In a Q&A session, Aerospace Manufacturing hears from Linz-based machining specialist, WFL Millturn Technologies and its compelling insight into the topic of ‘done in one’ machining.
WFL has developed its ‘clamp once – machine complete’ machining concept to meet the ever-increasing requirements when manufacturing complex, high-precision parts and components. This method enables the complete machining of parts in one continuous process within one machine and without any operator interventions. It is applicable for part types that were previously manufactured in several process steps on various different machines.
Q) Firstly, please provide a brief potted history of your company?
The world’s first complete machining centre, the MILLTURN WNC, was developed back in 1982. At the time, Voest-Alpine was still undertaking machine tool production. In 1993 WFL became an independent company focused on the manufacture of MILLTURN turning-boring milling centres. WFL – short for Werkzeugmaschinenfabrik Linz – was then taken over by the Autania Group.
Having focused on complete machining since 1983, WFL has become a technology leader in the field of metalcutting production machinery. The combination of different machining technologies, such as turning, milling, drilling or grinding in one machine tool is known as complete machining.
Clamp once – machine complete: this goes hand-in-hand with enormous economic and production-related advantages. Components for aircraft, turbines and vehicles – to name but a few – are manufactured from metallic raw materials, such as cast iron and forged parts.
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WFL’s new M20 machine includes increased strength and rigidity and a continuous motor-spindle design[/caption]
Thanks to strong development and a dedicated workforce, WFL has succeeded in becoming a global market leader in the high-tech niche technology of complete machining. As part of this continuous growth, existing production halls of the former Voest-Maschinenbau have been purchased, and two additional halls with office buildings have been newly constructed.
With a ratio of exports of 95% and subsidiaries and representatives in Germany, France, the USA, Brazil, Russia and China, the company achieved a record-breaking turnover in 2019.
Q) What types of aerospace components are your customers’ machine tools mainly used for?
WFL has been building complete machining centres for various well-known customers in the aviation, automotive, engineering and plastics machinery industries. The aerospace industry represents an important market segment for WFL. More and more materials, which are hard to machine are becoming prevalent in this sector. The most important requirement our products must satisfy is absolute process reliability.
Landing gear, turbine shafts, fuel pump housings and other aerospace components require technological solutions that have been specially adapted. The objective here is to ensure that machining is economical. Therefore, the advantages of complete machining are particularly illustrated in this sector. Thanks to the broad technological spectrum of the multifunctional turning-boring-milling centres and decades of experience, WFL customers can rely on the highest levels of productivity.
Q) What kinds of productivity benefits do your customers enjoy from the successful implementation of your CNC machine tools?
With the MILLTURNs, WFL provides a range of products that include a package of software solutions and special modules - in addition to having the widest spectrum of turning-boring-milling centres on the market. With a MILLTURN, customers are not only purchasing a CNC machine that meets the very highest demands for quality and precision, they are also getting the following competitive advantages:
Reduction of floor-to-floor time - the number of machines involved in the machining process is drastically reduced. Work scheduling and planning is extremely simplified. The cost-consuming stock piling of semi-finished parts is reduced; Increased flexibility - set-up of the tool magazine is possible during machining. Additionally expensive and complicated fixtures are not necessary; Increased utilisation - decreasing set-up times are equivalent to a significant increase in productive hours. Extended machining times due to complete machining allows processes to be continued even during breaks; Increased quality - as opposed to single-process machining where workpieces have to be clamped several times, complete machining saves clamping time, costs and at the same time avoids clamping and adjustment errors.
Q) What do you feel are the most important assets of a company?
The turning-boring-milling unit forms the heart of our machine and is where breakthroughs can be most readily seen. Software also plays a key role and thanks to impressive innovations, we have also been able to successfully conquer this market. Our approach is to offer customers a production solution. Not just a machine, but machining processes, tools, programs and methods. This idea has been with us right from the start and provided the ideal basis for creating a successful company.
Q) What differentiates your company from the competition - why should a customer use you over your nearest rival?
New technology, products and machines are being developed and adapted to meet the needs of the future. WFL will increasingly evolve into a system partner. Good examples of this include the acquisition of automation experts FRAI Robotic Solutions in 2018 and the introduction of our own system tools for the most challenging production tasks. The new organisation that we are currently developing enables us to give our customers more comprehensive and sustainable support, throughout the entire lifecycle of a MILLTURN machine.
Q) Lastly, what kinds of machine tool developments will we be seeing in the future?
We are about to launch a new product called the M20 MILLTURN. Its special features include the increased strength and rigidity of the machine, as well as the continuous motor-spindle design, which enables machining technologies, such as gear skiving.
The configuration of the machine allows for a wide range of possibilities: from a pure complete machining centre with steady rest and tailstock, as a counter spindle machine with up to two tool turrets or an individual tool holder at the bottom, as well as an optional integrated robot or bar feeder and unloading tray.
In addition, the trend towards the production of flexible gears on 5-axis machining centres has been continuing for many years. We have recognised the trend and have already been able to inspire our customers worldwide with numerous installations. In cooperation with the Swiss company Euklid, a leading provider of advanced CAD/CAM solutions for 5-axis machining, we are now going one step further.
In close cooperation with Euklid, a tailor-made GearCAM solution has now been developed especially for MILLTURN customers. This enables the production of gears to be optimised and the lead-time, measured against current industry standards and the highest quality requirements, to be reduced to a fraction. A digital twin of the MILLTURN allows a complete simulation of the process.
