Altenstadt, Germany, September 3, 2009 --- CNC multi-axis grinding machines using NUM's NUMROTOplus 3D simulation and control software are helping Miller Präzisionswerkzeuge GmbH to manufacture a new series of high-performance MAPAL-brand solid carbide twist drills. The new drill tools employ complex optimised profiles to accelerate cutting speeds.

The NUMROTOplus software allowed Miller Präzisionswerkzeuge to visualise and optimise the complex machining process required to produce the new drills in 3D, before putting the new drill range into volume production.

"The NUMROTO features helped during the development of our latest MAPAL drill products, and we made extensive use of the advanced 3D simulation capabilities of NUMROTOplus software, including its tool collision monitoring procedures, to optimise our manufacturing process," says Ulrich Krenzer, Technical Director of Miller Präzisionswerkzeuge. "We have used NUM's CNC software for a number of years, and are now in the processing of running it out across all our machines. By effectively standardising on this one package, with a consistent user interface, we will reduce our personnel training costs and help maximise productivity, while maintaining the product quality for which we are renowned."

To cope with demand, Miller Präzisionswerkzeuge recently doubled the size of its R&D and manufacturing operations at Altenstadt in Germany, culminating in the opening of a new 7000 m2 production facility in November 2008. The facility contains more than 40 CNC grinding machines equipped with the NUMROTOplus software - which operate for three shifts per day, 365 days of the year - making it one of the most modern solid carbide tool and drill production plants in the world.

It is widely acknowledged that more than 30 percent of productive machine time is nowadays taken up by drilling operations. Typically, these include pilot drilling and pre-centring, drilling, reaming, countersinking, boring out, de-burring and thread cutting. By combining some of these operations in a single step, it is possible to decrease machine time significantly, but only if the drilling tools feature task-optimised profile geometries - factors such as chip removal, heat dissipation and tool stability are critical.

The new MAPAL 'Mega Speed Drill' is designed for high speed drilling of steel and iron. It features an asymmetric tip, with reinforced cutting edges. The 3 margins are designed in such a way that the drill will slightly oversize the holes and the friction between the margin lands and the workpiece will be minimised. This geometry makes the drill relatively insensitive to high cutting edge temperatures and corner wear. The specific, polished flute geometry guarantees a free flow of chips. The drill can be applied with a very high cutting speed of about 200 m/min when machining steel, enabling drilling times to be reduced by as much as 70 percent compared to conventional products. For example, when used to drill annealed 42CrMo4 under these high performance cutting conditions, the tool has a typical lifetime of 60 to 70 m, reducing the production cost per bore by as much as 50 percent.

Miller Präzisionswerkzeuge has also just developed a twist drill which produces a bore with a flat 180 degree bottom. Normally, this would require two machining operations, one to drill the bore to the required depth and one to perform counter-boring. A special tip profile on the new 'Mega Drill 180' effectively combines the two operations in a single machine cycle. The drills are ground with an S-shaped point thinning, which delivers good chip control and a profiled concave flank to produce a flat bottom hole. The tool can also be applied for piloting at inclined surfaces. The flat point reduces here the radial forces compared to conventional drill points with a 140° point angle.

CGTECH has released version 7.0 of its VERICUT CNC machine simulation and optimisation software.According to CGTech, VERICUT 7.0 include performance-improving enhancements that reduce the time required for manufacturing engineers to develop, analyse, inspect and document the CNC programming and machining process.
CGTech claims VERICUT 7.0 is more stable and significantly faster than previous versions. As a CNC machine simulation, verification and optimisation software, VERICUT helps users eliminate the process of manually proving-out NC programs, reducing scrap loss and rework.
VERICUT simulates all types of CNC machine tools, including those from Mazak, Makino, Matsuura, Hermle, DMG, DIXI, Mori Seiki and Chiron.The software runs standalone, but can be integrated with CAM systems such as CATIA V5, NX, Pro/E, MasterCAM, EdgeCAM and GibbsCAM.

September 1, 2009 - Utilizing FHSS technology, Touch Probe Systems allow automated job set-up and in-process measurement of all sizes of CNC machine tools. Model RMP40, measuring 40 mm in dia and 50 mm long, is suited for multi-axis and mill-turn applications in which line-of-sight between probe and interface cannot be maintained. Designed for hostile turning environments, Model RLP40 is sealed to IPX8 and further protected by eyelid that prevents high velocity swarf and chips from causing damage.

New Ultra-Compact Radio Transmission Touch Probes Bring Probing Benefits to a Wider Range of CNC Machine Tools

Renishaw adds to its market-leading range of probe and software products with new touch probe systems for machines, including lathes, where line-of-sight issues cause difficulties or optical signal transmission.

Renishaw is making waves with the introduction of new touch probe systems that use its unique frequency hopping spread spectrum (FHSS) probe signal radio transmission technology to allow automated job set-up and in-process measurement on all sizes of CNC machine tools. The new ultra-compact RMP40 probe is especially suited to multi-axis and mill-turn applications, whilst its variant, the RLP40 touch probe, is specifically designed for more hostile turning environments. A transmission only module RMP40M is also being introduced.

Wide range of touch probes with radio transmission

These new products reinforce Renishaw's world leading range of probe systems and probing software, which bring a range of user benefits including reduced set-up times, reduced scrap, reduced fixture costs and improved process control. The range of radio-based inspection probes already includes the multi-award winning RMP60 touch probe, and the class-leading high accuracy RMP600 probe with Renishaw's patented Rengage(TM) 3D strain gauge technology.

Measuring just 40 mm in diameter and 50 mm long, the RMP40 probe system pairs the compactness of Renishaw's award-winning OMP40 optical transmission probe system with the robustness and versatility of Renishaw's unique FHSS radio transmission. This combination means that the RMP40 is suited for use on all sizes of machine tools, particularly multi-axis and mill-turn applications in which line-of-sight between the inspection probe and its interface cannot always be maintained.

Unique probe signal transmission system

The RMP40's FHSS radio transmission is the same unique yet tried-and-trusted system used by Renishaw's existing RMP60 and RMP600 probes in thousands of applications worldwide. It pairs with the standard Radio Machine Interface (RMI) and utilises the 2.4GHz frequency band, allowing it to be 'worldwide legal' so that machine tool builders and users can specify and operate the same types of probes wherever they are located. It also delivers unrivalled levels of robustness and flexibility through frequency diversity, whereby the probe and its interface continually hop from one transmission channel to another. This eliminates 'dead spots' within the working environment and allows the system to avoid radio interference, both of which are common problems for other fixed-channel and non-hopping radio transmission inspection probes.

Naturally the RMP40 touch probe incorporates Renishaw's patented Trigger Logic(TM) set-up and mode selection menus. This allows users to quickly and easily configure their probe systems to their own specific requirements, without tricky disassembly routines or changes to tiny switches.

New radio touch probe for CNC lathes

Sharing many features in common with the RMP40 touch probe, the RLP40 is a radio transmission inspection probe system for lathes, whilst the RMP40M is a radio transmission module that incorporates an industry-standard M16 adaptor for use with Renishaw's proven LP2 family of lathe probes.

Although it incorporates all of the key features and benefits of the RMP40, the RLP40 touch probe has been specially packaged to withstand the extreme environments more typical of lathes and turning centres. Like all Renishaw probes it is sealed to IPX8, but is further protected by a user-serviceable eyelid that prevents high velocity swarf and chips from causing damage.

The RMP40M module also gives all the benefits of the RMP40 system, allowing the flexibility of its FHSS radio transmission system to be applied to those situations in which the LP2 family of touch probes, adaptors and options are necessary.

Retrofit to existing machine tools

With a combined package of user-friendly operation, robustness, extreme flexibility and proven reliability, both the RMP40 and RLP40 probe systems are highly desirable and versatile additions to Renishaw's ever-growing family of inspection probes, and can be retrofitted to existing installations. Importantly for user confidence they are also backed by a trusted worldwide network of service, support and applications expertise.

Renishaw's range of tool setting probes, inspection probes and probe software caters for the complete cross-section of machine tool probing applications, from the setting of tools and workpieces through to process control and complex On-Machine Verification tasks, whether on simple milling machine or a complex multi-axis machine tool.

Find out further information about Renishaw's market-leading range of CNC machine tool probe systems and software