spurs f1 supplier’s growth... for more product information visit automated milling machine spurs...
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Automated Milling Machine Spurs F1 Supplier’s GrowthMatsuura UK, as agent for an Italian machine tool builder, provides just the unit to expand a customer’s capacity, capability and flexibility.
IN THIS ISSUE
• Machine Tools for Entry-Level Milling, Turning Sell Big
• Sourcing: Materials• MACH 2010
22
VOLUME XII NUMBER 5 � AN ACCESS COMMUNICATIONS INC. PUBLICATION JUNE 2010
32
Motorized probe heads for Hexagon CMMs offer 720 indexable positions and speedy indexing.
Sandvik Coromant’s new face-milling cutter has an eight-edge insert with an edge line that varies with the depth of cut.S U M M E R 2 0 1 0 I S S U E
Special Quarterly Supplement
Grinding in Motion
Körber Schleifring GmbHNagelsweg 33-35 · D-20097 HamburgTel +49-40-211 07-03 · Fax +49-40-211 [email protected]
You shouldn’t make any compromise concerning precision. As world-wide market- and technology leader the SCHLEIFRING Group offers you grinding machines with highest quality, productivity and reliability.
• Surface and profile grinding • External cylindrical and non-round grinding • Internal cylindrical grinding • Centerless grinding • Tool grinding
Ambitious Duties Demand Precise Processes
Precision
Visit us at the MACH in
Birmingham, April 21. - 25. 2008
Hall 5, Booth 5178.Visit us atHall 5Booth 5381
June 2010 � European Tool & Mould Making 3www.etmm-online.com
Editor’s Message
First the Global Frying Pan; Now the European Fire
While tool and mould makers in Europe continue to deal with the financial meltdown of 2008-2009, they have been hit with another crisis within the European Union brought about by the serious fi-nancial breakdown of Greece and its effect on the euro.
True, a less valuable euro can help European merchants by
bringing down the cost of their goods in global markets. That can even be very good news, because Europeans have long been at a big disadvantage in terms of pricing, one made worse by the fact that the Chinese yuan is pegged to the US dollar.
However, even though the new exchange rate could help Europeans, there is talk that the euro is “finished.” I don’t believe that’s so. Europe has too much invested in this new monetary unit—a global currency to rival the US dollar—to turn back now. (In my opinion, it is good to have two world currencies.) This is one of the first sig-nificant tests of the euro. Now we will see how strong the system is.
But the euro is just one aspect of the European Union’s importance to all of us. While the EU is basically a good idea—it makes trade within the continent easier for in-dustry and, as a global trading bloc, gives European busi-nesses more market power—its fundamentals scare me. A downside of the EU, in my view, is that it adds another layer of government, with its own rules and regulations additional to those of each national government. Already, Europeans face more taxes as a result of the EU’s existence. The bailout of Greece—and who knows what other com-ing crises—will surely bring new ones.
I hope that politicians learn something from this new stress to the system and address some of the fundamen-tal causes. For small companies like those engaged in tool and mould making, hoping is not enough, of course. We all need to make sure that our business models are strong and that our companies are well capitalized.
Douglas SellersMANAGING DIRECTOR/EDITOR-IN-CHIEF
See us atHall 10,
Stand 4010
4 European Tool & Mould Making � June 2010 www.etmm-online.com
June 2010
Industry News
7 Corporate, professional and educational events that define the direction of the industry
EuroMold News
13 Hall 8.0, the Showplace for Mould Making and Tooling at EuroMold 2010, Is Already More Than 75% Booked
ISTMA News
15 Focus of 2010 ISTMA World Conference to Be ‘Global Opportunities for Special Tooling & Machining Companies’
Interview
18 Interview with Ralph Christnacht of DMG: Building a Successful Business from Entry-Level Machine Tools
Table of Contents
Featured Supplier
20 Precision and Flexibility from a Single-Source Supplier of Modular Cutting Systems for Tool and Mould Making
Technology
22 High-Performance Indexable-Insert Face-Milling Cutter Provides Soft Cutting Action, Exerts Low Axial Pressure
24 Economical Deep-Drilling Milling Machine Is Adapted for Higher Performance in Drilling Graphite Blocks
Case Studies
26 Switching CAM Software Enables Automotive Supplier to Save Time in Programming and Machining Forging Dies
28 One Automated 5-Axis Milling Machine Revolutionizes a Rapid Tooling Specialist’s Operation; Another Is Coming
30 Sophisticated CAM System Helps Formula 1 Supplier Keep Up with Demand for Complex Precision Parts
Products & Services
32 Recently introduced equipment and services from all over
Quick Sourcing Grid: Tool & Mould Materials
44 A handy table of companies supplying materials to the tool and mould making industry
EDM Europe
45 The summer 2010 issue of our quarterly magazine for users of electrical discharge machining equipment and supplies
30 ���
Open Mind Technologies AG
A Formula 1 supplier can keep pace with increasing precision-
part complexity with the help of a sophisticated CAM system.
��� 11Meusburger Georg GmbH & Co. KGThe standard moulds supplier makes Spanish the 10th language in which its website is available.
18 ���
DMG Vertriebs- und Service GmbH
In an interview, the head of the machine tool builder’s new division for entry-level
machines explains his unit’s success.
AST Technology GmbHCollapsible-core technology is the foundation of a mould tool standard created for cap and closure moulders.
36 ���
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Türk+Hillinger GmbH78532 Tuttlingen Germany
Tel. +49 74 61 70 140 Fax +49 74 61 70 1410
www.tuerk-hillinger.de
since 1963
we are your best choice forheating elements
wide product range
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made in Germany
Volume XII Number 5
Zecha Hartmetall-Werkzeugfabrikation GmbHA line of high-reliability cutters for milling complex graphite electrodes includes tools with diameters as small as 0.1 mm.
46 ���
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Auerbach Maschinenfabrik GmbH
A deep-drilling milling machine has been adapted to deliver very high performance in
the drilling of graphite blocks.
Schott Systeme GmbHA CAD/CAM developer keeps upgrading its software while holding the line on cost.
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MACH 2010 Preview
50 Products to look for at the UK’s premier manufacturing technologies event, taking place June 7–11
Buyer’s Guide 2010-11
Coming in July/August: the 11th annual edition of our popular industry directory, broken into 12 product category sections with supporting articles and Quick Sourcing Grids™ to make it easy to locate the suppliers you need.
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NEXT ISSUE
Company Index
54 A listing of the industry suppliers who supported this issue with articles and advertisements
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V O L U M E X I I N U M B E R 6 � A N A C C E S S C O M M U N I C A T I O N S I N C . P U B L I C A T I O N
Annual IssueSourcing Directory
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VOLUME XII NUMBER 5 JUNE 2010
EUROPEAN TOOL & MOULD MAKINGAn Access Communications Inc. publication
Contract-published 9 times per year by SellersMedia
P U B L I S H E R
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R E P R E S E N TAT I V E A G E N T F O R TA I W A N, C H I N A & H O N G KO N G
Robert Yu, Worldwide Services Co. Ltd.11F-B, No. 540 Wen Hsin Road, Section 1, Taichung 408, Taiwan
Tel: +886 4 23251784 • Fax: +886 4 [email protected]
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MiSook [email protected]
EDITORIAL CONTRIBUTIONS: Product/service information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency. The publishers assume no responsibility for return of artwork, photographs or manuscripts. NOTICE: Every precaution is taken to ensure accuracy of contents; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein.
SUBSCRIPTIONS: European Tool & Mould Making is published 9 times per year, plus the supplemental EDM Europe Buyer’s Guide, and is distributed free of charge to qualified readers in Europe.
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www.etmm-online.com June 2010 � European Tool & Mould Making 7
Siemens brought its Si-numerik CNC platform to market in 1960. The first-ever industrial nu-merical control (NC), it immediately increased the productivity and flexibility of manufac-turing processes. As a partner to mechanical engineering companies, Siemens continues to develop Sinumerik. Cus-tomers use the control to network all areas of production, from exchanging data between the development and design departments through manufacturing operations performed on CNC machines.
“Sinumerik has made Siemens the leader for technology and innovations in the CNC field for 50 years,” says Uwe Frank, CEO of Siemens Motion Control Systems. “It started with the first NC, then progressed through the CNC with a microprocessor to the first CNC-integrated safety solution. We’re continuing to invest specifically in research and development so that we can keep on writing this success story in the future.”
The first CNC per se was the Sinu-merik 500C, originally available for turning and milling only. The advent
Jubilee Year for Siemens and Its Sinumerik CNC Platform, Which Has Been in Development for Half a Century
Industry News
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of inexpensive microprocessors accel-erated development. In the late 1970s, a CNC with multichannel capability and an integrated PLC could control drilling and nibbling as well as turning and milling. Specific control functions for grinding followed soon after. Later, Siemens offered open-design versions of the Sinumerik, including one for up to 31 axes of control. Other advances have appeared as recently as last year.
Siemens AGERLANGEN, GERMANYwww.automation.siemens.com
ETMM Weekly e-Newsletter
The European tool and mould making industry generates more news than ETMM’s Industry News section can hold. And of course some news is just too fast-breaking. That’s why the publishers of European Tool & Mould Making magazine developed a way for its readers to keep up with the cascade of industry events.
Subscribe to the ETMM weekly electronic newsletter. It’s free.
Sign up at: www.etmm-online.com
8 European Tool & Mould Making � June 2010 www.etmm-online.com
Industry News
The most recent NC Software and Related Services Market re-port from CIMdata shows that Delcam plc has completed a full decade as the world’s leading CAM specialist. In 2009 yet again, Delcam’s revenues were the highest of all companies whose central business is CAM software.
The company first attained its position of global leader-ship in 2000, according to CIMdata, a respected firm of in-dustry analysts based in the United States. Over this period, its revenues have grown from £17.0 million ($24.3 million) in 2000 to £31.8 million ($45.5 million) last year, and its market share has increased significantly as well. This is es-pecially noteworthy and interesting, because, as a conse-quence of the current economic recession, total worldwide vendor revenue from CAM products has actually fallen dur-ing that time, from $806 million to $804 million.
The CIMdata report also confirmed that Delcam has the largest development team in the industry, with 165 people working on CAM software. Only two other companies em-ploy more than 100 CAM developers. Further, the company was reported to have shipped more industrial seats of CAM software in 2009 than any other supplier.
The increase in market share is attributable to growth in the sales of Delcam’s established PowerMill and ArtCAM systems, the acquisition of the FeatureCAM and PartMaker families of software, and the addition of new dedicated soft-ware for the dental and orthotics industries and the Delcam for SolidWorks integrated CAM system.
First-quarter orders received by the German machine tool industry were sharply up in 2010 as compared with January to March 2009, running 43% higher. Domestic demand rose by 25% year-on-year, while foreign orders increased 54%. These developments were ascertained by the VDW (German Machine Tool Builders’ Association).
“Following this strong performance at the start of the year, it remains to be seen whether such gratifying growth levels can be sustained as the year progresses,” says Dr. Wil-fried Schäfer, managing director of the VDW. “We regard the fact that the service and spare parts sectors have per-formed so well as highly encouraging. Our customers are starting to use their machines again. Sooner or later, this is going to feed through to new investment.”
The sector is evincing a growing optimism. In April, ca-pacity utilization was 71.6%, up from 67.6% in January. The figure for orders on hand in February (6.6 months’ worth) compares favourably with 5.6 months last October. Howev-er, the sector isn’t out of the woods: order volumes remain low compared to the peak year of 2008. Schäfer observes that the liquidity of machine builders and their customers continues to be an area of worry.
“Even assuming that the demand for machine tools stays at the same level as at the start of the year, this will not be sufficient for an increase in production,” explains Schäfer. “Which is why we are expecting a further fall of 12% in production in the current year.”
Delcam Has Been World’s Top CAM Specialist for a Solid Decade, According to Report
VDW Reports Sharp Rise in German Machine Tool Orders, but Sees Production Falling
In the manufacture of pre-cision microparts, the wide variety of available mate-rials and the challenges posed by production proc-esses necessitate a specifi-cally coordinated process technology. The 2nd Indus-try Colloquium of Research Unit 702 presents the latest results of its investigations on this subject on June 24, 2010, at the Karlsruhe Technology Institute in Eggenstein-Leopoldshafen, Germany. One of four university institutes mak-ing up Research Unit 702 is the Insti-tut für Kunststoffverarbeitung (IKV; Institute for Plastics Processing) at
New Processes for Producing Microparts via Liquid Phases Are Focus of Technical IKV Colloquium in Karlsruhe in June
strate the ongoing development of new technologies from the point of view of both research and industrial application. Specific topics include micro–injection moulding, mould and machine technology for micro–injec-tion moulding, and microforming processes for metals.
The Industry Colloquium is target-ed mainly at users, processors and sci-entists working in the field of micro-technology and injection moulding who want to gain a deeper under-standing of the processes and materi-als involved.
RWTH Aachen. The others are at Er-langen, Hannover and Karlsruhe.
The focus of the event is machine, tool and new-process developments for the manufacture of microparts via the liquid phase of polymers, metals and ceramics. Presentations demon-
Institut für Kunststoffverarbeitung (IKV)AACHEN, GERMANYwww.ikv-aachen.de
Delcam plcBIRMINGHAM, UKwww.delcam.com
VDW Verein Deutscher WerkzeugmaschinenfabrikenFRANKFURT/MAIN, GERMANYwww.vdw.de
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10 European Tool & Mould Making � June 2010 www.etmm-online.com
Industry News
More than 900 companies were represented by the 2,000-plus visitors from Germany and abroad who attended the tra-ditional in-house exhibition put on by Maschinenfabrik Berthold Hermle AG in Gos-heim in April. Over 20 func-tioning machines on display in the company’s Technology and Training Centre showed how Hermle technology is being used in a variety of industries, including tool and mould mak-ing, medical technology, automotive and motor sports, energy technology, aerospace and many others. The Ice-landic volcano kept hundreds of other expected guests from reaching the ex-hibition, but they were accommodat-ed by a special Open Day in early May.
The Hermle demonstration particu-
In-House Machine Tool Exhibition Mounted by Hermle AG Draws Visitors Representing More Than 900 Companies
created Heidenhain controller.A special focus for visitors to
the open house was automation: a starter automation solution, the IH60 system, was presented, and a high-end RS 2 combined-robot system attracted consider-able interest. Other elements of the in-house exhibition were a “Tips + Tricks” display involving the operation and programming of Hermle machining centres; a presentation on current trends in Hermle’s service field; a spe-
cial tool technology show in which 50 exhibitors offering tooling, CAD/CAM and control technology had their own stands; and guided tours of the Gos-heim site.
larly emphasized 5-axis machining. Three new machine developments were prominent: the gigantic C 60 U dynamic 5-axis machining centre for workpieces weighing up to 2,500 kg, the C 42 U dynamic, and mill/turn versions of high-performance machin-ing centres that featured a specially
Maschinenfabrik Berthold Hermle AGGOSHEIM, GERMANYwww.hermle.de
Hardinge, a global designer and manufacturer of machine tools, has acquired the assets of Jones & Shipman, a UK-based manufacturer of grinding and superabrasive ma-chines and machining systems. Jones & Shipman, which has operated continuously in the UK, under various owners, since 1899, is now part of Hardinge’s Kellenberger grinding organization. It will continue to operate at the established facility in Leicester.
Jones & Shipman distributes surface, creep-feed and cy-lindrical grinding machines used in the mould tool and die making, aerospace, medical technology, power generation and high-end automotive industries.
“This transaction is a solid strategic fit for Hardinge, add-ing valuable product lines as well as the strong Jones & Ship-man brand name, to our grinding portfolio,” explains Rick Simons, president and CEO of US-headquartered Hardinge. “Along with expanding our European-based grinding busi-ness, Jones & Shipman products will help us expand our US and Asian market presence.”
Hardinge adds the Jones & Shipman brand name to the strong lineup of Hardinge, Bridgeport, Kellenberger, Hauser and Tschudin machine brands. Simons declares the acquisi-tion an indicator of Hardinge’s corporate strength.
Almost every third machine tool imported into China is made by a German manufacturer. Thus, a German group pavilion being organized for the Metalworking and CNC Machine Tool China Show 2010 (MWCS) in Shanghai in November represents a golden opportunity for machine builders wishing to enter the Chinese market. The machine tool, metal processing and metalworking exhibition is a key showcase in the world’s biggest market for machine tools.
MWCS 2010, taking place November 9–13 at the Shang-hai New International Expo Centre, is produced by Han-nover Milano Fairs Shanghai and Shanghai World Expo Group. The organizers expect more than 500 exhibitors and 110,000 visitors to participate.
China appears to be recovering quickly from the global economic crisis, and its metalworking industry is benefiting from this. The German pavilion at MWCS enables German companies to themselves take advantage of this resurgence at a reasonable expense.
German enterprises can secure their spot in the group pavilion by contacting Birgit Mertens of Hannover Messe International GmbH ([email protected]), which is organizing the pavilion on behalf of the Federal Ministry for Economics and Technology.
Hardinge Adds UK Grinding Specialist Jones & Shipman’s Name to Portfolio of Brands
Shanghai’s Metalworking China Trade Fair in November to Include a German Pavilion
Hardinge Super Precision Europe GmbHKREFELD, GERMANYwww.hardinge.com
Metalworking and CNC Machine Tool China Show 2010SHANGHAI, CHINAwww.metalworkingchina.com
www.etmm-online.com June 2010 � European Tool & Mould Making 11www.etmm-online.com
Industry News
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Meusburger Website Offered in Spanish
A Spanish-language version of its web-site brings to 10 the number of lan-guages in which the standard moulds supplier Meusburger Georg GmbH & Co. KG services its customers on-line. Also, the monthly Meusburger news-letter and the company’s digital pub-lications, such as the on-line and CD product catalogues, are now available in Spanish.
Designed to set high standards for customer service, the Meusburger website offers an overview of the cor-
UCIMU: Italian Machine Tool Orders Increase in First Quarter of 2010; However, Recovery Is Not Firm YetThe index of Italian machine tool or-ders returned to the positive side in the first quarter of 2010. Orders in-creased by 15.2% over the same period in 2009, with an absolute index value of 94.8 relative to the base of 100, which represents the 2005 level of or-ders. These statistics emerge from data gathered and analyzed by the Studies Department of UCIMU-Sistemi per Produrre, the association of machine tool, robot, automation system and auxiliary technology manufacturers.
Following six consecutive falling quarters, the turnaround that was only sensed at the end of 2009 now has substance. The recovery in order taking was seen in both the domes-tic and foreign markets. Orders from foreign customers collected by Ital-ian manufacturers in Q1 2010 was up 18.5% over Q1 2009. However, UCIMU points out that order levels in this year’s opening quarter stood a full
40% lower than during the pre-crisis peak period of 2007–2008. The year-to-year rise in first-quarter orders from Italian customers was 10%.
Giancarlo Losma, president of UCIMU-Sistemi per Produrre, notes that, while the recovery is real, par-ticularly in foreign markets, Italian manufacturers are concerned that improvement in domestic sales may be weakened if the Tremonti-Ter tax exemption measure that the govern-ment introduced to stimulate capital investments is not extended beyond its scheduled expiration on June 30, 2010. Consequently, UCIMU is calling for the Italian authorities to apply the benefits of Tremonti-Ter to production machinery ordered by December 31, 2010, and delivered within 18 months of the order.
UCIMU-Sistemi per ProdurreCINISELLO BALSAMO (MI), ITALYwww.ucimu.it
Meusburger Georg GmbH & Co. KGWOLFURT, AUSTRIAwww.meusburger.com
porate sales or-ganization and of all relevant company con-tacts, as well as picture galler-ies and short films and im-portant items for download, all of which are presented in a clear display.
The Meusburger customer service portal at the site affords registered cus-tomers easy personal access to current quotations, pending orders and infor-mation about expected deliveries, in addition to the on-line catalogue, and provides all customer-specific data and conditions. The customer is able to reach the portal from each page of the Meusburger website.
12 European Tool & Mould Making � June 2010 www.etmm-online.com
Industry News
The tooling giant Walter AG is part-nering with the machine tool manu-facturer Gildemeister (DMG) to offer purchasers of DMG machines a one-stop, highly productive machining solution based on the provision of Walter toolboxes tailored to the mate-rials and components to be machined. The system partnership benefits buy-ers of DMG’s DMF, DMC V and DMU 60-160 P duoBlock milling and ma-chining centres by embracing Walter’s application engineering expertise and extensive range of innovative tooling solutions. According to Peter Witte-czek, CEO of Walter AG, it “unites two technology leaders that pursue the
Walter, Gildemeister Offer Tooling-and-Machine Solutions through System Partnership
same goal: to serve the global market with user-oriented technologies and forward-looking product strategies.”
Walter supplies single-source com-plete tooling solutions to support high-productivity machining via the world-class brands Walter (carbide and PCD insert tooling systems for turn-ing, drilling and milling), Walter Titex (HSS-E and solid-carbide drilling and reaming tools), Walter Prototyp (HSS-E and solid-carbide thread generation and milling tools) and Walter Valenite (indexable inserts and “specials”).
Gildemeister supplements its core competencies in turning and milling centres with Lasertec laser-cutting ma-
visit www.mastip.com to find out more
Mastip Hot Runner SystemsGiving Your Business Global Support
Easymetal Still Looking East
Resale Used-Machinery Fair to Move from Karlsruhe to Stuttgart in 2011
The Austrian filtration technology and water processing system supplier Easymetal Prozesstechnik GmbH, which offers a wide range of prod-ucts for electrical discharge machin-ing and other industrial processes, has acquired two more sales partners in southeastern Europe. This is a mar-ket region that Easymetal has recently been developing as part of a strategy of business expansion into areas of Eu-rope in which the company has been attracting customers.
The new sales partners are Vertigo-precisa CNC Trade d.o.o. in Croatia, and Original Express S.r.l. in Romania. Easymetal expects these companies to help it set technological standards for osmosis-based fluid treatment in their respective countries.
Resale 2011, the next edition of the trade fair for used machinery and equipment, will be held at the New Stuttgart Trade Fair Centre April 6–8, 2011, as a joint project of Landesmesse Stuttgart GmbH and Karlsruher Messe- und Kongress-GmbH (KMK). Up till now, the 16-year-old event has taken place in Karlsruhe.
Though continuing to be presented in the strong German economic re-gion of Baden-Württemberg (B-W), the fair, which is geared toward a glo-bal audience—exhibitors come from more than 20 countries and visitors from over 100—moves to the heart of the market for mechanical engineer-ing and plant construction, and also to one of Europe’s most modern trade fair centres. A key consideration was the proximity of Stuttgart Airport.
KMK is still the licensor of Resale after the move to the larger Stuttgart
Walter AGTÜBINGEN, GERMANYwww.walter-tools.com
Resale 2011STUTTGART, GERMANYwww.messe-stuttgart.de
Easymetal Prozesstechnik GmbHSTOCKERAU, AUSTRIAwww.easymetal.com
chines and the Ultrasonic range for machining advanced materials.
facility, and will profit from its future success. This venue change is the first component of an agreement between the two major B-W trade fair com-panies to cooperate more closely on trade fairs and exhibitions.
“As a licensee of KMK, Messe Stutt-gart will be able to use Resale as an ex-cellent addition to its portfolio com-prising AMB, Lasys, O&S, Blechexpo, MOTEK and many other events relat-ing to the area of used machinery,” says Ulrich Kromer von Baerle, man-aging director of Messe Stuttgart.
Resale will make a strategic break-through with its new partner in that the fair focus in Stuttgart will extend beyond resale to retooling, retrofit-ting, rebuilding, remanufacturing, re-moval, reconfiguration and recycling.
www.etmm-online.com
EuroMold News
Hall 8.0, the Showplace for Mould Making and Tooling at EuroMold 2010, Is Already More Than 75% BookedDEMAT GmbH, the ex-hibition company that every year organizes the EuroMold World Fair for Moldmaking and Tooling, Design and Application Devel-opment, is reporting a strong demand for exhibit space at Euro-Mold 2010 from nu-merous market-leading technology companies. Inquiries and bookings have come mainly from Germany and Western Europe, of course. At press time, more than 75% of available space in Hall 8.0 had already been sold, according to DEMAT. That is the EuroMold area at the Frankfurt Exhibition Centre in which the focus will be on mould making and tooling.
EuroMold 2010 takes place in Frankfurt am Main, Germany, on December 1–4.
The largest number of exhibitors at EuroMold are always from the host country Germany. At this time, DEMAT says, Italy and France are leading all other nations in terms of internation-alizing the event; they have the sec-ond- and third-largest contingents of exhibiting companies already booked. Other foreign countries that will be well represented at EuroMold 2010 are, in order by size of representation, China, Portugal, Spain, the United Kingdom and Switzerland.
International exhibitor participa-tion in EuroMold 2010 now amounts to approximately 30% of the total, which is commensurate with last year. Comparing sign-ups to date with the status at this stage in 2009, DEMAT believes that France and Spain in par-ticular could be contributing a larger number of exhibitors this time.
Mould making and tooling is the core sector of EuroMold, comprising 24% of all exhibitors. The next most
heavily represented sectors are rapid prototyping and tooling, computer hardware and software, and pattern making and prototyping. DEMAT sees the hardware and software and design sectors potentially increasing their quota considerably in 2010.
Hall 8.0, the centre for mould mak-ing and tooling, has strengthened its profile. Many market leaders cover-ing various parts of the process chain will be there. The percentage of non-German exhibitors in Hall 8.0 is now 30.4%, with the most important coun-tries in this regard being Italy, Portu-gal, France, China, Spain, Austria and India. Among the notable Hall 8.0 ex-hibitors showcasing their innovations on stands exceeding 100 m2 in size are Böhler Uddeholm, Buderus, Deutsche Edelstahlwerke, DMG, Fooke, Has-co, Open Mind, Siemens, Tebis and Zimmer&Kreim.
Im Hüttental 3 D-85125 Kinding-HaunstettenTel. +49 (0 )84 67 / 84 00-0Fax +49 (0 )84 67 / [email protected]
www.inovatools.eu
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The especially developed crystallinediamond coating is optimally suited for the treatment of graphite, glass-rein-forced plastic materials and copper.
Edition Diamond
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EuroMold 2010FRANKFURT/MAIN, GERMANYwww.euromold.com
Dr. Eberhard Doring, director of DEMAT GmbH, oversees the EuroMold fair.
14 European Tool & Mould Making � June 2010 www.etmm-online.com
ISTMA
The International Special Tooling & Machining Association (ISTMA) is a well-established international organi-zation representing more than 30 na-tions’ special tooling and machining organizations across three continents: North America, Europe and Asia.
ISTMA Europe represents the in-dustry in matters concerning indus-trial relations in the European Union. Among its many activities, it conducts
Directory of ISTMA Europe Member Associationsa dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector; promotes communication among its members on a wide variety of industry concerns; maintains an information pool on technical investigation subjects; trans-fers performing management actions among its member associations; and supports European fairs and exhibi-tions focusing on special tooling.
CZECH REPUBLICTool Factories AssociationSvaz NastrojarenMr. Vaclav [email protected] Armady 118156215 Usti nad OrliciTel.+420 465 557101 · Fax +420 465 525128www.svaz-nastrojaren.eu
ESTONIAEstonian Special Tooling AssociationMr. Andres [email protected] tee 1 · 74001 Viimsi vald, Harjumaa Tel. +372 620 5902 · Fax +372 620 5901www.emliit.ee
FINLANDTechnology Industries of FinlandMr. Veli Matti [email protected]äranta 10 · 00130 HelsinkiTel. +358 9 1923373 · Fax +358 9 624462www.techind.fi
FRANCEAFIM (Association Française des Industries du Moule, Modèle et Maquette)Mrs. Catherine [email protected]/41 Rue Louis Blanc · 92400 CourbevoieTel. +33 1 47176412 · Fax +33 1 47176360www.afim-france.com
GERMANYVDMA Die and MoldDr. Wolfgang [email protected] Strasse 18 · 60528 Frankfurt/MainTel. +49 69 66031251 · Fax +49 69 66032251www.vdma.org
HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr. Sándor Markos · [email protected] u. 31/C · 1139 BudapestTel. +36 1 3402972 · Fax +36 1 3295425www.szmsz.hu
ITALYUCISAP (Unione Costruttori Italiani Stampi & Attrezzature Precisione)Mrs. Fausta Antinori · [email protected] Fulvio Testi, 12820092 Cinisello Balsamo (MI)Tel. +39 02 26255392 · Fax +39 02 26255214www.ucisap.it
LATVIALatvian Tool and Prototype Producer AssociationMrs. Natãlija Ivanova · [email protected] str. 2c · Riga 1046Tel. +371 678 07794 · Fax +371 678 07780www.lipra.lv
POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr. Maksymilian [email protected], ul. Graniczna 1005-816 MichalowiceTel. +48 22 7233812 · Fax +48 22 7235201www.stts.com.pl
PORTUGALCefamol (Associaçao Nacional da Industria de Moldes)Mr. Manuel Oliveira [email protected]. D. Dinis 17, Aptdo. 2572430-263 Marinha GrandeTel. +351 244 575150 · Fax +351 244 575159www.cefamol.pt
SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms. Janja [email protected] 9 · 1504 LjubljanaTel. +386 158 98308 · Fax +386 158 98100www.posvet-orodjarstvo.com
SOUTH AFRICAToolmaking Association of South Africa (TASA)Mrs. Alet Balaam · [email protected] Alexander Road, WestmeadKwazulu Natal · P.O. Box 661 · 3600 PinetownTel. +27 31 7005563 · Fax +27 31 7005562www.tasaweb.co.za
SPAINFEAMM (Federación Española de Asociaciones Empresariales de Moldistas y Matriceros)Mr. Josep Font · [email protected] Tecnològic del Vallès, Ceramistes 208290 Cerdanyola del Vallès (Barcelona)Tel. +34 93 5944747 · Fax +34 93 5944737www.feamm.com
SWEDENSvensk Industriförening (SINF)Mr. Niklas Eidersjo · [email protected] 14, P.O. Box 22307104 22 StockholmTel. +46 8 4401170 · Fax +46 8 4401171www.sinf.se
SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr. Peter Vogel · [email protected] 4, 8032 ZürichTel. +41 44 3844811 · Fax +41 44 3844846www.swissmem.ch
TURKEYTool Manufacturers’ Association of Turkey (UKUB)Mrs. Solmaz Ugurlar [email protected] Karaer Cad. Cigdem 2 Sok.PK:41 DOSAB, BursaTel. +90 224 2615892 · Fax +90 224 2615893www.ukub.org.tr
UNITED KINGDOMGTMA (Gauge and Tool Makers Association)Mrs. Julia Moore · [email protected] Forge House, Summerleys RoadPrinces Risborough, Bucks HP27 9DTTel. +44 1844 274222 · Fax +44 1844 274227www.gtma.co.uk
For information, contact:Mr. Fausto RomagnaniSecretariat, ISTMA Europec/o Cefamol · Av. D. Dinis 17, Aptdo. 2572430-263 Marinha Grande, PortugalTel. +351 244 575150 · Fax +351 244 [email protected]
June 2010 � European Tool & Mould Making 15www.etmm-online.com
ISTMA
Focus of 2010 ISTMA World Conference to Be ‘Global Opportunities for Special Tooling & Machining Companies’
For the 13th time in history, mem-bers of the Europe, Asia and Americas branches of the International Special Tooling & Machining Association (ISTMA) meet in general session this month for the triennial World Tool-ing & Machining Conference (ISTMA World). The event takes place June 20–24 at Caesars Windsor Hotel & Ca-sino in Windsor, Ontario, Canada. The host association for ISTMA World 2010 is the Canadian Tooling & Machin-ing Association (CTMA).
This year’s ISTMA World theme is “Global Opportunities for Special Tool-ing & Machining Companies.” Confer-ence participants have several ways to learn about these opportunities, and about more besides. The four days of professional events include such high-lights as the ISTMA annual meeting, which occupies Monday afternoon; plant tours—more than a dozen Wind-sor-area companies operating in the
tool and mould making industry are opening their doors to visitors—which fill the Tuesday “business hours”; and a full programme of technical, business and industry conference sessions on Wednesday, June 23.
Conference SessionsSixteen sessions fill Wednesday morn-ing and afternoon. Technical presen-tations have such titles as “New CAD Software to Reduce Engineering Time” (Canada), “New Developments in Tooling Material” (USA), “Advanced Tool Surface Treatments” (Austria), “Thermal Influence of Different Types of Cutting Steel” (Czech Republic), “Military Parts Converted to Castings” (USA) and “New Analysis of Machin-ing Conditions in Electrical Discharge Machining” (Iran).
Additional sessions on technical topics are the following: “Elastomer
Injection Moulding Influenced by Tool Surface Roughness” (Czech Re-public), “Injection Mould Engineer-
ing Using FEA and CFD” (Canada), “Modular Multifunction System for Micromachining of High-Value Tooling” (Canada) and “Process-ing Advanced High-Strength Steels (AHSS) with Rotary Bend-ing Technology” (USA).
More-general business- and industry-themed sessions are
these: “Practical Ways to Reduce the Cost and Time of Getting Tools into Production” (Canada), “World-wide Tooling Trends and Production” (Portugal), “Business Improvements for Tool Shops” (Germany), “En-hanced Service Provisions in the Tool-ing Industry” (Germany) and “Inter-national Trends in Workplace Health & Safety Specific to the Tooling and Machining Industry” (Canada).
In addition, the president of ISTMA, Joaquim Menezes of Portugal, talks about the “European 1.2-Billion-Euro Manufuture Tooling Platform.”
‘Meet the Buyers’CTMA, in partnership with the On-tario Ministry of Economic Develop-ment and Trade, WindsorEssex Eco-nomic Development Commission, Canadian Department of Foreign Af-fairs and International Trade, and Ca-nadian Association of Mold Makers,
Leaders of the worldwide special tooling and machining industry look forward to meeting every three years. The previous World Conference took place in Joensuu, Finland, in 2007. ISTMA’s
leader Joaquim Menezes will preside in Windsor this year.
16 European Tool & Mould Making � June 2010 www.etmm-online.com
ISTMA
Canadian Tooling & Machining Association (CTMA)WINDSOR, ON, CANADAwww.ctma.com
ETMM helps tool and mouldmakers stay competitive bykeeping them aware of newproducts, services andtechnologies. That’s why ETMMis an excellent way for you tointroduce your company’sofferings to this audience.
ETMM welcomes press releases from the industry.For submission guidelines, visit:
www.etmm-online.com/submit
Otto-von-Guericke-Ring 3A • 65205 WiesbadenGermany
Tel. +49 6122 95590 [email protected]
www.etmm -online.com
Submit YourPress ReleasesSubmit Your
Press Releases
is hosting a “Meet the Buyers” event on June 21. Manufacturing-company buyers from specifically targeted in-dustries and from the nations of Ger-many, Mexico, India and the United States will be participating in the In-coming Trade Mission.
Buyers have been attracted to this opportunity from the aerospace, auto-motive, construction and infrastruc-ture, consumer goods and packaging, environment and renewable ener-gies, information technology, min-ing equipment and other industries. They are coming to Windsor intent on the objectives of satisfying Canadian and North American content require-ments, identifying opportunities for joint ventures and partnerships, and carving a path to entry into the North American market.
The host partners have carefully re-viewed the buyers and matched them with local companies that have the world-class capabilities and technical expertise to fulfill the visitors’ manu-facturing requirements. The buyers have a chance to see Canada’s most advanced innovations and are be-
ing taken on tours of manufacturing plants in the area.
Plant ToursTuesday, June 22, is dedicated to plant tours. Fifteen mould and tool indus-try–related companies in Windsor have agreed to welcome visits from groups of delegates in town for ISTMA World. They include Active Burgess Mould & Design Inc., Anchor Danly, Anderdon Machine Tool & Mfg. Inc., Build-A-Mold, Crest Mold Technology Inc., Electromac Group and J & C Tool & Die Ltd.
Also hosting visitors are Manor Tool & Die Ltd., Midwest Precision Mould Ltd., Narmco Group, Platinum Tool Technologies, Redoe Mold, Sabre Ma-chine Tool Inc., Tool-Tec Welding Inc. and Valiant Machine & Tool Inc. These operations are all located near the con-ference site. Information about them is available at www.ctma.com.
Opportunities and SynergiesFor decision makers in the tool, die,
mould and machining industries, the ISTMA World Conference pro-vides a great opportunity for acquir-ing knowledge of global best practices that can be taken home for implemen-tation in their own facilities. It also is an occasion for networking with peers from around the world. The organ-izers expect that the delegates from the global tooling and machining community will share ideas regarding challenges the sector faces and ways to promote recognition of the industry and achieve greater visibility for it in political contexts.
ISTMA anticipates an attendance of 300 to 500 at ISTMA World 2010, the first meeting in the series ever to be held in Canada.
This ISTMA World meeting is dis-tinctive in that it convenes at the same time and in the same place as the 11th International Pattern-Model Makers Congress, an event that also takes place only every third year.
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18 European Tool & Mould Making � June 2010 www.etmm-online.com
Interview
The Ecoline series of machine tools for turn-ing and milling at the entry level offers so-phisticated technology at low cost. This line, which has successfully established itself dur-ing a period of serious economic downturn, is the responsibility of DMG Ecoline GmbH ( w w w. d m g e c o l i n e .com), a business unit of DMG within the Gildemeister Group. Ecoline was started in 2009. The high-tech machines have been remarkably successful in both the turning and milling markets. Thanks to growing demand in important target markets, the number of Ecoline machines sold will pass 1,000 this year.
In an interview, Ecoline managing director Ralph Christ-nacht discussed the reasons for this success and considered the future of the Ecoline series.
Why was the Ecoline series such a large and immediate success in the market for entry-level machines?Despite price sensitivity on the part of customers, we focus on technical performance in a segment that has seen low-
Interview with Ralph Christnacht of DMG: Building a Successful Business from Entry-Level Machine Tools
priced machines being pushed into the market through price dump-ing. In a nutshell: The reason why our Eco-line machines are suc-cessful is, because our customers can achieve efficient and reliable machining perform-ance for a reasonable investment commit-ment. Moreover, com-pared with competi-tors’ cheap products, Ecoline machines are distinguished by high asset-value stability and investment safety. Here, we and our cus-tomers both benefit from recognized DMG quality.
What is behind the Ecoline price advantage over DMG’s high-tech machines?Let me begin by stressing that the Ecoline concept is based on the high-quality, top-of-the-line machines in the DMG product portfolio. By contrast, other suppliers often design cheap machines to be cheap from scratch.
Ecoline machines offer proven DMG technology and rely on components sourced only from leading global suppliers. This applies, for example, to the spindle technology in mill-ing machines and to the fast 12-position turrets with up to
six driven stations sup-plied from the turning sector. In addition, we offer guideways, drives and 3D control technol-ogy in the unique SLIM-line® panel with its 15-in. screen, 3D software that allows fast programming, and operator-friendly SOFTkeys®, as well as the SMARTkey®.
As to why we are capable of keeping in-vestment costs low for customers despite this ex-
Owing to first-class DMG machines and excellent sales structures centred on the machine builder’s technology and service centres, China counts among the most successful markets for the entry- level Ecoline series.
Ralph Christnacht, managing director of DMG Ecoline GmbH.
June 2010 � European Tool & Mould Making 19www.etmm-online.com
Interview
DMG Vertriebs- und Service GmbHBIELEFELD, GERMANYwww.gildemeister.com
cellent product, well, our concept provides a high degree of standardization and streamlined options. This enables us to increase production volume and reduce product complex-ity. On the one hand, production costs are lowered through scale effects, while on the other, assembly processes carried out at our production sites are certain to be more efficient, which also keeps costs down.
Where are the Ecoline machines built, and how are sales and service organized?The CTX eco and the DMC V eco are built in our Shanghai production facilities and at Famot in Poland. A third manu-facturer is Deckel Maho Seebach GmbH, which has been making the DMU 50 eco 5-axis-milling machine for Ecoline since last autumn.
As for sales and service, the customer benefits from a net of outlets cast worldwide by the Gildemeister Group. This comprises 72 domestic German and international sales and service sites.
Which are the top markets for Ecoline machines?Ecoline was designed above all for the BRIC nations: Brazil, Russia, India and China. Last year, the majority of Ecoline machines were sold to companies in China. Ecoline sales in Poland and Germany also were very successful.
What does DMG Ecoline mean by the marketing slogan “Entry into the innovative world”?The Ecoline series has expanded the base of DMG’s portfo-lio, and often acts as a door opener. In 2009, 55% of Ecoline customers had not purchased from DMG before. Add to this the fact that DMG, as a full-line company, enables custom-ers to start at any level and purchase elite machine tools later as needed.
This flexibility is highlighted by the machines’ range of user-oriented control systems from Siemens and Heiden-hain. And, through our cooperation with Mori Seiki, we will offer the Mapps 4 with 3D programming soon. This will help us win over customers who have worked only with American and Japanese control systems.
What innovations can Ecoline customers expect?We will continue developing the Ecoline machines in close dialogue with the customer. The evolutionary steps in the areas of spindles, control technology and options will be rather small, however.
In parallel with the CNC machines, we develop new components and special-purpose products. At EMO 2009 in Milan, we introduced a special Ecoline bar loader, and now we are showing our first tool presetting system, the UNO 115 eco.
What are your goals for 2010?We will build on the Ecoline series’ good start by expand-ing the new-customer business and keeping our focus on the production of high-quality CNC machines at attractive prices. With better framework conditions, we will be able to increase our sales numbers in important target markets this year as compared with what we achieved in 2009. www.euroblech.com
For more information please contact:Mack Brooks Exhibitions Ltd, Email: [email protected]
21st International Sheet Metal Working Technology Exhibition
26 - 30 October 2010 Hanover, Germany
• Sheet metal, Tube, Section• Finished products, Parts, Assemblies • Handling
• Separation • Forming • Flexible sheet metal working• Tube / Section working • Machine elements
• Joining, Welding • Surface treatment • Tools, Dies• Controlling, Regulating, Measuring, Inspection
• Quality Control • CAD/CAM systems• Data capture / processing
• Factory and warehouse equipment• Safety at work • Environment protection, Recycling
• Research and development
20 European Tool & Mould Making � June 2010 www.etmm-online.com
Featured Supplier
The growing variety and complexity of manufactured products adds new challenges for companies involved in tool and mould making every day, so enterprises in that industry need high-precision machining solutions that support flexible and economical operations. Walter AG helps out here by providing a wide range of modular precision cutting tools for roughing and finishing all of the most popular mould making materials.
The greatest expertise and precision are needed to manufacture the moulds called for today. These same high de-mands are made on the cutting tools that are used. Walter’s product range, comprising solid-carbide cutters, mill-ing cutters with inserts, and thread-ing tools, offers the advantages of ef-ficiency, reliability and economy. The tool manufacturer supplies modular systems—and provides high-quality cutting-tool materials—that are suited for various machining strategies.
Precision and Flexibility from a Single-Source Supplier of Modular Cutting Systems for Tool and Mould Making
terial does not partic-ipate directly in the machining process but remains in the machine spindle in the form of a shank.
Responding to the demand for VHM mills, Walter has developed and just launched a modular interface specific to its ConeFit™ proto-type. ConeFit is a tool concept in which an expensive VHM milling head that is replaceable is com-bined with a holder made from cheaper material (image on facing page).
The aim, explains Michael Fink, head of product management at Wal-ter, was to develop a modular system that would set standards for process
reliability while being an economical alternative to one-piece tools. On aver-age, Fink says, modular milling heads are one-third cheaper than classic VHM shank mills.
ConeFit has a cone-shaped adapter consisting of a precision cone with a self-centring special thread that com-bines aspects of a trapezoidal thread and a sawtooth thread. The cone maxi-mizes repeatability and concentricity.
In addition, the sup-port face provides the connection with optimum rigidity. The resulting large cone-to-face contact area between the milling head and the shank allows for the transmission of max-imum torque. The system moves within a diameter range of 10 to 25 mm, can be used for many ma-chining applications involving ISO mate-rial groups P, M, K, N and S, and keeps in-ventory costs down.
Walter provides a modular screw-head system for insert tools as well, ScrewFit (image at left), which enables a user to put together tools for milling, full boring, reboring and precision bor-ing with just one interface. The con-nection is available for special tools as well as standard tools. The ScrewFit system provides high stability and pre-cision because of the NCT short taper with support face, and, with adapters, can be used on any machine spindle.
Longer Tool LifeApplying the correct coating to cut-ting tools will deliver important ad-vantages with respect to productivity and cost efficiency. In tool and mould making applications, the enhanced wear resistance extends tool lifetime and helps ensure the necessary high-quality finish. Through its Tiger·tec® range, Walter offers a comprehensive choice of cutting-tool materials for any application. The high-tech coat-ing is available in pure CVD Al2O3 and in a PVD version.
With its two-colour CVD Tiger coating, Walter combines high wear resistance with toughness. The CVD process provides outstanding coat-ing adhesion, and the posttreatment optimizes surface hardness and wear detection. The PVD Tiger multilayer coating offers the advantages of both
Flexibility through ModularityThe choice to machine with tooth numbers (z) of 4 or greater and the machining of complex contours are factors that have increased the de-mand for VHM tools, particularly in tool and mould making. However, the bigger the diameter of solid-carbide tools, the higher their considerable cost. And most of their high-tech ma-
Michael Fink, product manager for Walter AG.
Featured Supplier
Walter AGTÜBINGEN, GERMANYwww.walter-tools.com
chemical and physical vapour deposi-tion. (Walter pioneered in this.) It fea-tures extreme toughness, high abra-sion resistance, and thermal stability. Long-lived PVD Tiger is suitable for any carbide substrate.
Hard MachiningBesides modularity and high cutting-tool material quality, tool and mould makers are increasingly interested in hard machining up to 65 HRc. Walter engineers have developed for the Pro-totyp brand the Protostar® Ultra VHM mill family for such applications. The TiAl(Si)N coatings on these cutters in-crease thermal wear resistance and al-low use on high-speed-cutting (HSC) machining systems. The tools are de-signed for such hard-milling strategies as low cutting depths and HSC.
This product range includes toroi-dal, radius copying and radius mills. The smallest Protostar Ultra tools are radius copying mills 0.3 mm in diam-eter; the smallest available diameter for shank mills with shoulder radius is 0.4 mm. Various pitches are available for roughing and finishing work. All
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of these mills are manufactured with very narrow tolerances.
The Protostar Flash, a roughing end mill for machining materials in the hardness range of 55 to 65 HRc, comes in diameters of 4–20 mm. The geome-try of its four cutting edges makes pos-sible an extremely large feed per tooth.
The three cutting-tool brands of
Walter, Walter Titex and Walter Proto-typ provide tool and mould manufac-turers with a complete range of prod-ucts that can be supplied by a single source. The right tool for any machin-ing strategy is available.
www.etmm-online.com
Technology
High-Performance Indexable-Insert Face-Milling Cutter Provides Soft Cutting Action, Exerts Low Axial Pressure
Sandvik Coromant regarded the CoroMill 245’s square insert as the basis from which to develop a higher level of indexable-insert technology, where the macrogeometry of the cut-ter and microgeometry of the insert could be merged advantageously. The 345 insert edge-line varies according to the degree of cutter engagement. Be-sides providing the advantages of soft cutting action and low axial pressure brought about by the more positive axial inclination at small and medium
cutting depths, an increasingly more upright part of the edge comes into action as the depth increases. This
gives the insert a more substan-tial structure for unattended high-security machining, es-
pecially in tougher cuts.Combining the new
intelligent cutting ac-tion with a doubling of the number of avail-able cutting edges per insert was a signifi-cant challenge Sand-
vik Coromant faced in developing the CoroMill
345. The company solved the problem by employing
an insert that has a negative basic shape with positive, soft cut-ting-edge geometry where the in-
sert rake faces rest on four stra-
tegic support islands of the shim. This design provides full insert seat stabil-ity and optimum performance during machining.
The shims rest on seats located within the cutter body, which are de-signed to provide the ideal support and to accommodate closer insert pitches, which can increase metal re-moval by putting more teeth in cut. The HX extra-close-pitch CoroMill 345 is an option available for machine shops seeking such a solution.
The advanced, high-productivity CoroMill 345 tool concept is equally apt for small-batch mixed machin-ing and for high-volume dedicated machining. This cutter answers needs that range from roughing at a de-manding 6-mm depth of cut to mirror finishing by means of wiper inserts. Available in diameters up to 250 mm and featuring coolant supply to each insert pocket for diameters up to 125 mm, it is easy to select, apply, use and handle. A new generation of PVD- and CVD-coated insert grades maximizes tool life as well as speed and security. Inserts come in a range of geometries and edge profiles to match various operations, conditions and workpiece materials.
The new-generation CoroMill 345 in-dexable-insert 45° face-milling cut-ter from Sandvik Coromant incor-porates several new features building on those of the CoroMill 245 that pre-ceded it. The new eight-edge (double-sided square) insert has an advanced-design edge line that varies according to depth of cut, while a more positive axial inclination at small to medium depths provides a soft cutting action with low axial pressure on steel work-pieces. The result is a cost-effective high-performance cutter.
The four-edge CoroMill 245, a benchmark face-milling cutter when introduced as a versatile tool offer-ing 6- or 10-mm depths of cut, could machine virtually any material and perform operations from roughing to mirror finishing with both small- and large-diameter cutters. To make its functionality, performance and relia-bility available in an eight-edge-insert face mill became a mission for Sandvik Coromant. Extensive company R&D based on machine tool evolution and newly developed machining strategies resulted in the CoroMill 345, which provides high-security eight-edge cut-ting with a 45°-lead entering angle while lowering both tool and machin-ing costs.
Sandvik Coromant EuropeZAVENTEM, BELGIUMwww.sandvik.coromant.com
22 European Tool & Mould Making � June 2010
24 European Tool & Mould Making � June 2010 www.etmm-online.com
Technology
The deep-drilling specialist Auerbach Maschinenfabrik GmbH specially adapted one of its deep-drilling mill-ing machines in the AX3 TLF series for a customer that had to perform deep drilling of block heat exchangers made of graphite. An economical drill-ing operation that neverthe-less offered a high standard of chipping technology was the customer’s desire. With the successful completion of this project, Auerbach confirmed its capability to manufacture custom special-purpose deep-drilling machines.
Purpose and RequirementsThe machine in ques-tion was to be used in the chemical in-dustry for heat- and substance-exchanging processes. Previously, the huge number of holes on the bound-ary surface and plane side of such heat exchangers had
Economical Deep-Drilling Milling Machine Is Adapted for Higher Performance in Drilling Graphite Blocks
been produced by means of special multi spindle deep-drilling machines, but this resulted in long periods of downtime being
required for the ma-chine to be changed over. Manufactur-ers had to produce larger lots because of this inflexibil-ity, which meant a considerably higher storage fee than was ideal.
Upon receipt of this engineering commission, Auer-bach Maschinenfab-rik formed the in-tention of designing a deep-drilling mill-ing machine that could improve the hole deviation in or-der to allow a flow of aggressive and abra-sive fluids through a greater number of
holes within the heat exchanger. The block heat exchangers that have to be machined have dimensions as large as 2,100 mm, by the way.
As it happens, an Auer-bach AX5 TLF machine could have met the project requirements for loading and drilling depth without
Technologyany substantial changes having to be made in the basic machine configura-tion and capabilities. This is not the case with the AX3 TLF, however. The customer had elected to work with the latter machine for investment reasons.
Adapting the MachineNot only the basic construction of the AX3 TLF—which had to be changed—but also the machining of the graphite itself and the requirements for drill-ing accuracy posed challenges for the Auerbach engineers. But here their ex-perience in constructing high-speed-cutting bed-type milling machines for the graphite heat exchanger industry proved advantageous for them.
To meet the customer’s needs, Au-erbach reconstructed the existing AX3 TLF deep-drilling milling unit and adapted it for graphite machining. This involved protecting all sensitive machine parts against infiltration by graphite dust through the installation of special housings rated to the protec-tion category IP65. Linear guides in a special construction with integrated measuring systems and a ball screw
were installed, and these too were protected against graphite dust by the addition of stripper systems. Also, the deep-drilling process was reengineered to resemble the typical machining process for graphite.
Installing cooling lines with air pressure to extract the graphite dust at the hole-drilling site was one measure taken to change the machine technol-ogy and adapt it to the drilling job. Another was the use of special guide noses to enable the machine to drill holes on the boundary surface of the graphite cylinder. Additional adaptive techniques were applied as well.
One very interesting challenge was the task of creating a machining cycle by which the boundary surface could be processed. The software solution Auerbach devised, which is able to assign parameter values, saves future operators the trouble of having to per-form position calculations, allowing them simply to operate the machine.
New CapabilitiesThe range of products that the end user wanted to machine was another
area of challenge for the Auerbach en-gineers. The table size, drilling depth and load potentials all required that adaptations be made in the AX3 TLF deep-drilling milling machine. The most noticeable result of the changes was a bigger machine housing. In ad-dition, the drilling depth, normally a maximum of 1,300 mm with the AX3 TLF, was amplified; the greatest pos-sible depth is now 1,500 mm. In the future, it will even be easy to achieve a drilling depth of 2,100 mm with the use of a second tool.
The machine Auerbach Maschinen-fabrik finally constructed was able to fully meet the customer’s require-ments. The flexibility of the AX3 TLF CNC deep-drilling milling machine, along with the adapted unit’s straight-ness performance of better than 0.04 mm of deviation per 100 mm of ma-chining length, the enhanced surface quality it achieved at high feed rates, and its high positioning accuracy, give the customer sound reasons to expect very good operational efficiency.
Auerbach Maschinenfabrik GmbHELLEFELD, GERMANYwww.auerbach-x.de
26 European Tool & Mould Making � June 2010 www.etmm-online.com
A US-based Japanese joint venture, Kobe Aluminum Automotive Products LLC (KAAP) has been able to reduce machining times and minimize hand finish-ing by switching to the PowerMill CAM system developed by Delcam plc. The software that the company had pre-viously been using was difficult to learn and generated programmes that took longer to run than KAAP thought de-sirable. The changeover to PowerMill resulted in savings both during pro-gramming and on the machine.
“Switching to Power-Mill helped us reduce machining cycle times by 40%, primarily be-cause the rest-machin-ing capabilities in its offset area clearance strategies greatly reduce air-cutting time,” ex-plains Victor Steele, tool shop manager for KAAP. “Its optimized and in-terleaved constant-Z fin-ishing strategy has im-proved surface finish to the point that manual finishing has been re-duced by 50%.”
In addition, says Steele, “PowerMill is easier to learn, with the result that new programmers can be trained in less than an hour.”
KAAP invested $80 million in its 108,000-ft2 (10,044-m2) plant in Bowl-ing Green, Kentucky, in order to be able to meet demand by producing 280,000 forged aluminium compo-nents per month, principally for the automakers Nissan, General Motors and Honda. Automotive companies are using ever larger quantities of aluminium forgings for suspension systems so as to reduce weight and in-crease fuel economy.
Switching CAM Software Enables Automotive Supplier to Save Time in Programming and Machining Forging Dies
The company’s greatest CNC pro-gramming challenges are closed forg-ing dies. KAAP normally roughs out the parts on a Mazak FJV-3580 verti-cal machining centre (VMC) and per-forms finishing operations on a Mazak Nexus VMC.
“We were able to programme these parts with the CNC software that we used in the past, even though it was not very intuitive,” Steele says. “Roughing operations were relatively slow because the tools spent much of their time cutting air.” The problem with KAAP’s previous software was that each successive cutter traced the
complete path of the part profile, even where there was nothing for it to cut because the sec-tion had already been finished or the cutter was too large.
Majority owner of the joint venture is Kobe Steel. Its Japanese op-eration had successfully programmed this type of part with PowerMill and recommended that KAAP try the Delcam software.
“One of Kobe Steel’s programmers visited us and showed us how to use PowerMill,” re-counts David Taylor, an engineer at KAAP. “De-spite his limited English, he was able to teach us to use the programme without a great deal of difficulty. We liked the way the user interface is laid out.”
Later, KAAP program-mers had two days of on-site instruction from one of Delcam’s PowerMill trainers. “As we got to know the software bet-ter, we were impressed with the large number of powerful machining strategies that it offered to help optimize cycle
time and the accuracy of our machin-ing operations,” Taylor says.
David Taylor notes that PowerMill’s simulation capabilities are superior to those of the previous software, as well. Simulation in PowerMill gives the op-erator extra confidence by predicting axis reversals and surface quality. The virtual machine run often identifies opportunities for improvement. Then, the programmer can easily change or reorder operations in order to prevent crashes or reduce cycle time.
Simulations in Delcam’s PowerMill enable Kobe Aluminum Automotive Products to check surface quality in the finished die.
Delcam plcBIRMINGHAM, UKwww.delcam.com
Case Studies
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RECEIVE CATALOG PAGES AND TECHNICAL SUPPORT AT 44-0161-669-6191, WITH ANIMATIONS AT WWW.PROCOMPS.COM
28 European Tool & Mould Making � June 2010 www.etmm-online.com
Case Studies
One Automated 5-Axis Milling Machine Revolutionizes a Rapid Tooling Specialist’s Operation; Another Is Coming
With operations running 24/7, Formaplex employs leading-edge automated CNC milling equip-ment, supplying prototype com-ponents, master patterns and rapid tooling solutions to major global companies across a wide spectrum of industries. It follows an ethos of continuous improve-ment and thus constantly invests in state-of-the-art machines.
In 2009, the Hampshire com-pany began investigating technology that would offer the potential for sig-nificant performance growth in terms of 5-axis unattended machining and enhance the lights-out capabilities of its Machining division. This research process led it to Matsuura Machinery plc, the sole UK agent for Gruppo Par-pas machine tool brands.
Selecting the MachineThe Gruppo Parpas product range spans milling machine tools for every machining process. For its part, Matsu-
ura UK has an established track record of fully supporting all products from its portfolio through UK-based techni-cal engineers, service technicians and investment in critical frontline spares. Significantly for Formaplex, which was a new customer to Matsuura in 2009, the machine tool supplier also has vast experience in the area of oper-atorless machine running and lights-out manufacturing.
Formaplex identified the Famu Ac-tive 5 as the ideal fulfillment of its selection criteria and saw it as the machine to bring the company new growth and increased capacity, capa-bility and flexibility.
A high-speed fixed-portal-type ma-chine with a 3,050 x 1,100-mm table, the Active 5 is fully able to accommo-date large, heavy, awkward compo-nents and billets weighing up to 5,000 kg. Ergonomically designed, it occu-pies an 8,160 x 2,900-mm footprint. Two of its 5 axes are contained within the head configuration: the c-axis of-fers a movement range of 380° and
the a-axis a range of ±110°. X-, y- and z-axis travels are 3,000, 1,800 and 850 mm, respectively. Spindle speed on the Formaplex machine is 22,000 rpm.
Chris Carter, operations director at Formaplex, at-tests to the quality of the Famu Active 5, naming quality “our initial pro-curement demand when investing in new CNC ma-chines.” He and the For-maplex managing direc-tor Dave Shooter had seen Parpas machines in action in Italy and were impressed also by their robustness and fitness for purpose.
Putting It to WorkThe Active 5 now running in Hampshire is predomi-nantly engaged in cutting aluminium, especially mak-ing injection moulds for the Moulding division. “We
Displaying confidence within an ar-duous UK trading and manufacturing environment, the rapid manufactur-ing solutions group Formaplex has invested in two Gruppo Parpas ma-chine tools in a space of less than 12 months. The company offers a rapid-turnaround engineering service for Formula 1 teams in the UK, produc-ing tools and moulds for components used in tests. It also serves high-end, low-volume OEMs. The custom Famu Active 5 5-axis milling machine the company just acquired was supplied by Matsuura Machinery plc.
Formaplex operations director Chris Carter at the control of the versatile Famu Active 5, which now is running all the time and enabling the company to grow. Performing unattended aluminium cutting, the machine handles everything from roughing to fine finishing.
June 2010 � European Tool & Mould Making 29www.etmm-online.com
Case Studies
work our machines extremely hard—unmanned 24/7,” says Carter, commenting that a lights-out engineering approach is taken across the whole manufacturing operation.
“We work machines 100% of their available uptime,” Chris Carter goees on to say. “They have to be fit for pur-pose to maintain our production schedule and workloads.” Minor “teething” problems with the Active 5 were quickly sorted out, Carter notes. Backup and service are essential to Formaplex because of the nature of its business as “engi-neering paramedics,” as Dave Shooter characterizes it.
Carter concludes: “Our management team predicted some time ago that we would need more 5-axis capacity, and, with the complex nature of the shapes and forms we produce, we needed a 5-axis machine we knew to be du-rable, versatile and capable. The Active 5 gives us all that and the capacity to grow. The surface finish achieved on the Active 5 is absolutely superb: we have eliminated hand-finishing on the vast majority of our mould and die work.”
The Active 5 resides in the ultramodern machine shop in Formaplex’s Machining division, cutting 99% aluminium according to Ben Yule, the division’s works manager. “We need to put up a rough-sawn block and fully automate the machining process to run completely unmanned and pro-duce the finished article. Running unmanned—reliably—gives us a market advantage. The Active 5 does it all for us: from roughing to high-definition finishing work.”
The Shop-Floor StarYule recounts an unattended job over the 11-day Christ-mas break that truly tested the Active 5. Coming in after the break, he found the job “pretty much finished”—con-firmation that Formaplex had made the correct choice of machine and company strategy. The machine adds value that can be passed on to customers and makes possible very fast job turnaround, which is exactly the capability a rapid-service provider needs.
“It has massively reduced our machining times,” says Yule. “Our problem now is that every job is funnelling to-wards the Active 5 because of its capability and the time it can save us.” Hence the order for the second Active 5, which Yule says will be installed in August.
Matsuura Machinery plcCOALVILLE, LEICS, UKwww.matsuura.co.jp
30 European Tool & Mould Making � June 2010 www.etmm-online.com
Case Studies
The German precision-parts supplier Kaiser Werkzeugbau serves the Formu-la 1 and aeronautics industries, sectors that require the highest level of quali-ty from component providers and that look for the best price-to-performance ratio possible. Both owner Thomas Kaiser and most of his employees are master craftsmen. As professionals, they are all committed to always seek-ing out opportunities for further im-provement. Getting the most out of each process, they know, means close cooperation between the functional areas of CAD, CAM, tools, materials and machines, beginning with careful planning. The hyperMill® CAM sys-tem from Open Mind Technologies AG, which Kaiser has been using for three years, is central here.
The innovative workpieces required for Formula 1 racing push the limits of the possible in terms of contour complexity, tolerances and materials.
Sophisticated CAM System Helps Formula 1 Supplier Keep Up with Demand for Complex Precision Parts
The options afforded by the program-ming system Kaiser used to employ simply became inadequate, as greater flexibility and the leeway to develop new ideas increasingly were needed. In light of the demanding require-ments, hyper Mill was able to display its extraordinary capabilities on a dif-ficult part and thus became a critical element of the Kaiser operation.
Many complex geometries can be realized only with 5-axis simultaneous machining. Thus, Kaiser Werkzeug-bau has invested in advanced 5-axis machines run with hyperMill, which offers machining strategies that take
full advantage of the machines’ capa-bilities. Automated tools such as col-lision avoidance, feature technology, job linking and stock tracking have made possible reductions in program-ming and processing times while max-imizing pro cess reliability. The fully automated calculation of tool angles in 5-axis programming counters the inherent complexity of this technol-ogy, making programming no more difficult than with 3D machining.
Over the past three years, hyperMill has proved itself not only in terms of 5-axis simultaneous machining, but also in the realm of surface quality and
precision, allowing Kaiser to meet stringent customer de-mands easily. The wide spec-trum of available machining strategies and numerous op-timization functions gives the company the flexibility it needs to succeed. Wolf-ram Kraft, head of the CAM department, especially likes hyperMill’s intuitive interface and user-friendliness.
Because CAM is so critically im-portant to Kaiser Werkzeugbau, the company actively participates in the development of hyperMill as a beta tester. This way, it can voice its own requirements in day-to-day manufac-turing and help contribute to practice-oriented development.
Purchasing a CAM system as com-prehensive as hyperMill represents a long-term business decision. “Com-panies often shy away from investing in a high-end tool like hyperMill, yet the manufacturing advantages it offers after an introductory phase of only a few months speak for themselves,” says Stephan Kirschner, regional sales director at Open Mind.
Thomas Kaiser recognizes and likes those advantages. “We have been able to reduce the programming times for all 2D to 5-axis simultaneous machin-ing jobs way beyond all our expecta-tions while still ensuring maximum process reliability,” he reports.
Open Mind Technologies AGWESSLING, GERMANYwww.openmind-tech.com
Exhibit with DEMAT worldwide!
www.demat.com
Fairs + ExhibitionsDEMAT
December 1 – 4, 2010Frankfurt /Main, Germany
May 11 – 13, 2010Cincinnati, USA
June 2 – 4, 2010Moscow, Russia
March 18 – 21, 2010Mumbai, India
August 16 – 18, 2010Johannesburg, South Africa
September 15 – 17, 2010Guangzhou, China
Partner Country Turkey
at EuroMold 2010
32 European Tool & Mould Making � June 2010 www.etmm-online.com
Hexagon MetrologyUNTERENTFELDEN, SWITZERLANDwww.hexagonmetrology.com
Products & Services
Machining Productivity Benefits Follow from Enhancements to CNC Series and the Supplier’s Service and SupportThe CNC systems that Fanuc CNC Europe S.A. and its 12 regional sub-sidiaries supply to European machine tool builders and users have been en-hanced through the addition of new functions and are now supplemented with new service and support prod-ucts, all to enable customers to achieve higher productivity.
Particularly, the company’s Series 30i/31i/32i CNCs have been augment-ed with new features. These CNCs are especially suited for complex ma-chines, such as combined lathe/mill-ing centres, 5-axis machines, and multispindle and transfer machines. Additional 5-axis machining capabili-ties and some other enhancements, including the expansion of 3D Inter-ference Check to safeguard collision-risk areas, drive productivity to new heights.
Fanuc’s CNC Series 0i Model D of-fers nanointerpolation, a function that satisfies the most demanding finish requirements at high feed rates and speeds. Dual Check Safety is a new feature on the Series 0i. It employs the
control’s multi-ple processors to cross-check data in order to mon-itor safety-criti-cal parts of the machine, ena-bling machine operations to be in compli-ance with inter-national safety standards with-out the need for adding more safety units.
Also boast-ing new features are Fanuc’s user-friendly Manual Guide i software for workshop programming and its NCGuidePro PC-compatible software that can be used for developing machine control off-line and for training purposes.
Fanuc CNC service and support, backing the reliability and innovation
of Fanuc auto-mation and con-trol technology, ensures maxi-mum machine availability and p r o d u c t i v i t y. Through a con-tract designed to fit the customer’s need, mainte-nance costs for control and au-tomation can be minimized. Also, existing CNCs can be optimized or more-effective CNCs and drives retrofitted, oper-ators and main-tenance staff can
be trained, and customers can receive Fanuc replacement parts that come with strong warranties.
Motorized Probe Heads for CMMs Offer 720 Indexable Positions and Compatibility with Legacy Products
New versions of the TESASTAR-m and TESASTAR-sm motorized probe heads for DEA and Brown & Sharpe coor-dinate measuring machines (CMMs) offer a 7.5° indexing increment for maximum compatibility with legacy products. Available from Hexagon Metrology, the enhanced variants de-liver –180° to +180° of revolution and 0° to 105° of pitch, for a total of 720 indexable positions. The TESASTAR-sm presents the added benefit of an in-the-quill mount, which increases the effective measuring range along the CMM’s z-axis.
Providing positioning compatibil-ity with other legacy products on the market as well, the new probes also of-fer the advantage of indexing speeds that are as much as twice as fast.
As with the original 5°-increment TESASTAR motorized probe heads,
the new heads are available in both M8 and TESA Kinematic Joint (TKJ) versions. The M8 versions provide a mechanical interface suitable for con-nection to standard M8 touch trig-ger probes such as the TESASTAR-mp. The TKJ versions are for both contact and noncontact scanning probes, as, for example, the LSP-X1 and CMM-V video probes.
Further, the new probe heads are fully compatible with existing TESA-STAR-e and TESASTAR-ae probe head controllers, TESASTAR probe exten-sions and the TESASTAR-r probe rack.
TESA, a part of the Hexagon Group, makes over 5,000 dimensional metrol-ogy products, from precision hand-held tools to sophisticated systems.
Fanuc CNC Europe S.A.ECHTERNACH, LUXEMBOURGwww.fanuccnc.eu
www.etmm-online.com June 2010 � European Tool & Mould Making 33
Products & Services
Centring Vise for Efficient, Flexible, Precise Clamping of Workpieces for Five-Side Machining Is User-FriendlyFive-side-machining in a single clamping is the way to process workpieces both completely and economi-cally. Auxiliary processing times are reduced substan-tially, and reclamping errors are avoided. Any further productivity optimization then must come from im-provement in the workpiece clamping method. Erowa AG accordingly offers the 148 P/i centring vise, which constitutes a precise and flexible interface between workpieces and the machine. With the base body of a P pallet, the unit is compatible with Erowa chucks of the ITS PowerChuck P, PC210 Com-bi, and MTS/MTS+ Single Chuck types.
To safely absorb the changing forces generated by chip cutting and main-tain the highest possible stability, the
pallet and base body of the 148 P/i are made from a single block. The centre of the vise can still be adjusted. The entire body of the vise is constructed
of stainless hardened steel. Because the spin-dle is sealed (and thus requires no mainte-nance), the basic work-ing order of the vise is guaranteed even if con-siderable contamina-tion is present.
Erowa’s centring vise features user-friendly operation and easy ac-cessibility during the machining process. Its jaws can be positioned at grid distances of 15 mm. The entire clamp-ing range is suitable for parts ranging in dimen-sion from 5 mm to 155 mm. Workpiece clamp-
ing process repeatability is ±0.01 mm.
Erowa AGBÜRON, SWITZERLANDwww.erowa.com
www.etmm-online.com
Version 17.0 of the SmartCAM® suite of CAM system software delivers ad-vanced milling improvements, includ-ing a new Z-level roughing process and enhancements to the solid pocketing process, along with such substantial core enhancements as Web-format re-port generation, better graphics print-ing and new abilities to store the mask and visibility state with named views. The SmartCAM product family, devel-oped by SmartCAMcnc, consists of applications for CNC milling, turning, fabrication and wire EDM. Continuing the solids-machining theme of recent releases, SmartCAM V17.0 provides significant benefits for milling users working with both prismatic and free-form solid models.
New Z-Level Rough incorporates the many features in the Solid Pocket process introduced in V16, and ex-tends these capabilities to allow rough-ing strategies to be applied to virtually
to be captured with the named view. View orientation, size and position, as well as mask and visibility states, can be specified and saved independently, so that users can easily toggle between complex viewing states and save time.
Products & Services
any part configured with cores, cavity, and open pockets and profiles. Al-lowing one process to ef-ficiently machine many varying features saves time and reduces job com-plexity. This new process is found in SmartCAM Ad-vanced Milling, Advanced Turning and FreeForm Machining applications.
An HTML-based report generator added to all SmartCAM applications with Version 17.0 improves the flex-ibility and quality of job and shop-floor documentation. It allows a single customizable report to include tool and process-step information, plus job header and graphic images of the part.
In SmartCAM V17.0, extended Named View capabilities allow users to specify which view parameters are
of ±145º. The Absolute Tracker AT401 is designed to push the boundaries of size, weight, range and usability and to set a standard for accuracy. The absolute distance meter in this new CMM has a maximum uncertainty of just 10 μm over the full certified vol-ume. Other elements of enhanced Lei-ca Geo systems technology that users of the AT401 will benefit from, besides PowerLock and ATR, are maintenance-free piezo drives and a survey-grade precision level-to-gravity sensor.
Weighing only 8 kg with its con-troller, and standing just 29 cm high, the compactly configured AT401 can be transported as carry-on luggage on most large international airliners. The all-new laser tracker incorporates an advanced power management system that allows the batteries to be hot-swapped and enables the system to be run off of Power over Ethernet.
The new Leica Absolute Tracker AT401 portable coordinate measuring ma-chine (CMM) can provide highly accurate 3D meas-urements over ultralong ranges. The first laser tracker to be battery operated and designed for cableless op-eration, the IP54-rated meas-urement system includes PowerLock beam-recovery and Automatic Target Rec-ognition (ATR) features that make it the easiest-to-use 3D Absolute Tracker Leica Geosystems AG has ever cre-ated. It enables laser tracker solutions to address an even wider application base.
The instrument’s hori-zontal and vertical axes both allow infinite rotation. And, when its quick-release han-dle is removed, it has a full vertical measurement dome
First Battery-Powered Laser Tracker CMM Carries IP54 Protection Rating, Is Easy to Carry and Use
34 European Tool & Mould Making � June 2010
Latest Release of CAM Suite Features New Z-Level Roughing, Better Solid Pocket Milling, Core Enhancements
Leica Geosystems AGUNTERENTFELDEN, SWITZERLANDwww.leica-geosystems.com/metrology
SmartCAMcncSPRINGFIELD, OR, USAwww.smartcamcnc.com
www.etmm-online.com
Products & Services
Apfel Metallverarbeitung GmbH specializes in system solutions to sup-port lean manufacturing operations and minimize nonproductive periods for companies engaged in metal-cut-ting processes. Because lean opera-tions require efficient use of limited floor space as well as reduced machine downtime, a product Apfel introduced recently to optimize the running of turning and milling machines is a mobile cooling-lubricant station designed to provide a secure supply of coolant according to the kanban principle. The slim dimensions of the system allow its application even in confined spaces.
The mobile lubricant station mini-mizes the length of connections be-tween the barrel and the machine by
Mobile Cooling-Lubricant Station Saves Floor Space in the Shop While Ensuring a Steady Supply of Machine Coolant
Technology meets the market
From general manufacturing technology to special industrial requirements – AMB provides excellent opportunities! Over 1,000 exhibitors will present trends, innovations and highlights from in the fi elds of: metal cutting machine tools metal removing machine tools precision tools CAD/CAM/CAE, PLM as well as technical software measuring systems and quality assurance robots, workpiece and tool handling
AMB – the most important trade fair for the sector in Germany
5-MINUTE WALK FROM STUTTGART AIRPORT
Attractive travel and service packages at www.amb-expo.de
Landesmesse Stuttgart GmbH, Tel. +49 711 18560-0, [email protected]
supply of cooling-lubricant emulsion; when the operator switches from the first to the second canister, the system reliably keeps the delivery of cooling emulsion sufficient for machine op-eration. Thus, the mobile station com-bines lean lubricant supply with useful workshop equipment, all with a mini-mum space demand.
As each manufacturing company has its own requirements, Apfel will customize the station as needed.
Apfel Metallverarbeitung GmbHDOSSENHEIM, GERMANYwww.apfel-gmbh.de
virtue of the mixing taking place di-rectly at the unit. The station, which comes equipped with two 33-l canis-ters of lubrication liquid, a 20-m water supply hose and a mixing device, is brought to the machine. Such neces-sary equipment as a refractometer is stored in the integrated drawer, along with documentation.
While the machine is filling with lubricant, the operator can do neces-sary cleanup around the machine us-ing cleaning equipment provided with the lubricant station. A simple two-canister principle ensures a smooth
36 European Tool & Mould Making � June 2010 www.etmm-online.com
Products & Services
Collapsible Core Technology Is Foundation of Mould Tool Standard Specially Created for Cap and Closure MouldersAST Technology GmbH, which de-velops tool standards for OEMs and moulders, has created a new tool standard for cap and closure moulds that utilizes the DT-series collaps-ible core technology of its sister company Roehr Tool Corp. Besides providing a CAD database, AST assists the mould owner through a systematic comparison of collapsible cores versus unscrewing tools, includ-ing ROI cost justifications, followed by CAD library customization and installation, mould designer and mould maker ori-entation, and provision of guidance to moulding and maintenance room staff, all in order to pinpoint project-specific goals. To further ensure that these goals are met, the service com-pany offers its availability at start-up and for subsequent ongoing applica-
tion-specific consultation.The use of DT cores converts a com-
plex unscrewing tool into a straight-forward open-shut mould that lends itself to the complete standardization of parts that fall within a particular pa-
rameter. AST Technology can provide additional application support for parts that fall outside of that param-
eter. The company’s support includes determining whether, to improve and optimize cycle times, a serviceable mould tool should be totally rebuilt with DT-core technology or can be simply refurbished, with the hot runner and cavity half be-ing salvaged and only the core half being rebuilt with DT Core technology.
Mould owners not only re-alize a cost savings with the
preengineered designs and stand-ardized, globally available mould
components, but also benefit from being able to reuse the mould frames for one- to four-cavity prototype and preproduction tooling.
AST Technology GmbHHERFORD, GERMANYwww.ast-tech.de
Special Hot Runner Nozzles for Lateral Injection at Critical Points of Parts and When a Small Nozzle Tip Is Required
Often, Thermoplay S.p.A. is asked by a customer to create a special type of hot runner noz-zle for optimal part injection or to inject the plastic melt at a particular position in the mould cavity. The company then ap-plies its 30-plus years of expe-rience in partnering with the customer to develop the most suitable solution for the critical injection moulding application. Among the custom special-ap-plication projects Thermoplay has completed are the DL-8B extended nozzle for double-side direct injection and FL-1B extended nozzle for tilted side injection.
The DL-8B nozzle for edge gate injection is mostly used for internal injection at criti-cal points and when the shape of the moulding necessitates a small nozzle tip. It is also rec-
ommended when the heated part of the nozzle has to be kept away from the surface of the plastic part in or-der to avoid spotting and defects. The DL-8B thus is suitable for the internal moulding of container caps, small parts and extended containers, as long as abrasive materials are not involved. Depending on the request, it may be possible to individualize the distance between the injection point and the nozzle axis.
Featuring an extended tip with a maximum inclination of 45°, the FL-1B nozzle is suited for applications in which the injection point is located in a critical position and a very small tip has to be used. The tip inclination can be customized according to the posi-tion of the injection point. This nozzle can be used for both internal and ex-ternal injection of moulded parts.
Thermoplay S.p.A.PONT SAINT MARTIN (AO), ITALYwww.thermoplay.com
www.etmm-online.com June 2010 � European Tool & Mould Making 37
Products & Services
Large Machining Centre for Precision 5-Axis Processing of Big and Heavy Workpieces
The largest machine tool Maschinenfabrik Berthold Hermle AG has ever made is the new C 60 U dynam-
ic high-performance 5-axis CNC machin-ing centre. Designed for simultaneous and complete machining in
5 axes and featuring a gantry design, it of-fers universal preci-sion machining of large workpieces in tool and die making, energy, aerospace, drive technology and machine manufac-turing applications.
This machine has x-, y- and z-axis travels of 1,200,1,300 and 900 mm, respectively; this, plus a rotating c-axis, allows the complete machining of workpiec-es 1,200 mm in diameter and 900 mm high and weighing up to 2,500 kg. The collision diameter is 1,400 mm.
Owing to an ideal configuration of the linear axes and the axes in the NC swivelling rotary table (±130°), very short tools can be used for machining. The modular design of the machine enables any of three different tables to be used. Because the dimensions of the working range are tailored exclusively for 5-axis machining, the y-axis is longer than the x-axis to allow clearance for swivelling the workpiece.
The tool system interfaces SK40/HSK-A63 and SK50/HSK-A100 are compatible with this machine; the former holder can accommodate 70 tools and the latter as many as 50, with the tools having a maximum length of 500 mm and top weight of 15 or 30 kg. Tool change takes 9.5 seconds chip to chip. In addition, modular magazine add-ons en-able challenging workpieces or entire part families to be ma-chined without additional tool retrofitting and equipping.
The C 60 U dynamic is a hook machine with four-point setup. Its 17-ton one-piece machine bed (image) provides a very stable foundation with excellent damping properties. High-performance precision roller bearings are built into the linear guideways, and the x-, y- and z-axis feed drives are equipped with directly powered ball screw spindles and internal measurement systems. Acceleration of 6 m/sec2 and rapid traverses of 50 m/min in all axes ensure very high dynamics. Five different main spindle configurations with spindle speeds of 9,000 to 18,000 rpm are available.
This machine can be operated stand-alone or with a pal-let system, and can be further automated. It is controlled by a choice of top-end Siemens and Heidenhain CNCs.
Maschinenfabrik Berthold Hermle AGGOSHEIM, GERMANYwww.hermle.de
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38 European Tool & Mould Making � June 2010 www.etmm-online.com
Products & Services
Hard-Metal Roughing End Mills with Integrated Coolant Passages Are Versatile, Efficient and Long-Lasting
The new Uni-Mill power-roughing cutters VHM .48W and VHM .49W have been developed by Jongen Werkzeugtechnik GmbH & Co. KG as a product line extension, supple-menting the already established VHM .46W and VHM .47W. The integration of coolant passages in these hard-met-al roughing end mills ensures optimal cooling at the cutting edge and sup-ports chip flow. Designed for rough-milling of all current steels—tool steel, high- and low-alloyed steel, and struc-tural steel—the Uni-Mill tools offer smooth functionality, maintain high chip-removal volumes and have long working lifetimes, thus providing very high efficiency.
The availability of diameter options between 4 and 20 mm, the choice of three to five teeth, and spiral-slot an-gles that vary with the diameter all contribute to the universal applicabil-ity of these roughing cutters and make them optimally adaptable to a variety of machining methods and materials. Additional flexibility is granted by a
range of lengths: the short VHM .48W offers utility lengths up to 40 mm, while the VHM .49W comes in utility lengths to 53 mm.
These Uni-Mill end mills have a stable core geometry, and their opti-mized micro- and macrogeometries also enhance stability and tool life. Their symmetrical knurled profile is aligned optimally with the tool di-ameter and number of teeth in order to maximize productivity and ensure an extended operating lifetime. Being equipped with a central cutting edge, these milling cutters are suitable for boring operations as well.
The TS35 cutting material from which the mills are constructed is the finest-grain hard metal (ISO K10–K20) and offers outstanding tenacity with very good wear characteristics. The tools’ TiAlN-nanocomposite coating provides glazed surfaces, high thermal stability and oxidation resistance.
Jongen Werkzeugtechnik GmbH & Co. KGWILLICH, GERMANYwww.jongen.de
Performing mould tool optimiza-tion based on the results of meas-uring initial samples has been a standard practice among injection moulders. Efficient first-article inspection and targeted tool cor-rection can accelerate start-up of serial production. In fact, several manufacturers of moulded con-sumer products have reduced time-to-market for their products by more than 50% after introduc-ing optical 3D digitizing into their production systems. GOM offers the ATOS 3D measuring system to moulders and toolmakers look-ing to perform accurate shape and di-mension inspection of moulded parts in order to optimize tooling quickly.
The more accurate the first-article measurement data, the fewer correc-tive loops toolmakers need to perfect the mould. The high density and ac-
Optical 3D Digitizing System Supports Tool Optimization through First-Article Shape and Dimension Inspection
curacy of the ATOS 3D scanner’s meas-urements open up new possibilities here, because the accuracy of the tool correction depends greatly on finding that alignment of the measurements with the CAD data that necessitates only a minor change in the tool. Not
only large companies benefit by using 3D scan data to improve internal processes; measurement service providers and toolmakers also value the reduction in tool correction loops that optical 3D digitizing makes possible.
With tools that have many mould cavities, numerous identi-cal components must be inspect-ed in a short time, preferably via closed, simple-to-automate meas-uring and inspection cells. ATOS 3D measuring systems can be in-tegrated into such cells. The GOM multiaxis motion unit, with 6 free
axes, measures and inspects small to medium-sized parts automatically re-gardless of part complexity.
GOM Gesellschaft für OptischeMesstechnik mbHBRAUNSCHWEIG, GERMANYwww.gom.com
www.etmm-online.com June 2010 � European Tool & Mould Making 39
Products & Services
Horizontally or Vertically Positioned Rotary Table on Multisensor CMM Increases Measuring EffectivenessThe O-Inspect multi-sensor coordinate measuring machine (CMM) that Carl Zeiss Industrial Me-trology GmbH de-veloped enables small and complex parts to be inspected eas-ily, very accurately and thus efficiently. The O-Inspect CMM equipped with a rotary table pro-vides an even more effective measur-ing run, since round parts do not have to be reclamped for optical measure-ment (left photo) following contact measurement by stylus (right photo). Able to be mounted and removed by the machine operator, the table can be positioned horizontally or vertically.
This new table facilitates complete part inspection. Mechanical influ-ences are minimized, as the measuring axes of the CMM are subject to only
minimal movement when the rotary table is mounted.
O-Inspect unites the best features of optical measuring with the best of contact measuring. Where, in the past, four measuring machines—a profile projector, measuring machine, microscope and contour measuring machine—were needed to manage the entire range of measuring appli-cations, Zeiss’s system covers all four areas by itself, and simplifies and ac-celerates the entire measuring process.
Thanks to its multiple sensors, op-erators can alternate between optical and contact measurements in one measuring run. Optical measurements are performed using a 2D camera sen-sor with image processing being built into the Discovery zoom lens. Contact measurements are the domain of the VAST® XXT scanning probe. Carl Zeiss GmbH developed both sensors.
Carl Zeiss Industrial Metrology GmbHOBERKOCHEN, GERMANYwww.zeiss.com/IMT
40 European Tool & Mould Making � June 2010 www.etmm-online.com
Products & Services
Collaborative Mode and Other Enhancements in CAD/CAM Software Make Progressive-Tool Designers More ProductiveMissler Software has released the TopSolid’Progress 2010 CAD/CAM package for progressive die and press tool designers. TopSolid’Progress pro-vides all the functions designers need to compute sheet metal part blanks and design the strip layout and dies, and enables them to do it much faster than with standard CAD software. The software manages all cutting, folding and forming of the sheet metal, crea-tion of the die set, addition of stand-
ard components and their machining processes, creation of punches and nonstandard dies, and draft creation. The 2010 version helps toolmakers in-crease their productivity by offering a collaborative work option, improved strip creation, and many improve-ments in the design of punches and dies, components, and die bases.
The new collaborative-mode op-tion in TopSolid’Progress 2010 lets several designers work on individual
(but dependent) files of a master file simultaneously. Changes made in an individual file are immediately syn-chronized in the master file. Thus, several designers working on different parts of the tool at one time are always up-to-date, and tool design times can be much shorter.
In strip design, TopSolid’Progress 2010 simplifies the blank creation of complex transition zones between unbendable parts, which makes treat-ment of toric bends or tie-in zones in connector parts easier. Strips contain-ing several dozen stations can be de-signed much faster, and intermediary bending stages can be created to de-tect collisions.
Numerous enhancements that are introduced in the new release of TopSolid’Progress make the design of punch and die assemblies, standard components, and die bases much eas-ier, including automated actions, new reporting functions, and opportuni-ties for user customization.
Missler SoftwareEVRY, FRANCEwww.topsolid.com
A variety of innovative modular la-ser systems for welding, cutting and marking are offered by Trumpf La-ser- und Systemtechnik GmbH to support efficient production in such industries as tool and mould making, medical technology and electronics. Laser systems for processing small and large components that the com-pany now is promoting include the TruLaser Station 5004 (photo), a laser workstation well suited for the repair of individual pieces in tool and die fabrication. This machine also is ideal for manual 3D materials processing in medical technology applications and for the semiautomated manufacture of small batches of electrotechnology products. It features the first electronic stereomicroscope for laser processing.
Another featured Trumpf machine
Modular Laser Systems for Welding, Cutting, Marking in Tool and Die Making and Small-Component Manufacture
is the TruLaser Robot 5020, a stand-ardized and modularly designed ro-botic cell for 3D materials processing that is specially tailored to meet the re-
quirements of sheet metal processing companies. It consists of the laser with optic along with the robot, the posi-tioning mechanism and the safety en-closure. The TruLaser Robot also offers a high level of processing flexibility and gives users the option of switch-ing between cutting, welding, remote and deposition welding, and brazing.
Related machines available from Trumpf are the TruLaser Cell Series 1000 for the efficient, continuous welding of tubes, profiles and coils, TruLaser Cell Series 3000 machines for 2D and 3D welding and cutting of small and medium-sized technical components, and marking worksta-tions in the TruMark Station Series.
Trumpf Laser- und Systemtechnik GmbHDITZINGEN, GERMANYwww.trumpf.com
www.etmm-online.com June 2010 � European Tool & Mould Making 41
Products & Services
Special Forming and Punching Tools and Wear Components Custom-Made from Carbide Are Hard and ToughCarbide special components for forming and punching technology and for wear protection are avail-able from Gühring oHG, which, acting as a competent partner, provides customers with sup-port during component devel-opment. For example, a choice of drawing punches in various carbide grades is offered for use in manufacturing bever-age and food cans. These tools for cold-forming metals have to be wear resistant, hard and tough; thus, they are an ideal application area for carbides. They can withstand the high mechanical and thermal loading that occurs during the plastic deformation of the metal to be machined.
Cold heading dies in Gühring car-bides are used in the manufacture of screws, among other things. Drawing mandrels in a variety of carbide grades
meet the high processing demands for deforming steel and nonferrous metals through pressing and drawing. In ad-dition, Gühring offers carbide rib rolls, cold strip and smooth roll; mandrels; and dies for forming.
Carbide’s abrasion resistance ena-bles it to combat the heavy wear tend-
ing to occur on the running surfaces and pathways of conveyor belts and machines handling raw materials or finished goods. Accordingly, to extend processing machine and conveyor life, Gühring supplies strips, guide rails,
form linings, print-ing plates, grooved bushings and many other wear-protection parts made of carbide for these production
installations.Gühring’s customer
support includes advice regarding carbide’s application pos-
sibilities. Its patented manufacturing procedures and advanced production facilities enable the company to pro-duce close-toleranced high-perform-ance custom carbide components within short lead times.
Gühring oHGALBSTADT-EBINGEN, GERMANYwww.guehring.de
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COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 WEBSITEAbrams Engineering Services GmbH, Osnabrück, Germany, +49 541 357390 11 12 13 15 16 www.premium-stahl.deAlcan Aerospace, Transportation and Industry, Issoire, France, +33 473 557853 1 2 www.alumold.alcan.comAlcan Allega AG, Niederglatt/Zürich, Switzerland, +41 1 8524111 1 www.allega.chAlcan Distribuzione S.r.l., Bologna, Italy, +39 051 533506 1 2 www.alcandistribuzione.itAlcoa Europe, Birmingham, UK, +44 121 2528000 1 2 www.alcoa.comAlimex Metallhandelsgesellschaft mbH, Willich, Germany, +49 2154 91770 1 2 www.alimex.deAMPCO Metal Ltd., Coventry, UK, +44 2476 467011 4 www.ampcometal.comAMPCO Metal S.A., Marly, Switzerland, +41 26 4399300 1 3 4 9 17 www.ampcometal.comAubert & Duval, Gennevilliers, France, +33 1 55025844 9 12 15 16 www.aubertduval.comBCC Products Inc., Franklin, IN, USA, +1 800 556-0067 10 www.bccproducts.comBoehlerit GmbH & Co. KG, Kapfenberg, Austria, +43 3862 3000 17 www.boehlerit.comBöhler Edelstahl GmbH & Co. KG, Kapfenberg, Austria, +43 3862 207050 9 11 12 15 16 www.bohler-edelstahl.atBrush Wellman GmbH, Stuttgart, Germany, +49 711 830930 4 www.brushwellman.comBuderus Edelstahl GmbH, Wetzlar, Germany, +49 6441 3740 12 www.buderus-steel.comCarbone Lorraine Composants, Gennevilliers, France, +33 1 41854300 7 www.carbonelorraine.comDeutsche Edelstahlwerke GmbH, Witten, Germany, +49 2302 290 33 5 9 11 12 13 15 www.dew-stahl.comE.N.S. International S.r.l., Villanuova sul Clisi (BS), Italy, +39 0365 373367 3 12 www.ensint.comEDM Service, Jouy-le-Mouier, France, +33 1 34247070 3 4 7 10 www.edmservice.comEdro Specialty Steels GmbH, Appenweier, Germany, +49 7805 915790 11 15 www.edro.comEOS GmbH, Krailling, Germany, +49 89 893360 9 12 15 16 www.eos.infoFCPK Bytow Sp. z o.o., Bytow, Poland, +48 59 8229700 1 2 3 4 11 12 13 15 www.fcpk.plFine Cut Graphic Imaging Ltd., Lancing, W Sussex, UK, +44 1903 751666 1 3 4 6 8 10 www.fcadvancedengineering.co.ukGebr. Eberhard GmbH & Co. KG, Nordheim, Germany, +49 7133 1000 12 www.eberhard.deGebrüder Recknagel Präzisionsstahl, Christes, Germany, +49 36844 4800 11 12 13 15 www.stahlnetz.deHasco Hasenclever GmbH + Co. KG, Lüdenscheid, Germany, +49 2351 9570 11 12 15 www.hasco.comHSB Normalien GmbH, Schwaigern, Germany, +49 7138 8127490 1 2 10 11 12 15 www.hsb-normalien.deIbiden Europe B.V., Hoofddorp, Netherlands, +31 23 5543180 7 www.ibiden.comIndusteel, Le Creusot, France, +33 385 805162 11 12 15 www.industeel.infoIntercom S.r.l., Gorgonzola (MI), Italy, +39 02 95300202 2 3 4 11 12 www.intercomonline.itKantemir, Auray, France, +33 297 566521 1 15 www.kantemir.comKeronite International Ltd., Cambridge, UK, +44 1223 893222 1 8 www.keronite.comLucchini RS S.p.A., Lovere (BG), Italy, +39 035 963492 12 15 www.lucchinirs.itMeusburger Georg GmbH & Co. KG, Wolfurt, Austria, +43 5574 67060 4 7 11 12 13 15 www.meusburger.comMillutensil S.r.l., Milan, Italy, +39 02 29404390 8 10 15 www.millutensil.comNonnenmann GmbH, Winterbach, Germany, +49 7181 40870 11 www.nonnenmann-gmbh.deOCS S.r.l., Adrara S.M. (BG), Italy, +39 035 933487 11 12 13 www.ocs-stampi.itPoco Graphite SARL, Limonest, France, +33 472 520940 7 www.poco.comPräzi-Flachstahl AG, Everswinkel, Germany, +49 2582 7601 11 12 13 15 16 www.praezi.deSaglam Metal A.S., Istanbul, Turkey, +90 212 6712331 1 2 3 4 5 9 11 12 13 14 15 16 17 www.saglammetal.comSGL Carbon GmbH, Bonn, Germany, +49 228 841577 7 www.sglcarbon.comSSAB Oxelösund AB, Oxelösund, Sweden, +46 155 254000 11 12 www.ssabox.comTokai Carbon Europe Ltd., Oldbury, W Midlands, UK, +44 121 5525577 7 www.tokaicarboneurope.comTokai Carbon Italia S.r.l., Trezzano Rosa (MI), Italy, +39 02 90969190 7 www.tokaicarbon.co.jpUddeholms AB, Hagfors, Sweden, +46 563 17703 9 2 9 11 12 13 www.uddeholm.com
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SUMMER 2010 • EDM EUROPE 45www.edm-europe.com
SUMMER 2010
For more product information visit www.edm-europe.com
A Die-Sinking Machine Designed for Automation Versatility Has a CNC
for Simultaneous 6-Axis Operation.See page 47
46 49
Electrode DetailingCutters with diameters as small as 0.1 mm can produce fine features in complex graphite electrodes.
Faster Metal RemovalEDM wires with functional coatings offer advantages in precision, surface quality and productivity.
46 EDM EUROPE � SUMMER 2010 www.edm-europe.com
T E C H N O L O G Y
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Zecha Hartmetall-Werkzeugfabrikation GmbHKÖNIGSBACH-STEIN, GERMANYwww.zecha.de
SUMMER 2010 • EDM EUROPE 47www.edm-europe.com
P R O D U C T S & S E R V I C E S
ONA Electro-Erosion S.A.DURANGO, SPAINwww.ona-electroerosion.com
Die-Sinking Machine Designed for Versatile Automation Has a CNC for Simultaneous 6-Axis Operation
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P.O.Box 7, Eisenbahnstr. 71, A-1195 VIENNAPhone +43.1.370 22 33 0, Fax +43.1.370 31 0 [email protected] www.hig.at
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StarCut
48 EDM EUROPE � SUMMER 2010 www.edm-europe.com
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Boride Engineered AbrasivesTRAVERSE CITY, MI, USAwww.borideabrasives.com
Ibiden Europe B.V.HOOFDDORP, NETHERLANDSwww.ibiden.com
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SUMMER 2010 • EDM EUROPE 49www.edm-europe.com
Wires with Functional Coatings Make Better Metal Removal, Higher Productivity Possible
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Berkenhoff GmbHHERBORN, GERMANYwww.bedra.com
50 European Tool & Mould Making � June 2010 www.etmm-online.com
MACH 2010
Gallery of Sample Projects, Available as CD, Helps to Optimize Users’ Experiences with CNC Simulation Software
Measurement Option for Multiaxis Machine Tools That Is Added to Probing Software Improves Machining Efficiency
The introduction of a new version of the Productivity+™ suite of PC-based probing software carries the practice of measurement on multiaxis machine tools a step further. A key im-provement is a new multiaxis option that Renishaw plc has added to allow more creativity and efficiency in ma-chining processes. Supported by Ren-ishaw’s high-accuracy Rengage™ 3D technology–based touch probes and new ultracompact radio probes, this
CGTech Ltd.HOVE, E SUSSEX, UKwww.cgtech.co.uk
Renishaw plcWOTTON-UNDER-EDGE, GLOS, UKwww.renishaw.com
tems as CATIA V5, Siemens NX, Pro/Engineer, Mastercam, Edgecam, Gibbs-CAM, Delcam PowerMill, Missler Soft-ware’s TopSolid’Cam and Open Mind’s hyperMill. In addition to traditional
CGTech Ltd. is presenting a continuous dis-play of the 2010 Vericut® Virtual Machining Gal-lery on its stand at MACH. Vericut is well estab-lished as an in-dustry-standard CNC-simulation software tech-nology for detecting errors, potential collisions or areas of inefficiency in machining programmes, and the gal-lery it offers features all types of CNC machine tools, including complex multiaxis machines from such promi-nent manufacturers as DMG, Mori Seiki, Mazak, Makino and Matsuura. The gallery also provides examples of integration with such top CAM sys-
machining appli-cations, the Vir-tual Machining Gallery includes examples of sim-ulation projects involving paral-lel kinematics, robots, water-jet cutting, riveting and composites.
Visitors to the CGTech stand at the show in Bir-mingham will be offered the Veri-cut Virtual Ma-chining Gallery
as a CD. The gallery can also be viewed on-line at www.cgtech.com/vmg.
multiaxis capability gives process engi-neers and machinists a choice of flexible process solutions.
Productivity+ lets users take full ad-vantage of data from multidimensional probe actions. As soon as a component is loaded, logical tests can be performed on it to ensure that the
setup is correct. The software accurate-ly updates process parameters before cutting starts. Then, during cutting, it can be used to fine-tune machine variables, such as work offsets, or to make process decisions according to the conditions found on the machine.
Custom macros now allow complex logic or existing macro programmes to be embedded into Productivity+ code. Also, the software’s constructed-features capability has been expanded.
Still, Productivity+ code can be run en-tirely on a machine tool controller: no external PC or server is needed.
Because components produced on multiaxis machine tools have to be measured accurately in every direc-tion, Renishaw developed Rengage 3D strain gauge technology. The OMP400 and RMP600 touch probes both use a patented sensing mechanism and advanced electronics to enable sub-micron 3D probe performance on contoured surfaces, even with long styli. The latter probe, with Renishaw’s proven frequency-hopping spread-spectrum radio transmission for probe signals, especially benefits multiaxis-machine users. Its accuracy, combined with the process control benefits of Productivity+ software, makes it easy for machine operators to improve effi-ciency and eliminate machining errors through in-process measurement.
June 2010 � European Tool & Mould Making 51www.etmm-online.com
MACH 2010
The Matrix 3- to 5-axis deep-hole-drilling machines developed by Mol-lart Engineering Ltd. are a totally new lower-cost range with a full 1-m drilling specification. They are tar-geted at companies that need to carry out deep-hole drilling but do not re-quire the added sophistication of tool changing, probing, and unmanned machining.
The highly versatile Matrix ma-chines are well suited for such applica-tions as producing water-feed cavities in die and mould bases, performing off-centre and pattern hole drilling under CNC control, and manufactur-ing such components as tube plates at high levels of productivity. Also, the incorporation of a quick-change spindle adapter kit converts them into deep-hole-drilling machines that can conduct such additional tasks as milling, rigid tapping and thread mill-ing. This versatility can be further en-hanced: adding a 4th-axis rotary table
Basic Deep-Hole-Drilling Capability Is Delivered by Economical Machines Adaptable for Other Tasks Too
Latest Upgrade of Software Suite for Tool Design and Manufacture Offers Enhancements in All Operations
and programmable tilting of the spin-dle head between +24° and –15° ena-bles the machines to accommodate compound-angle hole requirements.
The Matrix standard range compris-es seven models with drilling capaci-ties of 3 to 35 mm and depth capabili-ties to 1,500 mm, the latter achieved at fully programmable penetration rates up to 3,000 mm/min. Two 6,000-rpm spindle drives are available, pow-
ered by 5.5- and 7.5-kW motors. Table dimensions between 700 x 600 mm and 2,700 x 1,200 mm can be speci-fied, with maximum table loadings to 15 tonnes. Included in the standard specification is a chip conveyor, high-pressure coolant and 20-μm filtration, with CNC control via a Fanuc 0i Mate.
Offering many new fea-tures in all areas of the suite, but with a continued focus on tool design and manufacture, VISI 18 CAD/CAM/CAE software from Vero Software plc is the latest release of the com-pany’s flagship product.
VISI Modelling is the base platform for all of the VISI software modules. Version 18 of Modelling delivers an updated GUI with graphic sliders that let the user interact dynamically with the working area. One major CAD development is the introduction of geometry defor-mation tools that provide such new features as complex spring-back defor-mation, draft application, and organic shape editing.
VISI Machining has been updated with tools to enhance the automated
Compass technology, including a new method to manage the smallest dis-tance between two or more sides of a geometric feature. This distance can be used to identify the smallest tool di-ameter for a pocket or to define other machining variables. Other CAM im-provements are in 3D constant step-over, 3D combi-finishing, rapid man-agement, and drilling.
Sheet metal development also has been significantly improved in VISI 18, adding dynamic animation of the forming process and a batch procedure for developing more than one component at the same time with a re-port for each piece, among other enhancements. Also, Vero has extended its part-nership with CADENAS and has integrated PartSolutions V9 into the VISI tooling
suite, VISI Mould and VISI Progress.VISI 18 completes the full integra-
tion of VISI Flow. Now, plastic-injec-tion analysis and simulation can be launched and calculated directly from VISI, eliminating the need to prepare a model for analysis.
Mollart Engineering Ltd.CHESSINGTON, SURREY, UKwww.mollart.com
Vero Software plcCHELTENHAM, GLOS, UKwww.vero-software.com
52 European Tool & Mould Making � June 2010 www.etmm-online.com
MACH 2010
Highly Automated Programming in Feature-Based CAM System Is Even Faster in the Latest Version
Broad Lineup of Turning, Milling and Newly Acquired Grinding Machines Includes World PremieresA significant expansion of the high-level grinding technology available from Hardinge is a featured element of the machine tool group’s capabil-ity demonstration at MACH. The dis-play of nine machines under power includes world launches of Hardinge lathes and Bridgeport machining centres along with Jones & Ship-man grinding machines added to the portfolio since the acquisition of J & S in April. Among the highlights of the Hardinge presentation are the
compact new Hardinge GS51A 3-axis pro-
Delcam plcBIRMINGHAM, UKwww.delcam.com
Hardinge Machine Tools Ltd.WHETSTONE, LEICS, UKwww.hardinge.co.uk
ance further. Combined drilling-and-milling functionality, a new option, increases hole creation efficiency on machines fitted with automatic tool changing. Other options premiering include spiral finishing functionality for faster machining and a finish with no dwell marks; automatic rest rough-ing to minimize air cutting when us-ing progressively smaller roughing cutters; and the capacity to add a 3D
The 2010 version of Feature-CAM feature-based machining software is enhanced across the full range of functionality, from 2D drilling and wire-cut EDM to 5-axis milling and mill/turn operations. Its high degree of automation had already made FeatureCAM the fastest-pro-gramming CAM system, but the improvements Delcam plc in-troduces with FeatureCAM 2010 make it even quicker. Chief among these is support for multithreading when generating 3D tool paths. With calculations spread across multiple cores in dual- or quad-core computers, time savings are significant.
Better algorithms within the user interface accelerate feature editing and changeover between machine tool set-ups, and more-efficient management of stock models enhances perform-
chamfer to a part for deburring and similar cleanup operations.
Also, two improvements copied from PowerMill make machining faster and surface finish better: FeatureCAM, too, now can redistribute the points within any tool path to provide faster, smoother machining; plus, it can undertake tool-axis smoothing to prevent sudden changes in cutter orientation
during 5-axis machining.Finally, machining simulation is
now faster and more accurate; a new dual-view option lets a part be viewed from two angles simultaneously; and the range of postprocessors available with FeatureCAM has been extended for 5-axis and mill/turn equipment.
duction cell, the Bridgeport XR1000 heavy-duty vertical machining centre (VMC) and J & S Suprema cylindrical grinding machines (photo).
The Hardinge GS51A, with a 10-platen patented modular magazine and collet-ready spindle, is designed to provide the precision for which the brand is noted, plus high productivity and machine utilization, all in an eco-nomical package.
The Bridgeport XR1000 VMC now features the latest 18,000-rpm HSK-A63 spindle devel-
opment to complement the options of high-torque 9,000- and 15,000-rpm spindles. Offering x-axis travel of 1,020 mm and y- and z-axis travel of 610 mm, this machining centre is equipped with 30 tool positions and a choice of Heidenhain iTNC 530 or Fanuc 18iMB control. Other Bridge-port VMCs on display at MACH are the totally new 5-axis GX250AX, the XR 600 5AX with an expanded working envelope, and the highly compact GX 480 designed for subcontractors.
Cylindrical grinding machines in the Suprema line can be specified with multiple wheelhead options: a plain 90° approach, an angled head or a uni-versal wheelhead with two external wheel spindles and one internal spin-dle. Fanuc hardware or a touch-screen control with proven Easy software ensures quick and simple setup, thus minimizing changeover time.
June 2010 � European Tool & Mould Making 53www.etmm-online.com
MACH 2010
One of two machining centres Yamazaki Mazak U.K. Ltd. is unveiling at MACH is the Hyper Variaxis 630 high-speed, high-precision, multisurface, simultaneous 5-axis machine tool. The machine was designed not only for ex-cellence in processing but also to have a distinctive design, through a partnership with the Ken Okuyama Design Co. The machine’s struc-ture and use of direct-drive linear motors maximize perform-ance, while its aesthet-ics convey an impres-sion of flow, with very few square corners.
Also, setup is sim-plified; the front door and top of the ma-chine can be opened to provide walk-in access to the machine table and allow crane delivery of large components directly onto the table.
The 4th and 5th axes of the gantry-style Hyper Variaxis 630 are provided by a tilting and rotating trunnion table capable of a- and c-axis rotational speeds of 50 and 120 rpm, respectively. The a- and c-axis strokes are +120°/–30° and 360°. These axes are powered by direct-drive motors offer-ing 4,300 and 1,800 Nm of torque, respectively. The centre accepts 500-kg workpieces on its 630 x 500-mm table.
The low-overhang x-, y- and z-axes have respective trav-els of 630, 1,100 and 600 mm. Linear motors on these axes make traverse rates up to 80 m/min achievable, and en-hance machine accuracy. The standard machine spindle is a 35-kW, 18,000-rpm unit that generates 168 Nm of torque.
Gantry-Type 5-Axis Machine Notable for High-Precision Performance, Striking Design
Machining Centre for Tight-Tolerance Processing of Big Workpieces
The new twin-column, bridge-type DCX22 3-axis ma-chining centre, available in 40-taper and 50-taper versions, exemplifies the progression of Hurco into the realm of large machining centres. Its construction format provides excel-lent thermal stability for higher- accuracy machining and allows heavier table loads and a larger y-axis travel range with no loss of rigidity. Thus, it can be used to machine large components such as dies, moulds and parts for the aerospace and energy sectors to tight tolerances.
The fixed-rail design of the DCX22-40 offers x-y-z travel of 2,200 x 1,700 x 750 mm with 24-m/min rapids, along with a 2,100 x 1,600-mm pallet. The 40-taper spindle with 18 or 26 kW of peak power is mounted in a box-type vertical ram for maximum cutting capability and rigidity. Spindle options of 8,000, 10,000 and 15,000 rpm are available. The centre’s 40-station swing-arm tool changer keeps the carou-sel clear of swarf and maximizes the working envelope.
Schott Systeme GmbHMUNICH, GERMANYwww.schott-systeme.com
Hurco Europe Ltd.HIGH WYCOMBE, BUCKS, UKwww.hurco.co.uk
Yamazaki Mazak U.K. Ltd.WORCESTER, UKwww.mazak.com
Up-to-Date Version of CAD/CAM Software Features Old Pricing, No Support CostsThe German software developer Schott Systeme GmbH is showcas-ing the latest version of its Pictures by PC CAD/CAM software at MACH. The release, building on more than 25 years of continuous product develop-ment, offers a cost-effective high-end solution for design and machining. Design features include dedicated 2D mechanical CAD; hybrid solid, sur-face and mesh modelling; graphic and artistic design; and rendering and animation. Standard machining capa-bilities are 2.5D, 3-axis and 3+2-axis
milling/drilling; professional engraving; and standard ma-chine postprocessors.
Additional modules cater for 5-axis simultaneous ma-chining, wire EDM and mill/turn machining. Schott offers the UK market an opportu-nity to invest in up-to-date CAD/CAM technology for any CNC machine tool while minimizing soft-ware costs. The price of the standard Pictures by PC design and machin-ing package has been unchanged for
14 years, and yearly maintenance and lifetime support are both free.
54 European Tool & Mould Making � June 2010 www.etmm-online.com
Company IndexAMB 2010 35
Apfel Metallverarbeitung GmbH 35
Asiamold 2010 54
AST Technology GmbH 36
Auerbach Maschinenfabrik GmbH 24
Berkenhoff GmbH 49
Boride Engineered Abrasives 48
Buchem Chemie + Technik GmbH & Co. KG 48
Canadian Tooling & Machining Association (CTMA) 15
Carl Zeiss Industrial Metrology GmbH 39
CGTech Ltd. 21, 50
CNC Software Inc. 7
Cumsa 23
Dassault Systèmes 17
Delcam plc 3, 8, 26, 52
DEMAT GmbH 31
Deutsche Edelstahlwerke GmbH 33
DMG Vertriebs- und Service GmbH 18
Easymetal Prozesstechnik GmbH 12
Erowa AG 33, 37
Euro Blech 2010 19
EuroMold 2010 13
European Tool & Mould Making 16, 39, 54, 55
Fanuc CNC Europe S.A. 32
GOM Gesellschaft für Optische Messtechnik mbH 38
Gühring oHG 41
Hardinge Super Precision Europe GmbH 10, 52
Hexagon Metrology 32
HIG Handel mit Industriegütern GmbH 47
Hurco Europe Ltd. 53
Ibiden Europe B.V. 48
Inovatools 13
Institut für Kunststoffverarbeitung (IKV) 8
ISTMA Europe 42
Jongen Werkzeugtechnik GmbH & Co. KG 38
Körber Schleifring GmbH 2
Leica Geosystems AG 11, 34
MachineTools.com Inc. 41
Maschinenfabrik Berthold Hermle AG 10, 37
Mastip Technology Ltd. 12
Matsuura Machinery plc 28
Metalworking and CNC Machine Tool China Show 2010 10
Meusburger Georg GmbH & Co. KG 11
Missler Software 40
Mitsubishi Carbide 6
Mollart Engineering Ltd. 51
Objet Geometries GmbH 56
ONA Electro-Erosion S.A. 25, 46, 47
Open Mind Technologies AG 30
Progressive Components Europe Ltd. 27
Renishaw plc 50
Resale 2011 12
Sandvik Coromant Europe 22
Sarix S.A. 49
Schott Systeme GmbH 16, 53
Siemens AG 7
SmartCAMcnc 34
Thermoplay S.p.A. 36
Trumpf Laser- und Systemtechnik GmbH 40
Türk + Hillinger GmbH 5
UCIMU-Sistemi per Produrre 11
Uddeholms AB 9, 44
Vero Software plc 29, 51
VDW Verein Deutscher Werkzeugmaschinenfabriken 8
Walter AG 12, 20
Yamazaki Mazak U.K. Ltd. 53
Yean-Lu-Yi Co. Ltd. 54
Zecha Hartmetall-Werkzeugfabrikation GmbH 46
Advertisers/advertisements shown in colour
COMPANY PAGE NO.COMPANY PAGE NO.COMPANY PAGE NO.
C O M P A N Y S H O W C A S EC O M P A N Y S H O W C A S E
Asiamold 2010GUANGZHOU, CHINAwww.asiamold-china.com
Yean-Lu-Yi Co. Ltd.TAICHUNG, TAIWANwww.uenlwue.com.tw
Asiamold 2010 is set for Septem-ber 15–17 in Guangzhou, China. Over 80% of last year’s exhibitors have confirmed participation, and 70% of the popular Automold Zone has already been reserved. Exhibiting in the new Plastic De-sign Zone will be suppliers of hot runner technology, related materi-als, injection moulding technol-ogy, engineering and CAD/CAM. Visit www.asiamold-china.com.
Through cooperation with a Japa-nese R&D team, Yean-Lu-Yi Co. Ltd. has developed and manu-factured a complete series of tool sharpeners, such as the compact ball-nose end-mill sharpener pic-tured. The company has some 15 partners worldwide, including in Japan, Turkey, India, Canada and China. Its machines feature easy operation, high accuracy and a one-year no-damage guarantee. They can be delivered within one week. The company is looking for dealers in Europe.
C O M P A N Y S H O W C A S E
European Tool & Mould MakingWIESBADEN, GERMANYwww.etmm-online.com
A company showcase in Euro-pean Tool & Mould Making offers a powerful yet cost-effective way to promote your company and let the 10,000 readers of ETMM know what you have to offer. Each showcase is a 1/6-page col-our classified dis-play containing a brief description of your company and its products and services and a logo or other image of your choosing. And the showcase includes your website to make it easy for readers to find out more about what you’re promot-ing. To learn more, send an e-mail to [email protected].
Your CompanyShowcase Here
YourCompanyLogo orImageHere
3D Printing? It’s time to call Objet
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