Welding service standards in the production of mechanical components – Know-How from SIM Gdynia
High-quality welding connections are a key element in the production of mechanical components used in a variety of industries – from machinery and energy, to defense, to automotive, construction and many others. The durability and strength of finished components depend not only on the technologies used, but also on the compliance of the welding process with strict standards. At SIM Gdynia, we use proven procedures that produce repeatable and durable joints that meet the highest industry requirements – regardless of the sector in which they are used. Standards governing welding processes In order for welding processes to comply with technical requirements and meet specific strength criteria, it is necessary to apply standards governing metal joining technology, welder qualifications and quality control methods. Of particular importance in the manufacture of mechanical components are: At SIM Gdynia, we attach great importance to adhering to the above standards, which allows us to provide mechanical components with high durability and compliance with customer requirements. Our processes are supervised by certified specialists and are subject to systematic verification to ensure that each weld meets stringent quality standards. Welding technologies used in the production of mechanical components TIG welding (141) – precision and heat control TIG (141) welding produces high-quality and precise welds. By using a tungsten electrode and shielding gas, the process minimizes the effect of heat on the structure of the material. This technology makes it possible to obtain clean and aesthetically pleasing welds, which is crucial for parts with increased corrosion requirements. MIG/MAG welding (135/136) – durability and efficiency MIG/MAG (135/136) welding is used in joining low-alloy steel, where the strength of the joint and resistance to dynamic loads are crucial. This process makes it possible to achieve durable welds while maintaining high production efficiency. Materials used in the welding process In the production of mechanical components, it is crucial to use the right materials, which must meet the requirements for mechanical strength, resistance to external factors and compliance with technical documentation. At SIM Gdynia, we weld both stainless steel, which requires precise control of thermal parameters to avoid overheating and structural changes, and low-alloy steel, used in machine structures and components subjected to intensive mechanical loads. Summary Professional welding services in the production of mechanical components must meet the stringent requirements of EN ISO 15614-1, ISO 9606-1 and EN ISO 9712 to ensure the durability and precision of joints. At SIM Gdynia, we ensure that each process is carried out to the highest standards, allowing us to deliver components that meet the expectations of customers in a wide range of industries. Thanks to the use of certified procedures, we are able to carry out both single projects and larger series. Constant quality control and supervision by an experienced team guarantee that each weld is made with the highest precision and in accordance with the technical documentation.
SIM Gdynia winner of OTIF95 Supplier Performance Award from KION Group
We are proud to announce that SIM Gdynia has been awarded the OTIF95 Supplier Performance Award from KION Group for on-time and complete deliveries in 2024. The OTIF95 award is given to suppliers who consistently deliver on schedule and in full quantity. Earning this title is the result of our efficient organization of production processes, precise logistics planning and the SIM Gdynia team’s commitment to maintaining the highest quality of service. SIM Gdynia’s cooperation with KION Group KION Group is a world leader in logistics automation, integrating modern transportation, warehousing and goods flow control software systems. As part of our cooperation, we supply high-quality mechanical components that are a key element of the systems used in modern distribution centers. Precision in manufacturing, timeliness and flexibility in order fulfillment make our solutions fully responsive to the requirements of the intralogistics industry. Achieving top performer status in the OTIF95 program confirms that our processes meet the highest standards for delivery reliability, which translates into stability for the KION Group’s supply chain and their customers around the world. Acknowledgements and commitment for the future We would like to thank the KION Group team for the award and our employees for their commitment and consistency in the pursuit of operational excellence. It is thanks to their collective efforts that SIM Gdynia has been ranked among KION’s top suppliers. For us, the OTIF95 award is not only a source of pride, but also a commitment to continue improving our processes to maintain the highest level of service and meet the expectations of our partners. We are not slowing down – we continue to work to maintain and further improve our delivery standards.
CNC machining of rims, gears and other large-size and complex parts.
Large-sized workpieces such as large rims, discs or gears place special demands on technologists and machine operators. Cutting large surfaces with relatively small widths is sometimes problematic due to stresses that can lead to undesirable deformations and difficulties in achieving part stability. However, proper cnc machining with the right machine tool can optimize the process, guarantee high dimensional repeatability and minimize the risk of errors. Challenges in CNC machining of large-sized parts. Hoops with large diameters yet small widths require precise clamping and balancing to avoid vibration during operation. Machining with suitable CNC lathes allows these tasks to be carried out efficiently, while maintaining stable parameters over the course of successive production runs. CNC lathe for large-size parts – the genesis of SIM Gdynia’s investment. In 2021, we decided to expand the technological capabilities of our company by purchasing a CNC lathe that would meet the requirements of large-format machining. The machine tool was to make it possible to cut parts with a diameter of more than 1 meter and weighing several tons. Such parameters turned out to be indispensable in the production of large-format components used in hydraulic, mining and other heavy industry sectors. Characteristics and specifications of the GV-1100 CNC machine tool. The purchased lathe model GV-1100 is equipped with a table with a diameter of 900 mm, which allows the machining of parts with a maximum diameter of up to 1,100 mm. The machine tool is capable of handling workpieces weighing up to 4,000kg, which is completely sufficient for machining parts of considerable dimensions. At the heart of the machine is a spindle with two gears, offering speeds from 1 to 500 rpm and a torque of up to 10,170 Nm. The 37 kW (continued) / 45 kW (30 min) main drive guarantees smooth operation, even during intensive material removal. An additional advantage is the presence of the C-axis (motor output 3 kW), with which more complex operations can be performed, such as milling outlines on the workpiece. The lathe has an X axis that allows travel of up to 1,300 mm (in the range -100 ~ 1,200 mm) and a Z axis with a stroke of 900 mm. Depending on your needs, it is also possible to use the W axis, which has a stroke of up to 600 mm. Servo motors of 7 kW (X-axis) and 9 kW (Z-axis) provide adequate dynamics and precision of movements, and the feed rate reaches 12 m/min in the X-axis and 10 m/min in the Z-axis. The machine is equipped with a tool magazine with a capacity of 12 pieces (taper BT-50), which makes it easier to carry out machining processes without frequent manual tool changes. The maximum tool weight reaches 50 kg, which allows the use of robust cutting heads. The whole machine is controlled by a FANUC Oi-TF Plus system, ensuring high repeatability and positioning accuracy, which for the X and Z axes is ±0.007 mm per 500 mm. Machining process – stages of operation. Preparing a workpiece for cnc machining first requires proper clamping and fixing the base. Then the operator selects the optimal cutting parameters, taking into account the dimensions, shape and material of the workpiece and the planned number of cycles. Due to the large size of the workpiece, it is sometimes necessary to gradually increase the spindle speed or feed rate so as to reduce the risk of vibration. At the final stage, quality control is carried out, including verification of dimensions, shape tolerances and surface evaluation. Summary. Cutting large-size parts requires specialized machines that provide power, stability and an adequate working range. The GV-1100 lathe purchased in 2021 allows machining parts with diameters of up to 1,100 mm and payloads of up to 4,000 kg, which has greatly expanded SIM Gdynia’s machining capabilities. All this makes the machining process for the most demanding large parts run smoothly and allows to achieve the desired quality parameters, regardless of the industry in which the workpieces are finally used.
CNC machining of shafts and workpieces – the role of grinders in achieving perfect concentricity.
CNC machining of shafts and workpieces requires high dimensional accuracy and appropriate geometric tolerances. Particularly important is concentricity, on which the smooth and trouble-free operation of rotating components depends. Metal grinding plays a key role in achieving the desired results, thanks to which perfectly smooth surfaces can be achieved and radial and overall runout can be reduced. The importance of concentricity in CNC machining. Coaxiality is a parameter that determines whether the axis of rotation of the workpiece coincides with the axis of the reference system along its entire length. Even slight deviations can lead to increased vibration, faster bearing wear, trouble during assembly or interference with the entire system. For shafts used for power transmission or serving as bearing elements, it is important to keep radial runout and total runout within strict limits. Precision metal grinding makes it possible to control this aspect with accuracy even to hundredths or thousandths of a millimeter. The role of metal grinding in achieving perfect tolerances. Metal grinding in the CNC machining process performs a finishing function, ensuring proper surface properties and shape. As a result, roughness is reduced, and the machining itself takes less time compared to traditional methods, since numerical control enables repetitive, tightly controlled tool movements. Okamoto 300 series grinder (model 350) – characteristics of our CNC machine tool. As an example of a machine that proves itself in precision machining, we can cite Okamoto’s 300 series grinder in the 350 model, which allows the machining of workpieces with diameters up to 350 mm. The machine’s design allows it to hold a workpiece of up to about 1,300 mm between the claws, giving it a wide range of applications. Thanks to a spindle with a speed range of 10 to 500 rpm, it is possible to adapt the working parameters to the type of material and the intended machining purpose – from precise finishing to efficient removal of overfeeds. A minimum set feed rate of 0.001 mm ensures high control over roughness and compliance with required tolerances. The robust design reduces vibration, resulting in better process stability. It also reduces radial runout and total runout and enables perfect concentricity. Efficient cooling and contamination separation systems help sustain consistent conditions during machining, so results remain repeatable. Conclusion. In CNC machining of shafts and other rotating components, it is important to strive for tight tolerances and concentricity. Metal grinding, especially grinding of metal surfaces with CNC machines, guarantees precision that is crucial in industries where even micrometer deviations can carry serious consequences. Grinding machines such as the Okamoto 350 make it possible to work with a wide range of workpieces while ensuring a high level of process control, stable conditions and low surface roughness. As a result, the finished products have excellent performance qualities: they are resistant to vibration, wear more slowly and require less frequent service intervention. At SIM Gdynia, the above-discussed approach influences the satisfaction of our customers and long-term cooperation based on quality and trust.If you are looking for a trusted mechanical components contractor, we warmly invite you to fill out our contact form: https://www.simgdynia.eu/kontakt/
Christmas wishes and summary of the year 2024
On the occasion of the upcoming Christmas and New Year, we would like to sincerely thank our employees, business partners, colleagues and customers for their support, trust and fruitful cooperation in the past year. 2024 was a period of intensive development for SIM Gdynia, especially in the defense sector, where we not only expanded our operations, but also established key strategic partnerships. SIM Gdynia’s most important events in 2024 MSPO 2024 Our presence at the International Defense Industry Exhibition (MSPO) 2024 was one of the highlights of the year. This trade fair provided an excellent opportunity to showcase our capabilities in manufacturing precision mechanical components for the defense sector. Through numerous meetings and discussions, we had the chance to establish new business contacts and consider potential projects using our technologies in advanced defense systems. Enforce Tac 2024 Enforce Tac 2024 is another important event on our calendar. The fair brought together more than 12,000 experts from around the world, creating a unique platform for sharing knowledge and experience. It showcased the latest defense-related technologies, including vision systems, autonomous vehicles and weapons solutions. SIM Gdynia’s participation allowed us to better understand the future needs of the industry, as well as showcase our solutions in areas such as the production of components for drones, weapons systems, and shielding and housing for electronic devices. Forbes Forum of Family Businesses honorable mention We were honored to be included in the prestigious Forbes Forum of Family Companies 2024. This honor is extremely valuable to us, as it highlights our financial stability, consistent growth and contribution to the regional economy. This achievement would not have been possible without the commitment of our team and the trust placed in us by our partners and customers. The award motivates us to further improve our processes and introduce new technologies to strengthen the company’s position in domestic and foreign markets. Thanks and good wishes from the SIM Gdynia team On the occasion of Christmas, we wish you many joyful moments with your loved ones, filled with peace and warmth. May the New Year 2025 bring health, success and the realization of professional and personal dreams. Thank you for your trust and cooperation so far. We look forward to the next year with hope, hoping to continue joint projects and further develop our relationship. Merry Christmas and prosperity in the New Year wishes the SIM Gdynia team!
How to measure workpieces in CNC machining? Measurement methods and their applications
Precise measurements play a key role in CNC machining processes such as milling, turning and drilling. The main goal is to ensure that the dimensions of the workpieces conform to technical requirements and maintain high production quality. Dimensional accuracy directly affects the functionality and durability of final products, so it is essential to constantly control machining parameters, especially in serial production, where repeatability is a priority. Measurements also make it possible to quickly detect and correct deviations, which minimizes material losses. In advanced manufacturing processes such as those used at SIM Gdynia, measurements are an integral part of quality assurance. Traditional measurement methods Traditional measuring tools, such as calipers and micrometers, have been the cornerstone of dimensional control in CNC machining for decades. Calipers can measure lengths, diameters and depths to an accuracy of about 0.02 mm, making them versatile tools. Micrometers, on the other hand, offer an accuracy of up to 0.001 mm, making them suitable for measuring workpieces that require greater precision, such as shafts and bushings. Despite their versatility, traditional tools have limitations. Measuring complex shapes or workpieces with complex geometries can be time-consuming and subject to greater risk of error. In such cases, it becomes necessary to use more advanced technologies that automate the measurement process and achieve greater accuracy. Modern solutions – coordinate measuring machines Coordinate measuring machines (CMMs) represent a state-of-the-art approach to dimensional control in CNC machining. They enable precise measurement of workpieces in three axes (X, Y, Z) using contact or non-contact probes. Measuring machines such as Mitutoyo’s offer the ability to measure complex geometries with accuracy down to microns. The machine works on the principle of collecting points from the surface of the workpiece, moving along pre-programmed trajectories. The measurement program for each workpiece is created once, which guarantees repeatability and standardization of the process for subsequent measurements. At SIM Gdynia, we use such solutions to obtain detailed dimensional analysis of parts with complex shapes, which allows us to maintain high quality standards. The design of the measuring machine makes it possible to measure parts with large dimensions, such as machine parts or components used in aviation. By automating the measurement process, the impact of human error can be minimized and the speed of dimensional analysis can be increased. 3D scanners and laser sensors in CNC measurement Today, industry is increasingly using non-contact technologies such as 3D scanners and laser sensors. Scanners allow comprehensive mapping of the geometry of a workpiece, which is particularly useful for parts with irregular shapes. The technology enables the creation of 3D models that can be used for comparison with CAD data and for further analysis. Optical and laser sensors offer precision and speed, making them ideal for real-time measurements, especially in mass production. Their use minimizes the risk of damage to the workpiece, which is important for delicate or deformation-prone materials. How to choose the right measuring methods? Choosing the right measuring tool depends on several factors, such as dimensional tolerances, workpiece geometry and surface quality requirements. For simple workpieces with less stringent tolerances, traditional tools such as calipers or micrometers may be sufficient. However, for more complex workpieces that require analysis in multiple planes, coordinate measuring machines or 3D scanners are the best solution. At SIM Gdynia, we take a diverse approach to measurement, adapting methods to the specifics of the project. As a result, we are able to ensure precision in both unit and batch production. Summary Measurement in CNC machining is the foundation of precise and efficient production. From traditional tools such as calipers and micrometers to advanced CMMs and 3D scanners, each technology has its place depending on the specifics of the project. At SIM Gdynia, we are constantly developing our measurement capabilities, using the latest technologies to deliver products that meet the most stringent technical standards. This allows us to offer our customers reliability, repeatability and the highest quality at every stage of order fulfillment.
Centerless grinders – the key to precision grinding in modern industry
What are centerless grinders and why are they important? Centerless grinders are specialized machines designed for precision grinding of straight-shaped workpieces, such as shafts or bushings. A unique feature of these machines is the lack of classic workpiece support, which means that the material is not fixed at a single point, as is the case with traditional grinders. The workpiece moves freely along the abrasive disc, which simultaneously rotates in the opposite direction. This solution eliminates so-called “fangs” – surface irregularities that are a common problem in traditional grinding processes. Thanks to this technology, it is possible to achieve high surface quality, which is crucial for workpieces requiring exceptional dimensional accuracy and appropriate finishing parameters. Principle of operation of centerless grinders In the process of centerless grinding, the control of parameters such as rotational speed, contact force and workpiece travel speed plays a key role. The workpiece is freely supported between two discs: one rotating at high speed and the other responsible for stable sliding. This arrangement eliminates the need for support points, which reduces the risk of surface damage. To maintain the quality of the process, cooling systems are also used to reduce friction and minimize the risk of material overheating. As a result, workpieces maintain dimensional stability and proper technical parameters, even when machining parts that require tight tolerances. Types of centerless grinders and their applications Centerless grinders can be divided into several types depending on their application and design: How do centerless grinders support production at SIM Gdynia? At SIM Gdynia, we have implemented centerless grinding technology to meet the demands of manufacturing high-precision parts. Thanks to the use of these machines, we have significantly improved the efficiency of our machining processes, which allows us to complete orders in less time while maintaining the highest quality. One of the main effects is the achievement of surface smoothness, which is crucial for parts used in dynamic systems, such as sealing rings and machine components. In addition, shortened machining cycles and reduced material losses translate into optimized production costs. With centerless grinders, we are able to offer our customers products that meet the most stringent technical standards. Summary Centerless grinders are an essential part of modern machining, enabling precise and efficient production of cylindrical parts and parts with irregular shapes. Their use makes it possible to achieve a high quality surface finish, eliminating the problems associated with traditional grinding methods. At SIM Gdynia, we use this technology to realize orders at the highest technical level, while optimizing production time and costs. This allows us to effectively support our customers in achieving their industrial goals.
CNC gear milling machine – the key to precision gear cutting
What are CNC gear milling machines? CNC orbital milling machines are specialized machines used in machining, designed for the production of gears with an orbital tooth profile. Thanks to the use of numerical control technology, they make it possible to precisely reproduce the shape of the teeth in accordance with strict dimensional standards. These devices are used in the production of components requiring high accuracy, such as drivetrain components used in the automotive, aerospace and engineering industries. How do CNC envelope milling machines work? A CNC orbital milling machine enables gears to be machined by precisely controlling the trajectory of the cutting tool, which allows the teeth shape to be accurately reproduced. The process is carried out on several working axes that operate simultaneously, allowing multidirectional movements of the tool. Thanks to CNC programming, it is possible to plan each machining step with high accuracy. This organization of work minimizes the risk of errors and ensures repeatable production. As a result, gears that meet quality standards can be obtained. Challenges in the gear cutting process The gear cutting process involves the need to maintain very tight dimensional tolerances. Even small deviations in the shape or dimensions of the teeth can affect the functioning of the mechanism in which they are used. An important part of the process is the geometry of the cutting tool – the peripheral cutter – and its proper alignment. Precise adjustment of parameters such as rotational speed, feed rate and tool angle is key to achieving a high-quality product. S&T Dynamics H200 envelope milling machine at SIM Gdynia In 2022, we expanded our machine park with a CNC S&T Dynamics H200 envelope milling machine. The machine allows us to machine components with a diameter of up to 200 mm, which significantly increases our gear production capabilities. The machine is equipped with a direct torque motor drive, which eliminates mechanical clearances and enables us to achieve high precision during machining. The tooth-cutting process on some parts takes as little as 4 minutes, which significantly reduces turnaround time compared to traditional methods. The S&T Dynamics H200 milling machine operates at a working table speed of up to 230 rpm and achieves a feed rate on the X and Z axes of 12 m/min. These technical parameters allow us to realize machining with high requirements in terms of accuracy and productivity. Semi-dry machining technology in our cutting process In our work, we use the MQL (Minimal Quantity Lubrication) system, which allows us to reduce lubricant consumption. The semi-dry machining technology used in the H200 milling machine not only reduces production costs, but also reduces the environmental impact of the process. By using MQL, the machining process is more efficient and the cutting tools have an extended service life. This approach allows us to optimize production without compromising on workmanship. Summary CNC circumferential milling machines are the backbone of the high-precision gear manufacturing process. The introduction of the S&T Dynamics H200 milling machine to our machine park has made it possible to increase the efficiency of our orders, as well as to guarantee the quality required in modern technical applications. Thanks to the continuous development of our production capabilities, we are ready to meet the requirements of the most demanding industries, such as automotive, aerospace and engineering.
Robodrill α-D21LiB5 Plus – precision CNC machining for demanding production orders
For more than 45 years at SIM Gdynia, we have been developing our machinery to offer CNC machining in accordance with the highest technical requirements. With the new Robodrill α-D21LiB5 Plus machine, we can even more effectively improve quality, process stability and work efficiency. The introduction of this unit allows us to maintain high precision and repeatability of workpiece machining at higher production volumes. Design and technical capabilities of Robodrill α-D21LiB5 Plus The Robodrill α-D21LiB5 Plus features a linear motion mechanism for the X, Y and Z axes, offering a working range of 700 x 400 x 330 mm and a large working area of 850 x 410 mm. The machine supports a maximum table load of 300 kg. Thanks to precision linear guides and a robust frame design, the machine maintains consistent rigidity, which is key to achieving dimensional repeatability. This functionality works especially well in the production of components for the defense sector, where quality and strength criteria are crucial. Powerful spindle for versatile metal machining The Robodrill α-D21LiB5 Plus spindle reaches speeds of 24,000 rpm, enabling dynamic machining of a variety of materials – from light alloys to tough metals. At lower speeds, the machine offers stability for working with denser materials, while at maximum speeds it provides excellent cutting of light alloys. Automation and quick tool changes The Robodrill α-D21LiB5 Plus is equipped with a storage system for 21 tools, with a changeover time of just 1.6 seconds. Shorter tool change times minimize downtime and increase efficiency in batch production, allowing for smooth and continuous execution of orders. Speed and precision – the key to completing demanding projects The Robodrill α-D21LiB5 Plus achieves a maximum traverse speed of 54 m/min and a working feed rate of up to 24,000 mm/min, enabling high-speed operations with high accuracy. Bidirectional positioning accuracy of less than 0.006 mm and repeatability of 0.004 mm ensure dimensional stability throughout the manufacturing process. Expand SIM Gdynia’s manufacturing capabilities with Robodrill α-D21LiB5 Plus Growing demand for high-precision components in the defense sector and other industries requiring the highest quality standards motivated us to invest in a machine that meets these challenges. The Robodrill α-D21LiB5 Plus makes it possible to fulfill orders with higher technical requirements while ensuring repeatability and reduced lead times. With this machine, we can manage resources and deadlines more efficiently, which is a significant-added value for our business partners. Summary The investment in the Robodrill α-D21LiB5 Plus has opened up new opportunities for precision machining that meet the highest technical requirements of our customers. The machine’s high performance enables precise tolerance maintenance, fast tool changeover times and minimal downtime. This strengthens SIM Gdynia’s position as a reliable partner for companies that expect stable production processes, dimensional accuracy and short lead times.
SIM Gdynia’s investment in a CMB-100CNC circular saw by Amada
At SIM Gdynia, we are expanding our production capabilities with the introduction of an Amada CMB-100CNC CNC circular saw to our machine park. This state-of-the-art tool allows us to cut materials such as structural steel, aluminum, brass and bronze even more precisely and quickly. Thanks to this investment, we are not only reducing lead times, but also improving the quality and range of components we offer. The new saw supports us in the implementation of more demanding projects, responding to the growing needs of our customers. CNC technology in circular saws – operating principle and key features CNC (Computer Numerical Control) technology in circular saws makes it possible to fully automate the cutting process, which significantly increases the accuracy and repeatability of machining. Thanks to a precise computer control system, the operator can enter cutting settings, such as angle, depth and speed, which are then implemented by the machine without additional adjustments. CNC technology in the saws allows dynamic adjustment of cutting parameters in real time, which is particularly important when machining materials with different physical properties. With features such as an automatic feeder and a blade wear monitoring system, CNC circular saws can operate without interruption and minimize the risk of human error, speeding up the processing of large orders. Technical specifications of the CMB-100CNC circular saw machine The CMB-100CNC is a versatile machine designed for cutting components of various dimensions: it handles materials with diameters from 25 to 100 mm for round parts, and from 25 x 25 mm to 75 x 75 mm for rectangular parts. Main technical parameters: Impact of the CMB-100CNC saw on SIM Gdynia’s production processes The implementation of the CMB-100CNC circular saw has significantly improved the efficiency of our production processes. Cutting precision and the ability to adjust parameters, such as blade speed and number of teeth, allow us to adapt the machine’s operation to the specific requirements of the material, which increases the fluidity of batch production. Thanks to the automatic feeder and the ability to work with large production batches, we better manage resources and deliver products to our customers on time. The CMB-100CNC, thanks to its power and automation, has become a key component of our production line, which allows us to meet the growing demands of the market and maintain the highest quality of production.
