At the CIMT 2023, which takes place from April 10th–15th, WFL will present its technology and software solutions, such as WFL iControl, scanning technologies, or the new operational data acquisition system myWFL. But that is not the end of the story. The actual highlight of the show is the presentation of the M30 Millturn and a machining demonstration of a roots rotor.
The little one for everything
The multifunctional turning-boring-milling center M30 Millturn allows complete machining of complex shafts and chuck parts with a swing of up to 520 mm and machining lengths of up to 2,000 mm. It can thus function as a lathe, a 5-axis machining center, and if needed as a gear-cutting or deep-hole drilling machine.
With this machine, the focus lies on the improved design of various machine components and further increases in reliability. Thanks to the diverse range of innovations and modernizations in the areas of functionality, ergonomics, and optimized serviceability, the smallest WFL Millturn is a powerful complete machining package that is available at a very attractive price.
The machine casing is equipped with large windows to ensure optimum visibility of the working area. Special attention must be paid to user-friendly access to the tool magazine (from the front via the large sliding window). Another advantage is a state-of-the-art robust NC drive for the steady rest slide. The machine base guarantees quick set-up and repositioning of the machine. Talking about user-friendliness: within the working area, integrated LED lamps provide long-lasting lighting.
A significant aspect in the production of rotors is the complete machining of the workpieces. Rotors are machined from the saw-cut section, forged or cast part in a single operation in the Millturn. The workpiece is then clamped in a vice for end machining. During turning and milling operations, the rotor is clamped between the tip and the chuck with retractable jaws, allowing the highest levels of runout accuracy and quality to be achieved.
The M30 Millturn is also able to scan these rotor profiles. Without unclamping the workpiece, the milled profile is scanned over the entire circumference. The form cutters are automatically corrected after the measurement cut, so that in the final cut machining qualities are achieved that come very close to the grinding quality. With this innovative method of rotor scanning, you are able to detect shape deviations in the machine. The advantages include early detection of errors, maximum precision and security, and minimized downtimes. Experience live machining of a roots rotor at the WFL booth!
Protection for machines, workpieces, and tools
Thanks to the fundamental redevelopment of its in-house process monitoring system, WFL has significantly expanded its range of functions. With the new "WFL iControl" system, process signals can be registered, evaluated, and recorded in the CNC-kernel of the control with the maximum sampling rate. The introduction of new monitoring strategies, such as so-called "yellow limits," results in considerable advantages in tool breakage and tool wear monitoring. Another new feature is the option of integrating external sensors into process monitoring. The latter allows, for example, continuous monitoring and recording of performance data from coolant pumps or conclusions about the condition of spindle bearings.
Process monitoring is typically divided into functions for protecting machines, workpieces, and tools, and functions for recording tool wear and ensuring constant productivity. Key new features for detecting tool wear and total breakage include the "wear limit" and the "tool missing limit." The goal was to develop a solution that would respond sensitively and reliably to all conceivable abnormalities in the machining process. This is complemented by a long-time data recording function for process data that WFL offers as an additional option under the name "iControl Data Record-ing", which is an important topic in the production of safety-relevant components in particular.
Operational data acquisition with myWFL
Another highlight at WFL is the myWFL Cockpit operational data acquisition system. Machine and program states over time, productivity, and technical availability will all be displayed, either on the control system, PC, or mobile device via a web browser. This means that the user can always be well-informed about their machine's productivity.
Another new feature is the myWFL Energy energy usage measurement device integrated into the myWFL Cockpit, which displays the current power data as well as the energy and compressed air consumption of each workpiece.
The Condition Monitoring cycle integrated into myWFL continuously records the status of the axes and spindles during a measuring run and saves them to the control system. Possible changes can easily be detected and displayed via the Condition Monitoring Viewer.
WFL will be at CIMT exhibition hall W1, booth B403.