Info catalogue about SORALUCE Innovation Days 2012

2. 02. INDEX
INDEX
THE 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

3. 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 DREAM
COME TRUE

4. 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

5. 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

6. 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.

7. 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 P4
Plant # 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

8. 08. NEW ADVANCED HEAD MANUFACTURING CENTRE
NEW ADVANCED
HEAD
MANUFACTURING
CENTRE

9. 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. 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

11. 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 kW
3000 / 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. 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 REVIEWOF 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 mm
mm
LOAD ON THE TABLE Up to 16.500 kg Kg
SPINDLE POWER 24 - 28 - 43 kW
HEAD SPEED 4000 – 5000 – 6000 rpm

13. 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. 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

15. 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

16. 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

17. 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
PATENTED
WO 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. 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

19. 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. 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
CNC
Adaptative control parameter
Adaptative
Control
algorithm
driver
motor spindle
Power consumption
Gain
WATTIMETRO
M

21. 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. 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

23. ACTIVE/PASSIVE DAMPING SYSTEM .23
ACTIVE / PASSIVE
DAMPING
SYSTEMNowadays, 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
depthofcut(%)
always unstable
stable with the actuator
stable without the actuator
ram output (mm)

24. 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
Tools
Machining
Training
Vericut Fixtures

25. INNOVATION 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

26. 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.

27. 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

28. Thisdocumentisnotcontractual.SORALUCEreservestherighttomakechangestoallmodelswithoutpriornotice.TheillustrationsinthiscatalogueremainthepropertyofSORALUCE.04/2012
SORALUCE
Osintxu auzoa
P.O. Box 90
E-20570 BERGARA (Gipuzkoa) Spain
Tel.: +34 943 76 90 76
Fax: +34 943 76 51 28
soraluce@soraluce.com
www.danobatgroup.com
AT YOUR DISPOSAL WORLDWIDE WITH
OUR SUBSIDIARIES AND PARTNERS.
LOCAL SALES AND SERVICE SOLUTIONS
ADAPTED TO YOUR NEEDS.
SORALUCE, S.Coop.
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e-mail: soraluce@soraluce.com
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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
Room 826, Golden Land Building, 32
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100016 BEIJING (China)
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e-mail: info@danobat.cn
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Row House No.21,
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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.
3, Allée Jean Image
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.
5301 E. State Street, Suite 203
61108 ROCKFORD, IL (USA)
Tel.: +1-815-315-9261
Fax: +1-312-205-0358
e-mail: sales@soraluce-america.com
Ul. Argunovskaya, 3/1
129075 MOSCOW (Russia)
Tel.: +7 495 7877445
dgmarketing@mondragon.ru
B-dul Muncil Nr. 14
400020 CLUJ NAPOCA (Romania)
Tel.: +4(0) 264 415 485
Fax. +4(0) 264 415 487