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Ann Arbor, Michigan – GMTA (German Machine Tools of America) represents various top-quality German metalworking machine builders, including Wera Profilator, K + G, Pittler, Praewema and WMZ, as well as Arnold lasers and Rosink parts washers. These machines are sold to the North American market exclusively by GMTA, primarily for gear and spline production, as well as other power transmission and various metalworking applications. The company’s target markets include automotive, off-highway, energy and other heavy equipment manufacturing. Machines are provided for gear honing, gear grinding, the patented Scudding® process for gearmaking, polygon milling, turning, gear tooth pointing and multi-task machining operations, as well as various laser operations or laser line integration and parts washing. This newsletter is provided to our friends in the media to keep you and your readers updated on News of Note at GMTA.

In the news…

ShannonLynch-GMTA continues their relationship with Eastern Michigan University (EMU), recently accepting Shannon Lynch, from the Masters in German and International Trade program, as an intern. Shannon’s mentor at GMTA and herself an MBA holder from EMU, the corporate treasurer Claudia Hambleton, remarked, “It’s the first time we’ve ever done anything like this. I feel really strongly about corporate responsibility for young people coming up into the industry…everybody needs experience, but how do you get it? I think this is a really good opportunity for Shannon.” The two shared several German classes at EMU, so the partnership was a natural fit. Shannon is responsible for assisting Claudia with daily office duties including receiving, invoices and translations, in communications with the company’s German partner firms. During her internship, Shannon has also had the opportunity to engage in industry-related educational and technical sessions such as the Economic Forum of the German American Chamber of Commerce, an Advanced Excel Workshop for data analysis and the recent North American International Auto Show Charity Preview, a very prestigious event and a great networking opportunity for the leaders in automotive manufacturing.

-GMTA participated in the annual Auto Show Charity Preview in Detroit and a good time was had by all.

-GMTA is running at “light speed” with their new Arnold laser work cells. Available as single or double work cells, the Arnold systems are offered as CO2 or fiber lasers, with full integration into a machining line, either by means of robotic part articulation or other automated transfer mechanisms, most of which are being supplied to customers by GMTA engineering. Leads from IMTS and the company’s aggressive ad program are already being developed into serious opportunities for the company, often in tandem with other machine tool lines and the Rosink parts washers now offered by GMTA.

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-Recently, a Diskus vertical double-disc grinder was sold to Hoergiger Fine Stamping in Canada. The DDS 600 machine feature two vertically arranged motor spindles, each equipped with 600mm grinding wheels used for simultaneous two-sided grinding of shims. The machine has a rotary through-feed system and an integral post-process measuring system, all developed by Diskus engineering and provided to the customer by the GMTA teams from Ann Arbor.

Präwema SynchroFine gear honing machines from GMTA

Präwema SynchroFine gear honing machines from GMTA

-The Mexico office of GMTA is reporting brisk activity, owing to the substantial procurement authority in-country now. According to VP Scott Knoy, “This contrasts with bygone days, when the decision-making and purchasing were largely centered in America and specifically in Detroit. It’s a whole new ballgame with the Mexican market today and we believe our new location (Queretaro) there is well positioned to serve this dynamic manufacturing environment.” GMTA already has a substantial installed base of machines in Mexico from all their partner companies.

-GMTA management will be attending EMO in Milan with its partners, then exhibiting at Gear Expo, being held this year in Detroit, October 20-22.

-The alliance with Star, through which GMTA is sourcing tooling locally, continues to prosper and mutually benefit both companies.

-GMTA was featured prominently in a recent article in Manufacturing Engineering magazine, covering the subject of gear making for the energy sector.

New Rosink front-loading parts washer shown at Rosink factory with (left to right) Jürgen Sünneker and Martin Schoolkate from Rosink, plus Stefan Kloos from GMTA

New Rosink front-loading parts washer shown at Rosink factory with (left to right) Jürgen Sünneker and Martin Schoolkate from Rosink, plus Stefan Kloos from GMTA

-Now available from GMTA, the Präwema SynchroFine 205 HS gear honing machine features direct-driven, digitally controlled spindles for the tool and the workpiece, enabling precise, rigid synchronization. The Präwema Honing gear finishing process produces quality comparable to grinding results for spur and helical gears, as well as shafts. The machine’s software checks the stock allowance and workpiece runout and then optimizes the X-axis approach distance. Measuring the workpiece does not affect the cycle time and the process can reduce overall cycle times by 3 to 5 sec.
-Stefan Kloos, product manager for Rosink at GMTA, recently visited the Rosink factory in Germany for the rollout of a new front-loading parts washer

For more information on this announcement, please contact:

GMTA (German Machine Tools of America)
4630 Freedom Drive
Ann Arbor, MI 48108
Phone:  734-973-7800
Fax:  734-973-3053
Web:  www.gmtamerica.com
Email:  scott@gmtamerica.com
Attention:  Scott Knoy, VP
Connect with GMTA online: yt twit gplus fb

Straight and angle head styles available for all popular machine tools; now offered on all tools in company’s current line

Heimatec, a world leader in live tools, angle and multi-spindle drill heads, today announces immediate availability of its newest development, a coolant-thru feature on all the company’s current line items.

Coolant-thru technology is often the answer for faster, cleaner cutting on larger and deeper parts, where the chips and excess heat build-up are significant challenges. Heimatec now offers high-pressure coolant-thru designs up to 1000 psi on straight and 2000 psi on angle head tools.

Company president Preben Hansen comments, “Production drilling should almost always be done with internal coolant tools and this development means we’ll be able to satisfy more customer needs in that area.”

A full range of styles and pressures is available immediately, according to the company.

Heimatec literature is offered, fully detailing all products available, both with and without this coolant-thru feature.

For further information and literature, or to arrange a demo on this new line, please contact:

Preben Hansen, President
HEIMATEC INC.
16 E. Piper Lane Suite 129
Prospect Heights, IL 60070
Phone:  847-749-0633
Fax:  847-749-2445
Email: info@heimatecinc.com
Website: www.heimatecinc.com

Connect with Heimatec Inc:  twitfbliytgplus

Fond du Lac, Wisconsin tooling supplier and metal stamper uses press and diework relationship with Heim to further develop its business, enter new markets and prosper

Deep draw gear cover entirely produced by Ultratech, ready to assemble at Amarillo Gear

Deep draw gear cover entirely produced by Ultratech, ready to assemble at Amarillo Gear

Covers for Corvette brake assemblies made by Brembo

Covers for Corvette brake assemblies made by Brembo

Ultratech Tool & Design Inc. (Fond du Lac, Wisconsin) began as a tool shop in 1990 (happy 25th anniversary!), serving the small engine manufacturing sector, Over the course of the past seven to ten years, the company has been supplying stampings from its 32-ton to 600-ton presses, with products ranging from simple washers to complex automotive and aerospace components.  As President Bill Melang notes, “We took the tooling expertise we had from the start and built the business around it.  This approach gave us the ability to see our customers’ challenges from the inside and help them find better solutions for their own production.” Major manufacturers in industries such as automotive, consumer goods, electrical products and aerospace populate the ranks of Ultratech’s North American customer base.

GM Sierra dust shields

GM Sierra dust shields

All jobs begin here with the tool design.  Ultratech uses Solidworks and Logopress software to produce its designs, then interacts with its customers in that fluid exchange of ideas, engineering suggestions and production fine tuning that creates the finished product.  That product is made entirely in-house at Ultratech on the latest CNC machines and CMM test equipment.   Melang comments, “We try our best to stay ahead of the competition with our machine tools and design protocols, using the best technology available in the market.”  Sensor selection on the dies, for example, is performed in the shop’s sensor lab, where simulation of the die-in-press scenario translates to a tool that is less likely to crash, plus Ultratech produces dies with complex in-die tapping and nut/stud insertion capabilities, as well as lamination dies.

Welding operations

Welding operations

Out on the production floor, another key reason for the shop’s success stands at the center of the operation.  Back in 2002, according to Melang, the company formed a working relationship with The Heim Group (Chicago, Illinois), buying their first Heim press.  Today, there is an 80-ton Heim OBS with 5000 lb. feed line, plus a 500-ton Heim Maxi-Stamper with 10,000 lb. feed and a 600-ton Heim Maxi-Stamper with 20,000 lb. feed.  Complementing this equipment is a full resistance welding, heat treating and assembly cell operation.   Ultratech also supplies its customers a range of finishing and part coating options to facilitate ready-to-assemble requirements.

PEM riveting operations

PEM riveting operations

Describing the partnership his company enjoys with Heim, Bill Melang observes, “Back in 2002, we bought our first Heim press.  It was an older machine and Heim helped us with a rebuild.  Since that time, we’ve developed a value-adding relationship with Heim, as they’ve provided us considerable assistance with press utilization and maintenance advice, while I think we’ve also been helpful to them with die design ideas.”

Heim President Katie Heim further comments, “Our relationship with Ultratech has benefited both our companies, over the years.  As our industry knows, the die dictates the press and we’ve worked closely with Bill and his team, as this particular customer’s knowledge of die design and performance characteristics in the press has created a real synergy with our engineers, who bring decades of press design and die handling mechanics to the task.  The fact that Ultratech also has some of the nicest people in the industry, starting with Bill, is the icing on the cake, so to speak,” Katie remarks.

Galvanized stakes for hold downs on a satellite receiver

Galvanized stakes for hold downs on a satellite receiver

This American-made press builder, Katie notes, is quite often asked for a turnkey system of press, die and coil handling equipment, including complex die and part handling mechanisms, in a single package.  She observes, “The knowledge we’ve shared with and acquired from Ultratech has made us both stronger players in the market today.”   She added that the decline in the workforce numbers and equipment manufacturers based in America has created the need for companies such as Heim to be more pro-active in the turnkey area, as customers today seek this assistance on a much more frequent basis than previously occurred.

Heim 80-ton stamping press at Ultratech

Heim 80-ton stamping press at Ultratech

Katie Heim is third generation owner of the business, which has built presses in Chicago for nearly 70 years and today boasts over 55,000 machines in the global stamping market.

Heim produces presses to 1000 tons and also supplies coil handling, part transfer mechanisms and complete die systems in turnkey packages for customers worldwide.

Ultratech is an ISO 9001:2008 certified supplier and is currently advancing to the TS automotive specification that will enhance the company’s involvement as a supplier to that industry.   The shop employs 25 people, including the next generation, as Bill Melang’s son is in the business and has recently completed a plant expansion of 30,000 square feet.

Lastly, Bill Melang mentioned the assistance he’s received from Jack Best and Tony Mase at Heim.  “There isn’t a single question we’ve thrown their way that went unanswered.  They do what they say they’ll do and that gives us great confidence in their abilities to handle our very fast-paced variety of needs for presses and support engineering.”

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For more information on this story, please contact:

Bill Melang, President
ULTRATECH TOOL & DESIGN INC.
1210 Scott Street
Fond du Lac, WI 54936-0548
Phone:   920-922-0257
www.ultratechtooldesign.com
bmelang@ultratechtooldesign.com

OR

Katie Heim, President
THE HEIM GROUP
6360 W. 73rd St.
Chicago, IL 60638
Phone:  08-496-7400
www.theheimgroup.com
katie@theheimgroup.com

Provided by German Machine Tools of America, the Rosink parts washer systems offer basket style, semi- or fully-automated parts handling for myriad applications

Rosink2

Ann Arbor, Michigan – Now available from German Machine Tools of America (GMTA), the Rosink parts washer line comprises a variety of machine styles, used for degreasing, cleaning, phosphating, applying corrosion control coatings and paint stripping. Either intermediate or final cleaning operations are typically performed on these machines, which are offered in basket style batch or in-line cleaning systems, with conveyorized integration to customer lines.

Rosink_Frontlader_RFL-165Highlighting the line is the Rosink Front Loader (RFL), ideal for cleaning very large parts with complex geometries. The base unit is a single tank, which includes a rotary grid workpiece carrier. This RFL unit can be used as a free-standing machine or integrated with a fully-automated production process.

Rosink4The most popular styles of basket cleaners are the RC and RCE. The RC is an economical, environmentally friendly, mobile water-based cleaning system, while the RCE features a stainless steel housing and lightweight thermoplastic cover to run more energy-efficient in use. Height adjustable drying, done by compressed air and a heat torch, add to the efficiency of the RCE operation.

Rosink washers are also offered for long tube and crossbeam section cleaning, as well as completely automated conveyorized cleaning inline, with part conveyors or fixturing offered. The aqueous cleaning solution is 96% water and 4% washing ingredients, which are recirculated through the machine.

GMTA also offers a complete line of biodegradable detergent solutions in various quantity packaging for user convenience.

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For a video of the Rosink machine in action, please visit:
https://youtu.be/bvvhL_TaXVk

For more information, please contact:

GMTA (German Machine Tools of America)
4630 Freedom Drive
Ann Arbor, MI 48108
Phone:  734-973-7800
Fax:  734-973-3053
Web:  www.gmtamerica.com
Email:  scott@gmtamerica.com
Attention:  Scott Knoy, VP
Connect with GMTA online: yt twit gplus fb

Large parts and one-off runs present particular challenges; common CNC platform offers many benefits to busy York, PA shop

Despite the large, heavy workpieces and frequent one-off production, Voith Hydro maintains a steady flow of work for its machining, typically holding +/- 0.002” tolerances on various carbon and stainless steels.  Workpieces here often exceed 25’ in diameter.

Despite the large, heavy workpieces and frequent one-off production, Voith Hydro maintains a steady flow of work for its machining, typically holding +/- 0.002” tolerances on various carbon and stainless steels. Workpieces here often exceed 25’ in diameter.


Voith Hydro in York, Pennsylvania is a major manufacturer of hydroelectric power generation equipment, especially the intricate turbines used in such operations, supplying hydroelectric generating companies and municipalities throughout North America. Over 12,000 units have been commissioned in the field with more than 65,000 MW of installed capacity, plus Voith Hydro has also upgraded over 600 existing power generation units. As a turnkey supplier to the industry, the company manages all phases of power plant projects, from analysis and planning, design and implementation, to commissioning and operation. Voith Hydro is ISO 9001 and ISO 14001 Certified.

Milling, line boring and turning operations are performed on large multi-axis machine tools, most equipped with Siemens SINUMERIK 840D CNC onboard to control all axes of motion.

Milling, line boring and turning operations are performed on large multi-axis machine tools, most equipped with Siemens SINUMERIK 840D CNC onboard to control all axes of motion.

At the York facility, very large multi-axis machining centers produce carbon and stainless steel work pieces, most often in a one-off mode and at sizes frequently exceeding 35’ in diameter. Adam Ward, the manager of maintenance & facilities at Voith Hydro, says the machining done typically holds +/- 0.002” tolerances here, nonetheless. “We do turning, line boring and milling on extremely large and heavy work pieces that often challenge us to design the optimum machining cycle. Our long cycles can frequently result in heat distortion on material surfaces and so we take great care in looking for problems before they occur.”

Voith Hydro maintains an impressive array of machine tools and multi-axis machining centers here. Despite a variety of builder brands, the majority of the machines have one common component, namely, the Siemens SINUMERIK 840D CNC onboard.

Remote condition monitoring is performed between Voith Hydro and many of its machine tool builders to troubleshoot and resolve issues in real time, using the CNC on the machine.

Remote condition monitoring is performed between Voith Hydro and many of its machine tool builders to troubleshoot and resolve issues in real time, using the CNC on the machine.

As Ward notes, “Our operators are quite comfortable with the CNC from Siemens and they use it for all motion control, plus the operator interface has the ability to afford us great troubleshooting capability and something else we value greatly, the commonality of the HMI on the control. That fact allows us to do a great deal of cross-training and that’s very important to us. We need to be highly flexible, given the one-off nature of our work here.” Most of the operators at Voith Hydro are capable of running multiple machines, while the maintenance personnel on his team can more easily service the machining equipment in the facility, adds Ward. He credits his machine builders and the Siemens team led by Howard Weinstein and Robert Stiefel for this ongoing flexibility.

Part designs are run through the company’s CAM system and simulated offline to preserve machine uptime.

Part designs are run through the company’s CAM system and simulated offline to preserve machine uptime.

Voith typically takes a customer design, runs it through their CAM system and simulates the cycle offline, in order to preserve valuable machine uptime. Since the work here involves highly complex geometries on the turbine sections, the simulation must be equally complex and account for all machine motions and collision avoidance. Once the program is finally determined for a part, it is fed over the Voith Hydro network to the appropriate machine tool or machining center for scheduling and production startup.

During production, a system of real-time remote condition monitoring is available through the CNC for troubleshooting by both the Voith Hydro maintenance personnel and, when required, machine builder personnel, working offsite.

Large Ingersoll milling machine was retrofit recently, with all new Siemens CNC, motors, drives and other hardware.

Large Ingersoll milling machine was retrofit recently, with all new Siemens CNC, motors, drives and other hardware.

Ward cites one example where an Ingersoll milling machine was completely retrofitted both mechanically and electrically by a Siemens Solution Partner, with a new CNC, motors, drives, encoders, other hardware and software. “Working with the builder and Siemens support personnel, we were able to resolve issues and implement changes to the programming, right on the CNC of the machine…and all done remotely, in a very short time period.”

Voith Hydro in York, PA produces a wide variety of power generation components for various machine builders and municipalities across America.

Voith Hydro in York, PA produces a wide variety of power generation components for various machine builders and municipalities across America.

Voith Hydro boasts machining capabilities on workpieces over 42’ diameter and 350 tons at the York facility. Surface finishes are typically 250 and 125 Ra, though occasionally 64 or 32 Ra is required. The finishes are achieved through both machining and secondary finishing operations, according to company sources.

Adam Ward further notes that, on most new machines required at Voith Hydro, “The cross-training capability of the CNC, the standardization of the HMI on various types of machines, the support provided and the previous successes our operators and maintenance personnel have realized, all combine to make specifying Siemens as our control of choice an easy decision.”

Howard Weinstein, business development manager for the power industry manufacturing sector at Siemens, comments on the relationship with Voith, “We’re a proud partner to Voith Hydro in York, Pennsylvania. Their facility is a great showcase for our flagship CNC, the SINUMERIK 840D, as used on an array of multi-axis machining centers to produce large, complex geometry parts for the hydroelectric power industry.”

For more information on this story, please contact:

SIEMENS INDUSTRY, INC.
DRIVE TECHNOLOGIES –  MOTION CONTROL (MACHINE TOOL BUSINESS)
390 Kent Avenue
Elk Grove Village, IL 60007
Phone: 847-640-1595
Fax: 847-437-0784
Web:  www.usa.siemens.com/cnc
Email:  SiemensMTBUMarCom.sea@siemens.com
Attention:  John Meyer, Manager, Marketing Communication

Follow us on Facebook: www.facebook.com/SiemensCNC or Twitter:  www.twitter.com/siemens_cnc_us.

Others involved in this story may also be contacted:

Voith Hydro
760 East Berlin Road
York, PA 17408-8701
Phone:  717-792-7512
Web:  www.voith.com
Email:  adam.ward@voith.com
Adam Ward, Manager of Maintenance & Facilities