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EMO 2015: FFG shows more than 30 machines in Milan

Uhingen, August 21, 2015 – At this year’s EMO, which will take place in Milan, Italy, between October 5 and 10, FFG will show a wealth of manufacturing solutions: In hall 2, E01-G01, the Asian, European and American brands of the group will present over 30 machine tools and industry specific technologies for various applications. The highlights include new machine concepts and machining technologies, manufacturing systems and flexible standard solutions.

The Fair Friend Group (FFG) has a dedicated growth strategy, which has been very evident in Europe recently. In 2013, the Italian FFG Europe brands Jobs, Rambaudi, Sachman and Sigma were joined by the German manufacturers VDF Boehringer, Hessapp, Honsberg, Huller Hille, Modul, and Witzig & Frank, followed by the Swiss Pfiffner Group in 2015. Finally, in August 2015, FFG and the MAG group signed a sale and purchase agreement. The acquisition of the MAG group by FFG is expected in 2015, subject to regulatory approval.

The overall approach of FFG has always been to utilize the potentials of its renowned original brands and to enhance their portfolio. At the upcoming EMO, FFG Europe will show substantial results of this approach. Martin Winterstein, Vice President Sales & Marketing at FFG Werke GmbH, is looking forward to presenting various new developments at the show: „Our strategy is to utilize the proven strengths of our machine tool brands as a strong base for innovative turning, milling and gear manufacturing concepts. EMO visitors will have the opportunity to see the substantial results of this strategy live at the FFG booth. One example: the NBH horizontal machining center series from Huller Hille is well known for its rigidity and heavy cutting capabilities. In Milan, we will prove that these qualities can be combined with impressive dynamics and a small footprint. There will also be turning, gear manufacturing and rotary transfer machines illustrating how proven strengths can be enhanced with new features. Additionally, we will have four exciting technology areas, showing our references and expertise for the Automotive, Aerospace, Rail and General Engineering industries“.

State of the Art production technology for various batch sizes:

Machining centers, flexible cells and volume manufacturing

The machine tools exhibited by FFG in Milan comprise an exemplary solution for a broad range of manufacturing tasks: From standard machining centers to high performance machines for flexible manufacturing cells and rotary transfer machines for volume production.

The newly developed NBH 5 machining center from Huller Hille will surely be an eye-catcher: First because it is a very slim direct load machine, with just 2400 mm width. The engineers managed to reduce the width by 1300 mm compared to the former model. They achieved this by applying a new, very dynamic chain-type tool magazine with 32 locations, shifting chip evacuation to the rear and optimizing aggregates and service units. The performance data are evidence that the machine was designed for use in cells and systems: already the standard configuration provides a rapid traverse rate of 65 m/min, acceleration of 8 m/sec? and a chip-to-chip time of approx. 3.2 sec. The optional speed package adds further dynamics, achieving rapid traverse of 90 m/min in all linear axes, 10 m/sec? acceleration and a chip-to-chip time of approx. 2.5 sec. The 52 kW (40% duty), 16 000 /min spindle extends the machine‘s application range for aluminum, HSC and light metal machining, a growing sector in the automotive, tier supplier and further industries. The new NBH 5 will be available with Siemens SINUMERIK 840D sl Operate control, as well as with Fanuc 0iF in the future.

Apart from the high speed center, Huller Hille is bringing a further premiere to Milan: The flexible standard machining center NBH P 80 is the first model of a series jointly developed within the Fair Friend Group. The series combines Huller Hille know how, rigid design, state of the art components and practical configuration options. Customers can thus profit from the high quality machines built in Mosbach-Diedesheim in a further extended application range. The wide work area (X:800 mm/Y:800 mm/Z:900 mm) with extended Y-axis allows for use of long tools even with large fixture interferences. The compact machine has a footprint of just 16.5 square meters and advanced dynamics with a rapid traverse rate of 60 m/min and acceleration of 7 m/sec2. A rigid, double nut ball screw drive (o 50 mm) provides for reliable machining performance. A choice of spindles, highly precise and dynamic rotary tables and CNC controls allow for flexible configuration. The chain-type magazine with 60 locations can be loaded manually during machine uptime. The machine has a pallet changer with an ergonomic 90 degree indexable setup station, and a service friendly drive unit on top of the machine.

Two of the most important manufacturers of rotary transfer machines for high volume manufacturing tasks are also part of FFG: Pfiffner and Witzig & Frank. At EMO, Pfiffner will present a hydraulically controlled HW 25/12 machine with up to twelve horizontal and 6 vertical CNC machining units, each configurable with up to four CNC axes each. The Swiss even bring two machines of the same model to Milan: a new machine as well as an entirely retrofitted system from their „ReVest“ Retrofit program. Witzig & Frank’s innovation strategy is addressing the field of technology integration and enhanced flexibility in volume manufacturing. Intelligent automation, new retooling systems and a range of adaptable technologies are designed to maximize the productivity of the TURMAT machine series. The Offenburg team will introduce new machine models with innovative tool changing systems and machining technologies at EMO, based on the vertical and horizontal rotary transfer machines TURMAT and LSA.

Straight to the finished part: Complete machining of shafts and flanges on turning and hobbing machines

Chemnitz is known as the birth place of hobbing as the process was invented here in 1900. The Modul plant in Chemnitz‘ Marienberger Strasse has always been contributing to the development of gear manufacturing technology. Most recently, the engineers caught the attention of the industry with the development of the CDT technology, adding two CNC controlled units in addition to the hobbing spindle. With the SynchroCut technology, hobbing, chamfering and deburring can be executed synchronously in one clamping. With a two-cut strategy, burr-free flanks can be produced with reduced cycle times. The gear manufacturing specialists have announced to present a further new, productivity-enhancing technology on the base of this technology. It will be shown on an improved H 200 CDT, which is now equipped with an NC-controlled, electrically driven quill and a new work piece feed unit, which will be connected with a robot load system at the show.

First part good part: Granite machine bed guarantees stability

The Taunusstein-based FFG brand Hessapp will bring a pick-up type vertical turning machine size 300 from the legendary DVT series. The series is characterized by uncompromising complete machining, performed by a hanging and a stationary spindle in one machine. Main features are an automatic part load and unload and NC-controlled handover from one spindle to the other. Apart from an enhanced dynamic (rapid traverse X: 85 m/min, acceleration Z: 3,5 m/sec2), both spindles are now equipped with Y-axes with increased stroke of +/- 75 mm. The main highlight of this newly developed machine is hidden in the machine bed: in addition to the proven casting and mineral casting machine bed variants, Hessapp is using granite here for the first time. One of the advantages is the environmental friendliness and overall improved ecological life cycle. Also, the thermal stability and damping characteristics of granite are much better than with cast components. This provides improved prerequisites for the integration of hard turning and grinding technologies in Hessapp DVT machines. Most notably, the stability of the material allows for achieving machining tolerances already with the first part, eliminating warm up phases. This way, even small batches can be produced efficiently.

Hessapp and its sister brand VDF Boehringer are very well known as specialists for railway applications, having successfully installed systems all over the world. Wheels and axles in various volumes, but also wheelset remanufacturing is being performed on their vertical and horizontal turning machines. These are characterized by stability, productivity and application-tailored designs. VDF Boehringer will bring a robust and versatile CNC turning center VDF 250 T with two direct driven turrets and steady rest, performing highly precise turning operations, end machining, threading and boring. They also introduce a new model size VDF 650 T, which is designed for use as pre-roughing machine in production lines for railway axles, for example. Its sister model VDF 450 T completes these lines for further roughing as well as finishing operations. In addition, VDF Boehringer will round out its universal machine series VDF DUS with a 1300 model size. This machine is also suitable for railway applications, for example as repair center for wheels, axles, and entire wheelsets.

Italian manufacturers - Jobs, Rambaudi, Sachman и Sigma

Apart from the German and Swiss FFG brands, the Italian FFG members Jobs, Rambaudi, Sachman and Sigma will of course also present their innovations on their home market. They include new technologies, machines and systems in the areas of portals, gantries and travelling column machines. One of the highlights will be the LinX, a linear-motor milling center, on which the entire process developed for composite machining in aeronautical applications will be shown, starting from the die machining to the part machining, the tool management, the treatment of machining residues and much more, with sophisticated and smart solutions for the in-process optimization of the various operations, up to the remote maintenance as well as the very successful eVer7 from Jobs. Rambaudi, Sachman and Sigma will add highlights, such as a highly dynamic milling center, 5-axis vertical milling machines and a double-column machining center.

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