Machining of metals - Import export

The perfect 4-axis machining centre must be capable of being configured to your requirements, produce reliably even under extreme loads and offer a fair price/performance ratio. Our solution: HELLER H-series 4-axis machining centres. Components that have been reliably used in mass production for years coupled with a high dynamic guarantee you robust processes – even at their limits, seven days a week in 3-shift operations.

Designed for Production: The new generation of 5-axis machining centres F sets a new benchmark for cutting performance and precision With its head kinematics, the new generation of the 5-axis F series has been designed from the ground up for flexible series production. Like all HELLER machines, they set a benchmark for cutting performance and precision. Other highlights include free chip fall, short idle times, optimum automation capability and compatibility with the H and FP series for a wide range of workpieces. In addition, the new models come with top-of-the-range specifications and the option to add technologies such as Mill-Turn, interpolation turning or power skiving.

Emulsion can do more than just cool... At least when using EWS Spinjet, the coolant is used to drive a turbine which allows the tool to rotate to up to 50,000 rpm, depending on the type. The turret's tool drive stops moving during this process! See the attached flyer for the technical requirements and details. Download Manual: PDF

EWS goes milling With its latest range of angular heads, EWS brings its trusted technology with new features to machining centres. The system range was presented to the public for the first time at EMO 2015. An elegant design houses high-performance technology, or to put it simply Precision meets Motion. Advantages: the smart solution for compensating for there not being a machining axis Machining hard-to-reach parts Centre boring stepless angle adjustment around the horizontal axis, with tangentially acting double cone clamp MR > 250 Nm Prerequisite: The prerequisite is a "stop block" on the machine. This prevents the entire unit from turning while simultaneously defining the position of the angel of rotation. Variations: basic duplex offset Request form: PDF

High-speed thread cutting with reversing kinematics The new EWS Tapmatic thread cutting head for driven tools enables thread cutting processes without having to reverse the direction of rotation thanks to its reversing kinematics. This saves time and energy and protects the motor – all this with a defined depth of thread. The units are available for M3-M12 threads.

The 5-axis machining centres from the HF series are optimally equipped to meet the exacting requirements of modern production processes. Enabling 5-sided and simultaneous 5-axis machining, they allow you to handle many different tasks on a single machine. Highly productive and flexible, with easy operation and maintenance, available with pallet changer or table loading. The second generation of the HF series provides numerous optimisations, including new spindle units with increased performance and the advantages of the HELLER zero-spindle system for minimised life cycle costs. Moreover, the option of a second drive in the Z-axis allows for even more universal application, including single-part production. In combination with the proven HELLER DNA of productivity, precision and reliability, they guarantee you increased performance, precision and flexibility for the production of your workpieces.

EWS quality now available for Swiss-type lathes. This new development in driven tools is EWS's response to many customers' requests. The tool systems may appear straightforward at first sight, but their simplicity belies their performance. The design concentrates on the mounting and the spindle concentricity. The requirement profile was developed jointly with an American medical technology company which uses very small drill bits and requires extreme concentricity properties. The spindle bearing technology used with labyrinth seals sets new standards in this field, and is associated with a long service life. Provision has already been made for service. The service centres in Germany, China, Korea and the USA have already been trained in the system and are ready to respond without delay. Third-party brands can also be serviced there at any time. Download catalogue: PDF

Trifix® is the new adjusting system for Gildemeister multi tasking machines. The double sided adjusting system is guided by a very precise key way at the surface of the turret. 

 The plates are preloaded, and the resiliency in the adjusting system eliminates static redundancy. This allow the exact position of the tool to be secured and significantly reduces the setup time of the machine. Because this is a highly sophisticated precision instrument it is not possible to use double serrated tool shafts. The tool is supplied fully adjusted and can be used right away. EWS is the DMG system partner for this tool generation. Trifix® advantages: Repeat accuracy below 6 µm at radius of 200 mm High positioning accuracy from one station to another (0.01 mm) Driven tools and static tool holders are completely aligned Static tool holders can be used together with additional drill pattern for mounting Heavy duty spindle noses can be used together with additional d

Mount tools safely and in the correct position while remaining flexible, all this is possible with the UMB100 mounting unit. The tool clamping units can be changed quickly, making the system an ideal mounting aid for multi-tasking machines. It only takes a few seconds to replace an adapter. The unit with snap-in swivel can be pivoted 4 x 90° at the touch of a button so that even angled holders can always be mounted in the ideal position. Universal mounting block UMB100 Tool holder for VDI holding fixtures Tool holder for Varia VX Tool holder for steep-angle taper holding fixtures

Keyway broaching on lathes is a common thing. What is new is to speed up this operation with low stress for the machine! Slot is driven by the tool turret of the machine, with the input rotary motion being converted to a translation with superimposed lift-off function. This makes programming extremely easy. The keyway broaching unit is positioned in the prepared bore – in such a way as to make the extended tappet oriented to the end position in the Z axis. The depth of the slot is produced by a constant X-feed moving between 0.04-0.08 mm/stroke. The speed of the spindle ranges between 400 R/min – 1,000 R/min, with one rotation corresponding to a complete stroke. This way, for instance, a feather key groove with a width of 6 mm and a depth of 5 mm is produced within 7.5 sec. (800 R/min and 0.05 mm feed/rotation). With this operation it is important that the chip can break at the end of the groove, that is that a cut-in or a bore exists.

Reaching concentricity 0 using a simple collet chuck and this within one minute: this is Zero-Zero. The specifically designed clamping nut with 6 symmetrically arranged screws at the circumference makes this step possible. The clamping nut is split, so that the inner ring can be minimally shifted. This simple technical finesse allows to eliminate tolerance additions. The machine operator only has to replace the previous clamping nut, which step opens up a new concentricity dimension – and this for a price starting at € 90.00. Zero-Zero is available for DIN 6499 collet chuck holders from ER 16-ER40.

The new EWS tcJet range Optimal chip transport thanks to EWS tcJet EWS tcJet transports the coolant through the inset directly to the cutter and guarantees optimal chip transport... At the same time, the cutting edges have a significantly longer service life. EWS's interior cooling version is available for normal and high-pressure applications for various tool holder fixtures and cutting insert manufacturers.

Compact and stable – this is EWS' new swivel head. The swivelling module, which is equipped with a Cylkro drive system, is 17 mm smaller than standard heads which, above all, offers greater flexibility in swivel ranges between 0° and 45° in the field of cutting tools. The swivel unit covers an angle of +/- 92°. During the swivelling process, the supply of coolant is directly carried along. A distance of at least 48 mm from the contact surface to the swivel axis can be proposed. Even a high-pressure interior cooling system of up to 70 bar can be built into the module without the exterior dimensions having to be modified. Rotational speed limit is 6,000 1/min, maximum transmittable torque is 16 Nm, and max. cutting tool diameter is restricted to 10 mm. The swivel head is mainly suitable for drilling or for simple machining tasks. EWS' TWK range is available. for greater demands with regard to torque and performance.

EWS takes measures against vibrations in deep drilling procedures Deep drilling procedures with drilling rods with a long overhang are one of the most demanding tasks in cutting technologies. What influences vibration, what amplitudes does it create, what is the effect of superimposed vibration and when are uncontrollable resonances encountered? All these are questions that are difficult to answer using theory alone. These findings formed the basis for the new development of EWS Rigid. The objective was to create a drilling holder with a passive damping system to counteract the vibrations that are created. This involves using variable vibration dampers with linear degrees of freedom in a floating mounting inside the cutter carrier. The damper position is set using a radially mounted setscrew, which allows optimum vibration conditions to be created. The improvement in surface qualities of bores is significant, as is the increase in the service life of cutter tools.

The best of both worlds! Insufficient stability was a fact increasingly associated with the VDI system in recent years. As a result, block tools were preferred more often, although the VDI tools still offer greater diversity and flexibility. So the next step appeared obvious: combining the best of both systems. In cooperation with DMG, we developed the EWS ProLine system in order to fully utilize the potential of new lathes. While EWS ProLine features a conventional VDI shank, it can be optionally mounted to the turret using four screws. For instance, the flexibility of the VDI system can be utilised for lighter machining, and the stability properties of block tools can be utilised for heavy cutting. The angular position of the radial tools is ensured through the Trifix®, the alignment system. Cutting data similar to HSK63 machining centres? The professional audience at the EMO 2011 watched an impressive live demonstration: on a Gildemeister CTX Beta 1250 4A, two surf

Make any centric or eccentric form desired 4, 6, or 8 edged, polygonal or free form with the EWS Multiform on the CNC turning/milling machines Free forms that used to be impossible can now be made with EWS Multiform on turning/milling or machining centres. For a six-edge outside the centre or a four-edge in the centre, additional processing steps such as reaming or eroding were necessary up until now. If a position change was also needed, complicated devices were needed for processing. This is now all possible with one chuck. What is behind this? EWS Multiform uses a custom internal cam disc unit to produce the required form. For conventional geometry like squares or hexagons, there are standard cam discs available. The cam forces the cutting tool to follow a path in order to get the desired geometric shape. Of course you can’t defy the laws of physics which means that there will be a small radius on the edges.

Gear hobbing on CNC lathes without B-axis Years ago, EWS was the first tool manufacturer to offer gear hobbing heads in its standard range, and has continued to develop the holders for gearing technology ever since then. With this technology, it became possible for the first time to produce external gearing on machines without a Y/B-axis. In contrast to a standard milling wheel holder, the tool head of the EWS modular cutter can be swivelled about the axis of the shank. This offers users the advantage of substituting a B-axis with a comparatively small investment. In the meantime, module 3 has become commonplace on VDI40/BMT65/BMT75 machines. The tool heads have become more stable at the same time as being more user-friendly. The alignment system using a sinusoidal profile has come into widespread use and saves considerable alignment and setup times. Operating instructions, flyers and press reports can be found in our download portal Video: Gear hobbing on the

EWS.PSC offers maximum stability and rigidity coupled with maximum flexibility. Significantly reduce your setup and changeover times while maintaining high mold flexibility. he EWS.PSC program includes a wide range of standard tools with PSC shank for milling spindles as well as tool systems with PSC spindle for lathes. Furthermore, tool holders with plate seat are available. The interface allows you to reduce the time spent measuring, setting up and changing tools. In addition, improved machine utilization can be achieved.

The rapid change system EWS-Varia allows to set-up a modern CNC lathe or a turning milling center – and this flexibly. A tool change will just take 20 seconds, which is an unbeatable argument especially in small batch productions whenever it is about reducing the set-up time and thus increasing the productivity. The advantages, however, are also evident in large batch productions. Preset twin tools lie at the machine, thus significantly reducing the down-times. A further advantage is provided by the variety of adaptations; so the optimal tool clamping can be selected for each operation. The inserts available include: Collet chuck holders Weldon/Whistle Notch Milling arbors Morse tapers Hydro extension Shrink adaptations The most important advantage is certainly created by the easy handling. The inserts can be changed with just one hand without counter pressure by the spindle.

Static tools form one of the EWS core areas. There is no other manufacturer in the world offering such a variety of products: More than 20,000 different tool holders are available for machine operators. Our portfolio includes VDI tool holders with shaft diameters of 16-80 as well as block tool holders of BMT55-BMT85 to machine-specific holders for MAZAK, Okuma or Mori Seiki, to name just a few. We also offer prism holders according to DIN 69881 (VDI3425 Bl.3) in all nominal sizes. Our standard portfolio includes Capto, HSK, KM and ABS adaptations in addition to the standard holders. Moreover, our scope of supply includes special holding fixtures made according to customer drawings or innovative solutions of the EWS engineers designed to master production engineering challenges. The tool holders are manufactured at our factory in Uhingen and rightly carry the label: Made in Germany! Boring bar holder BMT Capto C4 Double boring bar holder Capto Bar Gripper Infee

Driven tools form a further core area of EWS. More than 8,000 different tools are available at short notice. In addition to standard products like axial and angular heads, EWS offers swivel units, slot broaching tools, multiform tools and multi-spindle machines. There is just no limit. The tool clamping systems range from the classic collet chuck holder to Weldon and hydro extension to Capto, KM, ABS and HSK. The applications range from classic CNC lathes to highly complex turning milling centers. The rapid change system EWS-Varia has set a standard for a flexible modular system. With its safe handling and short change-over times, EWS-Varia ranks among the most successful systems in the market. This was impressively confirmed by the Innovation Award awarded by the German state of Baden-Württemberg in 2006. "Made in Germany" is of course guaranteed by EWS also for these tool systems.

The straightening machine RM-1000 was developed for straightening deep-hole drills, as 4- and 6-axis version. The radial run-out of a drill is straightened using the 4-axis version. The 6-axis machine additionally corrects the camber of the shank and the head run-out of the soldered carbide drill bits. The maximum length of the drills is 1,000mm, the accuracy of the straightening process is 0.08 mm (depending on the work piece). An exportable straightening protocol is created for each straightening process. A robot cell is available as an option. Using this robot cell, the insertion and removal of the drills is performed. The robot cell is mobile and can be disconnected at any time in order to allow manual straightening processes.

Special purpose machines are our specialty. We are able to adapt our standard machines to your needs within a short time or to develop and build completely new machines for your application. Our extensive know-how allows us to accompany you from process development through the design and detailed construction of a suitable machine to measurement, commissioning and the start of production in your plant. In addition, even maintenance or product adjustments if necessary.

We can offer a wide range of metal test specimens, starting from different grades of steel in various thicknesses and alloys right through to non-ferrous metals. Are you looking for galvanic finishing or machining solutions? Then you have come to the right place. Punching, deburring, and the rounding of corners are an important part of our portfolio. We will be happy to finish surfaces, for example by means of degreasing or sandblasting. Further finishing options are available upon request. We can also provide test panels with a customized serial number or marking if desired. Stainless steel 1.4301, 1.4571, 1.4401, 1.4310, other grades available upon request Test specimens According to A.F.E.R.A. 4001 (old standard), with defined finish With high-gloss finish (according to FINAT, PSTC standard, A.F.E.R.A. standard 5001, EN 1939) Titanium Grade 1 and grade 5, other grades available upon request Automotive grades painted

Our Breeze technology has many enormous advantages over the previous classic lubrication applications. Discover enormous savings potential for mass production when using our LSJ Mini in your process. This system can be used optimally in the event of always consistent tool operations. For the machining process, an average of between 5 and 50 ml of lubricant is used per process hour and tool. These consumption values can also be briefly — depending on the requirements of the individual operation — increased to up to 200 ml per process hour. In addition to this excellent advantage over the previous method, the HPM Breeze method offers further enormous advantages from an economic and ecological point of view. • For optimum use with a cooling channel diameter of 0,9 mm² and up. • Manual adjustment of the pressure parameters • Optimally suited for consistent series processes with one parameter

HPM Breeze is the consequent development of the common CL-, MQL and MQCL-procedures. Fluids will be checked during the production process and applied in a certain amount at a certain time and at a predetermined location. The HPM Breeze-procedure is extremely fine with an aerosol that adheres like a dense fog around the working area. HPM Breeze forms a completely closed and highly lubricating film. Where previously many litres of liquid were necessary it is now a small fraction thereof which suffices. The HPM Breeze process is used to lubricate and cool machining processes with extremely small quantities of cooling lubricant. An air-fluid mixture that prevents the development of frictional heat with optimal lubrication is employed for this purpose. The remaining heat is dissipated with the swarf. The LSJ Z35 is offered in 2 versions. 10 bar is standard. For more demanding applications, the LSJ Z35 is available in a version with 16 bar.

Universal spray head where the spray quantity is set via a scaled measuring drum. This makes it possible to check the set quantities at any time. Any changes are immediately visible and can be corrected. With constant parameters (fluid, spray and fluid pressure), the quantity is always 100% reproducible. The supply line exits at an angle of 90° to the spray jet. Our LEO spray head is available in two variants: The LEOR spray head has an M5 thread for fastening to a customer-side mount. The LEOB spray head has a ball joint. This allows it to be attached flexibly and precisely with the flexible HPM Technologie mounts. Low pressure range from 0,5 - 2,5 bar Air consumption from 2 -5,5 /min Viscosity range from 2.300mm²/s (20°C) - 500 mm²/s (40°C) Spray with nearly round cone full of about 15 ° Available in the nozzle lengths 30, 70, 105, 130 und 155 mm

The brand-new PPJ system impresses not only with its well-conceived components and size but also with its innovative form. In this system, we have combined our decades of experience in an attractive design. The independent regulation of fluid and spray air pressure achieves excellent results even with higher-viscosity media. Available for up to 6 spray heads and in versions with 1, 3 and 5 litres, this system has a very compact design and therefore takes up extremely little space when installed. The system is suitable for the initial equipment of machines as well as for subsequent installation. The PPJ system can be used with our spray heads (starting on p. 20) and the JOP drip-feed dosing device (p. 30) up to a maximum viscosity of 2300 mm²/s at 20 °C or 500 mm²/s at 40 °C (except for substances containing paint, resin and glue).