Un trasporto straordinario per una macchina di dimensioni eccezionali, lungo un itinerario che inizia a Cologno Monzese nella sera di giovedì 14 luglio e attraversa Monza per finire a Nova Milanese.

Un trasporto straordinario per una macchina di dimensioni eccezionali, lungo un itinerario che inizia a Cologno Monzese nella sera di giovedì 14 luglio e attraversa Monza per finire a Nova Milanese.

Saranno dunque imponenti le misure per lo spostamento di un pezzo per un’alestrice (una macchina utensile per le lavorazioni di fori utilizzabile anche per altre funzioni) appena uscita dall’officina di Carpenteria Viganò, azienda metalmeccanica nata alla fine degli anni Sessanta ad Arcore, in una delle tante cantine della Brianza, poi trasferitasi nel 2000 a Cologno.

Il più grande in Europa – Non un pezzo qualunque, bensì una particolare macchina utensile a portale mobile con un banco portapezzo rotante delle dimensioni straordinarie di 5 metri di larghezza per 15 di lunghezza (il più grosso mai realizzato in Europa forse nel mondo), chegiovedì sera attraverserà lungo il tragitto anche Monza.

Nello specifico partirà dopo le 22 da Cologno Monzese, percorrerà le strade provinciali 208, 121 e 13 per poi immettersi nelle vie comunali di Monza, imboccare la Valassina e quindi uscire a Lissone per percorrere le strade comunali tra la città del mobile, Desio e Nova Milanese, dove sarà presa in custodia dalla Trater, impresa di trattamenti termici dove l’alesatrice sarà sottoposta ad uno specifico trattamento.

Continua su http://www.ilcittadinomb.it/stories/Economia/trasporto-eccezionale-la-alesatrice-dei-record-andra-in-cina-ma-prima-attraver_1192514_11/

È interamente dedicato a Industria 4.0 il nuovo portale messo a punto da ICIM, ente di certificazione indipendente, insieme ad ANIMA-Federazione delle associazioni nazionali dell’Industria Meccanica di Confindustria e a UCIMU-SISTEMI PER PRODURRE, l’associazione dei costruttori italiani di macchine utensili, robot, automazione e tecnologie ausiliarie.

Il portale Industria 4.0 e iperammortamento, a cui si accede dai siti ANIMA, ICIM e UCIMU-SISTEMI PER PRODURRE, nasce con l’intento di fornire alle imprese italiane, di qualsiasi settore e dimensione, un sito completo di tutti gli elementi per potersi informare sulle opportunità e gli adempimenti previsti dal Piano, porre domande specifiche, richiedere preventivi, gestire lo scambio on-line di documenti necessari per la verifica dell’analisi tecnica.

Il portale è diviso in 4 sezioni: Industria 4.0 e iperammortamento – informazioni e documentazione aggiornata a cominciare dalle normative di riferimento (leggi e circolari del MISE), articoli, commenti e case histories ma anche le varie possibilità di finanziamento; Domande e risposte – dove trovare riscontri o porre nuovi quesiti sul proprio caso specifico in totale privacy; Come usufruire dei benefici fiscali. I servizi ICIM – modalità di accesso alle agevolazioni e come trovare il servizio ICIM adeguato alle proprie necessità; e Area riservata alle aziende clienti ICIM – con la possibilità di caricare in completa sicurezza informatica i propri progetti di innovazione 4.0 e richiedere a ICIM un’offerta per la valutazione tecnica e il rilascio dell’attestazione di conformità.

Per rispondere ai quesiti, ICIM, ANIMA e UCIMU-SISTEMI PER PRODURRE mettono in campo un team di esperti in grado di esprimere le migliori competenze per la corretta applicazione dei criteri della legge di bilancio 2017 e della relativa linea guida del Ministero dello Sviluppo Economico.

Possono accedere alle funzionalità del portale tutte le aziende che intendono valutare nel 2017 l’opportunità di investimento in ottica Industria 4.0.

Grande spazio viene dato, naturalmente, allo strumento cardine del Piano, l’iperammortamento al 250%:  per beneficiarne, le aziende devono fornire garanzia che il bene possa rientrare nell’agevolazione, con l’obbligo di un’attestazione di parte terza per beni di valore superiore a 500.000 €. La recente circolare dell’Agenzia delle Entrate precisa che l’attestazione di terza parte è sempre possibile anche per beni di valore inferiore, e consiglia di affiancare all’attestazione l’analisi tecnica, un documento di dettaglio che descrive il rispetto dei requisiti e ha l’obiettivo di evitare possibili contenziosi in futuro. A tal proposito ICIM, quale organismo di certificazione accreditato, offre ampie coperture assicurative a tutela dei clienti che dovessero avere contestazioni del beneficio fiscale goduto e competenze multisettoriali di processo, impianti e sistemi aziendali.

All’interno del portale vengono illustrate anche le altre misure di incentivazione e sostegno previste dal Piano Nazionale Industria 4.0, come la proroga del superammortamento e le agevolazioni a supporto delle PMI. Alla voce finanziamenti spicca, inoltre, un progetto di sistema di Federazione ANIMA, nato per diversificare le tradizionali fonti di finanziamento del debito bancario: è Meccanica Bond, studiato insieme al Politecnico di Milano, per consentire alle imprese di ottenere il capitale necessario per finanziare progetti di investimento di medio-lungo termine in tecnologie 4.0 per acquisire nuovi impianti, fare ricerca e sviluppo, investire in brevetti o acquisire altre imprese.

“ICIM è in grado di rispondere a ogni richiesta e a ogni dubbio delle aziende italiane sui temi dell’Industria 4.0 – dice Gaetano Trizio, Amministratore Delegato ICIM – dando tutte le risposte in piena sicurezza e riservatezza dal momento che trattiamo temi strategici per la concorrenzialità delle imprese. In particolare, è importante che vengano comprese le logiche del Piano, a cominciare dall’interconnessione, un requisito non sempre semplice da soddisfare ma basilare per la definizione dell’innovazione e, dunque, del beneficio fiscale. Inoltre – conclude Trizio – come ente accreditato possiamo anticipare e gestire tutti i rischi insiti nell’industria 4.0, volgendoli in vantaggio competitivo per le imprese”.

“Le nostre aziende guardano all’Industria 4.0 come una leva competitiva necessaria – dice Andrea Orlando, Direttore Generale di ANIMA – Il portale è uno strumento adeguato per passare dall’idea di una “fabbrica intelligente” al progetto. Le informazioni, i documenti e il confronto con professionisti ed esperti, tramite il portale, accompagnano l’imprenditore alla ricerca della migliore soluzione. Alcuni settori sono già all’avanguardia sul 4.0 e sono di esempio alla filiera e ai concorrenti. Il tempo è un fattore cruciale e il portale è uno strumento completo e veloce che risponde alle esigenze dei nostri imprenditori. La Quarta Rivoluzione Industriale, grazie ai benefici messi a disposizione dal Piano Nazionale, oggi è possibile”.

Alfredo Mariotti, Direttore Generale di UCIMU-SISTEMI PER PRODURRE ha aggiunto: “Il Piano Nazionale ha avuto il grande merito di rimettere la manifattura al centro dell’agenda politica economica del Paese e i primi dati di andamento ordini di macchine utensili sul mercato italiano confermano la validità della scelta operata dal Governo. Alle organizzazioni come UCIMU-SISTEMI PER PRODURRE spetta ora il compito di sostenere le imprese in questo delicato passaggio. Il nuovo portale, realizzato in collaborazione con ICIM e ANIMA, nasce proprio per accompagnare le imprese nei processi di innovazione e sviluppo e consentire loro di sfruttare le nuove fonti di creazione del valore della trasformazione digitale”.

Il portale è già stato preso come riferimento da alcune associazioni territoriali di Confindustria per supportare i propri associati in questa importante rivoluzione industriale.

http://www.industriameccanica.it/content/%C3%A8-online-il-portale-industria-40-e-iperammortamento

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Toolholding for rotating round tools—end mills, drills, and taps—continues to evolve with innovative designs aimed at guaranteeing precision, security, and repeatability. As a result, suppliers of toolholding technology have made supporting the precision, security, and repeatability of shrink-fit, mechanical, and hydraulic toolholding the highest priority. You don’t have to look any further than the recent offerings from tooling suppliers to find better ways to improve metal removal rates, part quality, and tool life.

The challenge always is to transmit machining force from the machine’s rotating spindle to a metalcutting tool. Toolholders have a front end to grip the rotating round cutting tool and a back end connection to the machine tool spindle. Back end choices to connect to the machine spindle include CAT (ISO), BT (JIS), HSK (DIN), KM (ISO), and Capto (ISO) standard interfaces and the proprietary BIG PLUS. Each has its particular strengths for milling, turning, and drilling, and each requires precision machining, usually grinding, gaging, and advanced inspection to be manufactured to the required precision specifications.
For front end connection to the cutting tool, there are a number of technologies to choose from that have been developed to meet the challenges of high-speed cutting (HSC), heavy-duty roughing of difficult-to-machine metals like Inconel, and sophisticated toolpath strategies. The main culprit that can lead to catastrophic and costly scrapping of workpiece is tool pullout from the toolholder. One chief remedy that has long been identified as beneficial is high gripping torque. To provide additional security, tooling manufacturers have come up with rather ingenious solutions to guard against the possibility of pullout.

Guarding Against Twisting Cutters Out of Holders

“When you look at toolholders, there are four important considerations: rigidity, accuracy, balance, and security,” said Brendt Holden, president Haimer USA (Villa Park, IL). “If you don’t have good taper contact and a properly made interface, you’re not going to be rigid to start with as far as how you interface with the machine spindle. You need balance so that the toolholder is able to hold the runout accuracy properly, and you need security to prevent tool pullout.
Safe Lock’s locking principle results from helical grooves that are ground on the cutter’s shank so that they can interface with the form-closed drivers in the holder. The helical form of the groove protects the tool against overturning and pulling out.
“For a long time, we in the industry talked about high gripping torque for example for our heavy-duty shrink fit chucks. High gripping torque systems of shrink-fit, milling chucks, and hydraulic chucks are all based on a high accuracy friction fit with 360° clamping,” said Holden. “However, if there isn’t a form fit in addition to the friction-fit to prevent the tool from spinning or twisting, the tool could ultimately pull out or begin to creep out even with high gripping torque.”

To counter this tendency Haimer developed SafeLock, which combines a shrink-fit chuck or another high-precision chuck with locking elements. The locking principle results from helical grooves that are ground on the cutter’s shank so that they can interface with the form-closed drivers in the holder. The helical form of the groove protects the tool against overturning and pulling out.

“The modification to the cutting tool shank is straightforward and symmetrical. In fact, cutting tool suppliers have found that they are able to add the SafeLock grooves to standard stock end mills, or even end mills that have an existing Weldon flat,” said Holden. “The grooves don’t greatly affect the balance, which is an issue with the Weldon flat. In fact, the modification keeps the cutting tool stronger since the grooves are very shallow as opposed to a deep Weldon flat cutting through a great portion of half the shank,” said Holden.

The SafeLock system isn’t limited to Haimer shrink-fit chucks. It can be integrated in a collet chuck, milling chuck, or in a hydraulic chuck. “We developed SafeLock based on customer needs but now we are finding that it is effective in dealing with pullout created by new aggressive milling strategies like trochoidal milling or peel milling. Both have a strong radial engagement of the cutting tool to the workpiece which tends to make the cutting tool really want to pull out of the chuck. So we believe that the Safe Lock has morphed into a timely and perfect solution for where the industry is going—toward aggressive milling for higher metal removal rates which translates into machining parts faster,” said Holden, “and we call SafeLock the seat belt for your cutting tool.”

Special Holder Design Locks Tools in Place

Recognizing that toolholders must provide strong gripping force, high precision, and vibration control in machining difficult-to-machine materials aggressively, Rego-Fix Tool Corp. (Indianapolis) developed secuRgrip, a special threaded insert or key that locks cutting tools in place, eliminating cutter pullout without the need to alter cutters. The simple and effective design of secuRgrip is part of the company’s well-established powRgrip mechanical toolholding system and one that allows the use of any off-the-shelf tool as long as it has a common standard Weldon flat on its shank.

The secuRgrip further enhances the already extreme holding capability of Rego-Fix’s well-established powRgrip mechanical holder system. To lock a cutter in place, the small insert of the secuRgrip system is placed in the Weldon flat of a cutter. The bottom profile of the insert matches that of the Weldon flat, and its exposed side has a thread pattern that matches with those of internally threaded powRgrip system collets. Users hold the insert in place while sliding the tool into the collet. The collet is turned so that its threads engage with those of the insert, and the tool is then screwed all the way into the collet. This cutter-collet assembly is pressed into a powRgrip system holder, and a special external cap nut is tightened onto the holder for added pullout security.
BIG Kaiser’s Mega Perfect Grip features a unique lock mechanism using a key grip prevents the slip and pullout of the tool during heavy cutting and accepts industry standard Weldon flat milling cutters (ASME B94.19-1997) and doesn’t require special grinding of the milling cutter.
Users with existing powRgrip holders can easily transform their systems into a secuRgrip holder by simply threading the outside of any powRgrip PG 25 or PG 32 holder for accepting the cap nut. Rego-Fix can either supply the necessary thread specifications or factory-threaded holders.

The secuRgrip holders accommodate cutter diameters from 0.472 to 1.000″ (12–25 mm). With holder body tensile strengths higher than those of the cutting tools being held, the secuRgrip holders will withstand cutting forces that could break the cutters before ever damaging the toolholder itself.

Vibration-dampening capabilities of secuRgrip are critical for today’s increasing machine tool spindle speeds and feed rates, leading to a tighter TIR, increasing tool life and improving part accuracies and surface finishes. The powRgrip and secuRgrip systems ensure concentricity (TIR) with deviations of less than 3 µm for tool lengths up to 3×D diameter and length pre-adjustment with a repeat accuracy of less than 10 µm.

The powRgrip system absorbs vibrations by creating “material breaks.” Rego-Fix’s use of different materials, all with their own unique harmonics/frequencies, creates breaks or gaps. These gaps—between the cutter and collet, collet and toolholder body—provide a natural vibration-dampening capability. As mechanical designs, powRgrip and secuRgrip are also faster than other systems when it comes to exchanging tools. Removing a tool from a holder and installing another takes about 10 seconds. Heat-shrink holders, on the other hand, must be heated, the cutter installed, then put in a chiller for two or three minutes before the tool can be used.

Innovative Toolholders for High-Production Tapping

The Speedsynchro tapholder from Emuge Corp.(West Boylston, MA) features an integrated transmission of 1:4.412 for optimizing thread production on CNC machines with synchronous spindles. Speedsynchro is achieving increased cost savings, time savings of up to 40%, and a reduction of energy consumption of more than 90% compared with synchronous thread machining, and a dramatic increase in tapping output. This is due to considerably shortened thread production cycles resulting from the combined fast acceleration and cutting speeds aided by the integrated transmission. This is particularly effective for high-production tapping operations such as those in the automotive manufacturing industry. In addition, tool life and thread surface quality are optimized due to a patented minimal length compensation function that reduces the axial force on the tap, enabling longer tool life.

The Speedsynchro technology combines the integrated transmission with minimum length compensation, offering a way to efficiently work with high cutting speeds and a relatively low synchronous machine tool speed that compensates for synchronization errors during the threading process. Through this technology, it is now possible to run machine spindles in a noncritical energy-saving RPM range during thread production.

Exact thread depths can be achieved with Speedsynchro as it doesn’t reverse the direction of rotation. Speedsynchro toolholder supports a maximum spindle speed of 2000 rpm and a maximum tapping speed of 8824 rpm. Cutting range is from M1-M8 and an ER16 toolholder size is offered. Internal coolant capability is provided.
Part of the powRgrip mechanical toolholding system, secuRgrip features a special threaded insert or key that locks cutting tools in place, eliminating cutter pullout without the need to alter cutters, allowing the use of any off-the-shelf tool as long as it has a common standard Weldon flat on its shank.
In addition, Emuge has expanded its patented Softsynchro tapholder line, adding two new holder series. Constructed from two separate, precision-ground sections, the body and the shank, Softsynchro’s patented design significantly increases tool life and performance. This proprietary design reduces axial force to just a fraction of the force typical in tapping applications, substantially extends tool life by up to 300% and improves thread quality.

Softsynchro’s technology features patented elastomer springs that separate the spindle from the tap, absorbing excessive axial forces and compensating for small errors in the machining process. Torque from the spindle is transferred seamlessly to the tap via ball bearings riding in precision ground grooves. These ball grooves minimize rolling friction on the torque transmission balls to guarantee precision micro-correction of lead errors in a rigid tapping cycle, even under the most demanding machining conditions.

The Softsynchro modular system also eliminates the need to purchase different holders for each application. The tapholders are designed for a wide range of applications and have coolant-through capability. New sizes can handle tap ranges from #0-1 and M2-M30. New sizes include Softsynchro 0 for tap ranges #2-10 and M2-M8, and the Softsynchro 4 for tap ranges 7/6–1″ and M12-M30.

Milling Chucks for Roughing Tough Aero Materials

The Mega Perfect Grip from BIG Kaiser Precision Tooling Inc. (Hoffman Estates, IL) is a highly accurate milling toolholder with fully concentric clamping with runout less than 0.0004” (0.010 mm) @ 4xD. It accepts industry standard Weldon flat milling cutters (ASME B94.19-1997) and doesn’t require special grinding of the milling cutter. “A unique lock mechanism using a key grip prevents the slip and pullout of the tool during heavy cutting. By simply using straight shank cutters with a Weldon flat, no special cutter is required. If the cutter doesn‘t have a flat, adding a flat according to the general Weldon standard allows its use in the Mega Perfect Grip,” said Alan Miller, engineering manager and product manager.

“Aerospace applications, for example machining titanium, Inconels, and high-volume aluminum milling require anti-pullout toolholders like the Mega Perfect Grip high-torque milling chuck,” said Miller. “They provide security so that the tool can’t pull out of the toolholder in roughing and high metal removal rates, which is especially important when machining larger structural aluminum workpieces. Aluminum cutters typically have a lot of axial forces that are trying to pull the cutter out of the holder. Any tool slippage can result in scrapping parts. With the key that goes into the Weldon flat there isn’t any chance of that happening,” said Miller.

“For smaller applications and general-purpose materials, BIG Kaiser’s Hi-Power Milling Chucks achieve powerful clamping for 100% optimized performance during heavy-duty end milling. Fine slots and needle bearings assure powerful and precise clamping. Even though a milling chuck is for heavy cutting, the Hi-Power Milling Chuck keeps runout accuracy of 0.0004″ [0.010 mm] TIR at 4×D. This product has recently expanded to now include direct clamping of Ø.500” and Ø12-mm cutting tools. We have labeled these chucks as the HMCJ series,” said Miller.

“The Hi Power Milling Chuck Type J is designed for roughing applications on 30 and 40-taper machines, providing higher clamping forces than a traditional collet chuck or end-mill-style collet chuck in roughing applications. Target for the Hi Power Milling Chuck is higher metal removal rates, better clamping on the smaller 30-taper high-torque spindles like those of Robodrills, allowing more aggressive machining,” said Miller.

“An HSK 25 hydraulic chuck is available for small tapers in applications like medical and mold and die. It’s a hydraulic chuck for applications where there have been only collet chucks available. The benefit of the hydraulic chuck is in microfinishing where vibration damping, and repeatability are required running at spindle speeds of 60,000 rpm or more,” said Miller.

“All of our collet chucks guarantee 3 μm at 4xD, generally three to five times better than what customers are getting as well as real improvements such as better finishes, better part geometry, and better tool life,” said Miller.

Drop-In Replacement for Shrink-Fit Holders

For those shops looking for an alternative to shrink-fit holders due to constraints in diameter, offsets, and length, Schunk Inc. (Morrisville, NC) has developed the Tendo Slim 4ax as a drop-in replacement manufactured to the same dimensions as a shrink-fit holder. “All you have to do is pull the shrink-fit out, and replace it with the Tendo Slim 4ax. You don’t have to go through the setup process, and the expensive equipment that is associated with shrink-fit,” said Matt Panosh.

With 28 variants, the Schunk Tendo Slim 4ax toolholder is designed for axial machining applications including reaming, drilling, counterbore/chamfering. and thread tapping. The Tendo Slim meets all requirements, including heat shrinking contour per DIN 69882-8, simple handling, short setup times, long tool service life, high flexibility along with plug & work, and applications with minimum quantity lubrication as well.

“The Tendo Slim 4ax is really designed for higher volume machining, typically for automotive applications where there are a lot of drilling, reaming, and holemaking with tools ranging from 6 to 32-mm diameter, as well as inch sizes,” said Panosh. “The Tendo Slim 4ax is also well suited for boring, counterbore/chamfering, reaming and threading in five-axis centers and in die and mold construction. Permanent run-out and repeat accuracy is less than <0.003 mm, and the toolholder is suitable for high rotation speeds with a balancing grade of G 2.5 at 25,000 rpm. Available in HSK A63, additional taper offerings will be added.