Installation service by Step-Four Tips from the experts
Installation service by Step-Four Tips from the experts
Installation service by Step-Four Tips from the experts
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No. 28 | March 2010<br />
www.step-four.at<br />
Maga zine<br />
<strong>Installation</strong> without renovation:<br />
<strong>Installation</strong> <strong>service</strong><br />
<strong>by</strong> <strong>Step</strong>-<strong>Four</strong><br />
Enormous:<br />
The Fairey Rotodyne<br />
model<br />
<strong>Tips</strong> <strong>from</strong> <strong>the</strong> <strong>experts</strong>:<br />
Professional know-how<br />
Face-lift for <strong>the</strong> hot wire cutting system | <strong>Tips</strong> & Tricks | Trade Fair Schedule
Editorial<br />
Dear readers!<br />
Ernst Ramberger<br />
Director<br />
<strong>Step</strong>-<strong>Four</strong> GmbH<br />
Spring awakening<br />
Just as nature will soon be in full bloom,<br />
we also want to break some ground and<br />
rise to <strong>the</strong> coming challenges with renewed<br />
zest and lots of energy, after a pretty<br />
turbulent year. In times such as <strong>the</strong>se,<br />
not only is it particularly important to manufacture<br />
products of <strong>the</strong> highest quality,<br />
but also to provide additional benefits. Although<br />
we have cultivated close customer<br />
relationships and followed a customer-oriented<br />
policy for many years, for 2010<br />
we intend to concentrate even more on <strong>the</strong><br />
areas of customer care, <strong>service</strong> and support.<br />
Because satisfied customers are and<br />
will always be <strong>the</strong> foundation of a prospering<br />
company.<br />
We find solutions<br />
Focussing on customer requirements<br />
has to begin even before machines are<br />
installed. With regard to this, we are<br />
able to provide our customer with solution<br />
proposals, even for <strong>the</strong> most tricky<br />
or cramped space conditions. More information<br />
can be ga<strong>the</strong>red <strong>from</strong> <strong>the</strong> inside<br />
pages. I am particularly pleased about <strong>the</strong><br />
delivery of <strong>the</strong> hi<strong>the</strong>rto largest <strong>Step</strong>-<strong>Four</strong><br />
system, an Xpert CUT 5000 with a cutting<br />
length of up to 8 metres!<br />
New look<br />
Here it is! The new <strong>Step</strong>-<strong>Four</strong> Magazine.<br />
After long and numerous brainstorming<br />
sessions, reams of ideas and a variety of<br />
layouts, we are very happy with <strong>the</strong> result.<br />
We not only revised <strong>the</strong> look of <strong>the</strong> new<br />
<strong>Step</strong>-<strong>Four</strong> Magazine, but we also decided<br />
to revise <strong>the</strong> content and perform a “relaunch”.<br />
After ten successful years of publishing<br />
our customer newsletter, you now<br />
hold a magazine in your hands that is more<br />
comprehensive than ever before. We hope<br />
that you like <strong>the</strong> new magazine. We would<br />
be pleased to receive your feedback.<br />
Shape <strong>the</strong> future with us<br />
Ano<strong>the</strong>r inspiring suggestion! Due to <strong>the</strong><br />
fact that we have enjoyed a pleasurable<br />
and successful collaboration with our customers<br />
over <strong>the</strong> many years, we would like<br />
to invite you to take part in launching new<br />
projects. Shape <strong>the</strong> future with us <strong>by</strong> informing<br />
us about your requirements and<br />
ideas. Perhaps this will lead to a joint<br />
project.<br />
Yours sincerely, Ernst Ramberger<br />
CONTENT<br />
3 Newsticker<br />
New at <strong>Step</strong>-<strong>Four</strong><br />
4 INTRODUCING<br />
Ascending Technologies<br />
5 TRAINING<br />
A visit at <strong>the</strong> HTBLA Ried<br />
6 Service<br />
<strong>Installation</strong> solutions<br />
<strong>by</strong> <strong>Step</strong>-<strong>Four</strong><br />
7 OFFERS<br />
Save cost-effectively<br />
10 Reportage<br />
The creation of a scale model<br />
12 Know-how<br />
<strong>Tips</strong> <strong>from</strong> our <strong>experts</strong><br />
Mas<strong>the</strong>ad: STEP-FOUR GmbH, Bayernstrasse 77, 5071 Wals-Siezenheim, Austria, Phone: +43<br />
(0)662/45 93 78-0 Fax: +43 (0)662/45 93 78-20, E-mail: office@step-four.at: www.step-four.at;<br />
Editorial staff: Ernst Ramberger, Reinhard Leithner, Dieter König; layout and production: JAGER<br />
PR, www.jager-pr.at<br />
10<br />
2 STEP-FOUR | March 2010
News<br />
Face-lift for <strong>the</strong><br />
PC-CUT Standard<br />
After many years of success, <strong>the</strong> tried and<br />
tested PC-CUT Standard hot wire cutting<br />
system has now been given an advantageous<br />
face-lift. The ingenious yet simple<br />
construction itself didn’t actually need to<br />
be modified, but <strong>the</strong> spindles and shafts<br />
were given larger dimensions, which will<br />
provide higher speeds with <strong>the</strong> lowest level<br />
of vibration.<br />
With immediate effect, 16 mm steel shafts<br />
and spindles with an increase of 3 mm are<br />
applied. The spindle motor couplings are<br />
made of aluminium <strong>from</strong> now on. Thanks<br />
to <strong>the</strong> application of cable carriers, cable<br />
spaghetti is also a thing of <strong>the</strong> past. Even<br />
though we have performed <strong>the</strong>se improvements,<br />
<strong>the</strong> prices remain unchanged.<br />
Railway<br />
histories<br />
On <strong>the</strong> occasion of <strong>the</strong> 25th year jubilee<br />
celebrations of <strong>the</strong> Model Railway Club in<br />
Eferding, Mr. Loidl, a faithful <strong>Step</strong>-<strong>Four</strong><br />
customer <strong>from</strong> Fraham in Upper Austria,<br />
proudly presented <strong>the</strong> model of <strong>the</strong> first<br />
locomotive of <strong>the</strong> Linz local railway, <strong>the</strong><br />
E22 002, model 1912. This particular locomotive<br />
travelled along <strong>the</strong> Linz – Eferding<br />
– Weizenkirchen line at that time. The<br />
construction and completion time for <strong>the</strong><br />
model amounted to 200 hours.<br />
New: Safe-Coat in<br />
500 g containers<br />
SAFE-COAT, <strong>the</strong> coating for EPS, XPS,<br />
wood, plastic, and lots more, is now also<br />
available in 500 g containers, as well as<br />
<strong>the</strong> hi<strong>the</strong>rto available 5 kg containers. The<br />
sales price lies at € 12.60 incl. VAT. The<br />
base colour of <strong>the</strong> coating is transparent<br />
and can be coloured according to choice<br />
<strong>by</strong> simply adding pigments. The material<br />
is applied <strong>by</strong> means of a brush or roller.<br />
Drying is performed without shrinking effects.<br />
The surface is smooth and even and<br />
can be painted. The Safe-Coat coating can<br />
be used as a base coating on EPS and XPS,<br />
so that a more “aggressive” coating (solvent-containing<br />
paint) can be subsequently<br />
applied. SAFE-COAT can be used without<br />
<strong>the</strong> necessity of breathing protection.<br />
Xpert Cut: Think<br />
big, cut bigger!<br />
At <strong>the</strong> end of February, we were able to<br />
deliver <strong>the</strong> hi<strong>the</strong>rto biggest system of <strong>the</strong><br />
new Xpert CUT series. With an operational<br />
range of 5000 x 2600 x 8000 mm, enormous<br />
parts, which previously had to be<br />
manufactured in painstaking detail work<br />
with several individual elements, can now<br />
be produced in one piece.<br />
Featured in <strong>the</strong> picture: Michael Schmalzer<br />
in <strong>the</strong> enormous Xpert CUT 5000 with<br />
a cutting length of 8 metres.<br />
STEP-FOUR | March 2010<br />
3
INTRODUCING<br />
Ascending Technologies: The specialist for<br />
multi-rotor aircraft systems<br />
We take particular pleasure in observing<br />
<strong>the</strong> success of young companies working<br />
with <strong>Step</strong>-<strong>Four</strong> systems. The two Achtelik<br />
bro<strong>the</strong>rs <strong>from</strong> Stockdorf near Munich acquired<br />
<strong>the</strong>ir milling machine in 2002 – at<br />
which time <strong>the</strong>y were still students-. Innovative<br />
ideas combined with diligence and<br />
perseverance finally led to <strong>the</strong> founding of<br />
a successful company.<br />
Ascending Technologies – <strong>the</strong> name of<br />
<strong>the</strong> company stands for innovative multi-rotor<br />
aircraft systems. Many years of<br />
experience, based on <strong>the</strong> award-winning<br />
“Jugend forscht” (Young Scientists) work<br />
performed <strong>by</strong> <strong>the</strong> managing partners and<br />
employees, as well as a great enthusiasm<br />
for flying systems, are a guarantee for sophisticated<br />
and innovative concepts, which<br />
have created one or ano<strong>the</strong>r revolution on<br />
<strong>the</strong> “quadrocopter skies”.<br />
The high-tech devices have been used for<br />
a number of special assignments, such as<br />
<strong>the</strong> examination of large-area coal fires in<br />
China, which was performed for research<br />
A quadrocopter<br />
<strong>from</strong> astec<br />
institutes, to fly over archaeological excavation<br />
sites in Mongolia, and to observe<br />
whales in Argentina. Many photographers<br />
use <strong>the</strong> robots for high-quality aerial photographs.<br />
Are you looking for a robust, light and manoeuvrable<br />
quadrocopter, with which you<br />
can impress your friends <strong>by</strong> letting it hover<br />
around your living room or soar across <strong>the</strong><br />
skies outdoors with a breathtaking aero-<br />
batic programme? Or do you need a<br />
means <strong>by</strong> which you can shoot aerial<br />
photographs and videos? Do you perhaps<br />
need a flying sensor carrier for<br />
research projects? Then visit <strong>the</strong> website<br />
www.asctec.de.<br />
By <strong>the</strong> way: Both <strong>the</strong> prototypes and<br />
<strong>the</strong> serial models are still being produced<br />
today with <strong>the</strong> aid of <strong>Step</strong>-<strong>Four</strong><br />
products.<br />
<strong>Step</strong>-<strong>Four</strong> system requirements<br />
Operating system<br />
CPU power<br />
Memory - RAM<br />
CD Rom drive<br />
Free hard disc<br />
storage<br />
Interfaces<br />
Graphic board<br />
Milling software S4PROV4<br />
Cutting software S4CUTV4<br />
Milling software XpertMill<br />
V2.xx<br />
MS DOS 6.0, Windows<br />
95, 98<br />
MS DOS 6.0, Windows<br />
95, 98<br />
Windows 2000,<br />
XP, Vista, Win7<br />
Wing Designer Windows 95, 98,<br />
2000, XP, Vista,<br />
Win7<br />
LiftOff Windows 2000,<br />
XP, Vista, Win7<br />
<strong>from</strong> 500 MHz 32 MB YES 20 MB LPT 1, LPT 2 VGA screen<br />
<strong>from</strong> 500 MHz 32 MB YES 20 MB LPT 1, LPT 2 VGA screen<br />
<strong>from</strong> 1,4 GHz 256 MB YES 100 MB USB <strong>from</strong> 1.1 Standard graphic<br />
board, open GL<br />
<strong>from</strong> 500 MHz 32 MB YES 20 MB LPT 1, LPT 2<br />
USB <strong>from</strong> 1.1<br />
<strong>from</strong> 1,4 Ghz 256 MB YES 20 MB LPT 1, LPT 2<br />
USB <strong>from</strong> 1.1<br />
Standard graphic<br />
board, open GL<br />
Standard graphic<br />
board<br />
Here you can see an overview of <strong>the</strong> system requirements needed for <strong>the</strong> various <strong>Step</strong>-<strong>Four</strong> software products. You can request drivers<br />
for <strong>the</strong> Windows 7. 64 Bit version, which you require for <strong>the</strong> WING designer V2 USB Dongle and <strong>the</strong> XpertMILL 2.PC USB Dongle,<br />
directly <strong>from</strong> <strong>Step</strong>-<strong>Four</strong>.<br />
4 STEP-FOUR | March 2010
Training<br />
HTBLA Ried in <strong>the</strong> Innkreis district<br />
Practical training for budding engineers<br />
On <strong>the</strong> 22 of January 2010, <strong>the</strong> brand new<br />
HTBLA State Polytechnic Institute in Ried,<br />
in <strong>the</strong> Innkreis district of <strong>the</strong> Upper Austrian<br />
Innviertel, presented <strong>the</strong>ir “Open Day”.<br />
The HTBLA Ried provides <strong>the</strong> students<br />
with <strong>the</strong> best possible foundation training<br />
for career entry of academic studies<br />
through hands-on, practical training. This<br />
is achieved <strong>by</strong> a collaboration between industry,<br />
commerce, and school, which is<br />
unique in Austria. A part of <strong>the</strong> training<br />
takes place as workshop tuition directly<br />
on <strong>the</strong> premises of <strong>the</strong> participating companies.<br />
Construction lessons are also provided<br />
directly in <strong>the</strong> companies or are “online<br />
connected”.<br />
<strong>Step</strong>-<strong>Four</strong> Head of Marketing Reinhard<br />
Leithner was able to assure himself, during<br />
his visit at <strong>the</strong> polytechnic, that <strong>the</strong> students<br />
are not only in good hands under <strong>the</strong><br />
supervision of Head Instructor Franz Liebl.<br />
The excellently equipped school provides<br />
<strong>the</strong> young ladies (yes, <strong>the</strong>re are a number<br />
of enthusiastic female engineers) and gentlemen<br />
with <strong>the</strong> best training for <strong>the</strong>ir futures.<br />
The <strong>Step</strong>-<strong>Four</strong> milling machine is,<br />
of course, an essential feature.<br />
<strong>Step</strong>-<strong>Four</strong> is pleased to have experienced<br />
a successful day at <strong>the</strong> school and wishes<br />
<strong>the</strong> students and teachers all <strong>the</strong> best for<br />
<strong>the</strong> future. Fur<strong>the</strong>r details can be ga<strong>the</strong>red<br />
under www.htl-ried-innviertel.at.<br />
A focus on manufacturing technology<br />
Under consideration of economic thinking,<br />
<strong>the</strong> field of manufacturing technology<br />
imparts knowledge on <strong>the</strong> <strong>the</strong>oretical<br />
and practical principles in<br />
<strong>the</strong> field of mechanics, construction<br />
of machines and systems, and manufacturing<br />
technology, supplemented<br />
<strong>by</strong> knowledge in electrical engineering,<br />
measurement, control and regulation<br />
technology, as well as operational<br />
sequences with particular consideration<br />
of quality management and product<br />
management.<br />
Learning is fun with <strong>the</strong> top equipment.<br />
Reinhard Leithner <strong>from</strong> <strong>Step</strong>-<strong>Four</strong> and Franz Liebl <strong>from</strong> <strong>the</strong><br />
HTBLA Ried.<br />
Content students working on <strong>the</strong>ir <strong>Step</strong>-<strong>Four</strong> system.<br />
Young ladies are also enthusiastic about technology.<br />
STEP-FOUR | March 2010<br />
5
Service<br />
How does <strong>the</strong> sailing ship get inside<br />
<strong>the</strong> bottle?<br />
You will perhaps ask yourself<br />
what this age-old<br />
question has to do with<br />
<strong>Step</strong>-<strong>Four</strong>. Quite a lot. Due<br />
to <strong>the</strong> needs and requirements<br />
of our customers,<br />
<strong>the</strong> <strong>Step</strong>-<strong>Four</strong> systems have<br />
become increasingly<br />
larger over <strong>the</strong> last few years.<br />
The Xpert series is a<br />
perfect example.<br />
Just as with <strong>the</strong> demands that our company<br />
has to meet, <strong>the</strong> machines get bigger<br />
all <strong>the</strong> time. Unfortunately, however, <strong>the</strong><br />
doors of our customers‘ workshops don’t<br />
grow at <strong>the</strong> same rate as <strong>the</strong> dimensions<br />
that are required of <strong>the</strong> milling machines.<br />
What’s <strong>the</strong> solution? Well, some providers<br />
leave this problem to <strong>the</strong> customer. <strong>Step</strong>-<br />
<strong>Four</strong> doesn’t.<br />
A tight fit. The <strong>Step</strong>-<strong>Four</strong> system is bigger than <strong>the</strong> workshop door.<br />
<strong>Installation</strong> without renovation<br />
We not only build high quality systems, but<br />
also ensure that <strong>the</strong>y can be installed without<br />
<strong>the</strong> need to perform extensive renovations.<br />
If necessary, we will bring out own<br />
marquee in order to protect <strong>the</strong> system<br />
and our experienced assembly fitters <strong>from</strong><br />
<strong>the</strong> whims of wea<strong>the</strong>r during <strong>the</strong> on-site<br />
unloading or assembly work. A high level<br />
of flexibility regarding <strong>the</strong> installation of<br />
machines is an integral part of our corporate<br />
maxims of customer care, <strong>service</strong> and<br />
support. We have meanwhile managed to<br />
ga<strong>the</strong>r a lot of experience in installing <strong>the</strong><br />
large Xpert systems. Even customers with<br />
very limited space conditions can safely<br />
assume that we are able to find a solution<br />
to (practically) every space problem.<br />
Just ask us.<br />
We’ll find a way.<br />
Xpert 2600P<br />
We install whatever <strong>the</strong> wea<strong>the</strong>r.<br />
Xpert 3D<br />
6 STEP-FOUR | March 2010
Shop<br />
Spring awakening offer<br />
Engraving unit<br />
15 % discount<br />
Suction clamp collar<br />
Toge<strong>the</strong>r with <strong>the</strong> appropriate<br />
gravers, this accessory<br />
provides constant engraving<br />
widths of less than 1/10<br />
mm. Whe<strong>the</strong>r applied for<br />
prototype production of circuit<br />
boards or for engraving<br />
light systems, <strong>the</strong> <strong>Step</strong>-<strong>Four</strong><br />
engraving unit works with<br />
<strong>the</strong> highest level of precision<br />
and reliability.<br />
If you mention <strong>the</strong> codeword “Spring Awakening” when<br />
placing an order, you will receive a 15% discount up until<br />
<strong>the</strong> 30th of April for this accessory.<br />
Whe<strong>the</strong>r you want to perform<br />
rough milling or fine<br />
engraving, your working<br />
space always remains clean<br />
with <strong>the</strong> <strong>Step</strong>-<strong>Four</strong> suction<br />
clamp collar. The plastic<br />
bristles enclose <strong>the</strong> milling<br />
area well without impeding<br />
<strong>the</strong> tool change. Simply<br />
state <strong>the</strong> codeword “Spring<br />
Awakening” when placing<br />
an order – and you save yourself 15%. Simply state <strong>the</strong><br />
codeword “Spring Awakening” when placing an order –<br />
and you save yourself 15%.<br />
Engraving unit for 43 mm milling motors:<br />
Suction clamp collar for 43 mm milling motors:<br />
price reduction <strong>from</strong> € 372.00 to € 316,20 price reduction <strong>from</strong> € 138.00 to € 117,30<br />
Offer<br />
Milling cutter type 2100<br />
Spring discount<br />
Plotting knife<br />
VHM milling cutter type 2100, 1/8“ shaft<br />
10 piece set with 2 pieces each measuring<br />
0.8 mm, 1.0 mm, 1.8 mm, 2.2 mm,<br />
and 3 mm<br />
2 flute routers, micro-spiralled toothing<br />
with chip breakers, fishtail tip, right cutting,<br />
right helix, fulfil <strong>the</strong> highest quality<br />
demands with regard to chip transport,<br />
clean cut edges.<br />
Particularly suitable for contour milling of<br />
circuit boards and fibrous composite materials,<br />
such as glass fibre reinforced plastic<br />
(GRP) and carbon fibre reinforced plastic<br />
(CRP). Also suitable for Depron with very<br />
high feed rates. Unsuitable for soft <strong>the</strong>rmoplastics,<br />
such as ABS, PE, PS, as well<br />
as wood and metal.<br />
price reduction <strong>from</strong> € 55.00 to € 28,00<br />
Plotting knife complete set:<br />
Retrofit your milling machine<br />
as a transparency<br />
plotter! Both self-adhesive<br />
and heat shrink films<br />
can be easily cut with <strong>the</strong><br />
aid of <strong>the</strong> <strong>Step</strong>-<strong>Four</strong> plotting<br />
knife unit. Included within<br />
<strong>the</strong> scope of delivery is<br />
<strong>the</strong> precision knife holder,<br />
a hard metal plotting knife,<br />
a sample disc, and a set of<br />
transparencies. Save 15 %<br />
with <strong>the</strong> codeword “Spring<br />
Awakening”.<br />
price reduction <strong>from</strong> € 264.00 to € 224,40<br />
Inclusive VAT. Valid until 30th of April 2010.<br />
STEP-FOUR | March 2010<br />
7
Seminare<br />
Friday, 6th of August, 2010<br />
Workshop: Milling novices<br />
Please register <strong>by</strong> phone<br />
under +43/(0)662/45<br />
93 78 or via e-mail to<br />
office@step-four.at<br />
Workshop target audience: This workshop<br />
is aimed at interested model makers<br />
who have not yet ga<strong>the</strong>red any experience<br />
with a PC controlled milling machine,<br />
but are considering using such a machine<br />
to build <strong>the</strong>ir models. The objective of <strong>the</strong><br />
workshop is to demonstrate <strong>the</strong> basics of<br />
milling technology.<br />
Content:<br />
• Basic functions and features of a contour<br />
milling machine<br />
• Material science<br />
• Selecting <strong>the</strong> right tool<br />
• Definition of <strong>the</strong> milling parameter<br />
• Differences in <strong>the</strong> 2, 2.5 and 3D milling<br />
process<br />
• <strong>Tips</strong> & tricks in milling<br />
Participant prerequisites: PC skills and<br />
possibly some experience with a CAD programme,<br />
such as CorelDraw or TurboCAD.<br />
Attendance fee: € 220,00<br />
Friday, 16th of April, 2010, and Friday, 1st of October, 2010<br />
Workshop: Model aircraft construction made easy<br />
Please register <strong>by</strong> phone<br />
under +43/(0)662/45<br />
93 78 or via e-mail to<br />
office@step-four.at<br />
Workshop target audience: Dedicated aircraft<br />
constructors who want to learn lots<br />
of new things and profit <strong>from</strong> <strong>the</strong> extensive<br />
experience and store of knowledge provided<br />
<strong>by</strong> our model making expert, Hannes<br />
Schmaltzer.<br />
Content: For an already existing glass fibre<br />
reinforced plastic (GRP) fuselage, wings<br />
are constructed with <strong>the</strong> aid of <strong>the</strong> Wing<br />
designer and rudders constructed with<br />
aid of Turbo-CAD. These constructions<br />
are <strong>the</strong>n milled and assembled. In addi-<br />
tion to profile removal techniques, profile<br />
digitalisation, and wing construction, participants<br />
will also learn how to prepare a<br />
rib set for CNC milling and <strong>the</strong> final assembly<br />
of a wing.<br />
Participant prerequisites: PC skills and<br />
possibly some experience with a CAD programme,<br />
such as CorelDraw or TurboCAD.<br />
Attendance fee: € 220,00<br />
Friday, 18th of June, 2010, and Friday, 10th of December, 2010<br />
Workshop: From 3D construction to <strong>the</strong> finished work piece<br />
Workshop target audience: For interested<br />
model makers, who are already familiar<br />
with 3 D construction programmes and<br />
now want to realise <strong>the</strong>ir constructions<br />
with <strong>the</strong> aid of milling technology. Experience<br />
with 3 D construction is essential<br />
and is, <strong>the</strong>refore, a precondition.<br />
SolidWorks etc. or a CAD programme,<br />
such as CorelDraw or TurboCAD.<br />
Attendance fee: € 260,00<br />
Please register <strong>by</strong> phone<br />
under +43/(0)662/45<br />
93 78 or via e-mail to<br />
office@step-four.at<br />
Participant prerequisites: PC skills and<br />
experience with a 3D CAD programme,<br />
such as TurboCAD, Rhinoceros, SolidEdge,<br />
8 STEP-FOUR | March 2010
Events<br />
Event and trade fair<br />
schedule 2010<br />
<strong>Step</strong>-<strong>Four</strong> is represented at a number of<br />
events in 2010. We look forward to seeing<br />
you <strong>the</strong>re!<br />
Date Event Venue<br />
6.3. - 7.3.2010 Rotor live Baden/Baden Baden/Baden<br />
25.3. - 28.3.2010 Faszination Modellbau Karlsruhe (Model Karlsruhe/DE<br />
Making Expo)<br />
24.4. - 25.4.2010 Salzburger Hangflugtournee RC/H2 Hochreith/Kuchl/AT<br />
(Slope Soaring)<br />
1.05.2010 Flugtag Lienz East Tyrol (Flight Day) Lienz Osttirol/AT<br />
15.5. - 16.5.2010 Wasserflugtreffen (Water Flight Venue) Grundlsee/AT<br />
29.5. - 30.5.2010 Salzburger Hangflugtournee RC/H2 Abtenau/AT<br />
(Slope Soaring)<br />
19.6. - 20.6.2010 Großseglerbewerb Trattberg (Large-Scale Trattberg/AT<br />
Glider Competition)<br />
3.7. - 4.7.2010 Großseglerbewerb Hochreith (Large- Hochreith/AT<br />
Scale Glider Competition)<br />
10.7. - 11.7.2010 Hangstreckenfliegen RC/H1 (Slope Soaring)<br />
Abtenau/AT<br />
16.7. - 18.7.2010 Oldtimer-Treffen (Vintage Glider Venue) Hochreith/AT<br />
14.8. - 15.8.2010 Flugtag Lehrte bei Hannover (Flight Day) Lehrte/DE<br />
11.9. - 12.9.2010 Salzburger Hangflugtournee RC/H2 Kaiserbuche/AT<br />
(Slope Soaring)<br />
17.9. - 19.9.2010 Jet Power Bad Neuenahr/DE<br />
25.9. - 26.9.2010 Salzburger Hangflugtournee RC/H2 Abtenau/AT<br />
(Slope Soaring)<br />
8.10. - 10.10.2010 Spielemesse und Modellbauwelt (Games Salzburg/AT<br />
and Model Making Expo)<br />
15./16.10.2010 <strong>Step</strong> <strong>Four</strong> in-house exhibition 2010 Salzburg/AT<br />
29.10. - 1.11.2010 Faszination Modellbau Friedrichshafen<br />
(Model Making Expo)<br />
Friedrichshafen/DE<br />
Intermodellbau 2010 without <strong>Step</strong>-<strong>Four</strong><br />
For <strong>the</strong> first time in 15 years, we will not<br />
participate as an exhibitor at this year’s<br />
“Intermodellbau” in Dortmund. You probably<br />
ask yourself: Why not?<br />
Well, during <strong>the</strong> last few years we have<br />
observed significant changes regarding<br />
<strong>the</strong> number of visitors and <strong>the</strong>matic focus,<br />
which, in our opinion, are anything<br />
but positive. Therefore, we had to ask ourselves<br />
whe<strong>the</strong>r or not a participation justifies<br />
<strong>the</strong> enormous expenditure of time<br />
and effort.<br />
New role model<br />
The “Intermodellbau” was once <strong>the</strong> leading<br />
trade fair for model building in Germany,<br />
but, in our opinion, this title has<br />
increasingly moved to <strong>the</strong> model mak-<br />
ing fairs “Faszination Modellbau” in Friedrichshafen<br />
and Sinsheim. By <strong>the</strong> way, this<br />
year’s “Spring - Faszination Modellbau”“<br />
exhibition will take place for <strong>the</strong> first time<br />
in Karlsruhe <strong>from</strong> <strong>the</strong> 25th till <strong>the</strong> 28th of<br />
March. Many discussions were held within<br />
our company and with fellow exhibitors,<br />
customers and prospective customers.<br />
The ultimate result was that we decided<br />
not to participate at <strong>the</strong> “Intermodellbau”<br />
2010. The future will show whe<strong>the</strong>r or not<br />
<strong>the</strong> “Intermodellbau” will again become<br />
what it once was. If so, <strong>the</strong>n we‘ll be happy<br />
to return.<br />
In order to still be able to reach as many<br />
customers and potential customers as<br />
possible in Germany, we will participate<br />
in numerous o<strong>the</strong>r events that focus on <strong>the</strong><br />
subject of model aircraft construction. We<br />
are convinced that those events will bring<br />
us closer to <strong>the</strong> real model makers. Fur<strong>the</strong>rmore,<br />
it would be our pleasure to be<br />
able to welcome you at our company base<br />
in <strong>the</strong> beautiful district of Salzburg, where<br />
we can give you a personal presentation of<br />
our products. Come and visit us!<br />
We would like to hear your opinion<br />
I hope for your understanding regarding<br />
our decision not to exhibit at <strong>the</strong> “Intermodellbau”<br />
this year, and hope that this<br />
causes you no inconvenience. We would<br />
very much like to hear your opinion on this<br />
matter. Simply write me an e-Mail to reinhard.leithner@step-four.at.<br />
STEP-FOUR | March 2010<br />
9
Rubrik<br />
The “Fairey Rotodyne” is ready for its maiden flight.<br />
An extraordinary scale model is created with<br />
<strong>the</strong> “Basic 540”<br />
Phillipp Gardemin <strong>from</strong> Baden-Württember,<br />
Germany,<br />
reports about building<br />
this helicopter model with<br />
<strong>the</strong> aid of a <strong>Step</strong>-<strong>Four</strong> Basic<br />
540. With a rotor diameter<br />
of almost three metres,<br />
this is a mighty big chopper.<br />
I dreamt for years about building a “Fairey<br />
Rotodyne” scale model. I flew this extraordinary<br />
helicopter in <strong>the</strong> late 50s, in England<br />
– but unfortunately this project didn’t<br />
get past <strong>the</strong> prototype status. This helicopter<br />
was extraordinary due to <strong>the</strong> fact that<br />
<strong>the</strong> almost 30 m main rotor was tip-driven.<br />
The tips were powered <strong>by</strong> a mixture<br />
of fuel and compressed air bled <strong>from</strong> two<br />
wing-mounted turboprops.<br />
The model was constructed at a scale of<br />
1:10. In order to be able to <strong>by</strong>pass <strong>the</strong> mechanical<br />
complexity of <strong>the</strong> tip drive, <strong>the</strong><br />
plan was to operate <strong>the</strong> model as an autogyro<br />
aircraft. This means that <strong>the</strong> rotor<br />
is driven <strong>by</strong> <strong>the</strong> airflow, thus, allowing <strong>the</strong><br />
model to take off. The first drawings were<br />
created on <strong>the</strong> CAD. The dimensions were<br />
<strong>the</strong>n taken over <strong>from</strong> a plastic model <strong>by</strong> <strong>the</strong><br />
Airfix company.<br />
Realisation with <strong>Step</strong>-<strong>Four</strong><br />
The fulfilment of <strong>the</strong> dream, however,<br />
could only take form with <strong>the</strong> acquisition<br />
of <strong>the</strong> “Basic 540” milling machine.<br />
The general layout drawings in <strong>the</strong> CAD<br />
gradually became a tangible plan. Thus,<br />
<strong>the</strong> individual parts separately drawn, exported<br />
to <strong>the</strong> milling software, and <strong>the</strong>n<br />
be directly milled. Only poplar plywood in<br />
thicknesses of four and three millimetres<br />
was used. The sheeting was made <strong>from</strong><br />
1,5 mm balsa.<br />
Ten month construction period<br />
During a construction period of over ten<br />
months, <strong>the</strong> milling machine became a<br />
best friend. Even <strong>the</strong> smallest of parts<br />
were drawn, exported to <strong>the</strong> milling software,<br />
and subsequently milled. The large<br />
cockpit, for instance, was quasi drawn<br />
<strong>from</strong> nothing in <strong>the</strong> CAD, <strong>the</strong> parts exported<br />
and milled. After a total construction<br />
period of twelve months, <strong>the</strong> model<br />
stood on <strong>the</strong> meadow, ready for flight.<br />
Two Hyperion external rotors with 4 blade<br />
airscrews <strong>from</strong> Varioprop and a 6s LiPo<br />
6500 mAh served for propulsion. The rotor<br />
blades – consisting of a Styrofoam cores<br />
with carbon reinforced plastic spars and<br />
plywood sheeting – rotated in a four-blade<br />
rotor hub <strong>from</strong> Varioprop and a self-built<br />
swivel mechanism. The entire model now<br />
weighed 10.5 kg.<br />
Test flights<br />
The “Fairey Rotodyne” was unfortunately<br />
unable to perform its maiden flight, which<br />
was due to <strong>the</strong> fact that <strong>the</strong> self-built autogyro<br />
mechanism wasn’t powerful enough<br />
for <strong>the</strong> enormous rotor diameter of almost<br />
three metres. The model is currently undergoing<br />
modifications, where<strong>by</strong> mechanical<br />
details are being improved upon, as<br />
well as <strong>the</strong> mechanic of <strong>the</strong> swivelling vertical<br />
tail fins. New test flights are planned<br />
for spring 2010. The “Basic 540” will certainly<br />
provide me with many more good<br />
<strong>service</strong>s until <strong>the</strong>n.<br />
Philipp Gardemin<br />
10 STEP-FOUR | March 2010
Model making<br />
The original „Fairey Rotodyne“ of <strong>the</strong><br />
50s unfortunately never quite past <strong>the</strong><br />
prototype status.<br />
The frames and spar caps were milled<br />
<strong>from</strong> 4 mm poplar plywood.<br />
The rotor tower with <strong>the</strong> mounted mechanism.<br />
The tail with <strong>the</strong> swivelling vertical tail<br />
fins consist of a spar-ribbed construction<br />
made <strong>from</strong> milled 3 mm poplar plywood<br />
parts.<br />
Thanks to CAD and CNC, retrospectively<br />
constructed parts also fit perfectly,<br />
such as <strong>the</strong> servo holder above.<br />
Many parts of <strong>the</strong> cockpit construction<br />
were designed as a basis on <strong>the</strong> CAD<br />
and <strong>the</strong>n milled.<br />
The wings are also rib constructions<br />
with standing crest spar.<br />
The engine nacelles consist of inner<br />
parts constructed and mounted as housings<br />
– all drawn and milled, of course.<br />
After a construction period of eight<br />
months, <strong>the</strong> body shell was practically<br />
complete.<br />
The rotor mechanism unfortunately<br />
proved to be insufficiently stable<br />
enough for flight.<br />
STEP-FOUR | March 2010<br />
11
PRACTICE TIPS<br />
<strong>Tips</strong> <strong>from</strong> our specialists<br />
Our modelling expert<br />
Hannes<br />
Schmalzer advises:<br />
Wing Designer: Show left wing and print<br />
out!<br />
In order to be able to show and print out <strong>the</strong><br />
wing in Wing Designer, proceed as follows.<br />
• Move <strong>the</strong> cursor on to <strong>the</strong> intersection of<br />
<strong>the</strong> two lines and click <strong>the</strong> right mouse<br />
button.<br />
• Select <strong>the</strong> line tab in <strong>the</strong> opened characteristics<br />
window.<br />
• Mark in <strong>the</strong> checkbox of <strong>the</strong> left pointing<br />
X arrow.<br />
• Confirm <strong>by</strong> pressing “accept” and <strong>the</strong><br />
left wing will be shown.<br />
• The wing can also be mirrored in <strong>the</strong> Y<br />
direction. Printing out is performed as<br />
with <strong>the</strong> left wing.<br />
S4CUT V4 cutting software:<br />
In order to ensure that <strong>the</strong> cutting software<br />
can be used with <strong>the</strong> second PC dongle<br />
on a Windows XP computer, <strong>the</strong> CON-<br />
FIG.NT has to be entered at <strong>the</strong> end of <strong>the</strong><br />
files=50 list.<br />
DXF import:<br />
The object dimensions are not correct after<br />
importing <strong>from</strong> CorelDraw. Important!<br />
CorelDraw draws metrically, but exports<br />
imperially. The unit 1 :25.4 must be entered<br />
in <strong>the</strong> import filter of <strong>the</strong> milling software.<br />
TurboCAD:<br />
Before exporting a drawing in <strong>the</strong> DXF<br />
format, ungroup all items, also known as<br />
exploding in TurboCAD. Text excepts and<br />
written items also have to be exploded.<br />
Thus, <strong>the</strong>y can be exported in DXF format<br />
and <strong>the</strong>n be opened or imported in <strong>the</strong><br />
milling and cutting software.<br />
Our design engineer<br />
Roman Tutschka advises:<br />
XpertMILL:<br />
What a lot of people don’t know: When<br />
moving <strong>the</strong> machine to set zero point or<br />
tool change point via <strong>the</strong> keyboard, one<br />
can move between XY and Z with <strong>the</strong> aid<br />
of <strong>the</strong> space key.<br />
Milling aluminium:<br />
Type F2422 milling cutters are particularly<br />
suitable for milling aluminium. Do not immerse<br />
too slowly into <strong>the</strong> material, o<strong>the</strong>rwise<br />
a built-up edge can form, which leads<br />
to premature wear of <strong>the</strong> milling cutter.<br />
And don’t forget <strong>the</strong> cooling agents! Recommended<br />
parameters:<br />
• Milling cutter diameter: 2 mm<br />
• Advance: 2 mm<br />
• Speed: 24000 r/min<br />
• Forward feed XY: 220 mm/min<br />
• Forward feed Z: 200 mm/min<br />
• Cooling: Atomised spray with n-paraffin<br />
Spring offer<br />
Precise 760<br />
Now till <strong>the</strong> 30th of<br />
April 2010!<br />
• Precise 760 ready assembled, operational range 750 x 458 x 100 mm<br />
• SF-C2 control electronics with XpertLINK Windows adapter<br />
• XpertMILL V2 professional milling software<br />
• Xpert[DRAW] software expansion module<br />
• Xpert[CAM] software expansion module<br />
• Maintenance set<br />
• Kress surface milling machine 800 FME<br />
Instead of € 6978.00 now only € 5500.00 incl. VAT<br />
Order now!<br />
Phone: +43 (0) 662/45 93 78-0 or e-mail: office@step-four.at<br />
You can save<br />
over € 1400.00<br />
Offer only applies in Germany and Austria. Plus shipping costs.<br />
12 STEP-FOUR | March 2010