EMO 2019 : Knoll Showcases Global Competence

KNOLL Maschinenbau at EMO 2019
Hall 7, Booth C34.

At EMO 2019, the world’s premier trade show for metal processing, KNOLL Maschinenbau will present itself as a global player, whose products –  Conveyors and Filtration Systems, Pumps, and Transport Systems – are widely used in plants all over the world.  KNOLL supplies not just innovative machine tool components, but also large turnkey central systems for coolant, lubricants and chip management.

  • Knoll Central Systems

KNOLL’s core business – systems for cooling lubricant and chip management – has taken on new dimensions. In addition to outstanding standard components for machine tools, there are also numerous large Central Systems, which KNOLL has delivered to metal processing production operations all over. These systems can supply 30 or more machines with up to 12,000 l/min of extremely clean cooling lubricant. Modular system technology enables them to achieve still greater total output. At EMO visitors can get an impression of this expertise.

In Hall 7, Booth C34, KNOLL will present cooling lubricant in the form of a stand-alone solution for two-stage cooling lubricant filtration.  After the show, this machine will be used by a customer in an HSS grinding shop. It contains a 240/AK5 MicroPur®filter, which is supplemented by a KNOLL KF 400-E compact filter with an endless filter belt. It handles the task of chip pre-separation, making superfine filtration easier.

Innovative Standard Components

The basis of every large system is innovative standard components that are also used in many individual machines. These include the modular superfine MicroPur® filter, which is designed to remove residues from grinding processes, whether carbide metal, HSS or Cast particles. At EMO, KNOLL will present the MicroPur® in the 120-F version, which contains two back flushable filter elements for approx 120 liters of filter capacity. It is particularly cost-effective when working with the integrated KNOLL AK5 automatic concentrator, which reduces the carryover of oil and can ensure a residual moisture content in the settled material of less than or equal to 10%.

For over a year, KNOLL Maschinenbau has offered the LubiCool® mobile high-pressure station for use on short and long automatic lathes. It supplies cooling lubricant at up to 150 bar, which ensures short processing times and longer tool service life for short-breaking chips. Machines are made suitable for even the most challenging of machining processes, such as machining high-alloy steels or titanium. The built-in belt filter with a filter fineness of up to 20 µm guarantees the cooling lubricant purity that is required for high-pressure applications.

At EMO, the “big brother” LubiCool® L will celebrate its premiere. It is designed for larger lathes and small and medium-sized processing centers that require higher flow volumes and flushing processes. Here, high-pressure pump KTS 25-50 can be used with a TG 30 centrifugal pump for flushing. Optionally available for integration is a BS 40 lifting pump, which guarantees independent high-pressure and supply systems.

Both LubiCool® variants use the new SmartConnect operating concept, with which a small industrial PC is connected to the PLC system. Using a 7″ touch display, the user can access the system, visualize states, check parameters, and thus change to manual mode.

Refreshingly Different – the Modular Machine

Based on the structural principles of a processing center and an ideal presentation platform for KNOLL OEM products: the Modular Machine.  KNOLL will display its Plate Conveyor design, as an example, whose distinguishing feature will be plates that are joined hinge-free so that it is suitable both for chip removal for wet and dry processing, as well as conveying small sheet metal parts.

For applications that create very fine, lightweight chips, KNOLL has developed another complementary solution: an attached, self-priming BS 40 dirty water pump which conveys cooling lubricant that contains chips into the chip separator, using the cyclone principle to separate the chips from the cooling lubricant and store them in the ascending area of the conveyor belt. The pre-cleaned coolant flows directly to the filter system.

This is present on the Modular Machine in the form of a KF 150/650 Compact Filter. The universally applicable tower model belt filter saves space since the filter elements sits on the tank.

As a conveyor alternative, the Modular Machine includes an RKR return pumping station with chip reducer, which will demonstrate how cooling lubricant and chips can be transported away from the machine reliably, cleanly, and in space-saving fashion to a central separator/filter.

At EMO 2019, the Modular Machine will, for the first time, contain a fluid cabinet, which includes a pressure boosting system with KTS screw pump, valve technology, and control filter.

MMS instead of Cooling Lubricant

For many chipping applications, Minimum Quantity Lubrication (MMS) is an alternative to using cooling lubricant. For this, KNOLL offers the modular ControLube MMS system, which works with injector technology and microprocessor control. The system developed by KNOLL already delivers a particularly fine aerosol within 0.1 seconds, which provides for improved process conditions, shorter processing times and lower costs. A core property of this MMS system is the oil quantity that can be regulated regardless of the air pressure; it is also available in the simplest ControLube model. Depending on requirements, the system can also be retrofitted process-specifically with additional modules and, for example, with a controllable air pressure of up to 20 bar.

 

 

 

EMO Preview : Economic Advantages with Form Tools

Turning with form tools allows customers to benefit from economic advantages in series production. Horn offers customised carbide form inserts based on the 117 tool system for machining diameters from 16 mm upwards on turning and mill-turn centres. The patented, precision insert seat of the 117 system guarantees high concentricity and minimal axial runout as well as high repeatability of insert exchange to within microns. The precision-ground cutting edges achieve a high level of accuracy and surface quality. Financial savings are achieved due to the possibility of re-tipping, lower tool costs and reduced machine downtime. The internal coolant supply to both cutting edges via the round shank cools the contact zone and carries the chips away efficiently.

Horn offers the tools in profile widths (w) of 16 mm, 20 mm and 26 mm. Special profiles are precision ground to suit the application. The maximum profile depth is tmax = 17 mm. The maximum profile width is w = 26 mm. The insert coating is specially selected for each application and is available for material groups P, M, K and N. The round shanks are available as standard with diameters of 16 mm, 20 mm and 25 mm in the A and E designs. All variants have an internal coolant supply.

 

EMO Preview: New Insert Clamping System for Horn Supermini

Horn has developed a new tool holder for its Supermini type 105 grooving and boring tools. In the new design, the process for clamping the carbide insert uses a tensioning wedge on the face rather than the circumference of the tool, as was previously the case. This enables the insert to be held in place with more force, which makes the entire system more rigid. Additionally, the new clamping design results in a higher level of repeatability when changing inserts and allows for better use of the space available for mounting it due to the face clamping concept. This is a significant advantage when working with Swiss-type lathes, as it enables users to change the insert without removing the tool holder.

The Horn Supermini tool system is able to bore holes from 0.2 mm to 8 mm in diameter. With over 1,500 varieties available as standard, there is a solution to suit every user. In addition to boring, the system is designed for grooving, chamfering, threading, broaching and other machining operations. The cutting geometries and the substrates can both be adapted to the materials being machined.

 

 

MAPAL: Milling Fibre-Reinforced Plastics

The High Requirements of Milling Fibre-Reinforced Plastics

 

 

 

 

 

 

 

The Machining Task

The machining of CFRPs (carbon fibre reinforced plastics) places high requirements on the tools used, their geometries and coatings. Due to the abrasiveness of carbon fibres in relation to the cutting material, standard tools very rapidly become blunt and the end of tool life is reached after only a few parts. To be able to cut carbon fibres that are laid in a matrix form, increased performance at the cutting edge is required. This statement applies above all if the carbon fibre content is more than 60 %. On milling the peripheral contour on a 21 mm thick structural part for a sports car, the customer had a clear requirement to double the tool life from the previous 10 parts to 20.

The Challenge

The challenge is to keep the milling tool sharp and therefore to prevent delamination at the part edges produced. In this way expensive, manual re-work is saved. At the same time, the issue is to reduce the machining time and to realise long tool lives.

 

 

 

 

 

 

The Mapal Solution

The eight cutting edge, diamond coated solid carbide end milling cutter OptiMill-Composite-Speed has a high performance geometry with a serration. This serration makes possible improved chip removal and therefore an extremely high volume of chips in one machining step. As a result the machining is undertaken using only one tool in one step and the roughing step necessary previously is saved. With twice the feed and three times the material removal rate the tool life is increased fourfold and the quality requirements in relation to surface roughness reliably achieved. As a result the customer’s expectation in relation to tool life were exceeded by a further 20 parts.

The MAPAL Effect

  • Four times the tool life reduces the tool costs
  • Doubled feed halves the machining time
  • Only 1 machining step

 

 

 

Gear Machining Solutions with Horn Tools

Complete machining of a Cyclo-Palloid Gear with HORN Tooling:

Horn has developed highly efficient gear machining processes for the Gear Industry.  We showcase here an example of machining a Cyclo-Palloid Gear with a HORN tooling solution.  The wide profile is opened with a custom multi-row M279 milling cutter, then the flanks are alternately roughed. The root diameter is machined with a DS cutter, the flanks are finished with a DGVZ tool and the sharp edges are chamfered with a DS cutter.

 

 

We showcase below another example of Gear Cutting with Horn Tools, from the machining of the Cyclo-Palloid Gear Teeth to the machining of External and Internal Splines by Broaching and Power Skiving.

 

 

Click here for the full range of Horn Milling Solutions.

Please contact us for any information you would like to have on any of the products showcased in this video.