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CNC Machining of a Lamborghini

CNC Machining of a Lamborghini

by | Mar 4, 2025 | Expertise

CNC machining of a Lamborghini Huracan Evo 2 Super Trofeo model Collaborative project demonstrates machining strategies for complex parts Blaser Swisslube, in collaboration with its industry partners, embarked on a unique and ambitious project: CNC machining a model of the Lamborghini Huracan Evo 2 Super Trofeo race car . This endeavor was carried out alongside Nigel Bailly, a Blaser-sponsored racecar driver in the international Lamborghini Super Trofeo Series. “From the beginning I thought this was a superb idea! The challenge to match the car and machine it at 1/8 scale shows the amazing abilities of the team at the Blaser technology center. I’m so excited to see this piece of art in person!” said Bailly. The partnership brought together machine tool OEMs, fixture and tooling suppliers, and software and programming experts. Each company contributed technology and expertise to over 40 projects in the past year. The collaboration culminated in this exciting Lamborghini video project, shared across social media platforms, reaching a wide audience of machining and metalworking enthusiasts. The Lamborghini was modeled and programmed using hyperMILL 2024 software from Open Mind Technologies. One month of designing and programming Blaser’s in-house machinists began by analyzing photos and videos of the racecar. Using hyperMILL software from Open Mind Technologies, the team meticulously modeled the car and developed the program required to machine it from a solid block of 6082 aluminum. Tool path clearance was a particular challenge. The 2024 release of hyperMILL saved enormous amounts of time by seamlessly linking CAD functionality to CAM programming. The intricate process involved one month of designing and programming, ensuring every detail of the race car was accurately captured.   Achieving complex angles, precision and realistic surfaces Once ready, the material was loaded into a GF Mikron Mill (E 700 U) at the Blaser technology center. The 5-axis GF mill, equipped with a tilting, rotating table with a range of -65° to +120°, was essential to achieving the required precision and complex contours of the car. Workholding was also tricky due to the model’s intricate shape and small size. Gressel AG provided a modular C2.0 series centric vise system offering maximum versatility while maintaining complete stability of the workpiece – imperative for achieving complex angles and precision. Specialized tool holders were applied to various tasks. The...
Blaser examines every chip in detail in an innovative series of tests

Blaser examines every chip in detail in an innovative series of tests

by | Nov 8, 2022 | Expertise

Blaser examines every chip in detail in an innovative series of tests The macro high-speed recordings are impressive: Viewed in slow motion, a carbide milling tool removes a perfectly shaped brass chip. The Blaser Synergy 735 metalworking fluid becomes cloudy around the curling chip – exactly where the heat is greatest. It leaves an oil-like phase and thus forms an even more effective lubricating emulsion. In an extensive series of tests in the in-house Technology Center, the metalworking fluid experts from Blaser Swisslube analyze machining processes down to the finest detail. The principle: To achieve better metalworking fluids faster through expertise and data. The idea of capturing the machining process, chip formation and the behavior of the metalworking fluid more precisely than ever before through photos and videos came about as part of a joint project with the renowned ETH Zurich. The research and development team at Swiss metalworking fluids experts, Blaser Swisslube, set about the planning and implementation. The use of a high-speed camera with a macro lens, which is placed behind a sight glass to keep the metalworking fluid at a distance, should make uniquely sharp, precise recordings possible. A ring light was used to provide the necessary light intensity, as well as a carbide cutter with a helix angle of 0° that was specially ground for this particular test. When machining titanium, the highest temperatures are reached near the cutting edge and in the chip. This is evidenced by a light-colored cloud forming around the chip. (Image: Blaser Swisslube) The results are fascinating: The high-speed recordings showed for the first time that the mechanism of action of oil-free, water-soluble metalworking fluid, Synergy 735 – namely its improved lubricating effect at higher temperatures – also occurs during machining and is fast enough to optimize milling processes. Synergy 735 thus changes its properties and adapts to the machining process like a chameleon.  Brass Comparsion Synergy 735 blue brass “Our Technology Center allows us to take a closer look than our competitors. This focus on all the details and the cooperation between our chemists and the machining experts enables us to develop metalworking fluids that improve processes sustainably, reduce production costs and prolong tool life,” explains Marc Blaser, CEO of Blaser Swisslube. As the Synergy 735 metalworking fluid used in the test described cools down, it becomes clear again,...
Technology speeds development of highly effective metalworking fluids

Technology speeds development of highly effective metalworking fluids

by | Jan 15, 2022 | Expertise

Technology speeds development of highly effective metalworking fluids Technology Center in Switzerland Blaser Swisslube’s experts are bringing efficient coolants to market. But not before the products are subjected to in-depth performance tests at the Blaser Swisslube Technology Center. The testing equipment now includes a microscope camera for measuring tool wear and the spike sensor system from pro-micron for measuring cutting force. This allows for faster collection of meaningful data that is of benefit to the user. How do you end up with an optimal coolant? Often more than a dozen ingredients are required, including oils, emulsifiers and additives. These sophisticated formulations from Research & Development are combined with the manufacturing expertise of machining technologists. Blaser Swisslube has relied on the collaboration between both disciplines for some time now. “Only if our chemists are able to get to know the coolant on site as part of a performance test and then interpret the data acquired by the manufacturing technologists, are we able to make great progress in coolant development,” explains Marc Blaser, CEO of Blaser Swisslube, with respect to the process. Blaser’s Competence Center Blaser Swisslube’s inhouse Technology Center has been undergoing gradual expansion for more than 10 years. Currently, the facilities house six CNC machines, including a state-of-the-art grinding machine, and cover an area of more than 1,500 m2 (16,000 sq ft). New developments are tested here, and customers’ production situations are simulated under close-to-reality conditions. In order to carry out meaningful wear tests and interpret the acquired data correctly, Blaser Swisslube depends on highly precise measuring devices and sensors. Key parameters here are the flank wear (vB,max) and the maximum cutting force (Fmax). The flank wear is now measured in a fully automatic process directly in the machine by means of a wear camera. The cutting force is measured directly in the tool holder using the spike sensor system. Get to the bottom of tool wear Dr. Linus Meier and Tobias Mathys discussing the test results Meaningful data collection “With this machine, we can feel out the tool wear,” says Tobias Mathys, Process Engineering Manager at Blaser Swisslube, with a smile, pointing to the Technology Center’s DMG Mori NVX 5060. This CNC machine is dedicated to coolant development at Blaser. It is equipped with a wear camera — an industry camera that is protected...
The metalworking fluid turbo for the automotive industry

The metalworking fluid turbo for the automotive industry

by | May 29, 2021 | Expertise

The metalworking fluid turbo for the automotive industry Everyone in the automotive industry is talking about emission values and downsizing of combustion engines right now. In order to accelerate basic research in the field of turbocharger manufacturing, Blaser Swisslube, in collaboration with their partners, have carried out extensive tests at the company’s own Technology Center. The automotive suppliers and sub-suppliers are extremely interested in the findings, especially the savings potential. The diesel scandal surrounding the manipulated emission values is still lingering in people’s minds. The CO2 requirements in Europe are ambitious. By 2020, output is to be limited to 95g CO2/km. Downsizing is a hot topic for the automotive suppliers. Turbocharger boosts help whip the engines into shape with low displacement. When it comes to passenger vehicles, the turbocharger production numbers are expected to increase to 60 million units per year by 2020. This is an increase of appr. 27 percent, despite growing electromobility. But the production of turbochargers is very complex. Stable and reliable processes as well as high productivity are crucial. Tests carried out at Blaser Swisslube’s own Technology Center in Switzerland have clearly demonstrated what can be achieved with carefully planned processes and the right metalworking fluid. Tool life increased from 1,200 to 2,000 drills In 2013, Blaser began to carry out tests together with a leading tool manufacturer in the field of turbine housing machining. This involved machining heat resisting cast steel (1.4849, 1.4848 as well as 1.4837). The aim of the tests was to find the ideal tool/metalworking fluid combination, thus creating added value for the customer. The benchmark for the testing was drilling and face milling using original components and test components. The tools and the metalworking fluid strategy were carefully planned for each machining process. Thanks to Blaser’s Liquid Tool, the tool life of 1,200 drills was increased to over 2,000 drills. When it came to face milling, the tool life was increased to up to 25 percent for rough cutting and appr. 45 percent for finishing. Higher tool life thanks to Blaser’s Liquid Tool Basic research In close collaboration with a leading OEM in the field of turbocharger production, a further project was launched in 2017. The aim of that basic research project was to answer the following question: What is the ideal metalworking fluid strategy for machining...
Minimum quantity lubrication – Industry 4.0

Minimum quantity lubrication – Industry 4.0

by | May 29, 2021 | Expertise

Minimum quantity lubrication (MQL) – ready for Industry 4.0 Oil quantity, volume flow and pressure of the MQL aerosol can be directly taken into account in the digital process chain. This offers a clear advantage in comparison to conventional metalworking fluids. Figure 1: Good spraying behavior Effective delivery of metalworking fluids Metalworking fluids, minimum quantity lubrication and cryogenic components are complex issues. Regardless of the method, the basic objectives of the cutting industry are high process reliability and high productivity. In addition to the economic ideas, ecological aspects are playing an increasingly important role. When things work out well, they can, in turn, also offer potential savings in energy and other resources. All metalworking fluid-related lubrication methods, including MQL, have a common characteristic: continuous targeted feeding of the metalworking fluid into the cutting zone. The metalworking fluid must be delivered accurately onto the rake and flank face of the cutting tool. This can best be achieved by means of an internal metalworking fluid supply. Processes and advantages with Minimum Quantity Lubrication (MQL) The MQL process creates an aerosol comprised of an oil-air mixture. This mixture forms a protective film, which reduces the friction and directly prevents the tool’s wear. Cooling of the cutting tool is achieved / controlled by means of forced convection via compressed air, wet surfaces and evaporation enthalpy. Processes such as high-speed cutting (HSC) or high-feed cutting (HFC) are fundamental prerequisites for cutting successfully with MQL. In this case, an MQL-optimized cutting process requires smaller, constant wrap angles in order to reduce the total heat input into the tool. In recent years, there has been a significant development both in the field of MQL devices, delivery systems and the cutting tools themselves. Compared to wet machining, MQL is a more flexible application, since smaller amounts of fluid are fed. However, due to this reduction of fluid, it is imperative to pay close attention to the continuous and targeted feeding of the cutting tool with the MQL aerosol. The low energy consumption, the cleanliness of the parts and chips, as well as good material compatibility are further advantages of this method.   MQL and Industry 4.0 The integration of MQL and modern MQL systems in the digital process chain can be realized more easily and quickly than with conventional...
Research on the processing of turbine blades with minimum quantity lubrication

Research on the processing of turbine blades with minimum quantity lubrication

by | May 29, 2021 | Expertise

Research on the processing of turbine blades with minimum quantity lubrication Demo blades at Liechti Engineering on a Turbomill 1400i (turnaround time: 63min). The mass of the blank amount to: 150x70x480mm. Blaser Swisslube has carried out an extensive analysis of the milling of steel turbine blades in collaboration with GF Machining Solutions AG – Liechti Engineering and Walter AG. Conclusion: Minimum quantity lubrication (MQL) makes it possible to optimise the process and offers a savings potential when it comes to tool costs. The collaborative effort began about 1.5 years ago. Liechti Engineering initiated the project, intending to optimize the processing of turbine blades with the support of Blaser Swisslube and Walter. The blades, made of high-alloyed heat-resistant steel, are first roughened, and then pre- finished before a final finishing. The key processing phase in particular (meaning: the longest cycle time, and thus the highest production costs) was carefully examined throughout the course of the project. Blaser Swisslube’s Technology Centre During the initial tests at Blaser Swisslube’s in-house technology centre at the headquarters in Hasle-Rüegsau, X20 chrome steel blocks were milled using a GF Mikron HPM 800U – both rough-ing and finishing. The processing was carried out using a metalworking fluid, MQL, as well as dry and with pure compressed air cooling, and subsequently compared. Various cutting parameters were used. The MQL processing demonstrated its merits when it came to reduced flank wear during finishing, and the surface finish was very good as well. It therefore proved to be the ideal choice for this process. Technology Center and Competence Center of Blaser Swisslube in Hasle-Rüegsau Research results obtained by Liechti Engineering Further tests were then carried out at Liechti Engineering in Langnau. Blades were machined using a Turbomill 1400i. The results obtained match the findings made at Blaser’s technology centre. Apart from X20 chrome steel, Liechti Engineering also processed hard-to-machine X2 chrome steel in order to put the MQL process under scrutiny. Conclusion: Thanks to the MQL processing, the wear on the cutting edge is reduced and the tools have a longer life. This offers a savings potential with regards to the tool costs. Test showed that when finishing with MQL, tool wear can be reduced by a factor of up to 5 compared to metalworking fluid Result of the collaboration “MQL processing is the perfect choice for...