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1 THINK PARTS - THINK TORNOS
Tornos Multispindle Turning machines Development:
New era for Parts of Automotive, Medtech, Watch & Electronics
托纳斯多轴车床的发展—— 汽车、医疗、钟表和电子零件的新时代
(the 11th) China International Metalworking Summit 2015 2015(第十一届)中国国际金属加工高峰论坛
Arnaud MACABIES (Technical sales manager) -21st of April 2015
马阿诺(技术销售经理)2015年4月21日
Hall W1, Booth 201展位号:W1-201
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Agenda日程
• Tornos company introduction…Meeting us is just the beginning.托纳斯公司介绍——约见我们只是开始
• Information and generalities about Multispindle Turning machines多轴车床概述
• What Multispindle solutions can propose Tornos?托纳斯多轴车床解决方案
• How to make the right choice between Single / Cam Multi's/ and Multispindle CNC machines?如何正确选择单轴、凸轮和多轴数控车床
• Some Multispindle applications多轴车床应用
• Questions问答
3 THINK PARTS - THINK TORNOS
Tornos company introduction
Meeting us is just the beginning
托纳斯公司介绍
约见我们只是开始
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Tornos Key numbers托纳斯关键数字
• 600 Employees (420 in Switzerland) 员工600名(瑞士420名)• Present in over 50 countries 遍布50多个国家和地区• Order entry 205 millions $/year 年订单额2.05亿
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• 1880 First Swiss type lathes in Moutier第一台瑞士型车床在瑞士穆捷诞生
• 1914 Tornos SA and Bechler SA already in deep competition托纳斯和贝希勒公司竞争激烈
• 1971 Petermann and Tornos merge彼得曼与托纳斯合并
• 1981 Tornos merge with Bechler to create Tornos-Bech.托纳斯与贝希勒合并成立托纳斯-贝希勒公司
• 2001 Public company公司上市
• 2008 Acquisition of Almac SA – (Micro milling sector)收购Almac公司(精密铣削领域)
• 2012 Establishment of manufacturing & development site in Taiwan在台湾建立生产研发基地
• 2013 Launch join venture with Chinese entry level machine在中国成立合资企业,生产标准型车床
The company - History公司历史
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Tornos Worldwide 托纳斯全球分支
Lombard – US 美国朗巴德
Leicestershire – UK 英国莱斯特郡 Warszawa – Poland 波兰华沙
Granollers – Spain
西班牙格拉诺莱斯
Milano – Italy 意大利米兰St-Pierre – France 法国圣皮埃尔 Pforzheim – Germany 德国普福尔茨海姆
Shanghai – China 中国上海Beijing - China 中国北京
Hong Kong – China 中国香港Bangkok – Thailand 泰国曼谷
Penang – Malaysia 马来西亚槟城
Brea – US 美国布雷亚
Brookfield – US 美国布鲁克菲尔德
São Paulo – Brazil巴西圣保罗
Dong Guan – China 中国东莞Tai Wan – China 中国台湾
Xi’an – China 中国西安
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Geographical production footprint 生产基地分布
Moutier穆捷
Chaux-de-Fonds拉绍德封 X’ian 西安
Taichung台中
1904
2008
2013
2014
Surface: 13500m2Capacity: 500 mc p.a
面积:13500平方米产能:年产500台
Surface: 2300m2Capacity: 250 mc p.a
面积:2300平方米产能:年产250台
Surface: 2500m2Capacity: 1000 mc p.a.
面积:2500平方米产能:年产1000台
Surface: 800m2Capacity: 100 mc p.a
面积:800平方米产能:年产100台
− Development and production capacities in the Asian growth markets在亚洲设立开发和生产基地,以更好的服务亚洲客户
− More balanced footprint responding to industry’s shift to Asia 随着工业向亚洲的转移,在亚洲开设开发和生产基地
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Tornos Greater China (China- HK-TW - KR)托纳斯大中华区(中国 - 香港 - 台湾 - 韩国)
Production plants 生产工厂
Sales office 销售公司
Show room/Customer service 展厅/客户服务
Tornos representation in Korea托纳斯韩国代表处
Korea 韩国
Beijing 北京
Shanghai 上海
Xi’an 西安
Taichung-Taiwan 台湾台中
Dongguan 东莞
Hong-Kong 香港
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Tornos Portfolio 托纳斯产品系列
Swiss-type瑞士型车床
Multi-spindle多轴车床
Micro-milling精密铣床
Core business< 32 mm bar核心业务<32 mm棒料
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Tornos Market Segments 托纳斯细分市场
Automotive汽车
Electronic电子
Medical医疗
Aerospace航空
Pneumaticand hydraulic
气动和液压
Watch industry钟表
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Tornos Values and Culture托纳斯价值和文化
品牌价值企业文化
团队精神
事实&数据
创新
关注
易操作 成品零件 物有所值 技术
产品/解决方案
客户满意
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Solution Provider解决方案供应商
From bar to parts a full Turn key solution
从棒料到零件的全方位交钥匙解决方案
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Information and generalities about Multispindle Turning machines
多轴车床概述
Why are Multispindle Turning machines a good investment?
为什么说多轴车床是很好的投资
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What is a Multispindle turning machine?什么是多轴车床?
Kinematics of a MultiSwiss 6x14MultiSwiss 6x14 动力结构Kinematics of a MultiSigma 8x28
MultiSigma 8x28 动力结构
Kinematics of a single spindle machine 5 axis5轴单轴机床的动力结构
Some Highligths 亮点:
• 6 to 8 main spindles/ slides working simultanously 6到8个主轴/滑块同时工作• 1 to 2 subspindles/Back working slides-> 1 to 2 part/cycle 1到2个背轴/背轴加工滑块 -> 1-2个零件/加工循环
• Bar diameter: 4-28 mm 棒料直径:4-28mm• Part length: up to 140mm 工件长度: 最长140mm• Can have Y axis 可配Y轴• In average 3 to 6 times faster than a single spindle 平均比单轴车床快3-6倍• Multi’s are made for high production and high precision 多轴车床设计用于大批量高精度加工• Flexible/Quick tool change 高灵活性/可快速换刀• Manpower costs reduced 用工成本降低• Less maintenance 修护需求更少• Less QC 质量控制需求更少
主轴 S11-S18
背轴
端面单元Z
滑块X11-X48滑块
主轴
背轴
背轴
主轴刀具
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Process on Single vs. Multi spindles单轴和多轴车床的工艺比较
3.56 sec
3.7 sec
2 sec
4.5 sec
3 sec
4 sec
Position/ Tool
工位/刀具
Production time on Multi / part
多轴车床单个工件加工用时
Production time on Single/ part
单轴车床单个工件加工用时
1 3.56 sec. 3.56 sec.
2 3.7 sec. 7.26 sec.
3 2 sec. 9.26 sec.
4 5.5 sec. 14.76 sec
5 4.5 sec. 19.26 sec
6-Cut off6-切断
3 sec. 22.76 sec
Back op背轴加工
4 sec. 26.76sec
Total production
time总加工用时
5.5 sec/part每件5.5秒
22-30 sec/part
depending on the model
根据车床型号不同,每件用
时22-30秒不等
Ex: MultiSwiss 6x14 vs. Single spindle例: MultiSwiss 6x14与单轴车床对比
Some Highligths 亮点:
• Each position is independent on Multi 多轴车床的每个工位是独立的
• Longest position gives cycle time on Multi循环时间取决于用时最长的工位
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Multispindles CAM or CNC ?凸轮多轴还是数控多轴?
Some Highligths 亮点:
• Cam machine are ideal for High production of simple part凸轮车床是大批量生产简单零件的理想选择
• Ideal for low part complexicity and easy material such as brass是黄铜等易加工材料和低复杂性工件的理想选择
- 工件类型少,产量大 - 工件类型多,产量大- 试产扩量
凸轮车床• 成型刀仅在Y轴移动• 调整困难,需要停车
数控车床• 所有标准刀具一起在X轴和Z轴进行形状车削• 调整简单,无需停车• 可在隐蔽时间内对新工件编程
Items 项目
Cam Multi凸轮多轴
Parts 工件
Simple, as with form tools简单,使用成型刀具
Flexibility灵活性
Cam & form tools difficult to set-up, turn-over takes long time.凸轮和成型刀安装困难,更换用时长
Tool Cost刀具成本
Tool cost high as with special form tools使用特殊成型刀具时,刀具成本高
Efficiency效率
Both tool correction/replacement, part turn-over take long time刀具校正和更换,以及零件更改用时长
Operators操作人员
Few & few很少
Ramp-up试产扩量
Impossible for production ramp-up, with more types missing flexibility无法试产扩量,工件类型多则会损失灵活性
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The Multispindles place(in the Turning Market)多轴车床的地位(车削市场)
Transfer Machines连续自动工作机床
Multi-SpindleMachines多轴机床
Machine Capability 机床功能
MultiAlphaMultiSigmaMultiswissSAS16.6
EVO-DECOSwissnanoST/GTCT
Almac
Niche ApplicationsMachining centers
特殊应用加工中心1’
000
50
’000
10
0’00
01’
000’
000
Mac
hine
inve
stm
ent
机床
投资
Mac
hine
Pro
duct
ivity
机床
生产
能力
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Turning machines in the Market车床在细分市场中的占比
33%
18%23%
6%
20% AutomotiveMedtecElectronicsMicromechanicsOthers
Swiss type lathe瑞士型车床
67%7%
13%
13% AutomotiveMedtecElectronicsOthers
Multispindle Lathe多轴车床
2%
16%
51%
31% AutomotiveMedtecElectronicsMicromechanics
Micro-milling精密铣削
Source 来源:Bishop and Associates *Year 2011
汽车医疗
电子微机械
其他
汽车
汽车
医疗
医疗
电子
电子
其他
微机械
19 THINK PARTS - THINK TORNOS
What Multispindle solutions can propose Tornos?
托纳斯多轴解决方案
20 THINK PARTS - THINK TORNOS
Tornos Multispindles product line托纳斯多轴产品线
MultiSwiss 6x14 MultiSigma 8x28 MultiAlpha 8x28
SAS 16.6 Cam
21 THINK PARTS - THINK TORNOS
Tornos Multispindles product line托纳斯多轴产品线
MultiAlpha 8x28
SAS 16.6
MultiSigma 8x28
Ø 30Ø 15
MultiSwiss 6x14
Ø 5
Tornos Multispindles - Turn key projects including integrated peripherals + Set-up + Tooling + Training and our best service and support托纳斯多轴 — 交钥匙项目包含集成的周边设备+安装+刀具+培训和最好的服务和支持
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Tornos Multispindles Product Line托纳斯多轴产品线
High 高
Complexity复杂性
Volume产量
Medium 中
Simple 低
MultiAlpha
MultiSigma
SAS 16
MultiSwiss
23 THINK PARTS - THINK TORNOS
MultiAlpha 8x28
Max spindle speed motor spindles电主轴最高轴速
8'000 t/min
Max part length:最大工件长度
Up to 140mm
Diameter capacity加工直径
Up to 28 mm.高达28mm
No of axis (linear) 轴数(直线轴) 25No of axis (circular) 轴数(C轴) 10Max tools in back operation背轴加工中最大刀具数
2x5 (2x3 revolving 动力刀)
Full CNC 全数控 Fanuc 30iSoftware 软件 TB-DECO
Available in 20 or 28mm:可加工直径20或28mm:MA8x28 or MA8x20
24 THINK PARTS - THINK TORNOS
MultiAlpha KinematicMultiAlpha 动力结构
1. 8 Motor spindles (Indep. speed) and slides
8个动力轴(独立转速)和滑块
2. High back operation capability(twin counter spindle) up to 2X5 tools in back operation
背轴加工功能强大(双背轴),高达2x5把刀具
3. Controlled part unloading
工件排出可控
4. Sub spindle including Y and Z axis
背轴有Y轴和Z轴
DM1 (单个背轴)
25 THINK PARTS - THINK TORNOS
Counter-operation kinematic-MA背轴加工动力结构—MA
3
21
5
4Y axis
(counter-spindle)
Y轴
(背轴)
X axis
X轴
26 THINK PARTS - THINK TORNOS
MA Back operation DM2MA背轴加工 DM2
Mainly recommended for:
主要推荐用于:
• Configuration to be used when the back operation is leading the time
背轴加工为主导加工用时时,推荐使用此配置
• For medium complexity parts produced in double cycle
可双节拍加工的中等复杂零件
• This machine is the most versatile version, can easily be convert from 2X4 to 1X8
这款机床是最通用万能的,可轻松从2X4转换为1X8
DM2 (双背轴)
27 THINK PARTS - THINK TORNOS
MA – 2 parts per cycle: 2x4 versionMA – 每个节拍生产两个工件:2X4版
1 x 8 2 x 4
Barrel index 轴筒分度45°
Barrel index 轴筒分度90°
Part 1
工件1
Part 2
工件2
28 THINK PARTS - THINK TORNOS
MultiSigma 8x28 (MSi 8x24 available)MultiSigma 8x28 (MSi 8x24 可用)
Main differences between these 2 models:两个机型的主要区别:
1. High back operation capability (twin counter spindle) up to 2X3 tools in back operation
背轴加工功能强大(双背轴),高达2X3刀具
1. Sub spindle including Z axis only
背轴仅有Z轴
Some Highligths:亮点:
• Ideal for medium complexity parts中等复杂工件的理想加工工具
• Available in DM2 and 2x4可选用双背轴加工和双节拍加工
Less tools in Back op than MultiAlpha背轴加工刀具比MultiAlpha 少
Spindle on Z axis but not on Y axis主轴有Z轴但没有Y轴
29 THINK PARTS - THINK TORNOS
SAS 16.6 – CAM Type MultispindleSAS 16.6 – 凸轮式多轴车床
Number of spindle主轴数 6
Max. Part length最大工件长度 75mm
Max. Diameter最大加工直径
Diam.16mm / Hex. 13/ Square 11
直径16mm/六边形13/正方形11
Max. productioncycle parts/min.每分钟最大生产件数
Up to 60-80 p/min高达60-80件/分钟
• Ideal machine for High production批量生产的理想机床
• Turning by Plunging operation使用成形车刀进行车削
• Cam driven凸轮驱动
• Reliable 性能可靠
• Basic design from 1960’s基础设计源于20世界60年代
30 THINK PARTS - THINK TORNOS
MultiSwiss 6x14MultiSwiss 6x14数控多轴自动车床
Number of spindle主轴数 6
Spindle (build in motor)主轴转速(嵌入式马达)
8‘000 rpm (5,6Kw)
Number of linear axis直线轴数 14
Number of circular axisC轴数 7
Number of tools (up to 2 tools per position)刀具数(每个刀位高达2把刀具)
13 (18)
Bar diameter mmBar diameter inch.棒料直径 mm棒料直径 inch.
4 to14 mm.0,15" to 0,55 "
Max. Length (4 X Ø)最大长度 40 mm. 1,575"
Barrel Indexing time轴筒分度用时 0.3 sec.
Max. production cycleparts/min.最大加工循环件数/每分钟
30 (35)
Integrated PC ISO or TB Deco集成式电脑ISO或TB Deco
Fanuc发那科
Ratio Length Vs diameter up to 4
times
长度与直径比高达4倍
Max. 40 mm . 1,575"
Ø 4 to 14 mm.
0,15 " 0,55"
31 THINK PARTS - THINK TORNOS
MultiSwiss 6x14 – KinematicMultiSwiss 6x14 – 动力结构
• Integrated Y axis in option in pos X3 or X4集成式Y轴,可选配在工位X3或X4
• Easy Chip management料屑管理简单
• Ergonomy人体工学设计
32 THINK PARTS - THINK TORNOS
Product position in our Products line产品定位
1’000 50’000 100’000 1’000’000 产量
Com
plex
ity工
件复
杂性
SAS16
Single spindle
MultiAlpha
MultiSigma/MultiDeco
MultiSwiss
34 THINK PARTS - THINK TORNOS
How to make the right choice between Single / Cam Multi‘s/ and Multispindle CNC
machines?
如何正确选择单轴车床、凸轮多轴车床和数控多轴车床?
35 THINK PARTS - THINK TORNOS
Starting point for the decision: Questions作出决定的第一步:问问题
• What is the volume of parts? 工件产量
• If over 50’000 parts-- Multispindle can be interesting (count for same part, or same part family)如果产量高于5万件- 多轴车床更合适(考虑相同或同类型工件)
• What is the target price per part?单个工件的目标价格
• What type/complexity of part工件类型和复杂性
• Type of bar material棒料类型
• What is the available floor space?可用车间面积
• Cost of material, Tooling, manpower, maintenance, QC Costs…etc.原材料成本、刀具成本、人工成本、维护成本、质量控制成本等
• What is the possible investment for this project?该项目的投资金额
Depending on the parameters: Single, CNC Multi’s or CAM Multi’s can be of course the right product根据这些参数来判断是单轴、数控多轴还是凸轮多轴合适
36 THINK PARTS - THINK TORNOS
Second point for the decision: Answers做出决定的第二步:看答案
• The parts volumes are really high and a production increase is expected in the next years工件产量很高,而且未来有可能增产
• The price/part becomes every day more and more challenging工件单价竞争日益激烈
• Part are from low to high complexity, you need to be flexible.Change over set-up often, you need a flexible solution.简单工件和高复杂性工件都有,机床调试更改频繁
• Type of bar material to machine becomes more and more difficult to machine棒料类型日趋难以加工
• Floor space becomes an issue车间面积紧张
• All the direct costs increase all the time所有直接成本一直上涨
It’s certainly time to invest on Multispindle products.Contact us we can help you making the right choice肯定需要投资多轴车床联系我们帮您选择正确的机型
37 THINK PARTS - THINK TORNOS
Multi’s are an investment for the future多轴车床是未来的投资趋势
项目 多轴 单轴 备注台数
单价(人民币)等同价格
产品一致性等同价格 差额
操作工
薪水(10万人民币/年/人)5年差额
用地(平方米)租金(1元/平米)
其它 节能
5年差额
制造能力高
质量控制成本低便于复制
38 THINK PARTS - THINK TORNOS
Tornos Multispindle Market PositioningTornos多轴车床的市场定位
复杂性
产量
凸轮车床界线
MSw标准界线
MSw最大界线
单轴车床的价格优势
MultiSigma的价格优势
MultiSwiss 的技术优势
MultiSwiss 的灵活性优势 SAS的价格优势
39 THINK PARTS - THINK TORNOS
Are Cam Multi’s more productive than CNC Multi’s: Not always凸轮多轴产量高于数控多轴:并不总是如此
Business case商业案例
Customer: France客户:法国Application: Aerospace应用领域:航空Material: Stainless steel 303 or Titanium原材料:303不锈钢或钛Batch size: from 10’000 to 100’000 parts批量大小:从1万到10万个工件
Highlights:亮点 Polygoning
多边形加工 Better tools life
刀具寿命更长 Precision
精度更高 Better finish
表面光洁度更好 Standard round material
标准圆形材料
8 mm. 0,31"
10 mm. 0,40"
40 THINK PARTS - THINK TORNOS
Business case — Process comparison商业案例 — 工艺对比
Multispindle - Cam凸轮多轴
MultiSwiss 6x14
Cutting Speed [m/min] 切削速度 65 120Spindle speed [Trs/min] 主轴转速 2800 4200Cycle time [s] 循环时间 8 6Material Over cost (cut bar)棒料附加成本(棒料预制) +8 %
Material saving(face, remnant)棒料节省(偏端面,尾料) 20%
Investment to start (machine)投资启动(车床) +20 %
Parts produced (cycle time, efficiency due to tool life, bar load)零件生产(循环时间,与刀具寿命相关的效率,上料)
+30 %
Tooling cost per piece单件刀具成本 0.05 Euros 0,01 Euros
Variable cost (operator, consumable)可变成本(操作工,消耗品) + 50%
Cost per piece (Material, tooling, variable, machine)单件成本(原料,刀具,可变成本,车床)
+30%
Gain after a year production生产一年后利润 25%
41 THINK PARTS - THINK TORNOS
Some Multispindle applications多轴车床应用
42 THINK PARTS - THINK TORNOS
Part example工件样品
Watch industrie钟表
Automotive汽车
Electronics 电子
Medical医疗
Aeronautics航空
43 THINK PARTS - THINK TORNOS
Market Segment – Automotive细分市场 — 汽车
• Injection systems 喷射系统
• ABS 防抱死系统
• Automatic transmissions 自动变速装置
44 THINK PARTS - THINK TORNOS
Market Segment – Medical细分市场 — 医疗
• Bone screws 骨钉• Implants 植入物• Devices 器械
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Market Segment – Electronic细分市场 — 电子
• Hard disk drive 硬盘驱动器• Contacts 接触器• Connectors 连接件
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Market Segment – Micromechanic细分市场 — 微机械
• Watch industry 钟表行业• Precision instruments 高精密仪器• Aerospace
… where thousands of cam operated machines can be replaced该领域有数千台凸轮车床可以升级换代
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Electronic电子
Machine 机床 MultiSwiss
Dimensions 工件尺寸 Ø 7.05 x 2.05 mm
Material 材料 430F
Cycle time 循环时间 28 parts / min
Challenges 难点 High production高产量Special part extraction特殊取件方式
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Medical – bone screw医疗 — 骨钉
Machine 机床 MultiSigma 8x28
Dimensions 工件尺寸
Ø 7.49 x 59.14 mm
Material 材料 Ti6 A14V 医用钛合金
Cycle time 循环时间
1.5 parts / min
Challenges难点
Thread whirling螺纹旋风铣Hex milling多边形铣削
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Medical医疗
Machine 机床 MultiSwiss
Dimensions工件尺寸
Ø 9.9 x 5.3 mm
Material 材料 Ti6 A14V 医用钛合金
Cycle time 循环时间 5.3 parts / min
Challenges难点
Tools wear刀具磨损Hex broaching六边形插削
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Automotive know-how汽车行业技术诀窍
Airbag安全气囊
BrakingSystem制动系统
Injection(Gasoline)
燃油喷射(汽油)Bearings轴承
Axis轴
Hydraulic液压
Gearbox变速器 Spark-
Plugs火花塞
Valves阀门 Injection
(Diesel)燃油喷射(柴油)
Turbo涡轮增压机Electric Motors
电子马达
Steering转向装置
Engine Component发动机元件
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Automotive - Glow plug汽车 — 电热塞
Machine 机床 MultiAlpha 8x28
Dimensions 工件尺寸 Ø 14.3 x 94.7 mm
Material 材料 1.4305 (303)
Cycle time 循环时间 1.8 parts / min
Challenges难点
Support of the part while machining加工过程中支撑工件Deep drilling深孔加工
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Brake – Housing制动器壳
MD208009b
Machine 机床 MultiAlpha 8x28
Ø 外径 21.0 mm
Material 材料 SAE1018
Cycle time 循环时间 8.5 sec
Challenges 难点 Chips management料屑管理Off-center milling偏心铣削
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Automotive - Regulation valve汽车 — 调节阀
Machine 机床 MultiSigma 8 x 28
Dimensions 工件尺寸
Ø 9.98 x 67 mm
Material 材料 AlMgSiPb
Cycle time 循环时间
9.6 parts / min
Challenges难点
Straightness 0.006+/-0.0035平直度 0.006 +/-0.0035
Axial deformation轴向变形
MD20017
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Automotive汽车
Machine 车床 MultiSwiss
Dimensions 工件尺寸
Ø 9.95 x 5.78 mm
Material 材料 Brass 黄铜
Cycle time 循环时间
7.7 parts / min
Challenges难点
OD tolerance ± 0.003 mm外径公差± 0.003 mmCross drill / deburring径向钻孔/去毛刺
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Watch industry – tenon钟表行业 — 榫
Machine 车床 MultiSwiss 6x14
Dimensions 工件尺寸
Ø 2 x 1.8 mm-material diam.4mm
Material 材料 1.4435 (316L)
Cycle time 循环时间
8 parts / min
Challenges 难点
Small size尺寸精细Tolerance (Ø 0.9 ± 0.003 mm)公差(Ø 0.9 ± 0.003 mm)Threading by polygoning多边形螺纹
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End
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