02. INDEX

INDEXTHE SATISFACTION OF A DREAM COME TRUE .03

MESSAGE OF THE MANAGEMENT .04

INNOVATION TOUR .06

NEW ADVANCED HEAD MANUFACTURING CENTRE .08

A SHORT REVIEW OF THE HEAD AND QUILL RANGE .10

A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE .12

MILLING & BORING: FINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL .16

IMPROVED PRECISION IN LARGE WORKING VOLUMES FOR ANY HEAD .17

MORE ACCURACY IN THE WORKING AREA .18

FV MODEL: 5 AXES CONTINUOUS HIGH SPEED MILLING .19

OPTIMUM PERFORMANCE UNDER CONTROL .20

CYCLES DEVELOPED FOR SPECIFIC NEEDS .21

PHOTOGRAMMETRY: FAST PART FITTING .22

ACTIVE/PASSIVE DAMPING SYSTEM: INCREASING PRODUCTIVITY .23

APPLICATIONS CORNER .24

INNOVATION CORNER .25

SORA-NEWS .26

THE SATISFACTION OF A DREAM COME TRUE .03

Half a century on, SORALUCE not only

continues to grow against the physical

backdrop of the banks of the Deba

River, but also continues to transcend its

geographical limits through the joint effort

of the founders and those who continue

their work, turning this local reality into a

globalised success. The SORALUCE brand

name, through a wide network of alliances

and subsidiaries, is today present in all five

continents and is a world reference point in

the design and production of milling-boring

machines, basing its prestige on constant

technology innovation and a philosophy

of excellence. These assets have provided

the heirs of this great undertaking with a

vocation for leadership, without forgetting

the original aspiration to create a company

model that would be solidarity-minded and

fairer for all.

THE SATISFACTION

OF A DREAMCOME TRUE

04. MESSAGE OF THE MANAGEMENT

SORALUCE is celebrating its first half-

century this year, but it is also embarking

on the start of a new stage in its existence.

The future is complex and there are major

challenges on the horizon, but there are

also many opportunities for a company

whose trademark has been to overcome

all the obstacles in its path with courage,

innovation and commitment. These are

complex times, and rapid transformation

means a company must mobilise all its

skills. SORALUCE S.Coop is therefore

conducting profound strategic reflection

to decide on the most efficient way of

using its resources and alliances to take

on the challenge of growing, changing and

assuming more risks. It is doing this through

an important process called SORALUCE’s

Third Cycle of Change, which involves a

series of projects and initiatives with the aim

of consolidating the company’s leadership

on a world level.

This far-reaching Strategic Plan aims to

encourage product and market development

and to empower SORALUCE’s teams of

people so that we can keep on growing

while at the same time accomplishing our

basic tasks with excellence and improving

the company’s day-to-day work. The aim

of this is to be able to compete globally,

meeting the needs of a wide, diversified

base of geographical markets and customer

sectors through technology, product range,

quality, service and competitive prices.

But this action must also be invested with

great dynamism. Today’s business world is

highly globalised, fast-moving and complex.

If a company stands still, it will be out of the

action. And advancement involves constant

heavy investment, which is only possible if

sufficient financial profit is generated each

year.

MESSAGE OF THE MANAGEMENT

MESSAGE OF THE MANAGEMENT .05

People

Placing all this in a working context and

taking into account the increasingly open,

demanding, changing, collaborative, self-

managed and international environments,

what matters is the experience acquired

by SORALUCE’s people and teams through

each project they are involved in.

It is therefore vital to develop a global vision

throughout the organisation, to trust in our

people and our management capabilities

and the company’s own management

capacity, and to promote and facilitate

empowerment and commitment of all the

people making up the organisation.

Associations

SORALUCE’s aim is also to enhance its

capacity for creating important associations,

both within the company and outside it,

encouraging people to help each other

to develop new possibilities for action, as

companies are more and more competitive

as regards skills and qualification.

High-performance systems and processes

It is necessary to implement high-

performance systems and processes.

High-performance systems require simple

processes, and simple processes have

complex work behind them, which means

people must produce more through the

work they carry out. This increased work

means a need for more highly qualified

people, with a global vision and a strategic

and operational framework of action backed

by new systems, processes and forms of

interaction within and outside SORALUCE.

Rafael Idígoras, Managing Director of SORALUCE

Bird´s eye view of the Headquarters in Osintxu

06. INNOVATION TOUR

The visit consists of a guided tour around

the company to see how SORALUCE applies

technologies it has developed itself and

adapted to the actual production range in

order to improve customer competitiveness.

The visit will be developed at the OSINTXU

PLANTS (P1 – P3 – P4). Detailed discussions

customised to the requirements / interest of

each customer will be able to be discussed

afterwards.

INNOVATION TOUR

We kindly request that you follow

the General Safety Rules, do not

trespass the marked lines.

The drawing shows the path to

follow as well as what can be seen

in each place.

Taking pictures / videos is strictly

prohibited without the permission

of SORALUCE personnel.

P1

P3

P4

Start

Area dedicated

to the assembly

of X-axis

subassemblies

as well as Y/Z

modules for the

machines.

P1

New advanced

head manufacturing

centre dedicated

to the design,

machining,

assembly, checking

and service for

HEADS and QUILLS.

Refer to Page. 8-9

Plant # 1 New Advanced Head Manufacturing Centre and Module Assembly Workshop.

INNOVATION TOUR .07

Milling and Vertical Turning in one machine.

New F-MT concept. Machining simulation

Refer to Page. 15

Applications Corner

Refer to Page. 24

Innovation Corner

Refer to Page. 25

Active damping system

Refer to Page. 23

5 axis continuous

high speed milling machine FV.

Life machining trial

Refer to Page. 19

Showed machine

In production

Refer to Page. 18

P3 P4Plant # 3 Assembly plant for SP-FP-FS-FR models.

Plant # 4 Assembly plant for FR-FX-FXR models.

P3 P4

Life machining trial

Volumetric calibration

Photogrammetry

demonstration.

Machining simulation

Refer to Page. 22

CUSTOMER AREA

Refer to Page. 16

Refer to Page. 17

Refer to Page. 20

08. NEW ADVANCED HEAD MANUFACTURING CENTRE

NEW ADVANCED

HEAD MANUFACTURING CENTRE

NEW ADVANCED HEAD MANUFACTURING CENTRE .09

“SORALUCE HAS A CLEAR TECHNOLOGICAL VOCATION THAT LOOKS AFTER THE PRECISION AND THE RELIABILITY AT ANY TIME. FOLLOWING THESE PREMISES SORALUCE PRESENTS THE NEW ADVANCED HEAD MANUFACTURING CENTRE.”

Running-in

Design

Assembly

Manufacturing

Verification

10. HIGHLY RELIABLE AND ACCURATE HEADS

SORALUCE milling-boring heads are

acknowledged as being in a class of their

own thanks to their high reliability.

The broad range of SORALUCE heads

(Universal, Orthogonal, Horizontal, Modular

Quill, Angular, Special, etc) are distinguished

by their precision and high performance,

enabling complex milling, boring, drilling,

reaming and taping operations to be

performed with great accuracy.

Complete design, manufacturing, assembly

and verification processes are conducted

in-house, under the same roof, by an

experienced team of highly skilled designers

and assembly engineers.

To ensure high quality heads, the

workshop is equipped with state-of-the-art,

temperature and humidity controlled, high

precision manufacturing machinery and

assembly equipment.

With strict in-process quality controls and

exhaustive run-off on specific test benches,

SORALUCE certifies the highest quality for

the most critical elements on this kind of

machines.

HIGHLY RELIABLE AND ACCURATE HEADS

A SHORT REVIEW OF THE HEAD AND QUILL RANGE .11

Automatic angular rotary head with manual tool change

Automatic indexing head

32 / 46 kW 2.5º x 2.5º / 1º x 2.5º / 0.001º x 0.001º 3000 / 4000 / 5000 / 6000 rpm

Fixed horizontal boring head

Up to 60 kW3000 / 4000 / 5000 rpm

Orthogonal head

32 / 46 kW 2.5º x 2.5º / 1º x 1º / 1º x 0.001º 4000 / 6000 rpm

NC facing and boring head Modular quill spindle

· Ø 130 mm, W=700 mm, 46 kW, 2500 (3000) rpm

· Ø 150 mm, W=1000 mm, 71 kW, 3000 rpm

· Ø 180 mm, W=1000 mm, 71 kW, 2500 rpm

A WIDE RANGE

OF GENERAL

PURPOSE

HEADS AND

QUILLS

AND SPECIFIC

SECTOR /

APPLICATION

HEADS

THAT CAN BE

INTERCHANGED

AUTOMATICALLY

Angular head for Railway bogie machining

5 Axis continuous head for Mould and Die and Aeronautics

Angular head for motor block machining

A SHORT REVIEW OF THE HEAD AND

QUILL RANGE

12. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE

T RANGE HIGH PERFORMANCE IN

A COMPACT MACHINE

_ Long-lasting precision, resulting from a strict design and assembly process.

_ Optimum stiffness and mechanical stability.

_ High stock removal capacity and precision machining in one single machine.

_ Customizable machine thanks to a huge variety of heads and options available.

_ Complete splash guarding.

_ Designed to be compact and ergonomic.

A SHORT REVIEW OF OUR CURRENT PRODUCTION RANGE

MACHINE VERSIONS

MACHINE MODELS

Moving table

TA-A / TR

Moving-rotary table

TA-D

LONGITUDINAL TRAVEL - “X” AXIS 2000 – 2500 – 3500 – 4500 – 5500 mm

VERTICAL TRAVEL - “Y” AXIS 1000 – 1250 – 1400 – 1600 – 1800 mm

CROSS TRAVEL - “Z” AXIS 1000 – 1200 – 1300 mm

TABLE SURFACE(TA-A / TR) 2200 x 850 mm to 5860 x 1200 mm

(TA-D) 1000 x 1000 mm to Diam 1400 mmmm

LOAD ON THE TABLE Up to 16.500 kg Kg

SPINDLE POWER 24 - 28 - 43 kW

HEAD SPEED 4000 – 5000 – 6000 rpm

A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE .13

S RANGE

ERGONOMIC AND LARGE CAPACITY

_ High flexibility and high precision finishing machining results.

_ High performance and efficiency provided by a high torque direct drive spindle motor.

_ A wide range of accessories can be installed in the work area to improve production capacities.

_ Pendulum machining, minimizing non-productive times.

_ First class ergonomy and stability with very low foundation cost.

MACHINE MODELS SL / SP

LONGITUDINAL TRAVEL - “X” AXIS 2500 – 3500 – 4500 – 6500 – +2000·n mm

VERTICAL TRAVEL - “Y” AXIS 1600 – 2000 – 2600 mm

CROSS TRAVEL - “Z” AXIS 1000 – 1300– 1500 mm

SPINDLE POWER 43 (Direct Spindle motor) kW

HEAD SPEED 4000 – 5000 – 6000 rpm

14. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE

MACHINE MODELS FL / FP / FS / FR / FX / FX-R

LONGITUDINAL TRAVEL - “X” AXIS 3000 – 4000 +2000·n mm

VERTICAL TRAVEL - “Y” AXIS 1400 – 8000 mm

CROSS TRAVEL - “Z” AXIS 1000 – 1900 mm

QUILL TRAVEL - “W” AXIS Up to 1000 mm

SPINDLE POWER 28 – 71 kW

HEAD SPEED 4000 – 5000 – 6000 rpm

_ Accurate and efficient machining results.

_ Remarkably versatile - efficiently and precisely customised for any specific customer need thanks to the wide range of options available.

_ Large range of Automatic Heads, Boring heads, Quills and special heads.

_ Low gravity centre design in all the range: improved stability and reduced foundation costs.

F RANGE PRECISION FOR

LARGE DIMENSIONS

MULTITASKING MACHINING

F-MT RANGE

MACHINE MODEL F-MT RANGE

LONGITUDINAL TRAVEL - “X” AXIS 3000 – 4000 – 5000 mm

VERTICAL TRAVEL - “Y” AXIS 1600 mm

CROSS TRAVEL - “Z” AXIS 1000 – 1300 mm

SPINDLE POWER 43 kW

HEAD SPEED 4000 – 5000 – 6000 rpm

_ Integration of several processes in one machine: traditional milling machine operations + turning capabilities for heavy duty components, providing the possibility of manufacturing complex components in one machine and in one single setup.

_ Flexible working area that can be configured to the customers’ needs with one or multiple working stations with fixed tables and rotary tables usable for both milling and turning operations.

_ High dynamics: 45 m/min for the X axes and 35 m/min for the Y and Z axes, with acceleration of 2 m/s2 in each individual axis.

MILLING & BORING MACHINE .15

MILLING & BORINGFINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL

SORALUCE has redefined the concept of

Milling & Boring thanks to its new patent,

unique on the market, for a Quill changing

system that helps combine the benefits of

the traditional boring machines with the

advantages of modern milling machines,

all in one single machine.

The system interchanges the modular quill spindle

with the rest of the heads totally automatically,

thus allowing different quill spindles with different

diameters and lengths (Ø 130 - 180 mm / W: 700

- 1000 mm), to be available together with all the

necessary heads to machine any component.

TRADITIONAL SOLUTION SORALUCE SOLUTION

Long distance from the column to the spindle nose in automatic heads.

That means:

Short distance between the automatic head and the column.

That means:

Less than 32 kW for the indexing heads.Most stable solution: up to 46 kW @ S1 with Automatic / Orthogonal heads;

up to 60 kW @ S1 with angular heads.

Need to move the component to machine one component on 5 faces.Compact solution: the spindle axis of the indexing head is at the same distance as

the spindle nose of the boring bar.

Machine stopped during quill repairs and revisions.Non-stop machining. The machine keeps on running all the time, even when chec-

king the quill.

Different quill diameters / lengths can be combined in the same machine.

Full interchangeability with standard heads.

Maximum flexibility thanks to the full Automatic Head & Quill Changing System.

16. MODULAR QUILL

The Dynamic CNC Ram Balance System,

patented by SORALUCE, basically takes care

of the geometrical accuracy –straightness

and parallelism- of the ram traverse over the

Y and Z axis travels, and is specially suitable

for machines equipped with extensive

traverses and a head changing system.

· CNC controlled

The system is driven by a numerically

controlled servomotor. Drive action is

measured using a direct-measuring scale

that checks actual system response.

The system is 100% controlled at any time

and in any position and with any head.

· Dynamic

Configurable compensation values. Tables

can be positioned anywhere in the work

area. Works for any position. Different

tables created for different heads. Real

time customised compensation.

· Balance system

The system works in both positive and

negative directions. This means that

optimum compensation can be achieved

for a wide variety of head weights.

The figures that can achieve are below

0.04 mm for the ram drop in the spindle

nose and 0.04 mm/m on the level over the

ram with any head and for a cross traverse

of 1900 mm. These values are typically

improved with figures below 0.025 mm and

0.025 mm/m respectively.

IMPROVEDIN LARGE WORKING VOLUMES FOR ANY HEADPRECISION

PATENTEDWO 2010/072856

Servomotor

Vertical Axis Saddle

Damping System

Fixed roller bearings

Loose roller bearings (one DOF)

Planetary reductor

Planetary roller screw

Measuring system

Figure of the DBS3 system

RAM BALANCE .17

18. ACCURA HEADS

Thanks to the specific SORALUCE

developments, head articulation positioning

deviations have been reduced to a

minimum. These allow for the compensation

of head kinematic values and orthogonal

position offsets (M10 functions), for any

position in the work area.

Some advantages of the system developed

by SORALUCE:

· Calibration for any type of head.

· Calibration for any position in the work

area.

· Calibration for any angle, not just

orthogonal.

· Offset error compensation due to thermal

expansion.

· Distance between different head spindle

noses is measured (machines with

automatic head changing system).

· Easy-to-use interface, 100% integrated

with HEIDENHAIN iTNC530 HSCI and

SIEMENS 840D SL.

Equip the machine with this pack and

recalibrate the head yourself in a few

minutes whenever and wherever you want!

MORE ACCURACY IN THE WORKING AREA

5 AXES CONTINUOUS HIGH SPEED MILLING .19

HIGH SPEED MILLING

5 AXES CONTINUOUSFV MODEL

MACHINE MODEL FV

LONGITUDINAL TRAVEL - “X” AXIS 6000 mm

VERTICAL TRAVEL - “Y” AXIS 2500 mm

CROSS TRAVEL - “Z” AXIS 1200 mm

SPINDLE POWER 40 kW

HEAD SPEED 8000 rpm

Specially designed for high precision moulds and dies machining, the FV high speed milling centre stands out for the following characteristics:

_ Linear motors in “X “ and “Y “ axes with acceleration of 4.5 m/s2.

_ “X “ and “Y“ axes at 60,000 mm/min speed and “Z“ axis at 50,000 mm/min.

_ High dynamics.

_ Centered cross slide.

_ Giroscopic head at 5 axes.

20. ADAPTIVE CONTROL

The current production scenario,

unattended machining is becoming more

and more important to continue with the

tendency of increasingly cost efficient

processes.

SORALUCE Adaptive Control consists of

an automatic adjustment of the defined

cutting parameters depending on the real

machining situation that is permanently

monitored by the Adaptive Control

Algorithm integrated into the CNC of the

machine.

This way, when the real working load on

the spindle is less than programmed (less

material than expected), the machine

can speed up the feed, shortening the

machining time. By contrast, when the

working load is higher than programmed

(more material than expected), the

machine automatically slows down the

feed to protect the machine and the

workpiece.

The technology that supports this

development is based on processing the

signals transmitted from the monitoring

process system to the machine control

unit.

This technology is indicated for roughing

and semi-finishing process.

OPTIMUM PERFORMANCE UNDER

CONTROL

· Optimum Cycle Time

· Unattended machining

· Increased Machine life

HMI

CNCAdaptative control parameter

Adaptative

Control

algorithmdriver

motor spindle

Power consumption

Gain

WATTIMETRO

M

CYCLES DEVELOPED FOR SPECIFIC NEEDS .21

Thanks to its accumulated knowledge of

the customer’s real needs, SORALUCE

develops and provides specific Custom

Made User Cycles to facilitate programming

of repetitive machining operations be

performed in on complex components.

This Custom Cycles pack includes cycles

such as:

· Pecking cycles drilling.

· Tapmatic tapping.

· Spiral milling by interpolation.

· Conical milling by interpolation.

· Radius milling by interpolation.

· Chamfer milling by interpolation.

Additionally, SORALUCE incorporates

cycles to guarantee the precision of rotary

travelling tables:

· Compensation of the rotary axis of the table.

· Compensation of the tilting axis of the table.

CYCLES DEVELOPED FOR SPECIFIC

NEEDS

22. PHOTOGRAMMETRY

Large raw parts require time consuming

alignment processes, even more than

the machining process itself for high

added-value parts. Before machining

starts, precise overstock distribution is

mandatory. Alignment processes require

two main steps: first, characterisation of

raw part geometry, and second, alignment

to machine axes. A new raw par set-up

system is presented, based on 3D vision

technology, with the aim of minimising the

raw part alignment process time.

The new solution consits of two main

modules: Fitting and Alignment.

Fitting module (stand-alone) enables

the fast and accurate raw part geometry

characterisation by photogrammetry. CAM

programs are decoded for automatically

determine the ideal part geometry to obtain

by the machining process. Optimal raw

part set-up in automatically determined,

ensuring an adequate overstock

distribution. As a result, optimal 3D

coordinates of specific optical references

fixed to the part are determined prior to its

set-up in the machine.

Alignment module (CNC integrated or

stand-alone) enables the non-contact

measurement of the optical references

during the alignment process in the

machine, by means of a machine

integrated 3D vision based wireless system,

automatically calculating the requerired

fixturing corrections for the precise raw part

set-up.

As a result, fast raw part fitting and

alignment is possible with 1 mm precision.

Main benefits of the system are:

· Time savings: 70% on Fitting & 60% on

Alignment processes.

· Reduction of non-quality costs and

Increase of work safety.

· Floor space flexibility and availability:

photogrammetric raw part measurement

for fitting calculatiion, and a portable

machin-integrated visión based system for

alignment.

· Independence from operator skills:

automatic fitting and alignment criteria

and algorithms.

Machine integrated 3D vision system

FAST PART FITTING RAW PART SET-UP

SYSTEM BY

PHOTOGRAMMETRY

ACTIVE/PASSIVE DAMPING SYSTEM .23

ACTIVE / PASSIVE

DAMPING SYSTEM

Nowadays, chatter is one of the

main limitations of milling processes.

Machine tool chatter vibrations cause

an unacceptable surface finish on the

workpiece reducing the life of the tool

and the mechanical components of the

machine.

SORALUCE offers the solutions to overcome

this problem through the ACTIVE / PASSIVE

DAMPING System which consisting of an

inertial actuator and a sensor placed close

to the cutting point. The sensor measures

the vibration and then the inertial actuator

produces a force on the host structure

according to a designed control law.

The control law is selected to introduce

damping in the process. The main

advantage of this technique is that the

controller can deal with any change in the

dynamics of the system.

The performed tests shows that the

appearance of chatter can be avoided

in most of the cases with the ACTIVE

/ PASSIVE DAMPING System and the

productivity of the milling machines are

increased considerably: the material

removal rate is doubled.

INCREASING PRODUCTIVITY

750 800 850 900 950 1000 1050 1100 1150

250

200

150

100

50

0

depth

of cut (%

)

always unstable

stable with the actuator

stable without the actuator

ram output (mm)

24. APPLICATION CORNER

APPLICATIONS CORNER

· Technological and production services:

- Turnkey projects: machining processes,

tools, equipment and machining.

- Individualized study of each production

phase.

- Analysis of cycle times with 3D

simulations.

- Analysis and optimization of production

processes.

- Advice on machining processes.

- Integral solution and investment return

study.

- Customized software development

depending on the application.

- CAD/CAM programming and

post-processor generation.

· Training services:

- Generic machine handling training.

- Specific CNC training.

- Advanced training in machining

processes:

· Tools, equipment, etc.

· Measuring

TURN KEY PROYECTS

Process

CNC

ToolsMachining Training

Vericut Fixtures

I NNOVATION CORNER .25

INNOVATION CORNER

Conscious of the need to develop and

innovate its products if it is to remain a

market leader for Boring-Milling Machines,

SORALUCE is backed by IK4-Ideko, the only

Spanish Research and Development Centre

dedicated exclusively to Machine Tools,

which belongs to DANOBATGROUP.

SORALUCE subjects all its components

and machines to constant development

at the IK4-Ideko Technology Centre. This

ensures that the design of its products and

productivity can be continually improved

and adapted to the latest technological

innovations.

A number of research lines are continuously

open in order to develop new solutions

suitable for current and future needs of

the manufacturing processes of different

industrial sectors.

During the present Innovation Days 2012,

some innovations jointly developed and in

pre-industrialization status will be shown in

live as:

· The Volumetric calibration, to improve

the precision of the machine in the whole

working area.

· The use of the Photogrammetry, for

setting up parts quickly and accurately.

· The Dardo system, to eliminate tool

vibrations by measuring and modifying the

cutting conditions.

· The Active damping system, to eliminate

the chatter effect by the increase of the

damping coefficient of the machine.

DRIVEN BY IDEAS, DRIVEN BY INNOVATION

PRESS RELEASE

26. SORA-NEWS

SORANEWS

SORALUCE, which specialises in the design and manufacture

of milling-boring machines and milling centres, is to invest 6

million Euros strengthening its BIMATEC-SORALUCE delegation,

in Limburg, Germany, with the aim of reinforcing its presence in

the country, extending its installations and projecting an image

to the world of its success in that country. Soraluce is part of

the DANOBATGROUP, the machine tool division of MONDRAGON

Corporation.

Its German headquarters’ showroom is currently 1,300 m2 in

size, and this is to be extended by 2,500 m2 in June 2012.

In addition to the showroom extension, its current offices are

also to be extended by 1,900 m2, which house administrative

and customer support services (turnkey projects, after sales

service, training etc.) in order to promote its activities. But the

most noteworthy aspect of the changes will be its new show-

room capacity, a 10 m crane height will allow the Guipuzcoa

firm to present its 8 m high machines in this market.

SORALUCE has been present in Germany for 20 years, where it

manages its customer relations, accounts, installation and after

sales services, etc. Fruit of its work over the years is its install

base of 800 machines with leading customers.

The Cimolai group, world leader in large-scale metal construc-

tions has, for the second time, put its trust in Soraluce Italia by

acquiring a Soraluce FXR-64000 milling-boring machine with re-

cord dimensions: 64000 mm longitudinal travel, 8000 mm verti-

cal travel and a cross travel (including quill travel) of 2900 mm.

The FXR-64000 is special not only because of its size, but also

because its technological innovations and advanced level of

automation. These include: Modular Quill, stepless universal

head, horizontal head, special measuring probes unit, angular

head, pick-up for heads, tool magazine and preparation for ro-

tary travelling unit.

At the end of 2008 it started extending its delegation in order to

maintain and increase its lead in this market, and consequently

in the rest of its export markets.

The Managing Director of the Guipuzcoa firm, Rafael Idigoras,

indicates that “Germany is of fundamental importance right now

in economic, political, technological and industrial terms”. It

is the leading consumer and producer of high technology ma-

chine-tools.

The start of works coincided with the recent EMO 2011 ma-

chine-tool fair in Hannover, and are expected to be inaugurated

in 2012, SORALUCE’s 50th anniversary, for which different

events are being organised.

It should also be mentioned that the FXR-64000 is ready for

integration with a second column during phase two to optimise

plant productivity.

The Cimolai group investment means yet another record: exe-

cution and machining of parts 65 metres long, 6.5 metres high

and 4.5 metres wide, forming part of a manipulation system to

be installed in a single industrial bay of special dimensions and

characteristics.

SORALUCE invests 6 million Euros extending its German delegation.

Soraluce Italia started 2012 on the right foot in the big dimensions milling and boring machines sector.

Worcester-based Joy Mining has taken delivery of a 5-axis SORA-

LUCE SP 8000 travelling column universal milling/machining cen-

tre from T W Ward CNC Machinery. The machine has replaced an

ageing Butler Elgamill CNC universal bed mill, which was used to

machine castings, as well as flame-cut large plates.

A key feature of the company’s work, of which 80% is exported, is

small batch manufacture parts, requiring complex machining cy-

cles – batches rarely exceed four-off. The expertise of its production

engineers is key in delivering such parts competitively.

As Robert Wilks, production engineering manager, explains: “Be-

cause much of our work is small batch and very diversified, the

extensive skills of our setters and operators are key to not only

running the machines, but also for tooling up, programming and

for taking complete responsibility for the manufacturing tasks.” And

in searching for a new replacement machine tool, Joy Mining was

adamant it had to allow the company to gain maximum advantage

from the strength of its skill base.

Installed in September, the SORALUCE SP 8000 has halved cycle

times and reduced tool costs on the castings and plates, while its

ability to produce other components, such as large gearbox hous-

ings, has also been exploited.

The machine’s Heidenhain iTNC530 with conversational interface

provides the two setter/operators that man the SORALUCE around

the clock with an ideal solution to prepare and program the next

scheduled component while the machine works through the exist-

ing product cycle.

Says day shift operator Ean Stamp: “As cycle times vary between

one hour to two days (four shifts), we have ample time to work

together and incorporate our machining experience in planning the

next task, while overseeing the cycle that’s being run. This may not

achieve the fastest cycle time, but ensures the part fully conforms

to requirements.”

After 15 months of engineering, cutting tests and negotiations,

SORALUCE has achieved one of the biggest orders of its history

from SMS Meer, consisting of a large automated production line.

SMS is a German company with a total annual turnover of EUR 1.2

billion and 2,400 employees. SMS Meer is a division of the SMS

group, world market leader in plant and machine engineering for

the industrial processing of steel, aluminium and non-ferrous (NF)

metals. Through organic growth and acquisitions of other leading

companies, SMS Meer has developed into the leading full-line

provider in the field of metal forming.

The contract consists of an automatic production line composed of

4 SORALUCE milling-boring centres which will be located in the plant

at Mönchengladbach. Additionally two milling-boring machines will

be installed in this plant, one of them for operator training.

Based on a 50-acre site, the 250-employee company produces

components for armoured face conveyors, large gear cases,

sprocket ring gears, framed components for powered roof assem-

blies and hydraulic rams, as well as performs assembly tasks on a

range of large valves.

As part of the justification, Ward CNC had to ensure the machine

met the specific requirements of Joy Mining’s management team

against five other competitor machine suppliers.

In addition, other key elements in the selection, justification and

purchase of the machine included its ability to operate in a self-

contained, cell-type environment, as well as the pedigree of the

builder and the supplier’s proven service record.

With all other areas satisfied, the final hurdle was machining trials,

carried out at SORALUCE’s HQ in Spain. As part of the buying pro-

cess, SORALUCE had to satisfy the machining demands of samples

of Hardox high strength and impact abrasion conveyor machinery.

DEMONSTRATED SAVINGS

Since installation, the machine has demonstrated overall savings of

some 50% on milling and, in particular, drilling cycles, plus provided

a significant reduction in tool costs, as a result of its inherent rigid-

ity. Says Mr Wilks: “We very rarely have to change inserts, which is

helping our tool inventory and costs.”

A key feature of the machine is its use of the BT50 Big Plus pat-

ented spindle system. This has enabled Seco’s latest Performax

indexable insert drills to be used for the first time as a test bed for

the tooling supplier. Holes in brackets between 10 and 70 mm

diameter, and bores up to 90 mm diameter have been produced

from solid, employing the 20-bar through-the-tool coolant pressure.

The SP 8000 also features adaptive feed control, DXF download

and dynamic collision monitoring, plus Renishaw non-contact la-

ser probing. Overall, the SORALUCE has achieved uptime of 80%

- 75% was the target.

Another two SORALUCE machines will be installed in the Aachen

plant, a bed type milling centre and a multitasking F-MT machine

for milling/turning large size components in the same machine in

the same setup.

The challenge of the project is based on integrating the SORALUCE

milling-boring machines into a flexible machining cell integrating

both an automatic parts feeder and a centralized tool management

system.

The keys to the success of the project have been the high dynamics

of the machines, a changeable head configuration that allows more

than 96% availability and local service and technical support from

Bimatec-Soraluce.

SORALUCE installs a new SP milling machine in the mining sector

SMS orders large SORALUCE automated production line

SORA-NEWS .27

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SORALUCEOsintxu auzoaP.O. Box 90E-20570 BERGARA (Gipuzkoa) Spain

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BIMATEC SORALUCE

Zerspanungstechnologie GmbH

In den Fritzenstücker 13-15

65549 LIMBURG (Germany)

Tel.: +49 6431 97820

Fax: +49 6431 71102

e-mail: info@bimatec.de

www.bimatec.de

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100016 BEIJING (China)

Tel.: +86 10 6467 3639

Fax: +86 10 6467 2119

e-mail: info@danobat.cn

www.danobat.cn

Row House No.21,

Aditya Breeze Park,

Survey No.1, Hissa No. 2,3,4

Mauze Balewadi

411045 PUNE (India)

Tel.: +91 20 66 094531

e-mail: danobatgroupindia@danobatgroup.com

SORALUCE ITALIA S.R.L.

Via Rovigo, 89

35042 ESTE - PADOVA (Italy)

Tel.: +39 0429 603 001

Fax: +39 0429 615 497

e-mail: soraluce@libero.it

SORALUCE FRANCE, S.A.R.L.

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77200 TORCY - MARNE LA VALLEE (France)

Tel.: +33 1 60 05 02 06

Fax: +33 1 60 06 56 47

e-mail: soraluce@club-internet.fr

SORALUCE AMERICA, INC.

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61108 ROCKFORD, IL (USA)

Tel.: +1-815-315-9261

Fax: +1-312-205-0358

e-mail: sales@soraluce-america.com

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129075 MOSCOW (Russia)

Tel.: +7 495 7877445

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B-dul Muncil Nr. 14

400020 CLUJ NAPOCA (Romania)

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Fax. +4(0) 264 415 487