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COVER STORY
Positive outlookfor 2017Page 20
SPECIAL
World ofTooling
Spotlight on Brazil andMexico
Page 16
THE MAGAZINE
www.etmm-online.comVolume XVIII | December 2016
ISSN 2194-7589€ 11.50
12
Product FocusAM growing fast towards industrialseries production
Page 34
ResearchHybrid laser processing centrefor automated mould repair
Page 42
K goes 4.0The world's largest plasticsshow in Düsseldorf ended ona very positive note.
Page 23
EUROPEAN TOOL & MOULD MAKING
Decem
ber2016
EUROPEAN
TOOL&MOULD
MAKIN
GVolum
eXV
IIIissue
12
document7988915699950227247.indd 1 14.11.2016 11:45:33
Progressive’s CVe Monitors are on moulds worldwide. Now,
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12-2016
EDITOR’S MESSAGE
3
From Brexit toTrump
In a shock result reminiscent ofthe Brexit referendum in June,Europe awoke on the morn-
ing of 9 November to find Don-ald Trump within striking dis-tance of victory in the US presi-dential election. Like manyothers, I never believedTrump would win. It isthe great Americanpolitical shock of thepast century. This hasbeen a revolt againstthe US establish-ment, against con-ventional politics,against the global status quo.
White Americans marched out to reclaim their country,save their traditional values, halt the structural changesdestroying their jobs and demand their economic interestsbe addressed. But this is also a vote against globalisation, itsinequities and the progressive cultural norms starting totransform America.
Opinion polls leading up to the election had been assured ofa win for the Democratic candidate, Hillary Clinton. If any-thing, the widespread confidence that she would triumphwas even greater than the misplaced certainty that theUnited Kingdom would never leave the European Union -especially after the publication of that famous video. Itshowed Trump boasting about how he could get away withkissing and groping women because he was famous. But itwas white women who pushed Trump to victory. Rejectingthe candidate who had aimed to be America’s first femalepresident, 53% of white women voted for Trump, accordingto CNN exit polls.
My vote would certainly not have been among those votes.Because I am a woman, but also because I detest any formof racism and dislike demagogic populism. "Demagogicpopulism is not only an America’s problem, there is analarming state also inWestern countries," said GermanFinance Minister Wolfgang Schäuble (CDU) after Trump’ssuccess in an interview to German newspaper Bild. "Every-one must be ready to learn. If we are open to a differentperspective and to rethink, demagogic populism will have ahard time." I hope so.
Barbara [email protected]
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document578864606574667554.indd 3 15.11.2016 10:45:35
4 12-2016
NEWS
BY THE NUMBERS
6 Industry trends, facts and figures
INDUSTRY
7 German machine tool industry oncourse for growth
8 Phoenix Contact is Toolmaker ofthe Year
9 Positive outlook for the globalsheetmetal industry
14 Inaugural tool and mould event agreat success in Austria
OPINION
10 VDWF President Prof. ThomasSeul on Toolmaking 4.0
MARKETS
16 World of Tooling: Spotlight Braziland Mexico
SHOW REPORT
K 2016
23 K 2016 ends on a positive note –more visitors and buyers
25 Latest products and advance-ments from the industry
27 Report: Sustained strong de-mand for lightweight, functionalpackages
Working with Günther Hot Runner Technology,writing instrument manufacturer Schneiderwas able to reduce material consumption byeliminating thick-walled gating systems (P.32).
COVER STORYPositive Outlook P. 20
Vehicle and aircraft manufacturersare positive for 2017. Increasedpassenger traffic is pushing updemand for new aircraft, whilstnew models are expected to driveautomotive sales.
TIP
More than 200 visitors cameto Meusburger's inaugural Tool andMould Making Days in Bregenz;I’m sure it will establish itself asa key event in non-Fakuma years(P. 14).Barbara SchulzEditor-in-Chief
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PRODUCT FOCUS
MACHINE TOOLS
28 5-axis machining centre cutsproduction time by 75%
CUTTING TOOLS
30 Advanced machining solutionssupport bearing designs
HOT RUNNERS
32 Hot runners to the fore in produc-tion of writing instruments
ADDITIVE MANUFACTURING
34 Growing fast towards industrialseries production
document9076564455138962454.indd 4 15.11.2016 10:47:15
512-2016
RankingThe month's best-clicked articles on etmm-online.com
1. Markets: World of tooling –Spotlight Japan and South Korea
2.Trade show: Excellent mood inDuesseldorf with 230,000 visitors,70% from abroad
3. Company event: Inaugural tool andmould making days a great success
4. Zoomed-in: Thinking outsidethe boxe
5. Photo gallery: September 2016product gallery
The demand for moulds from the automotiveindustry is high at this moment and the trendis expected to continue in 2017.
TOP ONLINE
Subscribe to our newsletteretmm-online.com/newsletter
Facebookfacebook.com/ETMMMagazine
Eventsetmm-online.com/events
Suppliers databaseetmm-online.com/suppliers
Photo galleriesetmm-online.com/galeries
Industry newsetmm-online.com/news
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Sch
ulz
since 1963
Türk+Hillinger GmbH78532 Tuttlingen, Germany
Tel. +49 74 61 70 14 0Fax +49 74 61 70 14 110
www.tuerk-hillinger.de
MADE INGERMANY
HLP - Cartridge heaters
RHK - Tubular heaters
RP - Tubular cartridge heaters
HP/HPQ - Nozzle heaters
TE - Temperature sensors
ALW - Power resistors
Technical support andother products on request
CASE STUDIES
31 Cutting tools - key factor forunmanned lights-out production
37 On-machine measurements cutlead times, improve accuracy
TECH FOCUS
R&D
42 Hybrid laser processing centrefor automated repair of injectionmoulds
TOOL MAINTENANCE
44 Proper mould maintenancetakes more than just the righttechnology
CASE STUDY46 Seismic change for earthquake
subcontractor
REGULARS
3 Editor’s Message
49 Zoomed in
51 Advertisers Index / Masthead
document9076564455138962454.indd 5 15.11.2016 10:47:17
NEWS BY THE NUMBERS
6 12-2016
TICKER
Zurich is the world’sMOST EXPENSIVE CITY to live, followed by Tokyo and Geneva. (Source: Statista) +++ With more than 11
million hectares of certified area or area under conversion in 2015, ORGANIC FARMING made up 6.2% of the European Union's
total utilised agricultural area. (Source: Eurostat) +++ 20 October 2016 marked the first ever EUROPEAN STATISTICS DAY. The“Destatis portal Europe in Figures“ enables comparisons between countries and regions, and provides a quick and easy access to
European statistics. +++ The EU has one of the densest transport networks in the world. The highestMOTORWAY DENSITY is
found in the regions of Germany, the Netherlands and Belgium. (Source: Eurostat)
QUOTE OF THE MONTH
TRENDS
Inflation rate in the Euro area
Tesla out-innovates the others
NUMBER GAMES NUMBER OF THE MONTH
Just the sheer number ofexperts visiting K 2016impressively confirms theappeal and importanceof the trade fair.Werner Matthias Dornscheidt,president & CEO of Messe Düsseldorf
+3.1%Global economicgrowth is projected toslow to 3.1% in 2016before recovering to3.4%t in 2017. The fore-cast, revised down by0.1 percentage point for2016 and 2017 is rela-tive to April figures.
(Source: IMF)
+22%Workholding spendingis projected to increase22% to USD 2.038billion, according to the2016 Tooling & Work-holding Capital Spend-ing Survey. Tool spend-ing is projected at USD4.138 billion, down 7%.
(Source: Gardner Media)
–1.3%On an internationalcomparison, in 2016,Marshall Islands rankedfirst with a negativeinflation rate of about1.35% compared to theprevious year, whileVenezuela has the high-est at 481.52%.
(Source: Statista)
Newly installed industry robots, worldwide until 2019 in million.......................... 1.4Number of industry robots, worldwide until 2019 in million.................................2.6
Industry robots sold, worldwide in 2015...................................................254.000Robots utilised in automobile, electronics and metal industries in %...................70
Robot density per 1,000 employees in Germany ..............................................301Robot density per 1,000 employees in South Korea .........................................531Robot density per 1,000 employees in USA......................................................176Robot density per 1,000 employees in China......................................................49(Source: IFR)
In 2015, €130 billion flowed from the EU budgetinto the 28 member states. Highest was Francewith 14.5 billion, Spain received 13.7 billion,Germany was fifth with 11 billion. But, offsetagainst contributions paid to the EU budget,Germany and France are net payers, contribut-ing 14.3 and 5.5 billion respectively, more tothe EU than they got back. (Source: IW Köln)
billion eurosEU budget formember states130
Inflation is the devaluation of money due to a perma-nent increase of the price level for products. In De-cember 2015, the inflation rate in the Euro area was0.2% compared to December 2014. (Source: Eurostat)
How Tesla out-innovates traditional carmakers:Graph shows R&D intensity (defined as the ratio ofthe company’s investment in R&D to its revenue) ofTesla and selected car manufacturers in 2015.
(Source: Company reports, Statista)
8/15 9/15 10/15 11/15 12/15 1/16 2/16 3/16 4/16 5/16 6/16 7/16 8/16
Tesla VW BMW General Ford Daimler ToyotaMotors
0.4%
0.3%
0.2%
0.1%
0%
–0.1%
–0.2%
20%
15%
10%
5%
0%
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17.7%
6.4% 6.0% 4.9% 4.5% 4.4% 3.7%
0.2%
17.7%
document7239295778931940430.indd 6 15.11.2016 10:48:50
INDUSTRY NEWS
SEEINGIS BELIEVING
We challenged large and small shops around the world to try Dynamictoolpaths. The results are nothing short of amazing. Dramatically shortercycle times, with extended tool life and less strain on machines.
See it for yourself. Get it at Mastercam.com/DynamicChallenge.
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New Technology Centre to support growing consumer demand
UK – Solidcam UK opened anewTechnology Centre basedin Little Horwood, MiltonKeynes, on 1 November 2016,in line with the company'sever-growing consumer de-mand and to stay ahead inwhat it describes as a compet-itive and fast-moving market.According to the company,
the Technology Centre willprovide additional dedicated
support and training to its cus-tomers by providing widergeographical options for ven-ues, and also will provide amore practical classroom ex-perience. It will be the perfectplace to demonstrate the pow-er of Solidcam software, thecompany says, and showcaseand test its latest technologiesand to prove them in-house.Live cutting demonstrations
showing the power of Solid-cam’smillingmodules, includ-ing the i-Machining module,will be shown on a RomiD-800VMC kindly supplied byRomi Machines UK.“At Solidcam UK, we are
dedicated to providing ourcustomerswith the very high-est levels of support and train-ing, which is the principalreason for our expansion to
guarantee that our customersreceive the highest levels ofservice right from the initialcontact, through to our af-ter-sales support and service,"MDGordon Drysdale says. "Weare dedicated to investing inthe development of all ele-ments of our company in orderto ensure we uphold our rep-utation for high standards."solidcam.com
On course forfurther growth
Germany – In the third quar-ter of 2016, the German ma-chine tool industry’s orderbookings rose by 8% comparedto the preceding year’s equiv-alent period, the German Ma-chine Tool Builders' Associa-tion (VDW) said. Domesticorders were down by 14%,while demand from abroadincreased by 22%. In the first
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Demand from abroad increasedby 22% in Q3, Schäfer said.
nine months of 2016, orderbookingswere up by 11% com-pared to the preceding year.Domestic orders showed aslight rise of 2%.“In the year’s third quarter,
our sector has been able tobuild on the encouraging busi-ness trends of 2016's first half.The good order situation ishere being crucially boostedby demand from abroad, Euro-and non-Eurozone,” explainedDr Wilfried Schäfer, VDW ex-ecutive director. In the Euro-zone, the southern Europeanmarkets of Italy, Spain andFrance are helping to drive theorder upturn forward. OutsideEurope, orders from the UShave been particularly buoy-ant, VDW reported.vdw.de
12-2016
document7762667394297309885.indd 7 15.11.2016 10:49:47
NEWS INDUSTRY
8 12-2016
NEWS IN BRIEF
Good credit ratingJoke Technology has once againearned a certificate (Crefo-Zert) forvery good credit rating.This makesJoke one of Germany's most solventcompanies, Joke says. The companyhas earned its first certificate in 2012and 2014. According to Joke, this yearmarks the sixth consecutive year ofgrowth.joke.de
Hermle: Sales up 11%
The Germany-based machine toolcompany Hermle says it has in-creased sales by 11% (€273.8m) in thefirst nine months of 2016 compared tothe same period last year. Accordingto Hermle, one of the reasons was thenew C-250 machine series, which wasintroduced this year.hermle.de
Dr-Richard-Escales-PrizeProf. Dr SonjaPongratz wasawarded withthe Dr-Richard-Escales-Prize atK 2016. TheJury praised her continuous dissemi-nation of knowledge in the area of thedurability of plastics.vdwf.de
Weaker demandIn the third quarter of 2016, the indexof machine tool orders, processed bythe Studies Dept. of Ucimu, Italy re-corded a 5.8% decrease compared to2015. Accordig to the Italian machinetool association, the outcome wasdue to the negative trend of foreignmarkets.ucimu.it
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Toolmaker of the year 2016Germany – Last year, they came in a closesecond behindAudi AG’s Tooling Division,but this year the continued developmenthas paid off for Phoenix Contact: TheWestphalian automation specialist’s in-ternal toolmaking division is the newwinner of the “Excellence in Production”competition and thus “Toolmaker of theYear 2016”.Since 2014, the expert toolmakers from
Blomberg have already twice reached the“Excellence in Produc-tion” finals in the com-petition for toolmaker ofthe year, and this yeartheirWestphalian perse-verance has paid off:During a festive eventwith about 300 guestsin the AachenTownHallCoronation Room, JörgSpindler, Head of Audi’sTooling Division handedthe cup over to Dr RalfGärtner, head of tool-making at Phoenix Con-tact, who accepted theprize on behalf of thecompany’s employees.In his laudation, Jörg Spindler praised
the internal toolmaking division’s definedbusinessmodel as a particular strength ofinternal toolmaking, fromwhich the com-pany derives new competencies and ser-vices in order to position toolmaking asintegral development partner in the entirecompany. The jurywas also impressed bythe global day-to-day transparency of allprojects, which is ensured by an informa-tion system and digital boards for ordertracking as well as daily Gemba walks.
Additionally, the consistent increase inthe level of automation in productionthrough the expansion of flexible auto-mation cells was also assessed positively.Phoenix Contact was founded in 1923
as a commercial agency for electrical prod-ucts in Essen. In 1966, the company relo-cated to Blomberg. The group currentlyconsists of twelve companies and around50 sales companies. Their product rangeincludes components and system solu-
tions for power supply,including renewable en-ergy, as well as for de-vice, machine and con-trol cabinet engineering.The company does notonly internally manu-facture screws, plasticandmetal parts, but alsohighly automated as-sembly machines andpunching, bending andinjection mouldingtools. Their global net-work for injectionmoulding tool construc-tion is controlled fromthe Phoenix Contact
headquarters in Blomberg. The productportfolio includes consulting services,prototypes, small series, rapid tools, andcomplex multi-cavity, high-speed tools.In addition to the overall victory, Phoe-
nix Contact also won the award in thecategory of “Internal Tool-Maker withmore than 50 employees”. Other finalistsin this category were Hirschvogel Auto-motive Group and the tool-making divi-sion of ZF Friedrichshafen.excellence-in-production.de
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Risen to the top of the industry: Phoenix Contact wins “Toolmaker of the Year 2016” competition.
“Phoenix Con-tact is a globallynetworked pro-duction enablerand industry 4.0pioneer.”Jörg Spindler, Head of Audi’s ToolingDivision
document3360966746695401494.indd 8 15.11.2016 10:53:41
12-2016 9
INDUSTRY NEWS
www.solidcam.com
The Revolutionin CNC-Machining!
iMachining saves 70% and more inCNC machining time
iMachining extends cutting tool lifedramatically
The unique iMachining TechnologyWizard, provides optimal feeds andspeeds, taking into account thetoolpath, stock and tool materialand machine specifications.
SolidCAM supports multi-taskMill-Turn machines, with seamlessly
integrated advanced Mill-Turn module.
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integrated advanced Mill-Turn module.
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iMachining 2D / 3D | 2.5D Milling | 3D High-Speed Machining | High Speed Surface MachiningIndexial Multi-Sided Milling | Sim. 5x Milling | Turning | Advanced Mill-Turn | Solid Probe
Positive outlook for the globalsheetmetal working industry
Germany – The 24th interna-tional sheetmetal technologyshow, Euroblech 2016, attract-ed total of 60,636 visitors fromsome 100 different countries.Held from 25 - 29 October inHanover, Germany the showhosted 1,503 exhibiting com-panies from 41 countries.„The trend for digitisedman-
ufacturing boosts innovationand business activity in thesheetmetal working industryand its leading industry exhi-bition,” commented NicolaHamann, managing directorof Mack Brooks Exhibitions.“The atmosphere at this year’sshowwas filled with an over-all fascination about the recenttechnological advancementsand the large number of posi-tive international businesscontacts.”According to Hamann, visi-
tor numbers increased by 2%compared to the previousshow, and clearly demon-strates a healthy economicoutlook for the industry sectoron a global scaleA total of 39% of visitors and
54% of exhibitors came fromoutside Germany at this year’sshow, Mack Brooks said. Thisis a further increase by 2%each compared to the previousshow and represents a recordpercentage in internationalattendance. Euroblech 2016saw amajor increase in Asianvisitors (+30%), but also in vis-itors from EU countries out-
side Germany (+11%). Majorvisitor countries, next to Ger-many, included the Nether-lands, Italy, Sweden, France,Spain, Switzerland, Austria,Poland, Great Britain, Turkeyand India.A great majority of the visi-
tors came from the sheetmet-al industry (80%), followed byvisitors fromworkshops, tradeand services. Most importantsectors the visitors belongedto were engineering, sheet-metal & products, steel andaluminium construction aswell as the automotive indus-try and its suppliers.According to the organisers,
99% of visitors were from thetrade sector. Besides the highrate of international visitorsthe exhibition could, onceagain, register a high percent-age of visitors from the topmanagement with deci-sion-making and buying ca-pacity. The percentage of visi-tors involved in decision-mak-ing has increased by 3% to atotal of 84%. The preliminaryresults of the exhibition sur-vey show that both exhibitorsand visitors at this year’s Eu-roblech were highly satisfied.The visitors praised the com-pleteness and internationalrange of the products on dis-play. The exhibitors praisedthe qualified and internation-al audience with its high per-centage of decision-makers.euroblech.com
A total of 60,636 visitors from some 100 different countries came toHanover to get an overview of the latest technical developments insheetmetal processing.
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document1504889453810640121.indd 9 15.11.2016 10:54:11
NEWS INDUSTRY
10 12-2016
OPINION
Toolmaking 4.0: The path is predeterminedVDWF (German Tool andMould Makers' Association)President Prof. Thomas Seulabout Toolmaking 4.0: Com-panies have to face the chal-lenges.
Toolmaking 4.0 - some mayalready be fed up with theterm. On the other hand,money in tool and mouldmaking is not made througheconomising, but throughexpertise, in which businessesmust invest in order to remaincompetitive and leaders ininnovation and training.Both management and
employees are equally re-quired to live and support thistransition, even if implement-ing it is not as easy as turninga switch and saying now wedo Toolmaking 4.0. But busi-nesses do not have a choice,just like their predecessorscould not stand against pastindustrial revolutions, like thesteam engine, electrification or
the introduction of computers.The path is predetermined andbusinesses must adapt to thenew conditions – preferablysooner than later, and even iftheir boss has grown up in aworld without Internet. This isa profound business transfor-mation, and consequently it iscrucial to address the issueand to clearly understand boththe opportunities and the risksassociated with this fourth
industrial revolution.Toolmakers must face the
digital transformation andre-align their business accord-ingly. The goal of Industry 4.0is to support staff in theirincreasingly complex work bymaking the required automa-tion technology smarterthrough self-configuration,self-diagnosis and self-optimi-sation, thus giving highly quali-fied employees the freedom to
focus again on processes thatrequire real creativity or a lot ofwork experience. This con-nected systems perspectiveon Industry 4.0 also meansthat smart production equip-ment will for example sendinformation coming from thetool, like viscosity, smeltingtemperature or injection pres-sure, to the injection mouldingmachine for process control.Such systems with embeddedmonitoring of process param-eters may also act as thetool’s brain and record infor-mation.Furthermore, electronics will
become increasingly import-ant in the mould making in-dustry. The application ofhigh-performance informationand communication technolo-gies in the industry will createnew opportunities for Germa-ny to remain and enhance itscompetitiveness as a manu-facturing location.vdwf.de
Prof. Thomas Seul :“The goal ofIndustry 4.0 is tosupport staff intheir increasinglycomplex work bymaking therequired automa-tion technologysmarter.”P
icture:S
chulz
DP Technology forges partnerships with academia
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DP Technology along with the College of Electromechanical Engineeringat Beijing Union University and the Beijing Intelligent Mechanical Innova-tive Design Engineering Research Center hosted the Esprit CAM & SmartManufacturing seminar in September.
China – The Esprit CAM &Smart Manufacturing seminarhosted by DP Technology inBeijing, China in Septemberwas a great success, the com-pany said. DP Technologyjoined the College of Electro-mechanical Engineering atBeijing Union University andthe Beijing Intelligent Mechan-ical Innovative Design Engi-neering Research Center tohost the seminar, whichbrought into focus the mostcritical manufacturing topicsin China today in order to bet-ter support the ten-year na-tional plan, Made in China2025.TheMade in China 2025 pro-
gram promotes the transferinto smart manufacturing,improves applications insmartmanufacturing and fos-ters the next generation in awide array of manufacturingindustries. The event was at-tended by more than 60 peo-ple from local manufacturingcompanies, universities and
members of the press. Theseminar was a joint speakingengagement for outstandingbusinessmen and technicians.It featuredmany topics to sup-port attendees and Esprit us-ers on their path to success,including Industry 4.0, smartmanufacturing, manufactur-ing automation and the part-nership between industry and
academia. Guang Cheng, Deanof College of Electromechani-cal Engineering of Beijing Un-ion University, addressed thecurrent status and majortrends in the future of smartmanufacturing from historical,conceptual and practical as-pects. Mr. Cheng stated thatthe College of Electromechan-ical Engineering is committed
to developing high quality ap-plication engineers with aninternational point of view. Healso stated that, “We wouldlike to facilitate cooperationwith DPTechnology to furtherthe development of smartmanufacturing. The currentresearch focus of Beijing Intel-ligent Mechanical InnovativeDesign Engineering ResearchCenter covers a wide range ofsmartmanufacturing technol-ogies, including prototype de-sign and manufacturing, hu-man-machine interaction andusability testing, and smartmanufacturing and service.”Formany years DPTechnol-
ogy has partneredwith highereducation institutions, techni-cal middle schools, technicalhigh schools, and technicalcolleges. DPTechnologyworkshand in hand with localschools and colleges to createcertification and training cen-tres and to help build the ed-ucation revolution in China.dptechnology.com
document1193209257748770054.indd 10 15.11.2016 11:07:03
12-2016 11
INDUSTRY NEWS
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11042
Arburg secures long-term localpresence in TaiwanGermany/Taiwan – Arburgofficially opened its Taiwanesesubsidiary in Taichung in Sep-tember. The eventwas attend-ed by 150 guests. According toArburg, a high-profile delega-tion from the German parentcompany was in attendanceto officially inaugurate thesubsidiary, which has alreadybeen actively operating sinceApril 2016. During the event,Arburg's Managing PartnerRenate Keinath andManagingDirector Sales Gerhard Böhmemphasised the great signifi-cance of Taiwan's high-techmarket.“The founding of the Arburg
organisation is an importantmilestone of the company'ssuccessful development in Tai-wan,” said Keinath andthanked the former tradingpartner on behalf of the entireArburg organisation.“Over the past 35 years, we
have enjoyed excellent rep-resentation by C & F Interna-tional Corp. in this importantmarket. However, Arburg hasnever been known to rest onits laurels.We always endeav-our to offer our customers aneven better range of productsand services.”Because Taiwan has great
significance for Arburg as aninnovative market with nu-merous high-end companies,the stated objective is to notonly to secure a local presencewith a subsidiary over the long
term, but also to strategicallyexpand it further. “In MichaelHuang, we have succeeded inrecruiting an experiencedplastics specialist as subsidi-ary manager. Moreover, be-causewe have taken onmanySales and Service employeesfrom our former trading part-ner, the same extensiveknowledge and familiar localcontacts will continue to beavailable to our customers inthe future,” Keinath said. Shewent on to explain that thenew premises offer some 550square metres of floorspace,providing the perfect settingfor the extensive service offer-ings. The showroom also pro-vides sufficient space for threeAllrounder injectionmouldingmachines.After the inauguration cere-
mony, the guests had the op-portunity to gain a first-handimpression of the extensivefacilities at the new subsidiary.Furthermore, two seminarsprovided expert knowledge ontrends and developments ininjectionmoulding in general,as well as on the processing ofliquid silicone (LSR).According to Arburg, the in-
frastructure in Taiwanwill beexpanded in a targeted man-ner, with the intention to en-sure customers the same first-class service and support inTaichung for which the com-pany is renownedworldwide.arburg.com
Official inauguration in Taiwan: Georg Anzer, HR MD, Michael Huang, MDof Taiwan subsiduary, Managing Partner Renate Keinath, Andrea Carta,overseas sales director, Andrea Carta, overseas sales director, GerhardBöhm, MD Sales and Hazel Liu senior finance manager in Taiwan (l-r).
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document3516537993205402181.indd 11 15.11.2016 11:07:32
NEWS INDUSTRY
12 12-2016
TICKER
WIN EURASIA Metalworking, which takes place from 9 to 12 February 2017 in Istanbul. In 2016, the show attracted approx. 30,000
visitors from more than 70 countries. +++ PRODWAYS announced a strategic partnership with A. Schulman, a leading international
supplier of high-performance plastic compounds and composites, to strengthen its laser sintering offerings. +++ Global precision
engineering company RENISHAW has announced that its subsidiary Renishaw (Taiwan) Inc has moved to a significantly larger facility
within the Taichung City Precision Machinery Innovation Technology Park. +++ SmarTech Publishing has just published its report “3DPRINTING SOFTWARE Markets 2016: An Opportunity Analysis and Ten-Year Forecast”. According to this report, such software will
reach $741m by 2021 and go on to achieve $2.2bn by 2025.
Systems expertise, customer proximity ensure continued growth
Austria – Engel Austria ex-pects growth of approximate-ly 10% for the current fiscalyear 2016/17, according to com-pany management as the Kfair got under way in Düssel-dorf in October. The world’sleading trade fair for the plas-tics and rubber industrywould provide importantmo-mentum to the second half ofEngel’s fiscal year, the compa-ny said. Current drivers ofgrowth include digital prod-ucts and solutions for thesmart factory, forming thecentrepiece of the stand of theAustrian manufacturer of in-jection moulding machinesand systems expert.“We notice demand levels
are slightly up on last year,”said Dr Christoph Steger, chiefsales officer at the EngelGroup, which has its head-quarters in Schwertberg, Aus-
tria. “We expect the trend tocontinue for the next two orthree years, although growthrates will be somewhat slow-er than in recent years.” In thelast full fiscal year (ending inMarch 2016), Engel achieved a14% increase on the previousyear. With 5,200 employeesaround the world, the Groupgenerated €1.25bn in turnover.
All of the company's regionsand fields of business contrib-ute to Engel's continuing suc-cess, Engel said. According tothe company, during the2015/16 fiscal year, Engel con-solidated its market positionin Europe while expandingmarket share in Asia andAmerica. High levels of exper-tise in technology, automation
and system solutions areamong the main reasons forthat growth, with innovativestrength, quality and custom-er proximity also playing apart. “Customer proximitymeans understanding the in-dividual needs of our custom-ers and meeting them withtailor-made solutions,” saidSteger. The company is closeto its customers in literalterms too: with nine produc-tion plants, 30 sales andservice subsidiaries and 60representatives, Engel staysnear to its clients around theworld.Moreover, Engel’s tailor-
made system solutions in-cludemore andmore productsin the inject 4.0 program, thecompany’s answer to the de-mands of the fourth industrialrevolution.engelglobal.com
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The two large-scale machine plants in St. Valentin, Austria (photo)and Shanghai, China will be enlarged. Current drivers of growthinclude digital products and solutions for the smart factory.
Plastics, rubber machinery manufacturers expect growth of 2%
Europe – Europe’s plastics andrubber machinery manufac-turers anticipate that sales willgrow by an average of 1.8% inthe current year and in the twoyears ahead. “This forecastmeans that the industry in themember countries of Euromapwill continue to grow,” LucianoAnceschi, president of Eurom-ap, the European umbrellaorganisation for the most im-portant national plastics andrubber machinery associa-tions, said. “Between 2005 and2015, sales in our countriesrose from €9.3bn to €13.5bn,up by a noteworthy 46%, albe-
it less than the 83% growthrecorded worldwide in thesame period.”“At the same time, exports
from Euromap countries roseby 52%," Euromap VP Dr Karl-heinz Bourdon added. "For usEuropeans, thewholeworld isourmarket, whereas in the lastdecade China was still pre-dominantly serving its ownmarket." In 2015, the Euromapcountries as a whole account-ed for 47% of world exports,while China’s share, followinga surge in exports, reached15%, Bourdon said.euromap.org
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In the years 2016 to 2018, global sales of plastics and rubber machineryare expected to grow by an average of 3.4%, with China as the maingrowth driver, Euromap said at a press conference at K 2016.
document6166402187902233067.indd 12 15.11.2016 11:07:54
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11042_ANZ_ETMM_2016_210x297_08.indd 3 18.03.2016 14:36:40
SPECIA
L SPECIAL REPORT
14 12-2016
Meusburger's inaugural Tool andMould Making Days a great success
From 12 to 13 October 2016, Meusburger hosted its inaugural Tool andMould Making Days in Bregenz, Austria. Organised in co-operation withVDWF and Form +Werkzeug, the event featured presentations and hadparticipants discussing trends, issues and developments in the industry.
The inaugural Meusburger Tool and MouldMaking Days were a successful event.
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From 12 to 13 October 2016,Wolfurt-based stand-ard parts manufacturer Meusburger hosted itsinaugural Tool andMouldMaking Days in Bre-
genz, Austria. Organised in co-operation with theindustry associationVDWFand Form +Werkzeug,the event featured presentations and an exhibitionand had participants discussing trends, issues anddevelopments in the industry.The event’s location exemplified its general
theme, as the festive air of the Festspielhaus Bre-genzwith its sea stage already set visual standards.Technical standards, on the other hand, were theevent’s lead theme, as the very first lecture, a key-note by Meusburger’s Gerhard Krammel titled“Standardisation in toolmaking”, showed. In hisspeech, he underlined theWolfurt company’s claimto “aim to realise significant time and cost savingsthrough consistent and continuous standardisationof products and processes, thus creating a key pre-requisite for long-term business success.”
Andreas Sutter, head of marketing at Meusburg-er, explained the concept behind the new event:“The ideawas to create an event in our home regionthat deals with tool andmould making topics andtakes place in years when there is no Fakuma.”A quick glance at the event’s agenda made clear
that thereweremore than enough topics to discuss.A focus was placed on process standardisation,automation and other forms of digitisation, whichwere repeatedly discussed in the following pres-entations. The first day’s sessions were mostlyabout punching toolmaking, those on the secondday aboutmouldmaking. Also, the concluding pan-el discussions on both days discussed to what ex-tent Industry 4.0will permanently change tool andmould making.How the industry views this development was
illustrated more clearly in the event’s second ses-sion: Bernd Krebs, managing director of Toolcraft,sees tool and mould making currently positioned
Florian Stocker
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SPECIA
LSPECIAL REPORT
1512-2016
somewhere “between evolution and revolution”,whereby he personally leaned rather toward thelatter, i.e., “revolution”. Proof for the latter can befound in Toolpark’s machinery, where robotics and3D printing are areas of rapid growth. The compa-ny now uses six laser melting facilities and Krebsbelieves that technology will require significantlyhigher investments in the future.
In the face of increasing competitivepressure, Industry 4.0 is important
In the German tool and mould making industry,Toolcraft is viewed as an all-rounder, serving adiverse customer base in areas including medicaltechnology, motor sports, aerospace, semiconduc-tor and special machines. According to the compa-ny, they have already focused on digitisation andautomation at a very early stage. Through theirsubsidiary Unicam, Toolcraft have also incorporat-ed their own software company and continue toinvest in the advancement of Industry 4.0 in theirbusiness: “CAD, CAM and robotics are only just thebeginning, but in the face of increasing competitivepressure, everybody should commit to it”, saidKrebs. Moreover, standardisation would still besought after in toolmaking.Andreas Wagle from Makino talked about “Re-
duction of manual post-processing in tool andmouldmaking”. He presented solutions that couldreduce or even completely avoid the need for cost-ly post-processing. According to the company, thesesolutions can help to reduce a tool’s or mould’stotal process costs.Walbert pointed out that manyelements provided by Makino, ranging from ge-ometrically optimised basic machine set-up to therelevant expertise in application technology andconsequently the CAM system and applicationsupport, would contribute to producing a steel im-age of the design data with the highest possibleaccuracy.Between presentations, the more than 200 visi-
tors of the event were able to inform themselvesabout the products and services of the show's 36exhibitors. Numerous breaks gave visitors thechance to share their knowledge with each other.Both days ended with an hour-long boat trip onLake Constance, followed by dinner and livemusic.
Tool and mould making: from craft toindustrial production
Ahighlight of the second daywas the presentationby VDWF President Thomas Seul, who discussedthe challenges and opportunities German, Austrianand Swiss manufacturers are facing in the globaltool andmouldmakingmarkets. On the one hand,producers today can work ever more flexibly andaccurately and significantly increase precision. Onthe other hand, this would also require further in-vestments in their machinery. Seul concluded that“tool and mould making is moving ever furtherfrom a classic craft towards industrial production.”Seul repeatedly emphasised his core statement
that “the others are good as well”. Citing variousexamples from emerging tool and mould makingmarkets like China, Portugal or Mexico, he urgedGerman, Austrian and Swiss producers facing ev-er-increasing global quality and pricing pressure to
In co-operation withVDWF and Form +Werkzeug, Meusburgersuccessfully hosted itsinaugural Tool and MouldMaking Days in Bregenz,Austria.
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INFOThe Austria-basedTool and MouldMaking Days aredesigned to bringindustry together insouthern Germany/Austria/Switzerlandin non-Fakumayears.
remember their specific strengths: Expertise, qual-ifiedworkers and particularly the ability to providesolutions to customers’ problems instead of justtechnologywould be key to remaining competitivein current markets and opening up new markets.“Price and quality are a must, but service and reli-ability are the icing on the cake. I wish tool andmould makers would already be involved duringthe customer’s product development stage, to beable to evaluate the specific quality demands fromthe get-go and to find solutions in co-operationwith the customer.We have a very high intellectu-al problem- solving capacity, which is an advantagecompared to other countries.”The presentations following Thomas Seul's appeal
were again more focused on specific solutions.PSG’s Andreas Kanamori presented the newly de-veloped hot runner concept called Pipeline, whichrequires 80% fewer pipes and could thus ensuresignificantly increased stability of the tool.Rudolf Derntl of Hermle Maschinenbau GmbH
talked about "Additivemanufacturingwith Hermlehybrid systems” and presented the MPA process,which combines the strengths of both subtractiveand additivemanufacturing and thus enables highdeposition rates, an application on freeform sur-faces and less clamping in the component. Also,the hybrid process would enable 3Dmulti-materi-als and the integration of hot wires and sensors incombination with cooling channels.The venue in Bregenzwas only a few kilometres
fromMeusburger’sWolfurt headquarters and thusthe ideal location for the standard parts manufac-turer. It also gave interested parties the opportuni-ty to gain deeper insight into the Meusburger fac-tory through a factory tour. Many visitors tookadvantage of this offer and made a short detour toWolfurt, thus rounding off their event with addi-tional practical examples.“We are very happy about the positive feedback
we received from visitors and exhibitors. The factthat the Tool and Mould Making Days were fullybooked is a motivation for us to continue workingwith out partners to further establish this industryevent,” concluded Andreas Sutter.meusburger.com
document5772361355982076976.indd 15 15.11.2016 11:09:10
Fig. 1: Political map of Braziland Mexico.
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NEWS MARKETS
World of Tooling –Spotlight Brazil and Mexico
Over the course of the entire year 2016, WBA AachenerWerkzeugbauAkademie presents spotlights of the most important international toolingmarkets. This edition focuses on Brazil and Mexico.
Dr. Wolfgang Boos,Michael Salmen M.Sc.,Thomas Kuhlmann M.Sc.,M.Sc., Dipl.-Ing. Dipl.-Wirt.Ing. Max Schippers,Dipl.-Wirt.-Ing. MaximilianStark
Brazil is the largest andmost populated countryin SouthAmerica. It is home to about 203mil-lion people, while UN estimates indicate that
the population will grow to 223 million by 2050.The United Mexican States is a federal republiclocated in Central Americawith approximately 120million citizens. Estimates of the UN suggest thatthe populationwill increase to 144million by 2050.Brazil is an emerging nation and belongs to theso-called “BRICS nations”, an association of upcom-ing economies that includes Russia, India, Chinaand South Africa. The country hasmade great pro-gress with regard to the quality of life while reduc-ing the enormous prevailing social imbalance andwidespread poverty. More than 26million Braziliansare said to have “escaped” acute poverty between2003 and 2013. Nevertheless, Brazil continues toface significant social and political challenges, es-pecially in comparison with highly developed in-dustrial nations. This applies to income distribution,the labour market, healthcare system, inner andsocial security as well as education. Only 45% ofBrazilian adults and 37% of the adult population inMexico have a higher educational degree. Still, Mex-ico invests the same share of its gross domesticproduct (GDP) in education as Germany (5.1%).
Mexico has made remarkable progress in recentyears, particularly in the improvement of livingconditions and the educational system. The mostsignificant change has been the reformation of thehealthcare system and an overall booming econo-my. The average income of Brazilian and Mexicanhouseholds is €7,732 and €8,034, respectively. Brazilis plagued by high crime rates and organised crimeand belongs to the top-20 countries in terms offrequency of capital crimes per 100,000 citizens.Despite numerous problems, Brazilians are signif-icantlymore satisfiedwith their lives than citizensof many other industrialised nations.
The Brazilian economy and industry
Brazil's GDP is the ninth-largest national economyworldwide in 2015. The economy has had an aver-age growth rate of 2% per year for the past fouryears. The GDP per capita was approximately€10,000 in 2015. By comparison, the German GDPper capita for the same period was €42,500. Brazil-ian growth rates fell by an average of over twopercentage points comparedwith the period, 2006-2010. The economic outlook for 2016 ismoderatelypositive, with an expected growth of 2.0%. Brazil
document1774169189423656606.indd 16 15.11.2016 11:11:37
12-2016 17
MARKETS NEWS
is currently the world’s 11th-largest export and21st-largest import nation. In 2012, the country ex-ported goods worth €228bn. The most importantexports were resources (iron ore and crude oil) andproducts related to the food and automotive indus-tries. The country has large deposits of raw mate-rials, including tin, iron ore, gold, aluminium anduranium. The level of wages was close to €14,500in 2013 and is below the average of all industrialnations. The unemployment rate of 6.9% is closeto historical lows. Brazil continues to be a volatilecountry with great potential, althoughmajor risksfor investors exist in terms of currency security,corruption and the administrative system. In par-ticular, trade regulations affecting import and ex-port customs complicate the activities of foreignmarket participants. The complex customs regula-tions, abrupt and temporary tax increases on certaingoods in the name of protection of local economieslead to an unstable foreign trade.
The Mexican economy and industry
Mexico's GDP is the world's 15th-largest economywith a GDP per capita of approximately €9,500 in2015. Over the last three years, the economy grewmoderately by 2.9% per year. The outlook for 2016is positive. In 2012, the country exported productsand goods worth €331bn. The three main exportgoodswere oil, food and automobiles. The countryis rich in natural resources like oil and gas andpossesses many mineral resources like silver, bis-muth and lead. The automotive sector has experi-enced rapid growth and is an essential driver ofemployment. Investments worth €22bn were an-nounced for Mexico by automotive OEMs over thelast four years. Its strategic geographical locationand the ports to the east and west also have apositive effect. Moreover, there is not only a freetrade agreement (NAFTA) betweenMexico, the U.S.and Canada, but also an agreement between Mex-ico and the EU. An automobile with a value of€55,000 exported from the U.S. to Europe wouldentail €5,500 in custom duties, which is not chargedfor the same automobile originating from Mexico.In 2011, the wage level was on average at €13,500and, despite moderate growth in engineering-re-lated jobs, the country still shows a wage-cost ad-vantage over the U.S. of €500 to €600 per employ-ee per month. Mexicans work an average of 2,239
Fig. 2: Gross domesticproduct of Brazil andMexico.
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INFOThe analysispresented here iswell-founded ona study entitled“World of Tooling”,published in late2015, whichpresents an in-depth analysis ofquantitative andqualitative data ontooling markets.
document1774169189423656606.indd 17 15.11.2016 11:11:43
NEWS MARKETS
18 12-2016
hours every year – almost 30% more than the av-erage of all industrialised nations.
Brazilian tools and tool manufacture
A total of 5,426 tons of tools and dies worth €64mwere exported in 2013, which consisted of injectionmouldsworth €42m, solid and sheetmetal formingtools worth €21m and castingmouldswith a valueof €1m. Almost 98% of the produced tools remainin Brazil and the total production is estimated atover €3bn. The industry has been growing in dou-ble digits for several years. Additional tools and dieswere imported to Brazil in 2013 with a total valueof €420m, comprising of €215m of injectionmoulds,€189m of solid and sheet metal forming tools and€16m of casting moulds. Fig. 4 shows its tool tradewith foreignmarkets in 2014. The largest trade part-ners for importing injection moulds are China,South Korea and Italy. Injection moulds are most-ly exported to Argentina, the USA and Columbia.The largest trade partners for importing sheetmet-al andmassive forming tools are Japan, China andSouth Korea, while they are exported mainly toMexico, the USA and Argentina. The heart of theindustry is in Joinville, south of Sao Paulo, whereabout 20% of the estimated 2,000 companies arelocated. There are almost nomajor companies withover 100 employees and the industry focuses on
simple tools or processing. The local automotiveindustry is the main customer for the industry,followed by the packaging and electronics indus-tries. Brazil has a large domestic market on whichthe local industry is focused. Unlike Mexico, inter-national customers and exports are an exceptionand this is unlikely to change in the foreseeablefuture. Still, Brazil is the only country in SouthAmerica with industrial and tool and die-makingexperience. The development potential is ratedaverage as the economy and the complex traderegulations will continue to hinder the exportabil-ity of tool and die products in the foreseeable future.
Mexican tools and tool manufacture
In 2013, tools and dies with a value of €340mwereexported, of which €288m were injection moulds,€38mwere solid and sheetmetal forming tools and€14mwere casting tools. In the same period, Mex-ico imported tools and dies worth a record valueof €1,803m, of which €1,115m were for injectionmoulds, €531m for solid and sheet metal formingtools and €157m for die-casting moulds. Its tradeof tools with foreignmarkets in 2014 is shown Fig.4. The largest trade partners for importing injectionmoulds are the USA, China and South Korea. Injec-tion moulds are mostly exported to the USA, Hun-gary and Canada. The largest trade partners forimporting sheet metal and massive forming toolsare the USA, Japan and China, while they are ex-ported mainly to the USA, Thailand and Canada.Tool and die imports (solid and sheetmetal formingtools) have increased over the last four years. Incontrast, injectionmoulds and die-castingmouldsshowed a lower growth rate, while tool exports(solid and sheet metal forming) have remainedconstant for the past four years.The local industry falls short of fulfilling high
quality requirements and cannot meet increasingdemands brought about by the growth of the au-tomotive industry. Almost all tools and dies re-quired for automotive serial production are import-ed from North America. There are currently noindependent companies that could boost the inter-national production or take on maintenance andrepair activities. The tool and die requirements andthe many OEM production sites and internationalsuppliers will help develop the local industry, andthe potential for development is rated high.Sources: Istma, OECD, UN Comtrade Database
werkzeugbau-akademie.de
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Fig. 4: Most importanttrading partners for injec-tion molds and sheetmetal and massive form-ing tools in million Euro(Comtrade, 2014).
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Fig. 3: Tool imports andexports (Comtrade, 2013).
document1774169189423656606.indd 18 15.11.2016 11:11:45
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11042_ANZ_ETMM_2016_210x297_08.indd 2 18.03.2016 14:25:34
COVER STORY
20 12-2016
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©NataliyaHora/Fo
tolia.com
INFO
Emerging marketsEmerging markets such as Brazil, Russia andIndia also remain promising despite somefallout from economic recession and slowinggrowth. IHS Automotive forecasts that around55 new vehicles will launch in the Brazilianmarket in 2017, for example, with models fromVolkswagen, Fiat, Honda and Renault fuelling aslow return to growth by 2018 after a difficultcouple of years. Separate forecasts from PwC’sStrategy Consulting Group also suggest thatemerging markets in Brazil, Eastern Europe,South Africa, China and India will show consis-tent growth in light vehicle sales in 2017.ihs.com, pwc.com
Positive outlookVehicle and aircraft manufacturers are positive about 2017. Increased passenger traffic ispushing up demand for new aircraft, whilst new models are expected to drive automotivesales.
Martin Courtney
New passenger car registrations/salesJanuary – September 2016
(Source: VDA)
Europe(EU28+EFTA)
European Union(EU-28)
W. Europe(EU15+EFTA)
New EU Countries(EU13)
Russia
USA
Japan
Brazil
India
China 16.189.500 +17.7%
3.157.100
13.044.100
10.752.100
11.243.300
11.607.300
855.100
+7.7%
+8%
+7.1%
+16.2%
–14.4%
+0.4%
–3.7%
–22.5%
+8.9%
1.020.900
1.460.600
2.217.200
Change 16/15 in %
Units
document6135950974150230385.indd 20 15.11.2016 11:24:52
COVER STORY
2112-2016
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The aerospace and automotive industries arekey sources of demand for plastics and metalcomponent manufacturers, and fluctuations
in associated economic activity often determinethe outlook for investment in machine tools andmoulding equipment.2016 appears to have been a good year for the
aerospace industry so far but 2017 looks equallypromising, with the commercial sector expectedto see continued growth in revenue and operatingearnings driven by expanding passenger numbersand demand for next-generation aircraft. Figuresfrom the International Air Transport Association(IATA) calculate that the volume of global air pas-senger traffic continue to increase in 2016, thoughat a slightly slower pace than in previous years.Nevertheless, it predicts solid growth for 2017, par-ticularly Asia, Latin America and the Middle East,and airlines are rushing to expand their fleet ca-pacity to handle the increasing demand for seats.Global consultancy Deloitte Touche Tohmatsu
Ltd estimates that by the end of 2016 1,420 largecommercial aircraft will have beenmanufactured,with a further 1,490 expected in 2017. As of Septem-ber of this year, aircraft manufacturer Airbus hadrecorded 380 orders for its latest passenger aircraftfrom global airlines including Vietjet, Quantas, Vi-etnam Airlines, the French Air Force, RwandAir,AirAsia, Pegasus Airlines, Emirates, China Airlines,Cathay Pacific, Finnair, Latam and Qatar Airways.That demand is filtering down the supply chain
to componentmakers who are upgrading their ownmanufacturing capacity tomeet orders fromAirbusand others. Spanish company Sofitec won a €45mdeal with Germany-based PremiumAerotec to sup-ply composite fuselage components for the A350X-WB, for example, with the first items due to shipbetween January and March 2017. Airbus also se-lected Stratasys’ ULTEM 9085 3D printingmaterialfor the production of resin flight parts for theA350XWB.UK-based supplier of fasteners, fixings and oth-
er components FSLAerospace saw an 18% increasein turnover in its last financial year after signinglong-term agreements with established aerospacemanufacturers expected to deliver £1m of addition-al revenue over the course of the next few years.
Investment in new machine tools,tooling technology
UK-based JJ Churchill estimates its aerospace saleshave increased 60% in the past 12months and saidin October that it is investing £1.5m in new tech-nology, people and systems to meet growing de-mand from the aerospace industry for engines andnext-generation aircraft in 2017 and beyond. Thecompany plans to invest in Makino 5-axis VIPERCNC grinding capacity and Doosan 5-axis machin-ing capacity linked to advanced informationman-agement systems to deliver precision nickel-basedally components. Moreover, it plans to increase itsheadcount by 20%, although it admits skilled peo-ple are still hard to find.Elsewhere, Renishaw is contributing its additive
manufacturing expertise to a new £17.7m projectled byAirbus in the UK dubbedWind DesignMeth-odology Validation (WINDY), partly funded by UKgovernment investment from the Department for
Concerning Portugal,the demand from theautomotive industry ishigh at this moment andIstma’s Manuel Oliveiraexpects that trend tocontinue in 2017.
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Business, Energy and Industrial Strategy (BEIS) andsupported by the Aerospace Technology Institute(ATI).It was estimated that the Andalusian Aerospace
industry in Spain turned over €2,343m in 2015,creating over 1,000 new jobs and reinforcing itsplace as one of the threemain European aerospacehubs alongside Toulouse and Hamburg. The regionis responsible for almost a quarter of all aerospacesales in Spain, having tripled its turnover from€848m in 2006.What's more, it expects growth tocontinue in 2017, driven bymanufacturing require-ments of the Airbus A400M and A350.
Emerging car markets driving growth
Multi-axis machining subcontract specialist HECPrecision has invested in its fourth Doosan mul-ti-tasking turning centre fromMills CNC to help itmeet what it expects to be increased demand foraerospace components over the next couple ofyears. Beaver Aerospace & Defense, a subsidiary ofPhillips Service Industries (PSI) and specialist inthe design and manufacturing of custom ballscrews for commercial and military aircraft, also
announced that it has upgraded its machin-ing centre with two new 4-axis eco Mill1100 Vmachines.
There is cautious optimism too forcar sales, despite slowing rates ofgrowth in the world's biggest market
in China. US analyst firm IHS Automo-tive has recently cut its forecast for salesof vehicles in China by 9million units
but still expects China to hit 32mil-lion annual sales by 2022 witha 5% sales increase expectedin 2017.Emerging markets such as
Brazil, Russia and India alsoremain promising despite somefallout from economic recessionand slowing growth. IHS Auto-motive forecasts that around 55new vehicles will launch in the Bra-
zilian market in 2017, for example,
UPSHOTThe fortunes of Europeantool and mould makers areamong other things dependenton what happens in the US,the second-largest passengervehicle market of any countryin the world.Barbara SchulzEditor-in-Chief
document6135950974150230385.indd 21 15.11.2016 11:25:01
COVER STORY
22 12-2016
Laurie Harbour, presidentand CEO of Harbour
Results, expects to seean unprecedented
number of new vehiclelaunches between 2017
and 2019.
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Harbo
urwith models from Volkswagen, Fiat, Honda andRenault fuelling a slow return to growth by 2018after a difficult couple of years. Separate forecastsfrom PwC’s Strategy Consulting Group also suggestthat emerging markets in Brazil, Eastern Europe,SouthAfrica, China and Indiawill show consistentgrowth in light vehicle sales in 2017.The picture inmatureWestern Europeanmarkets
is mixed, however. The EuropeanAutomobile Man-ufacturers Association (ACEA) calculated that carsales across the region increased 7.7% in the ninemonths up to and including September 2016, withGermany, Britain, France, Italy and Spain all show-ing growth. But there is uncertainty for 2017, par-tially caused by ongoing jitters around the econom-ic impact of the UK's exit from the European Union,whilst figures from LMCAutomotive suggest salescontracted 1% in October."European automobile demand appears to have
peaked," analysts at Moody's Investors Service, in-cluding Bruce Clark in NewYork, wrote in a reportpublished in October. "Manufacturers' ambitiousvolume expectations for their newmodels will keeppricing pressure high and could result in discountsand incentives eroding profit margins and cashflows."Analyst firm LMC believes Italy will see most
growth over the next few years, boosted by animproving economic outlook and the larger numberof older cars on the road that need replacing. Thecompany does predict a downturn for the UK inthe next few years, however, due to the weaknessof the pound and a broader economic slowdown.Manuel Oliveira, European secretariat at the In-
ternational Special Tooling &MachiningAssociation(Istma), said tool andmouldmakers are optimisticabout demand for their products for 2017.“Concerning Portugal, the demand from the au-
tomotive industry is high at this moment and weexpect that trend to continue in 2017,” he said. “Re-garding aerospace, we feel a slight increase but inour country [Portugal] this sector is still a nichemarket.”
US car sales set for boom
The fortunes of European tool and mould makersare also heavily dependent onwhat happens in theUS, the second-largest passenger vehiclemarket ofany country in the world. Sales of cars in the USare expected to peak at 18.2m in 2017, helped by jobgrowth, cheaper fuel, low interest rateswhichmakeloans more affordable and a greater availability ofcredit, according to IHS Automotive.Laurie Harbour is president and CEO of Harbour
Results, a research firm focussing on the globalautomotive industry. She expects to see an unprec-edented number of new vehicle launches between2017 and 2019, all of which will create demand fora much wider range of internal trim components,albeit in lower volumes than previously.“There are more models in the market than ever
but less volume across those models with lots ofmix but less volumes,” said Harbour, ”That is goodfor the tool industry because they have to makemore components so it is going to be specific tothose people thatmake something customer inter-facing an instrument or door panels, consoles,headlamps, fascias, that type of thing. If I do un-
derbody components or black plastic or things thatare not visible to the consumer, youmight see thatspread across more platforms, more componentsand more years.”Harbour estimates that up to 80% of the compa-
nies thatmake tools for Volkswagen, Mercedes andBMW cars sold in the US are based in either Ger-many or China.“With the market being so positive going for-
wards in terms of lots of European and Japanese[new car] launches here in NorthAmerica becausethey are building these plants inMexico, the outlookfor people making tools will be very strong for thenext 18 to 24 months,” she said.A sustained economic recovery seems likely to
boost US car sales further between 2017 and 2020.There are potential stumbling blocks ahead how-ever, particularly if interest rates rise whilst expen-sive technology required to meet new more strin-gent emissions and fuel economy standards in themight also increase vehicle costs and impact sales.“Data shows that the US consumer spend is slow-
ing andwe have a controversial election in Novem-ber,” predicted Harbour. “If it is a Clinton adminis-tration the expectation is that the current statusquo will continue, if its Trump there might be adrop in car sales which could take a couple of mil-lion units out of themarket, and that could be verytroubling to OEMs.”The big question is the extent to which slowing
or flat automotive sales growth in China, Europeand elsewhere will be offset by growth in otheremergingmarkets, and how carmanufacturers willreact – either by increasing or decreasing their pro-duction capacity.Whilst any slowdown in 2017 will undoubtedly
impact the bottom line of vehicle makers acrossthe globe, this will not necessarily affect salesof tooling in the near term as component manu-facturers invest to capitalise on future demandwhilst improving efficiency and increasing profit-ability. ETMM
INFOGlobal consultancyDeloitte estimatesthat by the end of2016 1,420 largecommercial aircraftwill have beenmanufactured, witha further 1,490expected in 2017.
document6135950974150230385.indd 22 15.11.2016 11:25:06
K 2016 SHOW REPORT
2312-2016
K goes 4.0 with more visitors -and buyers
The world's largest plastics and rubber trade fair in Düsseldorf ended on avery positive note. K 2016 showcased numerous innovations and develop-ments, with a focus on improved energy, resource and production efficiency.One topic, however, clearly dominated this year’s trade fair: Industry 4.0.
Impressions from K 2016. From 19 to26 October, the world’s leading plasticsprocessing companies, researchers andexperts came together in Düsseldorf.
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The 3,285 exhibitors from the fields of mechan-ical and plant engineering, materials andsemi-finished products and technical parts
presenting their product ranges at the trade fairwere met with considerable interest, with about230,000 industry visitors from over 160 countriesattending the show. These numbers were signifi-cantly higher than those of the previous event in2013, andmany exhibitors were able to convert thisinterest into tangible business deals. Ulrich Reifen-häuser, Chairman of K 2016’s Exhibitor AdvisoryBoard, was delighted: “Never before have I seen somany decisive customers willing to buy at a tradefair. The number and the amounts of the dealsclosed here, some of them very spontaneously, andthe numerous specific requests for new projectsgreatly exceeded our expectations." The successfultrade fair confirms the continued positive econom-ic outlook, with Europeanmachine and plantman-ufacturers expecting the plastic sector to grow by
1.8% and 2.0%, respectively in 2017 and 2018. Lu-cianoAncheschi, President of EUROMAP, is satisfiedwith the overall development: “Sales in our coun-tries increased from 9.3 to 13.5 billion euro between2005 and 2015.” Still, Europe lags behind, since inthe same period global sales in the industry in-creased by 83%.Many players in the plastics industry count on
the potential benefits of Industry 4.0 to remaincompetitive on the international market. Conse-quently, the topic of Industry 4.0was omnipresentat K 2016. Largemachine and plant manufacturersin particular showcased concrete results of Indus-try 4.0 implementations, like “smart” machines anduser interfaces, digital business platforms and“smart” products that for example are traceableover their entire lifecycle via QR codes.Furthermore, the plastic processing industry al-
so demonstrated increased interest in additivemanufacturing processes at K 2016.While 3D print-
Nadia Creutz
INFOK is the world'sleading triennialinternational tradefair for the plasticsand rubber indus-tries, held in Düs-seldorf. This year'sshow attracted230,000 visitors.
document7223859520134756836.indd 23 15.11.2016 11:12:19
12-201624
SHOW REPORT K 2016
ing in the past has been utilised primarily for pro-totyping, now it is also used for tool inserts, morecomplex component geometries, customised endproducts and small batch production – and thistrend will continue, as experts predict an increasein global sales in the 3D printing market fromaround €2.8bn in 2014 to around €8.7bn by 2020.
Industry 4.0 –the next growth driver?
Whilemany exhibitors showcased first Industry4.0 implementations, these provided only a glimpseof a much larger topic made up of many elements.The German Mechanical Engineering Association(VDMA) tried to provide an overview and dedicat-ed a whole pavilion to the topic of “Industry 4.0 -working for you”. One of its goals was to bring theabstract concept to life by presenting various prac-tical examples. In addition to discussions withrenowned representatives of various industries,the association also presented a "catch of the day"– products from different companies that specifi-cally demonstrated how Industry 4.0 canmake themanufacturing process more efficient and howproducts themselves can become "smart".PlasticsEurope, the plasticsmanufacturers' trade
association, dedicated a whole day of their specialexhibition “Plastics shape the future” to the topicof Industry 4.0. Attendees unanimously predicteddrastic changes in production processes and busi-ness models. Undoubtedly, networked productionwill lead to amassive increase in efficiency, whichwill benefit customers. However, increasing auto-mation through intelligent machines, robots and3D printers also has its risks: “Those whomiss outon this developmentwill go out of business," warnsDr. Dagmar Dirzus fromVDI/VDE. Also, the fact thatmanymanual tasksmay become redundant, whilenew areas of employment for specialists emerge,is a challenge politicians and the industry mustaddress together and in a timely manner.k-online.de
A focus on additivemanufacturing:“Touchpoint” 3Dprinting in Hall 4.
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www.etmm-online.com
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Like us onfacebook!
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document7223859520134756836.indd 24 15.11.2016 11:12:24
K 2016 SHOW REPORT
2512-2016
Expansion of award-winningvalve-gate technology
Nozzles – Expanding theaward-winning valve gatetechnology product line re-leased in 2015, Husky has nowpresented its Ultra Helix 350valve gate. This new series ofnozzles providesmore optionsfor creating a wider range ofapplications and to producebetter quality parts, the com-pany says.Husky conducted extensive
research to understand thefundamentals of valve gatedynamics, materials, wear andgate quality while developingthis nozzle. Coming as close aspossible to zero-gate vestigeperformance, Ultra Helix im-proves part quality.Additionally, Ultra Helix
nozzles build on the compa-ny’s track record of indus-try-leading thermal uniform-ity, which in turn virtuallyeliminates mechanical wear
on the valve stems and cavitysteel, Husky claims.“Husky’s Ultra Helix valve
gates have increased our con-fidence in hot runner valvegate moulding,” says CaseyMiller, senior tooling engineer,C&J Industries, an FDA-regis-tered Husky customer, focus-ing on the manufacture ofmedical devices. He adds, “Al-though other manufacturershave gates incorporated in thenozzle tips similar to the UltraHelix, we have not seen onethat has the valve stem withcontinuous guidance through-out the cycle.”In 2015, Husky won the
Ringier Technology InnovationAward for the development ofits Ultra Helix valve-gate tech-nology and its contribution toproduction efficiency and costeffectiveness.husky.ca
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The new series of nozzles issaid to provid customersmore options to producebetter quality parts.
Stand-alone, servo-driven valvegate hot runner solution
Valve-gate Systems – Italianhot runner specialist HRS-Flow premiered its newly de-veloped Flex-flow One, a ser-vo-driven valve gate systemfor hot runner nozzles at K.According to the company,
it workswithout a control unitand functions as a stand-alonesystem. For every hot runnernozzle in a multi-step setting,the needle stroke, position andvelocity can be fixed. The elec-trical drives of the valve pinsprecisely control themelt flowto allow the injection mould-ing of parts with high repro-ducible quality. These valuescan be individually set forevery nozzle of the hot runnersystem. The settings are savedin a drivermodule and assem-bled on the hot runner systemready for series production.Should the settings needchanging, this is easily done
with the device, ESI (ExternalSmart Interface), which is con-nected briefly to the drivermodule, HRS-Flow says.Themain benefit of this new
technology is the connectionwith the injection mouldingmachine, which provides thehot runner system with the24V-signal for opening/closingneedle. The process windowwith Flex-flow One is muchlarger for the variably adjust-able needle stroke that has arange of up to 18 mm. Thelow-maintenance electricalneedle valve works more pre-cisely. Without needing oil orwater, the system provides acleaner working environmentand is thus suitable for use inclean-room conditions. Otherapplications are in injec-tion-moulding machines andmoulds.hrsflow.com
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Freely selectableopening velocity of thevalve pins offers theability to optimise themould cavity filling.
Valve-pin velocity control optimises hot runner processes
Control – Among Incoe’s ex-hibits at K was its Soft-Gatevalve-pin velocity-controlwhich optimises processes inhot runner technology. Ac-cording to the company, in-stead of an abrupt opening ofthe valve gate nozzle, Soft-Gateallows continuous cross-sec-tion flow by opening and re-leasing the nozzle openingtime required for optimumquality to be set and thus en-sure reproducibly careful in-jection. As melt flow is con-trolled during cascade injec-tion moulding, all pressureand speed changes of themelt
during the process are bettercoordinated to avoid explosiveinjection and result in a con-tinuous melt stream.Soft-Gate is said to be us-
er-friendly and is operatedwithout further control tech-nology. Available in version 3.2,functions that are to be inte-grated into a process can beselected from amodular pack-age. It is used in many appli-cations: High surface quality,optimised melt flow or theenlargement of process win-dows, or direct HR injectionmoulding of sensitive films.incoe.de
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Incoe’s Soft-Gate valve-pin velocity-control is desiged for smart flow andprocess optimisation.
document8349076229747071206.indd 25 15.11.2016 11:12:47
SHOW REPORT K 2016
26 12-2016
Interaction in injection moulding processes ensures safety
Temperature Control – PSG'sgoal is to increase safety ininjectionmoulding processes.At K 2016 among the compa-ny's exhibits was its Profi-Temp+, which interacts withmachines or production partsto “understand each other”.Here, the standardisation ofdata interfaces is the key tolink the temperature controlsystem 4.0, PSG explains.Profi-Temp+ has a a variety
of data interfaces and protocolthat allow for connectivity tomachine controls, process con-trol systems or process datacollection systems to form the
basis for the temperature con-trol system 4.0. They access allprocesses and configurationparameters andmake the pro-cess clear. With its compactdesign, this system has a smallfootprint. The Smart PowerLimitation (SPL) function pre-vents the heating power re-quired by the heating outputsfor the control from exceedingthe available power. Profi-Temp+ measures the heatingcurrent that is required for theprocess to be carried out with-out interrupting the controland output of heating pulses.psg-online.de
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The profi-Temp+, designed for hot runner control 4.0 interacts withmachines or production parts to “mutually understand each other”.
Efficient, economical mould changes in small-series production
Components – Hasco’smouldsystem A8500/ is a variablequick-clamping system forinjection-mouldingmachines.Its standard components areintegrated in the clamping fix-ture to reduce costs with re-gard to the mould. The devicepermits reduced mouldchange-over times. Throughthe movable clamping bars,different-sized moulds can bechanged with minimal ma-chine downtimes.A8500/ is supplemented by
the K3600/ – a small seriesmould. It is a standard com-ponent package comprising
mould plates, ejector assemblyand associated components.Together, they have been de-signed for frequent mouldchanges in small-series pro-duction. The assembly can beexchanged easily on the ma-chine, allowing for minimalmachine downtimes. The useof predefined ejector assem-blies mean there is no reduc-tion in the usable plate sur-face. The mould plates comein materials 1.2767 and Toolox33. Hasco offers four standardmould sizes that are compati-ble with the K range.hasco.com
The A8500 + K3600 have been designed for frequent and rapid mouldchanges in small series production.
Smart moulds optimise overall cell performance
Mould Making –Milacron hasbeen showcasing its productsand services on two booths atthe recently held K show, fea-turingmultiple product brandtechnologies. The company’sdiverse portfolio covers themanufacture, distribution andservice of highly engineeredand customised systems, de-livery of equipment and ser-vice to customers throughoutthe entire lifecycle of theirsystems and an extensiveplastics portfolio covering run-ners, injection moulding, ex-trusion and blow moulding,equipment, controllers, mould
bases and premium fluids.Among many other exhibits,Mold-Masters was demon-strating a system that allowsinjection moulds to be made“aware”. The so-called Smart-Mold features sensors, strate-gically mounted in the hotrunner, generating telemetryfor use to track OEE, mainte-nance and potential issues viathe cloud or LAN. It then sendsand receives information fromother equipment in the workcell to optimise overall cellperformance. Drawings, set-upguides are then available.milacron.com
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Smart-Mold sends and receives information from other equipment in theworkcell to optimise overall cell performance.
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document4781518071207645624.indd 26 15.11.2016 11:13:49
K 2016 SHOW REPORT
2712-2016
Sustained strong demand forlightweight, functional packages
Maximum product protection with a minimum input of materials, decorativedesign and resource efficiency in production, storage and transport – therequirements are very diverse. K 2016 was a showcase for innovations indesign, production and applications.
The Germany recycle almost allhousehold packages, with more
than half (56%) being recycledrather than being inciner-
ated for the energycontent. About 20
years ago, the figurewas only 3%.
Barbara Schulz
Packaging of tomorrow is smart and geared tospecific target groups and convenience. Thatis what Germany's trade unions for themetal-
working, mining, chemical and energy industrieswrote about the packaging industry five years ago.And nothing of this will change in the coming years,either. For in its most recent report,“The Future ofGlobal Packaging to 2020”, Smithers Pira in Leath-erhead, UK, has again identified re-closable con-venience packages, extended shelf life, easy-openpackages and on-the-go packages as the outstand-ing trend themes of a sector that continues to showoverall growth. Theworldmarket will grow, Smith-ers Pira claims, by 3.5% from $839bn in 2015 to$998bn in 2020. Thismomentum in the packagingmarket is basically being driven by Asia but alsobyWestern and Eastern Europe, with growth beingstimulated among other things by advancing ur-banisation and sustainability.Packages are required in almost all sectors, but
the food industry enjoys high attention andmarketimportance within the packaging sector. In Euro-
pean countries alone, some 60% of foods still spoil,and this figure could be reduced significantly withappropriate packaging. What's more, according toa publication by packagingmarket researchers Ge-sellschaft für Verpackungsmarktforschung (GVM),product protection is always also climate protec-tion, which in turn is a subject of social relevance.The carbon footprint for the production of a newfood to replace one lost due to inadequate productprotection is usually much larger than that for theproduction of a suitable package that preventsspoilage.
Light weight as a perennial theme,recyclable design from the outset
The packaging sector continues to boom – andwithit the requirements it has to meet, its possibilitiesand the innovative solutions. Its sheer diversitycannot be covered exhaustively in a single article,so only a selection of topics and examples havebeen picked out in the followingwithout any claimto completeness..The weight of each package solution continues
to be important. A great deal has happened in thisarea in the last few years. The ideas and savingspotentials are many and varied: the omission ofpackage outers, flexible rather than rigid orsemi-rigid packages, new designs and the re-duction in wall thicknesses. From 1991 to2013, packages thus became 25% lighteroverall. In 2013 alone, 1 million tonnes ofplastics were saved worldwide as a re-sult of weight reduction, despite thegrowing expectations required onfunctionality.Growing in prominence, as it is
demanded increasingly by legisla-tors as well as by consumers, is re-source conservation. Closely associ-ated with this is the scope for pack-age recycling. In Germany today,almost all household packages arereutilised, withmore than half (56%)being recycled rather than being in-cinerated for the energy content. About20 years ago, the figure was only 3%. Inthe case of PET bottles, the rate is much
better, with 98% undergoing material re-covery and being returned to the production
cycle. Consequently, each new bottle producedtoday contains about 25% regranulate.k-online.de
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28 12-2016
5-axis machining centre reducesproduction time by 75%
Machining tool steel die nests is a complex operation at the best of times.A particularly intricate job used to be a loss-making operation for a UK-based toolmaking firm. But now the purchase of a 5-axis machine is saidto save enough time to make the process profitable.
Close-up of Op 2 in progresson a P20 tool steel die nest.
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Toolmaking and subcontract CNC machiningspecialist DSM-NE has increased its stock ofHurco machining centres to seven, including
a large three-axis model and a 5-axis machine.One job in particular is said to have benefited
from the arrival of the bigger machining centre. Atool steel (P20) die nest, part of a progressionmould-ing machine, initially took 75 hours to machine insix separate set-ups on a Hurco three-axis model(although, according to DSM-NE’s technical directorAndrew Wilson, the cycle would have reduced to50 hours after process optimisation).The same job is now claimed to take a Hurco
VMX60SRTi 5-axismachine two operations of five
hours and eight hours respectively. This is aroundone-quarter of the best possible time on a 3-axismachine and has turned what was originally aloss-making contract into profit.Mr Wilson explained, “We looked first at fitting
a 2-axis compound rotary table to a 3-axismachinebecause nobody here had experience of operatinga full 5-axis machining centre.“However, we saw the VMX60SRTi demonstrat-
ed at a Hurco open house in High Wycombe lastyear and were impressed at how easy it is to pro-gram.We were familiar with the 2D programmingcapability of Hurco’sWinMAX conversational CNCsystem, but it can also create quite complex 3D /
Chris Wright
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MACHINE TOOLS PRODUCT FOCUS
2912-2016
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Hurco5-axis routines involving two positional axes, which
takes only a few days to master.”For fully interpolative 5-axis cycles, DSM-NE em-
ploys two seats of Delcam’s Powermill, which arealso used for producing more complex three-axisroutines. However, half of all programs at NewtonAycliffe are generated on the shop floor at the Hur-coWinMAX controls.
Software to accept DXF drawing filesdirectly
They are said to allow intuitive, menu-driven datainput via a touch screen, with a second screen onthe 5-axis machine for simultaneously displayinga graphic of the part as it is built up. All controlsare claimed to accept DXF drawing files directlyfrom the subcontractor’s CAD system, lighteningthe load on the CAMdepartment. Apparently,Win-MAX can also easily take over programming ofmould plates, for example. MrWilson pointed outthat with most other control systems, this wouldnot be possible.Technical manager Steven Guz highlighted an-
other benefit of the Win-Max control, namely itsUltimotion software algorithm that is said to opti-mise look-ahead throughout the cycle to speed andsmooth the milling process, even around sharpcorners.He said, “Identical programs on our older Hurco
machining centres without Ultimotion take half aslong again to finish and the absence of chatter con-siderably improves the surface finish of machinedcomponents.Today, DSM-NE’s business is divided into three
parts: subcontract CNC machining; manufactureand repair of plastic injection moulds and com-pression moulds, particularly for the automotiveindustry; and injectionmoulding of plastic partsmainly for the automotive, medical and ag-ricultural sectors.The subcontract milling, turning
andwire erosion side of the busi-
Andrew Wilson (right) andSteven Guz, TechnicalDirector and TechnicalManager respectively ofDSM-NE.
ness has grown steadily since 2011 to account forone-third of turnover. It is largely down to the suc-cess of one of the subcontractor’s OEM customersspecialising in LED lighting, for which DSM-NE issole supplier of machined aluminium housings andheat sinks. Other contract machining on site in-volves producing ancillary parts for customers’moulding machines. Offshore work normally ac-counts for a reasonable proportion of turnover,although that sector is subdued at present.
Expansion of 5-axis machiningenvisaged
The broad base of the firm’s current activities stemsfrom the outflow of toolmaking mainly to the FarEast during the last decade. It is true that significantincome was retained by correcting poorly made
imported tools, work that sometimes costhalf asmuch as the originals, but it wasclear that this could not be relied uponlong-term.Shortly after the company moved
into its current premises on theAycliffeBusiness Park 20 years ago, the first Hur-co vertical machining centre (VMC) waspurchased, a VM1, which replaced a man-
ual-tool-change milling machine from thesame manufacturer. A larger BMC 4020 VMC
followed quickly.Looking to the future, he sees growth opportu-
nities in full 5-axismachining. TheVMX60SRTi hasalready taken over three-axis work from other ver-tical machining centres, which it completes moreeconomically using 3+1 and 3+2-axis cycles in few-er set-ups.Contracts are being sought that can exploit its
simultaneous 4-axis and 5-axis machining capa-bilities, which is enhanced by the B-axis spindlehead and rotary C-axis configuration, the latterbeing flush with the machine table. The arrange-ment offers a bigger machining envelope than anequivalent trunnion-type, 5-axismodel, especiallyfor 3- and 4-axis work, and was said to be the rea-son for the purchase of this type of machine.hurco.eu
Two die nests after completionof Op 1.
Source: H
urco
document847459798664251334.indd 29 15.11.2016 11:14:58
PRODUCT FOCUS CUTTING TOOLS
30 12-2016
Supporting bearing designs withadvanced machining solutions
Bearings are necessary for almost any mechanical system and other itemsthat require rotational motion. Iscar provides comprehensive solutions forbearings applications with efficient tools for parting, trepanning, grooving,profiling and turning operations, the company explains.
Iscar’s turning divisionprovides a large variety oflatest geometries andcarbide grades as well asceramic and CBN insertsfor finish turning opera-tions of hardened bearingrings up to 64 HRc.
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Barbara Schulz
If something, turns, twists ormoves, it most like-ly has a bearing in it. While the most popularbearing type in the market is the ball bearing,
roller bearings, needle, tapered, spherical and thrustbearings are also common. Bearings range in sizefrom very small diameters such as 2 mm for elec-tronic systems up to diameters of 6000mmmost-ly for wind-power turbines.When it comes to bearings, one of the most de-
manding industries today is the automotive indus-try. Every car has an average of 100-150 bearings,while motorcycles have between 25-30. With anannual production rate of over 93 million cars and140 million motorcycles a year, the demand forbearings is higher than ever and continues to rise.The need for bearings is also increasing in other
industrial sectors such as machine production,electrical appliances, construction and infrastruc-ture machinery, aviation and power generation.According to Iscar, its experienced engineers arecapable of supporting any bearing designwith ad-vancedmachining solutions that can ensure max-imum performance, efficiency and precision.Many Iscar inserts are designed as multi-corner
inserts, such as the Penta, and feature economicadvantages due to their five cutting edges, the com-pany says. These inserts are mostly used for part-ing-off operations, seal groovemachining and race-way grooving. The unique structure of the Pentainserts enable grinding unlimited numbers of dif-ferent shapes and geometries with a very attractivecost per edge, so helping customers to reduce pro-duction costs and increase competitiveness.
Inserts with five cutting edges can beused for trepanning, parting-off
Penta inserts can also be used for trepanning, anaxial operation for the separation of one thick forgedring into two separate outer and inner rings. Forsuch operations, Iscar also offers other types ofinserts such as BGR and BGMR for wider rings thatdictate deep separation operations.Iscar has also developed multi-parting systems
for customers that feature an assembled set of part-ing blades or adapters designed for parting a fewrings at a time. Such sets are provided with theTang-Grip and Do-Grip inserts, and also with thePenta inserts. Such parting systems dramaticallyshorten one of the most common operations inbearings production.Iscar’s unique parting-off products are provided
in very narrow sizes that enable manufacturers tosignificantly reduce the width of inserts, down to0.7 and 1.0 mm, therefore saving on rawmaterials,savings that help produce up to 15%more rings outof existing steel tubes, the company explains.For finish-turning operations of hardened bearing
rings up to 64 HRc, the company’s turning divisionprovides a large variety of the latest geometries andcarbide grades as well as ceramic and CBN inserts.CBN inserts with chipformers are Iscar's ultimatesolution for such operations and can easily replaceexpensive grinding processes.Wide-profiling operations on multi-spindle ma-
chines can be addressed with Iscar’s V-Lock andFTB inserts that provide a solution for wide profilesof 10 up to 51 mmwidth.iscar.com
document9042464722029924842.indd 30 15.11.2016 11:15:19
CASE STUDY PRODUCT FOCUS
3112-2016
Cutting tools a key factor forunmanned lights-out production
Mitsubishi Materials provided the tooling and expertise that enabled For-magrind, an ISO9001 company with 26 employees based the UK to fulfil achallenging automotive machining contract. Software and cutting toolswere among the key factors for lights-out production.
A 0.5mm diameter toolmachining apertureson base plates.
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Rhys Williams
Formagrind, whichwas established in 1983, hasbeen operating from a 1,000 m² factory sinceOctober 2015. Its equipment includes two new
HurcoVMX30Mimachines, in addition to its Mazak,Hardinge and Gildermeister turning centres, HurcoVMCs and Sodick EDMs. It also has three i-Machin-ing CAM software seats.Formagrind initially trialled Mitsubishi’s face
mills, then implemented the Alimaster aluminiumroughing end mill range on a long-term satelliteproject that had “brutal” material removal rates.The success of the face mills and the Alimastercutters gave the company complete confidence inboth Mitsubishi tools and the local engineer.
Machining hard-to-cut materials
The company machines molybdenum, titanium,Inconel and other hard-to-cut materials. It is nowa consignment stock customer and has had anAutocrib vending system since April 2016. It hasalso made use of Mitsubishi’s expertise in settingof performance parameters and structures.In February 2015 it received an order for over 100
complex titanium fixtures, each consisting of acarrier base and corresponding top plates thatclamp electronic PCBs assemblies during their pro-duction and final assembly processes. They wererequired in a batch size of 105 bases and 160 coverplates. With over 14 hours of machining for each
base and 110 minutes for each cover plate, For-magrind needed to run its new Hurco VMX30Mimachines 24 hours a day, seven days a week, foralmost two months. With i-Machining optimisingthe process, the key factor for lights-out productionwas the cutting tools; Mitsubishi’s solid carbideend mills were selected.Formagrind developed a fixture to clamp and
process two 300 mm by 200 mm by 9.5 mm baseplates at a time. The grade 2 titanium plates arefirst machinedwith an 8mmdiameter solid carbidefour fluteVQ Series endmill at 4.5 mmdepth, witha 1.2 mm step-over and a feed rate of 1400mm/min.After almost two hours, a 4 mm and a 3mmdiam-eter VQ end mill final details. Two, 3.5 and 4 mmdiameter VQ end mills are used for rough and fin-ishmachining pockets that have already beenwa-terjet cut. A 0.5 mm diameter MS2-SLB end millhandles fine details. Total machining time is ninehours for the top face. Formagrind changes the toolsafter each pair of bases; wear is hardly noticeable,even after 14 hours of machining.
Tool life is an essential aspect ofunmanned production runs
"We consulted with Mitsubishi at the very start ofthe project and they recommended the VQ endmills for the majority of base plate operations. Forus, the ability to confidently run unmanned forprolonged periods was crucial," says Formagrind'sshop floor manager, Mike John. "Tool life is an es-sential aspect of this."Formagrind created a fixture to machine 10 of
the smaller guide clamps in a single set-up. Thefirst stage takes over 110 minutes with a 6 mmdiameter VQ Series end mill at 4.5 mm depth andis followed by 3, 3.5 and 4 mm diameter VQ endmills for other machining and pocket milling. A 2mm diameter VFH long neck series with 0.5 mmradius and variable helix provides detail finishing.The 3.5 mm VQ end mill has a run-time of 55
minutes and hasn't been changed through the com-plete project, demonstrating life of 550minutes, ontitanium. The 6 mm roughing tool has conducted4.5 mm deep roughing throughout the completebatch, returning over 20 hours of machining.The final base plates and top plate covers have
now been delivered, after total machining time of2400 hours. The customer is moving to the nextgeneration electrical assembly and Formagrindwillagain be providing the clamping bases and guides.mitsibushicarbide.com
document8885066669519846770.indd 31 15.11.2016 11:15:53
PRODUCT FOCUS HOT RUNNERS
32 12-2016
Hot runners to the fore in production ofwriting instruments
For 70 years, Wernigerode-based company Schneider has been producinghigh-quality writing instruments. The company’s continued success today,which includes the production of 80 million ink cartridge cases each year,involves systems from Günther Hot-Runner Technology.
For 70 years, Schneiderhas been producinghigh-quality writinginstruments. Today, thecompany produces 80million ink cartridgecases each year.
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Schneider can look back on a 70-year history toits founding as Heiko Schreib- undZeichengeräte in 1946. Following German uni-
fication the company was taken over by the firmof Schneider Schreibgeräte in Tennenbronn in 1991and founded a new company with 56 employeesunder the name of Schneider GmbH Co. Produc-tions- and Vertriebs KG.Today Schneider has a staff of 135 employees and
a production floor space of 8,700 m², producingwriting products that are sent all over the world.Its injection moulding department comprises 28injection moulding machines and there are otherdepartments for assembly, printing and design aswell as a tool shop. The company places a highdegree of value on providing its own training forits future employees. As a rule, all apprentices aregiven employment in the company at the end oftheir apprenticeship.Hot runner systems were first used in the injec-
tion moulds in the year 1994 with the goal of in-creasing production capacity. The first hot-runnersystem for indirect injection in a 72-cavity produc-tionmould for ink cartridge casesmade it possibleto triple production capacity. Today over 80millionink cartridge cases are produced each year, the car-tridge cases also filled, sealed with glass balls andthen packed at Schneider.
Working with the firm of Günther Hot RunnerTechnology from Frankenberg (Eder) in North Hes-se, Germany, Schneider was able to reduce mate-rial consumption by eliminating thick-walled gat-ing systems which also significantly reduced thecycle time because of the shorter cooling time.In a next step the moulds were equipped with
an even greater number of cavities and with morehot-runner technology. Open hot runner nozzleswith a two-part shaft and naturally balancedman-ifolds are used. The gating is done with a subrun-ner, which ensures the cores’ position stability. Thetwo-part nozzle shaft made of titanium alloy andtool steel allows, in a confined installation space incombination with the integrated air gap in the hotrunner nozzle, a very good thermal separation be-tween the hot runner and the temperature-con-trolled mould.
Reduced cycle times, optimisedenergy input
Using Günther hot runner technology Blue Flownozzlesmeant that the cycle time could be reducedby a further 4 seconds. These nozzles have specialthick-film heating elements with 55% of the ener-gy in the area of the tip. This reduces the requiredtemperature input into the melt.Environment-friendly production with savings
in energy and resources is a strategic goal for Sch-neider. This has been proven by repeated EMAScertification since 1998. The use of hot-runner sys-tems is an important element in reducing theamount of plastics required in the process. In ad-dition, the Blue Flow nozzles in combination withthe two-part shaft need significantly less energyand help meet the requirements of EMAS certifi-cation.The production of ink cartridges is just one part
of the product manufacture at Schneider; otherbusiness units comprise the production ofhigh-quality pens and text highlighters. Multi-com-ponent injection moulding is increasingly used inthe production of these parts. In themulti-compo-nent injectionmoulding variousmaterials are com-bined together in the injection mould.As a rule, a lot of new articles have a softer, er-
gonomic gripping area made of an elastomer suchas TPE or TPU and a harder basic bodymade of PE,PP or ABS plastics. Up to 16 different colour com-binations are produced for individual writing in-strument series. The range of coloursmakes it nec-essary for the hot runner system to have good
Barbara Schulz
document6751938751803759355.indd 32 15.11.2016 11:16:41
12-2016 33
HOT RUNNERS PRODUCT FOCUS
colour changing properties to allow a very rapidchange from one colour to another during produc-tion. Likewise, as the colour batches are tempera-ture-sensitive during processing they require ahomogeneous development of temperature overthe entire melt channel in the hot runner systemwithout temperature peaks.The company’smarketing and sales departments
place an increasing focus on surfaces, contours andthe visibility of the products. This requires moreuse of valve-gate hot-runner systems. For the newSchneider “One“ series of ink pens both Blue Flownozzle types - 6NHF100LA-1.0S and 5NHF-100VA-0.8S - are used in the 2-C injectionmouldingprocess. To ensure that the needles open and closethe injection points precisely and evenly, the pneu-matic version of a lifting plate is used as a drive.These lifting plates aremoved by the correspondingquantity of cylinders and equipped with specialguide elements to allow operation with processreliability.To guide the coated needles in the valve-gate
nozzles, needle guides made of powder metallur-gical steel are used close to the gate. This ensuresa long service life. The valve-gate hot-runner sys-temwas delivered as a hot half completely assem-bled and wired by Günther.schneiderpen.de, guenther-heisskanal.de
Peter Witteweg (opera-tions manager) withFabian Voigtländer(design department atSchneider) and GüntherHot-Runner Technologytechnical adviser Chris-toph Deutschmann (l-r).
Wolfgang Lutz (head ofmould making) and PeterWitteweg (operationsmanager) talking toGünther Hot-RunnerTechnology technicaladviser ChristophDeutschmann (l-r).
Sou
rce:
Gün
ther/Sch
neider
Sou
rce:
Gün
ther/Sch
neider
Your specialist forSolid carbide tools
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INOVATOOLS Eckerle & Ertel GmbHD-85125 Kinding-HaunstettenIm Hüttental 3-6T l 49 (0)8467/8400 0Tel. +49 (0)8467/8400-0www.inovatools.eu
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document6751938751803759355.indd 33 15.11.2016 11:16:43
PRODUCT FOCUS ADDITIVE MANUFACTURING
34 12-2016
Additive manufacturing growing fasttowards industrial series production
Additive manufacturing is booming with worldwide sales in 2016 forecastto increase by around 30% to more than US$7bn. An industry pioneer isConcept Laser of Lichtenfels, Germany. The company continues to lead today,now with its vision of the “AM Factory of Tomorrow”.
Example of a part from the aviation industry:New design and lightweight constructionmeet serial character. The illustration showsan additively manufactured part (bottom)compared to a conventional part (top).
Sou
rce:
Airb
us
Astudy conducted by the international man-agement consultancy Bain & Company reck-ons that annual growth rates of more than
30% will continue to be achieved and the marketwill grow to around US$12bn by 2018.The AM option will always be the right solution
whenever the additively constructed part will bebetter, more powerful, availablemore quickly, light-er and/or cheaper. From the point of view of indus-try, build rates are probably the most importantcriterion when it comes to assessing economicefficiency and these limits are continuously shift-ing upwards thanks to technological progress.The move to an adaption phase for additive
methods can be seen as the first step toward in-dustrial series production. Freedom of geometryand the potential for lightweight construction,functional integration, production on demand, time
and cost savings and considerations in relation toresource-saving and sustainable production all playa substantial role here.The expectations placed on AM continue to rise.
What answers are the machinery and plant man-ufacturers offering in the medium term?Larger build envelopes? The X line 2000Rwith 2
x 1,000Whaswhat is currently theworld’s largestbuild envelope for the powder-bed-based lasermelting of metals (800 x 400 x 500 mm3). Evenlarger build envelopes are conceivable.More powerful laser sources? There is eager an-
ticipation here to seewhere technical progress willlead, but this route alone will not be the preferredchoice.Higher build rates? There is definitely one ap-
proach here that can be implemented quickly. Thekey concept is multilaser technology. However,
Oliver Edelmann, VicePresident Global Sales &Marketing, Dr FlorianBechmann, Head of R&D,Oliver Kaczmarzik,Technical ProductManager (Concept Laser)
document4286884633633476556.indd 34 15.11.2016 11:17:41
ADDITIVE MANUFACTURING PRODUCT FOCUS
multiple laser sources must be used skillfully toensure that there are no curtailments to the qual-ity of the parts.Current machines and installations are “island
solutions”. They operate as stand-alone solutionswithout really being integrated into the operation-al manufacturing environment. The machines arenot interlinked either with each other or with up-stream and downstreammanufacturing processes.They can only communicate to a limited extentwithin the digital process chain extending fromdesign through to fabrication. In this form they arenot suitable for the industrial series production ofthe future. The consistent automation of manualprocesses is still missing and it appears there is stillsomeway to go to achieve the objectives of Indus-try 4.0 in the guise of a smart factory.
What requirements does seriesproduction place on industry?
The problems that the existing stand-alone ma-chine solutions present for series production arebeing overcome at Concept Laser with a new ma-chine architecture. To this end, an initial separationof production and handling processes is takingplace by the creation of two physically separateareas. In addition, automated powdermanagementand the automation of other processes which havepreviously beenmanual enables the downtimes ofthe past to be reduced to a minimum.The new machine architecture is characterised
essentially by decoupling “pre-production”, “pro-duction” and “post-production”. The objective hereis to coordinate the process components in amoretargeted way with interfaces and to increase theflexibility of the process design to create an inte-grated approach. This becomes possible thanks toa consistentmodular structure of handling stationsand build and process units which, in terms ofcombination and interlinking, promises consider-ably greater flexibility and availabilities.
In addition, the laser power per square meter ofspace used is increased seven-fold. Dr Florian Bech-mann, Head of R&D at Concept Laser: “The buildrates have increased enormously thanks to themultilaser technology. The build envelope sizeshave also experienced considerable growth. Wenow want to use an integrated machine conceptto highlight the possible ways that the approachesof Industry 4.0 can change additivemanufacturingas the manufacturing strategy of the future. Thereis potential here to increase industrial added valueand enhance suitability for series production.”The new handling station has an integrated siev-
ing station and powder management. Unpacking,preparations for the next build job and sieving takeplace in a self-contained systemwithout the oper-ator coming into contact with the powder.The process station has a build envelope meas-
uring 400 x 400 x >400mm³. Laser sources, processgasmanagement and filter technology are integrat-ed in the module; the layer thicknesses are in theusual range.Conventionally, thematerial store, the processing
unit and the collecting unit for the excess materialhave been firmly connected together. The result ofthis is that, for example, if new powder is supplied,
INFOThe patented Laser Cusing processfrom Concept Laser is used tocreate high-precision mechanicallyand thermally resilient metallic com-ponents. The term "Laser Cusing,"coined from the "C" in ConceptLaser and the word "Fusing", de-scribes the technology: The fusingprocess generates componentslayer-by-layer using 3D CAD data.In this process, fine metal powder is
melted locally by a high-energy fibrelaser. The material solidifies aftercooling. The contour of the compo-nent is created by redirecting thelaser beam using a mirror redirec-tion unit (scanner). The part is builtup layer by layer (with a layer thick-ness of 15 – 500 μm) by loweringthe bottom of the build chamber,applying more powder and thenmelting again.
www.mastip.com
Your Partner in Technical MouldingMastip is a leading supplier of hot runner solutions to theglobal plastics injection moulding industry. Our extensive globalnetwork provides you with service and support throughout thelife cycle of the hot runner. This means you can be confidentthat spares and technical support is always available.
Contact us today for a solution designed specificallyfor your application.
See our website for our Global Network contacts.
document4286884633633476556.indd 35 15.11.2016 11:17:42
PRODUCT FOCUS ADDITIVE MANUFACTURING
36 12-2016
the build process has to be interrupted, which inturn leads to downtime.The new approach now envisages these three
sections being separated into individual modules,independent of one another and individually con-trolled. Themodules aremoved via a tunnel systeminside the process or handling station. This meansfor example that, when new powder is supplied,the empty powder storage module can automati-cally be replaced by a new module immediatelywithout the build process necessarily needing tobe interrupted. Finished build jobs can now alsobe moved out of the machine with the dedicatedmodule and replaced directly with a new preparedbuildmodule so that production operations can beresumed again immediately.In order to control and monitor machine com-
ponents and the flow of data, a software architec-
ture has been designed by Concept Laser whichcombines MDL (machine data logging) with ODA(operating data acquisition) and at the same timeorganises the flow of data in the complete digitalprocess chain.The integrated tool is intended to offer additive
manufacturing workers clear process monitoring,active process design and automation right throughto part documentation in one fell swoop. At thesame time, CLWRX 3.0 offers interfaces for incom-ing CLS data, automation tasks and links to thecompany's ERP systems.
Transparent process monitoring withnew software architecture
The CLWRX 3.0 software platform enables opera-tor-specific, transparent control andmonitoring ofall process operations. In addition, it is an openstructure with interfaces to CLS, ERP, machinetechnology and automation technology. The inten-tion is that the system should also be able to inte-grate remote diagnosis, service monitoring andlater also diagnostic devices. Another very impor-tant factor is the wide range of different outputmedia such as panels, PCs, laptops, and smart-phones that an employee can use to stay on top ofthings.The newmachine architecturemakes it possible
to link machines together flexibly, while automa-tion provides considerable time and cost savingswhich ensure the necessary level of economic ef-ficiency in series production.The main focus of this approach is not on a fur-
ther increase in the number of laser sources or evenmore powerful lasers, but on addressing the auto-mation and interlinking of machines that has pre-viously been lacking.The AM Factory of Tomorrow will be a smart
factorywithin themeaning of the basic idea of theIndustry 4.0 concept and the smar factor will ena-ble series production of metallic parts in an eco-nomically viable way.concept-laser.de
“AM Factory of Tomorrow” from Concept Laserfor industrial series production.
Linking together the “AMFactory of Tomorrow”:The “smart factory” is aflexibly expandable, high-grade automated andcentrally controllablemeta production systemwhich is focused fully onthe production assign-ments in hand and aimsto deliver industrial seriesproduction.
Sou
rce:
Con
cept
Laser
Sou
rce:
Con
cept
Laser
document4286884633633476556.indd 36 15.11.2016 11:17:47
CASE STUDY PRODUCT FOCUS
3712-2016
On-machine measurements cut leadtimes, improve accuracy
The production of high-quality aluminium extrusion tools is an art untoitself. Through the introduction of of laser measurement and touch probesin its machining centres, an Italian toolmaker has significantly reducedmachining time while at the same time improving accuracy.
The Alumat engineerswith an aluminiumextrusion tool.
Sou
rce:
Blum
INFOAlumat was found-ed in Ciserano nearBergamo in Italy in1994. It employsabout fifty staff inthe design andmanufacture ofsteel dies for alu-minium extrusion.
Rhys Williams
Competence, passion and know-how are attrib-utes that account for the international successof the Alumat-Almax-Matrex Group. Thanks
to continuous investment in research, developmentand cutting-edge facilities, as well as the selectionof the right partners, the enterprise has become apioneering manufacturer of aluminium extrusiontools in the international marketplace.Alumat was founded in Ciserano near Bergamo
in Italy in 1994. It employs about fifty staff in thedesign andmanufacture of steel dies for aluminiumextrusion. The continuous growth led to an expan-sion of the business resulting in increased produc-tion capacity and a tripling of sales within 4 years.“The special thing about our activities is the fact
that our tools are essentially individual items cre-ated specifically for our customers. Not only dowesupply individual dies, but also the entire planningand validation of the product," says Emanuele As-tolfi, manager at Alumat.“Reducing lead times has become a fundamental
component of our strategy. It is what differentiatesus from our competitors. From planning to com-pletion, a tool will undergo up to 15 productionsteps that we currently realise in about six daysThis took us as many as 15 days some ten yearsago.”
This improvement required the deliberate use ofmachining centres and the attempt to optimise allprocesses. The company looked for systems thatwould avoid any down time and facilitate ma-chine-integrated quality control. In addition, thesystems had to allow direct access during eachproduction phase, in order to correct any deviationsimmediately. Then, six years ago, Alumat decidedto confide in the technology and professionalismof BlumNovotest. Since then, themachining centreshave been equipped with Blum systems that bothcheck workpiece position, dimensions and alsomonitor the tools. These instruments soon facili-tated the achievement of the desired quality levelwhile delivering reduced lead-times.
Blum TC50 touch probes forworkpiece measurement
Today all operations of the company use the BlumLaser Control system for contactlessmeasuring andmonitoring of the cutting tools. In many machinetools, the Z-MTType tool setting probes ensure thehigh level of production quality.The robust measuring systems ensure exact po-
sitioning of the workpiece. The system automati-cally corrects the thermal expansion of themachinewhilst the impressive probing speed of threemetresper minute provides the speed to accompany theprecision. As with all Blum probes, the systemswork with a wear-free optoelectronic measuringmechanism that facilitates the precise acquisitionof all measured data even under strong coolantinfluence.TheMicro-Compact NT andMini NT lasermeas-
uring instruments allow reliable, contactless toolchecking andmeasurement despite the interferenceof coolant and chips. This is warranted by the com-bination of the patented NT technology that has aprotection system for the laser optics and also blow-ing nozzles for tool cleaning. Thanks to a focussedlaser beam, the system additionally impresseswithits particularly high measuring accuracy even be-low nominal speed. This is conducted 24 hours aday and seven days a week.“The Blum-Novotest products have definitely
proven themselves in recent years. This is whywedecided to gradually replace the systems from oth-er manufactures. Our Blummeasuring technologyfacilitates precise, reliable and competitive produc-tion. The customer service provided to us alsoplayed a decisive part.,” concludes Astolfi.blum-novotest.com
document7358421493101194574.indd 37 15.11.2016 11:17:59
SUPPLIERS DIRECTORY
38 12-2016
Quick Sourcing Grid:Hot Runner Systems,Components & Supplies
Adonpag
e
Hea
tingElemen
ts
HotHalve
s,Fully
Wire
d
HotRun
ner
Compone
nts
HotRun
ner
Man
ifolds
Company | Contact
Mastip Technology Ltd., Auckland, NZ | www.mastip.com 35
Türk+Hillinger GmbH, Tuttlingen, D | www.tuerk-hillinger.de 5
Dalton Electric Heating Co. Inc., Ipswich, USA | www.daltonelectric.com
DME Europe, Mechelen, BE | www.dmeeu.com
Dongsan Bearing Corporation, Namdong-gu, Incheon, KR | www.dongsanbearing.com
Ewikon Heißkanalsysteme GmbH, Frankenberg (Eder), D | www.ewikon.com
Friedrich Freek GmbH, Menden (Sauerland), D | www.freek.de
Gammaflux Europe GmbH, Wiesbaden, D | www.Gammaflux.de
Günther Heißkanaltechnik GmbH, Frankenberg (Eder), D | www.guenther-hotrunner.com
Guzzini Engineering, Recanati (MC), IT | www.guzziniengineering.com
Hales Tool & Die Ltd. Unit 14, Maldon, Essex, UK | www.halesmastip.co.uk
Hasco Hasenclever GmbH + Co KG, Lüdenscheid, D | www.hasco.com
Heitec Heisskanaltechnik GmbH, Burgwald, D | www.heitec.com
Hotset Heizpatronen- und Zubehör GmbH, Lüdenscheid, D | www.hotset.de
Hotsys Co. Ltd., Ansan, Gyeonggi-Do, KR | www.hotsys.co.kr
HRSflow, member of INglass, San Polo di Piave (TV), IT | www.hrsflow.com
Husky Injection Molding Systems Ltd, Bolton, ON, CA | www.husky.ca
Husky Injection Molding Systems S.A., Dudelange, LU | www.husky.ca
I-mold GmbH & Co. KG, Michelstadt, D | www.i-mold.com
Imtech Design Ltd., Chislehurst, Kent, UK | www.imtechdesign.com
Incoe International Europe, Rödermark, D | www.incoe.de
Kunststofftechnik Glittenberg GmbH, Frankenberg, D | www.glittenberg-gmbh.de
Männer Solutions for Plastics, Bahlingen am Kaiserstuhl, D | www.maenner-group.com
Master Flow AB, Västervik, SE | www.masterflow.se
MHS Heisskanaltechnik GmbH, Würzburg, D | www.mhs-hotrunners.com
MHS – Mold Hotrunner Solutions Inc., Georgetown, CA | www.moldhotrunnersolutions.com
MHT Mold & Hotrunner Technology AG, Hochheim am Main, D | www.mht-ag.de
Mold Masters Europa GmbH, Baden-Baden, D | www.moldmasters.com
Pedrotti S.p.A., Gavardo (BS), IT | www.pedrotti.it
Protool AG, Wynau, CH | www.protool-ltd.ch
PSG Plastic Service GmbH, Mannheim, D | www.psg-online.de
Sise, Oyonnax, FR | www.sise.fr
Strack Norma GmbH & Co. KG, Lüdenscheid, D | www.strack.de
Suma Consulting, Kaltbrunn, CH | www.suma.ch
Synventive Molding Solutions GmbH, Bensheim, D | www.synventive-europe.com
Thermodyne SIPA Div., Vittorio Veneto (TV), IT | www.sipa.it
Thermoplay S.p.A., Pont Saint Martin, IT | www.thermoplay.com
Tirad s.r.o., Zeletava, CZ | www.tirad.cz
Witosa GmbH, Frankenberg (Eder), D | www.witosa.de
document6411097968002295916.indd 38 15.11.2016 11:18:21
SUPPLIERS DIRECTORY
3912-2016
HotRun
nerPort
Plugs/Sea
ls
HotRun
ner
Sys
tems
HotSprue
Bus
hing
s
Melt-Man
agem
ent
Produc
ts
Nozzles
Run
ner-Balan
cing
Produc
ts
Stack
Mould
HotRun
ners
Temperature
Controls
Tip
Hea
ter
Produc
ts
ValveGate
Controlle
rs
ValveGate
Seq
uenc
ers
document6411097968002295916.indd 39 15.11.2016 11:18:21
SUPPLIERS DIRECTORY
40 12-2016
Quick Sourcing Grid:Machine Tools
Boring
Mac
hine
s
Drilling
Mac
hine
s
Company | Contact
Anca Europe GmbH, Weinheim, D | www.anca.com
Breton, SpA, Castello di Godego, IT | www.breton.it
Colchester Lathe Co., Heckmondwike, W Yorks, UK | www.colchester.co.uk
DMG Mori AG, Winterthur, CH | www.dmgmori.com
Emco Maier Ges.m.b.H., Hallein, AT | www.emco.at
Ewag AG, Etziken, CH | www.ewag.com
Exeron GmbH, Oberndorf am Neckar, D | www.exeron.de
F. Zimmermann GmbH, Neuhausen auf den Fildern, D | www.f-zimmermann.com
Fehlmann Maschinenfabrik AG, Seon, CH | www.fehlmann.com
Fidia, SpA, San Mauro Torinese (TO), IT | www.fidia.it
Fritz Studer AG, Steffisburg, CH | www.studerag.ch
GF Machining Solutions Management S, Meyrin 1, Winterthur, CH | www.gfac.com
Gruppo Parpas | www.gruppoparpas.com
Haas Automation Europe, Zaventem, BE | www.haascnc.com
Hardinge GmbH, Krefeld, D | www.hardinge.com
Heller Machine Tools Ltd., Redditch, Worcs, UK | www.heller.co.uk
Heto Corporation, SA Z.I. Santiago de Riba Ul, Oliveira de Azeméis, PT | www.iheto.com
Hurco Europe Ltd., High Wycombe, Bucks, UK | www.hurco.co.uk
imes-icore GmbH, Eiterfeld, D | www.imes-icore.de
Jobs, SpA, Piacenza, IT | www.jobs.it
Kitamura Machinery GmbH, Düsseldorf, D | www.kitamura-machinery.de
Körber Schleifring GmbH, Hamburg, D | www.schleifring.koerber.de
Mac Tec e.K., Emmelshausen, D | www.mac-tec.de
MAG Systems S.r.l., Abbiategrasso (MI), IT | www.magsystems.it
Makino Europe, Kirchheim unter Teck, D | www.makino.eu
Maschinenfabrik Berthold Hermle AG, Gosheim, D | www.hermle.de
Matsuura Europe GmbH, Wiesbaden, D | www.matsuura.de
Mersen France Gennevilliers SAS S.A.S., Gennevilliers, FR | www.mersen.com
OPS – Ingersoll Funkenerosion GmbH, Burbach, D | www.ops-ingersoll.de
Rainford Precision Machines Ltd., Rainford, St Helens, UK | www.rainfordprecision.com
Sarix SA, S. Antonino, CH | www.sarix.com
SHW Werkzeugmaschinen GmbH, Aalen Wasseralfingen, D | shw-werkzeugmaschinen.de
Suhner France S.A., Alfortville, FR | www.suhner.com
Toyoda Mitsui Europe GmbH, Krefeld, D | www.toyoda-mitsui.com
Unisig GmbH, Bad Urach, D | www.unisig.de
Yamazaki Machinery UK LTD, Worcester, UK | www.mazak.com
YMT Technologies Ltd., Yeovil, UK | www.ymtltd.co.uk
document6520857222495672999.indd 40 15.11.2016 13:12:26
SUPPLIERS DIRECTORY
4112-2016
Mac
hining
Cen
tres
,Graphite-E
lectrode
Grind
ingMac
hine
s
Gun
Drilling
Sys
tems
Mac
hining
Cen
tres
,High-Spee
d
Mac
hining
Cen
tres
,Horizo
ntal
Lathes
Mac
hining
Cen
tres
,5-A
xis
Milling/Turning
Mac
hine
s
TurningMac
hine
s
Mac
hining
Cen
tres
,Vertic
al
document6520857222495672999.indd 41 15.11.2016 13:12:27
TECH FOCUS R&D
42 12-2016
Hybrid laser processing centre forautomated repair of injection moulds
The Fraunhofer IPT, the Institute for Optical Systems of the University ofApplied Sciences of Konstanz and four industrial partners are are cooper-ating in the research project “Tool-Rep” to develop a fully hybrid laserprocessing centre for the automated repair of damaged injection moulds.
Laser structure: A soft-ware with new algorithmsfor planning the laser’smotion and for digitalstructure repair, theso-called texture synthe-sis, is designe to assistusers with setting up theprocesses.
Sou
rce:
Frau
nhofer
IPT
Injection moulds for the manufacture of plasticcomponents often have finely textured surfaceswhich can quickly wear out during operation.
Improper handling can also quickly render suchmoulds unusable or at least make time-consumingand costly manual repairs necessary. The Fraun-hofer Institute for Production Technology IPT, theInstitute for Optical Systems of the University ofApplied Sciences of Konstanz and four industrialpartners are nowworking together in the researchproject “Tool-Rep” to develop a fully hybrid laserprocessing centre for the automated repair of dam-aged injection moulding tools.Tool-Rep’s goal is the first-ever implementation
of a comprehensive and integrated process chainfor tool repair in an automated, laser-based process:The combination of two individual processes a sin-
gle system controlled by inlinemeasuring technol-ogy will offer end users significant competitiveadvantages through shorter setup times and smallfootprint. The project partners first define the re-quirements for the overall system and then designappropriate tools for measurement and controlsystems aswell as processmonitoring and control.A software with new algorithms for planning thelaser tool’s motion and for digital structure repair,the so-called texture synthesis, should assist userswith setting up the processes.The developed components are then combined
and tested in amachine demonstrator that is basedon an existing system concept. At the end of theproject, the partners aim to provide injectionmouldmanufacturers and end users with a complete solu-tion for rapid and comprehensive repairs.
Susanne Krause
document7773204123359199238.indd 42 15.11.2016 13:06:28
R&D TECH FOCUS
4312-2016
R&D IN BRIEF
Lightweight designLightweight technology can make a significantimpact by reducing material requirements andthe associated costs. A recent German studyhas shown that the production costs of a staticcomponent can be reduced by up to sevenpercent by using topology optimisation.Theamount of original material used could bereduced by about 30 percent. This amounts toa weight reduction from 251.2kg down to173.8kg. The required manufacturing costs fellas a result by approximately 7%.leichtbau-bw.de
3D-printed heart
Researchers at Harvard University created anentirely 3-D printed organ on a chip. The heartchip includes integrated sensing. A fully auto-mated, digital procedure produced the chip.This allows the chip to be customized to collectdata in either long-term or short-term studies.seas.harvard.edu
Bionic Award
The Fraunhofer IPT and their partners fromRWTH Aachen University and the JohannesKepler Unversity Linz received the “Internation-al Bionic Award” for best idea and most com-mendable interdisciplinary collaboration ofproduction engineers and natural scientists. Ina joint project, the team of four developedstructures for a unidirectional fluid transport onsurfaces of different materials.ipt.fraunhofer.de
The Federal Ministry of Education and Researchtherefore in November of 2015 granted the project“Tool-Rep” for the joint development of a compre-hensive repair solution byAcsys Lasertechnik, Eu-tect, Precitec Optronik, Werkzeugbau SiegfriedHofmann, the Institute for Optical Systems of theUniversity of Applied Sciences of Konstanz and theFraunhofer Institute for Production Technology IPT.
Industrial robot applies textures tolarge and complex moulds
The Fraunhofer Institute for Production Technolo-gy IPT and four industrial partners are also collab-orating in the “Robo-Tex” research project to devel-op a robot system that will require only about 20%of the current investment.Complex and large moulds for plastic injection
moulding, for example for interior car components,can be marked or engraved with high accuracyusing the technique of laser structuring. To be ableto uniformly apply repetitive patterns and texturesto the mould, the laser systemmust be accuratelypositioned in each run. However, plants that canmanufacture such large moulds currently oftenrequire investments of more than a million Euros.To achieve this, the Robo-Tex project partners for
the first time utilise a cost-efficient industrial robotfor large-scale laser structuring. By eschewing cost-ly and maintenance-intensive additional technol-ogy, the large-scale laser system should be particu-larly robust and cost-efficient and offer ecologicaland design advantages compared to conventionalsystems.The robot’s systemic inaccuracies are compen-
sated via a new smart method: In a first step thelasermarks defined positions on the surfacewhichserve as anchor points for the applied texture. Us-ing a camera that can identify both the markersand component edges, the robot can position thelaser accuratelywithin a known range of tolerance.The remaining miniscule deviation is then offsetby the integrated software against the laser's pro-cessing data and thus compensated. The laser au-tomatically overwrites the previously set markerswith each processing run.“Robo-Tex”, a joint project of Fraunhofer IPT, S&F
Systemtechnik, Zertrox, EschmannTextures Inter-national andModuleWorks, is sponsored by fundsfrom the European Regional Development Fund(ERDF) 2014-2020 under funding codeEFRE-0800314.ipt.fraunhofer.de
The Robo-Tex projectpartners use a cost-efficient industrial robotfor large-scale laserstructuring.
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INFOThe Fraunhofer IPTdevelops systemssolutions for pro-duction, focussingon the topics ofprocess technolo-gy, productionmachines, mecha-tronics, productionquality and metrol-ogy as well astechnology man-agement.
document7773204123359199238.indd 43 15.11.2016 13:06:32
TECH FOCUS TOOL MAINTENANCE
44 12-2016
Proper mould maintenance takes morethan just the right technology
As it expanded its moulding operations, US-based Henkel realised it wouldneed to add more than moulding machines - namely, a toolroom.
In addition to a 10-ton overheadcrane, Henkel Richmond’s tool-room is outfitted with grinders,mills, lathes, EDMs, drill pressesand a laser welder.
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Robert Gattshall has been in injectionmouldinglong enough to know a skilled toolmaker is amoulder’s best friend. When job No. 1 is run-
ning quality parts, and you know that isn’t possiblewithout a functioning, well-maintained tool, youbegin to appreciate just how important it is to havea mould maker on staff.In April 2014, Greg Krueger, director of operations
for Henkel’s Richmond, Missouri, site, recruitedGattshall to manage the engineering group for theAdhesive Technologies operation of the Germanconglomerate. Krueger’s big-picture plan was to
establish an in-house toolroom, and bringing inGattshall was just the beginning. As new productsbegan launching, the absence of a toolroom becamemore and more problematic for the plant, whichspecializes inmaking bonding, sealing and surfacetreatments.When it initially ramped up injection, Henkel
outsourced tool maintenance to Chicago-areamould makers that were more than 500miles andseven-plus hours away. “It was identified that therewas nowaywe could continue to do business hav-ing all those tools trucked to Chicago for repairs,”
Tony Deligio, senior editor,Plastics Technology
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TOOL MAINTENANCE TECH FOCUS
4512-2016
Gattshall says. Back then, it could take five daysjust to ship a mould to Chicago for maintenance,given the size of some of the tools Henkel dealswith.Converted from an old storage space, the tool-
room went live in January 2016. It was designedby Gattshall and journeyman mould maker CraigLinhart, whowas hired in April 2015. Henkel Rich-mond continues to round out the toolroom staffwith the addition of five full-time employees andplans for eight total in the near future.
Putting in a preventive maintenanceprogram
The changes at Henkel Richmond are new enoughthat a blueprint of the plant floor’s altered layoutstill hangs on Gattshall’s office wall. Green, blueand black markings denote where storage wouldbecome moulding bays and where the new tool-room would be carved out. Next to that is a sche-matic of the newly realised toolroom. On the topof the 8-by-11-inch black-and-white sheet is a designlayout, while below it equipment is listed by “item,”“quantity” and “voltage/amperage.”“We didn’t just put in a toolroom,” Gattshall says,
“we put in a state-of-the-art toolroom.” Equipmenton the floor in the newly refurbished space includesgrinders, mills, lathes, EDMs, drill presses and alaser welder, while a new 10-ton overhead cranelooks down from above.Adding the requisite equipment is just the first
step in creating an in-house tool-maintenance pro-gram. The next is to form a program that occupiesthat equipment, and the individuals running it, inthe most efficient manner possible. The additionof the toolroom coincided nicelywith Henkel’s bidto change its manufacturing culture from one offixing the symptoms of faulty processes and equip-ment, to fixing the faulty process or equipment.In the past, confronted by flash, for example, the
company would assign a worker to trim it or alterthe process to try to make it go away. Today, em-poweredworkersmake a decision based on a trou-bleshooting checklist that isolates the root causeas being related to process or tooling, or the ma-chine.
Finding the preventive maintenancesweet spot
“Our troubleshooting checklist doesn’t have thingson it like, ‘If you’ve got shorts or flash, here’s theprocess change you make,’” Gattshall says. “Noneof that.” Once the protocol has been followed andit has been determined that the validated processhasn’t been altered, a conclusion is reached. “Thenwe would have to make a business decision onwhether or not we can take the tool out of produc-tion immediately, but most of the time we do, andwe take it to our new toolroomwhere we have theability to fix the issue.”To keep tools from degrading to the point of flash,
Henkel has also put in place a preventive mainte-nance (PM) program. At this time, it’s based on thenumber of cycles, but it, too, will evolve. After ap-proximately 50,000 shots, Henkel’s toolroom willbring in a mould for a complete inspection. Whathappens before the next 50,000 shots depends. “If
Standing in HenkelRichmond’s newlyadded toolroom (fromleft to right): GregKrueger, director ofoperations; RobertGattshall, engineeringmanager; Craig Linhart,toolroom supervisor;Zane Cook, manufactur-ing engineer; and EdRoberson, toolmaker.
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a tool doesn’t make it to 50,000 shots, the preventa-tive maintenance frequency is too long,” Gattshallsays. If at 50,000 shots, you tear the mould apart,start looking at the components and everything isclean as a whistle, you know that you can extendthe preventative maintenance on that tool.”The sweet spot lies somewhere in between and
depends on a variety of factors, including themould’s cavitation, the part’s design and the ma-terial being run. “We don’t want to do preventativemaintenance on a tool if it’s not required,” he says,“and we want to make sure we’re doing more pre-ventative maintenance if it is.”Even further down the line, he says the goal is to
have its productionmonitoring system fromNorth-hamptonshire, UK-based Intouch Monitoring Ltd.trigger whenmaintenance is required. But beyonda cycle counter or process-monitoring software,Gattshall emphasises that Henkel’s operators aremost important to its maintenance program.“Our operatorsmight not be plastics experts, but
they’re the process experts, because they run thesetools every single day,” he says. “We rely on themwith this troubleshooting checklist, and we actu-ally empower them to make a decision.”
Understanding the value of onsitetool maintenance
Gattshall says the toolroom continues to ramp upand, despite only opening at the start of the year,its impact has already been felt on the company’sbottom line. He credits Krueger with having thevision to see the impact it would have before asingle grinder was installed. Krueger’s backgroundmight explainwhy hemade the choice: “Greg Krue-ger was a toolmaker - a tooling engineer,” Gattshallsays. “He understands the value of having onsitemaintenance tool.”This article first appeared in MoldMaking Technol-
ogy Magazine, courtesy of Gardner Business Media,Ohio, US.henkel.com
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CASE STUDY
46 12-2016
ITC delivers seismic change forearthquake subcontractor
The story for any subcontract business is evolve or dissolve. For Surrey-basedGPR, its progression from 3 to 5-axis machine tools initially evolved with abolt-on fourth axis for its Haas VF2 machines and now a full simultaneoushigh-end 5-axis machining centre from Matsuura.
ITC Widia ball nosetools with shrink fitholders profiling flange.
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The investment in a full 5-axis machine wasinstigated by the Camberley companywinninga two-year contract tomanufacture aluminium
housings for electronic assemblies. Long term tool-ing supplier Industrial Tooling Corporation (ITC)was on hand to support the subcontractor in pro-viding a complete solution for the project.Like any subcontractor with enhanced capabil-
ities and additional capacity, GPRwas on the look-out for more challenging work once the MatsuuraMX-520 arrived in May along with Edgecam CAMsoftware from Vero. The new work arrived in theguise of a “Hookes Joint Flange”, a critical compo-nent in an assembly for earthquake simulation andmeasuring equipment used in China.
The EN24T alloy steel flange joint is manufac-tured in a range of variants that demand numerousmachining strategies and tooling set-ups. SupplyingGPR for over a decade, ITC had engineer Dave Cleeveon hand alongwith Neil Franklin fromWidia. Com-menting on the machining strategy for the flange,GPR's machine shop programmer, Stuart Reynellsaid that "The key objective was to ensure that wecould attack all faces of the jobwith adequate clear-ance, tool rigidity andmachining tool performance”.The flange starts life as a 300 mm diameter by
225 mm deep 125 kg billet and the finished itemweighs in at just 28 kg. For heavy duty rough ma-chining of the flange, ITC recommended theWidiaM200 52 mm diameter shell mill that ran at a 1.5mmdepth of cut with a 35mm radial cuttingwidth.For this process, ITC applied the BIG KAISER BBT40toolholder with a face mill adaptor for maximumrigidity. With a spindle speed of 920 rpm and acutting speed of 150 m/min, the M200 with 5 in-dexable button inserts removed the majority ofmaterial at a rate of 84.34 cm3/min.With 12 index-es per insert, the M200 optimisedmaterial remov-al rates and performance while reducing toolingcosts for the subcontractor.
Attacking all faces with adequateclearance, performance
Following the 52 mm Widia shell mill, a 16 mmdiameter Widia 5777 Series solid carbide end millwas then introduced to machine the faces beyondthe reach of the shell mill. This tool was followedby the long series AlTiN coated Widia Vari-Mill 2with the Widia HPV shrink-fit toolholder. Thelonger-reachVari-Mill 2 and the extended shrink-fittoolholder finished the base of the flange with in-credible rigidity, stability and performance.For finishing the internal flanks and radii, ITC
introduced the 8 mm diameter ball-nose 47N0 Se-ries, with an 8 mm BT40 shrink-toolholder. Oncethe difficult-to-access faces were complete, ITCapplied the new Widia 20 mm diameter 7-fluteVari-Mill 3, 772E Series and the BT40 Hydroforcehydraulic chuck for machining the deep internalfaces of the flange."We've been a longstanding customer of ITC due
to the exceptional product quality, performanceand service. We are confident that whatever thejob, the ITC engineer can provide themost produc-tive and cost effective solution for our business,"said Mr Reynell.itc-ltd.co.uk
document2888978830735638351.indd 46 15.11.2016 11:22:11
PRODUCTS & SERVICES
4712-2016
Hot runners with modularactuators, no cooling lines
Hot Runners – Synventive haslaunched its SVG+ hot runnersystems. With several propri-etorial and patented designfeatures, they offer high per-formance, efficiency and reli-ability for sequential mouldingof large parts.The company says the sys-
tem’s simple design eliminatesthe need for cooling lines orplates. External monitoringand diagnostic tools byway ofa Valve Monitoring Interface(VMI) for monitoring, diagnos-tics and troubleshooting areclaimed to facilitate lessdowntime and less scrap. Also,this provides real time sequen-tial valve gate status, the easeof set-up and confirms that thepiston is traveling as intended.It is also designed for thestraightforward upgrade to thecompany’s “active Gate” tech-nology. Moreover, high quality
Class A part surface finishescan be achievedmore quicklyand that it can mould partswith complex geometries andhigh dimensional stability.The SVG+ actuated systems
are equipped with new mod-ular actuators and pat-ent-pending Syncool 3 tech-nology, which provides indi-rect cooling of the actuatorswithout the need for separatecooling lines. As such, it pre-heats without doing damageto actuator or seals, eliminatesclogged or leaking coolinglines and prolongs actuatorseal life. Additionally, manifoldtemperature uniformity is im-proved and removing the cool-ing plate facilitates quick-mould changes by eliminatingthe need to cool down the hotrunner to prevent the degrad-ing of the hydraulic fluid.synventive.com
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New standard for SequentialValve Gating (SVG+) fromAmerica-basedSynventive.
New developments to the DRand KR ranges
Components – At the recentK-Show in Düsseldorf, Spain-based company, Cumsa, ex-hibited a number of develop-ments to its rack family. Thesenew innovations will be dueto be released to the the mar-ket in the latter part of Novem-ber 2016.Cumsa explained that based
on the company's continuousresearch and in addition tocustomer feedback, it hasmade several improvementsto its rack system.As such, its DR range is be-
ing expanded with the addi-tion of a smaller 16 mm size.At the other end of the scale,two larger units, KR58 andKR76, are being added to theKR rang, specifically designedfor large tools.These changes include de-
velopments that were alsoshowcased at K, namely, a new
“fast fit” system that is de-signed to offer a quick andeasy solution for fitting theinsert to the shaft, and the uni-fication of the 100mmand 125mm stroke racks’ geometry.This would therefore meanthat all of these parts will havethe same installation process.The fixing key for the shaft inthe ejector plates have beenremoved, which will providemore latitude to the customersto implement their own be-spoke solution.The company added also
that the base units will nowbe given a black oxide treat-ment, while the material andhardness will remain thesame.Furthermore, the KR22 will
now include an O-ring on itsshaft, similar to the KR28 &KR34.cumsa.com
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From the DR range of the company’s rack family.
Data calculator offered as an App for quick and easy use
Cutting Data – Internationalsupplier of modular standardcomponents and accessoriesfor mouldmaking, Hasco, hasadded a cutting data calculatorfor tool steel to the core func-tions of the Hasco App. TheApp already features materialselection, hardness value con-version, DIN/ISO tolerances forshafts and holes, a tool for thelayout and dimensioning oflocking cylinders, and a threadtool for recognising pitch andoutside, core and flank diam-eters – all available on stand-ard smartphones. The cuttingdata enables relevant milling
data to be quickly and readilydetermined, for immediateuse. Users can enter individu-al parameters and have feed,rotational speed or cuttingvolume displayedwhile on themove, and can be appliedwithimmediate effect, the compa-ny says.News, videos, job vacancies
and general Hasco informationcan be called up at any time.Users can also find a personalcontact at the company, quick-ly and easily. All core functionscan also be used without anInternet connection.hasco.com
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The company’s data calculator is now available as an App and is acces-sible on standard smartphones.
document8787348553131824828.indd 47 15.11.2016 11:25:23
PRODUCTS & SERVICES
48 12-2016
Modular end mills acceleratemetal removal
Milling –Widia has announcedseveral developments intend-ed to extend the usability andefficiency of itsmachinery andequipment. In addition, isfrom its sister company, Han-ita, whose Vari-Mill technolo-gy includes a range of helixand cutting geometries, anasymmetrical flute design, andwear-resistant AlTiN coatingsfor productive use in titaniumand nickel-based super-alloys.The replaceable tip endmill
solution that features the Duo-Lock connection from Widiaand Haimer, is claimed to becurrently the only tool availa-ble that can take full-widthslotting cuts in stainless steeland aerospace alloys at 1xDdeep, and 50% cut widths at1.5xD. Its fast metal removalrate is achieved with a dou-ble-taper, face-contact mountand “intelligent” thread designthat is said to provide run-outaccuracy better than 5 µm; ax-ial repeatability of 10 µm orbetter; and up to 25% highertorque and chip load capabil-ities than its competitors. Ac-cording to the company, thesefeatures make the Widia sys-tem a budget-friendly alterna-tive to solid carbide end millsfor all shops, fromTier I and IIsuppliers in the aerospace andauto industries down to thesmaller, flexible job shops.
The Duo-Lock connectionwas originally designed forheavy roughing and semi-fin-ishing applications in difficultmaterials but the platform hasevolved since then.When cou-pled with the wide array ofcarbide, coatings and geome-tries from Hanita, Widia addsthat it can provide manufac-turers with amodular alterna-tive to solid carbide end millsin 80% of their machiningoperations. All of its modularcutting tools and adapters areavailable with the Safe-Locktechnology, which is claimedto assure zero pullout in tita-nium as well.widia.com
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The company has a variety ofintegral shank taper, lobed andHSK-style toolholders.
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Extending the affordability of3D-scanning technology
Metrology – Werth says thatits ultra-compact Scope-CheckS Probe coordinatemeasuringmachine has advanced scan-ning capability, giving it a goodprice-to-performance ratio.With ameasurement range of400, 200 and 200 mm in theX, Y and Z axes respectively, ithas a granite base and does
not require compressed airsupply. Precision mechanicalguides and a temperaturecompensation system guaran-tee reliable measurement re-sults, even under difficult en-vironmental conditions, thecompany says.It adds that gauging bench-
es, hard gauges and conven-tional measurement systemscan be supplemented or re-placed by this machine andthat its high-precision 3Dscanning probe system andrapid CNC-path controls canhandlemany areas of applica-tion. It has the newWin-Werth8.40 3Dmeasurement softwarethat provides user-friendlyfunctions for semi and auto-matic generation of scanningpaths and for modifying pro-grams. The interactive graphicuser interface enables dimen-sions to be captured by click-ing on the graphic.werth.de
Scope-Check S Probe has ahigh-precision 3D-scanningsystem and CNC-path controls.
Expanded range speed upclamping changeovers
Workholding – Hainbuch saysthat recent additions to itsCentrotex clamping systemenable even faster changeo-vers. The extensions meanthat users of Centrotex, whichis designed for clamping com-ponents of up to 300mm, canchoose and change over to thecorrect work-holding modulewithin five minutes with anaccuracy of below 0.008 mm.
The system can be used onturning, measuring and grind-ing machines as well as ondividing heads. It also acceptscollect chucks, mandrels,three-jaw chucks and fixtures.The clamping system is saidto be rigid and robust and de-livers shorter cycle set-uptimes, and improved repeataccuracy.hainbuch.com
Recent additions to Hainbuch’s clamping system, Centrotex.
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uch Automated quality control
Inspection – In response toincreasing production vol-umes and the need for fastermeasurements, companiesare opting for automatedmeasurement and inspectionsolutions. GOMhas addressedthis with its optical 3D meas-uring machine Atos Scan-Box4105.The standardised plug and
playmeasuring cell is suitablefor small and medium-sizedcomponentswith amaximumweight of 100 kg and a maxi-mum part size of 500 mm. Itcombines automaticmeasure-ment and inspection process-
es, mobility and industrialsafety in one device. Like allmeasuring cells from theAtosseries it is not localised andcan be set-up within one totwo days.gom.com
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Core component of the cell is arobot-driven Atos 3D scanner.
document3027868062103962869.indd 48 15.11.2016 11:29:02
ZOOMED IN
4912-2016
A spider monkey's careerUntil 1971, it was just a little-used keyboard
character. But in 1971, the career of the “@”sign really took off.What is known in English
as the “at sign”, or “commercial at” is called “spidermonkey” (Klammeraffe) in German, “little snail” inItalian, “dog” in Russian, “rollmops” in Czech, “littleworm” in Hungarian and “vortex” in Hebrew.Ray Tomlinson used this chameleon symbol in
1971 to set up the world’s first email address: tom-linson@bbntenexa. Today, email is the old man ofInternet communication - but still one of themostwidely used services. In 2014, 166 billion emailswere sent every single day. And that number isexpected to increase to over 200 billion by 2017.45 years ago, Ray Tomlinson worked as a com-
puter engineer at a private research organisationin Cambridge, which got a contract from the USDepartment of Defense in 1968 to build the AR-PANET, predecessor of today's Internet. In 1971,Tomlinson’s team set about developing a packetswitching protocol for this network. However, Tom-linson was more interested in the creation of net-work-enabled communication systems. One of hiscolleagues warned him: "Don’t tell anyone! Thisisn’t what we’re supposed to be working on." As isoften the case, the ingenious invention at firstseemed absolutely useless. After all, there was nosuch thing as an Internet back then. Traditionalmail was still the way to go, and for quicker com-munication, there were telex, teletex and fax. ButTomlinson’s gimmick became increasingly popular.In 1977, a first emailing standard was introduced,and in 1982, eleven years after its conception, thenew form of communicationwas called “email” forthe first time.
A little-used keyboard characterThe first mailbox protocol was specified in 1971.But what exactly did Tomlinson come up withwhen he worked on a computer as big as a ward-robe back in the winter of 1971? He got the idea tocombine network and protocol - CPYNET andSNDMSG - in order to send messages to users onother computers in the network - and not onlywithin the same local network, but across differentsystems. This was accomplished via a 3m cable andwas absolutely new and sensational 45 years ago.Before, messages could only be sent to user ac-counts on the same computer system. As a separa-tor between user and computer name, Tomlinsonselected the until then only seldom used @ char-acter.In the late eighties, the rise of email began, as it
was one of the first applications that utilised thepossibilities of the ARPANET. Until today, emailcommunication between two users is based onthree protocols: Simple Mail Transfer Protocol(SMTP) is used to send messages and for commu-nication betweenmail servers. POP and IMAP pro-tocols enable email clients to receive incomingmails. SMTP is responsible for the reliable relayingof messages between mail servers, but also for re-ceiving emails. The SMTP protocol can be imagined
as the path to the letterbox and post office vehicle,while the POP and IMAP protocols would be thepostman delivering the letters to the front door.The email format has changed very little since
its first standardisation and is flexible enough toincorporate optional extensions. Encoding today isthe same as 40 years ago, in ASCII format, becausemail servers can only communicate in ASCII. Spe-cial characters, umlauts and binary attachmentsmust also be converted into this simple characterset and then decoded again. This is themail client’sor webmail service's task.
The three parts of an emailEmails consist of three parts. The short "envelope"contains sender and receiver information and isonly used by the MTA (Mail Transport Agent). Thedetailed email “header” contains information rele-vant for the receiver: sender name, reply addressand the path the email has travelled. The "body"contains the actual message. This structure enablesfast processing, as MTAs, which receive and forwardhundreds of emails every second, only need tocheck the short information in the envelope, andnot the entire header.But how does an MTA know where to deliver a
new email it has just received via SMTP? The Do-main Name System (DNS) is not only key for ac-cessing web or FTP servers, but also key for send-ing emails. Special DNS entries are reserved foremail: the so-called “MX Record” (Mail ExchangerRecord) identifies the target server and its address-es. The MTA queries a domain in the DNS and re-ceives a list of servers (mail exchangers) acceptingmessages for the target domain. Every mail ex-changer has a 16-bit priority. The SMTP server nowtries to relay themessage to the relevant servers inorder of priority.In Germany, the very first email was received on
August 3rd, 1984, at 10:14 am CETbyMichael Rotertat the University of Karlsruhe. The groundwork forthis was the project application "Interconnectionof networks” filed two years prior byWerner Zorn,a professor at Karlsruhe. Germany and Israel werethe first countries connected to the United States'CSNET. Five years later, Germanywas first connect-ed to the Internet via Xlink.When Internet standards for email began toma-
ture the POP (or Post Office Protocol) servers beganto appear as a standard - before that each serverwas a little different. POPwas an important stand-ard to allow users to develop mail systems thatwould work with each other. These were the daysof per-minute charges for email for individual di-alup users. Formost people on the Internet in thosedays email and email discussion groups were themain uses. Theseweremany hundreds of these ona wide variety of topics, and as a body of news-groups they became known as USENET.Statistics by the Radicati Group estimate the
number of email users worldwide was 2.6 billion,and the amount of emails sent per day (in 2015) tobe around 205 billion. ETMM
Ray Tomlinson (left) usedthe @ symbol in 1971 toset up the world’s firstemail address: tomlin-son@bbntenexa.
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1971In December, RayTomlinson mailsout the first elec-tronic message.
1977Email communi-cation isstandardised.
1982The term "email"enter generallinguistic use.
1984On 3 AugustGermany receivesits first email.
1992Microsoft intro-duces Outlookafter the companyintroduced Micro-soft Mail in 1988.
2015205 billion emailsare being sentevery day.
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EUROPE
50 12-2016
Statistical year book 2016 releasedISTMA has just released a new edition of its statisti-cal year book. This publication presents statisticalinformation about international trade and the tool,die and mould industry, using extensive graphicalpresentations and numerical tables as a prevailingsupport. More than 900 figures on 250 pages are
accessible in order to fully describe product and country industrialtooling dynamics in long time-series presentations.istma.org
Business Conditions Report 2016ISTMA has recently released its BusinessConditions Report for the first half 2016.Documentation is already available for ISTMAmember associations in the private area ofthe website.istma.org
ISTMA Europe meets in DüsseldorfThe last ISTMAEurope Meetingwas held inDüsseldorf,Germany on 20October 2016. Delegates had the opportunity to combine attend-ance with the visit to the show and meet the latest developments ontechnology released in this area of business. Several ISTMA mem-ber associations have also been successfully exhibiting at the showas part of the national pavilions. ISTMA Europe has been expectinga large attendance in this event joining delegations coming fromdifferent member countries.istma.org
Meet the MoulderFollowing on from thefirst “Meet The Moulder”event which was held inOctober 2014, the GT-MA along with the BPFwill be holding a series of these events throughout 2016 & 2017. Thenext event is scheduled for 16 February 2017 at GF Machining Solu-tions Ltd, North View Coventry,West Midlands, UK.gtma.co.uk
ISTMA World News & EventsThe International Special Tooling & Machining Association (ISTMA) is an interna-tional association representing 19 special tooling and machining associationsthroughout the world. Collectively, ISTMAmember associations represent over8,000 companies and over $40bn in annual sales. ISTMAWorld is in charge of thecentral coordination and organisation of all international activities
For information, contact:Mr. Manuel OliveiraSecretariat, Istma Europec/o CefamolAv. D. Dinis 17Aptdo. 2572430-263 Marinha GrandePortugalTel. +351 244 575150Fax +351 244 [email protected]
MEMBERSTool Factories Associationwww.svaz-nastrojaren.eu
Estonian Special ToolingAssociationwww.estatools.ee
The Federation of FinnishTechnology Industrieswww.techind.fi
Association Française desIndustries du Moule, Modèleet Maquette (AFIM)www.afim-france.com
VDMAwww.vdma.org
The Gauge & Tool Maker’sAssociation (GTMA)www.gtma.co.uk
Szerszámgyártók MagyarorsazágiSzövetsége (SZMSZ)www.szmsz.hu
Unione Costruttori Italiani Stampi eAttrezzature di Precisione (UCISAP)www.ucisap.it
Stowarzyszenie Techniczne –Tworzywa Sztucznewww.stts.com.pl
Associação Nacional daIndústria de Moldes (CEFAMOL)www.cefamol.pt
Slovenian Tool and DieDevelopment Centerwww.tecos.si
Toolmaking Associationof South Africa (TASA)www.tasaweb.co.za
Swedish Moulding and Press ToolsAssociationwww.sinf.se
Swissmemwww.swissmem.ch
International Mould ManufacturersUnionwww.ukub.org.tr
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EVENTS
Moulds Event 2016
Portugal Pool-Net, Cefamol and Centimfe hosted the Portuguesebi-annual Moulds Event from 24 to 30 September 2016. The eventfeatured a set of international conferences, B2B meetings, factoryvisits and other networking events, involving the international toolingcommunity, clients, suppliers and all the cluster stakeholders.mouldsevent.com
ISTMA World Conference and General Assembly 2017
Joinville (Brazil), June 2017
ISTMA Networking Reception
Moulding Expo 2017, Stuttgart, Germany, 30 May 2017
NEWS
document5527321770272341260.indd 50 15.11.2016 11:30:01
MASTHEAD/COMPANY INDEX
5112-2016
Company Index
AAcsys Lasertechnik GmbH . . . . . . . . . . . 42Arburg GmbH & Co . KG . . . . . . . . . . . . . 11
BBlum-Novotest Ltd . . . . . . . . . . . . . . . . . . 37
CCNC Software Inc. . . . . . . . . . . . . . . . . . 7Concept Laser . . . . . . . . . . . . . . . . . . . . 34Cumsa . . . . . . . . . . . . . . . . . . . . . . . 47, 52
DDenos Consulting GmbH . . . . . . . . . . . . 47DP Technology Europe . . . . . . . . . . . . . . 10
EEngel Austria GmbH . . . . . . . . . . . . . . . . 12Euromap – VDMA, Plastics and RubberMachinery . . . . . . . . . . . . . . . . . . . . . . . 12Eutect GmbH . . . . . . . . . . . . . . . . . . . . . 42
FFraunhofer-Institut für Produktions-technologie IPT . . . . . . . . . . . . . . . . . . . . 42
GGOM Ges . für optischeMeßtechnik mbH . . . . . . . . . . . . . . . . . . . 48Günther Heißkanaltechnik GmbH . . . . . . 32
HHainbuch UK Ltd . . . . . . . . . . . . . . . . . . . 48Hasco Hasenclever GmbH +Co . KG . . . . . . . . . . . . . . . . . . . . . . . 26, 47Henkel Corporation . . . . . . . . . . . . . . . . 44HRSflow, member of INglass . . . . . . . . . 25Hurco GmbH . . . . . . . . . . . . . . . . . . . . . 28Husky Injection Molding Systems Ltd . . . 25
IIncoe International Europe . . . . . . . . . . . 25Inovatools Eckerle & Ertel GmbH . . . . 33Iscar Ltd . . . . . . . . . . . . . . . . . . . . . . . . . 30ITC Industrial Tooling Corp . Ltd . . . . . . . . 46
JJoke Technology GmbH . . . . . . . . . . . . . . 8
MMack Brooks Exhibitions Ltd . . . . . . . . . . . 9Maschinenfabrik Berthold Hermle AG . . . . 8Mastip Technology Ltd. . . . . . . . . . . . . 35Mepax . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Messe Düsseldorf GmbH . . . . . . . . . 23, 27Meusburger Georg GmbH & Co . KG . . . . 14MMC Hardmetal UK Ltd . . . . . . . . . . . . . . 31Mold-Masters Europa GmbH . . . . . . . . . 26
PPhoenix Contact Deutschland GmbH . . . . 8
Poco Graphite,Inc. an Entegris Company . . . . . . . . . . . 3Präzi-Flachstahl AG . . . . . . . . . . . . . . . 17Precitec Optronik GmbH . . . . . . . . . . . . . 42Progressive Components . . . . . . . . . . . . 2PSG Plastic Service GmbH . . . . . . . . . 26
SS.I.S.E. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9SolidCAM Ltd. . . . . . . . . . . . . . . . . . . . 7, 9
TTürk+Hillinger GmbH . . . . . . . . . . . . . . . 5
VVDWF – Verband DeutscherWerkzeug- und Formenbauer e .V . . . . . .8,10Verein Deutscher Werkzeugmaschinen-fabriken e . V . (VDW) . . . . . . . . . . . . . . . . . 7
WWBA Aachener WerkzeugbauAkademie GmbH . . . . . . . . . . . . . . . . . . 16Werkzeugbau Siegfried HofmannGmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Werkzeugmaschinenlabor WZLRWTH Aachen . . . . . . . . . . . . . . . . . . . . 16Werth Messtechnik GmbH . . . . . . . . . . . 48Widia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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