Five-axis machining is planned precisely, right down to the last detail, to ensure smooth production of turbine blades on a Millturn from WFL.
Machining, AMB, WFL Millturn Technologies

WFL puts complete machining in the spotlight at AMB

At AMB 2022, WFL Millturn Technologies will be presenting the new M20 Millturn complete machining centre for the first time. Alongside gear skiving technology, there is clear trend toward automation and the integration of sensors. The latest solutions from WFL range from smart software to screw programming through to intelligent tools and clamping devices.

WFL concentrates exclusively on the production of multifunctional complete machining centres. In many high-tech companies today, the trade name Millturn stands for the central machine tool for the production of complex components with the highest precision. In addition, digitization is high on the agenda of WFL. Norbert Jungreithmayr, CEO WFL Millturn Technologies, explains: "The digitalization of manufacturing systems is a key focus for WFL. The aim here is to use all available resources as well as possible and to integrate them into the manufacturing process. Sensory tools or tool holders with integrated sensors (like our ICOtronic tool), clamping force measurement during the machining process in the iJaw (Röhm) as well as various measuring and scanning technologies are used by us and our customers. Projects like myWFL - the WFL operational data acquisition or WFL iControl - the process monitoring, are our future topics, which can be constantly extended and expanded to stay on the ball."

M20-G with intCELL automation

The WFL M20-G showcased at AMB is equipped with an innovative automation solution - the intCELL. The integrated production cell is fitted on the right-hand side of the machine, the workpieces are supplied on a strip accumulator. With the integrated loading concept, WFL has reduced the space requirement by 50% in comparison to a conventional production cell. The M20’s integrated loading feature is designed for chuck parts with a diameter of up to 300mm and a workpiece weight of 15kg. For shaft parts, a workpiece diameter of 100mm and a workpiece length of 300mm is possible.

The turning-boring-milling unit with integrated spindle motor and a B-axis with torque motor are entirely new features. The individual tool holder with B-axis on the lower slide is another highlight. The upper and lower system can be used simultaneously, and both systems are supplied by a reliable and dynamic tool changer from a shared magazine. This allows even complex components to be machined with optimal efficiency, and the setup of the tool turret is no longer necessary. The tool can be moved up to 100mm below the turning centre, so drill patterns with diameters of up to 200mm can be produced on the face with a high level of precision and without turning the C-axis.

WFL Intcell automation
WFL intCELL: Integrated production cell for automatic loading and unloading.

Universal machining solutions with the M50-G Millturn

The new M50-G Millturn generation, with greater center distance and improved performance, will be another highlight of the AMB. The optional center distance of 6000 mm enables efficient machining of long shaft parts. When designing the M50, WFL implemented some of the features of the larger M80. The machine’s existing potential is fully utilised, particularly in terms of the increased drive power, combined with the HSK-A100 or Capto C8 tool accommodation. The turning diameter is available up to 670mm and the fully developed, proven machine concept of the M50 Millturn has also been given an attractive ergonomic finish. A separate pick-up magazine is also available for very long and/or heavy tools. Workpieces with a length of 1600mm can be automatically inserted and changed. The standard disc magazine can be expanded to up to 200 positions.

On this machine, trade fair visitors will be able to witness a turbine blade/screw being machined live. Components such as turbine blades or plasticising screws require both dynamic and stable machining concepts. A special clamp from the manufacturer Grasch can be used to clamp rectangular raw materials easily and securely, a fundamental requirement when machining turbine blades. Technologies known as ‘helical spiral milling’ and ‘helical longitudinal milling’ are used to machine the blade.

WFL M50-G Millturn turning-boring-milling centre
The new M50-G Millturn generation is a multifunctional turning-boring-milling centre is designed for thw complete machining of complex chuck and shaft parts.

Smart tools: ICOtronic and ultrasound measuring

The ICOtronic tool, which is fitted with sensors, provides information on the machining process as close as possible to the cutting edge. This should not only optimise milling processes in the future but also increase the machines’ productivity. The demo at AMB will give a small insight into WFL’s wide variety of development projects.

Ultrasound measuring will also be demonstrated live for the visitors to the trade fair. The automatically loading ultrasound measuring probe enables a fully automated measuring process. The large measuring range (1.5–30mm) offers further benefits. Ultrasound measuring is extremely well suited for calculating the hole run-out and diameter of very deep holes.

Easy screw programming with ScrewCAM

ScrewCAM will be used at AMB to demonstrate the latest and most innovative software for programming plasticising screws with complex geometries. The geometrical functions that can be manufactured include, among others, single or multi-threaded screws, variable depths, flexible pitch adjustment, wall shaping and wall incline. In addition, the entire NC program will be checked for collisions and the correctness of the workpiece geometry produced, using a material removal simulation and geometrical verification against the 3D target geometry of the screw. The result is a verified NC program with an estimated machining time.

Operational data acquisition with myWFL

As introduced at AMB, the new operational data acquisition system is myWFL Cockpit. Machine and program states will be displayed according to chronological order, productivity and technical availability. You can view this on a web browser via the control system, either on a PC or a mobile device. This means that the user can always be well-informed about their machine productivity.

Also new with myWFL Cockpit is the integration of the energy usage measurement device myWFL Energy which displays the current power and energy consumption data and that of each workpiece.

Another highlight of myWFL is the integrated Condition Monitoring cycle. When the cycle is running, the friction values of the axes and spindles, as well as the temperature in the milling spindle housing and the vibration or the rolling bearing condition value of the front milling spindle bearing are continuously recorded and stored on the control system. Using Condition Monitoring Viewer, it is possible to select the data of the various Condition Monitoring runs on the control system, graphically overlay them and analyse them according to time in this way. This allows for the early detection of possible malfunctions and minimises unplanned downtimes.

WFL myWFL Cockpit
With the new myWFL operational data acquisition system, you get a 24/7 overview and can exploit the optimisation potential of the smart factory.