_JUN11 24/5/11 17:29 Page 20
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FOR ULTRA
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Foundry Road, Stamford, Lincolnshire PE9 2PP
Tel No. 01780765965; Fax No. 01780765877
e-mail: [email protected]
www.kyalmachinetools.co.uk
21
INSPECTION
FIVE-AXIS SUPPLEMENT
The unexpectedSteed Webzell reports on the latest applications for measuring the features,
geometries and curves created by 5-axis machining
Parts made using 5-axis machining typically
offer complex features or freeform
surfaces and thus measurement often
requires a certain degree of innovation.
Few can testify to this better than
Cheltenham-based Future Advanced
Manufacture (Future AM), a precision
engineering company that recently won its
first significant aerospace contract in the US.
“We can’t say much about it,” says Craig
Peterson, managing director of the AS9100-
accredited company, “except that making
titanium blades for a new propulsion system
requires a very stringent validation process.
Our existing metrology wasn’t up to the job,
so we turned to the Revo 5-axis system.”
Revo from Renishaw (01453 524524) is a
measuring head and probe system that uses
synchronised motion and Renscan5
measurement technology to minimise the
dynamic effects of CMM motion at ultra high
speeds. It also uses Renishaw’s new Modus
software to take full advantage of CAD-
driven programming. The resulting
improvement in efficiency and accuracy has
also enabled the company to offer reverse
engineering services.
First, Future AM laser-scan the
component and turn the data into a point
cloud, which is run through SolidWorks
(01223 346900) CAD and Visi Reverse
software from Vero (01242 542040) to create
a virtual 3D surface. “We then use Revo to
compare the new virtual surface with the
original component to validate possible
engineering processes before making the
cloned parts,” says Mr Peterson.
IN-PROCESS MEASUREMENT
In-process 5-axis measurement solutions are
also proving popula, and a number of
applications are being driven by the
aerospace sector. A case in point can be
seen at Tods Aerospace, which has sites in
Somerset and Dorset. Tods specialise in the
design and manufacture of lightweight
structures in composite materials.
To help maintain its preferred supplier
status for customers such as
AugustaWestland, as well as bid for
increasingly complex 5-axis work, Tods
invested in a 5-axis router from CMS (0115
977 0055), a Renishaw RMP600 wireless
touch probe and OMV Pro measurement
www.machinery.co.uk • June 2011
Non-contact inspection of complex shapes
The HN-6060 from Nikon Metrology (01332 811349) is a next-generation, non-contact inspection
system that uses an advanced laser scanner, 5-axis synchronised hardware control and ultra
stiff design to inspect complex shapes, including gear teeth and turbine blades.
The HN-6060 captures high density 3D point clouds from part surfaces at a rate of 120,000
points per second and to an accuracy of 5 micron. A new laser scanning sensor extracts the
surface form and waviness data in one scan, whereas previous tactile gear inspection tools
relied on 2D sections of data. A core element of the HN-6060 is its 5-axis synchronised
hardware control. This gives optimum part orientation to the sensor, allowing it to measure from
different angles.
Renishaw’s Revo in action at Future AM
5axis_Inspection.qxp:Machinery 25/5/11 16:23 Page 21
June 2011 • www.machinery.co.uk
• Highest holding force lowest clamping pressure
• Save on material wastage clamp securely on only 3mm
• Full 5 face machining no clearance issues
• Repeatable positioning of material better than 0.01mm
• Self centring accuracy ±0.02mm
• Reversible clamping jaws for larger range
• Clamping ranges 0 to 355mm
• User friendly for short tools
• Precise strong design
• Competitive Price
For more information and a Demo call
THAME WORKHOLDINGField End, Thame Road, Long Crendon, Aylesbury, Bucks HP18 9EJ Telephone: 01844 208050 Fax: 01844 201699 Email: [email protected]
THE ART OF 5-AXIS WORKHOLDING
LOCKED IN PERFORMANCE
22
Call: 01543 478710
Click: www.hainbuch.com
Manual stationary chuck MANOK plus
Massive clamping force, easy to use
Ideal for 5-Axis machining
Accurate, fast, easy set-up
with pull back action
Can be used with all HAINBUCH
adaptations and clamping heads
MANOK plus RD with clamping
head
MANOK plus RD with jaw adapter
[clamp up to Ø 120 mm]
MANOK plus RD with
mandrel
MANOK plus RD horizontal
set-up [with through-bore]
P022_MCSP_JUN11 27/5/11 10:56 Page 22
Foundry Road, Stamford, Lincs. PE9 2PP
Tel: 01780 765965Fax: 01780 765877
e-mail: offi [email protected]
PowerJet Flood cleaning
system
Utilising
environmentally
friendly aquas
solutions
Customer benefits
• Modular structure with compact design.
• Multi stage spray, flood, immmersion process.
• High swarf removal PowerJet action.
• Rotation or oscillation with programmable angle.
• Drying by hot air/vacuum.
software. The RMP600 is a compact touch
probe, which incorporates Renishaw’s
patented Rengage strain gauge technology
and uses frequency hopping spread spectrum
(FHSS) radio signal transmission.
“One of the key reasons for purchasing
the probe was to align the cabin roof
of the AugustaWestland AW159
Lynx Wildcat and then machine it,”
says CNC manager Bob Young.
“This has proven very successful
and we are now producing our
own CMM reports, generated from
the use of the Renishaw OMV
software and the RMP600 probe. Without
the probe, we would not have been able to
machine the roof as accurately and we
couldn’t have aligned the jigs with such
precision.”
Blurring the line slightly between online
and offline 5-axis inspection systems are
portable CMMs: technically speaking, an
offline device, but one that can be walked to
the machine tool, if required. If the
application dictates, there are real gains to be
had here, as Coventry Prototype Panels
(CPP) can confirm. CPP specialises in the
prototyping and low-volume manufacture of
vehicles and components, such as the
Spyker Aileron – the firm builds 200 a year.
Some of the solutions offered by CPP vary
from traditional component prototyping to
what can almost be considered metallic arts,
looking at some of the contours achieved.
The company utilises measurement
technology from Faro (02476 217690) to
ensure the parts correlate to design
specifications. The Faro ScanArm uses laser
technology to inspect parts quickly, including
on the production line, should the need arise.
CPP expertise in this area has also led to
it being awarded the contract to supply Aston
Martin with parts for its million pound sports
car, the One-77.
Sports cars and motorsport vehicles are
big business in the UK, from Formula One to
amateur stock car racing. When the Brunel
Racing team from Brunel University was
seeking to improve its results in the annual
Formula Student championships, it knew
getting the Yamaha R6 engine fitted correctly
into the rear chassis space frame was one of
the most time-consuming.
The task involved gaining an accurate
measurement of the complete engine,
which, with its complex geometries, is
no easy task. A CMM might measure
a few points accurately, but to gain an
accurate picture of the entire surface
could take weeks. Meanwhile, a laser
scanner requires an expert operator and
may also entail a lengthy process to ‘patch’
individual scans together.
WHITE LIGHT SAVES TIME
As a result, Brunel Racing approached 3D
white light measurement specialist Phase
Vision (01509 839000), whose equipment
undertakes scans in a matter of seconds,
using sine wave technology that projects a
series of light stripes on to the object and
uses an integral camera to develop a
complete visual representation, based on
millions of points. “Having the engine
scanned cut around three weeks out of the
design process, meaning we will have longer
to test the final vehicle,” says Matt Carey,
powertrain manager for Brunel Racing.
Ralph Weir CEO of Phase Vision adds:
“This project is a further example of how
detailed scanning can create accurate virtual
representations of highly complex
components which can be manipulated using
CAD and so save both time and cost in the
final manufacturing process.” ■■
INSPECTION
FIVE-AXIS SUPPLEMENT
Hexagon’s new Cognitens technology at work
www.machinery.co.uk • June 2011
New white light device
The introduction of the manual measurement system Cognitens WLS400M and the automated
Cognitens WLS400A replace all former white light products from Hexagon Metrology (0870 446
2667). White light measurement uses digital stereo vision technology to generate highly accurate
3D data. “The new product generation comes with innovative LED technology, stable carbon fibre
housing and a compact system set-up”, says Duncan Redgewell, Hexagon Metrology’s vice
president portable products.
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