June2017
EUROPEAN
TOOL&MOULD
MAKIN
GVolum
eXV
IVissue
6
MarketsItalian machine tool marketon the rise
Page 12
Tech FocusGetting the correct dosingof cooling lubricants
Page 34
THE MAGAZINE
www.etmm-online.comVolume XVIV | June 2017
ISSN 2194-7589€ 11.50
6
EUROPEAN TOOL & MOULD MAKING
SPECIAL
EDM EuropeSupplementSee what's new in EDM
technology
Page 39
EDM Case StudyHow a German companyoptimises the handling ofelectrodes
Page 40
COMPONENTS
Unbeatable duofor mouldsPage 28
document7892778495319105394.indd 1 19.05.2017 13:09:04
Progressive’s CVe Monitors are on moulds worldwide. Now,
this mould monitoring platform continues to advance to enable
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• Status can be viewed from any mobile device or PC
CVe Live displays data in an easy to understand format that allows
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6-2017
EDITOR’S MESSAGE
3
Finding the perfectsolution
Solution is a wordused nowadays foran inflationary
number of occasions.There is hardly anycompany that says itsells products or ser-vices anymore. In-stead, the current trendis towards selling solu-tions. The term solutionrefers to the practice ofproblem solving, which origi-nates from disciplines likemathematics and engineering,and psychology as well. In allthese areas, the term impliesthat there is a problem thatneeds solving. In this regard, all companies offering solu-tions are addressing problems their customers would havewithout them. The good news is that in the ever-changingindustrial world, there will never be a shortage of newproblems in need of a solution.
Researchers of the University of Kaiserslautern are workingon a solution for one of the huge problems of digitalisation:the interconnectivity of devices from different manufactur-ers. The software is meant not only for industrial machinesbut household items as well (page 24). A problem known toevery manufacturer is the choice of the right supplier of aspecific service from a wide range of options. While there ismore than one answer to that problem, a guideline can helpmake the decision – in our case, for the correct hot runnersupplier. Our article gives advice on what needs to be con-sidered, concerning capabilities, design and product range(page 26). In April, I visitedWalther Wolf, a German mould-maker. I was impressed with how the company is constant-ly working on optimising itself. It also found some veryinteresting solutions for the automisation of their EDMprocesses (page 40).
When Lundbech Intelligent Tooling wanted to find a solu-tion for a more homogeneous temperature distribution ininjection moulds, – to avoid hot spots and to also reduceinstallation space – it worked with Hasco to come up witha completely new product – the Cool Cross. This particularproject shows that, indeed, a very small plastic product canbe the solution for a number of problems (page 28).
Rosemarie [email protected]
document7595252098654820204.indd 3 22.05.2017 07:46:53
4 6-2017
NEWS
BY THE NUMBERS
6 Industry trends, facts and figures
INDUSTRY
7 Engineer Powerwoman 2017
8 Digitalisation and Industry 4.0were the hot topics in Hanover
10 UN and Covestro launchsustainability competition
10 Schunk's JL1 wins HermesAward 2017 at Hannover Messe
MARKETS
12 Italian machine tool orders risingin 2017
SPECIAL REPORT
HORN TECHNOLOGY DAYS
14 Presentations with focus onapplication instead of products
PRODUCT FOCUS
SURFACE TREATMENT
20 Grinding update for precision andquality
TECH FOCUS
MATERIALS
16 Inspiring ideas for lightweightconstruction
R&D
24 Solution for connecting machinesfrom different manufacturers
CASE STUDIES
CUTTING TOOLS
30 Milling threads without a tappingdrill bore
Johannes Kölsch (left) and Christopher Heinzare developing a user-friendly software systemthat connects devices from different manufac-turers.
TIP
If you haven't been atMoulding Expo 2017,you can find all importantinformations, highlightsand reports on the showon etmm-online.com/moulding-expo.Rosemarie StahlEditor
Sou
rce:
University
ofKaiserslautern
TECH FOCUSComponent duofor practical small-series P. 28
GUIDE
26 How to choose the correcthot runner supplier
EQUIPMENT
34 Getting the right dosing ofcooling lubricants
document7268170292879912246.indd 4 22.05.2017 15:01:27
56-2017
MACHINING EQUIPMENT
37 Delivering complex tools withinseventy-two hours
EDM EUROPE
CASE STUDY
40 Numerous possibilities ofautomatising the handling ofelectrodes
TOP ONLINE
RankingThe month's best-clicked articles onetmm-online.com
1.R&D: Researchers find way to easilyconnect machines from differentmanufacturers
2. Q&A: Uncovering potential savingsin tool and mould making
3. Product gallery: May 2017 productgallery
4. Event: AMB Iran 2017 –Iran optimistic about the future
5. Markets: Global metal additivemanufacturing market
Subscribe to our newsletterW etmm-online.com/newsletter
FacebookW facebook.com/ETMMmagazine
EventsW etmm-online.com/events
Suppliers databaseW etmm-online.com/suppliers
Photo galleriesW etmm-online.com/galleries
Hasco’s small seriesmould K3600/… incombination with CMSA8500/…
Sou
rce:
Hasco
since 1963
Türk+Hillinger GmbH78532 Tuttlingen, Germany
Tel. +49 74 61 70 14 0Fax +49 74 61 70 14 110
www.tuerk-hillinger.de
FLEX - Flexible tubular heaters
HLP - Cartridge heaters
RHK - Tubular heaters
RP - Tubular cartridge heaters
HP/HPQ - Nozzle heaters
TE - Temperature sensors
ALW - Power resistors
Technical support and otherproducts on request
NEW!
MADE INGERMANY
TECHNICAL FOCUS
44 Complex, fast and fully auto-mated: the art of wire erosion
48 The advantages of wet-millingelectrodes
REGULARS
3 Editor’s Message
38 Zoomed in
51 Advertisers Index /Masthead
document7268170292879912246.indd 5 22.05.2017 15:01:31
NEWS BY THE NUMBERS
6 6-2017
TICKER
For most countries worldwide, LABOUR DAY, which occurs on 1 MAY, is synonymous/ or linked with INTERNATIONAL WORK-ERS' DAY. Some countries vary the actual date of their celebrations so that the holiday occurs on a Monday close to 1 May, while
USA and Canada celebrate on the first Monday of September instead. (source:Wikipedia) +++ Over €330 BILLION was spent in
2014 in the European Union (EU) on FAMILY/CHILD BENEFITS. This represents 8.6% of total social benefits, ranking the function
"Family and children" on the third position after "Old age and survivors" (45.9%) and "Sickness, healthcare and disability" (36.5%).
(Source: Eurostat) +++ Spring seasonal vegetable, ASPARAGUS, is the NUMBER ONE vegetable in Germany. In 2016 it ranked first
in terms of area under cultivation (27,000 hectares; +5% on 2015), and about 120,000 TONNES was harvested. (Source: Statista)
QUOTE OF THE MONTH
TRENDS
National debt of EU in Q3 2016
CO2 emissions in the EU in 2016
NUMBER GAMES NUMBER OF THE MONTH
The Horn Technology Days 2017were the most successful of all time.The Technology Days will take placein 2019 in Tübingen again.Lothar Horn
Managing Director of Hartmetall-
Werkzeugfabrik Paul Horn
–0,1%In March 2017 com-pared to February 2017,industrial production fellby 0.1% in the euro area(EA19) and remainedstable in the EU28. InFebruary 2017 it also fellby 0.1% in EA19 andremained unchanged inthe EU28. (Source: Eurostat)
+6,0%Orders received by theGerman machine toolindustry in the firstquarter of 2017 went up6% compared to theprevious year. Domesticdemand rose by 2%,while overseas ordersgrew by 8%.
(Source: VDW)
+2,4%In March 2017, realdisposable income grew2.4% compared to oneyear ago in the US.March real disposableincome was US$12,881billion, which was anall-time high in realdisposable income.
(Source: Gardner Media)
The average price of virtual reality (VR) glasses in 2014 in US$.........................350The average price of VR glasses in 2018* in US$..............................................100
VR-hardware sold worldwide in 2016, in m ......................................................... 10VR-hardware sold worldwide in 2021*, in m ........................................................72
Worldwide sales in augmented reality in 2016 in b.............................................0.2Worldwide sales in augmented reality in 2021 in b...........................................48.7Worldwide sales in virtual reality in 2016 in b ..................................................... 2.1Worldwide sales in virtual reality in 2021* in b ..................................................18.6* forecast (Source: Kzero, Deloitte)
London acts as a go-between for buyers andsellers of financial products priced in eurosthat play a vital role in Europe's economy.About $1.5 trillion is traded each day throughLondon or about 75% of all such transactions.The ECB has long argued that the activityshould take place inside the group of 19 coun-tries that use the currency. (Source: CNN)
trillion$1.5
The national debt of EU member states in Q3 2016 inbillion €. They comprise the debts of central govern-ments, provinces, municipalities, local authorities andsocial securities. (Source: Statista)
In 2016, CO2 emissions from fossil fuel combustiondecreased by 0.4% in the EU, compared to 2015.The biggest drop was Malta (-18.22%) while Finlandrecorded the highest, an increase of 8.5%.
(Source: Eurostat)
0 500 1,000 1,500 2,000 2,500
10%
5%
0%
-5%
-10%
-15%
-20%
2,212.6
EU = -0,4%Sou
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Sch
ulz Italy
FranceGermany
UKSpain
BelgiumNetherlands
GreeceAustriaPortugalPolandIrelandSwedenFinnlandDenmark
Malta
Bulgaria
Portugal
UKLuxemburg
Greece Italy
Romania
Estonia
Cz. Republic
Belgium
Netherlands
Germany
France
Poland
Ireland
Spain
Slovakia
Sweden
Austria
Hungary
Latvia
Lithuania
Croatia
Denmark
Slovenia
Cyprus
Finland
document808758174406149660.indd 6 22.05.2017 10:14:03
INDUSTRY NEWS
6-2017
SEEINGIS BELIEVING
We challenged large and small shops around the world to try Dynamictoolpaths. The results are nothing short of amazing. Dramatically shortercycle times, with extended tool life and less strain on machines.
See it for yourself. Get it at Mastercam.com/DynamicChallenge.
ONCE YOU SEE IT,YOU’RE GOING TO NEED TO TRY IT.
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www.mastercam.comNOW AVAILABLE
Engineer Pow-erwoman 2017Germany – 2017 marks thefifth time that DeutscheMessehas presented the coveted En-gineer Powerwoman award toa female STEM professional forher initiative, ideas and dedi-cation in promoting innova-tive technologies at her com-pany or organisation. Thisyear’s award winner is MariaBelén Aranda Colás. Aranda
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Maria Belén Aranda Colás is theEngineer Powerwoman 2017.
was presentedwith the award,which is worth €5,000, at theopening ceremony of theWoMenPower conference atHannover Messe by YasminFahimi, State Secretary of theFederal Ministry of Labour andSocial Affairs, and DeutscheMesse’s Managing BoardChairman Dr. Wolfram vonFritsch.The jury chose Maria Belén
Aranda Colás as this year’swinner not just because of herachievements as a projectmanager, but also because ofher commitment to promotingwomen in STEM professions.She is a shining example forgirls and young women withan interest in pursuing tech-nology-centred careers.hannovermesse.de
Incoe's new dual leadership to take over in summer
Management – ChristianStriegel and Frank Daniel willbe the new general managersas part of the new dual lead-ership of hot runnermanufac-turer Incoe International Eu-rope as of 1 August 2017.While Striegel has been run-
ning the Technology and Prod-uct Development division fornine years, Daniel has headedthe Finance division since
2015. The company says it hasenjoyed continuous globalgrowth over many yearsthanks to the increase in com-munication and coordinationwork between Incoe Europeand other Incoe entities world-wide to match the pace ofshifting trends in internation-al markets. This is also thereason for the set-up of a pow-erful dual leadership in man-
agement as well. “Laying thetasks of the future into thehands of two peoplewho com-plement one another out-standingly well, both person-ally and professionally, had acrucial significance for us,”says Gunnar Gramatzki, whohas headed Incoe for nineyears now but is planning aprofessional change.incoe.com
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Inco
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Current General Manager, GunnarGramatzki (centre), hands overthe responsibility to the new dualleadership, Christian Striegel(right) and Frank Daniel.
document7697016414806526114.indd 7 22.05.2017 10:05:26
NEWS INDUSTRY
8 6-2017
NEWS IN BRIEF
PSE Europe 2017
The first International Exhibition forPolyurethane Solutions will be held atthe MOC Munich, Germany, from27-29 June 2017. With this event, thePU industry will gain a new market-place for visitors from varied industrysectors, introducing new develop-ments and innovations.pse-europe.com
AM Solutions CentreRenishaw has an-nounced an agree-ment with Falcon-Tech Co. to be itsSolutions Centrepartner and distrib-utor for its additivemanufacturing (AM)technology in China, using Ren-ishaw’s latest AM systems. The latterfocuses on the rapid manufacturingof high-performance components foraerospace, biomedical, marine,chemical and other engineering ap-plications.renishaw.com
Best first quarterDMG Mori's positive development inorder intake continued at the begin-ning of 2017. It rose by 17% to €693.9 million in the first quarter (pre-vious year: € 591.6 million). This resulttranslates into the highest quarterlyvalue in the company's history.dmgmori.com
Asco at congressAsco Carbon Dioxidewas pleased with theresonance at therecently held Metal-casting Congress inthe US. It said there isa high demand fordifferent cleaningsolutions and providers in the US.ascoco2.com
Sou
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Mac
kBrook
sExh
ibition
sSou
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Asco
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Ren
isha
w Digitalisation at HMI 2017Hannover Messe – Making the benefitsof digitalisation tangible – that was thedeclared objective of Hannover Messe2017. After five action-packed days at theworld’s leading trade fair for industrialtechnology, the organisers spoke of a thriv-ing event. A large number of solution-seek-ers gathered in Hanover to immerse them-selves in the potential ofintelligent robots, adap-tive machines and inte-grated energy systems,taking attendance to newheights.“More attendees, more
solutions, more interna-tional – that aptly sumsupHannoverMesse 2017,”commented Dr. JochenKöckler, Member of theManaging Board atDeutsche Messe. “Overthe past five days, Hano-ver has served as a globalhub for all things relatedto Industry 4.0. Everysector involved in thedigitalisation of industrywas on hand to showcaseits answers to the keyquestion faced by indus-trial enterprises everywhere: How can Ibest get my company into shape for thedigital future? Hannover Messe has re-soundingly underscored its value as aprime source of orientation for deci-sion-makers from around the globe,” headded.In his summation of the event, Thilo
Brodtmann, Managing Director of the Ger-
man Engineering Federation (VDMA), said:“Hannover Messe 2017 has served as anunsurpassed showcase for themechanicalengineering sector. Industry 4.0 is nowwell past the trial stage, and is alreadygenerating real benefits in application. Theshow clearly reflected the industry’s buoy-ant mood – a mood powered by having
exactly what it takes toget the job done for thebenefit of people every-where. And when itcomes to internationalcompetition, we are defi-nitely among the front-runners. In short, Han-nover Messe 2017 hasbeen nothing short ofoutstanding.”Of the show’s 225,000
attendees (up from217,000 in 2015 as themost recent comparableevent), more than 75,000came from abroad. Thelargest number of foreignvisitors came from China(9,000), followed by theNetherlands (6,200), In-dia (5,300) and Poland,whose 5,000 visitors set
a new Partner Country record. The long-term impact of Partner Country partici-pationwas underscored by an impressive3,000 visitors from the U.S. as last year’sPartner Country.The next Hannover Messewill run from
23 to 27 April 2018, with Mexico as its of-ficial Partner Country.hannovermesse.de
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Automation and cobots(collaborative robots) werethe main topics at Hanover.
“With morethan 500 appli-cation scenari-os, the showgave real shapeto the promisethat digitalisa-tion holds forthe industry.”Dr. Jochen Köckler, Deutsche Messe
document2713132926467898332.indd 8 22.05.2017 10:21:07
INDUSTRY NEWS
96-2017
INFO:VDW – Generalkommissariat EMO Hannover 2017Verein Deutscher Werkzeugmaschinenfabriken e.V.Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANYTel.: +49 69 756081-0 · Fax: +49 69 [email protected] · www.emo-hannover.de
Top keynotes at conference
UK – Two free-to-attend con-ference streams addressingkey issues, best practice andtechnological innovation willrun alongside Subcon, the Ad-vanced Manufacturing Showand The Engineer Design &Innovation Show.World-classspeakers will come from glob-al blue-chip organisations in-cluding Microsoft, Siemens,BAE Systems, Jaguar LandRover, Bureau Veritas, Strata-sys, Lloyds Bank and Ren-ishaw.
The programme will alsofeature leading technologicalexperts from top research anddevelopment bodies and spe-cial presentations giving anexclusive behind-the-sceneslook at companies showingthe highest levels of engineer-ing innovations and ingenuityin their products – includingOcado Technologies, BACMo-no and leading HiFi turntablemanufacturer Rega Research.The sessions will be held intwo separate streams hostedbyThe Engineer andTheMan-ufacturer, respectively.Thirty-six sessions across
the three dayswill cover topicsranging from virtual reality,additive manufacturing andIndustry 4.0 to materials test-ing, updates to AS9100, mag-nesium components and bigdata.subconshow.co.uk
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Renishaw’s Marc Saunders willtalk about metal AM.
A perfect 50th birthday present
UK – Alucast, the UK-basedaluminium casting foundry, iscelebrating its 50th birthdayin style after announcing plansfor a new £1.2m technical cen-tre and machine shop.The company will start
work on the new facility inJune that will house its CADandMagma casting simulationfacilities, non-destructive test-ing capabilities and its new5-axis CNC technology.It’s part of a strategy that
will see the company target upto £3m of new “lightweight-ing” opportunities for complexcastings in the automotive andagricultural markets. This willalso mean recruiting 20 moreemployees to cope with theplanned expansion to £10mil-lion sales, including engineersand apprentices, the companysays. Its offerings include ini-tial design support and Mag-
ma casting simulation soft-ware, through to prototypesupply and delivering ma-chined castings line-side, pro-duced by a number of differentin-house processes includingsand, gravity, low and highpressure.“2017 will be a year where
we celebrate our history andachievements. It will also be atime where we put a markerin the sand for the next 50years,” MD John Swift said.alucast.co.uk
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Aluca
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Members of Alucast staff cele-brate 50 years in business.
document6462935660346428760.indd 9 22.05.2017 10:22:32
NEWS INDUSTRY
6-2017
UN and Covestro launch sustainability competition
Sou
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Pixab
ay
The competition will provide a global platform for young people to show-case innovative projects to improve the health of the planet.
Germany/World – The UnitedNations Environment Pro-gramme has launched “YoungChampions of the Earth”, anew initiative that aims to cel-ebrate and support individualsbetween the ages of 18 and 30with outstanding ideas to savethe environment. The initia-tive is sponsored by Covestro,leading polymer company anda strong proponent of innova-tion for environmental sus-tainability. According toCovestro, this competitionprovides a unique global plat-form for young people toshowcase innovative thinkingand positive contributions tothe health of the planet.The initiative aims to bal-
ance negative discourse on theenvironment and inspire thenext generation of environ-mental leaders. The competi-tion on environmental solu-tions is open to people in thisage group. Every year, six
young people – one from eachof the UN environment’s glob-al regions – will be named“Young Champion of theEarth”. These winners willeach receive USD15,000 inseed funding as well as inten-sive training and tailoredmen-toring to help their big envi-ronmental ideas to becomereality.“We are delighted to support
the UN Environmentwith this
excellent initiative,” saidCovestro CEO Patrick Thomas.“Sustainable thinking and act-ing is critical in preserving ourplanet and improving the safe-ty and quality of millions ofpeople. The company seeks tocontribute to this goal withproducts and technologiesthat benefit society and reducethe impact on the environ-ment. This is the basis of ourvision: To make the world a
brighter place – and the youngare invited to participate – allwho care for our future.”UN Environment Executive
Director Erik Solheim added:“As I’ve seen time and again,when young people are givenopportunities and support,they can be powerful catalystsfor change. It is our hope thatthis initiative will inspirethousands of young peoplearound the world to developinnovative ways to tackle theenvironmental issues thatmatter to them.”Thewinners will be selected
by a global jury that includesboth Solheim andThomas. Thewinners will also be invited toattend the “Champions of theEarth” gala dinner, which willbe held in Nairobi in Decemberthis year.Application is now open (as
of 22 April) until its close on 18June 2017.covestro.com
Schunk's JL1 wins HermesAward 2017 at Hannover Messe
Germany – This year’s HermesAward winner is Germa-ny-based innovative grippingsystems company Schunk. Theprestigious industrial technol-ogy prizewas presented at theHannover Messe opening cer-emony in April.Schunk's JL1 co-act gripper
is an intelligentmodular grip-ping system for human-robotcollaboration that can directly
interact and communicatewith its human operator. TheJL1’s integrated sensor sys-tems envelop the module inits own safety “bubble” bycontinually tracking the prox-imity of humans and triggersevasive action to avoid directhuman-machine contact. Itcan grip, handle and assembleobjects of all geometries.schunk.com
Schunk’s JL1, said to be suited for highly flexible Industry 4.0 manufac-turing environments, wins the award.
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STRACK NORMAGmbH & Co. KGKönigsberger Str. 11D-58511 LüdenscheidGermanyTel.: +49 2351 8701-0Fax: +49 2351 [email protected]
++ Snap-in plates arehardened, thus no wearat the slide or mould platearises
++ Appropriately combinablewith our slide holdingdevices Z5130 and Z5140
++ The insertion in the slideor mould plate can beintroduced easilySlide holding
device Z5130
Slide holdingdevice Z5140
Snap-in plateZ5131 and Z5141
Snap-in plate Z5131compatible with Z5130
Snap-in plate Z5141compatible with Z5140
document3193185700055518127.indd 10 19.05.2017 11:34:48
Indexable SolidCarbide Endmills WithMinimum Setup Time
• Minimize Machining Downtimefor Higher Productivity
• Over 15,000 Combinationsof Assembled Endmills
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www.iscar.comMachining IntelligentlyISCAR HIGHQLINES
A4 STARTUP 2017 ADS ETMM.indd 2 5/4/17 10:22
MARKETS ITALY
12 6-2017
The National Plan Industry 4.0 implemented bythe government has already yielded good re-sults. This is highlighted by the quarterly data
report by Ucimu concerning the collection of ma-chine tool orders. In the first quarter of 2017, it reg-istered a 5.1% increase compared with the sameperiod of the previous year. The absolute value ofthe index amounted to 187.7, considerably over theaverage of100 established in 2010.In particular, the overall outcome of the index,
processed by the Studies Deptartment of Ucimu– Sistemi per produrre, was due to the excellentperformances of the orders collected in the domes-tic market, increasing by 22.2% versus the periodof January-March 2016. The absolute value of theindex was 236.3.Abroad, the index remained stationary, recording
a 0.3% rise. The absolute index was 168.1.After the decrease experienced in the last quarter
of 2016, owing to thewaiting effect for the govern-ment's National Plan Industry 4.0 announced bythe Minister of Economic Development, Carlo Cal-enda, the Italian demand for manufacturing sys-tems started to move again and in a significantway. This is a testimony to the positive situationof the domesticmarket that also benefits importanttax incentives, such as super- depreciation andhyper-depreciation.Massimo Carboniero, President of Ucimu – Sis-temi per produrre, asserted: “The choice of thegovernment authorities giving our country asolid industrial policy, aimed at fostering theenterprises' technological and organisationaldevelopment, has surely been forward-looking,not onlywith regard to the provisions includedin the Plan, but also considering the currenteconomic situation.”“Actually, after years of difficulty, since 2014 theItalian market has started to invest again in
production systems. The factors that
Italian machine tool orders risingin 2017
According to the Italian association for machine tools, robots and auto-mation manufacturers, Ucimu, the increase in machine tool orders in the firstquarter of 2017 is a result of government implementations. The NationalPlan Industry 4.0 is stated as the main influence on the numbers.
Claudia Mastrogiuseppe
made the temporal context 'perfectly suitable' forapplying the Plan are the recovery of demand andthe concomitant data about the ageing of manu-facturing plants, whose average age turned out tobe 13 years.”According to Massimo Carboniero, the order in-
dex of the first quarter of 2017 regarding the do-mestic market is evidence that the programmeimplemented by the government authorities isyielding good results: “The propensity of the Italianmanufacturing industry to invest in industrial tech-nology and connectivity systems needed a boost,which has been ensured by the National Plan In-dustry 4.0.”
The future of the National IndustryPlan
On the other hand, the positive situation of theItalianmarket, which has come back to a consump-tion level closer to that reported before the reces-sion, is also confirmed by the figures of Lamiera.This exhibition will have its first Milan edition intwo weeks. Hosted at Fieramilano Rho from 17 to20 May, the biennial trade show dedicated to thesector of sheet-metal forming technologies presentsitself with a sold-out exhibition space. Over 450enterprises and 40,000 square metres of total ex-hibition area are the starting point of the “new”Lamiera, held in Milan this year after 18 editions,with the goal of further developing the networkingbetween demand and supply in this sector.The next years, however, will show whether It-
aly will be successful: “Now, we have to under-stand,” Carboniero concluded, “whether one yearis enough to give back the necessary impetus toItalian enterprises in order to enable them to in-crease their competitiveness level, which is essen-tial for facing foreign competitors.”ucimu.it
“The propensity of the Italian manufacturingindustry to invest in industrial technology andconnectivity systems needed a boost, which has beenensured by the National Plan Industry 4.0.”Ucimu President Massimo Carboniero
document7855653047684536868.indd 12 19.05.2017 11:36:32
NEWS MARKETS
6-2017
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Iran optimisicon the futureIran – Technology transfer andtraining are key topics in Iran'sindustry today. Prior to AMBIran, industry get-togetherstook place to discuss these.With over 180 exhibitors, the
second AMB Iran in Teheranfrom 23-26May is almost fullybooked. Organisers MesseStuttgart and the GermanMa-chine Tool Builders' Associa-
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Stuttga
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Members of Messe Stuttgart andIran’s venue operator.
tion recently invited keynotespeakers to three get-togethersin Iran in the industrial hubsof Isfahan, Teheran andTabriz.600 representatives from pol-itics, industry and industrialassociations discussed thecurrent situation following thelifting of the sanctions and thenew opportunities in Iran'sindustry. Topics included tech-nology transfer from abroad,potential for foreign invest-ments and the importance ofcompany and on-the-job train-ing.In Iran, imports are expect-
ed to increase by USD20 billionfrom 2015 to 2017. It is estimat-ed that machines and acces-sories will account for 20% ofthis growth.messe-stuttgart.de
UK goods demand positive both at home and abroad
UK –Manufacturers in the UKhave reported strong growthin orders both at home andfrom abroad for the first quar-ter of 2017, although costs andprices have continued to riseat an elevated pace, accordingto the latest quarterly CBI In-dustrial Trends Survey.The survey of 397manufac-
turers found that domesticorders had improved at the
fastest pace since July 2014 inthe same period. Export ordersalso recorded the strongestgrowth in six years, supportedby strong rises in competitive-ness, particularly in non-EUmarkets.The weak pound continued
to push up costs, with manu-facturers reporting the strong-est rises in unit costs in sixyears. Output growth firmed
to a three-year high and is ex-pected to accelerate over thenext quarter. Manufacturersanticipate that new orders willgrow more moderately overthe near-term, owing to a pre-dicted slowdown in domesticdemand outweighing exportorders growth. Expectationsfor the latter are at theirstrongest in over two decades.cbi.org.uk
The survey was based on 397manufacturers.
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SPECIA
L SPECIAL REPORT
14 6-2017
Presentations with focus on applicationinstead of products
Germany-based cutting tools manufacturer Horn invited professionals to itsheadquarters in Tübingen. The centrepiece of the event consisted of severalpresentations, which were aimed at the exchange of knowledge and technol-ogy and were therefore focused on the application rather than products.
Horn Technology Dayshave been inspiringcountless visitors fromacross the globe since2009.
Sou
rce:
Horn
HornTechnology Days took place between 10thand 12th May 2017 in Tübingen, marking thesixth time the event has been held. Eight pres-
entations and associated practical demonstrationsprovided the centrepiece for the event. The twomanufacturing plants of Paul Horn, plus the HornHartstoffe plant, also opened their doors to visitors.Rounding off the Horn Technology Days were var-ious exhibitions from a wide range of customerindustries as well as around 40 partner companiesattending as co-exhibitors. The event welcomedmore than 2,800 visitors.Lothar Horn, Managing Director of Paul Horn,
said: "We don't see our Technology Days as a pro-motional event. We want to engage with our cus-tomers in order to advance technology, innovate
and pool our knowledge. This is alsowhy the pres-entations are application-specific rather than prod-uct-specific."Most of the specialist Horn presentations –which
numbered eight in total – were supported by prac-tical demonstrations. The presentationswere avail-able in up to five languages: German, English,French, Italian and Turkish.The presentation topics included "High-feedmill-
ing cutters for cost-effective titaniummachining","Turbo-whirling and rotary whirling - Thread cut-ting redefined", "Perfect gear teeth" andmanymoreabout milling, lathes and coatings.
Several expansions in the last yearsfor Horn
Paul Horn currently has around 930 employees inGermany and 400 elsewhere. It develops andman-ufactures solid carbide tools as well as carbide, CBNand PCD indexable insert tooling in Tübingen andGomaringen, Germany. In 2016, the company re-corded sales of approximately EUR 167 million inGermany. Abroad, Horn is present in more than 70countries on all continents. Aside from Germanythere are additional production facilities in England,Italy, the Czech Republic and the USA.Horn says that, to further extend its leading po-
sition in the global market, it built an additionalmanufacturing plant in Tübingenwith a productionarea of approximately 5,500 square metres. Thiswas completed in 2008 and is adjacent to the headoffice and existing production area of around 6,000square metres. The production processes were re-organised when the plant started operation.In 2011, Horn also built a new plant for Horn
Hartstoffe covering an area of around 5,000 squaremeters. According to the company, this enables allshaping processes for carbide tools to be carriedout in-house. (Investment in 2011/2012: approx. EUR30million). The new plant has also been producingblanks and wear parts made of carbide for othercompanies since 2013. In 2016, Horn moved into anew manufacturing plant covering a total area of20,000 squaremeters dedicated to tool holder pro-duction, the coating department and logistics.Furthermore, a new administration buildingwas
added. The total amount invested in the two build-ings amounted to EUR 70 million.HornTechnology Days take place every two years.
Lothar Horn has already announced the next event,scheduled for 2019.phorn.de
document5083717838921082360.indd 14 19.05.2017 14:42:58
DRRF
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16 6-2017
TECH FOCUS MATERIALS
Inspiring ideas for lightweightconstructionUltra-high-strength materials are highly popular inthe mechanical engineering sector because theyare often comparatively light and at thesame time very sturdy. A research teamat Fraunhofer Institute for Produc-tion Technology (IPT) nowfocuses on this material.
Nikolaus Fecht
Machine tools often come up against theirphysical limits when processing ultra-high-strengthmaterials. This can be remedied by
using structural parts formachinery that aremadeof lightweight fibre-reinforcedmaterials. This, how-ever, entails mastering some serious obstacles, asevidenced by an as-yet-incomplete research projectat the Fraunhofer IPT in Aachen, which will alsobe on show at EMO Hannover.The researchers in Aachen usually adopt a holis-
tic approach to optimising designs. In other words,they consider the machine’s design as a coherentwhole, thus also including the development of im-portant drive elements in the machine tool. Theyhave currently joined forces with a machine toolmanufacturer fromMagdeburg to examine how aninnovativemachine component for vertical move-ments (Z-axis) made of carbon fibre-reinforcedplastic (CFRP) behaves in a machine tool and howthe Z-slide can be optimised.“We began developmentwork on the CFRP slide
in 2013,” relates ChristophTischmann, BranchMan-ager of MAP Werkzeugmaschinen GmbH fromMagdeburg. “We already possess plenty of experi-ence with linear and rotary axes, for machiningaluminium, for instance. But for high-strengthma-terials like the titanium alloy Inconel they do notpossess the requisite drive power.” SoMAP decidedto develop a machine tool with very powerfuldrives: For example, 55 and 72-kilowatt spindles(torque 210 and 273 Newtonmetres, respectively, inS1 or S6mode) are now used, which are significant-
ly heavier and larger. “So as not to have to compro-mise on the dynamics, we were looking for a wayto compensate for the greater weight,” explainsChristoph Tischmann. “That’s why we opted forthe CFRP variant.” In comparison, themachine toolused to operate in the Z-axis with spindles ratedat 28 to 36 kilowatts.So what’s involved here is roughly doubling the
drive power. At the same time, using CFRP reducesthe mass by around 60 percent compared to anaxle made of steel. “However, we’re not aiming forany particular weight, we’re targeting an optimumratio between weight and mechanical strength,”explains Filippos Tzanetos from the scientific staffof the Fraunhofer IPT.The question arises here of how the change-over
from a steel guide slide to a CFRP design with adrive weighing around twice as much will affectthe design as a whole. The Fraunhofer IPT has forthis purpose analysed the thermal and dynamicreactions of the entire machine on the Z-guideslides. “The machine was subjected to an exhaus-tive scrutiny,” reports Christoph Tischmann. “Weused thesemeasurements to develop several solu-tional approaches in order to improve the design.”Becausematerials cannot be simply replaced on
a one-for-one basis, the design needs to bemodifiedto suit the newmaterial concerned. Finite-elementsimulation has proved its practical worth in thiscontext. “At the computer, we take a detailed lookat the specific points in the design that are themostyielding in order to determine the causes involved,”
Sourc
e:MA
P Werk
zeugma
schinen
Replacing steel: Using CFRPsreduces the mass of the Z-axisby 60 percent.
document301301377595353904.indd 16 19.05.2017 14:42:19
MATERIALS TECH FOCUS
176-2017
explains Filippos Tzanetos. “We then attempt toreplace some of the existing componentswith theirequivalents in aluminium or CFRP, or to improvethe dynamic behaviour at certain critical points bymeans of reinforcements or ribs.”Working with CFRP is a particular challenge for
design engineers, since the material behaves ani-sotropically: “Anisotropy” is a term describing thedirection-dependence of a property or an operation.Thismeans that in the case of fibre-reinforcedma-terials the mechanical strength or rigidity will de-pend on the direction of the fibres. A CFRP compo-nent, however, behaves differently in a simulationto its behaviour in reality. Filippos Tzanetos laysout the details for specialists: “Themeaningfulnessof the simulation is estimated using the uncertain-ty propagation defined in DIN ISO 21748:2014-05.The uncertainty of the model’s parameters exertsa certain influence on the uncertainty of the mod-el’s output variables. This is calculated using theMonte Carlo simulation method.”
The entire design is modified to suitthe new material
In projects of this kind, the Fraunhofer Institute isoften assisted by other institutes or spin-offs, butin this case the scientists found the support theyneeded in-house. “In our institute, we have a de-partment for fibre-reinforced composite and la-ser-system technologies”, reports Filippos Tzanetos.“This department has over the course ofmany yearsaccumulated a lot of can-do competences in thefield of dimensioning machine tool componentsmade of fibre-reinforced plastics (FRPs), and pro-vides us with proactive support in the shape ofsimulation expertise for fibre-reinforced compo-nent dimensioning.”
Support of this kind is in-dispensable for solving
questions encounteredwhen it comes to us-ing FRP compo-nents in plant andmachinery con-struction, sincethese materials,by virtue of theiranisotropic prop-erties, are not oftenused here. “Up tonow, there has beena notable reluc-
tance to use
INFOThe Fraunhofer IPTdevelops systemsolutions for pro-duction. It focuseson the topics ofprocess technolo-gy, productionmachines, produc-tion quality andmetrology as wellas technologymanagement. Itsclients and cooper-ation partnersrepresent all fieldsof industry: fromaerospace technol-ogy to the automo-tive industry.
FRPs because in contrast to conventional materialsthere is no recourse available to existing design anddimensioning standards and therefore it’s not thateasy to predict an FRP component’s dynamic be-haviour in conjunction with the rest of the ma-chine’s structure,” explains the Aachen-based sci-entist. “Mistakes are made, for example, when acomponent is dimensioned in terms of its mechan-ical strength in just one axis direction, while ignor-ing the mechanical strength in the other axis di-rections. But if we use simulation tools to fine-tunethe interrelationship between the FRP componentand themachine tool’s own dynamics, nothing cango wrong. So to solve the problem, the requisitecompetences are brought together in our companywithin this project.”
Lasering, not bonding
Another critical consideration is joining CFRPs tometals. Up to now, an adhesive bonding processhas been used, which according to Filippos Tzan-etos has four disadvantages:W The CFRP surface has to be machined mechani-cally. This leads to unsteadiness and aweakeningof the CFRP’s properties.
W It guarantees only a low level of mechanicalstrength (per joint: 10 to 40 megapascal).
W It is closely dependent on the ambient conditions(e.g., temperature, soiling, chips, cooling lubri-cant).
W Bonded joints possess a low resistance to wear.All these disadvantages are eliminated by a laseringprocess. But it’s not only the joining technologythat MAP’s branch manager sees as problematic.“In order to assure precise positioning and repro-ducibility accuracies in the machine even in thecase of high dynamic response, we scrape off thelayers on the linear guides by hand,” says ChristophTischmann. “It’s now an enormous challenge forus to accomplish this with CFRPs as well.”Despite all these difficulties, the change-over to
CFRP has been worth it, opines the expert with aview to EMO Hannover. The machine tool manu-facturer is thinking about a shared informationstandwith the Fraunhofer IPT in order to showcasethe advances and procedures involved with this“newmaterial”. “Basically, at the end of this projectwe aim to be putting a dynamic, high-precisionand above all powerful machine on the market,”explains Christoph Tischmann. “We would like tosee it becoming widely accepted in the aerospacesector, particularly.”ipt.fraunhofer.de
“So as not to have to compromise on thedynamics, we were looking for a way to compensatefor the greater weight by using a CFRP variant.”Christoph Tischmann, Branch Manager of MAP Werkzeugmaschinen from Magdeburg
document301301377595353904.indd 17 19.05.2017 14:42:34
SUPPLIERS DIRECTORY
18 6-2017
Quick Sourcing Grid:Tool & Modul Materials
Adonpag
e
Compan
ypr ofileat
etmm-online.co
m
Aluminum
Allo
ys
Aluminum
Plate/Sets
Company | Contact
Hasco Hasenclever GmbH + Co KG, Lüdenscheid, DE | www.hasco.com 1
Meusburger Georg GmbH & Co. KG, Wolfurt, AT | www.meusburger.com 13
3D Systems GmbH, Darmstadt, DE | www.3dsystems.com
Alcoa Europe, Birmingham, UK | www.alcoa.com
Alimex Metallhandels. mbH, Willich, DE | www.alimex.de
Allega GmbH, Niederglatt, CH | www.allega.ch
Ampco Métal SA, Marly, CH | www.ampcometal.com
Aubert & Duval, Gennevilliers Cedex, FR | www.aubertduval.com
AW Precision Ltd., Rugby, UK | www.awprecision.co.uk
Boehlerit GmbH & Co. KG, Kapfenberg, AT | www.boehlerit.com
Böhler Schmiedetechnik GmbH & Co. KG, Kapfenberg, AT | www.bohler-forging.com
CMT Materials Inc., Attleboro, USA | www.cmtmaterials.com
Deutsche Edelstahlwerke GmbH, Witten, DE | www.dew-stahl.com
Deville Rectification-Buderus, Pont-Salomon, FR | www.deville-recti.com
DME Europe, Mechelen, BE | www.dmeeu.com
DME UK, Oxon, UK | www.dmeeu.com
Dytron Corp., Fraser,MI, USA | www.dytroncorp.com
E.N.S. International S.r.l., Villanuova sul Clisi (BS), IT | www.ensint.com
Eberhard Werkzeugtechnologie, Nordheim, DE | www.eberhard.de
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de
EOS GmbH Electro Optical Systems, Krailling, DE | www.eos.info
European Metal Supplies, Merchtem, BE | www.emsmetals.be
FCPK Bytow Sp. z.o.o., Bytow, PL | www.fcpk.pl
Fibro GmbH, Haßmersheim, DE | www.fibro.de
Fine Cut Graphic Imaging Ltd., Lancing, W Sussex, UK | www.fcadvancedengineering.co.uk
Hales Tool & Die Ltd. Unit 14, Maldon, Essex, UK | www.halesmastip.co.uk
Hitachi Metals Europe GmbH, Düsseldorf, DE | www.hitachi-metals.co.jp/e
HSB Normalien GmbH, Schwaigern, DE | www.hsb-normalien.de
Huntsman Advanced Materials (Switzerland) GmbH, Basel, CH | www.huntsman.com/advanced_materials
Industeel Creusot, Le Creusot Cedex, FR | www.industeel.info
Injecdesign Moldes para Plastico Lda., Oliveira de Azeméis, PT | www.injecdesign.com
Lucchini RS S.p.A., Lovere (BG), IT | www.lucchinirs.it
Lugand Aciers, Oyonnax Cedex, FR | www.cfam.fr
Mersen France Gennevilliers S.A.S., Gennevilliers, FR | www.mersen.com
Millutensil s.r.l., Milano, IT | www.millutensil.com
Nonnenmann GmbH Präzisionsteile, Winterbach, DE | www.nonnenmann-gmbh.de
Pedrotti S.p.A., Gavardo (BS), IT | www.pedrotti.it
Poco Graphite, Inc. an Entegris Company, Decatur, TX, USA | www.poco.com
Poco Graphite Sarl, Limonest, FR | www.poco.com
Präzi-Flachstahl AG, Everswinkel, DE | www.praezi.de
Saglam Metal A.S., Istanbul, TR | www.saglammetal.com
SPI Lasers, Southampton, UK | www.spilasers.com
Synthesia, Pont-Sainte-Maxence, FR | www.synthesia.com
Tau Metalli S.p.A., Travagliato (BS), IT | www.taumetalli.it
Tokai Carbon Europe Ltd., Oldbury, W Midlands, UK | www.tokaicarboneurope.com
Uddeholms AB, Hagfors, SE | www.uddeholm.com
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document5241047805937710485.indd 18 22.05.2017 11:11:49
SUPPLIERS DIRECTORY
196-2017
Brass
Copper
Allo
ys
Foam
s
Graphite
MouldCoatings
Nicke
l-Bas
eAllo
ys
Res
ins/Polymers/Silico
nes
Steel,H
arden
ed
Steel,M
ild
Steel,P
orous
Steel,S
tainless
Steel
Plates
Sup
eralloys
Tung
sten
Carbide
document5241047805937710485.indd 19 22.05.2017 11:11:50
PRODUCT FOCUS SURFACE TREATMENT
20 6-2017
Grinding update forprecision and quality
Cornwall-based pharmaceutical companyWest PharmaceuticalServices develops pharmaceutical packaging components. For their
moulds, they recently acquired grinders by Jones & Shipman for the sur-face treatment of their high-grade stainless steel moulds.
Sou
rce:J&
SWest
The specialised grinding sectionwithin the Bod-min, Cornwall, moulds and tooling manufac-turing operations ofWest Pharmaceutical Ser-
vices Cornwall Limited has maintained its loyaltyto Jones & Shipman grinding machines followingan investment and upgrade programme. Recentlyinstalled have been a Jones & Shipman Ultramat650 Easy cylindrical grinder, two J&S 524 Easy sur-face grinders, and a Hauser H35 jig grinder – alsosupplied through Jones & Shipman.West is a leader in the development of pharma-
ceutical packaging components and delivery sys-tems for injectable drugs. It prides itself in beingat the forefront of pharmaceutical and biotech in-novation, developing new therapies that will be-come tomorrow's healthcare solutions. In Bodmin,the extensive toolroom operation reflects the stand-
ards of the pharmaceutical industry – themachinetools and environment are spotless – and as JohnChaffe, Manufacturing Manager at the plant, ex-plains, there is a culture of not just cleanliness butabsolute precision.“Consistency, accuracy and surface finish are the
mantras across everything we manufacture,” saysChaffe. “Mostly, we work in stainless steel withrubber mould manufacture predominating andthese are bespoke to themanymouldingmachinesin operation inWest’s worldwide operations.Primarily, the mould consists of two matching
plates containing inserts that create the seals orstopper vials. Plates can accommodate anythingfrom a few hundred inserts to the very largest wemanufacture that contains 11,000,” the manufac-turingmanager explains. “There is no compromise
The J&S touchscreencontrol with Easy software.
Source:J&S West
INFOMachine tool man-ufacturer Jones &Shipman, foundedin Leicester, En-gland, in 1899,produces a widerange of grindingmachines likeprecision cylindricalgrinding machinesand serves preci-sion industriessuch as automo-tive and mouldmaking.
document5640511281863271023.indd 20 19.05.2017 11:31:49
6-2017 21
on precision or quality and component repeatabil-ity is a major factor that frequently necessitatescomplex ground surfaces to low micron finishes.We always flood the component andwork table incoolant,“ he adds, “a time proven way of negatingthermal expansion.”As well as rubber moulds in many formats, the
Bodmin operation also manufactures plasticmoulds for products such as tamper-proof tips; veryfine- ground cones for producing needle shieldsand trim dies used for precision- cutting the fin-ished seals after moulding. High-grade stainlesssteel is the first- choiceworkpiecematerial for boththe surface finishes achievable, and also becauseof the arduous sterilising regime that involves sub-mersing the moulds in 400°C saline solution.
Grinding high-grade stainless steel
And, as John Chaffe explains, Jones & Shipman haslong been the preferred grindingmachine supplierto West in Bodmin. “We have operated two older1300’s for some years, but when it came time toupgrade, wewere impressedwith the Easy softwareJ&S has developed for programming and operatingits latest-generationmachines.We first invested ina 524 surface grinderwith the touchscreen and Easysoftware, and when we added another 524 alongwith an Ultramat Easy 650 cylindrical machine,they readily integrated with our manufacturingprocesses.”Operator acceptance of the Easy software has
been excellent, and while the many different pro-grammes are accessed from a network, skilled andsemi-skilled operators alike find the software usedat the machine "easy" as its name suggests. Thelatest-generation Ultramat 650 specified by Westfeatures the optional B axis with its wheelheadswivel for grinding negative tapers. The B axis pro-vides the ability to not only grind multiple diame-ters but to angle features on components in oneprocess and to automatically externally and inter-nally grind in one set-up. This not only improvesthe cycle time but also the important repeatabilityand concentricity of parts as the component doesnot have to be remountedwhen undertaking batchwork.
Running micron accuracies
Another specified option is anACL (acoustic listen-ing device), which allows for very precise pick-upby the operator when the wheel touches on thepart. It is very accurate and allows the operator torun the machines to micron accuracies. There isalso a special adaptor to accommodate occasionalpolar grinding.The Ultramat 650 design features a one piece "Tee
Bed" designwith a fully supported table combinedwith technical innovation and the ability to offerhigh geometric accuracy.The control panels have membrane-type touch
keys and electronic handwheels, while themachinealso has automatic dressing and grinding cycles,which means it can be quickly set, then left un-manned. As standard, it is equipped with Heiden-hain "Absolute" Nano linear scales and Fanuc Dig-ital AC servo-motors and control.jonesshipman.com
SURFACE TREATMENT PRODUCT FOCUS
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SolidCAM supports multi-taskMill-Turn machines, with seamlessly
integrated advanced Mill-Turn module.
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The unique iMachining Technology Wizard, provides optimal feeds and speeds, taking into account the toolpath, stock and tool material
SolidCAM supports multi-task Mill-Turn machines, with seamlessly
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A collection of members of the EuropeanTool and Mould Making industries andthose who are interested in the sector.
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Join us on Linkedin
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2
document5640511281863271023.indd 21 19.05.2017 11:31:53
SUPPLIERS DIRECTORY
22 6-2017
Quick Sourcing Grid:Mould Surface Treatment
Adonpag
e
Compan
yprofileat
etmm-online.co
m
CLEANING
Clean
ers,
Nonu
ltras
onic
Clean
ers,
Ultras
onic
Company | Contact
Meusburger Georg GmbH & Co. KG, Wolfurt, AT | www.meusburger.com 13
Acrolab Ltd., Windsor, CA | www.acrolab.com
Alpha Mold Tech Limited, Shenzhen, UK | www.alpha-mold.com
Asco Carbon Dioxide Ltd., Romanshorn, CH | www.ascojet.com
Boride Engineered Abrasives, Traverse City, MI, USA | www.borideabrasives.com
Buchem Chemie + Technik GmbH & Co. KG, Köln, DE | www.buchem.de
Diprofil Diamantprodukter AB, Spånga, SE | diprofil.com
DME Co., Madison Heights, MI, USA | www.dme.net
Dong Guan T-Tech Tooling & Plastic Ltd., Dong Guan City, CN | www.tsunngai.com
Dytron Corp., Fraser,MI, USA | www.dytroncorp.com
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de
Eko Plastic Improvements, Jordan Valley, IL | www.eko-plastic.com
Engis (UK) Ltd., Henley-on-Thames, UK | www.engis.com
Engis Corp., Wheeling, USA | www.engis.com
Finnsonic Oy, Lahti, FI | www.finnsonic.com
Fodesco OY, Lehmo, FI | www.fodesco.fi
Gesswein & Co. Inc., Bridgeport, USA | www.gesswein.com
H.G. Hassfurther GmbH & Co. KG, Lüdenscheid, DE | www.hgh-luedenscheid.de
Irmamolde Lda., Maceira-lra, PT | www.irmamolde.pt
Joke Technology GmbH, Bergisch Gladbach, DE | www.joke-technology.de
Kemet International Ltd., Maidstone, Kent, UK | www.kemet.co.uk
Master Abrasives Ltd., Daventry, Long March Industrial Estate, UK | www.master-abrasives.co.uk
Matissart Nord, Labourse, FR | www.matissart.com
Micro Fusion Technology Inc., Hemingway, USA | www.micro-fusion.com
Millutensil s.r.l., Milano, IT | www.millutensil.com
Nakanishi Inc., Kanuma-shi, Tochigi-ken, JP | www.nsk-nakanishi.co.jp
O.C.S. srl, Adrara S. Martino, IT | www.ocs-stamp.it
O.R. Lasertechnologie, Dieburg, DE | www.or-laser.de
oelheld GmbH, Stuttgart, DE | www.oelheld.de
Otto Suhner AG, Brugg, CH | www.suhner.com
Petform Ltd t/a Anker Moulding Systems, Accrington, Lancs, UK | www.ankerhouse.com
Rofin-Sinar Laser GmbH, Hamburg, DE | www.rofin.com
Saint-Gobain Ceramic Materials, Worcester, USA | www.amplexproducts.com
Saint-Gobain Grains & Powders, Avignon, FR | www.saint-gobain.com
Sobef-Sierom, Saint-Priest, FR | www.sobef-sierom.fr
SST Microwelding, Bordeaux, FR | www.sstmicrowelding.com
Starrett Precision Optical Ltd., Skipton, UK | www.guyson.co.uk
Suhner France S.A., Alfortville, FR | www.suhner.com
Suhner Su-Matic Handelsges. mbH, Wien, ST | www.suhner.at
Trumpf Werkzeugmaschinen Deutschland Vertrieb + Service GmbH, Ditzingen, DE | www.de.trumpf.com
Sou
rce:
Müc
ke/Jun
g
document8397739602415938701.indd 22 22.05.2017 10:32:06
SUPPLIERS DIRECTORY
236-2017
EQUIPMENT SUPPLIES
MouldClean
ingAgen
ts
MouldClean
ingSys
tems
Lase
rWeldingEquipmen
t
MouldPolis
hing
Equipmen
t
MouldRep
airEquipmen
t
WeldingMac
hine
s
Abrasive
s
Diamond
Compoun
ds
Lubrica
nts
MouldRelea
ses
Polis
hing
Abrasive
s
Polis
hing
Sup
plie
s
Rep
lace
men
tParts
document8397739602415938701.indd 23 22.05.2017 10:32:07
TECH FOCUS R&D
24 6-2017
A solution for connecting machinesfrom different manufacturers
One of the biggest problems with digitalisation is that it either needs ma-chine manufacturers to open their software systems to other brands, or itneeds a connection software that can work with machines regardless of theirproducers. The latter is being attempted by researchers from Germany.
Johannes Kölsch (left)and Christopher Heinzare developing a user-friendly softwaresystem that connectsdevices from differentmanufacturers.
Sou
rce:
University
ofKaiserslautern
The Internet of Things is steadily progressing.Not only computers, but also machines, carsand household appliances are connected. Link-
ing devices from differentmanufacturers is provingto be difficult. Researchers from the University ofKaiserslautern have found a solution. They are de-veloping a user-friendly software system that con-nects devices from different manufacturers. Theuser can decide who has access. The system isideal for companies, private households, trafficsystems and building technology. The technologywas also presented at the research stand of theState of Rhineland-Palatinate at Hannover Messein April.Users can conveniently turn on the heating or
lights remotely by smartphone, while machinesexchange data in an automotive production facil-ity. These are just two examples that show how
devices are becoming increasingly interconnected.The Internet of Things (IoT) has been part of oureveryday lives for quite some time. “An increasingnumber of devices have their own network con-nection and IP address,” says Christopher Heinz,doctoral student of Prof Christoph Grimm, who ishead of the design of cyber-physical systems de-partment at the University of Kaiserslautern. Theabbreviation ‘IP’ stands for Internet Protocol andrepresents a unique web address.In the near future, an array of devices could be
interconnected in many households, exchangingdata – such as the vacuum cleaner with the coffeemachine and refrigerator. “Currently, the deviceshave to originate from the same manufacturer,”adds Johannes Kölsch, another doctoral student ofthe professorial chair. “Companies typically offertheir own web solutions for this purpose.”
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R&D TECH FOCUS
256-2017
R&D IN BRIEF
Efficient deliveriesA team of mathematicians at the Alpen-Adria-Universität, assembled by optimisation expertPhilipp Hungerländer, has succeeded in in-creasing the efficiency of the delivery routes ofa global retail brand based in England by morethan 10 percent. As a result, the corporationhas reduced its costs by several million eurosper year.aau.at
Correcting postures
Researchers in Hanover are about to develop acamera system that observes assembly work-ers and warns them of unergonomic move-ments. Companies can use the system tomaintain their employees’ productivity perma-nently.iph-hannover.de
Data scienceA newly foundedinitiative at Har-vard will work ondata science.The university-wide pro-gramme willwork on makingsense of massive
amounts of data and how it can benefit people.harvard.edu
Industry 4.0“Swedish-German Testbed for Smart Produc-tion” is the name of a newly established Ger-man-Swedish initiative, which serves as acommunication platform for the concrete im-plementation of various Industry 4.0 technolo-gies.ipt.fraunhofer.de
The two computer scientists are working on asoftware system that aims to connect devices andmachines from differentmanufacturers. “Our tech-nology is similar to the concept of an adapter usedto connect differently shaped plugs with electricalsockets abroad,” Kölsch explains. Experts also referto this as interoperability. This term describes thecapability of technical systems from variousman-ufacturers to communicate with each other andrecognise different signals, for instance.The researchers at the University of Kaisers-
lautern would like to connect the devices using asoftware interface. The system is intended to be asimple and user-friendly solution. Special hardwareis not necessary. It is conceivable that the technol-ogymay be used on network devices already avail-able in private households, for example, Internetrouters. “The devices would only have to be regis-tered in the system,” Heinz continues. A particularadvantage is that the user retains control over whocan control and use the appliances. “Users cangrant permission to someone else. Datawould thenbe encrypted before being transmitted from send-er to recipient according to the latest securitystandards,” Kölsch says.
Combining different machines inproduction facilities
This technology is not only of interest to privatehouseholds. Companies could use it to combinedifferent machines in their production facilities,hospitals could connect important medical equip-ment in laboratories and treatment rooms, andtransport enterprises could link buses and trainsto display screens at stations. The distribution sys-tems of large building complexes could also becontrolled more easily in this way, including heat-ing, ventilation, air-conditioning and lighting.Moreover, the power supplied by renewable ener-gy sources could easily be distributed. This systemwould allow solar panels to deliver stored electric-ity directly to applianceswhen they require power,such as electric cars, in order to recharge.The research work is taking place as part of the
‘Vicinity’ project, which is supported by the Euro-pean Union to the tune of 7.5 million euros. Profes-sor Grimm coordinates the project in Kaisers-lautern. Altogether, 16 European partners are in-volved in the work.uni-kl.de
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University of KaiserslauternOver the years, the university, thesole institution of higher educationdedicated primarily to the study oftechnology and natural sciences inthe State of Rhineland-Palatinate,has gained a considerable regionaland international reputation.Students can benefit from the
many well-known research institutesoperating directly on campus. Spe-cial networks link engineering and
natural sciences with social andeconomic sciences. The universityconsists of 12 departments andoffers over 100 courses to 14,200students.Situated in the heart of Europe,
close to France and the Beneluxregion, just an hour away fromFrankfurt Airport, Kaiserslauternoccupies an important economiclocation.
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TECH FOCUS HOT RUNNERS
26 6-2017
How to choose the correct hotrunner supplierWhen confronted with the increase in available hot runner systems onthe market, making the correct choice for a hot runner supplier is critical.Three qualities are particularly important to consider in the decision-makingprocess: analysis capabilities, design input and product range.
When looking for asupplier, manufacturersoften feel overwhelmedby the countless offers.
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During the infant stages of a new mould buildit is critical that a hot runner designer canprovide input and feedback on the part design
and layout of the mould. Analysis software pro-grams can assist with the correct gate location andnumber of gates, warpage, shrinkage, pressure drop,weld lines, gas traps, shear stress, temperature riseand part fill time so that the performance of thehot runner and the mould are optimised.Incorrect use of a hot runner can adversely affect
the performance of a mould and the product itproduces. An example of this is the degradation ofmaterial within a hot runner ormould cavity. Somefactors affecting plastic material degradation are:Poor venting, increasingmelt temperature or injec-tion velocity, dead areas or shear points within thehot runner, and long residence times inside the hotrunner.Proper hot runner analysis andmanufacture can
assist with:W Identifying likely areas for gas traps to determinevent placement
W Optimisingmelt channel diameters to keep shearstresses at ideal values
W Thermocouple placement for accurate and reli-able heater control
W Advice on profiling and polishingmelt channelsand the use of correct diameter reduction tech-niques
W Optimising melt channel lengths to each cavity,particularly in family moulds
Thermal finite element analysis (FEA) can assistwith determining the optimum thermal profile ofthe hot runner system. Through the use of properanalysis tools and techniques, the hot runner sup-plier can predict issues at an early design stage andmake recommendations to the mould-maker foran improved result.During the design process, mould-makers should
look for a partner that can supply hot runner draw-ings andmodels that are easily integrated into theirmould designs. Hot runner 3-D models used forapproval drawings ensure they are simple for themould designer to check and can easily providegate insert or plate drawings for manufacturing.The hot runner supplier’s ability to be flexible withdrawing file formats and CAD packages is key to asuccessful partnership.Correct part design is crucial to a successful
mould build and there are many areas where thehot runner supplier can offer advice based on ex-perience in the injectionmoulding industry. Designfeatures such as cooling circuits around the gate,dimples in the gate area and thinwall sections canbe commented on and improvementsmade beforea commitment to a particular design. When hotrunner suppliers are invited to be involved in pro-jects at an early stage they are able to provide input
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HOT RUNNERS TECH FOCUS
6-2017
into part design, cavity design and mould layoutthat can be crucial to a successful mould.Competition, the rising costs of materials, time
restraints and new technologies are pressures thatare not new, but exponentially increasing. Efficientuse of time, mould and plastic materials is criticalto the success of every new tooling program. En-suring optimisation at the earliest stage of designwhen the cost of change is lowest will save timeandmoney throughout the build process. Commis-sioning, production efficiency, part quality, cycletime and material content isalso influenced by time invest-ed with your hot runner sup-plier during the early designstage.The cost of making correc-
tions or modifications to a hotrunner after manufacturing isexpensive and time-consum-ing. Quick yet accurate engi-neering is critical to keeping anew tool on time and withinbudget. The use of leading-edgetechnology and the knowledgebasewithin the hot runner sup-plier's engineering group is cru-cial when building a high-per-formance and high-qualitymould.
Product Range
Hot runner technology has ad-vanced significantly in the lastdecade. A hot runner suppliershould be able to assist you inall areas of gating styles, dimpledesign, cooling requirements,electrical optimisation and gat-ing position for precise flowbalancing.When facedwith thedifficult choice of selecting thecorrect hot runner for yourmould, accurate professionaladvice and clear explanationsof the complex technology areimportant to the build of ahigh-performance solution.A broad product range that
covers all applications andmar-kets is critical. Using a singlesupplier for all applications re-moves compatibility and con-sistency issues that potentiallycan occur when working witha variety of suppliers. A strongworking relationship with onesupplier streamlines thewholeprocess for a mould-maker,whether it is a simple hot sprue,complex multi-material, hothalf or family mould. Workingclosely with a hot runner spe-cialist enables mould-makersto deliver runnerless toolingthat is right for the applicationand performs to the customer’sexacting specifications.
The Hot RunnerPlatform that ExceedsAll ExpectationsRegardless of your molding application, Mold-Mastersengineers a range of hot runner solutions focused onsolving industry challenges that are proven to deliverprecision, control, reliability and results. See how theMaster-Series hot runner can solve your next moldingchallenge.Collaborate with us on your next system.milacron.com/master-series
Precision gate geometryand pin guidance technology.
Highest gate quality formillions of cycles.
The mould-maker’s choice in a hot runner sup-plier can dramatically influence the quality andperformance of the mould and the moulded parts.The ideal hot runner supplier will assist with anal-ysis during part design andmould design, providecompatible and accurate design information andutilise the latest technology to improve productperformance. Overall customer satisfaction buildsstrong mould-maker and moulder relationshipsthat result in repeat business and sales growth.Article provided by Mastip: mastip.com
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28 6-2017
TECH FOCUS COMPONENTS
Unbeatable duo for practical smallseries
For modern components of tool and mould making, simply doing one's job isnot enough. Nowadays, they have to fulfill a number of requirements. Aco-operation between Hasco and a Danish customer was able to prove thattwo particular components from Hasco go this extra mile.
Hasco’s small series mouldK3600/… in combination withCMS A8500/…
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With the Duo Clever Mold System (CMS)A8500/… and the small-series mould K3600/…, Hasco enables its customers to save
time and money in the production of small series.The Hasco Clever Mold System A8500/... is an
efficient and variable mould system for injectionmoulding machines. It encompasses all the com-ponents of a classicmould unit, so that the custom-er need only focus on the cavity and ejector platesystems.The A8500/... mould system is fastened to the
machinewith just four screws on each side, ensur-ing that it can be rapidly switched between ma-chines. Infinitely variable clamping bars ensure thatmoulds of different sizes can be readily exchanged.The small series mould K3600/… incorporates all
the elements of relevance on the cavity. The stand-ard component package encompasses the cavityplates, ejector package and corresponding accesso-ry components. It is available in four differentmouldsizes in the materials 1.2767 and Toolox 33; othersizes and materials can be supplied on request.
Since the small-series mould does not requirecentring on themachine, several cavities, eachwiththeir own gating position, can be placed in amould.For articles with an identical mass and colour, set-up times of less than fiveminutes can be achieved.For the small-series mould that goes with the
Clever Mold System, the plate dimensions and thick-nesses, the system diameter, the hole spacing andthe bore packages have been adopted from the clas-sic Hasco K-range. This allows each Hasco K3600/…to be made into a “normal” injection mould toolshould production demand exceed expectations,freeing up the A8500 for future product develop-ment.Using the Clever Mold System in combination
with the small-series mould opens up innovativesolutions to low-cost small production runs throughrapid mould changes on all standard injectionmouldingmachines. Undercuts, core pullers, slidesand hot runners can be directly integrated in theCMS and are available as an adaptor solution for allK3600/… small-series moulds. By employing this
Jochen Müller
INFOHasco was found-ed in 1924 inLüdenscheid.Today, the compa-ny is one of theleading globalsuppliers of modu-lar standard com-ponents and ac-cessories. Throughits invention of themodular standardcomponent systemin 1960 and itsclaim of simplifyingmould-making,Hasco has be-come a pioneer ofpresent-daymould-making.
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6-2017 29
COMPONENTS TECH FOCUS
duo, customers are able to consistently makesmall-series moulds in a simplified and reducedform, thus saving time andmoney from the designstage right through to the application of the mouldon the injectionmouldingmachine. This newmouldphilosophy is based on the clever separation of theclamping system and the mould.
Co-operation with customer forinnovative solution
Michael Lundbech, a longstanding Hasco customerfrom Lundbech intelligent tooling in Ringsted (Den-mark), came up with an idea.Wishing to achieve amore homogeneous temperature distribution ininjectionmoulds, avoid hot spots, reduce the instal-lation space and, not least, achieve time and mon-ey savings, hewas thinking about a design solutionthat would allow cooling channels to cross on asingle plane. Working together with the team atHasco, it proved possible to further develop andimplement this solution.The idea behind the Hasco Cool Cross Z99/... was
thus born. The outcome – a small plastic elementthat is fitted at the crossing point in the mould –offers the user completely new options for design-ing the cooling system in the injection mould. Byemploying the Cool Cross Z99/..., it is possible tohave independent cooling channels crossing eachother flexibly and inexpensively on the same planewithout any major manufacturing outlay. A com-bination of transverse and vertical holes is possible.It is possible to get bywith thinner plates and hencefit shorter nozzle, guide and fastening elements,thus achieving cost reductions.But before this ingenious little part was produced
in series, the first step was to manufacture proto-types. In a joint research project that tested stand-ard prototypingmethods, the A8500/… and K3600/…duo was able to demonstrate its potential.The first Cool Cross prototypes were produced
with a combination of the Clever Mold System andthe small-series mould, in conjunction with inter-changeable inserts produced by differentmethods.The advantage for the customer is the simplicity ofthe concept. A proven quick-changeable mould,including cooling, guides and all the connections,is combinedwith a comparatively small insert thatcan be produced in just a short period of time. Inthis way, the time and cost outlay formodificationsor variants can be kept within limits.hasco.com
The Cool Cross enables users to have independent cool-ing channels crossing each other flexibly on the sameplane without any major manufacturing outlay.
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Start your subscription today:
www.etmm-online/magazine
The Magazine forEurope’s tool &mould makingindustry
Start your subscription today:
Inside your Industry
document921042995162930868.indd 29 22.05.2017 11:27:44
CASE STUDY CUTTING TOOLS
30 6-2017
Milling threads without a tapping drillbore
As a precision manufacturer at the high end of its sector, Eropräzisa makesno compromises with its milling tools. This is why, for the last few years, ithas decided to commit to using the MMC Hitachi Tool range of tools for 'hardmilling' operations, i.e., machining after the heat treatment process.
Whenever ultimate preci-sion is called for: Here, asa wire-eroded folding core.
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INFOFounded in 2002,Eropräzisa is aGermany-basedmanufacturer ofprecision parts. Itscostumers comefrom various areas,such as optics,medical technolo-gy and car racing.
Thomas Richter explains with a smile: “Sooneror later, everyone comes to us”. Of course, hemay be exaggerating slightly, but the many
years of rising demand for high-quality productionservices from Eropräzisawould certainly support hisconclusion. Thomas Richter is CEO of a companythat is not actually that old at all, and with a payrollstaff of just 18 people at the present time, it is notreally all that big, either. Despite that, andwithout aword of exaggeration, this is already a company thatbelongs in the premier league of the Thuringian SMEsector. “We have established ourselves on themarketas a production service provider for high-end preci-sion components made of metal and other compo-nents, a market where it is not uncommon to bedealing with precision levels in the single-digit mi-cron range,” explains the graduate engineer, whofounded Eropräzisa back in 2002 with his partner– who has now gone his own separate way – in the
Thuringian town of Hermsdorf. Ever since it wasfounded, the company has been on a growth path.“We really don't mind what the component lookslike. The important thing for us is that the requiredtolerances and surface roughness levels are suffi-ciently challenging.” In other words, components ofthe kind that not everyone else canmanufacture areproduced here in fully air-conditioned rooms.As well as wire erosion and die-sinking, Eropräzi-
sa viewsmilling – and here specifically the ultra-pre-cise HSC milling of hardened materials – as a keytechnology. For a long time now, the customer basehas extended right across Europe. This customerbase spans sectors such as toolmaking andmould-building, medical technology, precision me-chanics, power station technology and the aircraftindustry, as well asmotor racing. “We alsomanufac-turemany parts for the optical industry, which arosebecausewe are based close in geographical terms to
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CUTTING TOOLS CASE STUDY
6-2017
Carl Zeiss Jena or Jenoptik,” em-phasises Richter. In Hermsdorf,close collaboration with technol-ogy partners is viewed as beingimportant to the success of theproject, for example, in respect toprecision tools for HSC machin-ing. “In this sector, we wish to beamong the leading providers, andhere too, we are breaking newground,” emphasises Heiko Mey-er, the production manager re-sponsible for the milling sector.One example of this is an order
where all that was really involvedwas to equip two finish-ma-chined and hardened mould in-serts with 32 additional M6threads. “This involved strips be-ing bolted on, and the mouldbuilder did not take account of thethreads during pre-manufacture,”recalls Meyer. Both inserts weremade from 1.2343 (X38CrMoV5-1)hot-forming steel that was hard-ened to about 53 HRC. “Thismeant that, although the insertswere not particularly hard, theywere sufficiently hard for threadsto be eroded in them.” The disad-vantage of this was that the ero-sion times were extremely long,and each mould insert took atleast 32 hours to produce.
Recommendation camefrom the applicationstechnicianIt was at this point that the appli-cations technician fromMMCHi-tachi came into his own. To agrowing extent in its hard ma-chining operations, alongside thetools it sources from other provid-ers, Eropräzisa is now using pre-cision tools from this Japanesemanufacturer. To date, the expe-rience gained with MMC HitachiTool has been entirely favourable.Productionmanager HeikoMeyerremembers that the applicationstechnician, Jörg Hecker, addressedthe topic of thread milling onceduring one of his visits. That wasin connection with the Epoch Di-rect Thread series (EDT), whichcanmill into heat-treatedmateri-al in a process-reliable and di-mensionally accurate manner.The great thing about the EDTrange from MMC Hitachi Tool isthat the tapping drill hole can bedone away with altogether. Al-though Heiko Meyer was not re-ally all that convinced, bothmould inserts appeared to be ab-solutely perfect to try this thingout.
Strong team: ProductionPlanning Manager RenéSchaft (left), ProductionManager Heiko Meyerand Jörg Hecker (right)from MMC Hitachi Tool.
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www.uniontool.com [email protected]
Milling video link
Seeing is believing
8000 mm/min ForSteel & Hardened Steel
Up to 55HRC
HIGH SPEED ROUGHINGCXRS / CXLRS
document4725913392413450310.indd 31 22.05.2017 09:08:12
CASE STUDY CUTTING TOOLS
32 6-2017
The practical test by the applications technicianfrom MMC Hitachi Tool then took place using theappropriate M6 threadmiller EDT-1.0-15-TH. The EDTseries covers the standard sizes M2 toM16 aswell asother threadmillers with a pitch of 0.4 to 2 millime-tres. The Japanesemanufacturer states that the pre-ciselymatched cutting edge geometries, the specificultrafine grained substrate and the exceptionally lowproduction tolerances of the EDT range – in conjunc-tion with MMC Hitachi Tool's own nano-crystallinePVD coating ATH (TH60+) – assure high dimension-al integrity of threads over extremely long servicelives. The application range, tried and tested in prac-tice, is a broad one, and comprisesmaterials rangingfrom soft metals to hardened steel alloys of up to 66HRC.With this tool, it is possible to mill directly in-to the solid material of a helix without the need forany pre-machining. This is because the EDTproduc-es the core drill hole with face-cutting blades –whilethe thread flanks are being milled.
Only a few clicks of the mouse
The applications technician fromMMCHitachi Toolworked with the customer on the CAM system toadapt the cutting parameters to suit themould insert(Hypermill). “Then we were all standing by the ma-chine fairly quickly,” recalls René Schaft. As manag-er of production planning at Eropräzisa, he is alsoresponsible for NC programming. In this case, themachine was the OPS Speed Hawk 650. Thanks toits fourth and fifth axis in the table, themould insertfixture settings do not need to be altered. “The actu-
al programming process only took a few clicks of themouse, thanks to the preliminary work done on themacros, and to the support provided by the applica-tions technician from MMC Hitachi Tool,” explainsSchaft. Jörg Hecker adds: “The important thing isthat the spindlemust rotate counter-clockwise (ccw)because the millers in the EDT series are all ccwtools.” This creates synchronous movement at thecutting edge, which reduces cutting pressure andincreases service life.
32 threads and no abrasive wear
The outcome was a solution that immediatelyconvinced everyone involved. “We milled all 32threads on the mould insert with the EDT-1.0-15-THdirectly into hardmaterial in a single fixture setting,albeit with several presentations to the tool,” reportsHeiko Meyer, who went on to say that the cuttingresult from the thread miller still looked like newafter the last thread had been cut, without any signsof abrasive wear. “That really did impress us”. Theapplications technician was also satisfied thateverything simply ran as smoothly as he still remem-bers today. “In terms of compressed air cooling, andtherefore with swarf removal on the 5-axis SpeedHawk 650, we regrettably did not have ideal condi-tions.” The key to successful threadmilling is reliableswarf removal, without which tool failure is likelyto occur. Nonetheless, everything ran as smoothlyas planned right from the very first thread.“Until I saw it withmy own eyes, I would not have
believed that you could mill straight into hardenedmaterials in a process-reliable manner withoutpre-drilling,” admits Heiko Meyer openly. “Certainlynot with materials of 60 HRC and more.” Preciselythis was demonstrated in Hermsdorf a short whileago at a customerworkshop. This involved using EDTtools to mill several M6 and M8 threads into 1.2379(X155CrVMo12-1) coldworking steel with a high alloycontent. “What we demonstrated here was thatthread milling, even at 60 HRC, functions in an ab-solutely process-reliable manner, and that evengauge-compliant threads can be manufactured in areproducible manner.” This is of particular interestto a production service provider such as Eropräzisabecause, to a growing extent, this is what customersare calling for.
100 percent faster
The Hermsdorf-based precision specialist also im-pressed with the enormous saving in time it wasable to achieve. Milling of all 32 of theM6 threads onthe form insert was completed within about half anhour, so roughly one minute per hole. “The die-ero-sion of a single thread could otherwise have takenan hour, after which we would have had to changethe fixture setting to reflect the physical arrangementof the threads,” explains Heiko Meyer. “Withthread-milling, wewere therefore 100 percent faster.”To which Thomas Richter had this to add: “We aredeeply impressed by MMC Hitachi Tool. Their toolsare really good, and in some cases are even indispen-sable to us.” The Eropräzisa boss also praised theirapplication-specific advice and their on-site support.“After all, it is on this that any machining outcomestands or falls.”hitachitool-eu.com
Thread miller EDT-1.0-15-TH 5 in the shrink-fitchuck together with thered nozzle body on themedium distributor thatdoes not co-rotate. Athigh pressure, an airshroud is generatedaround the miller shankthat blows swarf awaysafely during thethread-milling operation.
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MMC Hitachi Tool in briefMMC Hitachi Tool Engineering isone of Japan's leading tool man-ufacturers.
The company has concentrated fordecades on tool and mould con-struction as a target industry andhas developed a tool range thatcovers the entire process chain.More than 25 specialists operate inGermany alone and the companyhas more than 30 years of experi-ence in Europe. The in-house-de-
veloped TAR database with over10,000 reference reports and testsis especially helpful. Thein-house-developed Production50manufacturing concept providesshorter process times and moreefficient machining methods ne-cessitated by increasing pressureon time and costs in tool andmould construction. MMC HitachiTool offers innovative tool technol-ogies and individual service tomeet these high demands.
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6-2017 33
CUTTING TOOLS CASE STUDY
Machining processesfor any materialStarrag UK has expanded the number of machines it hasin-situ at the Advanced Manufacturing Park with a sev-en-axis Bumotec s191 linear CNC turn-mill centre beinginstalled at the AMRC with Boeing Centre.
The working area ofthe seven-axisBumotec s191 linearCNC turn-mill centreinstalled at theAMRC with BoeingCentre.
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INFOStarrag Group is aglobal technologyprovider ofhigh-precisionmachine tools formilling, turning,boring and grindingworkpieces ofmetallic, compositeand ceramic mate-rials.
According to Starrag, the Swiss-built machinehas linear drives and high-level thermal sta-bilisation that achievesmachining accuracies
of 2.5 microns in the six-sided single set-up ma-chining of even themost complexworkpieceswith-in the X, Y and Z axes capacity range of 400 mm,200 mm and 410 mm, respectively.Dr David Curtis, Technical Fellow at the AMRC
with Boeing Centre, explains: "The Bumotec s191gives us opportunities to develop revolutionarynew machining processes in any material and forany sector. We are now looking for projects wherewe can take small, complex components and de-velop optimised, cost-saving solutions that addvalue to UK industry."With the main spindle complemented by a
sub-spindle that can turn in both horizontal andvertical planes, themultifunctional machine offersa host of functions including turning, milling, drill-ing, thread generation, grinding, gearcutting andhobbing, Starrag says.According to the company, the tool magazine
options extend to up to 90 pockets to enhancesingle set-up operations on a machine with a barcapacity of 42 or 65 mm. Rapid traverse rates of 50m/min and a 30,000 or 40,000 revs/min spindlespeed also contribute to the machine’s fast cycletimes.The Bumotec s191 joins six other Starrag-supplied
machines at the Advanced Manufacturing Park;three each at the AMRCwith Boeing Centre and theNuclear AMRC.Bumotec was acquisitioned by Starrag in 2012.
starrag.com
®
INOVATOOLS Eckerle & Ertel GmbHD-85125 Kinding-HaunstettenIm Hüttental 3-6Tel. +49 (0)8467/[email protected]
INOCUTcutting-data
Your specialist forSolid carbide tools
www.inovatools.euINOSCREW
document6506882418505830458.indd 33 22.05.2017 10:33:00
34 6-2017
How to get the correct dosing ofcooling lubricants
Cooling lubricants are essential in machining metals for reducing heatand to remove chips. To achieve efficient results during production, it isimportant to use the correct cooling lubricant dosing. This can beachieved with a proportional dosing device.
Lubricants in the metalworkingindustry are used to dissipateheat during machining.
In themetalworking industry, lubricants are usedto dissipate heat during drilling, milling, cutting,grinding and other machining processes. They
are also used to flush chips away from the surfacearea of theworkpiece and improve surface quality.The areas of energy efficiency and sustainabilityare important considerations in selecting a fluidfor this application and this has led to the devel-opment of new cutting fluids.With the successful launch of the innovative
two-component-process Bonderite Dual-Cys, Hen-kel Adhesive Technologies has set a new benchmarkin the development of metalworking lubricants.Synergies between lubricant and cleaner are usedto reduce costs, improve performance, save energy,reduce waste and improve working conditions.In this new dual process, the cleaning bath is
100% recycled into the cutting lubricant. The pro-
cess enables a type of pre-cleaningwith low foam-ing at low cleaning temperatures in the toolingmachine.Martin Desinger, Business Development Manag-
er for Machining Lubricants at Henkel, comments:“Recycling the cleaning solution instead of dispos-ing of it and using the synergies between the clean-er and the water-soluble cutting fluids results inhigh lubrication performance, superior purity ofthe parts and excellent corrosion protection.”For companies, the use of Bonderite Dual-Cys
results in cost reductions of up to 40% due tomoreefficient use of coolant, water and energy consump-tion aswell as reduced disposal volumes. To furtherincrease the energy efficiency and sustainability ofthe tooling machine, Henkel recommends the useof the LDTDosatron Proportional Pumps for routinedosing of the lubricants.
Dipl.-Ing. Jens Voigt
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MACHINING EQUIPMENT TECH FOCUS
356-2017
LDT Dosiertechnik of Hamburg is a leading dis-tributor in the supply of non-electric dosing pumps,offering its customers over 25 years of experience.The companywas founded in 1991 in Hamburg andfor the past 25 years has been operatingwithin thedosing-pump industry in Germany and Europe.High expertise, a comprehensive range of products,fast response times and short delivery times havebeen the driving force behind the company's con-tinued growth. In the anniversary year of 2016, LDTDosiertechnik moved to new premises with a ser-vicingworkshop and expandedwarehouse capac-ity. Since the founding of the company, LDT Dosi-ertechnik has become amarket leader for non-elec-tric proportional dosing pumps in Germany.
The operating principle of theDosatron proportional dosing pump
The Dosatron proportional dosing pump workswith a volumetric hydraulic motor that providescontinual injection of the liquid or soluble concen-trate. It uses water pressure to operate and onlyrequires connection to the water supply. The con-centrate for dosing is drawn in independently fromthe water supply and is mixed with the drive wa-ter. The dosing quantity always stays proportionalto the water throughput, as per the manually ad-justed dosing rate, even if there are flow or pressurefluctuations in the water supply system. Further-more, the metering accuracy of the pump is notaffected by piping lengths, which simplifies itsinstallation.The proportional dosing system combines the
functions of a water meter, dosing pump andmix-er into a single unit with a design that does not
allow for any dosing errors. The dosing system issimple to operate and has low maintenance re-quirements. Its compact form gives flexible instal-lation options including mounting as a single me-tering device directly on the tooling machine, as ametering device on a mobile metering carriagetogether with a concentrate container, ormountingat a central location as a filling station. It is availa-ble in a selection of housingmaterials with a choiceof seal elastomers to suit the application needs.ATEX certification is also available for use in po-
INFO
Henkel Adhesives and BonderiteHenkel Adhesives is a provider foradhesives, sealants and function-al coatings.
According to the company, it offers acomprehensive portfolio of tai-lor-made solutions for its industrialcustomers and high-quality consum-er and in addition various profes-sional products. It is representedworldwide by its global team ofpartners with the aim to deliverbest-in-class service.One of the areas where Henkel
Adhesives is present is Releasecoatings are release coatings. Theseare specified by manufacturersworldwide in a variety of plastic and
rubber moulding processes. Whenapplied to a mould, the releasecoatings form micro-thin, thermallystable surfaces that are chemicallybonded to the mould surface, result-ing in multiple, contaminant-freereleases and reduced manufacturingcosts.Bonderite is one of Henkel's
brands responsible for surface tech-nology and process solutions includ-ing lubricatns for forging, formingand machining, as well as cleaners,metal pretreatment and coatings.Bonderite's customers come fromvarious industries like automotive,aerospace, agricultural and con-struction.
The Bonderite Dual-Cys process in comparison with the standard process with a 100 m³ central coolant system.
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36 6-2017
tentially explosive atmospheres as well as FDAcertification for food safety applications.In co-operation with Henkel, LDTDosiertechnik
has created a special solution that satisfies eventhe most stringent requirements. The use of thewater-powered pump, which requires no electricsupply or other utilities such as compressed air,offers customers further potential to reduce energyand installation costs.Martin Desinger says, “Thanks to the excellent
co-operation with LDT, we have succeeded in de-veloping a tailor-made ‘plug and play’ system,whichmeets all requirements of our customers anddifferent packaging sizes. This is exactly the flexibleand safe solution we were looking for.”For the Bonderite Dual-Cys process, two propor-
tional pumps are connected in series. Feed pumpsare used to load lubricant into the toolingmachine.The LDT Dosatron dosing pumps are then used tomake up the coolantmixture and refill the recycledsolution to maintain the desired concentration.
Individual units to complete plug-and-play packages
The first proportional pump draws cleaning con-centrate into the water stream and mixes it withthe water. This water-cleaner solution is thenpassed through the second proportional pump,which furthermixes the solutionwhile drawing inthe cutting fluids. The result is a well-homogenizedmixture that is supplied ready for use, volumetri-cally to the tooling machine to replenish evapora-tion losses and replace drawn-out lubricant.Martin Desinger adds: “Previous dosing systems
have not been able to reliably and correctly producethe low levels of subsequent quantities of our Du-al-Cys process. In addition, the use of differentpackaging sizes from the canister to the IBC (Inter-mediate Bulk Container) totemust also be ensured.High reliability, long lifetime of the devices andexact dosage according to the motto, '.... What I set
comes out at the end of the tube...' were of utmostimportance in our Dual-Cys process. Measurementswith a diverse selection of customers have result-ed in a deviation of +/- 0.05% from the set value– a first-class result!”These innovative dosing devices can be integrat-
ed as individual units into existing systems at thecustomers' premises. Alternatively, they can besupplied as plug-and-play packages in the form ofcomplete, non-electric dosing cabinets.“Furthermore, the dosing devices are character-
ised by the fact that the pipeline system for thefilling hose can be almost endlessly long, whichdrasticallyminimises the required number of dos-ing devices,” says Desinger. “Thanks to its compactfootprint, the whole system can also be designedas a mobile safety pan for two drums. Everythingis quick and easy to assemble (“Plug & Play“) andall required screws and other connections are in-cluded. In addition, the package includes a timerto prevent overflow, return flow protection, watermeter, flow limiter and a filling gun. The dosingcabinet is also lockable to prevent unauthorisedaccess or tampering,” the business developmentmanager concludes.The benefits of combining the Bonderite Dual-Cys
process and the LDTDosatron Proportional Pumpsare already being recognised in the marketplace.The Sales &Marketing of LDTDosiertechnik com-
ments: “In addition to individual proportionalpumps, the compact dosing cabinets are increas-ingly being requested and sold beyond the bordersof Europe. In January 2017, the first dosing units forHenkel India were delivered and we await furtherinquiries from home and abroad. Our extensivewarehouse, located in our new company building,means we can usually meet even rapid deliveryexpectations of our customers.”
Ability to produce low levels ofsubsequent quantities
Martin Desinger concludes: “As a globally operatingcompany, we have found a sales partner in LDTDosiertechnik that can deliver our common ideato our customers worldwide - and very quickly!Having a partner that is straightforward to dealwith, reliable and very responsive is very importantto us.In addition, the price-performance ratio fits -
which is 100% to our customers’ benefit. We arelooking forward to providing our customers withthe steadily growing Dual-Cys with high-qualityand reliable dosing systems, especially as the LDTproportional pumps support the sustainability con-cept of our Dual-Cys process.” The combination ofthe Bonderite Dual-Cys process and LDT DosatronProportional Dosing Pumps offers machine tooloperators a great deal of benefits. In addition tocost reductions and quality improvements provid-ed by the new two-component process from Hen-kel, energy savings are achieved from the use ofthe current-free dosing devices. Overall, the systemoffers reliable, repeatable performance that willhelp improve plant availability, lower operationalcosts and, with less waste, improve the sustaina-bility of machining processes.henkel-adhesives.com,ldt.info
A DT Dosatrondosing cabinets fortwo concentrates.
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376-2017
Delivering complex tools withinseventy-two hoursTool manufacturer Fanar is known for its uncompromising quality. The Polishcompany supplies a wide range of cutting tools for threading, drilling, millingand turning. Technical Director Dariusz Ptaszkiewicz explains how theyfound a solution to produce tools for a highly demanding market.
Dariusz Ptaszkiewicz,Technical Director atFanar, and a colleague,standing in front of theirnew Anca MX7 LinearCNC grinder.
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From the beginning, Fanar has invested in thenewest technology andmachine tools to ensurethey have the capability to offer the latest prod-
ucts. However, in 2016, Fanar realised that if it wasgoing to remain ahead in themarket it would needto improve the production time formanufacturingcomplex cutting tools.Dariusz Ptaszkiewicz, Technical Director at Fanar,
said: "In the era of eBay, people are accustomed tothe convenience of online shoppingwhere productsare delivered within two to three days. This mind-set can be challengingwhen customers expect thissame type of service, especially when purchasingspecialist cutting tools.We needed to find away tomeet our customers’ expectations without com-promising on quality."The more complex the tool, the longer it takes
to produce, and it might require several machinesand different set-ups as part of the grinding process.Essentially, this process can be quite lengthy. How-ever, at Fanar we are not afraid of a challenge andwe set ourselves the ambitious goal of delivery toour customers within seventy-two hours from re-ceipt of the order.
"We looked for a supplier who could provide asolution that enabled fast changeovers, precisionand repeatability. Another important requirementwas that the grindingmachine had a software pack-age that was intuitive to use and didn’t requirehighly skilled programmers."After reviewingwhatwas available on themar-
ket, wewere confident that Anca’s MX7 Linear wasright for our businesses because of its numerousinnovative features. The polymer concrete base,linear motors, ability to prepare tools (wheels) onthe machine and integrated measuring systemmeant that we could achieve our goal of seven-ty-two-hour delivery with a grinding machine ofthe highest standard."
Being able to produce the tools withthe demanded complexity
Ptaszkiewicz continued: “When investing in a newproduct, there is always some concern that themachinemay not deliver what was promised. An-ca’s MX7 Linearmachine exceeded our expectationsand I am yet to find a product that offers so manyinnovations and features that are unique to themarket."Once we had the latest technology, combined
with our years of experience in grinding and met-alworking, we could quickly begin production ofthe most complex geometry and high-dimension-al precision tools."I am excited that Fanar is now in a position
where we can consider orders that we avoided inthe past. The technology means we have the ca-pacity to produce complex tools, even for individ-ual orders, at the highest qualitywithminimal risk.With the investment, we have achieved our goal ofsignificantly reducing lead times and productioncosts, while opening new potential markets for ourbusiness."Special features such as RoboMate have enabled
simple but accurate automation andAnca’s in-pro-cessmeasuring system, Laser Plus, hasmeant thatfor the first time our company has implementedunmanned production without any concern thatthe products may be defective."Furthermore, themachinewas orderedwith the
Statistical Process Control (SPC) software packagefor quality control purposes. This enables Fanar (asa trusted supplier of cutting tools) to continue tomeet ISO 9001, ISO / TS 16949 standards," concludesPtaszkiewicz.anca.com
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38 6-2017
Birth of the Red GoddessOne colour, one sound, one legend! On 12th
March 1947, Enzo Ferrari sat down in his Fer-rari 125 S for the first time and turned on the
V-12 engine with an engine displacement of 1.5 l.The "Red Goddess" was born.What many people do not know is that the Fer-
rari 125 S was not the first car produced by Ferrari.It is "only" the first one with his name. The reasonfor that can be found in themodern "Ferrari Myth".Enzo Ferrari was a trained mechanic who had
already taken an interest in combustion engines asa child. It was at his father's metal fitter’s shopwhere he carried out repairs and first worked ondeveloping engines. After his application to be afactory driver for Fiat, the motor manufacturer,failed, Ferrari began looking for private sponsorsin 1919. He had managed to gather enough moneytogether with his personal savings to construct hisown car and take part in races throughout the re-gion.The way he drove helped him to his initial vic-
tories and also brought him the necessary attention,which led to the position he had hoped for as theoperational test driver with Construzioni Meccan-iche Nazionale (CMN). TheAlfa Romeo racing teambecame aware of him thanks to him being placedhigh in mountain races. He switched over and be-came Alfa Romeo's head factory driver by 1920.
The foundation of Scuderia Ferrarithrough motor racing
Nine years later, he took the next daring step andfounded Scuderia Ferrari. Evenwith his own racingteam, he continued to drive Alfa Romeo vehicles.After finishing his active racing career, he becamethe Alfa Romeo team's acting head. The companyactually wanted to incorporate Scuderia, althoughthe plan led to a rift appearing between Ferrari andAlfa Romeo. For that reason, Scuderia Ferrari be-came an independent racing team in 1939 and Fer-rari was ordered not to construct any competitioncars under the name of Ferrari for the next fouryears.Enzo Ferrari subsequently founded Auto Avio
Costruzioni Ferrari, which initially manufacturedmachine parts, and flouted the agreement. Alongwith Alberto Massimino, he constructed the ACCType 815 for the Mille Miglia 1940, a race alongpublic streets. This vehicle was in fact the firstFerrari, although the agreement with Alfa Romeomade it impossible to give the car the name of thecompany's founder. The cancellation of races cou-pled with the Second World War put an end todevelopment continuing on the racing car.Ferrari finally concentrated fully on the already
mentionedmachine parts during thewar and trans-ferred the company's headquarters from Modenato Maranello in 1943. When the war ended, he hadpartially rebuilt his destroyed factory and dedicat-ed himself to building racing cars.By 1947, it was all under way: Along with the
former Alfa Romeo engineer, Giacchino Colombo,
Enzo Ferrari built the first Ferrari for internationalmotorsport: the Ferrari 125 C (Competizione), alsoknown as 125 S (for sport). Two models were built,each equipped with a V-12 engine and with an en-gine displacement of 1.5 l, a 60° fork angle, an over-head camshaft for each cylinder bank as well assingle ignition.The first Ferrari was not destined formotor sport-
ing success, however, although a road car did comeabout as a result of the racing sports car. From thatmoment on, Scuderia Ferrari was the racing divisionof the automobile manufacturer, Ferrari. It wasthanks to design specialists such as Pininfarina,Scaglietti, Bertone and Vignale, who were respon-sible for the extraordinary design, that Ferrari be-came both famous and popular.
Cars that later became myths andlegends
In the 1960s and 1970s, the Italian automobileman-ufacturer had to deal with its own difficulties. Inthe 1960s, Ford had wanted to absorb Ferrari butwas ultimately unsuccessful. Nevertheless, theAmericans were able to outdo the Italian racers ininternational motorsport. Another phenomenalracing competitor was Porsche and it was onlywithFiat's entry in 1969 that Ferrari mustered up thefunds to successfully position the 512 S at the be-ginning of the 1970s. From then on, it was quiet forthe red racers from Maranello.It was only in the 1980s that a special cult start-
ed to form around Ferrari. There were a variety ofreasons for it. Hollywood definitely contributed toits publicity: The road-faring versions of the racingcar became the preferred vehicle for testers of theseries. Subsequently, Sonny Crockett and RicoTubbs drove a black, and later white, Ferrari Testa-rossa inMiamiVice from 1984 to 1989. A Ferrari 308GTS was as much a part of Magnum as the mous-tache and Hawaiian shirt. In the cult 1986 film"Ferris Bueller's Day Off ", the truants spent the dayin New York in a 1960s Ferrari 250 GT Spyder.Enzo Ferrari's death in 1988 led to an increase in
demand, especially for classics, as there was a lotof doubt as towhether the Italian sports car wouldhave a futurewithout the company's founder. This,in turn, led to the evocation of the "Ferrari Myth".Racing legends themselves also contributed to
the fascination of Ferrari. Niki Lauda won the For-mula 1 title in 1975 for Ferrari. The 1976 struggle forthe title with James Hunt in the Hesketh 308 islegendary, which Lauda lost in the last race of theseason. Gilles Villeneuve went on to become thehero of the Ferrari owners due to his driving style,but it was only with Michael Schumacher thatFerrari was able to rise to new heights in the 1990sand 2000s.Ferrari is one of themost successful racing teams
in history, with 16 conductor's and 15 driver's worldchampionships.ferrari.com
Andrea Gillhuber
Ferrari celebrates its 70thanniversary in September.
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TIMELINE
1929Enzo Ferrari foundsthe Scuderia Ferra-ri racing team on16th November.
1947Ferrari initiallyconstructs a racingcar under his ownname: the Ferrari125 C, also knownas the Ferrari 125S. 1947 is seen asthe year when theautomobile manu-facturer Ferrari wasfounded.
1969Fiat steps in andbuys 50% of thestricken automo-bile manufacturer.
1988The company'sfounder, EnzoFerrari, dies andthe "Ferrari Myth"is born.
1996Michael Schum-acher takes Ferrarito new heights.
2015Ferrari goes public.
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Volume XVI | Issue 2 | 6 2017 www.edm-europe.com
Special SupplementCase StudyHow to optimise electrodehandling 40
Tech FocusThe art of automated wireerosion 44
Tech FocusAdvantages of wet-millingelectrodes 48
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The many possibilities of automatisingthe handling of electrodes
Walther Wolf is one of those mould makers that is constantly optimisingmanufacturing processes. When they wanted to further perfect their automa-tion in machining electrodes, they turned to Zimmer & Kreim to build an au-tomated 23-metre-long machining centre: A Chameleon.
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When Jochen Dorlöchter, executivemanagerofWaltherWolf, talks about the company’sachievements of the last years, one can’t
help but recognise the pride in his voice. In therecent years, many things have changed in theproduction halls in Wendelstein near Nuremberg,Germany. For the installation of an automatedma-chining centre, Dorlöchter even had to pull downa wall. Less visible but still evident are the effectsof consequently working towards an automatedproduction. A number of changes has led to signif-icant time savings and an increase in turnover.
Dorloechter's great-grandfather foundedWaltherWolf in 1907. At that time, it still was an engravingplant. Later, they started towork inmouldmakingand today specialise in plastic injectionmouldiing.The current staff of 55 employees work mainly onmoulds for technical components. AmongWaltherWolf ’s customers are big players such as Siemens,INA, ZF Friedrichshafen and Bosch.Jochen Dorlöchter is someonewho always seems
to think about how to optimise processes and thequality of his products. This is one of the reasonswhy Walther Wolf has its own department for
Rosemarie Stahl
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measuring. Five workers are engaged in the spe-cially established measuring room, working withtactical and optical methods to ensure thatWaltherWolf ’s customers only receive high-quality prod-ucts. Dorlöchter is proud to be able to verify theaccuracy of his products himself.One of his largest projects started in 2008. In
co-operationwith EDM specialist Zimmer & Kreim,he converted his section for the processing of graph-ite electrodes to a complex and fully automatedmachining centre. This centre is able to erode, meas-ure, mill, engrave with a laser and clean the elec-trodes simultaneously, therefore combining a hugenumber of processes into one single unit. Since itsimplementation, the cell enabled Walther Wolf todrastically reduce idle times: With the help of asoftware thatmanages different jobs, the automat-ed processes are carried out simultaneously and 24hours a day.According to Dorlöchter, the decision for working
with Zimmer & Kreim was an easy one. “Theirsoftware is very user-friendly,” he explains, “and itruns very reliably.” Another advantage of Zimmer& Kreim’s software is its flexibility. Users do notdepend on particular machines but are free to de-cide whose products they use in their production.Because of its interface function, Dorlöchter is alsoable to implement further advanced features in thesoftware.
Room for about 1,000 electrodes in a23-metre machining centre
The 23-metre-long machining centre in WaltherWolf ’s halls consistc of Laser stations by Acsys, ameasuring station by Zeiss, RXP machines byRöders and cleaning stations and EDM systems byZimmer & Kreim. All these different stations, com-pleted by several metres of storage cupboards, areserved by a tower unit with a gripper that is movedelectronically. In this automated cell there is roomfor about 1,000 electrodes at the same time.All jobs executed by the individual stations are
managed with the software by Zimmer & Kreim.This software is one of the significant advantagesof the automated cell. The job manager handlesoffset data, co-ordinates the different processes andcollects data around the stored andmachined elec-trodes.Dorlöchter is particularly happy about the usa-
bility of the software. According to him, Zimmer &Kreim's updates are also a great help. Due to them,themachining cell works faster andmore efficienttoday than it did when he first installed it. Addi-tionally, the software has an interface function thatallows operators and users to implement their ownprograms. Moreover, Dorlöchter is very glad aboutthe support of Zimmer & Kreim. “If therewere prob-lems, they were settled very quickly and efficient-ly in co-operation with Zimmer & Kreim,” he says.The open structure of Zimmer & Kreim allows
Dorlöchter and his company to implement process-es or optimisation measures that are not availableon the market. For the company's manager, this isan incomparable advantage, as every company hasits own needs and its own optimisation potential.It is Dorlöchter’s goal to take full advantage of theinterface. In past years, he was able to realise sev-eral projects that were only possible because it is
so easy to combine own innovationswith Zimmer& Kreim’s job manager.
Automation allows for high utilisationeven at night
One thing that has changed since the new cell wasimplemented is that many tasks that had to bemonitored before can now be carried out at night.Things that take up a lot of time therefore do notdemand precious working hours. The measuringunit, for example, primarily works at night timewithout the necessity for an operator being present.For further improvements, Dorlöchter had sev-
eral cameras installed. One camera is attached tothe tower unit and another camera to themeasur-ing station. That way, the manager or any otheroperator can checkwhether everything is runningaccording to plan.The night-time operation is only one result of
Dorlöchter's automation project. All in all, thechanges have lead toworkingmore time-efficient-ly. Staff working time was tremendously reducedto two and a half minutes per electrode. Beforeimplementation, thesame work took upmore than elevenminutes of work-ing time. All to-gether, there wasa strong decreasein the restingtime of everyelectrode. Forthe company,
INFO
About Zimmer & Kreim’s ChameleonFounded in 1985, Zimmer & Kreimlooks back on more than 30 years ofexperience in working on EDM. Itsfirst cavity-sinking EDM machinewas delivered to Lego. Today, thecompany offers solutions coveringcavity-sinking, handling and soft-ware-controlled process optimisationin tool and mould making.With Chameleon, the company
was able to offer an innovative linear
handling system for tool manufac-ture and mould making. The systemis able to automate the entire pro-duction process. The modular de-sign enables manufacturers to oper-ate it flexibly and to expand it when-ever necessary. From cleaning tomachining and measuring, the sys-tem can integrate all processes thatare needed for an automated andtime-efficient process chain.
“The software byZimmer & Kreim isvery user-friendly.An it runs reliably.”
Jochen Dorlöchter, executive manager
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this means that the machines are working with ahigher workload.“Vacancy can't happen,” says Dorlöchter. Auto-
mation for him led to an increase in not only occu-pancy but consequently to better planning predict-ability. One reason is that the job-manager softwaremonitors all electrodes, which prevents breaks inprocessing. At the same time, this monitoring pro-vides detailed projections about machining times.This allows the company to plan ahead and there-fore prevent vacancies.
Small changes make a hugedifference
Walther Wolf is a company that always tries to gofurther. Dorlöchter is particularly proud of certainadded features that are – as he says it – ”not avail-able on the freemarket”. One of these projects is anautomatic correction function he was able to im-plement in the existing software. As Dorlöchterexplains, the advantage of this correction is that ithad to be programmed only once. This feature isable tomakemodifications on the calculated spark-gap. The necessity to control the electrode individ-ually and to adjust themachining process is there-fore gone.But Walther Wolf 's innovative spirit has not
stopped there. One part of the process ofmachiningelectrodes had been particularly time and cost-con-suming in the past:Whenever a new electrodewasneeded, first of all, a graphite blank had to be or-dered to size. What's more, the graphite needed tohave varying dimensions for different applications.The part that took up most of the time in this
processwas the incorporation of every single graph-ite bar. Once it was ordered, the graphite needed tobe installed into the system including its measure-ments. Once the electrode had been used, it had to
be removed again. So the company came up witha newway of dealingwith this process. Dorlöchterstarted to order graphite bars that were three timesthe size of what was needed. According to calcula-tions, this was the largest size that was still ma-chinable in every one of the many units of theprocess. The longer graphite bar is installed in thesame way as it had been in the case before.The huge difference is that the graphite can now
be used an average of three times. After it has beenused for the first time, the electrode is not removedfrom the system but stored in one of the cupboards.There it sits and waits until an electrode is neededthat fits to the dimensions of the remaining graph-ite bar. Thanks to the aid of the software that storesall important information about the graphite bars,this is an automated process without the need tomonitor the bars. Each electrode additionally cankeep its original registration in the system. Thesoftware is capable of identifying the electrode thatfits best the requirements for the next project.According to Dorlöchter, the same graphite bar
can be reused three times. Additionally, the set-uptime of each electrode has been reduced. Before, ittook roughly tenminutes per electrode to install itin the system. This time was cut in half because itis not necessary to install the graphite part overand over again. Instead, it can remain in the system.When Dorlöchter is asked whether he will ever
complete his project of automation, he just smilesand remains silent. Then he points to the end ofthe machining centre and explains: “Well, it is ob-vious that we ran out of space for extending thelength of this automated cell a while ago. To haveenough space for installing it on around 23 metreswe even had to tear down a wall and now there isno room for an expansion here. But I can promisethat I haven’t run out of ideas yet.”zk-system.com, waltherwolf.de
The complete Chameleon how it isinstalled at Walther Wolf: Everythingneeded for machining electrodescan be found on the 23m long linearhandling system.
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6-2017 43
PRODUCT FOCUS
Simplify demandingapplicationsToday, EDM machines need to have many different tal-ents. For example, they have to offer a broad applicationarea and be time and cost-efficient. GF Machining Solu-tions wants to offer exactly such an all-rounder.
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GFMac
hining
Solutions
INFOSwiss-based GFMachining Solu-tions' productsrange from electricdischarge machinesand high-speed andhigh-performancemilling machines to3D Laser surfacetexturing machines,services, spare andexpendable parts,consumables andautomation solu-tions.
The fourth industrial revolution—also knownas Industry 4.0—represents an era of innova-tion shaping thewaymanufacturers work. The
Agie-Charmilles Cut P wire EDM series by GFMa-chining Solutions delivers intelligence to advancetheir speed, flexibility and quality whilst helpingthem get to the heart of even the most critical ap-plications, the company says. According to GFMa-chining Solutions, the Cut P wire EDM series pro-vides access to twice the number of dedicatedsolutions afforded by a standard EDMmachine. CutP users can realise a range of possibilities acrossvarious quality-centric industries, including elec-tronic components, automotive and medtech.From producing a surgical tool weighing only a
few grams tomachining a six-ton die-castingmouldfor automotive, the Cut P series is designed to helpmanufacturers. The solution’s Intelligent SpeedGenerator (IPG) enables precision parts as well asmould and diemanufacturers to increase their cut-ting performance by 20 percent, GF MachiningSolutions says. This includes obtaining the ther-mostabilisation and machining repeatability toachieve accuracy down to 2 µm and finer surfacefinishes down to Ra 0.08 µm. According to GFMa-chining Solutions, advanced taper accuracy below10 seconds with straightness, sharp contours andno lines becomes easily achievable with the Cut Pseries’ Expert systems. Furthermore, the solution’scollision protection system prevents costlymachinemaintenance and ensures long-term accuracy andreliability. The Cut P series is also equipped forsmart manufacturing and connected solutions.gfms.com
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document1519366424236639036.indd 43 22.05.2017 11:47:51
TECH FOCUS
44 6-2017
Complex, fast and fully automated: Theart of wire erosion
Wire erosion is a very versatile method. As long as a material is conductive, itcan be machined with EDM. The downside of the process, like its speed, arecompensated by its accuracy, low running costs and minimal requirementsfor human intervention.
EDM is a particularly accuratemethod. The shape andboundaries can be specifiedwith minute precision.
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The UK manufacturing industry is under morepressure than ever to meet demanding salestargets, streamline operations and increase
productivity to compete in the global marketplace.To do this successfully, manufacturers need to besure their machines and tools are up to the task.While traditional machinemethods such asmill-
ing, lathing and grinding remain popular for certainprocesses, wire EDM, or Electronic Discharge Ma-chining, has built a reputation as a more precise,efficient and cost-effective machining method.Initially used in the 1960s as a means of makingtools from hardened steel, wire EDM has since de-veloped into a highly reliable and accurate process
for the manufacture of complex and durable com-ponents.Andrew Spence, Robocut Product Manager at
Fanuc UK, says: “The principle of wire EDM is aspark that is generated between theworkpiece andthe electrode, similar to the spark that you see infilmswhen themain character hotwires a car.WithEDM, you control this spark, which melts the ma-terial and creates the shape you need.”“Wire EDM involves a thin piece of wire, which
is pulled between two guides to act like a high-pre-cision bandsaw. Pre-determined computer numer-ical controlled (CNC) drive systems guide the wireinto making complex shapes.”
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The CNC aspect of themachine allowsmanufac-turers to specify the shape and boundaries of thecut with minute precision. As Andrew explains,this helps them to produce the same result everytime.“EDM is accurate down to +/- 3 µ on tolerance
and +/- 1.5 µ on positioning,” he says. “You canonly achieve that with milling if the shape is rela-tively simple. With an EDM process, once you’veproven the first one, the repeatability is the samefor each one.”The accuracy of wire EDM, guided by the CNC
drive systems, has led to the introduction of suchmachines across a variety of sectors.Andrew says: “EDM has been a very big part of
themanufacturing process for toolmakers, but youcan now also see wire EDM in motorsport, aero-space, university R&D and general engineering.Medical is also amajor sector for wire EDM,whichis used to manufacture medical devices such asstents or implants. This is because EDMdoesn’t usea cutting force like traditional machines, so you cancut very thin and accurate components.”“Wire EDM can also cut a different form for the
top and bottom of a piece ofmaterial, which allowsyou to create extrusion dies for door seals on cars,for example.”
EDM's main disadvantage is itscomparatively slow speed
The versatility of wire EDM also extends to its abil-ity to cut thick and hardmaterials – even polycrys-talline diamond.Andrew says: “It has always been difficult to
grind, mill or lathe hard, thick materials using tra-ditional processes because the force of the cut caus-es wear and damage to the machine tooling. WireEDM doesn’t require any force or impact, whichreally opens up the kinds ofmaterials we can shapewith this machine.”“For example, you could shape a piece of hard-
ened D2, 60 Rockwell, Inconel, Tungsten carbide ortitanium. Awire EDM can even cut polycrystallinediamond, aman-madematerial on a carbide back-ing. The only proviso is that the material must beconductive, so plastics and other non-conductivematerials are not suitable for EDM manufacture.”“Modern machines are also capable of cutting
materials up to and over 500mm thick, and becausethe material is cut instead of chipped, you can usethe waste material – or ‘slugs’ – to manufactureeven smaller components – another cost saving!”However, there is a downside to the EDM’sman-
ufacturing capabilities, as Andrew explains: “WireEDM is a highly regarded process across the man-ufacturing industry, but its main disadvantage isspeed. It’s not a fast process – if you’re cuttinga material that is 500mm thick, the machinewill only be able to work at about 0.1mm aminute.”“Having said that, it only takes one passwith the
machine to create the object youwant, as opposedto traditional machining methods where it mighttake three or four. Furthermore, if youwant to cre-ate the same shape several times, you can put three,four or even ten pieces of material on top of oneanother and make identical copies of the compo-nent at the same time. In effect, what you lose in
the initial speed of the process, you gain in efficien-cy overall.”With the rise of Industry 4.0, themost important
consideration for manufacturers is the role thatautomation can play in streamlining their process-es.Wire EDMmachines are powered by pre-deter-mined automated commands, which, as Andrewexplains, can offer a significant cost saving to in-dustry.“Traditional machine methods such as milling
or grinding would usually require an operator tobe present, whowould check thewear on the grind-ers and make sure the tools are functioning cor-rectly. It might only be £5 an hour to run the ma-chine, but if you’ve got an operator standing thereat an extra £15 an hour, you’re then looking at fourtimes the cost of an automated solution. That’salso time the operator could have spent workingon other processes, so you’re losing output aswell.”
Modern EDM machines are built tolast longer than 30 years
“A Fanucwire EDM, for example, requires less than10% of operator intervention to run a full program.That 10%will be the initial contact to program themachine and set the component. After that, themachine can be left to run all the way through aprogram without interference. It can even recoverand repair itself if the wire breaks.”Expenses or unexpected halts to production are
also kept down by the low running costs and longerlifespans of EDM machines.Andrew says: “A Fanuc machine runs at approx-
imately £5 an hour. This covers wire, filters, elec-
INFO
Wire EDM machinery by FanucAt its state-of-the-art head-quarters in Ansty Park,Coventry, Fanuc UKbrings togetherworld-leading capabili-ties in industrial robots,machine tools andplastic injectionmoulding machinesto facilitate thecomplete integra-tion of factoryautomation sys-tems for UK manufac-turers.Fanuc UK works in partnership
with Fanuc Europe Corporation toprovide a range of customer sup-port services, including sales, prod-uct support, parts, repairs, andtraining, as well as development ofbespoke engineering systems.Fanuc UK is a subsidiary of FanucEurope Corporation and employsapproximately 107 staff.Fanuc is a leading global manu-
facturer of factory automation solu-
tions using Computer NumericalControl (CNC) systems. From itsinternational headquarters at thebase of Mount Fuji in Japan, Fanucspecialises in the development andmanufacture of factory robots andautomation machinery, includingwire EDM machinery (Robocut),high-speed milling machinery (Ro-bodrill) and injection moulding ma-chinery (Roboshot). More than400,000 Fanuc robots are currentlyoperating worldwide.
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trodes, resins, etc. The machines are also built tobe as eco-friendly as possible, so energy costs arekept to a minimum.”In terms of service, it’s good practice to regularly
replace consumable parts, such as bearings, ratherthan wait for them to fail. With wire EDM, it’s un-likely that you’re going to need a full service morethan once a year because you’re not dealing withthe force and impact of traditional, heavy-dutymachines, so preventativemaintenance is key. Fa-nuc offers a tailored service to suit each business,but we also do a minor/major service betweenwhich you can alternate, depending on how longyou’ve had the machine and how long it’s beensince you had it serviced."Saying this, however, modern EDM machines
are built to last. Machines are now 30 years old andstill going strong. More modern machines couldlast even longer. Compare this with the ten-yearlife expectancy of a typical machine tool, and you
can see how much of a saving you could achieve.Furthermore, no matter when you purchased themachine, Fanuc will always supply you with thepart you need, so an EDMmachine really does lastfor life."When it comes to implementing automat-ed machining processes such as wire EDM, manymanufacturers are concerned that they do not havethe skills in-house to do this successfully. For An-drew, a user-friendly interface and training are key:“Many think EDM is a bit of a black art, but I’ve
worked with people who became proficient in aweek, despite having little to no CNC experience,”he says. “The key is to work with the machine asmuch as you can and build your experience – youdon’t even need to know any coding because thiscan be produced automatically.”
Complexity and precision in minimalworking time
“Training to build those initial skills also helps.Weoffer a set schedule or can tailor it to a customer’sneeds. The user-friendly nature of the machinesmeans that even someone with no knowledge ofCNC can operate the machine to a basic level in aweek. After that, it just comes down to practice andexperience.”Formanufacturers that are already implementing
wire EDM into their processes, the advantages areclear: a complex, precise cut with low running costsandminimal requirements for human intervention.Furthermore, the versatility of these machinesmeans that they can be implemented for a rangeof uses, from the smallest medical devices to thebuilding blocks of an aeroplane.“If it conducts, we can cut it," Andrew says. "By
controlling that spark, you’ve got a highly repeat-able and precise manufacturing process that willkeep you achieving quality output for the next 40years and beyond.”fanuc.eu
A product example thathas been machined withFanuc’s Robocut. S
ource:
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According to AndrewSpencer, working withEDM takes a bit of experi-ence and practice. S
ource:
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PRODUCT FOCUS
Improving existing technologyfor today's requirements
EDM Drilling – The first EDMdrilling units of Heun to beplaced on the market weremodules that consisted of anall-purpose, adaptable erodinghead with servo-unit and amobile generator withhigh-pressure pump. Thesemodules are still availablenow, although with an im-proved design. They are stillused to carry out special tasks,for example, the removal ofrivets from the outer platingof airplanes during mainte-nance, relief drillings, bleederholes as well as cooling holesinto metallic moulds, drillholes into injection nozzlesand EDM drilling with ex-tremely pointed angles.According to Heun, the erod-
ing unit can be applied inmany different fields of EDMdrilling. Every kind of conduc-tivematerial can bemachined,independent of softness orhardness, the company says.The fast EDM drilling speed isthe main feature of this ma-chine.The unit is of compact de-
sign and appropriate for ma-chining especially big workpieces. The generator and themonitor are locatedwithin thesold, mobile control cabinet.Thewater-cooled generator isextendable up to 80 ampere.The operating interface, whichis – as Heun says it - self-ex-planatory, is controlled bytouch-screen terminal. The
eroding head can be attachedto existing machining centresor to robot tooling.Independent use bymount-
ing on a stand or drill rig isalso possible. Copper or graph-ite can be used as electrodematerial brass. Different ce-ramic guides can be installed.Therefore, the electrode diam-eter range can be modifiedfrom Ø 0.3 – 3.0 mm. Elec-trodes of Ø 0.1 – 6 mm can beclamped with special colletchucks.Optionally, machining with
electrodes of up to 50 mm aswell as with form electrodesis possible, the company says.Every electro-conductive com-ponent can be machined. Un-til now, eroding heads of dif-ferent length have been con-structed. At present, 3,000mmis the vastest travel distancethat has been reached. Thehead-generator unit has ananalysis tool to control thedrilling process. It is also pos-sible to connect the unit to theparticular machine und topass signals to this respectivemachine.The functions are the same
as on standard EDM drillingmachines. A special feature isthat the spindle can also belocked in place in order to beable to carry out die-sinkingor cut off parts as, for example,threaded bolts or sheet-metalparts.heun-gmbh.de
The eroding unit by Heun can be applied in many different fields of EDMdrilling.
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document7537945334153427504.indd 47 22.05.2017 11:19:18
48 6-2017
The advantages of wet-millingelectrodes
Cooling lubricants are often used to prevent stubborn graphite dustwhen milling electrodes. This means that it is not necessary to acquirean additional milling machine for graphite machining. Cooling lubricantshelp to extend tool life and to improve dimensional accuracy.
The Seagull milling toolsare perfectly suited for thewet machining of graphite.
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The numerous advantages mean that graphiteelectrodes are indispensable in spark erosion– no manual work, no deburring, hardly any
burning, even intricate geometries are possible andthe electrode comes out of the milling machineready to use for erosion. However, as before, graph-ite dust is the spectre that haunts production. Mill-ing electrodeswith cooling lubricants offers a goodalternative to dry machining. A comprehensivecomparison test with Seagull tools from Zechashows the many advantages of wet-milling: great-er cleanliness, more flexible machine utilisation,higher dimensional accuracy and less tool wear.Because of stubborn graphite dust, machining
graphite and copper on one machine has hardlybeenworth considering up to now. Drymachiningalso creates additional financial obstacles, particu-larly for small andmedium-sized enterprises, sinceanother milling machine has to be purchased forthe eroding machine for graphite machining. Theuse of cooling lubricant allows themillingmachineto be used flexibly. The graphite dust producedduringmilling is washed away by the cooling emul-
sion and then filtered from the emulsion by specialequipment. This keeps lines and machines cleanand free of graphite deposits. But what effect doesthis have on the tools, the electrodes and the fin-ished component? A comparison test with Seagullmilling tools produced amazing results.With Seagull milling tools, the finest ridges and
most delicate electrode geometries can be producedto an excellent finish. The reason? The patentedshort cutting – only 0.6 mm at a diameter of 2 mm– and the coordinated combination of high-qualityhard metal, diamond coating and a special geom-etry with the tightest tolerances of only 5 µm en-sures minimal cutting pressure and cutting forces.This allows for excellent surface quality and max-imum tool life. Zecha offers the Seagull milling toolsin two quality levels: The Quality line – dividedinto the 568 series (ball milling tool) and 578 series(torus milling tool) – provides an optimumprice-performance ratio for standard applicationsand targets the price-conscious user, who never-theless relies on quality results – even in thewet-milling process. The tools have proven diamond
Andreas Weck
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TECH FOCUS
INFOZecha Hart-metall-Werkzeug-fabrikation developsand manufacturesgeometries andtools for uniqueapplication purpos-es and internationalmarkets, includingautomotive, avion-ics, turning technol-ogy and mechanicalengineering.
coating concentricity of 0.005 mm and diametertolerances of 0/-0.015 mm. For excellent surfacefinish and narrow tolerances (in diameter of 0/-0.010mm and concentricity of 0.003mm), the HighEnd line, with ball milling tools of the 567 seriesand torusmilling tools of the 577 series, is the rightchoice. Thanks to the 10µm-thick high-performancediamond coating, the tools also shine with longtool lives. In both the High End and the Qualitylines, each tool is measured individually and theactual size is noted on the packaging. This alwaysguarantees the same narrow tolerances and highestprocess safety in the manufacture of the delicategraphite electrodes. All Seagull milling tools areavailable from 0.3 to 12 mm. Arndt Fielen, salesmanager of Zecha Hartmetall-Werkzeugfabrikation,says: “The Seagull tools have made a significantcontribution to the further improvement of drygraphitemachining.Wewanted to go a step furtherand see what was possible with wet processing.”
Higher dimensional accuracy
For this, graphite electrodes were specially manu-facturedwith Seagull ball milling tools (B-2-20-60)on two Mikron Mill S400 machines from GF Ma-chining Solutions. Cooling is performed directly atthe milling point with compressed air on the onehand and emulsion on the other. To check the runand the diameter of the milling tool, it was meas-ured before and after with the 1210 lasermeasuringdevice from z-Mike. Contour and surface were op-tically checked with C-View from Cimtrode with1,000-fold magnification.“The results speak clearly for wet machining:
After 290 minutes of milling time, the tools usedwith cooling lubricant showed 30 percent less wearthan those from drymachining. After 490minutes,the result was even more clearly in favour of wetmachining: 40 percent less wear,” said an impressedDaniel Gruber, Managing Director of Cimtrode. Thewear with cooling lubricant was, at most, 0.0052mm; without it, it was 0.0087 mm.Here, wet machining was not only responsible
for longer tool life but also the significant increasein the dimensional accuracy of the electrodes. After490 minutes, the dimensional accuracy of thewet-processed electrode was still within the toler-ance range of 0.005 mm. In dry machining, therewere significant dimensional deviations.“Excellent time results for the milling tools and
high levels of sustainability in the electrodes wereone side of the coin, now the erosion results alsohad to be right,” says Arndt Fielen. For this, theerosion time, the surface roughness on the finishedcomponent and the erosion of the electrodes werecompared in several conducted tests. In the testset-up, a roughing electrode and a finishing elec-trode were used. The erosion was between 3 and 6µm, the roughness of the surface at the componentbetween Ra 0.82 to 0.87. All electrodes were usedfor around 40 minutes.In contrast to drymilling, using lubricant enables
tool andmouldmanufacturers tomachine copper,graphite and steel on the same machine and en-sures greater cleanliness. Tool lives are extended,tool costs reduced and the dimensional stability isincreased.zecha.de
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document8310719063056433601.indd 49 19.05.2017 11:39:15
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Ucisap and Cefamol together in ItalyCefamol (Portuguese MouldMaking Association) dele-gates visited Italy, hosted byUcisap (Italian Mould MakingAssociation). The delegatesvisited companies in theNorth, namely the regions ofVeneto and Emilia Romagnathat included toolmakers,industry suppliers, special cars and motorbike manufacturers aswell as HRS-Flow, an Istma global partner.istma.org
ISTMA Lounge @ Moulding Expo showThe programme of the VI EuropeanTooling Forum at the Moulding Expotrade fair to be held in Stuttgart,Germany. Hall 4, Booth C30.30 May14:30 – VI European ToolingForum opening - Jari Saaranen,President ISTMA Europe14:45 – European Tooling Industry:Vision 2030, Joaquim Menezes,European Tooling Platform31 May10:00 – ISTMA Global Partners:Trends and Innovation in Technology, Hidehiko Yamamoto(Makino), Alessandra Bosco (HRS-Flow),Markus Piber (DMG Mori)14:00 – The Finnish Tooling Industry, Jari Saaranen (Techind)14:30 – Brexit and Manufacturing in UK, James Selka (MTA)15:15 – Outlook for Americas, Laurie Harbour (Harbour Results)1 June10:30 – Manufacturing in Europe: Challenges and Opportunities,Gunter Hoercher (Effra)11:15 – Stay on top with tooling technology - production inEurope depends on technical education and research funding,Alfred Zedtwitz (VDMA)14:30 – Brazil and the 15th ISTMA World Conference,Christian Dihlmann (Abinfer)15:15 – Portuguese Mould-making Industry Outlook,Manuel Oliveira (Cefamol)
istma.org
ISTMA World News & EventsThe International Special Tooling & Machining Association (ISTMA) is an interna-tional association representing 19 special tooling and machining associationsthroughout the world. Collectively, ISTMAmember associations represent over8,000 companies and over $40bn in annual sales. ISTMAWorld is in charge of thecentral coordination and organisation of all international activities
For information, contact:Mr. Manuel OliveiraSecretariat, Istma Europec/o CefamolAv. D. Dinis 17Aptdo. 2572430-263 Marinha GrandePortugalTel. +351 244 575150Fax +351 244 [email protected]
MEMBERSTool Factories Associationwww.svaz-nastrojaren.eu
Estonian Special ToolingAssociationwww.estatools.ee
The Federation of FinnishTechnology Industrieswww.techind.fi
Association Française desIndustries du Moule, Modèleet Maquette (AFIM)www.afim-france.com
VDMAwww.vdma.org
The Gauge & Tool Maker’sAssociation (GTMA)www.gtma.co.uk
Szerszámgyártók MagyarorsazágiSzövetsége (SZMSZ)www.szmsz.hu
Unione Costruttori Italiani Stampi eAttrezzature di Precisione (UCISAP)www.ucisap.it
Stowarzyszenie Techniczne –Tworzywa Sztucznewww.stts.com.pl
Associação Nacional daIndústria de Moldes (CEFAMOL)www.cefamol.pt
Slovenian Tool and DieDevelopment Centerwww.tecos.si
Toolmaking Associationof South Africa (TASA)www.tasaweb.co.za
Swedish Moulding and Press ToolsAssociationwww.sinf.se
Swissmemwww.swissmem.ch
International Mould ManufacturersUnionwww.ukub.org.tr
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EVENTS
Moulding Expo 2017
The International Trade Fair for Tool, Pattern and Mould Making, “bythe industry for the industry” will open its doors on 30 May to 2June in Stuttgart, Germany. With over 700 registered exhibitors, theorganisers are certain the second edition of this event will crack the20,000 visitor mark this year. The show is also lined up with confer-ences and forums, namely; BME Forum, Moulding Expo Forum,Istma Forum and The Future Forum.
Advanced Manufacturing Show
In its third year, UK’s dedicated market place for advanced manu-facturing technologies returns from 6 - 8 June 2017, to NEC, Bir-mingham.
NEWS
document3674784064869163036.indd 50 19.05.2017 11:36:54
MASTHEAD/COMPANY INDEX
516-2017
Company Index
AAnca CNC Machines . . . . . . . . . . . . . . . . 37Asco Kohlensäure AG . . . . . . . . . . . . . . . . 8
BBumotec SA . . . . . . . . . . . . . . . . . . . . . . 33
CCBI - Confederation of British Industry . . 13Centaur Media plc . . . . . . . . . . . . . . . . . . . 9CNC Software Inc. . . . . . . . . . . . . . . . . . 7Covestro Deutschland AG . . . . . . . . . . . . 10Cumsa . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DDeutsche Messe AG . . . . . . . . . . . . . . . 7, 8
FFanuc Deutschland GmbH . . . . . . . . . . . 44Ferrari Deutschland GmbH . . . . . . . . . . . 38Fraunhofer-Institut fürProduktionstechnologie IPT . . . . . . . . . . 16
GGF Machining Solutions GmbH . . . . . . . . 43
HHasco HasencleverGmbH + Co. KG. . . . . . . . . . . . . . . . . 1, 28
Heun Werkzeugmaschinen &Industriebedarf GmbH . . . . . . . . . . . . . . 47HIG Handel mit IndustriegüternGesellschaft m.b.H. . . . . . . . . . . . . . . . 43
IIncoe International Europe . . . . . . . . . . . . 7InovaTools Eckerle & Ertel GmbH . . . . 33Iscar Ltd. . . . . . . . . . . . . . . . . . . . . . . . . 11
JJones & Shipman Hardinge Ltd . . . . . . . 20
LLandesmesse Stuttgart GmbH . . . . . . . . 13LDT Dosiertechnik GmbH . . . . . . . . . . . 34
MMack Brooks Exhibitions Ltd . . . . . . . . . . . 8Mastip Technology Ltd . . . . . . . . . . . . . . 26Meusburger Georg GmbH & Co. KG . . 13MMC Hitachi ToolEngineering Europe GmbH . . . . . . . . . . 30Mold-Masters Europa GmbH. . . . . . . . 27
PPaul Horn Hartmetall-Werkzeugfabrik GmbH. . . . . . . . . . 14, 52Progressive Components. . . . . . . . . . . . 2
SSarix SA . . . . . . . . . . . . . . . . . . . . . . . . . 47Schunk Gmbh & Co . KG . . . . . . . . . . . . . 10SolidCAM Ltd. . . . . . . . . . . . . . . . . . . . . 21Starrag Group Holding AG . . . . . . . . . . . 33Strack Norma GmbH & Co. KG . . . . . . 10
TTechnische Universität Kaiserslautern . . . 24Türk+Hillinger GmbH . . . . . . . . . . . . . . . 5
UUcimu-Sistemi per Produrre . . . . . . . . . . 12Union Tool Europe SA. . . . . . . . . . . . . . 31
VVerein Deutscher Werkzeug-maschinenfabriken e. V. (VDW) . . . . 9, 16
ZZecha Hartmetall-Werkzeugfabrikation GmbH . . . . . . . . . . 48Zimmer & Kreim GmbH & Co KG . . . . . . 40
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document2206139148620773640.indd 51 19.05.2017 11:34:58
Feed rates at their peak
Rapid removal of high chip volumes. The DAH high feed milling cutter system rough machines steel,
cast iron, non-stainless steel and aluminium with excellent stability and long tool life. The special
cutting geometry of the triple-edged indexable inserts enables rapid plunging, gentle cutting as well
as cutting depths of up to 1.2 mm – and the same standard DAH.37 insert fits the range of cutter
bodies from 20 mm to 50 mm diameter. This enables you to achieve considerably shorter processing
times and rationalise insert stocks for tool-making, mould-making and many other applications. The
internally cooled, coated milling cutters are available as end mills, screw-in heads and arbor milling
cutters. www.phorn.de
G R O O V I N G P A R T I N G O F F G R O O V E M I L L I N G B R O A C H I N G C O P Y M I L L I N G R E A M I N G
HORN – EXCELLENCE IN TECHNOLOGY
www.phorn.de
036_A_DAH_en_DE.indd 1 25.04.17 08:35
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