02. INDEXINDEXTHE SATISFACTION OF A DREAM COME TRUE .03MESSAGE OF THE MANAGEMENT .04INNOVATION TOUR .06NEW ADVANCED HEAD M...
THE SATISFACTION OF A DREAM COME TRUE .03Half a century on, SORALUCE not onlycontinues to grow against the physicalbackdro...
04. MESSAGE OF THE MANAGEMENTSORALUCE is celebrating its first half-century this year, but it is also embarkingon the start...
MESSAGE OF THE MANAGEMENT .05PeoplePlacing all this in a working context andtaking into account the increasingly open,dema...
Bird´s eye view of the Headquarters in Osintxu06. INNOVATION TOURThe visit consists of a guided tour aroundthe company to ...
INNOVATION TOUR .07Milling and Vertical Turning in one machine.New F-MT concept. Machining simulationRefer to Page. 15Appl...
08. NEW ADVANCED HEAD MANUFACTURING CENTRENEW ADVANCEDHEADMANUFACTURINGCENTRE
NEW ADVANCED HEAD MANUFACTURING CENTRE .09“SORALUCE HAS A CLEAR TECHNOLOGICAL VOCATIONTHAT LOOKS AFTER THE PRECISION AND T...
10. HIGHLY RELIABLE AND ACCURATE HEADSSORALUCE milling-boring heads areacknowledged as being in a class of theirown thanks...
A SHORT REVIEW OF THE HEAD AND QUILL RANGE .11Automatic angular rotary headwith manual tool changeAutomatic indexing head3...
12. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGET RANGEHIGH PERFORMANCE INA COMPACT MACHINE_ Long-lasting precision, res...
A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE .13S RANGEERGONOMIC ANDLARGE CAPACITY_ High flexibility and high precisionfin...
14. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGEMACHINE MODELS FL / FP / FS / FR / FX / FX-RLONGITUDINAL TRAVEL - “X” AX...
MULTITASKINGMACHININGF-MT RANGEMACHINE MODEL F-MT RANGELONGITUDINAL TRAVEL - “X” AXIS 3000 – 4000 – 5000 mmVERTICAL TRAVEL...
MILLING&BORINGFINALLY BOTH CONCEPTS IN ASINGLE MACHINE IS 100% REALSORALUCE has redefined the concept ofMilling & Boring th...
The Dynamic CNC Ram Balance System,patented by SORALUCE, basically takes careof the geometrical accuracy –straightnessand ...
18. ACCURA HEADSThanks to the specific SORALUCEdevelopments, head articulation positioningdeviations have been reduced to a...
5 AXES CONTINUOUS HIGH SPEED MILLING .19HIGH SPEEDMILLING5 AXESCONTINUOUSFV MODELMACHINE MODEL FVLONGITUDINAL TRAVEL - “X”...
20. ADAPTIVE CONTROLThe current production scenario,unattended machining is becoming moreand more important to continue wi...
CYCLES DEVELOPED FOR SPECIFIC NEEDS .21Thanks to its accumulated knowledge ofthe customer’s real needs, SORALUCEdevelops a...
22. PHOTOGRAMMETRYLarge raw parts require time consumingalignment processes, even more thanthe machining process itself fo...
ACTIVE/PASSIVE DAMPING SYSTEM .23ACTIVE / PASSIVEDAMPINGSYSTEMNowadays, chatter is one of themain limitations of milling p...
24. APPLICATION CORNERAPPLICATIONSCORNER· Technological and production services:- Turnkey projects: machining processes,to...
INNOVATION CORNER .25INNOVATIONCORNERConscious of the need to develop andinnovate its products if it is to remain amarket ...
PRESSRELEASE26. SORA-NEWSSORANEWSSORALUCE, which specialises in the design and manufactureof milling-boring machines and m...
Worcester-based Joy Mining has taken delivery of a 5-axis SORA-LUCE SP 8000 travelling column universal milling/machining ...
Thisdocumentisnotcontractual.SORALUCEreservestherighttomakechangestoallmodelswithoutpriornotice.Theillustrationsinthiscata...
SORALUCE Innovation Days 2012
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SORALUCE Innovation Days 2012

  1. 1. 02. INDEXINDEXTHE SATISFACTION OF A DREAM COME TRUE .03MESSAGE OF THE MANAGEMENT .04INNOVATION TOUR .06NEW ADVANCED HEAD MANUFACTURING CENTRE .08A SHORT REVIEW OF THE HEAD AND QUILL RANGE .10A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE .12MILLING & BORING: FINALLY BOTH CONCEPTS IN A SINGLE MACHINE IS 100% REAL .16IMPROVED PRECISION IN LARGE WORKING VOLUMES FOR ANY HEAD .17MORE ACCURACY IN THE WORKING AREA .18FV MODEL: 5 AXES CONTINUOUS HIGH SPEED MILLING .19OPTIMUM PERFORMANCE UNDER CONTROL .20CYCLES DEVELOPED FOR SPECIFIC NEEDS .21PHOTOGRAMMETRY: FAST PART FITTING .22ACTIVE/PASSIVE DAMPING SYSTEM: INCREASING PRODUCTIVITY .23APPLICATIONS CORNER .24INNOVATION CORNER .25SORA-NEWS .26
  2. 2. THE SATISFACTION OF A DREAM COME TRUE .03Half a century on, SORALUCE not onlycontinues to grow against the physicalbackdrop of the banks of the DebaRiver, but also continues to transcend itsgeographical limits through the joint effortof the founders and those who continuetheir work, turning this local reality into aglobalised success. The SORALUCE brandname, through a wide network of alliancesand subsidiaries, is today present in all fivecontinents and is a world reference point inthe design and production of milling-boringmachines, basing its prestige on constanttechnology innovation and a philosophyof excellence. These assets have providedthe heirs of this great undertaking with avocation for leadership, without forgettingthe original aspiration to create a companymodel that would be solidarity-minded andfairer for all.THE SATISFACTIONOF A DREAMCOME TRUE
  3. 3. 04. MESSAGE OF THE MANAGEMENTSORALUCE is celebrating its first half-century this year, but it is also embarkingon the start of a new stage in its existence.The future is complex and there are majorchallenges on the horizon, but there arealso many opportunities for a companywhose trademark has been to overcomeall the obstacles in its path with courage,innovation and commitment. These arecomplex times, and rapid transformationmeans a company must mobilise all itsskills. SORALUCE S.Coop is thereforeconducting profound strategic reflectionto decide on the most efficient way ofusing its resources and alliances to takeon the challenge of growing, changing andassuming more risks. It is doing this throughan important process called SORALUCE’sThird Cycle of Change, which involves aseries of projects and initiatives with the aimof consolidating the company’s leadershipon a world level.This far-reaching Strategic Plan aims toencourage product and market developmentand to empower SORALUCE’s teams ofpeople so that we can keep on growingwhile at the same time accomplishing ourbasic tasks with excellence and improvingthe company’s day-to-day work. The aimof this is to be able to compete globally,meeting the needs of a wide, diversifiedbase of geographical markets and customersectors through technology, product range,quality, service and competitive prices.But this action must also be invested withgreat dynamism. Today’s business world ishighly globalised, fast-moving and complex.If a company stands still, it will be out of theaction. And advancement involves constantheavy investment, which is only possible ifsufficient financial profit is generated eachyear.MESSAGEOF THE MANAGEMENT
  4. 4. MESSAGE OF THE MANAGEMENT .05PeoplePlacing all this in a working context andtaking into account the increasingly open,demanding, changing, collaborative, self-managed and international environments,what matters is the experience acquiredby SORALUCE’s people and teams througheach project they are involved in.It is therefore vital to develop a global visionthroughout the organisation, to trust in ourpeople and our management capabilitiesand the company’s own managementcapacity, and to promote and facilitateempowerment and commitment of all thepeople making up the organisation.AssociationsSORALUCE’s aim is also to enhance itscapacity for creating important associations,both within the company and outside it,encouraging people to help each otherto develop new possibilities for action, ascompanies are more and more competitiveas regards skills and qualification.High-performance systems and processesIt is necessary to implement high-performance systems and processes.High-performance systems require simpleprocesses, and simple processes havecomplex work behind them, which meanspeople must produce more through thework they carry out. This increased workmeans a need for more highly qualifiedpeople, with a global vision and a strategicand operational framework of action backedby new systems, processes and forms ofinteraction within and outside SORALUCE.Rafael Idígoras,Managing Director of SORALUCE
  5. 5. Bird´s eye view of the Headquarters in Osintxu06. INNOVATION TOURThe visit consists of a guided tour aroundthe company to see how SORALUCE appliestechnologies it has developed itself andadapted to the actual production range inorder to improve customer competitiveness.The visit will be developed at the OSINTXUPLANTS (P1 – P3 – P4). Detailed discussionscustomised to the requirements / interest ofeach customer will be able to be discussedafterwards.INNOVATIONTOURWe kindly request that you followthe General Safety Rules, do nottrespass the marked lines.The drawing shows the path tofollow as well as what can be seenin each place.Taking pictures / videos is strictlyprohibited without the permissionof SORALUCE personnel.P1P3P4StartArea dedicatedto the assemblyof X-axissubassembliesas well as Y/Zmodules for themachines.P1New advancedhead manufacturingcentre dedicatedto the design,machining,assembly, checkingand service forHEADS and QUILLS.Refer to Page. 8-9Plant # 1New Advanced Head ManufacturingCentre and Module Assembly Workshop.
  6. 6. INNOVATION TOUR .07Milling and Vertical Turning in one machine.New F-MT concept. Machining simulationRefer to Page. 15Applications CornerRefer to Page. 24Innovation CornerRefer to Page. 25Active damping systemRefer to Page. 235 axis continuoushigh speed milling machine FV.Life machining trialRefer to Page. 19Showed machineIn productionRefer to Page. 18P3 P4Plant # 3Assembly plant forSP-FP-FS-FR models.Plant # 4Assembly plant for FR-FX-FXRmodels.P3 P4Life machining trialVolumetric calibrationPhotogrammetrydemonstration.Machining simulationRefer to Page. 22CUSTOMER AREARefer to Page. 16Refer to Page. 17Refer to Page. 20
  7. 7. 08. NEW ADVANCED HEAD MANUFACTURING CENTRENEW ADVANCEDHEADMANUFACTURINGCENTRE
  8. 8. NEW ADVANCED HEAD MANUFACTURING CENTRE .09“SORALUCE HAS A CLEAR TECHNOLOGICAL VOCATIONTHAT LOOKS AFTER THE PRECISION AND THE RELIABILITYAT ANY TIME. FOLLOWING THESE PREMISES SORALUCEPRESENTS THE NEW ADVANCED HEAD MANUFACTURINGCENTRE.”Running-inDesignAssemblyManufacturingVerification
  9. 9. 10. HIGHLY RELIABLE AND ACCURATE HEADSSORALUCE milling-boring heads areacknowledged as being in a class of theirown thanks to their high reliability.The broad range of SORALUCE heads(Universal, Orthogonal, Horizontal, ModularQuill, Angular, Special, etc) are distinguishedby their precision and high performance,enabling complex milling, boring, drilling,reaming and taping operations to beperformed with great accuracy.Complete design, manufacturing, assemblyand verification processes are conductedin-house, under the same roof, by anexperienced team of highly skilled designersand assembly engineers.To ensure high quality heads, theworkshop is equipped with state-of-the-art,temperature and humidity controlled, highprecision manufacturing machinery andassembly equipment.With strict in-process quality controls andexhaustive run-off on specific test benches,SORALUCE certifies the highest quality forthe most critical elements on this kind ofmachines.HIGHLY RELIABLEAND ACCURATE HEADS
  10. 10. A SHORT REVIEW OF THE HEAD AND QUILL RANGE .11Automatic angular rotary headwith manual tool changeAutomatic indexing head32 / 46 kW2.5º x 2.5º / 1º x 2.5º / 0.001º x 0.001º3000 / 4000 / 5000 / 6000 rpmFixed horizontal boring headUp to 60 kW3000 / 4000 / 5000 rpmOrthogonal head32 / 46 kW2.5º x 2.5º / 1º x 1º / 1º x 0.001º4000 / 6000 rpmNC 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 rpmA WIDE RANGEOF GENERALPURPOSEHEADS ANDQUILLSAND SPECIFICSECTOR /APPLICATIONHEADSTHAT CAN BEINTERCHANGEDAUTOMATICALLYAngular head for Railway bogiemachining5 Axis continuous head forMould and Die and AeronauticsAngular head for motor blockmachiningA SHORTREVIEW OF THE HEAD ANDQUILL RANGE
  11. 11. 12. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGET RANGEHIGH PERFORMANCE INA COMPACT MACHINE_ Long-lasting precision, resulting froma strict design and assembly process._ Optimum stiffness and mechanicalstability._ High stock removal capacity andprecision machining in one singlemachine._ Customizable machine thanks to ahuge variety of heads and optionsavailable._ Complete splash guarding._ Designed to be compact andergonomic.A SHORT REVIEWOF OUR CURRENT PRODUCTION RANGEMACHINE VERSIONSMACHINE MODELSMoving tableTA-A / TRMoving-rotary tableTA-DLONGITUDINAL TRAVEL - “X” AXIS 2000 – 2500 – 3500 – 4500 – 5500 mmVERTICAL TRAVEL - “Y” AXIS 1000 – 1250 – 1400 – 1600 – 1800 mmCROSS TRAVEL - “Z” AXIS 1000 – 1200 – 1300 mmTABLE SURFACE(TA-A / TR) 2200 x 850 mm to 5860 x 1200 mm(TA-D) 1000 x 1000 mm to Diam 1400 mmmmLOAD ON THE TABLE Up to 16.500 kg KgSPINDLE POWER 24 - 28 - 43 kWHEAD SPEED 4000 – 5000 – 6000 rpm
  12. 12. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGE .13S RANGEERGONOMIC ANDLARGE CAPACITY_ High flexibility and high precisionfinishing machining results._ High performance and efficiencyprovided by a high torque direct drivespindle motor._ A wide range of accessories can beinstalled in the work area to improveproduction capacities._ Pendulum machining, minimizingnon-productive times._ First class ergonomy and stabilitywith very low foundation cost.MACHINE MODELS SL / SPLONGITUDINAL TRAVEL - “X” AXIS 2500 – 3500 – 4500 – 6500 – +2000·n mmVERTICAL TRAVEL - “Y” AXIS 1600 – 2000 – 2600 mmCROSS TRAVEL - “Z” AXIS 1000 – 1300– 1500 mmSPINDLE POWER 43 (Direct Spindle motor) kWHEAD SPEED 4000 – 5000 – 6000 rpm
  13. 13. 14. A SHORT REVIEW ON OUR CURRENT PRODUCTION RANGEMACHINE MODELS FL / FP / FS / FR / FX / FX-RLONGITUDINAL TRAVEL - “X” AXIS 3000 – 4000 +2000·n mmVERTICAL TRAVEL - “Y” AXIS 1400 – 8000 mmCROSS TRAVEL - “Z” AXIS 1000 – 1900 mmQUILL TRAVEL - “W” AXIS Up to 1000 mmSPINDLE POWER 28 – 71 kWHEAD SPEED 4000 – 5000 – 6000 rpm_ Accurate and efficient machiningresults._ Remarkably versatile - efficiently andprecisely customised for any specificcustomer need thanks to the widerange of options available._ Large range of Automatic Heads,Boring heads, Quills and specialheads._ Low gravity centre design in all therange: improved stability and reducedfoundation costs.F RANGEPRECISION FORLARGE DIMENSIONS
  14. 14. MULTITASKINGMACHININGF-MT RANGEMACHINE MODEL F-MT RANGELONGITUDINAL TRAVEL - “X” AXIS 3000 – 4000 – 5000 mmVERTICAL TRAVEL - “Y” AXIS 1600 mmCROSS TRAVEL - “Z” AXIS 1000 – 1300 mmSPINDLE POWER 43 kWHEAD SPEED 4000 – 5000 – 6000 rpm_ Integration of several processes in one machine:traditional milling machine operations + turningcapabilities for heavy duty components, providing thepossibility of manufacturing complex components in onemachine and in one single setup._ Flexible working area that can be configured to thecustomers’ needs with one or multiple working stationswith fixed tables and rotary tables usable for both millingand turning operations._ High dynamics: 45 m/min for the X axes and 35 m/minfor the Y and Z axes, with acceleration of 2 m/s2in eachindividual axis.MILLING & BORING MACHINE .15
  15. 15. MILLING&BORINGFINALLY BOTH CONCEPTS IN ASINGLE MACHINE IS 100% REALSORALUCE has redefined the concept ofMilling & Boring thanks to its new patent,unique on the market, for a Quill changingsystem that helps combine the benefits ofthe traditional boring machines with theadvantages of modern milling machines,all in one single machine.The system interchanges the modular quill spindlewith the rest of the heads totally automatically,thus allowing different quill spindles with differentdiameters and lengths (Ø 130 - 180 mm / W: 700- 1000 mm), to be available together with all thenecessary heads to machine any component.TRADITIONAL SOLUTION SORALUCE SOLUTIONLong 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 asthe 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
  16. 16. The Dynamic CNC Ram Balance System,patented by SORALUCE, basically takes careof the geometrical accuracy –straightnessand parallelism- of the ram traverse over theY and Z axis travels, and is specially suitablefor machines equipped with extensivetraverses and a head changing system.· CNC controlledThe system is driven by a numericallycontrolled servomotor. Drive action ismeasured using a direct-measuring scalethat checks actual system response.The system is 100% controlled at any timeand in any position and with any head.· DynamicConfigurable compensation values. Tablescan be positioned anywhere in the workarea. Works for any position. Differenttables created for different heads. Realtime customised compensation.· Balance systemThe system works in both positive andnegative directions. This means thatoptimum compensation can be achievedfor a wide variety of head weights.The figures that can achieve are below0.04 mm for the ram drop in the spindlenose and 0.04 mm/m on the level over theram with any head and for a cross traverseof 1900 mm. These values are typicallyimproved with figures below 0.025 mm and0.025 mm/m respectively.IMPROVEDIN LARGE WORKING VOLUMESFOR ANY HEADPRECISIONPATENTEDWO 2010/072856ServomotorVertical Axis SaddleDamping SystemFixed roller bearingsLoose roller bearings (one DOF)Planetary reductorPlanetary roller screwMeasuring systemFigure of the DBS3 systemRAM BALANCE .17
  17. 17. 18. ACCURA HEADSThanks to the specific SORALUCEdevelopments, head articulation positioningdeviations have been reduced to aminimum. These allow for the compensationof head kinematic values and orthogonalposition offsets (M10 functions), for anyposition in the work area.Some advantages of the system developedby SORALUCE:· Calibration for any type of head.· Calibration for any position in the workarea.· Calibration for any angle, not justorthogonal.· Offset error compensation due to thermalexpansion.· Distance between different head spindlenoses is measured (machines withautomatic head changing system).· Easy-to-use interface, 100% integratedwith HEIDENHAIN iTNC530 HSCI andSIEMENS 840D SL.Equip the machine with this pack andrecalibrate the head yourself in a fewminutes whenever and wherever you want!MORE ACCURACYIN THE WORKING AREA
  18. 18. 5 AXES CONTINUOUS HIGH SPEED MILLING .19HIGH SPEEDMILLING5 AXESCONTINUOUSFV MODELMACHINE MODEL FVLONGITUDINAL TRAVEL - “X” AXIS 6000 mmVERTICAL TRAVEL - “Y” AXIS 2500 mmCROSS TRAVEL - “Z” AXIS 1200 mmSPINDLE POWER 40 kWHEAD SPEED 8000 rpmSpecially designed for high precision moulds and diesmachining, the FV high speed milling centre stands out forthe following characteristics:_ Linear motors in “X “ and “Y “ axes with acceleration of4.5 m/s2._ “X “ and “Y“ axes at 60,000 mm/min speed and “Z“ axisat 50,000 mm/min._ High dynamics._ Centered cross slide._ Giroscopic head at 5 axes.
  19. 19. 20. ADAPTIVE CONTROLThe current production scenario,unattended machining is becoming moreand more important to continue with thetendency of increasingly cost efficientprocesses.SORALUCE Adaptive Control consists ofan automatic adjustment of the definedcutting parameters depending on the realmachining situation that is permanentlymonitored by the Adaptive ControlAlgorithm integrated into the CNC of themachine.This way, when the real working load onthe spindle is less than programmed (lessmaterial than expected), the machinecan speed up the feed, shortening themachining time. By contrast, when theworking load is higher than programmed(more material than expected), themachine automatically slows down thefeed to protect the machine and theworkpiece.The technology that supports thisdevelopment is based on processing thesignals transmitted from the monitoringprocess system to the machine controlunit.This technology is indicated for roughingand semi-finishing process.OPTIMUMPERFORMANCE UNDERCONTROL· Optimum Cycle Time· Unattended machining· Increased Machine lifeHMICNCAdaptative control parameterAdaptativeControlalgorithmdrivermotor spindlePower consumptionGainWATTIMETROM
  20. 20. CYCLES DEVELOPED FOR SPECIFIC NEEDS .21Thanks to its accumulated knowledge ofthe customer’s real needs, SORALUCEdevelops and provides specific CustomMade User Cycles to facilitate programmingof repetitive machining operations beperformed in on complex components.This Custom Cycles pack includes cyclessuch as:· Pecking cycles drilling.· Tapmatic tapping.· Spiral milling by interpolation.· Conical milling by interpolation.· Radius milling by interpolation.· Chamfer milling by interpolation.Additionally, SORALUCE incorporatescycles to guarantee the precision of rotarytravelling tables:· Compensation of the rotary axis of the table.· Compensation of the tilting axis of the table.CYCLESDEVELOPED FOR SPECIFICNEEDS
  21. 21. 22. PHOTOGRAMMETRYLarge raw parts require time consumingalignment processes, even more thanthe machining process itself for highadded-value parts. Before machiningstarts, precise overstock distribution ismandatory. Alignment processes requiretwo main steps: first, characterisation ofraw part geometry, and second, alignmentto machine axes. A new raw par set-upsystem is presented, based on 3D visiontechnology, with the aim of minimising theraw part alignment process time.The new solution consits of two mainmodules: Fitting and Alignment.Fitting module (stand-alone) enablesthe fast and accurate raw part geometrycharacterisation by photogrammetry. CAMprograms are decoded for automaticallydetermine the ideal part geometry to obtainby the machining process. Optimal rawpart set-up in automatically determined,ensuring an adequate overstockdistribution. As a result, optimal 3Dcoordinates of specific optical referencesfixed to the part are determined prior to itsset-up in the machine.Alignment module (CNC integrated orstand-alone) enables the non-contactmeasurement of the optical referencesduring the alignment process in themachine, by means of a machineintegrated 3D vision based wireless system,automatically calculating the requeriredfixturing corrections for the precise raw partset-up.As a result, fast raw part fitting andalignment is possible with 1 mm precision.Main benefits of the system are:· Time savings: 70% on Fitting & 60% onAlignment processes.· Reduction of non-quality costs andIncrease of work safety.· Floor space flexibility and availability:photogrammetric raw part measurementfor fitting calculatiion, and a portablemachin-integrated visión based system foralignment.· Independence from operator skills:automatic fitting and alignment criteriaand algorithms.Machine integrated 3D visionsystemFAST PART FITTINGRAW PART SET-UPSYSTEM BYPHOTOGRAMMETRY
  22. 22. ACTIVE/PASSIVE DAMPING SYSTEM .23ACTIVE / PASSIVEDAMPINGSYSTEMNowadays, chatter is one of themain limitations of milling processes.Machine tool chatter vibrations causean unacceptable surface finish on theworkpiece reducing the life of the tooland the mechanical components of themachine.SORALUCE offers the solutions to overcomethis problem through the ACTIVE / PASSIVEDAMPING System which consisting of aninertial actuator and a sensor placed closeto the cutting point. The sensor measuresthe vibration and then the inertial actuatorproduces a force on the host structureaccording to a designed control law.The control law is selected to introducedamping in the process. The mainadvantage of this technique is that thecontroller can deal with any change in thedynamics of the system.The performed tests shows that theappearance of chatter can be avoidedin most of the cases with the ACTIVE/ PASSIVE DAMPING System and theproductivity of the milling machines areincreased considerably: the materialremoval rate is doubled.INCREASING PRODUCTIVITY750 800 850 900 950 1000 1050 1100 1150250200150100500depthofcut(%)always unstablestable with the actuatorstable without the actuatorram output (mm)
  23. 23. 24. APPLICATION CORNERAPPLICATIONSCORNER· Technological and production services:- Turnkey projects: machining processes,tools, equipment and machining.- Individualized study of each productionphase.- Analysis of cycle times with 3Dsimulations.- Analysis and optimization of productionprocesses.- Advice on machining processes.- Integral solution and investment returnstudy.- Customized software developmentdepending on the application.- CAD/CAM programming andpost-processor generation.· Training services:- Generic machine handling training.- Specific CNC training.- Advanced training in machiningprocesses:· Tools, equipment, etc.· MeasuringTURN KEYPROYECTSProcessCNCToolsMachiningTrainingVericut Fixtures
  24. 24. INNOVATION CORNER .25INNOVATIONCORNERConscious of the need to develop andinnovate its products if it is to remain amarket leader for Boring-Milling Machines,SORALUCE is backed by IK4-Ideko, the onlySpanish Research and Development Centrededicated exclusively to Machine Tools,which belongs to DANOBATGROUP.SORALUCE subjects all its componentsand machines to constant developmentat the IK4-Ideko Technology Centre. Thisensures that the design of its products andproductivity can be continually improvedand adapted to the latest technologicalinnovations.A number of research lines are continuouslyopen in order to develop new solutionssuitable for current and future needs ofthe manufacturing processes of differentindustrial sectors.During the present Innovation Days 2012,some innovations jointly developed and inpre-industrialization status will be shown inlive as:· The Volumetric calibration, to improvethe precision of the machine in the wholeworking area.· The use of the Photogrammetry, forsetting up parts quickly and accurately.· The Dardo system, to eliminate toolvibrations by measuring and modifying thecutting conditions.· The Active damping system, to eliminatethe chatter effect by the increase of thedamping coefficient of the machine.DRIVEN BY IDEAS,DRIVEN BY INNOVATION
  25. 25. PRESSRELEASE26. SORA-NEWSSORANEWSSORALUCE, which specialises in the design and manufactureof milling-boring machines and milling centres, is to invest 6million Euros strengthening its BIMATEC-SORALUCE delegation,in Limburg, Germany, with the aim of reinforcing its presence inthe country, extending its installations and projecting an imageto the world of its success in that country. Soraluce is part ofthe DANOBATGROUP, the machine tool division of MONDRAGONCorporation.Its German headquarters’ showroom is currently 1,300 m2insize, and this is to be extended by 2,500 m2in June 2012.In addition to the showroom extension, its current offices arealso to be extended by 1,900 m2, which house administrativeand customer support services (turnkey projects, after salesservice, training etc.) in order to promote its activities. But themost noteworthy aspect of the changes will be its new show-room capacity, a 10 m crane height will allow the Guipuzcoafirm to present its 8 m high machines in this market.SORALUCE has been present in Germany for 20 years, where itmanages its customer relations, accounts, installation and aftersales services, etc. Fruit of its work over the years is its installbase 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 byacquiring 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 alsobecause its technological innovations and advanced level ofautomation. These include: Modular Quill, stepless universalhead, horizontal head, special measuring probes unit, angularhead, 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 tomaintain and increase its lead in this market, and consequentlyin the rest of its export markets.The Managing Director of the Guipuzcoa firm, Rafael Idigoras,indicates that “Germany is of fundamental importance right nowin economic, political, technological and industrial terms”. Itis 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 inauguratedin 2012, SORALUCE’s 50th anniversary, for which differentevents are being organised.It should also be mentioned that the FXR-64000 is ready forintegration with a second column during phase two to optimiseplant productivity.The Cimolai group investment means yet another record: exe-cution and machining of parts 65 metres long, 6.5 metres highand 4.5 metres wide, forming part of a manipulation system tobe installed in a single industrial bay of special dimensions andcharacteristics.SORALUCE invests 6 million Euros extending its German delegation.Soraluce Italia started 2012 on the right foot in the bigdimensions milling and boring machines sector.
  26. 26. 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 anageing Butler Elgamill CNC universal bed mill, which was used tomachine castings, as well as flame-cut large plates.A key feature of the company’s work, of which 80% is exported, issmall batch manufacture parts, requiring complex machining cy-cles – batches rarely exceed four-off. The expertise of its productionengineers 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, theextensive skills of our setters and operators are key to not onlyrunning the machines, but also for tooling up, programming andfor taking complete responsibility for the manufacturing tasks.” Andin searching for a new replacement machine tool, Joy Mining wasadamant it had to allow the company to gain maximum advantagefrom the strength of its skill base.Installed in September, the SORALUCE SP 8000 has halved cycletimes and reduced tool costs on the castings and plates, while itsability to produce other components, such as large gearbox hous-ings, has also been exploited.The machine’s Heidenhain iTNC530 with conversational interfaceprovides the two setter/operators that man the SORALUCE aroundthe clock with an ideal solution to prepare and program the nextscheduled component while the machine works through the exist-ing product cycle.Says day shift operator Ean Stamp: “As cycle times vary betweenone hour to two days (four shifts), we have ample time to worktogether and incorporate our machining experience in planning thenext task, while overseeing the cycle that’s being run. This may notachieve the fastest cycle time, but ensures the part fully conformsto requirements.”After 15 months of engineering, cutting tests and negotiations,SORALUCE has achieved one of the biggest orders of its historyfrom SMS Meer, consisting of a large automated production line.SMS is a German company with a total annual turnover of EUR 1.2billion and 2,400 employees. SMS Meer is a division of the SMSgroup, world market leader in plant and machine engineering forthe industrial processing of steel, aluminium and non-ferrous (NF)metals. Through organic growth and acquisitions of other leadingcompanies, SMS Meer has developed into the leading full-lineprovider in the field of metal forming.The contract consists of an automatic production line composed of4 SORALUCE milling-boring centres which will be located in the plantat Mönchengladbach. Additionally two milling-boring machines willbe installed in this plant, one of them for operator training.Based on a 50-acre site, the 250-employee company producescomponents 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 arange of large valves.As part of the justification, Ward CNC had to ensure the machinemet the specific requirements of Joy Mining’s management teamagainst five other competitor machine suppliers.In addition, other key elements in the selection, justification andpurchase of the machine included its ability to operate in a self-contained, cell-type environment, as well as the pedigree of thebuilder 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 samplesof Hardox high strength and impact abrasion conveyor machinery.DEMONSTRATED SAVINGSSince installation, the machine has demonstrated overall savings ofsome 50% on milling and, in particular, drilling cycles, plus provideda significant reduction in tool costs, as a result of its inherent rigid-ity. Says Mr Wilks: “We very rarely have to change inserts, which ishelping 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 Performaxindexable insert drills to be used for the first time as a test bed forthe tooling supplier. Holes in brackets between 10 and 70 mmdiameter, and bores up to 90 mm diameter have been producedfrom solid, employing the 20-bar through-the-tool coolant pressure.The SP 8000 also features adaptive feed control, DXF downloadand 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 Aachenplant, a bed type milling centre and a multitasking F-MT machinefor milling/turning large size components in the same machine inthe same setup.The challenge of the project is based on integrating the SORALUCEmilling-boring machines into a flexible machining cell integratingboth an automatic parts feeder and a centralized tool managementsystem.The keys to the success of the project have been the high dynamicsof the machines, a changeable head configuration that allows morethan 96% availability and local service and technical support fromBimatec-Soraluce.SORALUCE installs a new SP milling machinein the mining sectorSMS orders large SORALUCEautomated production lineSORA-NEWS .27
  27. 27. Thisdocumentisnotcontractual.SORALUCEreservestherighttomakechangestoallmodelswithoutpriornotice.TheillustrationsinthiscatalogueremainthepropertyofSORALUCE.04/2012SORALUCEOsintxu auzoaP.O. Box 90E-20570 BERGARA (Gipuzkoa) SpainTel.: +34 943 76 90 76Fax: +34 943 76 51 28soraluce@soraluce.comwww.danobatgroup.comAT YOUR DISPOSAL WORLDWIDE WITHOUR SUBSIDIARIES AND PARTNERS.LOCAL SALES AND SERVICE SOLUTIONSADAPTED TO YOUR NEEDS.SORALUCE, S.Coop.Osintxu auzoaE-20570 BERGARA (Spain)Tel.: +34 943 769 076Fax: +34 943 765 128e-mail: soraluce@soraluce.comwww.danobatgroup.comBIMATEC SORALUCEZerspanungstechnologie GmbHIn den Fritzenstücker 13-1565549 LIMBURG (Germany)Tel.: +49 6431 97820Fax: +49 6431 71102e-mail: info@bimatec.dewww.bimatec.deRoom 826, Golden Land Building, 32LiangMaQiao Road. Chaoyang District.100016 BEIJING (China)Tel.: +86 10 6467 3639Fax: +86 10 6467 2119e-mail: info@danobat.cnwww.danobat.cnRow House No.21,Aditya Breeze Park,Survey No.1, Hissa No. 2,3,4Mauze Balewadi411045 PUNE (India)Tel.: +91 20 66 094531e-mail: danobatgroupindia@danobatgroup.comSORALUCE ITALIA S.R.L.Via Rovigo, 8935042 ESTE - PADOVA (Italy)Tel.: +39 0429 603 001Fax: +39 0429 615 497e-mail: soraluce@libero.itSORALUCE FRANCE, S.A.R.L.3, Allée Jean Image77200 TORCY - MARNE LA VALLEE (France)Tel.: +33 1 60 05 02 06Fax: +33 1 60 06 56 47e-mail: soraluce@club-internet.frSORALUCE AMERICA, INC.5301 E. State Street, Suite 20361108 ROCKFORD, IL (USA)Tel.: +1-815-315-9261Fax: +1-312-205-0358e-mail: sales@soraluce-america.comUl. Argunovskaya, 3/1129075 MOSCOW (Russia)Tel.: +7 495 7877445dgmarketing@mondragon.ruB-dul Muncil Nr. 14400020 CLUJ NAPOCA (Romania)Tel.: +4(0) 264 415 485Fax. +4(0) 264 415 487

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