WFL connects all machining technologies in one machine

WFL customers enjoy tailor-made solutions. Complete machining is subject to different demands today, which is why WFL is always on the ball, striving to integrate a wide range of technologies, measuring tasks, finish machining operations, gear teeth and much more into their MILLTURN complete machining centres, all to suit the customer‘s needs. Right from the very start, our motto has been “clamp once – machine complete“. That is and remains our goal. Machining operations are increasing in complexity, so we are responding accordingly and ramping up our technological processes. However, we focus on more than just the machining operation itself; we cover the entire process. And by this we mean defining the machining process, workpiece programming, simulation, production and finally, support throughout the entire service life of a machine. We want to play our part in maximizing productivity.

WFL’s objective is to always exceed its customers’ expectations in terms of quality, reliability, and efficiency. Reducing the amount of clampings decreases the risk of clamping errors and consequently improves the process quality. Embodied automatic measuring solutions ensure highest possible process quality. These measurement readings can be recorded and monitored in the WFL Process Monitoring advanced software. This helps the traceability that is required for such aerospace components.

In terms of productivity benefits customers enjoy from the implementation of WFL’s machine tools, the main advantage being the reduction in the amount of different machines required to produce a part. This reduction in complexity has many positive effects on the customers production environment. For example, less workpiece clampings, results in less complexity and simpler production planning. Furthermore, a large tool magazine helps in changeover times since all tools can be kept in the machine for different parts or different clampings. Lately highest rigidity for efficient machining of exotic alloys and the compact design of the machine, as well as the latest in-machine cutting-edge metrology in conjunction with process control software round off the total package.

Mobile Robot Solution: the mobileCELL

Automation tasks are becoming ever more challenging. Using intelligent software in combination with the relevant automation solutions not only enables workpieces to be loaded and unloaded but also means that machine tools can be set up fully automatically through automatic replacement of tools and clamping devices. Together with our automation expert, FRAI Robotic Solutions, we support customers at all stages of their project such as initial concept development as well as implementation, commissioning, and maintenance of the automated system. FRAI’s gantry robots and robot cells allow for an extensive range of high-quality automation solutions and maximum customer benefit.

Because of innovative developments and intelligent automation concepts, WFL can meet the constantly growing requirements regarding customized solutions. Our standard components are combined with high-quality purchased components to manufacture flexible solutions for small batches and high-productive series production.

The latest innovation is the mobileCELL: A generously sized automated guided vehicle (AGV) with a robot cell design with everything that you need. In other words, the robot, workpiece, and tool gripper, along with buffer positions for workpieces and tools, and the necessary control & safety technology. The machine is freely accessible. It is not blocked or obstructed. The AGV collects the required tools and workpieces in the warehouse, it then travels to the front of the machine, locks itself in place on the floor and exchanges parts and/or tools. The vehicle then moves away again and receives the travel instructions for the next machine. The space in front of the machine it has just loaded becomes clear again.

WFL software solutions

The realistic 3D simulation software CrashGuard Studio is the ideal tool for testing and optimising CNC programs after they have been created or modified. This can be done either on an external workstation or directly on the machine control unit. Thanks to the optimisation of the entire processing sequence and an error correction at an early stage, the risks of collisions and of producing scrap parts as well as unproductive run-in and down times are now a thing of the past.

This allows the use of a whole new range of potential features and thus achieves significant competitive advantages. CrashGuard Studio is the ideal supplement to any CAD-CAM software and for the WFL CrashGuard collision prevention software. Data for workpieces, tools and clamping devices can be transferred as required.

With the interactive graphics of the Millturn PRO programming software, NC programs can be created efficiently and easily, thereby enabling CrashGuard Studio to become a universal programming system for complex workpieces (without freeform surfaces). Programming can be carried out on an external programming station or directly at the control panel of the machine itself. The programmed machining operations can be checked continually and step by step in CrashGuard Studio.

The technology cycles of WFL cover an extremely broad range of standard and special technologies for all conceivable cases of application. These program modules, which only require the input of parameters, make it possible to carry out efficient programming directly on the machine control or on a PC. The program can therefore be created for both complex and simple workpieces within the shortest period.

Furthermore, we offer the appropriate technological solution for every gear cutting operation - from filigree internal gears with high accuracy requirements to large external gears, which require high roughing efficiency.

New chapter in the UK

WFL Millturn Technologies has set up WFL Millturn Technologies Ltd. UK. The UK has always been a very important market for WFL, especially in the aerospace industry. To guarantee the best possible service, continuous and consistent customer support in all market-relevant regions is particularly important for WFL.

WFL and Kyal Machine Tools have been working together for over a decade now, ensuring that customers in the UK receive the best possible service. The combination of Kyal Machine Tools' in-house expertise and WFL's technical expertise delivers the desired production solutions and provides customers with an exceptional level of service and support. The transfer encompasses Kyal employees and in turn maintains all our valuable UK business relationships.

This strategic decision aligns with WFL’s global expansion strategy and fortifies our UK market presence, ultimately benefiting our customers. The transfer of the WFL business from KYAL to WFL UK became effective from the 3^rd of November 2023.