1

EDITION

102011

TECHNONEWS

AND

INFORMATION

Solutions formany applicationsColgar has developed during the

last years different new machine

concepts and in the meantime it

has performed existing machine

according to customers requests.

Every final machining process

needs the right kind of machine

configuration with high flexibility

since the beginning and the

possibility of upgrading in future

with additional special heads or

tables.

OPERATOR’S SUPPORT

Every Colgar boring and milling

machine is equipped with the last

market products in particular for

the NC where all the machine

parameters are stored and where

we study and load the machine

software in house. Colgar with

the “in house” strategy makes

itself the entire main electrical

board of the machines, the wiring

on board, the main software

and all the additional interface

softwares for accessories,

for probing and for testing.

Diagnostic and teleservice are

always integrated.

In this edition

66 years of Colgar P.1

FV line – new line P.2

FRAL line – USA case History P.4

FVG line – the vertical way P.6

Press brake line – Solution for tube P.8

World activities and Bric P.10

Every year the market gives us the possibility to

choose new products or new relies of existing

product. The reason of this fast development is

to be input 100% to the final user. The final users

of the boring and milling machine are like all the

other users and for this reason in order to stay in

market for a long time with a good reputation, we

think and plan new machine components or entire

new machines

This happened to Colgar in its history too. At first, with

the manual shears and the manual press bending

machines to the first automatic machines, and later on

with a new product branc: the horizontal and hydrostatic

boring and milling machines floor type at the beginning,

and table type later with the clear target to offer to the

market flexibility with boring spindle and head changer

in easy way. From the horizontal boring and milling

machine to the vertical gantry machine the step has

been short and easy. During the last 10 years Colgar has

been entering into the market: big machining centres

with pallets from 15 ton. to 45 ton capacity and 4500 Nm

torque and max. power of 60 KW duty rates; big floor

type with vertical travel of 7.000 mm and 100 KW; new

table type and floor type machine with linear motion and

head in the centre of the column available from spindle

diameter 130 mm up to 160 mm, and vertical travel up-

to 5000 mm; vertical hydrostatic gantry machines with

a good combination of power torque and speed 1000

KW, 4000 Nm, 4500 rpm available with fixed crossbeam

and travelling crossbeam and with maximum opening

range between the column of 7.000 mm; vertical linear

motion gantry machines with fixed crossbeam, travelling

crossbeam and the configuration with fixed portal and

movable table is coming soon.

All these Colgar products are sold with minimum two

accessory heads for each machine and one rotary

table at least. The accessory heads have always been

projected and assembled at Colgar’s, and today just

several of them are standard while all the other ones

are customized, as well as the big tables up to 200 ton.

loading capacity.

NEW OPPORTUNITIES EVERY YEAR

After sales support

Colgar is supporting its worldwide

customers directly from Milan

but also from local Colgar teams

already present in Germany,

in Russia, in India, in China, in

Brazil, in USA, in Mexico.

TechnoNews Edition 10 2011

Next Main Event in 2012

•Metav@Dusseldorfforboringandmillingmachines

Colgar will be at Metav from 28/02 to 03/03 with its own both and its technical and sales team.

•Lamiera@Bolognaforpressbrakeandshears

Colgar will be at Lamiera from 09/05 to 12/05 with its own both and its technical and sales team.

•IMTS@ChicagoforbothColgarproducts

Colgar will be at IMTS from 10/09 to 15/09 with its technical and sales team and local area support.

•AMB@Stuttgartforboringandmillingmachines

For the second time Colgar will at Stuttgart to be part of this important appointment of the machine tools. From 18/09 to 22/09

•BIMU@MilanforbothColgarproducts

The largest machine tool event in Italy from 02/10 to 06/10

•BLECH@Hannoverforpressbrakeandshearsmachines.

Like every two year this will be again the most important event in the world for metal forming machine. From 23/10 to 27/10

Via Marconi, 6320010 San Pietro all’OlmoMilanoPh. +39 02936151 www.colgar.it

Colgar Quarto d’Altino Ph. +39 0422 824483

Colgar Germany Ph. +49 (0) 8231 – 9171-40

Colgar ChinaPh. +86 10 84720758

2 3

Linear motion Linear guideways achieve high

precision linear motion by using

recirculating rolling elements

between the rail and the guide

block.

Advantages of Linear Guideways:

High positional accuracy

Long-life with high motional

accuracy

High speed motion with low

driving force

Equal loading capacity in all

directions

Easy installation

Easy lubrication

Interchangeability

FV - Fast milling machines

The machining performance

achieved by Colgar customers

with the fast milling machines

of the FV line has confirmed the

high performance anticipated

during the design stage.

As always, the steel structure

represents a strong point typical of

and differentiating Colgar machines.

With its extensive experience in the

deformation sector, where Colgar

is one of the world leaders in the

construction of bending machines of

up to 3000 tons, the FV remains one

of the few boring milling machines

on the market to have monolithic

uprights with an integrated base,

a central head and angles folded

with an extensive range and not

welded. The axis movements are

made by means of roller guides

which have, by now, become an

imperative for machining centres

for three advantages which can

be summarised briefly as follows:

speedy, rigidity and simplicity which

make it possible to use them for

both rough machining and finishing

and boring.

automatically. These heads can

have mechanical transmission

up to 6000 rpm in S1 100% or

electro-spindle.

The new FV line becomes a

palletised work cell with a tool

magazine in the form of a rack

with space for 500 tools while in

the floor type version the length

of the X-axis makes it possible to

manage more than one working

area in pendulum mode.

The floor type

of the FV line

is divided into

two families, the

family FV101 and

its bigger sister

FV301, the new entry in Colgar’s

production range. While they

retain the same motorisation, the

two machines have different size

structures to guarantee different

travel along the axes.

Like all other FV models, the

FV301 has two recirculating ball

screws one on front and one on

rear side but it also has a ram

with 1500mm travel with thermal

The FV line has two versions, one

with a floor type and one with a

table type upright. The starting

point for the description of the

main characteristics of this line

of machines is the dimensions

of the structures calculated on

the basis of the frequency of the

“maximum removal” cut that they

can support combined with the

FEM analyses. Thus dimensions

are not chosen solely on the

masses to be machined but also

on the dynamics of

the masses during

machining. Indeed,

by checking mass

dynamics while

also maintaining

the concept of the

machine with a central head, the

colum of the table type machine is

significantly different from that with

a floor type upright. The boring

mill has always represented

Colgar’s core business thanks to

the spindle transmission with: two

gear ranges; the spindle cartridge

lodged inside the ram; and the

possibility of being able to replace

accessory universal indexed or

continuous heads quickly and

FV - New line and good performances.

We decided to develop this new line following the continuous development of tool manufacturers.

“Patented system

for the

management

of spindle extension”

FOCUSWIKIPEDIAA linear-motion bearing

or linear slide is a bearing

designed to provide free motion

in one dimension. There are

many different types of linear

motion bearings and this family

of products is generally broken

down into two sub-categories:

rolling-element and plane.

Motorized linear slides such

as machine slides, XY tables,

roller tables and some dovetail

slides are bearings moved

by drive mechanisms. Not all

linear slides are motorized,

and non-motorized dovetail

slides, ball bearing slides and

roller slides provide low-friction

linear movement for equipment

powered by inertia or by hand.

All linear slides provide linear

motion based on bearings,

whether they are ball bearings,

dovetail bearings or linear roller

bearings. XY Tables, linear

stages, machine slides and

other advanced slides use linear

motion bearings to provide

movement along both X and Y

multiple axis.

management of the extensions

and boring spindles between

150mm and 180mm.

The FV line has adopted

a patented system for the

management of the extension

of active feedback and an anti-

tailing system for the mills.

All full optional FV machines

are easy to manage during

production both in terms of

maintenance and operation while

also guaranteeing high levels of

precision.

It is clear that the versatility

offered by the FV line remains the

same as that offered by Colgar

with the FRAL and FVG lines: the

possibility of choosing between

the Siemens and Heidenhain

NC, interchangeable indexed

or continuous heads as already

mentioned above, chain or rack

tool magazines, tool breakage

or wear adaptive control systems

and multi-media diagnostics.

Linear motion – FV line

Horizontal type witH roller guide waysColgar type Floor type “t” typeColgar name FV 101 FV 301 FV 101 t FV 201 t

dati tecnici – Campo di lavoro specifications – Capacite d’usinagetechnical features – work range technische daten - arbeitsbereich

Corsa longitudinale Course longitudinaleHorizontal travel Längsverschiebung

mm No limits No limits Max5000

Max5000

Corsa verticale Course vertical Vertical travel Vertikalverschiebung

mmMAX 3000 5000 3000 3000

Corsa testa Course poupéeHeadstock travel Verschiebung des Spindelstockes

mm 1250 1500 Column2500

Column2500

dimensione testa Section poupéeHead dimension Querschnitt des Spindelstockes

mm 480x495 500x500 Fixed445x445

Fixed445x445

Corsa mandrino di alesatura Course brochespindle travel Bohrspindelverschiebung

mm 700 900 700 700

diametro mandrino Diamètre brochespindle diameter Spindeldurchmesser

mm 130 150÷160 130 150÷160

performances

potenza mandrino Puissance de brochespindle power Spindelmotor Leistung

kW S1 41 41 41 41

kW S6 40% 61 61 61 61

Coppia mandrino Coupletorque Drehmoment

Nm 1700 2300 1700 2300

giri mandrino Vitesse brochespindle speed Spindeldrehzahl

rpm 4000 3000 4000 3000

spinta assi Puissance de travailworking thrust Axialkraft

kN 15 30 25 25

rapidi assi Déplacement rapideFeed rates Vorschübe

m/min MAX 30 25 25 25

Components

equilibratura EquilibrageBalancing Ausgleich

HYDRAULIC

Cambio gamma velocità Change gamme vitessesgear box speeds Drehzahlbereich-Wechsel Getriebe

n° 2 2 2 2

guide Glissièresguydeways Führungssystem

LINEAR MOTION

testa automatica intercambiabile Tête automatique échangeable automatic interchanging head Automatischer austauschender Kopf

YES YES YES YES

Le caratteristiche possono essere variate e quindi non sono impegnative Specifications can be changed without notice.

Customer SupportOrder

Management

Sales & Discovery

Installation &Training

4 5

For a better project managementColgar has a big team of project

engineers, everyone focused on

different machine components

and this team is not the same of

R&D team.

After many years of work and

after many experience exhanges

with leading companies also

from other fields different

from machine tools, we have

discovered that is better to split

the idea of project. The engineer

who works on new project

cannot be influenced by other

internal problems concerning

application of valves, of switches

or other small components.

In a separate office out of Colgar

but in the same location, a new

Colgar R&D team works on new

projects perfoming the machine,

its components and calculating

the material stress using the

FEM system and other kinds of

testing softwares.

By using the 3D software the

project can be finally uploaded

and performed by each Colgar

engineer.

COLGAR USAColgar USA located in Cincinnati

offers today a very strong after

sales support with spare parts

and service.

Periodic Preventive Maintenance

is the most appreciated after

sales service for the USA

customers. The machines are

always under the control of

Colgar’s engineers also for the

geometric and laser set-up.

Colgar USA provides for entire

transport, insurance and

customs duties.

SOFTWARENewsAlready since

different months

Siemens is

pushing on its

840Dsl control where “sl” means

solution line and replaces the

“pl” version or power line. The

big difference is mainly for the

manufacturer than for the end

users who will continue to use

the control on the machine in

the same way and with the

same pages and subroutine.

Many applications from Colgar.

Every kind of material needs the right machine performance to obtain accuracy after its transformation

Hydrostatic – FRAL line

Customized solution

Maximizing

Machine Performance

Whether gaining insight into

machine conditions or precisely

controlling processes, advanced

sensors and other electronics

provide crucial information to

operators.

Asset management is a phrase

that has come to mean a number

of things. Sometimes it means a

formal and comprehensive software

solution, but it can also refer to

preventive maintenance of expensive

equipment, efforts to save energy,

and use of high-tech instrumentation

to guide machine performance.

Big equipment equals

big challenges

Smart management of industrial

machinery is essential to LeTourneau

(formerly LeTourneau Technologies,

www.letourneau-inc.com), a Longview,

Texas-based manufacturer of machines

and fabricated components for large

rubber-tired loaders used worldwide by

the mining industry, as well as jackup

rigs that drill for oil and gas offshore in

places such as the Gulf of Mexico, the

Persian Gulf, and the North Sea. The

company also makes drilling equipment

used on offshore and land-drilling rigs.

1970, has become a leader in the

manufacture of a variety of high-

quality machinery, including boring

machines. In 1999, Colgar became

ISO 9001 certified. In use at the

LeTourneau facility are two Colgar

FRAL 401 Floor Type Horizontal

Boring Mills. They are equipped with

107 HP (80 kW) spindle motors and

have 196-inch (5m) of Y axis travel.

“When researching machine tool

manufacturers for a machine that

could machine a gear box of this

size in one setup, we found very few

OEM providers,”

Le Tourneau said.

“There were none in

North America. The

Colgar FRAL 401

model seemed to fit

our need, and their

delivery was within

our expectations.”

LeTourneau purchased the first

one, a 5 meters by 10 meters, and

another, 5 meters by 10 meters, two

years later.

Exceptional reduction in

process time

A stunning benefit that the company

realized was drastically decreased

machining process time for the gear

boxes on the Colgars. Compared with

the older, smaller machines that the

“Our major structure that we machine

is a gear box for the jackup rig,”

LeTourneau machine shop manager

said. There are 12 such gear boxes

required per rig. There are four

different models, ranging in size from

up to 12 feet high to 20 feet; these

weigh up to 100,000 pounds.

“Once machined, we assemble all

the subcomponents and ship the

assembly to various shipyards such

as Vicksburg, Miss., and Brownsville,

Texas, where they are installed onto

the jackup rig. Once a jackup rig is

constructed and

moved on location,

these gear boxes

push the legs down

to the ocean door

and ultimately,

once settled in on

the bottom, raise

the drilling platform

to a working height of approximately

50 feet above the water.”

LeTourneau has five rig models

designed to operate in harsh

offshore environments, drilling in

depths that range from 300 feet to

550 feet of water.

Italian expertise plays into this

challenging production process:

Colgar S.p.A. (www.colgar.it ) based

in San Pietro all’Olmo, Italy, is a

66-year old company that, since

company had used, time was reduced

from 200 hours to 120 hours on the

largest gear box and from 60 hours to

32 hours on the smallest.

“We had expected to reduce process

time,” Shop Manager said, “but

certainly not by this amount.” Computer

numerically controlled (CNC) software

programs track production stats,

timelines, tool life monitoring, and

maintenance reminders (e.g., 1,000

hour hydraulic filter service needed),

along with fault history.

The company’s equipment has been

at work for about 100 hours per week

since installation. In order to manage

their assets and maintain that kind of

production level, LeTourneau employs

a preventive maintenance (PM)

system for weekly and monthly checks

on the Colgar machines. Additionally,

factory representatives come in

annually to perform a more thorough

check-up.

“Our shop, being 60-plus years old,

is not a controlled environment, so all

our machine tools must operate in a

rugged environment,” Shop Manager

said. “Both Colgars perform well and

have met our expectations to date.

When considering future capital

needs, additional Colgars are certainly

on the list.”

“We had expected

to reduce process time,

but certainly not by

this amount”

Machine Shop Manager,LeTourneau

Horizontal type witH HydrostatiC guide waysColgar type Floor type “t” typeColgar name Fral 401 Fral 501 Fral 601 prog 401 t

dati tecnici – Campo di lavoro specifications – Capacite d’usinagetechnical features – work range technische daten - arbeitsbereich

Corsa longitudinale Course longitudinaleHorizontal travel Längsverschiebung

mm No limits No limits No limits Max5000

Corsa verticale Course vertical Vertical travel Vertikalverschiebung

mmMAX 5000 6500 6500 3500

Corsa testa Course poupéeHeadstock travel Verschiebung des Spindelstockes

mm 1500 1500 1500 Column2500

dimensione testa Section poupéeHead dimension Querschnitt des Spindelstockes

mm 410x505 450x550 500x540 Fixed450x550

Corsa mandrino di alesatura Course brochespindle travel Bohrspindelverschiebung

mm 900 1000 1400 900

diametro mandrino Diamètre brochespindle diameter Spindeldurchmesser

mm 150-160 180-200 225-260 150-160

performances

potenza mandrino Puissance de brochespindle power Spindelmotor Leistung

kW S1 60 85 110 60

kW S6 40% 90 125 138 90

Coppia mandrino Coupletorque Drehmoment

Nm 4700 6250 15000 4300

giri mandrino Vitesse brochespindle speed Spindeldrehzahl

rpm 3000 2000 1500 3000

spinta assi Puissance de travailworking thrust Axialkraft

kN 35 40 50 35

rapidi assi Déplacement rapideFeed rates Vorschübe

m/min MAX 20 15 15 20

Components

equilibratura EquilibrageBalancing Ausgleich

MECHANICAL HYDRAULIC

Cambio gamma velocità Change gamme vitessesgear box speeds Drehzahlbereich-Wechsel Getriebe

n° 2 2 2 2

guide Glissièresguydeways Führungssystem

HYDROSTATIC MOTION

testa automatica intercambiabile Tête automatique échangeable automatic interchanging headAutomatischer austauschender Kopf

YES YES YES YES

Le caratteristiche possono essere variate e quindi non sono impegnative Specifications can be changed without notice.

6 7

Double set-upA long axis is always an

advantage for double set-up

and pendular machining.

The cost of investment is high

but the difference to extend the

X axis does not influence a lot

the final price.

When the double set-up is

available on gantry machine

the fixed floor plates are divided

in two areas using electrical

switches and phisical wall.

The switches are used to delimit

the working area and the wall

with windows is used to ensure

the set-up area. The operator

from his cabin decides the

working areas and, by removing

manually the wall, can use the

entire length of the floor plates

as a 3° area.

5 axisAerospaceThe 2 axes continuos head in

combination with the 3 axes

machine gives the possibility

to work form and special angle

surface.

The aerospace industries are

familiar with this application

for composite, aluminium and

titanium. In the first and in the

second case, the main customer

request is the accuracy, but in

the third case the accuracy is in

combination with the rigidity.

A subsidiary company of China

Aviation Industry Corporation

selected Colgar for its final

performances.

Solution

Gantry or notgantryGantry is a machine fitted in

a hoist trolley and can move

horizontally on a rail or pair of

rails fitted under a beam through

columns. At top of the column

the beam is the floor and it can

also move in vertical direction

changing the gap to the floor.

Not gantry is a similar machine

but the portal is fixed to the

floor and configurated with the

table which is moving under the

beam with longitudinal travel.

This machine is better called

Plano Mill.

Milling, turning or multitaskingThe multitasking machine

or better the apparent

simultaneous performance of

two or more tasks, is always

more and more requested.

The large components located

under the gantry machines can

be milled and turned using the

same machine, reducing the

set-up time. However in this

configuration the main spindle

is the machine spindle when the

milling operations are requested

and it changes into table spindle

when turning operations are

requested.

At least two different heads

will be used and double tool

changer for high flexibility.

The “mechanic world” is moving fastinto big sizecomponents.

Machine like the vertical FVG Colgar gantry joints together a lot of functions and quality.

Gantry – FVG line

Easy work piece set-up

HydrostatiC gantry typegantryFVg 40 Colgar type gantry

FVg 60gantryFVg 80

dati tecnici - Campo di lavoro Specification - Capacite d’usinagetechnical features - work range Technische Daten - Arbeitsbereich

6000÷30000 mm Corsa longitudinale del portale - asse X Course longitudinale du portique - Axe Xgantry travel - X axis Längsverfahrweg des Portals - X-Achse mm 6000÷30000 6000÷30000

3500÷5000 mmCorsa trasversale utile del carro sulla traversa - asse y Course transversale utile du chariot d’usinage sur la traverse - Axe Y useful transversal travel of machining saddle - y axis Querverfahrweg des Querschlittens auf dem Querbalken - Y Achse

mm 4000÷5400 5800÷8800

1500 mmCorsa verticale della testa - asse z Course verticale de la poupée - Axe Z

Vertical headstock travel - z-axis Vertikalverfahrweg des Spindelschlittens - Z-Achse

mm 1800 2000÷2500

1500÷2500 mm OPTIONtraversa mobile - asse w Traverse mobile - Axe W

Movable saddle - w-axis Beweglichem Querbalken - W-Achse

OPTION mm 1500÷2500 2000÷3500

2700÷4200 mm passaggio tra i montanti Passage entre les montantsdistance between columns Durchgang zwischen des Ständern mm 3700÷6200 4300÷7300

2000÷3500 mm larghezza dei piani di staffaggio Largeur des taques porte piècesFloor plate width Breite des Aufspannplatten mm 2500÷5000 3000÷6000

8000 Maxmm OPTION tavola mobile Table mobile

Movable table Beweglichem Tisch OPTION Maxmm 8000 8000

1500÷2000 mm passaggio sotto mandrino Passage sous brocheClearance under spindle Durchgang unter Spindel mm 2000÷2500 2000÷5500

500x500 mm sezione testa Section broche Headstock Spindelstock mm 420x420 580x580

performance

45 kW S1potenza motore mandrino Puissance moteur de broche

spindle motor power Leistung des Spindelmotors

kW S1 60 80

60 kW S640%

kW S640% 90 100

2300 Nm Coppia massima Couple maximum Max. torque Max. Drehmoment Nm 3300 8000

3÷5000 rpm Max velocità di rotazione del mandrino Vitesse de rotation de la broche maxMax spindle rotation speed Spindeldrehzahl max rpm 3÷4500 3÷3000

15 kN spinta - asse z Poussée - Axe Z thrust - z-axis Vorschubkraft - Z-Achse kN 30 40

25 m/min rapidi assi X-y-(z) Déplacement rapides X-Y-(Z)Feed rapid X-y-(z) Eilgänge X-Y-(Z) Achsen m/min 20 15

Components

HYDRAULIC equilibratura Equilibrage Balancing Ausgleich HYDRAULIC

2 n° Cambio gamma velocità Change gamme vitessesgear box speeds Drehzahlbereich-Wechsel Getriebe n° 2 4

LINEAR MOTION guide Glissières guydeways Führungssystem HYDROSTATIC MOTION

YES testa automatica intercambiabile Tête automatique échangeableautomatic interchanging head Automatischer austauschender Kopf YES YES

Le caratteristiche possono essere variate e quindi non sono impegnative Specifications can be changed without notice.

“Colgar uses

FVG 60 to work

with high degree

of precision”

The purchase of technologically

advanced products is today a

business imperative irrespective

of the reference market involved.

The solutions adopted by

Breton are of the highest quality

available in its industrial sector.

To maintain its advantage over

its competitors, Breton uses

Colgar’s FVG60 vertical gantry

type milling machine.

Guaranteed precision

The precision required in some

markets segment such as, for

example, aerospace, means that

machine tool manufacturers are

required to use the greatest possible

care and attention in machine

construction. We are always talking

about machines manufacturing other

machines.

Who is at the first step of this supply

chain has often to face with orders

making demands in terms of quality

and precision which are almost

unthinkable.

Sharing skills

This is the situation Breton found

itself in, where Colgar has recently

installed a Gantry machine FVG 60.

Already a market leader in the sector

for the production of machines for

online analysis of the force of the

ram during its working stage and

the third for viewing the area where

the work is being effected. All the

tools are stored in a magazine rack

running along the entire length of

the machine’s X-axis, 250 tools each

weighing 50 kg with Big Plus flanges.

The automatic accessory head

replacement system allows the

machine to be ready to possible

changes in production with great

speed. One of the

most advanced

features of this

FVG60 is the

hydrostatic support

along all sliding

guides which, thanks

to the 0.02mm film

of oil controlled by thermal-regulators,

allows it to reach a maximum speed of

25m per minute. This is the maximum

that can be achieved with hydrostatic

machines, maintaining precision over

the years without exerting too much

force on the machinery. The ram is

also hydrostatic, entirely wrapped on

its four corners and so completely

guided in its outwards movement up

to its maximum extension of 1,800mm.

A 60 kW motor, through gear box,

machining stone, in recent years it

has also experienced success in the

machine tool sector.

Colgar’s FVG60 is a machine able to

achieve a level of performance which

would otherwise be impossible.

Colgar uses this machine to work

with a degree of precision, reliability

and positioning times which are still

extremely competitive and can be

set up with a mobile cross-beam, a

rotating table and many accessory

heads for rough

milling, finishing and

grinding.

The FVG60

installed in Breton

has a wide passage

between columns

combined with a considerable

working length along the X-axis.

The working area made with floor

plates cover a surface measuring

3,500 x 18,000 mm, all levelled

with a tolerance of one hundredth

of a millimetre. The space between

columns is 4,700 mm with the

distance under the spindle of 2,200

mm. The machine is also fitted with

a high-performing control panel with

three monitors, one for viewing the

currently-running program, one for

makes possible to reach 4500 rpm

both on the main spindle and on the

accessory heads with a maximum

torque of 2500 Nm.

A device compensating the central

curve of the cross-beam has been

installed in order to correct the portal

structure based on the temperature.

Important details

On machines of this size with a weight

of 100 tons, Colgar guarantees

that the axes in movement will

be perpendicular to a precision

of 0.05mm per 500mm and that it

will maintain a straight line with a

precision of 0.01mm per 1000mm.

The maintenance of such precision

over time can also be attributed to the

technical solution used by Colgar and

immediately appreciated by Breton: a

safe and clean working area thanks

to the covering of the foundations on

the X-axes beds with self steel tapers

specifically and securely fixed at their

base to the foundations.

The machine seems to float on

the floor, the milling chips are

easily removed and the hydrostatic

elements are further guaranteed

by an additional folding protection

which slides over the beds under the

telescopic protection.

8 9

Synergies and support for growing

Either in case of chip removal

or of sheet metal working, the

solutions proposed by Colgar

are based on technology and

services aimed at improving

the quality and the productive

process of the user.

FEMallows detailed visualization of

where structures bend or twist,

and indicates the distribution

of stresses and displacements.

FEM software provides a wide

range of simulation options for

controlling the complexity of

both modeling and analysis of

a system. Similarly, the desired

level of accuracy required and

associated computational time

requirements can be managed

simultaneously to address

most engineering applications.

FEM allows entire designs to

be constructed, refined, and

optimized before the design is

manufactured.

Flash

Once the positionof the material is acquired by

the back gauges, the bending

cycle starts with the automatic

calculation of the bending

distances for the Y1 and Y2

axes based on the thickness

of the material, the angle to be

obtained and the tools utilized.

A “tandem” for bending 18 msheet metal

Colgar has built an impressive bending installation composed of two synchronized PIS 160.71/91 TAC hydraulic bending presses placed in tandem, each of 9,100 mm, for a total of 18 m maximum bending length.The machines have been installed at the largest Chinese train manufacturer’s facilities for bending sheet metal for carriages in a single piece.

Press brake – 1600 Ton. Tandem

“The Dalian

bending parts

requires high

structures machines”

For some time now, Colgar has

been concentrating its efforts

on largescale bending presses

as part of its production range;

complete installations built ad hoc

for the specific needs of users. The

success of the strategy has been

demonstrated by the impressive

bending installation that the

company from San Pietro all’Olmo,

Italy, has manufactured for the

Dalian Locomotive & Rolling Stock

Works, the main Chinese train

manufacturer.

Carriage components

in a single piece

The installation concerned is composed

of two synchronized PIS 160.71/91 TAC

hydraulic bending presses placed in

tandem, each of 9,100 mm, for a total

of 18 m maximum bending length and

a force of 3,200 t. A length that will allow

Dalian Locomotive to make carriage

components in a single piece (from 10

to 18 m), thereby reducing machining

times and production costs.

Optimal bending results

from the very first piece

Returning to the specific application,

the greatest problems were related to

handling the sheet to be bent in front

of the presses, which, as seen, are of

such size and weight as to require the

use of front support lays to move the

automatic control of the bending angle

provides the possibility of changing

the material’s characteristics relatively

easily because the numerical control

unit automatically up-dates the related

data so as to be able to compensate

the elastic return

detected by the three

laser sensors that

form the automatic

system.

FEM technology

is at the base of the “intelligent

structure”

The Dalian bending parts requires high

structures machines.

During design development we made

use of innovative FEM technology

(the checking of structural calculations

using the finite element method) to

establish the dimensions of the folding

press. In this way we were sure of its

behaviour under stress, a decisive

aspect for the control, and automatic

compensation, of deformation”.

The structures of both the PIS160.71/91

material up against

the sensor-equipped

back gauges with

the use of motorised

pushers; the back

gauges then provide

input to the numerical

control unit, which

acquires the starting

data and starts the bending cycle.

Each of the two bending presses is

equipped with a back gauge with two

independent turrets, each with 3 axes

(X/Z/R), so as to ensure maximum

flexibility of use, including the possibility

of using the machines

individually.

The most prominent

characteristic is

represented by the

utilization of a laser

control system for the

bending angle, which assures optimal

bend results right from the first piece,

eliminating unnecessary bending tests

and, above all, substantial economic

losses considering the importance, also

in cost terms, of the sheet to be bent.

Once the position of the material is

acquired by the back gauges, the actual

bending cycle starts with the automatic

calculation of the bending distances

for the Y1 and Y2 axes according

to the thickness of the material, its

physical characteristics, the angle to

be obtained and the tools utilized. The

TAC bending presses have been

designed with the aid of finite elements

technology and built with a “multilayer”

construction method, in which the

thickness of the structure varies from

one point to another according to the

work stresses acting on it.

A perfect knowledge of how the

machine deforms under load and

its critical points has allowed the

designers to create a “made-to-

measure” structure, modulating the

thicknesses on the basis of a high

overall rigidity closely linked to its

use. The result is two heavyweight

machines (each with an approximate

mass of 228,000 kg) and, above all,

“optimized rigidity”; one can rightly

speak of “intelligent structure”.

The independent pumps

calibrate the flow of oil

during bending

Another constructional characteristic

of these folding presses (which can

each exert a force of 16,000 kN and

with a space of 7,100 mm between

the uprights) is the synchronized

hydraulic system (Colgar patent)

with two variable-flow servo-

assisted pumps with greater than

95% efficiency and a structure built

according to the “TAC” method, based

on the use of profiled bars with variably

inclined planes positioned directly

below the die table, allowing automatic

compensation of flexure during bending.

The machines are equipped with a

automatic correction of bending flexures.

Long-term precision and reliability are

guaranteed, while the installation has

been conceived to allow high flexibility,

particularly appreciated by operators

involved in processing different materials

every day.

The ram down stroke, work and up

stroke speeds are 80, 8 and 80 m/min

respectively. The ram can be inclined

with respect to the bed plane by up to

±30 mm and has a maximum travel of

800 mm, while the gap in the uprights

is 1,010 mm.

The variable-opening “die table” system

is quite innovative. It is composed of a

“container” made of high-grade steel

and a series of blocks and spacers

that, opportunely employed, determine

the width of the slot to be used. The

minimum and maximum slot widths

are determined on the basis of the

processing requirements; in this

case, 60 mm (minimum) – 250 mm

(maximum).

The integrated safety systems include

laser barriers to ensure that personnel

are not present in the working area

during the sheet-bending phase.

3000 ton. 16 meters

10 11

Large Press Brake and STEEL TUBE application.

The main Colgar business has

today moved into large size of

press brakes up to 4000 ton

stand alone machine or even

more in tandem.

THICKNESS: 50,8 mm.

DIAMETER: to be defined.

LENGTH: 12.200 mm.

MATERIALS: Duplex – Super

duplex – AISI – Titanium

Colgar and BRIC

BRIC is a grouping acronym

that refers to the countries

of Brazil, Russia, India and

China, which are all deemed

to be at a similar stage of

newly advanced economic

development.

Colgar is working on BRIC with

different strategy according

the local rules and habit. The

presence of Colgar is always

direct and include minimum first

line after sales service support.

COLGAR WEB

Just online, it is new, friendly

and usefull to check what Colgar

does, where Colgar is.

The new web page of Colgar

includes a lot of information,

photos and videoclips of

machines applications and

single components. In an easy

way all the Colgar activities can

be visualized on your computer

with a simple double click.

The new web page includes

also the application for iPhone

in order to be always connected

everywhere and every

minute. You can send us your

request through the webmail

and customers will have the

possibility to download or check

with personal ID and PSW their

order summary and their lay-out.

CRMCustomer relation management

is also a new internal Colgar

instrument to improve

chronology of customers

activities, offers, requests for

new machines and spare parts.

Huge installation of big machining centres

Colgar – Brazil

With a great support of a local

customer and partner MAUSA,

that has decided to come into the

business of machine tools with Colgar

technology and its total support,

the business of boring and milling

machines are increasing. Only 30%

of each machine manufactured in

Mausa is imported from Colgar.

The advantage for the end user is

now to become more competitive

buying a last boring and milling

machine tool technology available

on the world market without paying

the high import taxes. The financing

of COLGAR- MAUSA machines

is made through the line of credit

Finame BNDES (Banco Nacional

do Desenvolvimento) regarded as a

thermometer of the economy; it has

increased by 146% in the first two

months of this year compared with

the same period of 2009.

Colgar – China

Colgar China in Beijng is growing

every year more and more.

Actually an Italian Team for sale

and after sales is living in China

for a direct connection with the

customers.

The orders for Colgar are coming for

both the divisions of metal cutting

and metal forming. The Chinese

customers often have new buildings

to fill in with every kind of machine

tools and both Colgar divisions

became interesting for them. Actually

all the product range is installed in

China for every kind of application

energy, aerospace, automotive –

trucks, mining, chimical. The decision

of Colgar to improve the local

support has given the possibility to

consolidate its tournover despite the

negative world market situation of the

last years. Colgar has signed also

an agreement to supply stand alone

technology components.

Colgar – Europe

Europe and mainly Germany is

still the strategic market for high

technology machinery as Colgar

manufacturers.

Colgar Germany in Koenigsbrunn

has been the first Colgar experience

out of Italy. Colgar learnt how to

manage the sales activities and how

to support the customers during

the warranty and after the warranty

period often proposing the preventing

maintenance programs.

Liebherr, Voith, SEW, Sennebogen,

Weir, Bucyrus, Ruukki, are just a

few of the main important Colgar

customers. Thanks to the future

visions and the production managers

ideas, Colgar boring and milling

machines have added every day

small details that finally make the

difference between high quality and

standard quality machines. More than

90% of Colgar machines in Europe

are with boring bar.

Colgar – Italy

Domestic market is always an

important market because the

Italian industries are still keeping

the desire to be a world leader in

their field.

With the increasing tournover coming

from the boring and milling machine

business Colgar is still investing mainly

in training for all the internal division

and in new projects. The old building of

Colgar located in Quarto d’Altino near

Venice is now 80% autonomous for

assembly and testing the boring and

milling machines of the FV line. With

the support of Cimsa also, a subsidiary

Colgar company near Milan for the

production of automatic punching

lines, the division of accessory heads

is growing for Colgar proper use and

for future support of other company.

The Colgar headquarters in San

Pietro all’Olmo, in the middle of small

village, is always open to you!

Colgar – Russia

Since beginning of 2000 Colgar

started to improve its presence

on the Russian market.

A lot of press brakes and shears

are now installed and the boring

and milling machines are now

more requested with different

configurations. Colgar has its own

team Russian speaking to support

and easy follow the commercial,

the transports and the imports

phases of the orders . It is expected

that by 2013-2014, the majority of

Russian machine tool equipment

will “turn into scrap.” According

to the Russian government, it is

estimated that the growing demand

will require procurement of 700,000

new machine units by 2015. Industry

experts say that Russian end users

are appreciative of new advances in

technology to optimize and facilitate

production processes.

Colgar – India

Punj Lloyd signed a big order

for gantry type machine with

movable crossbeam, two 5axis

continous head one for roughing

and one for finishing operation

opening the right way for Colgar

into this market.

Punj Lloyd is an engineering and

construction group in India providing

integrated design, procurement and

project management services for

energy and infrastructure sector

projects. Punj Lloyd operations

are located in the Middle East,

the Caspian, the Asia Pacific, the

Europe, Africa and South Asia. Punj

Lloyd has 50+ subsidiaries and has

executed upwards of 200+ projects

in 20+ countries. Its main offices

are in Gurgaon, Haryana and its

stock is listed on the Bombay Stock

Exchange and also on National Stock

Exchange.