innovation and design in the machining of...

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EDITORIAL

INNOVATION AND DESIGN IN THE MACHINING OF STONE MATERIALS

TECHNICAL FOCUS: HOW TO GIVE BIRTH TO AN IDEA

TECNOCUT IN THE NAUTICAL SECTOR

CLIENTS: CASE HISTORY

FAIRS: EMO

FAIRS: MARMOMACC, VITRUM

SOFTWARE

SPARE PARTS

WATERJET TECHNOLOGY

During the course of 2005, the company strategy of Tecnocutwas faced with an extremely demanding acid test and it is exactlyfor this reason that we look at the results obtained with particularsatisfaction and pride. The international and domestic contexthas been undeniably difficult, the economic system ischaracterised by deep uncertainty, and several fundamentalfactors, from the value of financial assets to the price of oil,have led to a condition of instability on the international markets.Naturally, every difficult moment brings with it an opportunityfor regeneration and Tecnocut has grasped this opportunity. Wehave continued to steer the tiller more towards the service ofour customers and we have had faith in the made in Italyaggregation becoming a part, through the subsidiary companyCMS, of the SCM Group, world leader in the production ofwoodworking machines.All of this has been possible thanks to the fact that Tecnocuthas not limited itself to following the rules that allow the marketto function correctly, but has behaved in such a way as toanticipate the phenomena and demonstrate with clarity thequality of its actions, even when courageous decisions werenecessary, such as our integration into the ideology of the SCMgroup or choosing the procedures by which to create thedistribution structure for overseas countries, in order to perfectlymatch our solutions and services to the various productionspecificities of each country.

It will be sufficient to recall just a few significant results.

Thanks to our process of integration into the group, we are nowable to provide complete solutions to the demands of severalproduction processes such as the machining of stone materialsand glass (flat and curved), the machining of plastic materials(flexible and non-flexible), nautical and aerospace productionprocesses.We have supplemented our biggest selling range of systems,Idra and Idro, with accessories that are unique in the market ofwater jet cutting systems: the new water jet system ‘Firejet’ and

the innovative dynamic control of the taper ‘IKC’.With the aim of expanding our presence in overseas markets,we have sought out, chosen and trained retailers, in order to beeven closer to our customers and respond in a more efficientmanner to their demands. Our first sales followed in the USA,one of the reference markets for water jet cutting technology,characterised by extremely strong competitive dynamics.We have strengthened our relationship with our customers bymeans of Customer Satisfaction actions and instruments, makingthese the point of reference for eventual corrective actions. In2005, many of our customers again decided to renew their faithin us, confirming their satisfaction with our organisation,purchasing new solutions by Tecnocut.In the face of unsolved challenges, all of this certainly does notconstitute the conclusion of our efforts, but represents an injectionof faith. Obtaining worthy results on the road of action, particularlywhen the context in which we operate raises criticism andcomplexity, motivates us to make our mission more incisive.

We are therefore well aware that what awaits us will not be aneasy challenge, but I am sure that our company can count ona solid organisational and technological structure that canguarantee us a consistent competitive advantage.Further to all of this, Tecnocut can place its firm trust in all ofyou, the collaborators who over the years have showncompetence, professionalism and dedication, making Tecnocuta leading concern.For this I wish to offer you all my personal thanks for the excellentresults achieved.

Stefano Ing. Dal LagoChairman of the Boardof Directors

Born from the necessity to combine innovation and service withits products, Prunotto Marmi, after careful selection, has chosenTecnocut as a partner, a world leader in the design and productionof complete water jet cutting systems. Tecnocut, with a team thattoday boasts more than 60 professionals dedicated to water jetcutting technology, in collaboration with Prunotto Marmi, hasrevolutionised the application of traditional water jet cuttingsystems in processes for the transformation of marble, graniteand natural stone. Strong in its know-how in the field of ultra highpressure, Tecnocut has created Firejet, an integrator systemcapable of increasing the added value of water jet machiningoperations, allowing the traditional cutting system to carry out aunique and exclusive treatment on the surface of the material.

TECNOCUT SOLUTION

The integrator system transforms the cutting head into a headthat is capable of flamming the surface of the slab.

When machining a piece, Firejet aims a jet of water onto its surfacewhich reduces the projection of fragments of material during thesurface treatment. The projection of the jet can be adjusted interms of height, inclination and speed in order to guarantee thehigh flexibility of the system, enabling it to carry out treatmentson any type of stone material with the possibility of obtainingdifferent surface finishes.

The Firejet integrator system is controlled on board the machineby a parametric ISO program that controls all variables that arenecessary for the customer to carry out the treatment to the flatslab.

enables you to safely flamejet small thicknesses of up to 10 mm(we are currently completing tests to evaluate the possibility offlamming smaller thicknesses).

enables the client to flamejet not necessarily all of the slab, butonly the part that will be subsequently machined

enables you to be independent without necessarily having to usea separate machine for the flame jet treatment.

is an integration to the water jet cutting machine, with anextremely worthwhile additional cost; it enables you to carry outthe surface treatment to the material, creating a product with ahigh added value: the ideal user does not deal in mass production,but carries out specific machining processes with shape cuttingtogether with flame jet treatment that increase the value of thematerial itself.

CORSO BRA, 17 - 12051 ALBA (CN) - ITALYTel. - Fax: 0039.0173.440080E-mail: [email protected] site: www.prunottomarmi.it

Established in 1958 and a specialist in the machining of stonematerials, Prunotto Marmi addresses the market with an offerof high added value products that are without equal. Thecompany’s mission is to create articles in marble, granite andengineering stone that have a high level of design while beingfunctional at the same time. In the tradition of Prunotto Marmi,the study of the design and practicality is fully combined withthe ability to interpret and anticipate the client’s demands, alsoby means of the use of innovative materials with absolute respectto the environment.Innovate, for Prunotto Marmi, means exploiting the potentialityof materials and applying technology in order to create newmanufactured articles and make it easier for the client to derivebenefit from them, renewing the production processes with theuse of extremely modern systems capable of creating productsthat are completely different from those currently on the marketdue to their refinement, functionality and the avant-gardismpresented by the combination of machining processes andmaterials. Prunotto Marmi has always believed in the use oftechnology for machining its manufactured articles, and to dateit can boast a machine pool of the highest order which, as wellas bridge cutters and polishing machines, consists of a numericalcontrol machining centre from the company Brembana Macchine.

Carry out the water jet cutting of shaped steps for a staircaseand afterwards, using the Firejet system, surface treat apart of the step in order to create the anti-slip surface withthe same shape as the step itself.

Create a shaped kitchen top with water jet cutting andafterwards, using the Firejet system, surface treat its base.

Create wall coverings with designs realised by means ofsurface treatment with Firejet.

‘The results achieved – points out Bruno Prunotto, proprietor ofPrunotto Marmi, - have exceeded our expectations; we aimed toarrive at a versatile system, capable of carrying out machiningprocesses of high added value, allowing us to achieve productionperformance and quality, thus enabling us to maintain a positionof leadership in this sector, namely the machining of manufacturedarticles in stone’

Flame jet treatment is a thermal process that is achieved usingoxygen and gas (propane or equivalent): the flame impingeson the surface to be treated at a high temperature (2500 -3000° c); the surface is subjected to a thermal shock at around600° c; this, combined with the immediate water cooling of thesurface, causes an expansion phenomenon and thereforethermal cracking of the quartz or silicon, thus emphasising thenatural structure and colour of the material.

APPLICATION FIELDSThis type of machining is normally suitable for volcanic rocks,preferably those with a higher quartz content, i.e. most granites,serizzi and gneiss. On these types of stone flame jet treatmentguarantees high production levels. The flame jet process offersvarious advantages including the vitrification of the treatedsurfaces, which thus become more resistant to atmosphericagents.

Bush hammering is a mechanical process which can be carried out on any type of material, adopting a few simple precautionsin the event of extremely small thicknesses or delicate materials.

APPLICATION FIELDSWith the bush hammering machine it is possible to carry out various types of processes depending on the tool that is used: fromsubstantial bush hammering to extremely fine bush hammering, various types of scoring using cutting tools with fixed guides,or special types of scoring using cutting tools without fixed guides.

Water jet treatment is a surface treatment that uses only a high pressure water jet (from 1000 up to 2500 bar).The result is similarto that of bush hammering or flame jet treatment, except in this case the mechanical resistance of the rock is not jeopardised,as it is not subjected to mechanical or thermal shock. The original colour of the rock is emphasised without yellowing phenomena.

it can be used for the surface treatment of all granitesand marble, stones, synthetic materialsit is possible to flamejet thicknesses smaller than 20 mmit is possible to achieve different degrees of roughness,by varying the parametersit is possible to treat the surfaces of the slab followingrather complex shapes.

APPLICATION FIELDS

‘The passion with which we follow thedevelopment of every singlecomponent, making use of the mostsophisticated design technologies,together with a craftsman’s care intheir creation, is not limited to makingthe proposed solutions functional, butextends to an exhaustive and selectivestudy of the materials and designaspects that are aimed at theachievement of total Tecnocut quality.The ever increasing expectations ofour clients motivates us to beconstantly committed to thedevelopment and creation of new ideas,that are unique, innovative and reliable,offering a service that makes thesatisfaction of our clients our mission’

Paolo RomittiEngineering MechanicalDepartment

What is an idea? The dictionary defines the word idea as somethingthe mind produces, a mental sensation, a recurring thought, anobsession.But what was Tecnocut’s most magnificent obsession? Topopularise the water jet cutting system in the world of sheet metal,in order to shatter the false myth (due to scarce knowledge) thatthe part of this sector dedicated to non-conventional machiningis the exclusive dominion of the laser, and the presumption thatthe cutting of non-metallic materials was the most important fieldof application for the water jet. We imagined a modular portalmachine specifically for working sheets of large dimensions but,at the same time, capable of working unconventional materialsof large proportions, taking advantage of the flexibility of the waterjet.The idea was that this machine would offer, for the same largesurfaces, the possibility of also having traditional machiningoperations combined (e.g. water jet cutting and drilling,countersinking and threading with mechanical tools).

The idea that we had was also to conceive a water jet tool thatwas in line with the concepts of machining centres, that wouldestablish new parameters in terms of robustness, precision, speedof execution and the possibility of being programmed and used onseveral continuous shifts.As can be observed from this long preamble, the challenge wasone of those that strikes fear into the heart but, as Giorgio Gabersang, ‘An idea, a concept, while it remains an idea, is merely anabstraction’.

The machine that we imagined had to offer the following possibilities:

The possibility of machining large surfaces with the necessityto support the heavy weight of the sheets and enableloading/unloading operations that could not be done manuallybut which would have to allow for accessibility on three sidesand the use of a bridge crane

the possibility to have a modular extension of the work area

the possibility to fit additional bridges to the same structure inorder to increase the production capacity

the possibility of having a 5 axis cutting head controlled nextto the traditional 3 axis one

the possibility of having a zone dedicated to the machining oftubes by means of a rotary axis, without reducing the usablesurface area intended for the machining of sheets.

Tra laser e getto d’acqua non vi sono sovrapposizioni di ruoli,ma il taglio a getto d’acqua è di più semplice utilizzo eprogrammazione, fermo restando l’impossibilità da parte deilaser di andare oltre certi spessori di materiali, l’assolutamancanza di deformazioni termiche del getto d’acqua e laflessibilità in termini di tipologia di materiale tagliabile (titanio,alluminio, leghe, rame, ottone, acciaio inossidabile ed acciailegati con spessori fino a 200mm).Spero vi siate fatti una “Idea” di quello che si può fare con questamacchina e vi frulli per la testa una certa “Idea” di passare atrovarci toccando con mano la bontà dei nostri prodotti.Noi non vendiamo utopie ma bensì splendide realtà e sappiateche acquistando una nostra macchina acquistate anche noirendendoci così degli “accessori” viventi utili per farvi produrreal meglio ciò di cui la vostra azienda è particolarmente dotata.

Movement occurs by meansof recirculating ball slidingblocks driven by brushlessmotors with recirculating ballscrews (class 25) and racks ofhigh quality and precision(class H5), and the parts incontact with water are instainless or treated with specialpaint. The acceleration value,which may seem low forsomebody who is used to alaser cutting machine, isactually perfect taking intoconsideration the speed withthe abrasive cutting of the sheet and allows the cutting speed tobe reached in fractions of a second. Furthermore, the operator canmove together with the portal, as his station is situated on a platformanchored to the portal, making it possible for him to perform histasks during the programming/verification phase while the machineis operating (all in compliancewith the provisions of regulation626, as the machine is fittedwith adequate guards andsafety bumpers).The machine may have one ortwo heads that worksimultaneously on the sameshape that is to be cut (with thepossibility to simultaneouslycarry out cuts on two sides ofa large symmetrical shape inrelation to the axis , with thisaxis of symmetry parallel to thedirection of movement of the

portal) and whose axis is controlled electronically by means ofCNC. Each head (Z axis travel 200 mm) is naturally fitted withan automatic tracer so that it can follow the undulations of thesheet.On request, the machine canbe supplied with a rotating tubeaxis controlled independentlyof the main tank in an externalone and with a maximum tubelength of up to 12 metres!!The tank for the collection ofwaste abrasive material andthe structure near the workingarea is made completely fromstainless steel, and alsocontains the dredge for theremoval of waste abrasivematerial which has a settlerincorporated. All of this servesto avoid annoying and costly machine standstills due to the periodicemptying of waste abrasive material from the tank.The CNC is high speed execution, with automatic tool diametercorrection, automatic vectorial adjustment of the profile andparametric deceleration on edges.CNC controls the three axes of the machine in simultaneousinterpolation and has a latest generation PC as an interface; thePC has ample memory, can be connected to the network and isalso equipped with an extremely practical USB key and the Windowsoperating system. The control is provided with a colour displaywith graphic simulation of the path of the cut. The software alsoprovides for the nesting helpful in optimising the useful residualspaces on the sheets that were previously machined (more flexibility= greater productivity = lower costs).The final jewel is that the machine is fitted with a centralisedautomatic lubrication system which provides constant greasing ofall relevant parts (automatic maintenance = no oversight = nomachine standstill = lower costs)

By realising this vision and not letting it remain just a dream wecreated the machine known as ‘Idea’, a machine that combinesthe characteristic qualities of our Tecnocut products (versatilityand ease of use) with those typical of machines for working sheetmetal.The basic portal structure has an area of 3000x4000 (Idea 3040)and is composed of a work table (tank) capable of supportingloads of 1200 Kg/m2 and an incredible system of precise slidingguides that are extremely well protected by a system of labyrinthsthat is a masterpiece of simplicity, beauty and functionality.Imagine seeing an enormous bridge weighting 3000 Kg movingby means of two orthogonal reduction gears that moving inseidethe labyrinth covers that protects ball screws dust.The rapid movement speed is 20m/min (that’s 3000 Kg in motion!!)with an acceleration of 1 m/s2 with a precision of ±0,08mm!!Incredible, you say, but this machine is no giant with feet of clay,but rather the fruit of a daring, but not reckless, plan.

‘The introduction of water jet cuttingtechnology in the design and production ofnautical parts, has not only improved thecutting process when machining them’ explainsGiovanni Tempesta of the company Allufer‘but also allows the optimisation of ordermanagement, rationalising the design, optimisingproduction processes and company logistics’".

The lowest common denominator of this case history is theoptimisation of production processes in the nautical sector,identified as the ability to make the most of technology andmaterials in order to satisfy the demands of the market in anintelligent and innovative manner. The relationship that linksTecnocut to the world of production processes for the nauticalsector is situated in this context. The intensification of competitionand demand has led the players in this specific sector to adoptnew strategies for the development and optimisation of processes.One of the most promising and newest strategies is the use ofwater jet cutting technology in the machining process.In the nautical environment, the aluminium (PERALUMAN) andAISI 316 stainless steel are the preferred materials, thanks to agood combination of mechanical properties, resistance to corrosionand lightness (the latter only in the case of aluminium). Whencutting these materials, the so-called ‘hot’ processes (plasma,laser oxygen cutting) are generally used; these present severalweaknesses, especially from the point of view of flexibility. Infact, these technologies present two main problems with regardto production processes for this sector:

Rationalisation of production processes:with a single system, it is possible to carry out cutting, markingand drilling operations on the same component. In particular,it is possible to regulate the marking operation, which isusually carried out manually, as it is realised with a Cadoutline and is therefore available in digital support forsubsequent jobs.

The use of water jet cutting technology enables the optimisationof order management, thanks to the following advantages:

difficulty of machining and managing the various materialsand required thicknessesthey cause thermal shocks to the material in the proximityof the cut profile, making subsequent machine work moredifficult.

Versatility:possibility to machine any type of material from stainlesssteel to aluminium, independently of the thickness, as wellas the possibility to carry out machining on sheets, tubes orsection bars. This allows the rationalisation of both thewarehouse and the machines necessary to manufacture allcomponents that are required by the nautical industry.

Ex. The ability to use a single system to machine the entirerange of materials and thicknesses required for themanufacture of nautical components: Peraluman aluminiumbetween 5 and 20 mm and AISI 136 stainless steel between5 and 40 mm, allowing optimisation of material stores andguaranteeing prompt delivery to the client.

Ex. Construction complete stern doors: with the introductionof water jet technology, the checking jigs are eliminatedand, by means of an optic measurement system in thedockyard, generation of the model in cad format andsubsequent transfer to the machine for machining.

Reduction of manpower costs:carrying out several machining processes with the samesystem (cutting, marking and drilling), eliminating machinework for the elimination of the cut flash and reducing timesand difficulties for the subsequent machining works, aperceptible reduction of the production time for each pieceis obtained.

Time to market:reduction of order despatch time, as water jet cuttingtechnology brings about the transition from design tomachining, independently of the material and the thickness,and thanks to the qualitative improvements of the machinework itself.

Optimisation of production costs:elimination of the effect of thermal deformation and the burr,thus reducing and facilitating the machine work that will takeplace after cutting.

Ex. The tool for threading holes used on surfaces obtainedwith ‘hot’ cutting has a life of 30 uses. The same tool usedon the same holes created with water jet technology has itslife increased to 500 uses. A company that carries out workon nautical parts carries out around 5000 tappings a month,with a subsequent saving of around 3000 Euros inexpendable materials alone, due to the optimisation of thecutting process. Without considering the advantages of themachining process itself, by avoiding work hardening of thematerial, a reduction in the time required to carry out themachine work is obtained and highly specialised personnelare not necessary.

Ex. A kit for the construction ofa tank requires a productiontime of approximately 380hours. Following theintroduction of water jet cuttingtechnology and the consequentrationalisation of the productionprocesses, the same kit can beproduced in 180 hours.Considering that they produce10 kits each year, they haveachieved a reduction inproduction time of 2000 hoursper year.

Reduction of costs and increase in the quality of theproduct:the current challenge in the nautical component industry isdecided in these fields, to be more competitive, improvingquality and service, optimising the processes of developmentand realisation of the product, while at the same time increasingthe profitability of the company.

Increase net output:it is possible to offer the client a better service in terms ofdelivery times, a product that is made to measure and theoverall quality of the produced component

Ex. Construction porthole flange- Production steps before the use of water jet technology:plasma cutting, lapping of oxidised parts, straighteningcaused by thermal alteration, pressing.- Production steps with the use of water jet technology: cutto shape, and pressing

All of this is supported by a continuous use of machinery ofa high technological level, such as computer numericalcontrol (cnc) machines, new welding systems, the innovativewater jet system ‘Idea’ by Tecnocut with a working area of6000x3000mm and continuous updating of our collaborators’training.

Furthermore, numerous certifications have been obtained:

in 1988, certification for Tig and Mig welding proceduresfor stainless steel and aluminium alloys;in 1997, the Italian and international certification ISO 9002and CE marks on our products.

The company was established as a craft business in 1972,and specialised over the course of the years in the nauticalsector before becoming a leading company in the productionof accessories in stainless steel and light alloy. Quality anda high level of finishing are the strengths that distinguishour production, which is able to satisfy the demands of themost prestigious Italian and international dockyards. Clientscan count on the experience and know-how of engineersand designers, and on competent and effective co-operationfor the resolution of the various problems regarding thedesign and construction of pleasure boats.

Evidence of this are:

industrial invention patent for automated sliding side doors;to deal with the problems of space that nautical designershave encountered when organising the areas insidepleasure boats.industrial invention patent for automated pantograph sidedoors; to resolve problems of watertightness even in theevent of strong opposing pressure, and with much limitedcharacteristics of angular dimensions, with reference tothe surrounding space.industrial invention patent for an escape hatchway; toresolve the problem, in a harmonised manner with theboat, of rapid escape from belowdecks to the upper deckin the event of emergency.

ALLUFER TEMPESTA SNCVia A. Manunzio - Z.A. Zoccolanti04018 SEZZE (LT) - ITALYTel. 0039.077.388180 - Fax 0039.077.3804410E-mail: [email protected] site: www.allufertempesta.it

Planning and designProduction of woodwork items and mechanical componentsalso through outsourcingWater jet cutting, also outsourcing, of any metallic or non-metallic material in stock such as LL alloy 5083 – stainlesssteel AISI 316 L up to a thickness of 40 mm, using theinnovative Idea system by Tecnocut with a working areaof 2000x6000 mm.Production of boat names of any size or font in polishedAISI 316 L as well as company logosTig-mig welding, electrode with qualificated welders,classification register and regulation ASME

CARPEN CARPENTERIAE RIPARAZIONI MECCANICHE SRLLocalità Lagoscuro, 2119020 CEPARANA (SP) - ITALYTel. 0039.0187.933612 - Fax 0039.0187.932748E-mail: [email protected] site: www.carpen.it

Carpen was established in 1988 with the acquisition of abranch of C.R.M. snc of the Bertera Bros, operational since1956 in the sector of industrial naval repairs and maintenance.Since 1994, particular attention has been paid to sail andmotor pleasure boats, and in order to adapt to the growingdevelopment of this sector they have invested in specificmachinery and equipment, increasing the manufacture ofaccessories for fitting out boats.

Production is carried out in the factory located in the communeof Vezzano Ligure (SP), which occupies a covered area of1400 sq.m and an uncovered area of 1500 sq.m. Activitiesinclude:

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Tecnocut’s balance sheet is unequivocally positive. The levelshown by our clients towards our technology and the latestinnovations by Tecnocut have roused an extremely high levelof interest that in many cases has turned into a concretecommitment.At the forefront is the IKC system by Tecnocut, which has onceagain proved to be the Tecnocut innovation capable of redefiningthe standards of water jet cutting technology.Finally, in this edition of 2005, Tecnocut presented itself for thefirst time as part of the SCM group, a closely-knit group capableof offering complete solutions for cutting and surface finishingin the sheet metal working sector, previewing the DMC lappingsystem, a brand within the SCM group, an international leaderin solutions for the lapping of sheet metal.

The 2005 EMO trade fair in Hanover, which took place betweenSeptember 14th and 21st in Germany, reasserted its role as themost important international meeting place for the metalworkingindustry. Over 160,000 visitors from 82 different countries hadthe opportunity to explore the latest trends and advancementsin the field of non-conventional cutting technologies for themanufacturing industries, as showcased by approximately 2,000exhibitors from 39 different nations. There were 300 Italianconstructors present in Hanover, the highest number of foreignersin attendance, second only to the Germans hosts.‘This – commented Alberto Tacchella, chairman of UCIMU-PRODUCTION SYSTEMS – confirms the dynamism of the Italianoffer and the importance that this event, unique due to itsinternational character, holds for constructors such as ourselvesthat are strongly orientated towards foreign markets. In fact,since the beginning, about half of domestic production in thissector has been destined to serve overseas demand.’The overseas trade data relative to the first five months of 2005confirm Mr Tacchella’s optimistic words, recording a growth of14.7% when compared to the first five months of 2004. Inparticular, the most significant increases relate to exports toGermany (+15.1%), the United States (+47.9%), Spain (+3.6%)and France (+14.1%). Amongst the emerging countries: Turkey(+68.8%), Russia (+39%) and India (+186.1%).Made by Italians continues to draw great success, confirmingonce again that our country is amongst the sector leaders.

HANOVER – GERMANY14th–21st September 2005

At EMO 2005, Tecnocut presented the IKC system: IntelligentKerf Compensation. This solution was designed in order to satisfyour most demanding clients who need to increase productivitywithout jeopardising the quality of the machine work or theoptimisation of costs.

With the Intelligent Kerf Compensation system a newstandard is set in water jet cutting technology

The IKC defines new standards with regards to performance,quality and precision for water jet cutting. The technologicallimits of traditional systems have been reset.

VersatilityWith the IKC-technology 5-axis cuttinghead it is possible to carry out flat machiningor obtain inclined cut profiles (+/- 60° withrespect to the vertical).

High performanceFor the first time, IKC byTecnocut combines highperformance and unheard-of cutting precision, all withthe maximum optimisationof the production costs.The first 5-axis cutting headin the world with IKCtechnology, it is capable ofimproving the error that istypical of traditional water jet cuttingsystems by 90%, allowing for an increasein performance in terms of cutting speed.

Cutting cost optimisationIKC is the only technology that actuallyimproves, right from the beginning, therelationship between performance

I-H&S GMBHMairichweg 50 - D - 71546 Aspach - GERMANYTel. +49 7191 34140 - Fax +49 7191 341414E-mail: [email protected] site: www.ihs-gmbh.de

TUWI NEDERLAND B.V.Technopark 2 - NL-7102 JM Winterswijk -THE NETHERLANDSTel. +31 543549549 - Fax +31 543549501E-mail: [email protected] -Web site: www.tuwi.de

Traditional process

Marmomacc affirms itself as the worldwide capital of the stone-marble universe. The 40th edition of the International Marble,Stone and Technology Exhibition, which ended on 2nd October2005, recorded a positive balance, after four days of meetings,contacts and trade exchanges.The initial data indicates that more than 62,000 visitors attendedthe exhibition (approximately 3% more than in 2004), of which38% were accounted for by foreign visitors from 112 differentcountries, recording a 6% increase compared with the previousyear. There were around 1,500 exhibitors (of which 600 fromoverseas) originating from 51 different countries, covering a netarea of more than 64,000 square metres. This data highlights therole played by Marmomacc in promoting this important productionsegment, which in Italy numbers over 11,000 companies (and60,000 employees) with a turnover of between 3 and 3.5 billionEuros. ‘We are satisfied with the results achieved from ourparticipation in the exhibition’ – declares Matteo Traini, MarketingManager – ‘we were able to sign important agreements and werecorded an increase in foreign visitors, which has enabled us topursue our aim in 2005 of increasing our presence and visibilityin several foreign countries.Tecnocut, which has been a proven leader in this sector for sometime, gave a world-exclusive preview of its latest ‘gem’: Firejet, asystem which aims to provide our customers with even morecompetitiveness and that offers the production world, and theuniverse of architects and designers, a new machining standard

for high-added value manufactured goods.

Firejet changes the rules where the machiningof stone materials is concerned. In a systemmeasuring just a few square metres, theTecnocut designers have concentrated all oftheir knowledge of ultra high pressure systems,in order to perfectly integrate the various

production stages: from shape cutting to theinnovative surface finishing of the piece. Tecnocut

is the inventor of this production course: its systems and technologyguarantee, in a single transformation process, the certainty of highqualitative standards, optimising production times and costs.

VERONA - ITALY29th September – 2nd

October 2005

Decidedly positive results for the fourteenth edition of Vitrum, theinternational Trade Fair specialising in glass, machinery, equipmentand systems for the processing of plate and hollow glass, andtransformed products for the industry, which took place in thestands of Fiera Milano between 5th and 8th October 2005. Theexhibition recorded a remarkable increase in the number ofvisitors, which was up by almost 23% compared to the previousedition. There were 10,103 Italian dealers present at the fair(+24.89%) and 5,915 foreign visitors (+19.70%). Overall, duringthe four days that it was open, 16,018 professionals from theglass industry visited Vitrum, including retailers, wholesalers,glaziers, agents, window and door frame manufacturers, recyclers,production sector representatives, trade journalists and instituteand association directors. An astonishing result considering thedifficult economic situation that the sector is facing.

In this edition, Tecnocut again presented itself as a leader in thefield of glass shaping.

MILAN - ITALY5th – 8th October 2005

For the first time in the glass-processing sector, Tecnocut presentedthe exceptional 5-axis cutting head, which is capable of openingpossibilities for new applications. This is due to the flexibilitypresented by the combination of high performance traditionalprocesses with low operating costs, and 5-axis processes capableof producing innovative products that give extremely high addedvalue.

This exceptional new 5-axis head will improve machiningperformance in the field of glass processing, making it even moreextensive, more productive and more reliable.

CADSIGN is a powerful vectorising and graphic design softwaresuitable for users who reprocess images, who create designs,logos or signs to be realised with water jet cutting technology orother CNC technologies.With CADSIGN you have total control over images and objects,enabling you to realise extremely simple pieces of work or projectsof larger dimensions, all with professional quality and the maximumease of use.With CADSIGN, besides creating new designs (logos and signs),it is also possible to deform imported images.

Integration with CADSIGN allows you to increase the functionalityof the AutoCAD® software in use. With CADSIGN the generateddata behaves like vector data, which facilitates use and reducesthe project realisation time. Maximum interfacability with allsuppliers or corporate institutions that use files in vector format.CADSIGN contributes towards improving projects based mainly

on images, signs and logos. You will draw the maximum advantagefrom designs on paper or images on paper or file format converting

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them into vector objects that are easy to import into CAD systems,or into dxf format suitable for CAM systems. With designs createdwith CADSIGN it is also possible to insert geometrical figuresand lines of text created with True Type alphabets or otherssupplied with the program.Once it is ready, it is possible to etch or cut the design, exportit in another format or transfer it to the program for emptying ordrilling.

With CADSIGN it is also possible to export the design in the mostcommon vector formats, in order to facilitate interaction with otherprograms.

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e

B013.03A


HP CYLINDER PUMP

816,41653,13

e

e

B018.03


DELIVERY VALVE SEAT

49,6339,70

e

e

B023.03


INTAKE VALVE PIPE

69,5655,65

e

e

B033.03A


BODY VALVE

228,27182,62

e

e

B074.04


HP CYLINDER BUSHING

103,6782,94

e

e

B128.07


FILTER GUIDE

5,374,30

e

e

B134.43B


SELF-CENTRINGWEAR INSERT

44,0335,22

e

e

B136.03


SELF-CENTRINGNIPPLE

122,4697,97

e

e

B137.03


WEAR INSERT BODY

300,79240,63

e

e

B176.03


HP FILTER

77,5362,02

e

e

B365.03A


NEEDLE BODY

189,06151,25

e

e

14

For the whole month of January 2006, you can buy the spare parts mentioned with a discount of 20-25% on the pricelist.Write the name "MAGAZINE OFFER" in your order and the discount will be applied!

15


38,6730,94

e

e


12,419,93

e

e


33,3026,64

e

e


39,7531,80

e

e


239,55191,64

e

e


48,2638,61

e

e


17,1913,75

e

e


37,6030,08

e

e


105,2884,22

e

e


34,9127,93

e

e

On many advertisement photos of waterjet cutting, the jet oftenappears to be a glass-rod-like stream, coherent and static. Thiskind of picture is taken with a stream at very low velocity and sucha stream is not suitable for cutting (good for pictures though). Inreality, stream in waterjet cutting usually breaks up into dropletsbecause of the high velocity. The stream also tends to spread outto be a larger diameter as it travels through air and before it reachesthe material to be cut. Such a stream is not desirable in mostcutting applications. It wastes more materials (such as in fish filletcutting and other food processing jobs). It brings unwanted moistureinto the products it cuts (such as in paper product cutting). It createsundesirable ripples on the cut surface (such as in foam cutting,cake cutting, etc.). It also reduces the cutting efficiency becauseof the energy wasted on removing wider kerfs.

There are a few things that can be done to make the stream tighterto minimize the undesirable effects of the spreading stream. Ifthings are done right, you may see a glass-rod-like stream withina short distance from the exit of the orifice. The length of such aglass-rod-like stream shows the coherency of the jet and can beused to measure the effects of the controlling factors. Among theseveral controlling factors, orifice edge geometry is the most criticalone. A sharp edge orifice (usually made of sapphire or ruby)produces the tightest stream (the longest "glass-rod"). However,because the sharp edge is taking a high level of stress, it isvulnerable to the impacts of impurities in the water and tends tobe more easily chipped. A chipped orifice will destroy the integrityof the stream and usually becomes unusable. A rounded edge canreduce the stress and is thus more robust, but the length of the"glass-rod" will be shorter. This suits well for cutting thin materials.Otherwise a sharp edge diamond orifice can be used, which ismore robust at a higher cost. The geometry and the spaceimmediately above the orifice is also important. Geometry with astreamline design and a larger volume will produce a longer "glass-rod". For some applications that demand a long and tight stream,using a longer inlet tube often does the trick. However, keep it inmind that a larger upstream volume takes a longer time to dischargeand therefore a longer dwell time is needed at the end of cuttingbefore the nozzle traverses to next location. Minimizing the distancebetween nozzle and the material to be cut is also a good thing todo. A higher pressure and a larger orifice present more challenges.If nothing else works or an extra long "glass-rod-like" stream isneeded, some additives can be added into water to enhance thestream coherency. "Super-Water‚" from Berkeley ChemicalResearch, Inc. is an example and it has showed strong effect inenhancing stream coherency. This may be another topic for thefuture.

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