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Novem
ber2018
EUROPEAN
TOOL&MOULD
MAKIN
GVolum
eXX
issue11/12
CUTTING TOOLS
Indexable toolsfor small diametersPage 40
EXTRA
EDMBuyer's GuideAnnual sourcing directorywith supplier database
Page 49
THE MAGAZINE
www.etmm-online.comVolume XX | November 2018
ISSN 2194-7589€ 12.00
11/12
Show PreviewThe next generation of manufacturingtechnologies at Formnext 2018
Page 22
Zoomed InOkuma: From noodle machinesto high-tech machining centres
Page 48
Additive technologyand toolsHow toolmakers can applyadditive manufacturing
Page 18
EUROPE A N TO OL & MOULD M A KING
document4033139523248042388.indd 1 18.10.2018 14:14:26
Progressive’s CVe Monitors are on moulds worldwide. This mould
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• PressManagementModule to schedule, track, and store PM actions
• Expanded filing cabinet for storing non CVe assets to database
• Enhanced report options for viewing deviations from set targets
CVe Live displays data in an easy to understand format that allows
users to identify mould issues today, that could impact the supply
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ETMM-NovDec-2018.indd 1 10/16/2018 6:53:40 AM
11/12-2018
EDITOR’S MESSAGE
3
Welcome tothe jungle!
Are you able to spon-taneously explainthe difference
between FDM andPEM? Short hint: Bothare abbreviated termsfor additive manufac-turing processes. To behonest, I could not haveexplained it either. FDMstands for Fused Deposi-tion Modelling and is avariant of material extrusion.Wire-shaped material, so-calledfilament, is plasticised in a noz-zle unit and selectively dosedlocally in layers. PEM or PasteExtrusion Modelling also be-longs to the field of material extrusion. Here, however, thematerial is dosed selectively and locally layer by layerthrough a piston-nozzle unit. If you compare the two pro-cesses visually, you can immediately see the difference. Theterminology, however, is sometimes too abstract to keeptrack of – especially since there is a seemingly endlessnumber of different additive processes and new ones arebeing added constantly.
For beginners, this makes it particularly complicated. Andone cannot always separate the procedures at first sight.Especially with metal processes that work with a powderbed, the machines cannot be distinguished at first glance.And then, there is the fight through the jungle of abbrevia-tions. Besides FDM and PEM, there are of course SLS, SLA,SLM, NPJ and MJF. Everything clear?
Fortunately there is help. The organisers of the Formnexttrade show (see p. 22) have developed the “Additive Manu-facturing Field Guide” together with Reutlingen University.The information brochure not only provides a clear over-view of the most important processes but also a descriptionof the entire process that is necessary for additive manufac-turing, which is often neglected. This gives all newcomersto the field the opportunity to gain a quick overview and bebetter informed for discussions at the trade fair. The guidewill not only be available at the trade fair but also online onthe Formnext homepage. Even if you don't plan to visit thetrade show, you can use the guide as a quick informationtool whenever you feel lost in the additive manufacturingjungle.
Rosemarie [email protected]
www.mmc-hardmetal.com
iMX
2 NEW GRADES EP8110 & EP81202 NEW BALL NOSE GEOMETRIES
IMX-B2SBALL NOSE,
2 flute, Ø10 - Ø20
iMX - Mitsubishi’s advanced technology,interchangeable head end mill series.
EP8110 and EP8120 multi-layer coatedgrades for hardened steel applications.
iMX-B2S and iMX-B3FV ball nosegeometries for finishing andlong overhang applications.
IMX-B3FVBALL NOSE,
3 flute, Ø10 - Ø20
document9040628953430970057.indd 3 19.10.2018 12:47:37
4 11/12-2018
NEWS
BY THE NUMBERS6 Industry trends, facts and figures
INDUSTRY8 Attacks cost €43 billion damage
10 Incoe USA completes move intonew global headquarters
12 Technology Days focus on trendsin automotive sector
MARKETS14 Forming processes are increas-
ingly digital
SPECIAL REPORT
HOT RUNNERS16 Günther invests in a successful
future
SHOW PREVIEW -FORMNEXT
SHOW SPECIAL22 Additive solutions for everyone at
Formnext 201824 Q&A: It is worthwhile for every
company to take a look at thetechnology
26 Tool and mould suppliers guide toFormnext 2018
28 Additive Manufacturing: Costfactors and cost optimisation
31 Five tips for additive manufactur-ing designs with SLM
PRODUCTS32 “Big version” Freeformer for in-
dustrial AM of complex parts33 Ensuring safe, trouble-free AM
and side-stepping risks
PRODUCT FOCUS
TOOL & MOULD COMPONENTS36 Backlash-free and high-precision
connection
TECH FOCUS
CUTTING TOOLS40 Indexable tools challenge solid
carbide for small diameters42 Creating a new cutting tool –
From concept to spindle
CASE STUDY
CAD/CAM, DESIGN &SOFTWARE
45 Simulation and direct designmakes the difference
EDM EUROPE BUYER'SGUIDE
ELECTRICAL DISCHARGEMACHINING
50 When does EDM make sense?
COVER STORYAdditive manufactur-ing and tools P. 18
No, additive manufacturingwill not replace mass pro-duction processes any timesoon. However, as a sup-porting technology, it canimprove mould-making pro-cesses drastically, upgradingmanufacturing efficiency. Wecompiled several examplesof how tool makers can useadditive manufacturing atdif ferent stages of their pro-duction processes to in-crease their efficiency.
TIP
Looking for EDM equipmentand supplies? This issue includeseight supplier grids thatcan help you find the rightsupplier.Rosemarie Stahl
Editor
document6805001791856717302.indd 4 19.10.2018 12:48:10
511/12-2018
PRODUCTS AND SOURCINGGRIDS
53 Software54 Materials56 Machining Accessories58 EDM Accessories & Supplies60 Automation61 EDM Equipment62 Machining Equipment64 Quality Control
REGULARS
3 Editor’s Message
48 Zoomed in
67 Company Index / Masthead
TOP ONLINE
RankingThis month's most-clicked articles on etmm-on-line.com
1. Hot Runners: Mold-Masters cele-brates its 30th anniversary in Germany
2. Picture Gallery: Product highlights inOctober 2018
3.Additive Manufacturing: HP wantsto make 3D printing ready for massproduction
4. Materials: The future of metal tradingis digital
5. Hot Runners: Specialist offers solu-tions for plastic processing
Subscribe to our newsletterW etmm-online.com/newsletter
FacebookW facebook.com/ETMMMagazine
EventsW etmm-online.com/events
Suppliers databaseW etmm-online.com/suppliers
Photo galleriesW etmm-online.com/galleries
Industry newsW etmm-online.com
ETMM MediaW media.vogel.de/etmm
since 1963
Türk+Hillinger GmbH78532 Tuttlingen, Germany
Tel. +49 74 61 70 14 0Fax +49 74 61 70 14 110
www.tuerk-hillinger.de
FLEX - Flexible tubular heaters
HLP - Cartridge heaters
RHK - Tubular heaters
RP - Tubular cartridge heaters
HP/HPQ - Nozzle heaters
TE - Temperature sensors
ALW - Power resistors
Technical support and otherproducts on request
NEW!
MADE INGERMANY
The coverimage ofthis issue issponsoredby Iscar.
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document6805001791856717302.indd 5 19.10.2018 12:48:18
NEWS BY THE NUMBERS
6 11/12-2018
TICKER
BHUTAN, one of the greenest countries in the world, is CARBON NEGATIVE. It removes more greenhouse gasses from the atmo-
sphere than it emits. Spanning 14,800 sq/miles, some 70% is covered by woodlands that act as a natural carbon sink, absorbing
CO2. Bhutan says its 750,000 inhabitants remove three times as much CO2 than it produces. (Source: CNN) +++ UnescoWORLDHERITAGE SITES can trace its origins back to November 1972 when Unesco signed a convention to protect the common cultural
heritage of humanity. Of the 1,092 Unesco World Heritage Sites worldwide, 845 are cultural, 209 natural and 38 a mixture. (Source:
Unesco) +++ The value of the €50 banknote in CIRCULATION was highest in 2017, amounting to €491.3 BILLION; the lowest in
circulation is the €5 banknote at €9.3 billion. Only the ECB has the right to authorise the issuance of € banknotes. (Source: ECB)
QUOTE OF THE MONTH
TRENDS
Trade, industrial production
Climate-related-disaster costs
NUMBER GAMES NUMBER OF THE MONTH
In almost all productionareas, the use of additivemanufacturing bringsadvantages.Sascha WenzlerVice-President of Formnext atMesago Messe Frankfurt
+1.0%In August 2018, com-pared to July 2018,seasonally adjustedindustrial productionincreased 1.0% in theEA19 and 0.8% in theEU28. Compared toAugust 2017, it rose0.9% (EA19) and 1.2%(EU28). (Source: Eurostat)
+11%2017 was great formanufacturing, but 2018will be record-breakingthroughout the industryin the U.S. Machine toolconsumption will mark$7 billion and a forecastof a further 11% growthin 2019. (Source: Gardner
Business Media)
+0.02%In 2016, the annualaverage exchange rateof the € to the USD was1.11, meaning €1 couldbuy USD1.11. In 2017,this rate was 1.13, anincrease of 0.02%.Highest over the last 20years was in 2008 at1.47. (Source: ECB)
Market share of the most widely used mobile voice assistants (as of May 2018):
Siri from Apple .......................................................................................... 45.64%Google Assistant from Google .....................................................................28.7%
Alexa from Amazon......................................................................................13.2%Bixby from Samsung....................................................................................6.23%
Cortana from Microsoft................................................................................4.88%Others..........................................................................................................1.35%
(Quelle: voicebot.ai, Statista)
The search engine Duck Duck Go receivesnearly 30 million searches daily. Unlike Google,it does not collect user data nor use person-alised advertising. In 2015, the 10 million-per-day mark was cracked. It was 20 million in2017 and in October 2018, almost 30 million.Techcrunch says, Google, however, handles atleast three billion per day. (Source: Statista)
million a day30
World trade & global industrial production: Economicoutlook is down since early 2018. Economic uncer-tainty is high: Index average of May-July 2018 is 90%higher than the 1997-2015 average. (Source: CPB, IWKöln)
Seen here are total economic costs globally over 20year periods. Storms, droughts, floods and heat-waves caused about $895 billion of losses from1978-1997. From 1998-2017, this increased 151% to$2.25 trillion. (Source: UN Off.-disaster risk reduction, Statista)
1/14 7/14 1/15 7/15 1/16 7/16 1/17 7/17 1/18
125123121119117115113111109107105
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Worldtrade Global industrial production
Three-monthmovingaverages:
priceandseasonallyadjusted,2010=
100
document2373061048953903566.indd 6 19.10.2018 12:48:32
INDUSTRY NEWS
11/12-2018
To see how Mastercam 2019 helps streamline your entire process,from job setup to job completion, visitMastercam.com/2019.
CNCProgramming
Job Management& Documentation
Preparation/Setup
ValidationTool Support
THE FUTURE STARTS HERE
Global interest in German connectivity initiative
Germany – VDW has justlaunched Umati (universalmachine tool interface), astandard interface for ma-chines. Unveiled recently atAMB Stuttgart by VDWChair-man Dr. Heinz-Jürgen Prokop,its purpose is to provide great-er visibility to the industryinitiative, Connectivity forIndustry 4.0, which waslaunched a year ago. As a
brand, Umati is open, fu-ture-oriented and internation-ally connectable, Prokop said.Demo applications dis-
played at AMBwere developedby a team of eight machinetool suppliers and Germancontrol manufacturers. Now, ayear later, over 100 parametersserve as the basis for develop-ing the interface. The grouphas defined 21 use cases for the
standard interface formachinetools based on the open OPCUA communication protocol.Launched initially as a Ger-
man initiative, internationalco-operation was actually thegoal, which, meanwhile, is al-so attracting global attention.Talks are underway with theU.S. sister association, AMT,especially regarding the openinterface, MTConnect. The ex-
tent towhich parts of this canbe used in Umati or whetherboth standards can be alignedin the long term is being as-sessed, VDW explained. Fur-thermore, Japan, China andSouth Korea have expressedinterest in the new standard.The progress of the project
can now be tracked on the In-ternet as well.umati.info
UK's futureengineers
UK – Renishaw attended therecent South West Big BangFair at the University of theWest of England (UWE) inBristol to help inspire a newgeneration of engineers. Thecompany offered career adviceand ran engineering activitiesfor visitors at its booth.Engineering UK research
found that only 36% of eleven
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Children’s activities at the BigBang Fair 2018.
to fourteen-year-olds knowthe steps to take after finishingsecondary school to becomean engineer. To change this,Engineering UK set up BigBang Fairs across the countryto give students access to ca-reer advice from local engi-neering companies.Some of Renishaw's science,
technology, engineering andmaths (STEM) ambassadors(apprentices, graduates andengineers) attended the fair tohelp students and parents un-derstand more about the sec-tor. Visitors had the opportu-nity to speak to these ambas-sadors about the differentpaths into engineering, offer-ing practical advice based ontheir own experiences.renishaw.com
document2853637592614976706.indd 7 19.10.2018 12:49:14
NEWS INDUSTRY
8 11/12-2018
NEWS IN BRIEF
30th anniversaryShareholder MD ofAHP Merkle, Chris-tian J. Merkle,recently celebratedhis 30th anniversa-ry at the company.Merkle, who
turned 50 in March, joined the com-pany at a time it was having financialdifficulty. Since the turnaround sever-al years later, AHP has been markingsteady growth, manufacturing hy-draulic cylinders for tool andmould-making, machine tools, spe-cial machine construction, aluminumdie casting, hydroforming and de-burring tools in Germany.ahp.de
New territory managerfor CNC SoftwareCNC Software,developers ofMastercam, re-cently announcedthat Mike Bebouthas assumed thenew role of West-ern U.S. Territory Manager to furtherdevelop the company’s distributionchannel and identify areas for growthand improvement.mastercam.com
Boeing and Haimerpartnership
The partner-ship be-tween Boe-ing and theGerma-ny-basedHaimerGroup hasbeen strate-
gically expanded to include a jointmembership at the OMIC R&D (Ore-gon Manufacturing Innovation CenterResearch and Development) institute.Now totaling 17 manufacturing indus-try partners and three Oregon publicuniversities, the Scappoose, Oregon,USA-based R&D institute continuesto build a world-class operation todevelop advanced metal manufactur-ing technologies with a strong mem-bership base and through its collabo-rative research and developmentactivities.haimer.de
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aimer
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CNCSoftw
are Attacks cost €43 billion damage
Germany – Sabotage, data theft and espi-onage have caused the German industrya loss of €43.4 billion in the past two years.Seven out of ten industrial companies(68%)were victims of such attacks duringthis period; one in five companies (19%)suspected this. This isbased on a study by thedigital association, Bit-kom, in which 503 man-aging directors and secu-rity managers from allbranches of the industrywere interviewed."With its global market
leaders, the German in-dustry is particularly in-teresting for criminals,"says Bitkom PresidentAchim Berg. "Anyonewho does not invest in ITsecurity is behaving neg-ligently and is endanger-ing his company.” In thepast two years, a third ofthe companies (32%) hadIT or telecommunica-tions equipment stolen, while almost aquarter (23%) lost sensitive digital data."Illegal knowledge and technology
transfer, social engineering and economicsabotage are not rare individual cases buta mass phenomenon," Thomas Halden-wang, Vice President of the Federal Officefor the Protection of the Constitution (BfV),notes. And it is not only theft that causesproblems for the industry: Every fifth in-dustrial enterprise (19%) reported digitalsabotage of company information and
production systems or operational pro-cesses. In 11% of the cases, digital commu-nicationwas spied out from channels suchas emails or messenger services. Overall,digital IT attacks caused damage for al-most half the respondents (47%). Classic
analogue attacks are alsoan issue for the industrybut are comparativelyless significant. Some 21%of the respondents foundthat sensitive physicaldocuments, samples ormachines had been sto-len. In 10% of the cases,analogue sabotage ofcompany informationand production systemsor operational processesoccurred, e.g., through themanipulation of deviceson-site.Haldenwang adds: "In
addition to classic indus-trial espionage, we areincreasingly concernedabout attacks on the as-
sumption that malware is introduced in-to IT systems with the aim of preparingto sabotage files.”According to Bitkom, it is often the em-
ployees (61%) who ensure that criminalactivities in affected companies are final-ly uncovered. Some 40% of those affectedreceived indications of attacks by theirown security systems, whereas almost aquarter (23%) was alerted purely bychance.bitkom.org
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In almost two-thirds of the cases(63%), the perpetrators wereformer or current employees.
“Illegal know-ledge and tech-nology transfer,social engineer-ing and eco-nomic sabotageare a massphenomenon.”Thomas Haldenwang, VP of BfV
document6495901445375767959.indd 8 19.10.2018 12:49:42
NEWS INDUSTRY
10 11/12-2018
Manufacturing show breaks all-time records in Chicago
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IMTS
2018
AMT President Douglas K. Woods (r) and Deutsche Messe CEO Dr.Jochen Koeckler opened IMTS 2018.
USA – IMTS 2018, the Interna-tional Manufacturing Technol-ogy Show, which ended 15September, has set all-timerecords for show metrics.Owner cum producer of theshow, The Association forManufacturing Technology(AMT), noted that the 32ndedition drew a record of 129,415visitors with 2,123 booths and2,563 exhibiting companies on1,424,232 sq/ft of exhibition
space at Chicago’s McCormickPlace in Illinois, recording in-creased numbers, from regis-trants through to booths andexhibiting companies.“Connectivity, the digital
transformation ofmanufactur-ing, automation, additivemanufacturing and a strongeconomy drove record num-bers at IMTS 2018,” says PeterR. Eelman, Vice-President, Ex-hibitions & Business Develop-
ment at AMT, adding that thesix-day showwitnessed a highdegree of collaboration amongexhibitors to develop additivemanufacturing, automationand connected systems.In his address to the IMTS
audience, Illinois GovernorBruce Rauner stated: “Thereare four reasons why manu-facturers from around theworld are coming to the stateof Illinois to build great prod-ucts – people, transportation,innovation and energy.” Raun-er added that Illinois is the17th-largest manufacturingeconomyworldwide, generat-ing 600,000 manufacturingjobs and producing manufac-tured goods worth USD 100billion.Historically, the years be-
tween IMTS lead to incremen-tal machine improvements,which are now reaching phys-ical limits. “The velocity ofchange has become different,”Tim Shinbara, AMTVice-Pres-ident says.
Notable growth areas atIMTS included an expandedAdditiveManufacturing Pavil-ion, while the strong partner-ship with Hannover MesseUSA and its four co-locatedshows aswell as an expandedSmartforce Student Summitdrew more visitors comparedto the last edition in 2016. Over2,500 visitors attended confer-ence sessions during theweekof IMTS, with additive manu-facturing and connected/digi-tal manufacturing being themost popular themes at con-ference sessions. AMT Presi-dent Douglas K. Woods says:“Hannover Messe USA andIMTS bridge the gap betweenSilicon Valley technology andmain street manufacturing.”“We want all visitors to be
more competitive in this glob-al world. People need to con-nect and collaborate,” says Dr.Jochen Koeckler, CEO ofDeutscheMesse AG, HannoverMesse’s parent organisation.imts.com
Incoe USA completes move into new global headquarters
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The new global headquarters of Incoe accommodate sales, design,manufacturing and an injection-moulding technical centre on a totalarea of 12, 820 sq/m.
USA – Incoe Corporation USAannounced the successfulmove of three facilities in theMetro Detroit area into theirnew 12,820-sq/m global head-quarters, which took placethroughout the month of Au-gust. Formerly headquarteredin Troy, Michigan, the newfacility is located within Oak-land Technology Park at 2850High Meadow Circle, AuburnHills, Michigan 48326. BobFons, Plant Manager for Incoe,commented, “We planned themove in as much detail as wecould in the time that we had.We executed the plan success-fully, and over the four-weekmove of manufacturing andoffice equipment we were al-ways operational in some ca-pacity. Hot runner systemswere continually being de-signed, manufactured, in-spected and assembledthroughout the entiremovingprocess.”Developed by the General
Development Company, the
USD 20 million facility is de-signed to improve operationalefficiency within the organi-sation by situating dependentprocesses in closer proximityto one another.Within the office area, open
collaboration spaces alonghigh traffic pathways havebeen created to provide casual
meeting spaces. The7,900-sq/mmanufacturing ar-eawas designed around a cen-tral space containing QualityControl, Inventory Manage-ment and shop offices tomax-imise process flow.Ghafari Associates was the
project consultant for Incoeduring layout and build of the
new global headquarters facil-ity. Ghafari helped customisethe manufacturing layout forIncoe’s specific needs, and al-so provided interior office de-sign recommendations. Court-ney Seres, VP Corporate Ad-ministration and buildingproject manager for Incoe,said, “We couldn’t have donethis without the expertise ofGhafari. We know hot runnersystems but we’re not facilityexperts. We knew what wewanted for our employee ex-perience inside the new build-ing, and Ghafari helped realisethese expectationswith guid-ance on best practices for cur-rent facility trends. The resultsare stunning.”The project reached its com-
pletion during the year thatIncoe is celebrating their 60thanniversary. Incoewas found-ed in 1958 by Alex Seres, whoreportedly developed and pat-ented the first commercial hotrunner nozzle.incoe.com
document5320023475403644713.indd 10 19.10.2018 12:49:57
www.iscar.com
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LOGIQ ADS ETMM.indd 2 27/09/2018 13:35:52
NEWS INDUSTRY
12 11/12-2018
Tool’s profile accuracy, complex geometry cut out to be winner
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a
All six finalistsin a row.The winning toolfrom Contour360is second fromright.
Australia – Anca announcedthe winner of its first Tool ofthe Year award at the recentIMTS in Chicago. Contour360,designer andmanufacturer ofhigh-performance solid car-bide round shank tools, wonthe Anca Tool of the Yearaward for its creative andeye-catching tool.Contour360 Vice-President
and General Manager CharlesR. Day said: “While indeed thisrecognition speaks for thecraftsmanship of our toolmak-ers, it also makes a tremen-dous statement about the
craftsmanship of the ma-chine-maker and the supportprovided.” Day added thatContour360 utilisesmany dif-ferent types of Ancamachines,including three recent addi-tions of new equipment – theFX7 Linear wheel exchangers,lasermeasurement equipmentand a Fanuc Robomate.For the competition, Anca
said its customers could sub-mit their favourite tool. Theprize is a trip for two to theAustralia-based Anca HQ inMelbourne to see, firsthand,how the technology is created
and also tomeet the team thatis dedicated to finding evenbetter solutions for customerneeds. All other finalists – Dai-ly Grind Industrial Tool, AcuTwist, Miltera Machining Re-search Corp., San Engineeringand Supply aswell as ZakładyMechaniczne Kazimieruk – re-ceived anAnca software pack-age of their choice.To determine the top tool,
the panel of judges applied thefollowing criteria:W Best surface finish in Ra(roughness average) valueon the flute or gash surface
W Tool closest to the nominaltolerance as stated on thedrawing in terms of diam-eter and profile (for e.g., ifthe diameter tolerance is+/- 0.010mm and the toolis measured to 0.005, thenthis will rank favourably)
W Tool ground to the tightesttolerance as per the draw-ing (tool with the lowesttolerance will rank favour-ably)
W Complexity level (in termsof the number of steps,profiles)“After measuring the surface
finish and geometry on theAlicona and Zoller machines,respectively, all votes weretallied and Contour360 wonfor their complex tool, whichwas brilliantly executed.Grinding a complex tool likethat requires sharp wheels,accurate qualification ofwheels and a perfect set-up,”Anca co-founder Pat Bolandnoted.anca.com
Technology Days focus on trends in automotive sector
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Full house in Bensheim: The Technology Days organised by Synventivebrought tool and mould makers together with experts in surface tech-nology.
Germany – On 07 September2018, hot runner specialistSynventive invited injectionmoulders and mould-makersto Bensheim, Germany, for the20th Bensheim TechnologyDays. This year's edition of theannual event was themed“Trends in Automotive – In-creased requirements in injec-tion moulding with regard tosurface finish and functional-ity of new part concepts”.A total of seven presenta-
tions were held by experts ondifferent aspects related toautomotive design and func-tionality.All in all, it became clear that
the demands placed on thequality and functionality ofsurfaces are rising sharply. Thechanges in the automotivesector have a great influenceon which technologies willplay a role in the future. Thepresentations by experts pro-vided insights into differentperspectives on the subject ofsurface finishes.
Klaus Gerst from BertrandtIngenieurbüro spoke about thevehicle interior of the futureand the challenges for a devel-opment service provider. Henoted that his company is al-readyworking on concepts forsurfaces to be adapted in au-tonomous driving.The second presentation
was held by Ruud Heerkens
from Sabic Innovative Plasticson the topic of “Improving thesurface aesthetics of large pan-els using active gates”. Heshowed examples of improve-ments of the surface qualitywhen applying advanced flowcontrol in injectionmoulding.Philipp Lachner fromKrauss
Maffei Technologies spokeabout “Surface technology 2.0
– Trends and process solutionsfor an economic application.”Among the solutions present-edwere DynamicMould Heat-ing (DMC), Color-Form, a tech-nology combining paintingand injection moulding, andlabelling and decorating pro-cesses.Other speakers included
Christian Götz, Hans-JörgSchreyer, and Volker Gründelfrom Synventive MoldingSolutions. The experts present-ed applications and develop-ments of Synventive's hotrunner technology, for exam-ple, hot runner systems forapplications with long glassfibres.The day was rounded off
with a guided tour of Synven-tive's facilities, including thedepartments for manufactur-ing, development and assem-bly. Afterwards, the partici-pantsmet for dinner followedby a visit of the traditionalBensheim wine festival.synventive.com
document3037611111135623817.indd 12 19.10.2018 12:50:22
TaeguTec Ltd. World Headquarters1040 Gachang-ro, Gachang-myeon, Dalseong-gun, Daegu 42936, KOREA
+82-53-760-7640 +82-53-768-8055 www.taegutec.com
Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Bulgaria _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Finland _ FranceGermany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Lithuania _ Malaysia _ The Netherlands _ New ZealandNorway _ Pakistan _ Philippines _ Poland _ Portugal _ Romania _ Russia _ Serbia _ Singapore _ Slovakia _ SloveniaSouth Africa _ Spain _ Sweden _ Taiwan _ Thailand _ Turkey _ Ukraine _ United Arab Emirates _ United Kingdom _ U.S.A. _ Vietnam
INDUSTRIAL APPLICATIoNS
Quick change system - head indexing on the machineFlexibility - one drill body for a series of different sized headsTwisted coolant channel and polished chip gullet- Smooth and excellent chip evacuationRigid connection - remarkable performance andmaximum number of head indexingNew multi-layered coating grade (TT9080) - prolong tool life
ti C h R D k Fi l d F
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P2Double margin for premium hole quality
14 11/12-2018
Industry 4.0 is also finding itsway into forming technology.Among other things, thisraises the question of thefuture demand for employees.
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Digital change does not stop at any industry.Step by step, Industry 4.0 is expanding.Whatwas a vision of the future a few years ago is
already reality in many areas today. Forming tech-nology is also changing as a result of increasingdigitisation and interconnection. However, manysuppliers are still cautious about the concrete im-plementation. The implementation of a connectedIndustry 4.0 environment is usually associatedwithhigh investment costs. At the same time, theamount of data generated is enormous. Only witha targeted analysis of this data can a company ul-timately generate added value for itself. For com-panies, thismeans reacting to the requirements forappropriate tools and trained personnel.However, digital and connected production can
also help companies to increase their efficiency andcut costs. Within the framework of Industry 4.0,for example, processes can be automated andmademore transparent. At the same time, increased flex-ibility ensures that suppliers can meet individualcustomer requirements better. Additionally, they
can respond to changes in the market much morequickly. Intelligent monitoring solutions enablepredictive maintenance. Those who invest in dig-itisation and connected processes at an early stagecan possibly gain a competitive advantage.
Transparent processes and highflexibility
The Fraunhofer Institute for Machine Tools andForming Technology shows how Industry 4.0 canbe implemented in the field of forming technology.The institute has developed a compact-format pressfor demonstration purposes. It was presented forthe first time at this year's Hannover Messe andwas also on display at Euroblech 2018 in Hannover.The press permanently and in real time monitorsthe condition of its own hardware, as well as thestarting material, the forming process and, finally,the quality of the components it produces. A digitaltwin of the machine and process is generated viasensor data from the machine structure and tool,
Forming processes areincreasingly digitalWhen it comes to the introduction of Industry 4.0 applications,many suppliers are currently still holding back in the field offorming technology. However, interesting new developments andsolutions for digitised and connected forming already exist.
Rebecca Vogt
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MARKETS NEWS
ensuring transparency in all production-relevantprocesses.Trumpf, for example, has developedTruconnect,
a range of solutions for the intelligent factory (SmartFactory). With Truconnect, the supplier wants tosupport companies on their way to connected andsmart production that canmeet the increasing de-mands for smaller batch sizes, for example. Theaim is to improve the entire value chain. Particularattention will be paid to indirect processes. Theseare decisive for competitiveness, as Florian Langer,head of Truconnect at Trumpf, reported in May ata conference titled “Recent developments in sheetmetal forming”. Indirect processes account foraround 80% of the throughput time, while only 20% is accounted for by the actual processing.
Application examples and solutionofferings
TheMobile Bending Cell from Bystronic, for exam-ple, takes account of the increasing demand forflexible production. The bending cell consists oftwo parts – a press brake and a mobile bendingrobot. Complex small series can be producedman-ually with the device, large series automatically.Mathias Hasecke, Managing Director at supplierHa-Beck, has been using the Mobile Bending Cellin his company since 2017. “The trend is clearlytowards bending automation,” Hasecke told
21– 24 May 2019#MEX2019
After AMB is
before MEX!
Messe Stuttgart, Germany
www.moulding-expo.com
ETMM's partner magazine, MM Maschinenmarkt,in August.
Will the Smart Factory still needemployees in the future?
All in all, the increasing automation in the courseof Industry 4.0 raises the question of the future roleof employees. Against this background, the Wis-senschaftliche Gesellschaft für Produktionstechnik(Scientific Society for Production Technology) hasdeveloped a position paper on the industrial work-place of 2025. Some 120machine tool manufactur-ers and operators were surveyed. The scientistsused the results of the survey to define automationlevels for production. This way, companies shouldbe able to obtain a kind of benchmark for theirdegree of automation. They are also able to recog-nise whether there is any need for action. After all,automation is not meaningful or necessary every-where. However, future production plants presum-ably will take over their optimisation and that ofthe associated processes increasingly by them-selves, according to Prof. Bernd-Arno Behrens, oneof the scientists involved in the study and head ofthe Institute for Forming Technology and FormingMachines at Leibniz University Hanover. “Never-theless, we believe that, even in the smart factoryof the future, people will still be able to make theirdreams come true in the long run.”
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SPECIA
L SPECIAL REPORT
16 11/12-2018
Günther invests in a successful futureGünther Hot Runner Technology has plenty of reasons to celebrate. Firstly,the company has been founded exactly 35 years ago. Secondly, theexpansion and renovation of the company's headquarters in Frankenberg,Germany, have been completed.
The new design of Günther’smain building in Frankenbergis based on the heaters onthe Blue Flow nozzles.
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Ayear ago, a scaffold blocked the view of thefaçade of themain building of Günther's head-quarters. When visiting today, one can see a
radiant, new front. Taking a closer look, the designof the building automatically makes sense. Thewhite panels, which draw wide curves across thebuilding, are based on the heating of the Blue Flowhot runner nozzles.The company invested a total of 2.2 million euros
in the renovation. Some 600 squaremetres of spacehave been created. In addition, the interiors weredesigned using a modern mix of wood and glass.Managing Director Siegrid Sommer states: “Theextension of the administrative, manufacturingand order-processing areas created around 600square metres of additional space, forming the ba-sis for the further optimisation of internal process-es. Management, accounting, controlling and de-velopment are now united on the new upper floor.”
The building renovation was only one part of alargermodernisation project. According to the com-pany, Günther invested a total of 5 million euros.Whatwas not invested in the renovationwas spenton new technologies and machines. “Only a con-tinuous investment in machinery and infrastruc-ture ensures the high quality of our hot runnernozzles and systems,” said Sommer. In addition toits headquarters in Germany, Günther also has sub-sidiaries in many other countries. The customerscome from all over the world. To ensure thateverything takes place on the same platform, thesubsidiaries in Italy andAustria were also recentlyconnected to SAP.In regard to equipment, a new cylindrical grind-
ing machine, two CNC lathes and another screenprinter for thick-film production were purchased.“We must always remain on the cutting edge oftechnology, especially with regard to the possibil-
Rosemarie Stahl
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11/12-2018 17
SPECIAL REPORT
ities of digitisation,” said Sommer. The clear objec-tive of the investments was to facilitate the intro-duction of new technologies while taking automa-tion into account. With the new Index CNC lathe,for example, set-up times can be minimised andset-up costs saved thanks to a change magazinewith 120 tools. As with the milling machines, allthe necessary tools are now available on the ma-chine and can be changed automatically duringoperation. Another positive effect on process andthroughput times is automatic loading via palletand conveyor belt systems on the grinding ma-chines.
Two information-packed days
At the end of September, Günther opened the doorsto their production facility. Visitors of the Technol-ogy Days were able to see the results for them-selves. Almost 300 visitors attended the first dayin Frankenberg. The two-day event featured lec-tures on current topics such as surfaces and coat-ings, digitisation, lightweight construction andsimulations.In her opening speech, Siegrid Sommer talked
about the topics of the Technology Days: “In keep-ingwith the times, we deal with the current topicsand questions of our industry.Which new technol-ogies make it possible to increase efficiency in in-jectionmoulding?What possibilities does automa-tion offer? What will the next steps of digitisationbring? What direction is the industry taking ingeneral? All these questions are certainly of concernto you and certainly to us. And our speakers andwe would like to take the opportunity to answersome of these questions – or shall I say try to an-swer them – and explore the latest trends in injec-tion moulding.” The lectures were held in bothEnglish and German so that visitors from outsidethe German-speaking area could also learn moreabout new technologies and materials. On specialexhibition areas set up in the production hall, some24 companies took the opportunity to provide in-formation on products and to talk to visitors of theevent.guenther-hotrunner.com
Twenty different presentations were held in German and English during the two-dayevent.
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INFOGünther Hot Run-ner Technologywas founded on01 October 1983by Herbert Güntherin Allendorf-Rennertehausen,a village close toFrankenberg,where Günther isstill located today.
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International exhibition and conferenceon the next generation ofmanufacturing technologiesFrankfurt, Germany, 13 – 16 November 2018formnext.com
@formnext_expo#formnext
Discover the futureof manufacturing atformnext!
Is your head full of ingenious ideas?Are you looking for innovative partners torealize them using additive manufacturingand the latest manufacturing technologies?We provide the ideal platform.
Where ideas take shape.
document888857231611580870.indd 17 19.10.2018 12:51:52
COVER STORY
Printing the mouldNo, additive manufacturing will not replace mass production processes any time soon.However, as a supporting technology, it can improve mould-making processes drastically,upgrading manufacturing efficiency.
Rosemarie Stahl
Global AM system deployments
This statistic represents worldwide additive manufacturing systems de-ployments (including 3D printers) as at 2017, with a breakdown by use.Around 33.8 percent are functional parts. (Source: Statista/Wohlers Associates)
Share of expenditure 0% 5% 10% 15% 20% 25% 30% 35% 40%
Functional parts
Fit and assembly
Education/research
Patterns for metal castings
Patterns for prototype tooling
Tooling components
Visual aids
Presentation models
Other
33.8%
16%
10.7%
8.3%
7.4%
7.4%
7.3%
7.1%
2.8%
document3518284007867085423.indd 18 19.10.2018 12:52:58
COVER STORY
1911/12-2018
Rapid Manufacturing does not apply addi-tive manufacturing per definition. How-ever, this manufacturing method standsfor quick and flexiblemethods to produceparts without using tools. Nevertheless, it
often involves additive manufacturing. RapidManufacturing especially makes sense when a
For several years now, there has been a lot oftalk about disruptive innovations and technol-ogies. A number of trends are said to be able
to change the manufacturing industry forever.Smartmanufacturing, digitisation, Industry 4.0 andlately also 5G are set to disrupt how we work. Inall these cases, what is meant is that if the tech-nology succeeds, it will change and transform ex-istingmarkets and value networks. The problem isthat no one can truly say whether a technologysucceeds or not.In 1996, Nokia presented the first smartphone to
a world that was just not ready for it yet – or may-be Nokia's marketing teamwas not able to convincetheworld that it needed the smartphone. The com-pany that was able to successfully launch thesmartphonewas, of course, Apple, nine years later.Many innovations have failed the test of time. An-other example is Google Glass. Once praised as thenext leap in consumer technology, it was discon-tinued in 2015 (There is however still a so-calledEnterprise Edition for working environments.).There are countless stories like this in technolo-
gy – products that failed almost immediately. Theinteresting thing about the story of Google Glass isthat it was hyped so much and finally had to sur-render to real concerns: People did not like to besecretly recorded. That is the thingwith disruptivetechnology. It might be groundbreaking and itmight be innovative. But it is only disruptive if iteventuallymanages to change or displace existingmarkets.
Additive manufacturing and the hype
Additive manufacturing has also been praisedmany times as a game changer for the supply chain.It was said that 3D printing would lead to house-hold production of goods, that therewould bemorelocal production instead of centralised plants. Onevery common news title was “3D printing willchange the world”, followed by texts stating that“life on earth will soon change radically” and “in-stead of customers, we are now creators”. Thoseheadlines are now more than five years old and itseems that theworld is still prettymuch the same.The hype was exaggerated, expecially concerningthe influence 3D printingwould have in our privatelives. However, there are areas inwhich 3D printingis widely accepted as an important technology. Itjust has not reached the point where it replacesexisting markets. Rather it enhances them. Onereason for this is that additive manufacturing isnot quite as simple as you might imagine. Thereare several reasons for this.W Additive manufacturing needs a broaderknowledge base:
Inmany cases, knowledge of the various tech-nologies and the associated advantages anddisadvantages and applications is simply notavailable. Sincemany of these technologies havenot been on the market for decades, it will takequite some time before the knowledge has spread.For example, only a few universities are reallyspecialised in AM technology.W Additivemanufacturing demands a rethinkingof design:
It is very important to be familiar with thisprocess. Before actual production, there is con-
struction – and this differs clearly from the tradi-tional subtractive methods, so much so that thedesign process looks completely different. Thisstarts with the fact that support structures have tobe included in the planning phase and continueswith the fact that the company takes nature as itsmodel and imitates bionic structures completelyremoved from the usual forms.W Post-processing: It doen't stop with printing:Another building block is the knowledge of theprocess itself. How time-consuming are the con-struction phase, the production phase and thepost-production phase really? How quickly can youhold a finished part in your hands? How long willit take to achieve the surface finish that is needed?
Additive Manufacturing in tool andmould-making
In toolmaking, additive manufacturing can be ap-plied in different stages of the process.W Rapid Prototyping:Rapid Prototyping is used to create physical mod-els to review and validate a design. It is a typicalapplication for additive manufacturing technolo-gies as othermethods aremore cost-intensive. Theadvantage of using additivemanufacturing here isthat the model's design and functionality can bereviewed very quickly, thus reducing lead times.W Rapid Tooling:Rapid Tooling is the method of producing a toolusing additive manufacturing. This is especiallyuseful when the tool is used to produce small series.A traditionally manufactured tool is often muchtoo cost-intensive. If a tool is manufactured ad-ditively, it also has the same advantages as inrapid prototyping, namely, design changes canbe applied more quickly.
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UPSHOTFormnext offers avariety of supportopportunities for becomingbetter acquainted withadditive manufacturing.Rosemarie StahlEditor
INFO
Additive manufacturing: The end of massproduction?
The great promise of additive manufacturing was that with individualisedproducts we would not need mass production anymore. The fact is, we live ina very diverse and individualised world. It has become normal that every carmodel exists in a range of different configurations – from design and enginekits to safety features and infotainment systems. When listening to marketingpeople speak of additive manufacturing, one cannot help but assume thateverything around us should and will be individualised in future, ideally adapt-ed to our personal needs and preferences.While this does make sense for cars and prostheses, it is not true for
everything that is mass-produced today. Some 89 billion litres of water arefilled into plastic bottles each year. An impact that additive manufacturingcould have on mass production is to introduce more flexibility to mass pro-duction processes. Lead times on product developments could be shortenedand thus lead to an improvement or modification of existing products.
W Rapid Manufacturing:
document3518284007867085423.indd 19 19.10.2018 12:53:08
Cooling enables foam injectionwith high-gloss surfaceFoaming technologies in the injectionmoulding process bring vitaladvantages. However, theprocess that results inmaterial savings andspeed gains is also associ-ated with a loss of quality onthe surfaces of the parts. Until now, this foaming procedure was only applica-ble to parts for which surface quality was not important.
The German laser specialist BKL-Lasertechnik has developed a process bywhich high-gloss areas can be achieved with the material-saving foam injectionmoulding technique. According to the company, they addressed this problembecause the geometries necessary for the process of the conformal cooling oftools can only be realised with additive manufacturing in the laser meltingprocess.bkl-lasertechnik.de
Manufacturing with 3D-printed jigs, fixturesand toolingsPankl Racing Systemsspecialise in developingand manufacturing engineand drivetrain compo-nents for racing cars,high-performance vehiclesand aerospace applica-tions. Every single partthat Pankl makes requiresa series of custom jigs,fixtures and other toolingsthat are designed andfabricated specifically forthat part. The result is a proliferation of custom tools, adding significant costand complexity to the manufacturing process.To meet tight production deadlines, Pankl introduced the additive stereoli-
thography (SLA) technology by Formlabs to produce custom jigs and otherlow-volume parts directly for their manufacturing line. 3D printing turned out tobe an ideal substitute to machining a variety of these tools. In one case, itreduced lead time for jigs from two to three weeks to less than a day, which isa decrease of 90 percent. It also decreased costs by 80-90 percent, leading to€150,000 in savings.formlabs.com; pankl.com
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3D printing and software make the design of cooling channels easierOver the last decade or so, conformal cooling – cooling channels that naturally follow the contours of the part to beproduced – has been positioned as a solution for controlling injection-moulding temperatures. But conformal cooling
adds new layers of design and production complexity to the mould-making process, placing it beyond themeans of most shops.
Bastech, an Ohio-based one-source solution provider for shop floors, additive manufacturing servicesand equipment sales, has long wrestled with temperature issues, but now believes it has found a way tointroduce a new level of simplicity, efficiency and economy to conformal cooling. Bastech’s breakthrough,documented in two recent benchmark tests, is based on 3D Systems’ Cimatron mould-making software and
its Pro X DMP 200 direct-metal printing system.Cooling time was reduced from 10.5 seconds for the conventional mould to 7.5 seconds for the conformal
mould, and the all-important cycle time was reduced by 14%.bastech.com; 3dsystems.com
20 11/12-2018
COVER STORY
Source: BKL-Lasertechnik
Source: 3DSystems
part not only needs to be produced quickly butalso has a geometry that is hard to realise withtraditional methods.W Other applications in toolmaking:Particularly in toolmaking, there are many otherpossible applications of additive manufacturing.While the aforementioned applications describethe direct production of either finished part or fin-ished (prototype) tool, additivemanufacturing canalso be applied to manufacture components orparts. This may include producing mould insertsor even equipment needed to optimise the manu-facturing process.Another common application is the optimisation
of the mould itself. Here, speed is not the decisivefactor but rather the added possibilities that addi-tivemanufacturing offers.With additivemanufac-turing, cooling channels can be added to injectionmoulds that cannot be produced with traditionalmethods like millling and drilling. Using additive-ly manufactured cooling channels within the tool,even areas that are difficult to access – for example,those surrounding the ejector and slider – can becooled conformally. The injection moulding cyclecan run much more quickly than before. As a con-sequence, cycle times in injectionmoulding can bereduced by up to 40% if the temperature profile ishomogenised simultaneously.
Application examples for an efficientuse of AM
These applications all represent extremely individ-ual processes and solutions. The decision as towhether such an implementation is worthwhilefor a companymust always bemade on a case-by-case basis.In order to convey a good idea of what is possible,
the case studies presented on this double page areevidence of how different companies use additivemanufacturing in prototype, mould and toolmak-ing. The full stories of these use cases have beenpublished on etmm-online.com and can be foundthere.
document3518284007867085423.indd 20 19.10.2018 12:53:25
HOLLOW POROUS NO EDM TIME
Berta-Cramer-Ring 21 D-65205Weisbaden-Delkenheim GERMANY
Tel: +49 (0) 6122 78 03 - 0Fax: +49 (0) 6122 78 03 -33
Email: [email protected]: www.matsuura.de
MATSUURA Europe GmbHMATSUURA Machinery GmbHGee Road Whitwick Business Park
Coalville LeicestershireLE67 4NH ENGLAND
Tel: +44 (0) 1530 511400Fax: +44 (0) 1530 511440
Email: [email protected]: www.matsuura.co.uk
MATSUURA Machinery Ltd
Seamless Metal Laser Sintering & Milling ProcessHybrid Additive Manufacturing
Build Volume:(D)250mm x (W)250mm x (H)185m(D)250mm x (W)250mm x (H)300m *(* Option)
More information at www.lumex-matsuura.com
Hall 3.0 - Stand E80
Prototyping: Audi reduces leadtimes by using 3D printing for taillight coversBefore a new vehiclegoes into production,the Audi Pre-SeriesCenter in Ingolstadtbuilds physical modelsand prototypes for thebrand to evaluate newdesigns and conceptsthoroughly. This requires allocation of most parts of the vehicleat an early stage of product development – everything fromwheel covers and door handles to radiator grilles.Traditional methods, such as moulding and milling, are com-
monly used to create and replicate new designs. However, theuse of plastics 3D printing has become an integral part of theautomotive design process at the Audi Pre-Series Center, ena-bling the team to overcome limitations of conventional process-es and accelerate design verification.Stratasys announced that the Audi Pre-Series Center with its
Plastics 3D Printing Center in Ingolstadt, Germany, will use afull-colour, multi-material 3D printer – the Stratasys J750 – toinnovate its design process and accelerate design verification.For the production of tail light covers, Audi expects to reduceprototyping lead times by up to 50 percent.audi.de; stratasys.com
3D printing slashes manufacturingcosts of prototype moulds
French multinational, Schneider Elec-tric, is epitomising the ‘Factory of theFuture’ concept and has incorporat-ed 3D printing technology across its
manufacturing oper-ations.
One area inparticular thatunderscoresthe efficiencybenefits deliv-
ered by thecompany’s Stratasys 3D printing technology is the production ofinjection mould inserts used to print functional parts. This hasseen the company slash the cost of producing injection mouldinserts used for prototyping designs to just €100, compared to€1,000 when manufacturing the same item in aluminium.schneider-electric.com; stratasys.com
COVER STORY
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Source: Stratasys
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SHOW PREVIEW FORMNEXT 2018
22 11/12-2018
Additive solutions for everyoneat Formnext 2018
Formnext 2018 is approaching rapidly. The event will show the en-tire process chain of additive manufacturing and modern industrialmanufacturing methods. The growth of the trade show is a clearsign of the importance of additive manufacturing.
Rosemarie Stahl
The trade show will be held in Frankfurt from13 to 16 November. Now in it's fourth year,Formnext continues to grow. Tenweeks before
the trade show, the exhibition hall was alreadybooked.While the trade show used exhibition spaceof 28,000 sq/m last year, Formnext 2018 will reach36,000 sq/m. The number of exhibitors is rising aswell. Some 470 companies will present their prod-ucts and services this year, 80 more than last year.For Mesago, organiser of Formnext, all signs seemto point to success.According to the organisers, exhibitors from 33
nations and the world elite of additive manufac-turing will be represented. At around 55 percent,the proportion of international exhibitors under-
scores the global importance of Formnext. AfterGermany, the major exhibitor nations are China(13.4% of international exhibitors), USA (10.8%),Italy (8.2%), UK (7.5%), as well as France, Spain andthe Netherlands (6.6% each). Some 165 new exhib-itors from 26 countries will also exhibit for the firsttime.An even wider range of topics will be covered
along the relevant process chains, and key areassuch as software, material, and pre-and post-pro-cessing (for example, for powder removal, surfacefinishing or heat treatment) will also receive in-creased attention. Here, traditional companies suchas BASF, Böhler Edelstahl, HC Starck, Höganäs andLinde will be demonstrating their latest develop-ments and their industrial application know-how.Numerous start-ups and young companies will beoffering visitors ground-breaking innovations, rang-ing from AI software to specialised additive pro-duction technologies. This way, Formnext 2018 isoffering a unique spectrum of innovations that willenable visitors frommany user industries to unlockthe potential of additive manufacturing in theirown production processes.TCT, Formnext’s content partner, is also organis-
ing another high-quality conference programme inHall 4 that is aimed at bringing the AM industry’sleadingminds together with industrial users duringthe exhibition.
Additive manufacturing for beginners
The organisers of Formnext are very keen on bring-ing beginners closer to additivemanufacturing andthe process behind it. To achieve this, the organis-ers, together with Reutlingen University of AppliedSciences, have developed the AM Field Guide, ashort introduction to the most important proce-dures and the manufacturing process in general.The guide will be available at the fair and also fordownload from the Formnext homepage.The “AM4U” platform, which started successful-
ly last year, will continue, offering career opportu-nities, further training, and the chance tomake newcontacts in the additive manufacturing industry.The diverse agenda includes an international co-op-eration exchange, a career day, and the “Discov-er3Dprinting” seminar series. This event is gearedtoward midsize companies that are looking to getstarted in additive manufacturing and is being or-ganised in co-operationwith the Aachen Center forAdditive Manufacturing (ACAM).formnext.com
A look back at 2017. The trade show is expected torecord further growth in 2018 as well.
Source: Mesago
document1059580155119224336.indd 22 19.10.2018 12:52:48
Cross-technology solutions from a single source
For more information visit www.renishaw.com/additive
Additive manufacturing provides design freedom so fluid-bearing channels can be arbitrarily adjusted to the contour of cavities.
It offers new possibilities for the conformal cooling and heating of mould inserts – achieve highly efficient temperature control
solutions to increase the throughput and quality of your parts.
Our services at a glance:
• Manufacture and supply of metal 3D printing systems
• Training in design for AM
• Tool insert optimisation through redesign, simulation and cooling optimisation
• Process control solutions for CNC machining
• Advanced metrology and part verification technologies.
From CAD modelto a cutting-edgemould
www.renishaw.com
Renishaw Conformal cooling ad ETMMs 1018_EN.indd 1 11/10/2018 11:07:51
SHOW PREVIEW Q&R
24 11/12-2018
It is worthwhile for every companyto take a look at the technology
Sascha F. Wenzler is Vice-President of Formnext and the man behind thetrade show. In this interview, he explains why additive manufacturinghas become so important for the manufacturing industry and whoshould visit the trade show.
Sascha Wenzleris Vice-Presidentof Formnext atMesago MesseFrankfurt.
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With Formnext approaching, we wanted toknowwhat is special about the trade show.SaschaWenzler explains the importance of
additive manufacturing, the current state of thetechnology andwhat he looks forward to at Form-next 2018.
Who should definitely visit Formnext 2018?The entiremanufacturing industry is one of Form-next's visitor target groups, be it aerospace, auto-motive, medical technology, dental technology,mechanical engineering, construction and archi-tecture, electronics, research, offshore, healthcare,jewellery or white goods. The overall processes,from design, material, software and pre-processingto actual production and post-processing, are be-coming increasingly important for visitors from themanufacturing industry as a solution to their man-ufacturing questions, and Formnext provides theanswers.
One of your slogans for promoting the trade show is“I produce, therefore I am at Formnext 2018”. Is it stillpossible to produce without additive manufacturing?
Every manufacturing company concentrates onfaster or more efficient production and considersnewmanufacturing processes in order to stand outfrom the competition. Additive manufacturing(AM) makes many things possible that, until re-cently, were unthinkable or simply impossible toproduce. In almost all production areas, the use ofadditivemanufacturing brings advantages. Poten-tials can be exploited in the form of faster time-to-market, new and free design, lighter or bionic struc-tures, lower use of resources and more. And newapplications are added almost daily. Whether inthe metal sector, plastics, ceramics, CFRP, sand,glass or fabric printing – it is worthwhile for everycompany to take a look at the diverse applicationpossibilities of the technologies and processes thatwill be on show at Formnext.
For a long time, there have been inflated expectationsabout 3D printing, for example, that in future wewillall have our own printers and will be able to printalmost everything we need. To what extent do youthink there are still exaggerated promises in the in-dustry, or have they lost touch with reality in themeantime?There are still articles circulating in the generalpress that are catchy and promise all sorts of thingswith the “3D printer”. Attention is good, but theindustrial reality of additve manufacturing looksdifferent. The advantages of the technology areeminent and additive technologies have long sincefound their way into industrial production far be-yond prototype construction and into series pro-duction. This path has only just begun. But as inevery technology, there are limits that shift butnever disappear completely. Standardisation andprocess reliability are such tasks that have to besolved. AM will find its rightful place in industrialproduction andwill supplement conventional pro-cesses wherever it makes sense and is economical,but will never replace them completely.With AM,many new and serious possibilities openup, but the idea that we'll be printing everythingourselves in our own garage at some point in thefuture is fanciful. But it certainly makes sense togive children a playful approach to the subject, forexample, with a table printer and the appropriatesoftware. 3D printing in particular manages toarouse enthusiasm for technology, even among thelittle ones.
Together with the Reutlingen University of AppliedSciences, you have developed the AM Field Guide. Is
Rosemarie Stahl
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Q&R SHOW PREVIEW
it difficult to organise a trade show for a technologythe basics of which have yet to be conveyed to manyvisitors?Like any highly specialised capital goods trade fair,Formnext also requires explaining and transferringknow-how on the increasingly complex proceduresand processes of AM technologies to visitors. Manyvisitors are very familiar with the manufacturingprocess of their own products and its properties,but the potential benefits of using AM are not yetknown or not sufficiently known. Just looking atthe latest cutting-edge machines is no longerenough to make the necessary investment deci-sions, especially when it is no longer just the largecompanies familiar with AM that are being ad-dressed. Fact id, today, more and more medi-um-sized companies and suppliers are consideringentering the industrial 3D printing market.As organisers, we provide various offers for knowl-edge transfer both throughout the year and at thefair in order to explain the various technologies andproducts at the fair to both the technology crackand the newcomer. These include the high-endconference organised by our content partner, TCTat Formnext, the “Discover 3Dprinting” seminarseries for beginners, which we organise togetherwith the Aachen Center for AdditiveManufacturing(ACAM) during the year and at the fair, the “Read-y4Industry” special area with best-practice exam-ples presented by our honorary sponsor, the projectgroup “AM” at theVDMA, the German EngineeringFederation and, for example, the new publication,the “AM Field-Guide”, which we published in thisform together with FH Reutlingen as a “WorldMapof AM” for the 2018 trade fair.
What will be your personal highlight of the upcomingFormnext?I am particularly enthusiastic about the“Life-Changing” aspect, which the use of AMmakespossible in a wide variety of places and applica-tions. Each year, there are so many new things todiscover for manufacturers and applications. Theforward-looking results of the Purmundus DesignChallenge or the refreshing ideas and products ofthe start-ups are always astounding. Enormouschanges are taking place in the materials sector.Large materials groups such as BASF, Solvay, Mit-subishi Chemicals, Heraeus or Linde and Henkelhave recognised a clear technology of the future inadditivemanufacturing and are going to Formnextwith their ownmaterial areas and a variety of dif-ferent materials in this market.Moreover, the world of additive manufacturing isnow becoming colourful. Plastic can now be print-ed or coloured in all imaginable colours. Multi-ma-terial printing in one process is also on the rise. Thenumber of lasers in metal printing continues toincrease, as does the printing speed and installationspace, which are becoming larger and smaller over-all, down to nano-scale structures. Big players likeHP, for e.g., are also usingmetal printing in additionto plastic printing or vice versa. Pre and post-pro-cessing opens up new opportunities formany com-panies. It is this colourful bouquet of innovations,the rousing dynamism, the discussions, the atmos-phere in the halls and being part of this fascinatingcommunity that I look forward to every year.mesago.com
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Plan your visitat formnext 2018
Visit companies at Formnext mentioned in this issue
Company Hall Booth Page
A Arburg GmbH & Co. KG 3.1 E70 32
B BKL-lasertechnik 3.0 G81 18
F Formlabs GmbH 3.1 C88 18
Fraunhofer-Institut für Werkzeugmaschinen undUmformtechnik IWU 3.0 E70 14
G Gebr. Becker GmbH 3.0 H69 33
L LEO Lane Ltd. 3.1 B30A 33
Company Hall Booth Page
M Matsuura Europe GmbH 3.0 E80 21
R Renishaw plc 3.1 D68/E68 7, 23
T Trumpf GmbH + Co. KG 3.0 D50 32
V ViscoTec Pumpen- und Dosiertechnik GmbH 3.0 H54 33
Vogel Communications Group GmbH & Co. KG 3.0 J81
Advertisers shown in bold
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VISIT USAT FORMNEXT
IN FRANKFURT!
NOVEMBER, 13 –16
HALL 3.0, BOOTH J81
is a brand of
www.etmm-onl ine .com
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ETMM – For Europe’s tool &mould making industry.
With print media, digital channels and live events.
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Additive Manufacturing:Cost factors and cost optimisation
Additive manufacturing of components can be an economical solutionfor many companies. However, there are several cost factors that shouldbe considered.
Before a decision can be made onwhether to use additive technologies, thecosts have to be precisely calculated.
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benefits and is therefore decisive in answeringthe question of whether series production is
economical or not. Since the cost structures of con-ventional and additive manufacturing processessometimes differ significantly, the cost factorsmustbe carefully weighed up against each other. Aninitial cost estimate for additively manufacturedproducts is usually measured by means of cubiccentimetresmanufactured. The post-processing ofthe additive components is also a cost factor. Look-ing at the overall cost structure of additive manu-facturing, it is largely determined by the costs forthe AMmachines, followed by the costs for mate-rials and labour costs. Other factors such as con-sumables (e.g., gas) and energy costs can be ne-glected in the overall cost structure. Machines forselective laser sintering (SLS) and laser melting(SLM) are very capital-intensive, which increasesthe total costs per cubic centimetre. The cost ofpowder bed-based processes is often comparedwith that of tool-intensive conventional manufac-turing processes such as injection moulding anddie casting or with machining processes such asCNC milling (Figure 1).
Cost advantages of additivemanufacturing through lower fixedcosts
Despite the higher variable costs, the use of additiveprocesses in production can be economical, as aglance at fixed costs makes clear. For conventionalmanufacturing technologies, fixed costs are onlyallocated to a specific component design. For ex-ample, a die can only be used in die casting tomanufacture the specific product for which it wasdeveloped. Accordingly, the costs of themouldmustpay off in terms of the number of parts produced.The costs for setting up amachine tool or changingtools on an injection moulding machine must bedistributed over the number of parts produced inthis production batch until the next set-up. If onlya few units are produced per batch or small seriesare produced, the fixed costs can exceed the vari-able costs. This makes additive production morecost-effective than production with conventionalprocesses.Additive manufacturing also involves a certain
degree of fixed costs, but these costs can be more
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easily offset by the number of different productsthat are produced in a single batch. The actual costsincurred per cubic centimetre in an additive con-struction job depend on a complex combination oftechnical parameters and the operating conditionsof the machines.W Machine DataW MaterialsW Construction Job ParametersW Consumables DataW Operational CalculationsBy changing the parameters, machinemanufactur-ers and operators can reduce the overall costs ofadditive production. Since laser sintering and lasermelting machines are very capital-intensive, theproductivity of themachines is a critical parameterthat influences the overall costs. The productivityof the machines results from the quotient of theactual throughput of a construction job (i.e., theexact material volume of the finished parts) andthe throughput time of the construction job (i.e.,the time required to execute the construction job).It is therefore important to know the structure
of the lead time of the construction job in powderbed-based processes, as they are key to optimisingoverall costs.The lead time Includes:
W Time for setting up the machine, loading the 3Dfiles and removing the finished components
W Time themachine needs for preheating and cool-ing in additive production
W Time required for the laser to expose and meltall component surfaces
W Time required to apply and, if necessary, warmup the powder layers
W Time for quality control in the current construc-tion job, if necessary
Cost factor "Production Time" in theadditive manufacturing process SLS
Looking at the SLS process, the actual productiontime, i.e., the period that is determined exclusivelyby the activity of the AMmachine and is independ-ent of the operator, accounts for about 90% to 95%of the total cycle time of the construction job withefficient operation. The production time consistsof preheating the machine, building the parts andcooling. The periods required for preheating andcooling are largely constant for each constructionjob and depend on the size of the installation spaceof the respective AMmachine. The actual construc-tion phase takes up about 60% to 70% of the pro-duction time, depending on the machine and in-stallation space utilisation. For an initial estimation
The variable costs percubic centimetre for addi-tive production andconventional productionare compared using threecomponents selected asexamples. The costs fortool construction, set-uptimes and other costsincurred per batch areexcluded in this example.Depending on theprocess and componentdesign, the variable costsfor additive productioncan be five to fifty timeshigher than for conven-tional production, forexample, in the process-ing of polymers andmetals.
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of the space requirement of a component in theinstallation space, the envelope volume, also knownas the bounding box, is often used. During normaloperation, 50% of the construction time consistsof exposure / melting and 50% of heating/applica-tion of new powder layers. These figures generallyalso apply to the SLM process, although the per-centages differ considerably in some cases, as themelting of themetal powder takes placemuchmoreslowly.A number of technical and operational measures
can reduce the total costs per cubic centimetre.Technical measures on the part of the machinemanufacturers include the reduction of the timerequired for exposure and application of powderlayers as well as the reduction of preheating andcooling times. This is often achieved by the appli-cation of a larger number of lasers and the devel-opment of concepts for faster application of thecoatings. Figure 3 gives an impression of howmuchthe production time can vary depending on themachine.
Investment in additive manufacturingmachines
For in-house production, a company invests in AMmachines and operates them for their own produc-tion. In order for the machines to pay off, high ca-pacity utilisation is necessary. These measuresshould also be taken into account in order to keepthe overall costs as low as possible:W To ensure a tight filling of the installation spacewith components
W Maximising the share of actual exposure time inthe overall throughput time, for example, throughhigh installation space utilisation
In laser melting, tight packing can only take placeon the horizontal plane of the machine, since inthis process, the components cannot be producedin several layers on top of each other. The lasersintering process achieves the best economic effi-ciency if the components are manufactured tight-ly packed in several layers on top of each other.Figure 4 illustrates the effects of a high packingdensity on the unit cost of a small lever. It is appar-ent how the total costs largely stabilise after thefirst level has been filled. For efficient operation oflaser-sintering machines, at least one dense levelof components should be achieved. The disconti-nuities in the graph result from the fact that eachtime a new layer is started, the total time for ap-
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Comparison of through-put time for an exemplaryconstruction job on twodifferent SLS machines.
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plying the layers in the construction job increases.However, due to the shape of the components, theheight of the components in themounting direction(z-direction) usually does not require the entireavailable horizontal space (x-y-direction) of themachine. Accordingly, the increase in time and costof construction is not fully spread over a new,densely packed horizontal layer. It is therefore rec-ommended that the height of the superstructure isplanned as evenly as possible for the entire con-struction job. Some areas that reach higher z-coor-dinates unnecessarily increase the costs of theconstruction job.Furthermore, it should be noted that in additive
manufacturing, the factors of time and componentquality must be weighed against each other, sincehigher quality always goes hand in hand with in-creased time required for production. In this case,the selected parameters are decisive, for e.g., layerthickness.Thinner layers enable greater accuracy of detail
and better surface quality but require more pro-duction time and thus increase overall costs. Inlaser sintering in particular, the factor of powderrecycling also plays an important role in construc-tion costs. The higher the proportion of recycledused powder, the lower the costs for the construc-tion job. However, too much used powder can in-fluence the flowability and deteriorate the con-struction quality or even lead to defects in thefinished components.
An alternative to in-house production is externalprocurement (buy). External procurement is thesimplest method for a company to gain access toadditive manufacturing technologies. It does notrequire any specific knowledge about the operationof the machines or any major investments in ad-vance. The decision for external procurement alsomeans lower risks and price fluctuations in pro-duction for the company, as the efficient use of AMmachines is the supplier's responsibility.The prices for external procurement depend on
the total material volume of the order (in cm3) aswell as on the effect of the component design oninstallation space utilisation. For example, bulkylightweight structures can take up a lot of space onthe construction panel, although they only have asmall volume of material. Orders with larger ma-terial volumes and higher packing density arecheaper because they are easier to produce on thesupplier’s machine. Figure 5 gives an overview ofaverage prices for external procurement for SLS andSLM procedures.According to a study conducted in 2014, two dif-
ferent price strategies can be identified for AM ser-vice providers. The study compares 21 offers fromdifferent AM service providers worldwide. Theirresults are shown in Figure 6 for prices per cubiccentimetre when ordering in quantities of 1 and100. The dashed linemarks prices that are the samefor quantities of 1 and 100. The AM service provid-ers can be divided into two categories (A and B):
Category A (purple ellipse):TheAM service providers demand similar prices
per cm3 for quantities of 1 and 100, which suggeststhat the suppliers in Category A want to ensureoptimum space utilisation of their machine bycombining orders from different customers. Thisprocedure allows the supplier to offer stable pricesper cubic centimetre.Category B (green ellipse):AM service providers charge higher prices for
small quantities (between 5 and 10 euros per cm3)than for larger quantities (between 0.5 and 1 europer cm3). Category B service providers obviouslyprioritise fast delivery and do not combine ordersor only subordinate orders. The resulting cost sit-uation is more similar to the one that would occurin the case of in-house production by the company,i.e., inversely proportional to the quantity of theordered component volume.The awareness of these two strategies of the ser-
vice providers allows the planners of the companyto optimise their purchasing methods and thusminimise the total costs of additive production.
INFO
New reference book “Additive Fertigung”in German language
The topic of “Cost Structures of Additive Manufactur-ing” is taken from a new reference book entitled “Ad-ditive Manufacturing”. In addition to cost factors, thewell-known experts at ETH Zurich also focus on othertopics: Integration of additive manufacturing process-es in production, 3D data generation, quality assur-ance and selection of components. Would you like toknow more? You"ll find the book in our online shop atvogel-fachbuch.de
Representation of unit costs as a function of the number of units of one or moreproduced in a construction job with SLS.
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Price offers of different additive manufacturing serviceproviders for batch sizes of 1 and 100.
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Five tips for additive manufacturingdesigns with SLM
The most widely used process in 3D metal printing is probably selectivelaser melting (SLM). A contract manufacturer gives design tips to achievethe best results for this process. However, every method has its limits.
Professional designtips help achieve betterresults of the SLMprocess.
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Christoph Erhardt
3D metal printing, or more precisely, selectivelaser melting (SLM), is a cost-effective and fastmethod for manufacturing prototypes, being
equally suitable for producing complex geometries.With an optimised design and a large number ofparts to be produced, the process offers enormouseconomic advantages. In 3Dmetal printing, a pow-der layer of 0.02 to 0.06mm is applied to the build-ing platform by a scraper or coater. Then the laserstarts melting the first layer. In the next step, an-other layer of powder is applied after the buildingplatform is lowered by exactly one layer. The laserthen fuses the first layer with the next. This processis repeated layer by layer until the entire componentis completed. When the last layer of the part isfinished, themetal powder is removed and the partattached to the platform appears.In typical 3D metal printing, support structures
are both important and a burden because they slowdown the manufacturing process. Good designpractices can, however, reduce the number of sup-ports required and thus the required time. In orderto get the most out of this technology, Protolabshas named five tips to achieve a production-ori-ented design in 3D metal printing:W Wall thickness:Awall thickness of less than 1 mm cannot be pro-ducedwith all materials and still depend on geom-etry. The rule of thumb is: Ratio height to wallthickness 40:1 (at > 1 mm).W Self-supporting angles:Angles of 45° are optimal. Angles below this valuerequire additional, time-consuming support struc-
tures in order to keep the object stable during pro-duction.W Overhangs:If the layer to be exposed to the laser is larger thanthe underlying layer, this is referred to as an over-hang. Overhangs of 0.5mm can be realisedwithoutsupport material.W Channels and holes:Channels and holes are self-supporting features upto a certain diameter and do not require supports.However, all holes in the X/Y direction generallycollapse during the manufacturing process.W Residual stress and distortion:Changes in the cross-sectional areas can lead todistortion of the component. In the worst case,building platforms and shear bolts bendwhen largevolumes accumulate.
The limits of selective laser melting
Additive manufacturing is not the solution to allproblems. 3Dmetal printing using the SLM processhas the following geometric limits:W Minimum wall thickness: 1mmW Minimum dimensions of protruding details:0.5mmhigh andwide, 0.8mm in order to achievelegible text and clear images.
W Minimumdimensions of indented details: 0.5mmdeep and wide, 1mm wide for legible text andclear images
W Diameter of exit holes: minimum of 4mm for oneexit hole, 2mm for two or more exit holes.
protolabs.co.uk
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Process reliability in 3D printing boosts efficiency
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The automatic process in Truprint 5000 eases the manual workload andenhances mass additive manufacturing.
3D Printing – Trumpf willpresent automated 3D printingsolutions at Formnext, focus-ing on its Truprint 5000 sys-tem. Visitors will see demon-strations of how powder bedand melt pool monitoringenable quality inspection onthe fly during printing – in linewith the company’s goal offully automated, 3D print-driv-
en production to enhancemass additivemanufacturing.According to Trumpf,
Truprint 5000, like all Truprintmodels, features Laser MetalFusion (LMF) technology. Thistechnologyworks on themul-ti-laser principle, with threelasers joining forces to meltthe component's geometry inthe powder bed. Being able to
preheat up to 500°C, this sys-tem is said to be the first toprocess heat-resistantmateri-als such as carbon steels. Thisfeature also improves thema-chining quality of materialssuch as titanium, as it reducesstress in the component andrequires less reworking.At the show, Trumpf will
unveil a new automatedmeth-od of handling lids for buildand supply cylinders. Truprint5000 features dual lids tomax-imise safety. One lid on theprocessing chamber conservesthe inert gas atmosphere fromone printing job to the next.The other one prevents pow-der loss during transport. Acarriage that replaces the re-coater's applicator spreads thepowder coating in the buildchamber during printing. Aninsert in the carriage keeps thelids in place during travel. Sup-ply cylinders ascend inde-pendently and latch their lidsinto the processing chamber'sceiling, which places them be-
yond the laser's scanningrange, where they remain un-til the process runs its course.Automation also allows for
more reliable 3D printing, asdemonstrated by Truprint5000's scanner monitoringand levelling system. It en-sures that the three laserbeams are properly aligned.Here, the recoater has a cali-bration target that measuresthe laser beams' positions andsends the coordinates to a soft-ware programme. The level-ling monitor checks the sub-strate plate's position. It usesa camera and laser sensorsystem to gauge the heightand orientation when settingup a job. For deviations, theoperator adjusts the substrateplate to measuring systemspecifications.Also on show will be quali-
ty assurancemonitoring solu-tions with powder beds andmelt pool monitoring.trumpf.com;Hall 3.0, Booth D50
“Big version” Freeformer for industrial AM of complex parts
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The new Freeformer 300-3X that will debut at Formnext will open up newfields of application in AM.
Plastic Forming – Freeformer300-3X from Arburg, a newlarge machine that processesthree components using theArburg Plastic Freeformingprocess, will celebrate its pre-miere at Formnext. The newmachine enables the industri-al additive manufacturing ofcomplex functional parts inresilient hard/soft combina-tionswith a support structureandwill open up new fields ofapplication, the company says.The “300” designation
stands for the available partcarrier surface area in squarecm, which is about 50% largerthan that of the 200-3X ver-sion. The build chamber of the300-3X offers space for largersmall-volume batches as wellas 50% wider parts and hasdimensions of up to 234 x 134x 200 mm. The 3X stands forthe moving axes of the partcarrier in the x, y and z axes.The two-part build chamber
door of the new machine,which is a new feature, allows
for feed hoppers, for example,to be refilled during ongoingoperations by opening the tophalf of the door. The heatedbuild chamber now onlyneeds to be opened to insertthe part platform or to removefinished parts.Automatic opening and
closing of the build chamberdoor as well as optional inter-
faces also provide automationof additivemanufacturing pro-cesses and the integration ofthe Freeformer in completeproduction lines.Other exhibits at the booth
include two Freeformer 200-3Xmachines and visitors willalso get to see part samplesand test these themselves atfour interactive stations.
At the show, three exhibitswill serve to demonstrate thepossibilities of the Freeformers200-3X and 300-3X. A widerange of parts will also be ex-hibited, including a selectionof two and three-componentitems. Exhibits of functionalparts will include a two-com-ponent gripper as a hard/softcombination, cable clipsmadefrom PP, transparent test discsmade of PMMA and bellowsmade of medical TPE-S.The Arburg material data-
base documents qualifiedstandard granulates such asABS (Terluran GP 35), PA10(Grilamid TR XE 4010), PC(Makrolon 2805), TPE-U (Elas-tollan C78 A15) and PP (Bras-kem CP 393). Other examplesinclude special plastics forspecific applications such asmedical PLLA (Purasorb PL18,Resomer LR 708) and a PC(Lexan 940) approved for aer-ospace use.Arburg.com;Hall 3.1, Booth E70
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Ensuring safe, trouble-free AMand side-stepping risks
Cloud Solutions – With thecompany’s cloud-based SaaSsolution, LEO Lane enablesindustrial manufacturers/brands to securely manageadditivemanufacturing (AM).At Formnext, LOE Lanewill
show how companies canmaintain brand integrity andIP protection by securelyman-aging AM every time parts areproduced through an innova-tive, Software as a Service(SaaS) solution. The companyexplains that brands can con-duct scale production in AMwhile protecting their IP, se-curing digital assets and en-forcing control over the qual-ity, consistency and quantityof their parts and products. To
overcome risk issues in AM,LEO Lane provides and en-sures lock-tight protection invirtual inventories, on-de-mand production or other pro-duction capacities.Once a brand has identified
which part to additivelyman-ufacture and the way to pro-duce it (printer type, material,machine settings etc.), thecompany’s SaaS solution se-cures it as a LEO (Limited Edi-tion Object) file. This is a digi-tal asset that protects andpreserves a product or partdesign by controlling how it isproduced. The files are han-dled according to the client’sexisting IT policies and proce-dures, without the need forextra installations, appliancesor special handling. A transferprotocol is not reqiured. Withminimal disruption, the crea-tion of LEOs and their controlpoints can be integrated to beautomatic and seamless.When the file is ordered via astandard ERP system, the LEOLane service is called in thebackground and the protectedLEO is triggered. The companyis integrated with many eco-system platforms includingSAP andMaterialise to ensuresmooth and seamless end-to-end processes, LEO Lane says.leolane.com;Hall 3.1, Booth B30A;
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The SaaS solution provides brandintegrity by securely managingAM when parts are produced.
Blowers for demanding additivemanufacturing processes
Blowers – To producehigh-quality components inselective laser melting (SLM),a stable, inert gas atmospherein the building chamber of themachine and a specified tem-perature range are essential. Itis also necessary to removemetal splash and smoke de-veloping during the meltingprocess.Gebr. Becker will present
two blower types developedfor such applications. The keyfactor in these blowers is theirgas-tight design, which per-mits the precise control of gasflow as well as the removal ofcontamination during the pro-cess. Used together with gas-tight heat exchangers, whichGebr. Becker also offers, theseblowers provide the condi-tions for exact temperaturecontrol in additive manufac-turing processes.For plants with small build-
ing chambers, the ideal blow-er is the gas-tight, speed-con-trolledVasf side-channel mod-el in the 1.50 size. According tothe company, this model hasa very compact constructionand can be easily integrated insuch plants to allow for inertgas flowmanagement withinthe closed circuit. Moreover,this blower has low-energyoperation requirements. Forlarger plants in additive man-
ufacturing and the corre-spondingly higher volumeflows of inert gas, the gas-tightside channel blowerVariair SV300 is used. The speed-con-trolled, energy-efficient driveof this model allows for thedelivery rate to be adapted toactual requirements.Both blowers are designed
for 24/7 industrial operationsand are said to bewell provenin numerous demanding ap-plications. Thanks to their gas-tight designs, they are suitablefor the requirements of addi-tive manufacturing processeswith high-grade atmospheres.becker-international.com;Hall 3.0, Booth H 69
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The gas-tight Variair SV 300 sidechannel blower for greater inertgas volumes.
Beauty classic in optimised, automated production
Filling Systems – ViscoTecPumpen- u. Dosiertechnikmanufactures systems re-quired for conveying, dosing,applying, filling and emptyingmedium to high-viscosity flu-ids. Among its innovations areits emptying and filling sys-tems that optimise productionlines in the cosmetics industry.The beauty classic mascara
is produced in quantities andmade available in barrels forpackaging. Getting the mas-cara paste into small applica-tors that millions of womenworldwide use is where Vis-cotec comes in.
The company says it offersa simple solution especiallysuited for masses with highviscosities (up to 7.5 millionmPas). The mascara is re-moved from barrels with abarrel-emptying system basedon the endless piston principleand fed directly to the fillingmachine via a hose. The bar-rel-emptying pump is con-trolled by a two-point pressurecontrol at the end of the hose.Next is the filling: Viscotec’s
filling systems are based on amodular series. The dispenserfor this application is put to-gether and adapted to require-
ments in terms of hygienicdesign, documentation, elas-tomer resistance, implemen-tation and dosing volume.These configuration optionsallow, for example, a variantto be easily disassembled,manually cleaned and auto-claved. Alternatively, the dis-penser can also be connectedto a CIP/SIP system and beautomatically cleaned andsterilised. The dosing principleenables precise filling evenwith temperature fluctuationsduring production.viscotec.de;Hall 3.0, Booth H54
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Filling mascara into small appli-cators using the ViscotecHygienic Dispenser.
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Quick Sourcing Grid:Additive Manufacturing
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Company | Contact
Matsuura Europe GmbH, Wiesbaden-Delkenheim, DE | www.matsuura.de 21
Renishaw plc, Wotton-under-Edge, Glos, UL | www.renishaw.com 23
3D Systems Corporation, Burlington, MA, USA | www.3dsystems.com
Alphaform AG, Feldkirchen , Kr München, DE | www.alphaform.de
Alzmetall Werkzeugmaschinenfabrik und Gießerei Friedrich GmbH&Co. KG, Altenmarkt a.d.Alz, DE | www.alzmetall.de
Arcam AB, Mölndal, Sweden | www.arcam.com
Arrk Europe Ltd. – Gloucester Technical Centre, Gloucester, UK | www.arrkeurope.com
Concept Laser GmbH, Lichtenfels, DE | www.concept-laser.de
DMG Mori Deutschland GmbH, Wernau (Neckar), DE | www.dmgmori.co.jp/en
EOS GmbH Electro Optical Systems, Krailling, DE | www.eos.info
ExOne GmbH, Gersthofen, DE | www.exone.com
Fives Landis Ltd., Keighley, West Yorkshire, UK | www.fivesgroup.com
German RepRap GmbH, Feldkirchen, DE | www.grrf.de
GF Machining Solutions Management SA, Nidau, CH | www.gfms.com
GOM GmbH, Braunschweig, DE | www.gom.com
Hybrid Manufacturing Technologies, Ltd, Moia, Leicestershire, UK | www.hybridmanutech.com
Ibarmia Innovatek, Azcoitia, ES | www.ibarmia.com
Imes-icore GmbH, Eiterfeld, DE | www.imes-icore.de
Keyence Deutschland GmbH, Neu-Isenburg, DE | www.keyence.de
MachineWorks Ltd., Sheffield, UK | www.machineworks.com
Maschinenfabrik Berthold Hermle AG, Gosheim, DE | www.hermle.de
Materialise N.V., Leuven, BE | www.materialise.com
Mazak Machine Tools, Worcester, UK | www.mazak.com
Midas Pattern Co. Ltd., Bedford, UK | www.midas-pattern.co.uk
Prodways Group , Paris, FR | www.prodways.com
Proto Labs Ltd, Telford, UK | www.protomold.co.uk
ReaLizer GmbH, Brochen, DE | www.realizer.com
SLM Solutions GmbH, Lübeck, DE | www.slm-solutions.com
Solidscape Inc., Merrimack, NH, USA | www.solid-scape.com
Stratasys GmbH, Rheinmünster, DE | www.stratasys.com
Trumpf Laser- und Systemtechnik GmbH, Ditzingen, DE | www.trumpf-laser.com
Voxeljet AG, Friedberg, DE | www.voxeljet.com
WFL Millturn Technologies GmbH&Co. KG, Linz, AT | www.wfl.at
document2912719501917561874.indd 34 19.10.2018 12:57:58
SUPPLIERS DIRECTORY
3511/12-2018
PrototypingService
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Hyb
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s
Rap
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,DMLS
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edDep
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nModeling(FDM)
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s,Polyjetmatrix
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s,Selec
tive
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)
AM
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s,Stereolitho
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etallic
,Nonm
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/Plastic
Software
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nningEquipmen
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document2912719501917561874.indd 35 19.10.2018 12:57:59
PRODUCT FOCUS TOOL & MOULD COMPONENTS
36 11/12-2018
Backlash-free and high-precision connection
Centring Units – For theman-ufacture of injection moulds,interchangeable inserts areused inmastermoulds that areoften also used for injectionmoulding variants. Thus, thesame family of parts is usedfor producing both similar anddissimilar injection mouldingparts. Very often, small seriesare produced (“just in time”production), resulting in theinjection press undergoing fre-quent mould insert changesand the inserts needing quickchanging.For such jobs to run smooth-
ly and accurately, the 7980/1fine mini-centring unit fromAgathon is used for back-
lash-free centring of mouldinserts for standardmoulds ininjection moulds. This cen-tring unit can also be used forhigh-precision connections inthe construction ofmachineryin mechanical engineering.Agathon says the ability to
use a bush-free assembly en-ables ultra-precision as errorsin the concentricity of theguide bush are avoided and apositioning accuracy of lessthan 1µm is thus achieveable.The company also offers ball
guides and roller guides, back-lash-free for high-performanceinjectionmoulds aswell as forhybrid and cutting tools. Theuse of bearing guidance sys-tems eliminates the need fora fine centring device or anadditional fine centring sys-tem. The cage retention sys-tem proposed for this purpose,combined with an applica-tion-specific compressionspring, allows for the completewithdrawal of the preloadedbushing. Accurate cage posi-tioning is therefore guaranteedwhen the two tool halves arereunited, Agathon claims.Apart from the offerings pro-vided in the company's stand-ard catalogue, Agathon alsomanufactures special parts asper customer plans, like rust-proof guide elements.agathon.ch
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The 7980/1 fine mini-centring unitis for backlash-free centring ofmould inserts.
New compact series of lockingdevices for high productivity
Locking Devices – WagnerWerkzeugsysteme, part of theSwabian Müller Group, spe-cialises in producing precisiontools for the rational manufac-turing of external threads.The company recently pre-
sented at AMB in Stuttgart, itsnew series of closing safetydevices.Wagner claims that its
thread-rolling and cuttingheads arewell known for theirhigh quality and long tool life.Users who value high produc-tivity benefit from the shortcycle times of the tools, thecompany adds.To further reduce cycle
times, locking devices havelong been used in the axialrolling heads and thread-cut-ting heads. The locking devic-es have the task of closing thehead that automatically opensin the process. This is especial-
ly whereWagner pays particu-lar attention to quality andreliability.Essentially, closing is done
parallel to time the job processis happening. As this is notnecessarily possible all thetime, engineering developersat the company reduced theclosing time to less than 0.2seconds. This new range oflocking devices thus expandsthe job programme. Further-more, thanks to the reducedinstallation space required bythe new series of closing safe-ty devices, they now also pro-vide solutions for machines,which previously had to beworkedwith othermethods tosave space.The locking devices are easy
to control, which is donethrough the cooling lubricantor controlled pneumatically.wagner-werkzeug.de
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To reduce cycle time, lockingdevices are used in the axialrolling heads and threadcutting heads.
Digital counter increases efficiency in mould-making
Digital Counters – One of thelatest additions to leadingstandard part supplier StrackNorma's product portfolio isits new Z5265 digital counter,which has an eight-digit dis-play and is thus able to countup to 100 million.According to the company,
the Z5265 is suitable forhigh-frequency punching ap-plications and high-speed in-jection moulds in mechanicalengineering and automationtechnology. Users can detectand monitor high stroke fre-quencies of up to 1.000 strokesper minute.
Other technical features in-clude the counter being ableto observemaintenance plans.It can also be operated withStrack Norma's mechanicallimit switches Z76xx. The dig-ital counter has a magneticsensor and is contact andwear-free with a built-in lith-ium battery of type CR123A 3V.The ambient temperature ofthe counter is between -10 to40°C, while that of the sensoris between -10 to 75°C. Its re-taining plate for the sensor isbendable and it comes in arobust aluminium housing.strack.de
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The Z5265 is suitable for high-frequency punching applications andhigh-speed injection moulds.
document8433103167071528393.indd 36 19.10.2018 12:59:04
TOOL & MOULD COMPONENTS PRODUCT FOCUS
11/12-2018 meusburger.com/stress-relieving-heat-treatment
WEHEAT TREAT
PROPERLY FORYOUR SUCCESS.
Simple andflexible sleeveCentring Sleeves – Leadingsupplier of modular standard-ised components and accesso-ries, Hasco Hasenclever, saysits new centring sleeve Z21...offers manufacturers a solu-tion that can be deployed sim-ply and flexibly for the precisealignment of plates that are tobe joined together on injectionmoulds.
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The space-saving centring sleeveoffers flexibility in mould design.
With its space-saving posi-tioning above the screw con-nection, this centring sleeveallows plates to be very easilycentred in relation to one an-other and thereby offers evengreater flexibility in moulddesign, states the Germa-ny-based company.The space-saving assembly
in the build-up screw connec-tion is further facilitated by a15-degree, lead-in chamfer. Thecentring sleeve is alsoequipped with an integratedpull-out thread for particular-ly easy dismantling.The new centring sleeve
Z21/…, which is versatile in use,is suitable for maximum ser-vice temperatures of up to200°C.Hasco.com
Industry 4.0-ready mould monitoring device
Monitorng Device – Progres-sive Components’ CVeMonitoris an electronic mould-moni-toring device that is mountedto an injectionmould. It inter-faces with CVe Live wirelessdevices to relay data to thecloud-based CVe Livewebsite,providing unprecedented re-al-time visibility of a toolingfleet, located at any facilitythroughout the world.
At Fakuma 2018, Progressiveintroduced the v3 CVeMonitorand CVe Live with new fea-tures and functionalities thatare designed to meet the re-quirements for Industry 4.0readiness, the company says.These features include a
Press Management Modulethat allows for scheduling,tracking, monitoring and filingof all preventative mainte-
nance actions. There is also anexpanded electronic filing cab-inet, which provides the abil-ity to add non-CVe assets tothe database and store relateddocuments.“The CVe Monitor and CVe
Live together provide an intu-itive platform that has ad-vanced the way the industrymonitors and maintains itstools,” states John Wakefield,
Managing Director of Progres-sive Components. “The latestfeatures enable users to accessmore meaningful KPI and ex-ception reports and to usethese in the decision-makingprocess. It also provides OEMsandmulti-plant organisationsthe ability to view data for allor select plants in a single,comprehensive view.”procomps.com
document9104342951600508418.indd 37 19.10.2018 12:59:27
SUPPLIERS DIRECTORY
38 11/12-2018
Quick Sourcing Grid:Tool & Mould Components
ADonpag
e
Co.Profileon
etmm-online.co
m
Bas
es
Bus
hing
s
Cav
ities
Conn
ectors/C
oup
lings
Company | Contact
Cumsa, Sant Just Desvern (Barcelona), ES | www.cumsa.com 9
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de 58, 63
Meusburger Georg GmbH&Co. KG, Wolfurt, AT | www.meusburger.com 37
Progressive Components, Wauconda, USA | www.procomps.com 2
Türk+Hillinger GmbH, Tuttlingen, DE | www.tuerk-hillinger.de 5
Agathon AG Normalien, Bellach, CH | www.agathon.ch
AHP Merkle GmbH, Gottenheim, DE | www.ahp.de
A-One Moulds, Pune, IN | www.indiamoulds.com
Braunform GmbH Kunststoff- und Pharmatechnik, Bahlingen am Kaiserstuhl, DE |www.braunform.com
Carrs Toolsteel Technologies, Tipton, W Midlands, UK | www.carrs-tool.co.uk
Deutsche Edelstahlwerke GmbH, Witten, DE | www.dew-stahl.com
DME Europe, Mechelen, BE | www.dmeeu.com
Dongsan Bearing Corporation, Namdong-gu, Incheon, KR | www.dongsanbearing.com
Eberhard Werkzeugtechnologie, Nordheim, DE | www.eberhard.de
FCPK Bytow Sp. z.o.o., Bytow, PL | www.fcpk.pl
Fibro GmbH, Haßmersheim, DE | www.fibro.de
Hasco Hasenclever GmbH + Co KG, Lüdenscheid, DE | www.hasco.com
Helix Tools/Arti Takim, Bursa, TR | www.artitakim.com
Hitachi Metals Europe GmbH, Düsseldorf, DE | www.hitachi-metals.co.jp/e
HSB Normalien GmbH, Schwaigern, DE | www.hsb-normalien.de
Knarr Vertriebs GmbH, Helmbrechts, DE | www.knarr.com
MHS – Mold Hotrunner Solutions Inc., Georgetown, CA | www.moldhotrunnersolutions.com
Millutensil s.r.l., Milano, IT | www.millutensil.com
Nonnenmann GmbH Präzisionsteile, Winterbach, DE | www.nonnenmann-gmbh.de
Opitz GmbH, Aschaffenburg, DE | www.opitz-gmbh.de
Padm Tooling, Capelle aan den Ijssel, NL | www.padm-tooling.com
Pedrotti S.p.A., Gavardo (BS), IT | www.pedrotti.it
Präzi-Flachstahl AG, Everswinkel, DE | www.praezi.de
Roehr Tool Corp., Hudson, USA | www.roehrtool.com
Schöttli AG, Diessenhofen, CH | www.schoettli.com
Stäubli Faverges SCA, Faverges, FR | www.staubli.com
Strack Norma GmbH&Co. KG, Lüdenscheid, DE | www.strack.de
Tecnomagnete, SpA, Lainate (MI), IT | www.tecnomagnete.com
Tekis Teknik Erozyon Kalip Sanayi Ve Ticaret A.S., Kocaeli, TR | www.tekiskalip.com.tr
Tirad s.r.o., Zeletava, CZ | www.tirad.cz
Tribo Hartstoff GmbH, Barchfeld-Immelborn, DE | www.tribo.de
Weber Manufacturing Technologies Inc., Midland, CA | www.webermfg.ca
Wema GmbH, Lüdenscheid, DE | www.wema.de
document2389927658943872969.indd 38 19.10.2018 12:59:50
SUPPLIERS DIRECTORY
3911/12-2018
Coolin
gSys
tems
Cores
EjectionSys
tems
EjectorPins/Sleev
es/
Plates
Fas
tene
rs
Frame/Inse
rtSys
tems
Guides
Hea
tingEquipmen
t
Hyd
raulic
Cylinders
Interlock
s
LatchLo
cks
Lead
erPins
MouldPortPlugs/Sea
ls
Quick
Mould-C
hang
eSys
tems
Slid
es/Slid
eLo
cks
Sock
ets
Spring
s
StopPins/Sleev
es
Sup
portPillars
document2389927658943872969.indd 39 19.10.2018 12:59:51
40 11/12-2018
Indexable tools challenge solidcarbide for small diameters
While solid carbide tools represent the traditional tool choice for small di-ameters, today's indexable tools present several advantages over one-piecesolid tools. The manufacturer Iscar offers various indexable insert optionsfor these applications.
The cutters of the new families of indexable millingcutters, for example, the Micro3Feed series, carrytriangular-shaped inserts with three cutting edges,while the mechanical part that secures the insertsis represented by a screw.
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Rotating one-piece solid carbide tools tradition-ally dominate the market for diameter rangesof up to 20mm (.75”) and indexable tool man-
ufacturers have not yet succeeded in penetratingthis solid stronghold. Several important factorscontribute to the historical perception of solid car-bide as a better bet for tooling reliability.Solid carbide tool accuracy compares favourably
to that of indexable tools, particularly for small-di-ameter end mills and for tools with diameters be-yond the range. However, the role of reduced accu-racy for tools of small diameter (for example, amilling cutter’s radial run-out) increases in signif-icance as a factor affecting tool life.An indexable tool is made up of a tool body, re-
placeable inserts and mechanical parts such asclamping screws or wedges, which secure the in-serts in the body. Decreasing the tool diameter ne-cessitates reducing dimensions of the assembly
components. Reducing the size of the securing el-ements weakens their strength and the tool be-comes unable to withstand cutting loads undernormal machining data. This seriously limits toolapplication; further decrease may cause degrada-tion of the entire assembly structure.The prices of small rotating tools are often high
compared to the assembled concept, which addsto the perceived limitations of indexable tools inthe small diameter range.
The indexable option
Indexable tools possess several distinct advantag-es thatmake applying these tools within the aboverange very attractive in the eyes of the customer.In many cases, especially in rough machining,changing a worn cutting edge by simple indexingprovides economic benefits comparedwith having
document3378833555778620371.indd 40 19.10.2018 13:00:20
CUTTING TOOLS TECH FOCUS
4111/12-2018
INFOThe term indexablederives from index-ing, meaning thatsomething is mov-ing (or in this case,moved) into a newposition quicklyand easily but alsoprecisely. Com-pared to solid mills,indexable insertscan therefore beexchanged quicklyand easily.
to replace awhole life-expired solid tool with a newtool. In addition, there is no need to use up timeand resources on regrinding and recoatingworn-outone-piece cutters.Tool manufacturers have made significant pro-
gress in developing reliable designs that could becommercially viable against the solid carbide con-cept. Work in this direction has shown results al-ready, and assembled mills and drills with inter-changeable cutting heads are proving to be a real-istic alternative to solid carbide tools.The introduction of tools with replaceable solid
carbide cutting heads signifies a change in focus.Cutting tool manufacturer, Iscar, provides two ex-amples of this concept with the Iscar Multi-Mastermilling line and the Chamdrill line in drilling.Performance and accuracy characteristics have
positioned the new tools to be functionally com-petitive with solid carbide designs. Versatility ofthese lines, where a head can be mounted in dif-ferent bodies and vice versa where a single bodycan carry different heads, facilitates various assem-bly combinations and contributes to reducing itemsin tool stock.
Cutting cycle time
Another important design approach – “no set-uptime” – characterises these lines. Aworn-out headdoes not require spending time on set-up and canthus be replaced while the tool is still clamped inthemachine tool spindle. This cuts cycle time and,consequently, reduces production costs.In contrast, replacing a worn-out solid carbide
mill or drill inevitably leads to a new set-up proce-dure.In addition, the concept ensures sustainable use
of cemented carbidewith all the associated advan-tages. The principle of “indexable” carbide tools hasdistinct merits and features strongly in tool designwithin the diameter range that is under discussion.The minimum diameter of Multi-Master millingheads is 5mm and that of Sumocham drilling headsis 4 mm, while the Multi-Master combined coun-tersink heads for centre-drilling feature aminimumdiameter of 1 mm.Iscar recently introduced a new range of small-
size indexable rotating tools under its new Logiqline campaign. The company proposes several fam-ilies of cutters with a nominal diameter of up to 20
The minimum diameter ofSumocham drilling headsis 4 mm.
The design of the Heli-3Mill family is committedto the classic principle ofinsert-securing via aclamping screw throughthe central hole of aninsert.
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mm.A brief look at some of these families providesa clearer understanding as towhether the new toolswill be able to breach the solid stronghold.The new families of indexable milling cutters
within the diameter range of 8-16 mm attract themost interest. They have several common features:The cutters carry triangular-shaped inserts withthree cutting edges, while themechanical part thatsecures the inserts is represented by a screw. Thesefamilies are intended for milling square shoulderor fast-feed (high-feed) milling. But here the simi-larity ends, and the difference begins. While thedesign of the Heli3Mill andMicro3Feed families fortool diameters of 10-16 mm is committed to theclassic principle of insert-securing via a clampingscrew through the central hole of an insert, theNanmill and Nan3Feed families for tool diametersof 8-10 mm have adopted another concept.Within such a small diameter range, the central
clamping screw, as noted previously, does not pro-vide an acceptable solution. According to the newconcept, the screw is located above the insert whilethe screw head plays the role of a wedge. This ap-proach provides reliable and rigid clamping, ensuresa durable and homogeneous insert structure withno hole, and allows insert indexing to be quick andsimple.It is predicted that these new families will be
particularly effective in manufacturing compactparts and inmachining small-in-size cavities, pock-ets and small parts utilised in industrial sectorssuch as die and mould-making, as well as in pro-ducing miniature components.
Small change, large impact
A 1-mm change in size: Is this a lot or a little? Forindexable tools in the small diameter range, itmakes a noticeable difference. Iscar’s new Sumo-cham 4-mm-diameter drilling head represents animportant step ahead in expanding the applicationfields of indexable drills.Within the small diameter range, indexable tools
offer precision and performance advantages thatposition them competitively against the more tra-ditional solid carbide tools. Indexable tools arebeginning to shear their way into metalworkingpractices - and the industry is taking note.iscar.com
document3378833555778620371.indd 41 19.10.2018 13:00:23
TECH FOCUS CUTTING TOOLS
42 11/12-2018
Creating a new cutting tool –From concept to spindleNew cutting tools are continuously being introduced to the market, butwhat is the process needed to develop a product from concept through tothe spindle? Global company Dormer Pramet tasks its product manage-ment and development department with creating new tools every year.
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In January 2015, Jan Bittner joined Dormer Prametand became part of the company’s project to de-velop an assortment of high-feed milling tools.
Almost three years later, a new range of SBN10cutters and BNGX inserts were launched on theglobal market. The time taken to introduce a prod-uct is an indication of the investment a manufac-turer makes to create a new product that will addvalue to customers for many years.At Dormer Pramet, the process of creating a new
tool begins with its product management depart-ment, which identifies the market needs and gapsin the company’s current assortment. Karel Tiefen-bach is the company’s product manager for index-able milling and he created a brief and clear objec-tive for the development team.
Dormer Pramet’s aim was to create an assort-ment of tools for its double-negative cutters thatenabled feed rates for increased productivity. Thedesign needed to be for double-sided inserts tomaximise the economic value (four edges) and pro-vide good chip control, allowing for a higher ramp-ing angle. At the same time, the tool needed tooffer process security and a versatile range formould and die operations, covering roughing tofinishing.Bittner began the process with Jan Vlcek from
the company’s product design and informationdepartment, responsible for all aspects of tool de-velopment. This included compiling high-qualitydata on every tool produced, the design of productsand supporting manufacture. The department’s
Jan Vlcek and Jan Bittner work on the developmentof new indexable inserts at Dormer Pramet.
ˇ
document198175500528670676.indd 42 19.10.2018 13:09:22
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CUTTING TOOLS TECH FOCUSSou
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first task in designing a new high-feedmilling tool– later known as SBN10 – was to research whatproducts were already available on themarket fromcompetitors and howDormer Pramet could be dif-ferent, while still meeting the needs of customers.
Design concepts
Jan Bittner said: “We started with a series of pre-liminary studies and initial prototype designs, put-ting a number of ideas forward before we couldstart to produce samples. There are always difficul-ties and challenges to overcome, but some smallchanges at this stage can have a big impact. For e.g.,with one of the first samples created, we realisedthere was a conflict with an existing patent froma competitor.With many companies creating newinserts all the time, it is a very crowded market.“However, weworkedwith the designer tomod-
ify our concept to make it unique, whilst still ful-filling the original brief. This led us to liaise closelywith colleagues in Sweden and North America tomake sure our designs did not conflict with anypatents. We discussed with colleagues in Intellec-tual Property (IP) how we can make our designunique and this was a new experience for me. Ateach stage, wewere in discussionswith IP over thedesign and any slight changes being made. Weneeded to confirmwewerewithin patent pendingat every point and not conflicting with others al-ready submitted. Eventually, wewere given the OKto proceed.
On-site tests with customers
“At the start of the process in 2015, we had a sched-ule to follow and aimed to launch the BNGX insertsby November 2017.We had pressure from our salesteams who wanted it earlier! Our aim was to keepthe process going as fast as possible and we keptto schedule. By the second quarter of 2016, wewereable to start the testing stage. This included sever-al on-site tests with customers as this is the bestway to check how good a product really is.“We were confident it was a good product, but
no amount of in-house testing can match trying itout in the real world. We learned so much from
INFODormer Pramet isa global manufac-turer and supplierof tools for themetal-cuttingindustry. Its prod-uct programmeencompassesboth rotary andindexable drilling,milling, threadingand turning toolsfor use in a widevariety of produc-tion environments.
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Curve Segment CuttingDiscover the most innovativetechnology with the new curvesegment mills from Inovatools
Up to 90% time savings
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We produce the new CURVEMAX,tailored to your personal workpiece.in just 3 weeks, including coating!This offer is valid until the end of 2018!
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Jan Bittner has beendeveloping high-feed mill-ing tools at DormerPramet since 2015.
document198175500528670676.indd 43 19.10.2018 13:09:34
TECH FOCUS CUTTING TOOLS
44 11/12-2018
The SBN10 cutters are suitable for copy milling, ramping,helical interpolation, slotting and plunging.
these tests, which allowed us to identify areas offurther improvement.“A test we didwith a customer in France involved
machining a titanium-bearing austenitic, chromi-um-nickel, stainless steel. It is an extremely toughand ductile material. It requires a powerful ma-chine, capable of heavy feeds and slow spindlespeeds. We put it up against a competitor’s high-feedmilling tool with similar features to our SBN10.“After machining three parts, the cutting edge of
the competitor’s insert was worn, forcing the op-erator to index the cutting edge to continue pro-duction. After machining eight parts with theSBN10 cutter and BNGX inserts, the cutting edgeshowed minor flank wear and was still in a goodenough condition to continue cutting. In additionto significant longer tool life, themetal removal ratewas 20 percent higher. The customer was so im-pressed, he immediately bought one cutter andpre-ordered seven more by early 2018.“We did more than 20 tests with customers in
France, Brazil, Poland, China, Italy, the Czech Re-public and Germany. Altogether, five of these testsdid notmatch our expectations, so it allowed us togo back and look at what needed improving. Thisis an important process and can only help improveproduct performance and reduce limitations. Thecrucial part is to react quickly during the testingprocess; speed is crucial. Any issues need to be
Dormer Pramet’s new BNGX and ANHX inserts.
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eliminated and the design of the tool improved assoon as possible, before putting it back in for moretests.“In July 2017, we returned to Germany to a cus-
tomer where one of the tests did not go as well asthe others. Going back to the same location meantwe could perform the exact same trial in the sameconditions as before. This was important to verifywhether the improvements wemade hadworked.The application ran very successfully and it wasgreat to show the customer the new and improvedversion!“We realised at this stage that we were ready to
launch the product on the market. We had furtherdiscussions with IP to make sure our patent wasin place and everything was prepared. This led tomeetingswith production to ensure enough insertswere manufactured for the time of launch and li-aisons with the marketing and communicationsdepartment on creation of all the support material,such as brochures, images, videos, press releasesand online content.”
Launching the product on the market
Dormer Pramet launched its range of BNGX insertsand SBN10 cutters in November 2017, almost threeyears after the initial design brief was prepared.During 2018, the company will manufacture morethan 30,000 BNGX inserts, comprising differentsizes and chip breakers, alongside 450 cutters, inthree different variants: end mills with threadedshank, endmills with parallel shank and shell mills.Bittner added: “Product development is very
much a team effort. There are many people fromaround the world involved in the creation of newcutting tools – from product management and de-sign to the technology team, production, testing,through to sales and marketing.“No department is independent of the rest. We
are all connected and one area cannot be success-ful without the support of the rest. They all mustwork together to get a product to market.“Also, any new product created will become the
futurework for our production department. Some-timeswe can be focused on today andwhat is newnow, but it is our job to look at the future andwhatwill be important in five to ten years’ time.” rsdormerpramet.com
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Dormer Pramet has introduced an assortment of BNGX10 inserts for high-feedroughing.
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document198175500528670676.indd 44 19.10.2018 13:09:49
CAD/CAM, DESIGN & SOFTWARE CASE STUDY
4511/12-2018
Simulation and direct design makethe difference
Erbiwa sees itself not only as a specialist for back injection moulds, but alsoas a think tank for design-oriented high-tech surfaces and components.Since its foundation 13 years ago, the Allgäu-based company has relied onVisi for 3D CAD and filling simulation - and recently also for milling.
Visi Flow determines the positioning of nozzles and injection points,and the module is also used for distortion calculations.
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Double-digit growth rates testify to the fact thatErbiwa has done just about everything rightin its relatively young company history.
Founded in 2005 in Röthenbach, Germany, it is nowbased in neighbouring Lindenberg and has devel-oped from a design office for injectionmoulds to agroup of companies with 136 employees. Fifty-fiveof them are employed at Erbiwa Mould Industrialalone, the joint-venture subsidiary in Dongguan,China, founded in 2015 together with a co-operationpartner. Erbiwa LLC was founded in the USA in2007. Erbiwa currently focuses primarily on theautomotive sector.In toolmaking, the core competence of the All-
gäu-based company lies in back injection mouldsweighing up to seven tons for components in ve-hicle interiors, which can also include support inarticle development. The surfaces to be back-mould-ed are stainless steel, aluminium, wood or carbon.In addition, there are two-component tools, among
others with slide gate technology (without rotaryplate), gas and water injection technology (GID /WID), stamping and forming tools for aluminium,wood or stainless steel panels and tools for down-stream processes for further surface finishing.Series production of plastic parts began back in
2008, for which Erbiwa Tech is responsible. Thefocus is on visible and decorative parts for the au-tomotive sector, such as wheel hub covers orback-injected decorative trim panels, which areusually injection-moulded in medium batch sizesbetween 5,000 and 50,000 units.“As a Tier 1 supplier to BMW, we have even been
delivering directly to the assembly line since 2015,”reports Matthias Wagner, son of the companyfounder and technical director of Erbiwa GmbH.“We also use the injection moulding sector as apilot plant to sample newmoulds, produce proto-types or test the functions of handling systems suchas robots and grippers.”
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CASE STUDY CAD/CAM, DESIGN & SOFTWARE
46 11/12-2018
Erbiwa pursues the strategy of acting as a full-range supplier to the customer in toolmakingthrough the consistent integration of partners,while at the same time keeping the vertical rangeof manufacture low. With this goal in mind, thefirst projects with a nearby company specialisedin the development and production of decorativealuminium parts for the automotive industrywereinitiated soon after the company was founded. Atthis company, aluminium shells were for the firsttime directly back-injected, which made previousgluing or crimping processes unnecessary. The de-mand for injection moulds therefore increasedstrongly and the companywas looking for a strongpartner in this area. Together, they grew rapidlyand entered the vehicle interior and decor sector,which is now the focus of Erbiwa's activities.
From product development to milling
The success story is also closely linked to the inte-grated 3D CAD and CAM system, Visi, a productfamily for tool andmould-making that is developedand expanded by the British manufacturer, VeroSoftware. “Our decision to rely on Visi was maderelatively quickly in 2005: During the market re-search at the time, it quickly became clear thatVisi was verywell tailored to the needs of tool andmould-making,” says Matthias Wagner, looking
The design team at Erbiwa’s Lindenberg location currently consists ofeight employees. Design is carried out exclusively with the 3D-CAD VisiModelling, together with the Mould module, which enables largely auto-mated mould construction around the finished mould inserts.
At Erbiwa, injection moulds and entire mould families are produced indifferent designs with weights of up to ten tons. Almost all parts aremanufactured mechanically by partner companies – and by ErbiwaMould Industrial in China.
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back. “Erbiwa's initial focus was clearly on tooldesign and product development paired with pro-ject management, and Visi was used to illustratethis. The milling area was added after a steepgrowth phase in 2014.”At Erbiwa, all parts and components of a tool are
supplied, at least until recently: Mould bases, hotrunner systems and standard parts are obtainedfrom suppliers such as Meusburger, Hasco andKnarr. Moulding areas such as cavities, cores orsliders are manufactured by local partners – andsince 2013 also by the Chinese joint-venture sub-sidiary, Erbiwa Mould Industrial. For small parts,however, the process is multi-track, which also hasto dowith tools for further surface finishing, man-ufactured at the Allgäu site. Two newly acquired3-axis machining centres, which are also integrat-ed into the Visi workflow with the Visi MachiningCAM module, are evidence of this. With variousmodules, Visi is installed on a total of elevenwork-stations, supplemented by six licenses for the VisiViewer. In both CAD and CAM,Visi modelling formsthe basis in the 3D area, which is supplemented bytask-specific modules. At Erbiwa's design area, thismodule is Visi Mould, which enables largely auto-mated mould construction around the finishedmould inserts.The basic 3D CAD module, Visi Modelling, is a
so-called hybrid modeller. “This term means thatVisi uses the Parasolid core used here in combina-tion for solid modelling and surface modelling,”explains Marco Wiest, Sales Engineer at Mecadat,official distributor of Visi in Germany, Austria andSwitzerland. “In contrast to CAD systems workingpurely parametrically, this has clear advantages intoolmaking, as you can design much faster andmore flexibly.”
Simulation of demould process
The people of Erbiwa are advocates of direct design,whichworks verywell withVisi. MatthiasWagner,who used to design tools with other well-known– parametrically structured – CAD systems, is par-ticularly enthusiastic about the simplicity that Vi-
Erbiwa headquarters inLindenberg/Allgäu: Thenew building in the West-park industrial estate wasoccupied in 2011 andexpanded in 2016.
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CAD/CAM, DESIGN & SOFTWARE CASE STUDY
4711/12-2018
INFO
Erbiwa: Mould-making from Germanyto ChinaErbiwa sees itself as a think tank with a focus on design, project manage-ment, assembly and prototyping. The company's philosophy is to be able tooffer tailor-made complete solutions in the field of plastics via a network ofspecialists wherever the customers are active. These mainly come from theautomotive industry, which is why the company has its own locations in theUSA and China. However, the company's roots lie in the Allgäu region. Sinceits foundation in 2005, the Lindenberg-based company has focused not onlyon project management but also on the construction of injection moulds.
After Erbiwa's automotive customers repeatedly expressed the wish thatthe company should also be present in Asia and above all in China, companyfounder Ernst Wagner finally found a toolmaking and injection moulding spe-cialist who seemed to fit exactly into the planned activities in China. Thetwo-year co-operation was so successful that in 2015 a joint venture wasfounded, Erbiwa Mould Industrial. Today, Erbiwa obtains almost all individuallymanufactured parts from the Chinese joint-venture subsidiary, from which thefinished mould is then assembled for domestic customers in Allgäu. ErbiwaMould Industrial supplies the Chinese market – this also applies to Germancustomers active there – with tools directly.
si offers. For example, it often happens in everydaylife that an employee of the design department,which has a total of eight employees, has complete-ly finished the tool design and later colleaguesmakeadjustments or changes. It would not be so easy toget started with parametric design data. The othercolleagueswould first have to understand the phi-losophywithwhich the tool was built, since every-one has their own style and proceeds somewhatdifferently. Even the simplest changes would thentake a lot of time.WithVisi, on the other hand, thisis very simple, uncomplicated andwithout any lossof quality.At Erbiwa, Visi parametrics are mainly used for
the simulation ofmotion sequences. In Lindenberg,for example, the movements of the inclined slidesare simulated: Can the parts be demouldedwithoutproblems or is there a danger of collision with thecomponent or with other tool components? WithVisi, this can be displayed steplessly over the entirestroke, so to speak.“Rotary movements of gearwheels, which are
carried out via gear racks, are also a typical case forsimulation. Or looking at sliders with oblique boltswhen opening the tool, whereby we use this tech-nology relatively little and prefer to control it viacylinders," explainsMatthiasWagner. "Where thereused to be problems, kinematics simulation nowenables us to achieve results very quickly. I regardthe dynamic simulation of movements as a realhighlight of Visi.”At Erbiwa, theVisi Flowmodule has been ensur-
ing for ten years that the parts to be produced haveoptimum rheological properties. All phases of theinjection moulding process that take place in themould are analysed by FEM (Finite ElementMeth-od) filling simulation during the design process.This works very well in everyday life, because thesimulation is started directly from the 3D-CAD ofVisi. This allows the company to easily view gatingconcepts and filling behaviour, compare themwitheach other and quickly see whether, for example,
temperature or air problems occur. If required, themodule can also be used for distortion calculations.The good import functions that Visi provides in
the form of various interfaces are also of particularimportance in everyday design work. This is con-sidered very important in Lindenberg, both forcustomer data and for co-operation with Chinesecolleagues. All CAD data is exchanged here via Par-asolid. The background is that Erbiwa Mould In-dustrial designs with Siemens NX. In some cases,designs are now also being created in China, whichare thenmodified in Germany. Erbiwa has not on-ly gained very good experience with this, but italso runs absolutely smoothly via Visi's Parasolidinterface.erbiwa.de; visicadcam.com; mecadat.de
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document399405803878554303.indd 47 19.10.2018 13:03:11
ZOOMED IN
48 11/12-2018
It all started with noodlesIt was in the Japanese city of Nagoya that EichiiOkuma founded his company in 1898. Unliketheir modern counterparts, the early Okumama-
chines were not built to meet the requirements ofthe aviation or automotive industries. Instead, thefirst Okuma products were machines for makingudon noodles. Eichii Okumawas dissatisfied withthe quality of the devices available on the market.Instead of reducing his demands, he developed hisownmachines. Over the years, this philosophywasto lead to numerous milestones in mechanical en-gineering.In the first year, Eichii Okuma built and sold 20
machines. In the course of this first success in 1904,he directed his ambitions towards themanufactureofmachine tools. At the beginning of the FirstWorldWar in 1914, Okuma applied for his first patent fora lathe: the Okuma Automatic Gear Cutting Lathe.As a result of this new orientation, the companywas renamed OkumaMachineryWorks in 1918. Inthe same year, Okuma started selling its OS Centrelathes, which became a great success. With morethan 2,000 units delivered in 25 years, themachinetool became one of the best-selling products in thecompany's history.At that time, the reputation of Okuma's high-qual-
itymachines had already been heard in the highestcircles, which led to Okuma being contracted forseveral orders from the Japanese government. Thecompany diversified its range in the years to comeand was able to survive the Great Depression andthe Great Kanto Earthquake of 1923. As part of alarge-scale plan by the government to establishNagoya as an international centre for the automo-tive industry at the Detroit level, Okumawas com-missioned by the mayor in 1930 to build an 8-cyl-inder engine for the first carmanufactured in Japan,the “Atsuta-Go”. By 1937, Okuma was already themarket leader in Japan for machine tools.After the outbreak ofWorldWar II, however, the
Japanese government limited production to lathes,grinding machines and milling machines. Despitethis temporary setback, by 1958, the Okuma brandstood for both turning and industrial drilling ma-chines. On this diverse basis, Okuma later devel-oped versatile machining centres andmultitaskingmachines as well as – as in the recent past – supermultitaskingmachines for additive and subtractivemachining processes on a single machine.In 1963, Okuma developed its first numerical
control OSP III NC.With it, Okuma became the firstand until today only “single-source”manufacturerof machines and controls. From then on, manyOkuma products were available bothmanually andNC-controlled. With the introduction of the firstcomputerised NC control in 1972, Okuma usheredin anothermachining era. Thismilestone paved theway for many of the high-tech solutions that Oku-ma offers today: They are all based on a compre-hensive understanding of all the components in-volved – from the machine to the controller to thesoftware. Soon afterwards, Okuma developed theOSP 300withmicroprocessors. This new generation
of controls played a decisive role in the develop-ment of CNC lathes for simultaneous 4-axis ma-chining. In the 1980s, Okuma developed furthermachine tools to increase productivity in manu-facturing. In the 1990s, portal milling centres suchas the MCR-BIII for 5-sided machining went intoproduction.The transition to the 21st century represented a
major leap forward in manufacturing technology.The performance-enhancing applications in theIntelligent-Technology series deliver maximumefficiency and productivity by creating the opti-mum machining conditions for each application.The first of these solutions, the Thermo-FriendlyConcept introduced in 2001, allowsmanufacturersto significantly increase machining precision byeffectively compensating for thermal deformation.Other applications soon followed, such as the Col-lisionAvoidance System to prevent costly collisions.
Industry 4.0 solutionsBy successfullymergingmachine, control and soft-ware, Okuma laid the foundation for its state-of-the-art Industry 4.0 solutions. In 2013, Okuma es-tablished the Smart Factory Dream Site 1 (DS1) inJapan for the manufacture of multitasking ma-chines aswell asmedium and large lathes. In 2014,the control system also became “smart”: OSP suiteoffers users access to the Intelligent TechnologyApps and at the same time plays a major role inthe handling of "Big Data" in the Industrial Internetof Things (IIoT).At that time, high-precision 5-axis machining
centres for industries such as aerospace also be-came an integral part of Okuma's product offering.New solutions for difficult-to-machine materialssuch as titanium or Inconel followed. In 2016, Oku-ma presented its Super Multitasking machines. In2017, Dream Site 2 (DS2) was opened, which has aneven higher degree of automation than DS1. EichiiOkuma died in 1950, but his legacy lives on todayin every new innovation. Roman Oncsakokuma.com
With 30,000 units sold in over 40 countries, the OS-Centre lathe has become one of Okuma’s most success-ful products.
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maTIMELINE
1898Eichii Okumafounds the Okumacompany in theJapanese city ofNagoya.
1904Okuma directs hisambitions to themanufacture ofmachine tools.
1914The machine man-ufacturer registersits first patent for alathe.
1918As a result of thisnew orientation,the company isrenamed “OkumaMachinery WorksLtd.”
1972With the introduc-tion of the firstcomputerised NCcontrol, Okumaintroduces a newmachining age.
2013Okuma establishesthe first SmartFactory in Japan.Four years later, asecond, morehighly automatedSmart Factoryfollows.
document4024622806028480451.indd 48 19.10.2018 13:03:43
Volume XVII | Issue 4 | 11/12 2018 www.edm-europe.com
Buyer's Guide 2018Annual Directory Issue
• Software • Materials • EDM Equipment • EDM Accessories & Supplies• Automation • Machining Equipment • Machining Accessories • Quality Control
document595275560202909944.indd 49 19.10.2018 13:03:57
50 11/12-2018
Back to the basics:When does EDM make sense?
When traditional machining methods reach their limits, electricaldischarge machining can be the answer. The EDM process allowsfor high accuracy and is applicable to any conductive material.
Electrical discharge machiningdoes not use any force to removematerial. Instead, an electricdischarge occurs between work-piece and tool. In this case, awire is used to “cut” the material.
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Electrical discharge machining, or EDM, is anon-traditional method in which material isremoved from aworkpiece using thermal ener-
gy. Much like processes such as laser cutting, EDMdoes not need mechanical force in the removalprocess. This is the reason why it is considerednon-traditional, contrary to, for example, processingwith cutting tools.In tool and mould-making, EDM is very popular
thanks to its applicability, especially for hard ma-terials like titanium or for particularly complexshapes that are hard to achieve with milling.Simply put, electrical discharge machining is a
manufacturing process that precisely removesma-terial from conductivematerials using an electrode.Similar to pushing a form into soft material, theelectrode leaves a negative imprint in the work-piece. The physical process is a little more compli-cated: In a small gap betweenworkpiece and elec-trode, a discharge occurs that removes materialthroughmelting or vaporising. For this process, theelectrode and theworkpiece have to be submergedin a dielectric fluid.
The principle behind this process is the ability ofcontrolled electric sparks to erode material. Theworkpiece and electrode do not touch during thisprocess. In between is a gap that is roughly as thickas a human hair. The amount of material removedwith a single spark is small, yet the discharge occursroughly several 100,000 times a second.While the electrode ismoved closer to thework-
piece, the electric field in the gap, also known asspark gap, increases until it reaches the breakdownvolume. For this process, it is necessary that thefluid inwhich this discharge occurs is not conduc-tive, or dielectric. The discharge causes high heatingof the material, melting away small amounts ofmaterial. This excess material is removedwith thesteady flow of the dielectric fluid. The liquid is alsouseful for cooling during machining. Moreover, itis necessary for controlling the sparks.There are three different types of electrical
discharge machining. The one described above iscalled sinker EDM. It is also known as die sinking,cavity type EDM, volume EDM, traditional EDM, orRam EDM. Using die-sink EDM allows users to pro-
Rosemarie Stahl
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duce complex shapes. This method requires elec-trodes (often made from graphite or copper) thatare pre-machined to have the necessary shape. Thiselectrode is then sunk into theworkpiece, creatingthe negative version of its original shape.The second type of electrical dischargemachining
is calledwire EDM and is also known as wire ero-sion, wire burning or spark EDM. In wire EDM, athinwire is used to cut theworkpiece. In this case,thewireworks as the electrode. Duringmachining,thewire comes constantly from an automated feedwith a spool. If the cut has to bemade in themidd-le rather than the outside of the workpiece,small-hole drilling EDM is used to make a hole inthe workpiece throughwhich the wire is threadedafterwards.The wire is held with diamond guides. Usually,
the liquid is deionisedwater. Thewire is oftenma-de from brass or copper.The last type of electrical discharge machining
is called hole drilling EDM. As the name suggests,this process is used for drilling holes. Comparedwith traditional drilling methods, EDM is able tomachine extremely small and deep holes. Additi-onally, EDM-drilled holes don't need any deburring.The electrodes in this process are tubular and thedielectric fluid is fed through the electrode itself.In general, every conductivematerial can bema-
chined with electrical discharge machining. Com-monmaterials includemetals ormetal alloys suchas hardened steel, titanium, and composites.
Advantages: When applying EDMmakes sense
Typically, the electrodes for die sinking EDM aremade of copper or graphite. The main factors thatinfluence the decision for an electrodematerial arethe electrode's conductivity and its resistance toerosion. Graphite has the advantage that it is easiertomachine than copper. However, copper is highlyconductive and strong. Brass, an alloy of copperand zink, is often used for wire EDM or small tu-bular electrodes.Contrary to electrodes for die sinking, the wire
used for wire EDM does not have to offer good re-sistance characteristics, as new wire is fed cons-tantly during the cutting process.The main advantage of electrical discharge ma-
chining is that it can be used on any material aslong as it is conductive. It is therefore possible tomachine workpieces made from tungsten carbideor titanium that are hard to machine with traditi-onal cutting methods. Another advantage of elec-trical discharge machining is the lack of mechani-cal force put into the workpiece. Fragile outlinesare easier to produce because there is no high cut-ting force needed to remove the material.EDM also allows for shapes and depths that are
impossible to reachwith a cutting tool. Especial-ly deep processingwhere the tool length to diame-ter ratio would be very high is a usual applicationfor EDM. Sharp internal corners, deep ribs and nar-row slots are other specialities of electrical dischar-ge machining. Another argument for using EDM isthat the surface finish is usually better than withtraditional methods. Electrical dischargemachiningproduces surfaces with a fine finish and high pre-cision.
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The Metalforming Magazine gives tips on howto ensure process safety. These are some of themeasures that need to be taken to run an EDMmachine safely:W Operators and workers have to be properlytrained toworkwith electrical dischargemachi-ning.
W Make sure that fire protection measures are in-stalled and regularly maintained.
W Keep an eye on the fluid: The level of the dielec-tric fluid is of utmost importance. The liquidprevents the discharge from crossing to conduc-tive materials other than the workpiece.
W Proper ventilation can clean the air of gases thatmight be produced in the fluid due to chemicalreactions accompanying the discharge.
W You have to monitor the dielectric fluid when itis circulating to ensure it retains its non-conduc-tive characteristics.
EDM machines and automation
There are numerous suppliers of EDM machines.Among the most well-known producers are Mit-subishi Electric, OPS Ingersoll, Makino, Excetek,Sodick, GF Machining Solutions and Ona.A current trend is the automation of the EDM
process. This does not only include the spark orwire erosion itself but also the machining of theelectrodes. Using CNC machine tools to machineelectrodes, EDMmachines, cleaning andmeasuringstations and — last but not least — storage areasand robotic units to handle the electrodes, the EDMprocess can be executed automatically. This en-sures that a sparker is always fed quickly enoughwith electrodes. Themachining of these electrodesand the erosion process can be programmed totake place overnight, thusmaking production pro-cesses much more time-efficient. Moreover, a hig-her workload can be processedwithout additionalworkforce. Several processes can happen simulta-neously, including eroding, measuring, milling,laser engraving and cleaning. Companies that haveimplemented automation in their production pro-cesses havewitnessed significant time savings andan increase in turnover.Companies like Zimmer & Kreim offer automa-
tion systems particularly for EDM processes. OPSIngersoll is anothermanufacturer that offers a one-stop automation solution designed to fulfil theneeds of their clients in the toolmaking industry.
An example of parts machined with wire erosion: Thesepieces have been machined on a Sodick wire EDMmachine.
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MMoreover, EDM allows users tomachine hardenedworkpieces.Whereas other machining techniquesneed to be executed before the workpiece is har-dened with heat treatment, electrical dischargemachining can be applied on the hardened ma-terial aswell. Thus, any potential deformation fromheat treatment machining can be avoided.
EDM and safety?
However, there are numerous exampleswhere elec-trical dischargemachining is not the right solution.EDM is a high-precision machining method. EDMis a rather slow method compared to traditionalmachining. High-volume tasks are therefore notsuited for this method. At the same time, the elec-trothermal process requires high power consump-tion.Similar to traditional chippingmethods, the tool
life in EDM is not endless. In sinker EDM, the elec-trode is also vulnerable to erosion. Because of thetool wear, the electrode has to be replaced regular-ly. In sinker EDM, it is also necessary to producethe correctly shaped electrodes before the work-piece can be machined. This is an additional stepcompared tomachining processes with traditionalcutting tools.There are numerous examples of companies that
have managed to implement electrical dischargemachining for their benefit. In many cases, an up-date to a newer and more modern EDM machinehas done the trick. The following are case studiesthat tell the stories of some successful companiesand their experience with electrical discharge ma-chining:How safe is EDM?This is actually a question that
worries many technicians coming in touch withEDM for the first time. The need for high voltageand reoccurring sparks make it seem like a safetyhazard to inexperienced workers. As long as themachine is used according to manufacturer speci-fication, however, there is no great danger involved.
The Eagle G5 Precision isan example of an electri-cal discharge machine byOPS Ingersoll. Thedie-sinking machine issaid to offer high-preci-sion machining combinedwith low electrode wear.
INFOThanks to its prop-erties, EDM is notonly used inmould-making, butalso often in jewel-lery production.Here, too, specialmetals have to bemachined withsmall tolerances.
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CNC Software Inc., Tolland, CT, USA | www.mastercam.com 7
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4D Engineering Ltd., Cirencester, Glos, UK | www.mastercam.co.uk
CADCAM-E.com Inc., Farmington Hills, USA | www.cadcam-e.com
Camtek Ltd., Cheltenham, Glos, UK | www.peps.com
Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen, DE | www.zeiss.de/imt
CGTech Ltd., Hove, UK | www.cgtech.co.uk
Charlyrobot S.A., Cernex, FR | www.charlyrobot.com
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Dassault Systeme SolidWorks Corporation, München, FR | www.solidworks.com
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Delcam International PLC, Birmingham, UK | www.delcam.com
DeskArtes Oy, Espoo, FI | www.deskartes.com
Desktop Engineering Ltd., Long Hanborough, Oxon, UK | www.dte.co.uk
DP Technology Corp., Camarillo, CA, USA | www.dptechnology.com
Esprit CAM Software, Montpellier, FR | www.dptechnology.fr
Geometric Technologies Inc., Scottsdale, USA | www.camworks.com
Gibbs and Associates, Moorpark, CA, USA | www.gibbscam.com
Hexagon Metrology S.p.A., Grugliasco (TO), IT | www.dea.it
Imes-icore GmbH, Eiterfeld, DE | www.imes-icore.de
Imtech Design Ltd., Chislehurst, Kent, UK | www.imtechdesign.com
Kubotek Europe S.r.l., Costabissara, IT | www.kubotekeurope.com
Leica Geosystems AG, Unterentfelden, CH | www.leica-geosystems.com/metrology
MachineWorks Ltd., Sheffield, UK | www.machineworks.com
Materialise N.V., Leuven, BE | www.materialise.com
Mazak Machine Tools, Worcester, UK | www.mazak.com
Metalcam S.L., Barcelona, ES | www.metalcam.com
Metris UK Ltd., Derby, UK | www.metris.com
Missler Software (Topsolid), Evry , FR | www.topsolid.com
Moldex3D, Chupei, TW | www.moldex3d.com
Moldflow Vertriebs-GmbH Büro München, München, DE | www.autodesk.de
Open Mind Technologies AG, Weßling, DE | www.openmind-tech.com/de/startseite.html
Parametric Technology (UK) Ltd., Cambridge, UK | www.ptc.com
PeyerConsult S.A., Cadenazzo, CH | www.pcam.com
Planit Holdings Ltd., Ashford, UK | www.planit.com
Qarm Pty. Ltd., Cleveland, AU | www.onecnc.com.au
Scan Technology (Scantech) ApS, Ringsted, DK | www.scantech.dk
Schott Systeme GmbH, München, DE | www.schott-systeme.de
Sescoi International SAS, Macon cedex, FR | www.sescoi.fr
SolidCAM GmbH, Schramberg, DE | www.solidcam.com
Surfcam, Inc. Corporate Headquarters, Thousand Oaks, USA | www.surfcam.com
System 3R Europe GmbH, Groß-Gerau, DE | www.system3r.com
Tebis Technische Informationssysteme AG Pressestelle, Planegg, DE | www.tebis.de
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BES Funkenerosion GmbH, Fluorn-Winzeln, DE | www.bes-edm.de
Buchem Chemie + Technik GmbH&Co. KG, Köln, DE | www.buchem.de
Bunol EDM Supplies, Wermelskirchen, DE | www.bunol.com
Carbon Industrie-Produkte GmbH, Buchholz (Westerwald), DE |www.carbon-graphit.de
CRDM Ltd., High Wycombe, Bucks, UK | www.crdm.co.uk
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EDM- Deutschland Zeller&Hofmann GbR, Kahl a. Main, DE |www.edm-deutschland.de
EDM Service, Jouy-le-Mouier, FR | www.edmservice.com
Erodex (U.K.) Ltd., Halesowen, W Midlands, UK | www.erodex.com
Erowa AG, Büron, CH | www.erowa.com
GDE-Werkzeuge GmbH, Halver, DE | www.gde-werkzeuge.de
George H. Cook Div. of Cogne UK Ltd., Sheffield, UK | www.ghcook.com
GF Machining Solutions Management, Genf, CH | www.gfms.com
GTD Graphit Technologie GmbH, Langgöns, DE | www.gtd-graphit.de
H.G. Hassfurther GmbH&Co. KG, Lüdenscheid, DE |www.hgh-luedenscheid.de
Hirschmann Engineering UK Ltd., Denbigh, UK |www.hirschmannengineering.co.uk
Ibiden Europe B.V., Hoofddorp, NL | www.ibiden.com
IC-Hungary Kft., Sziget-Szentmiklós, HU | www.ichungary.hu
Imtech Design Ltd., Chislehurst, Kent, UK | www.imtechdesign.com
Irumold, Pamplona, ES | www.irumold.com
Keronite International Ltd., Haverhill, UK | www.keronite.com
Oerlikon Metaplas GmbH (Oerlikon Metaplas GmbH),Bergisch Gladbach, DE | thinfilm.sulzermetco.com
Poco Graphite SARL, Limonest, FR | www.poco.com
SGL Carbon AG Werk Ringsdorff Werk Ringsdorff, Bonn, DE |www.sglcarbon.com
System 3R Nordic, Vällingby, SE | www.system3r.com
System 3R Schweiz AG Spannsysteme u. Automation, Flawil, SE |www.system3r.comTokai Carbon Europe Ltd., Oldbury, W Midlands, UK |www.tokaicarboneurope.com
Tokai Carbon Italia S.r.l., Trezzano Rosa (MI), IT | www.tokaicarbon.co.jp
Uddeholms AB, Hagfors, SE | www.uddeholm.com
document2299855457708485416.indd 54 19.10.2018 16:15:06
55
PRODUCT FOCUS
11/12-2018
Die-sinking family forflexibility and qualityWith the Form family of die-sinking electrical dischargemachining (DSEDM) solutions, GF Machining Solutionswants to advance manufacturers' success.
The Agie CharmillesForm P 350.
INFOGF MachiningSolutions is aprovider of machi-nes, diversetechnical solutionsand services notonly to the tool andmould-makingindustry but also tomanufacturers ofprecision compo-nents. The portfolioranges from electri-cal dischargemachines, high-speed andhigh-performancemilling machines tosolutions for too-ling and automati-on, services, spareparts, expendableparts, consumab-les and digitalisati-on solutions.
The Agie Charmilles Form X, Form S, Form Pand Form E series advance their precursors'software and technical innovation, manufac-
turer GFMachining Solutions announced.Wheth-er the requirement is a singlemachine for straight-forward use or full automation, Form solutionsenable users to meet challenges with greater flex-ibility andmachining accuracy to eliminate costlymanual operations, GF Machining Solutions says.According to the company, the machines offerEconowatt technology to save energy, a variety ofIndustry 4.0-oriented connectivity features to sup-port manufacturers’ digital transformation, ande-Tracking software for EDM process monitoringand full traceability.From faster rib machining to micromachining,
the Agie Charmilles Form family is the outcome ofcontinued investments to advance DSEDM research.The result is that Agie Charmilles Form series usersachieve better performance in machining withgraphite and copper, the company says. The seriesallows for repeatable machining of micro-cavities.Simultaneously, this series’s “iGAP” technologyguarantees the rigidity of plastic, injection-mould-ed end products with deep, plastic-reinforced ribs.It also ensures fast, accurate machining of rib cav-ities with respect to the required demoulding taperand VDI homogeneity throughout the cavity sur-face. Additionally, manufacturers requiring maxi-mumuse of the Agie Charmilles Formmachine canexploit the range’s “eConnectivity” features and“MTConnect” capability to stay informed of themachine’s status.gfms.com
Sou
rce:
GFMac
hining
Solutions
The HIGH-Perfomance US/EU-Patented Wire
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HIG Handel mit IndustriegüternGesellschaft m.b.HP.O.Box 7, Eisenbahnstr. 71, A-1195 VIENNAPhone +43.1.37022330, Fax [email protected] www.hig.at
The Authentic People Since1973
Available from central stock in VIENNA/Austriaor from authorized distributors across Europe
High-PerformanceEDM Wire New Developed, Patent Pending
Pyroelectic the ADVANCED Coating ofWire CuZn40
document3746777830592630958.indd 55 19.10.2018 13:05:00
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Quick Sourcing Grid:Machining Accessories
Adonpag
e
Cuttin
gFluids
End
Mills/
Ball-Nose
Cutters
forGraphite
End
Mills
Micro
Cuttin
gTo
ols
Micro
Positio
ning
Sys
tems
Spindles
Toolholders
ToolC
hang
ersan
dMag
azines
Company | Contact
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de58,63
Matsuura Europe GmbH, Wiesbaden, DE | www.matsuura.de 21
Big Kaiser Präzisionswerkzeuge AG, Rümlang, CH | www.kaisertooling.com
Delfer, SPA, Beinasco (TO), IT | www.delfer.it
DME Europe, Mechelen, BE | www.dmeeu.com
E.N.S. International S.r.l., Villanuova sul Clisi (BS), IT | www.ensint.com
EDM Service, Jouy-le-Mouier, FR | www.edmservice.com
Erodex (U.K.) Ltd., Halesowen, W Midlands, UK | www.erodex.com
Exeron GmbH, Oberndorf am Neckar, DE | www.exeron.de
Fenn Tool Ltd., Braintree, Essex, UK | www.fenntool.com
GDE-Werkzeuge GmbH, Halver, DE | www.gde-werkzeuge.de
Goudsmit Magnetic Systems BV, Waalre, NL | www.goudsmit-magnetics.nl
Gühring KG, Albstadt, DE | www.guehring.de
Haimer GmbH, Hollenbach, DE | www.haimer.de
Hangsterfers Laboratories Inc., Mantua, NJ, USA | www.hangsterfers.com
Hermann Schmidt Co., South Windsor, USA | www.hschmidt.com
Hirschmann GmbH, Fluorn-Winzeln, DE | www.hirschmanngmbh.com
ITC Industrial Tooling Corp. Ltd., Tamworth, Staffs, UK | www.itc-ltd.co.uk
Jongen Werkzeugtechnik GmbH, Willich, DE | www.jongen.de
LMT Tool Systems GmbH, Oberkochen, DE | www.lmt-tools.com
MachineTools.com Inc., West Bloomfield, USA | www.machinetools.com
Mapal Fabrik für Präzisionswerkzeuge Dr. Kress KG, Aalen, DE | www.mapal.com
Misumi UK Ltd., Staines, Middx, UK | www.misumi-europe.com
MMC Hitachi Tool Engineering Europe GmbH, Hilden, DE | mmc-hitachitool-eu.com
Nakanishi Inc., Kanuma-shi, Tochigi-ken, JP | www.nsk-nakanishi.co.jp
Oelheld GmbH, Stuttgart, DE | www.oelheld.de
Otto Suhner AG, Brugg, CH | www.suhner.com
Pennine Machine Tools Ltd., Halifax, W.Yorksh., UK | www.pennineuk.com
RobbJack Europe, Schiedam, NL | www.robbjack.eu
Sandvik Coromant, Sandviken, SE | www.sandvik.coromant.com
SGS Tool Co., Munroe Falls, OH, USA | www.sgstool.com
Sideco S.p.A., Grumolo delle Abbadesse (VI), IT | www.sideco-spa.it
Sommen-edm B.V., Waalre, NL | www.sommen-edm.nl
Sphinx Werkzuege AG, Derendingen, CH | www.sphinx-tools.ch
Stäubli Faverges SCA, Faverges, FR | www.staubli.com
Steelfluid S.r.l., Genoa, IT | www.steelfluid.it
Streuli technologies AG, Birmensdorf, CH | www.streuli-techno.ch
Suhner Abrasive Expert AG, Brugg AG, CH | www.suhner.com
Suhner France S.A., Alfortville, FR | www.suhner.com
System 3R Europe GmbH, Groß-Gerau, DE | www.system3r.com
Tool-Flo Mfg. Inc., Houston, TX, USA | www.toolflo.com
Tungaloy Germany GmbH, Monheim am Rhein, DE | www.tungaloy.de
document2153022118945735994.indd 56 19.10.2018 15:22:09
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PRODUCT FOCUS
Performance and productivityEDM Machining – Makino says its wireEDM UP6 machine improves perfor-mance, increases productivity and canmachine with better part accuracies.Featuring a hollow casting, parts of the
UP6 are flushed through with dielectricwater at constant temperature to preventthemachine suffering from heat displace-ment. The arm seal plate is constantlycleaned by a water cur-tain to reduce frictionand ensure smooth op-eration in the X-axis.Very long, high-preci-sion roller slides reducemotion vibrations andimprove rigidity.High-precision ballscrews are covered toprevent dirt ingress andextend their lifespan.According to the compa-ny, its wire drive allowsfor better corner accura-cy, more reliable wirethreading in complicat-ed shapes and smallstart holes. Also, the au-tomatic wire threadingsystem now enhances threading capabil-ities andworks dry as well as with waterjets.The company's CAM software, EDCAM
2017, allows for several automatic tasks.Among them are creating and adding cav-ities from a 3D model, ascertaining allelectrode positions, recognising and cal-culating spark areas, recognising and ac-quiring depths, findingmeasuring pointsand recognising workpieces. The main
benefit is thus minimising input errors.New features of the Hyper i Control oper-ating panel are smartphone, tablet-styleflick, pan, pinch, spread and swipe func-tions. Moreover, EDCAM data is editableat the machine control interface and ma-chine settings can be automatically down-loaded.Makino's upgraded EDAF series now
has a newly developedgenerator, the compa-ny's first implementa-tion of its H.E.A.T. tech-nology for sinker-EDM,and a programmableflushing control. The im-proved EDAF comeswith higher feed rates ofup to 5,000 mm/min inthe X andY-axes. Anoth-er feature, HS-Rib, ena-bles a jump speed of20m/min in the Z-axis– a 31% increase over thecurrent model. Thismore powerful genera-tor has a 80A-peak cur-rent in standard, whilereducing power con-
sumption by 44%.Makino CEODr. P. Anders Ingemarsson
said: “The upgrades and extensions to ourEDM portfolio have considerably im-proved their appeal tomachining compa-nies targeting awide range of industries.”Application fields for Makino's EDM port-folio are the die and mould, electronics,food and packaging, health and cosmeticsand precision metalworking industries.makino.eu
Sou
rce:
Mak
ino
Makino UP6 is equipped with a newlydeveloped wire drive system to enablebetter corner accuracy.
“Our EDMportfolio hasimprovedits appeal
to companiestargeting a wide
rangeof industries.”Dr. P. A. Ingemarsson, Makino CEO
The world class graphite material for
EDM electrodes
We have the
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document3914958223772600324.indd 57 19.10.2018 13:05:44
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Quick Sourcing Grid:EDM Accessories&Supplies
AD
onpag
e
Co.Profileonetmm-online.co
m
Additive
s/Rus
tInhibito
rs
Dielectrics
forSinke
rs
Dielectrics
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EDM
Polis
hing
Sup
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s
ElectrodeHolders
Electrodes
Filtratio
n/Dus
t/Fum
eExtraction
Equipmen
t
Fixtures
Fluids
Graphite
ElectrodeHolders
PipeElectrodes
Res
in/Filters
SoftwareMan
agem
entSys
tems
Wea
rParts
Wire
s
Work
HoldersforSinke
rMac
hine
s
Work
HoldersforWire
Mac
hine
s
Company | Contact
Boride Engineered Abrasives, Traverse City, MI, USA |www.borideabrasives.com 59
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de 58,63
HIG Handel mit Industriegütern Ges.m.b.H., Wien, AT | www.hig.at 55
Mersen France Gennevilliers SAS S.A.S., Gennevilliers, FR |www.mersen.com 57
Sarix SA, S. Antonino, CH | www.sarix.com 51
Berkenhoff GmbH, Herborn, DE | www.bedra.com
Boehlerit GmbH&Co. KG, Kapfenberg, AT | www.boehlerit.com
Buchem Chemie + Technik GmbH&Co. KG, Köln, DE | www.buchem.de
Cimtrode, The Electrode Company GmbH, Mattighofen, AT | www.cimtrode.com
Easymetal GmbH, Wolkersdorf, AT | www.easymetal.com
Erowa AG, Büron, CH | www.erowa.com
Exeron GmbH, Oberndorf am Neckar, DE | www.exeron.deFluid Conditioning Systems Ltd. Innovation Centre, Warwick, UK |www.fluidcs.comGF Machining Solutions, Genf, CH | www.gfms.com
GTD Graphit Technologie GmbH, Langgöns, DE | www.gtd-graphit.de
Heinrich Stamm GmbH, Iserlohn, DE | www.stamm-wire.deHirschmann Engineering UK Ltd., Denbigh, UK |www.hirschmannengineering.co.ukHirschmann GmbH, Fluorn-Winzeln, DE | www.hirschmanngmbh.com
Houghton plc, Manchester, UK | www.houghton.co.uk
Ibiden Europe B.V., Hoofddorp, NL | www.ibiden.com
IC-Hungary Kft., Sziget-Szentmiklós, HU | www.ichungary.hu
JS GmbH, Fluorn-Winzeln, DE | www.jauchschmider.com
MAG Systems S.r.l., Abbiategrasso (MI), IT | www.magsystems.it
Makino Europe, Kirchheim unter Teck, DE | www.makino.eu
Mann + Hummel GmbH, Ludwigsburg, DE | www.mann-hummel.com
Matra-Werke GmbH, Hainburg, DE | www.matra.de
Poco Graphite Sarl, Limonest, FR | www.poco.com
Misumi UK Ltd., Staines, Middx, UK | www.misumi-europe.comMitsubishi Electric Europe B.V. Mechatronics CNC Division, Ratingen, DE |www.mitsubishi-mmd.deOelheld GmbH, Stuttgart, DE | www.oelheld.de
Ona Electroerosion, S.A., Durango, Bizkaia, ES | www.onaedm.com
Opitz GmbH, Aschaffenburg, DE | www.opitz-gmbh.de
PeyerConsult S.A., Cadenazzo, CH | www.pcam.com
SMS Elotherm GmbH, Remscheid, DE | www.elotherm.de
Sommen-edm B.V., Waalre, NL | www.sommen-edm.nl
Steelfluid S.r.l., Genoa, IT | www.steelfluid.it
System 3R Nordic, Vällingby, SE | www.system3r.comTokai Carbon Europe Ltd., Oldbury, W Midlands, UK |www.tokaicarboneurope.comTokai Carbon Italia S.r.l., Trezzano Rosa (MI), IT | www.tokaicarbon.co.jp
Zimmer&Kreim GmbH&Co KG, Brensbach, DE | www.zk-systems.com
document5735270075878539374.indd 58 19.10.2018 15:20:54
11/12-2018 59
PRODUCT FOCUS
OUR COMMITMENTTO OUR CUSTOMERS IS
SET IN STONEContact us to schedule a meeting at Fakuma 2018
THEPREFERREDBRANDFORMOLDPOLISHINGSUPPLIES IN EUROPE
PHONE: 231.929.2121 | TOLL FREE: 800.662.0336
BORIDEABRASIVES.COM | [email protected]
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Smart resin exchange
Service – In the segment ofthe die and mould-makingsector using erosionmachines,deionised water is the funda-mental working base. Focus-sing on the resin-based crea-tion of deionised water, EDM-Tec has found a carefreesolution, namely its system ofmobile resin exchange. Theunique part is that EDM-Tecoffers their high-quality,full-service spectrum at thecustomer's work site.After a service call, their net-
work of eight sites and 28 ser-vice vans throughout Germa-ny ensures prompt resin ex-
change. Once on site, thetechnician empties, cleans andrechecks the resin container.After about 20minutes of ser-vice time, the customer’s resincontainer is ready for useagain. Disposal of old resin isalso included in the fixedprice. This service is providedeither for existing customer’sresin containers or specialEDM-Tec models. The SUSsteel containers are highly rec-ommendable for their inte-grated system of resin-loosen-ing to prevent unused resinresiduals in the container.edm-tec.de
Revolutionising surfacequalities for graphite
EDMMachining – OPS Inger-soll claims that its new EagleG5 Precision EDM machinecan achieve both the highestprecision results and the low-est electrode wear, unobtain-able until now, thanks to awhole new, innovative ma-chine concept.The Eagle G5 Precision has
a completely closed designthat minimises the influenceof temperature changes fromits surroundings during themachining process. Despitethis, there are no restrictionsin accessing the working areafor automation or manualloading.High thermal stability is re-
quired for precise results thatallow for a deviation below5µm – an accuracy that theEagle G5 Precision is able toachieve, OPS claims, therebymaking the machine ideal for
multi-cavity applications. An-other advancement in thema-chine is the new and powerfulEagle Power Spark generator,which replaces the outdatedcondensation stages, OPS ex-plains. “We produce the finest,homogeneous and even dullshining surfaces, which couldnever be realisedwith graphitebefore,” Dr. Max Schwade,technical manager at OPS,says.The Fraunhofer IPTAachen,
Germany, an institute that de-velops systems solutions forproduction-related topics suchas process technology, produc-tionmachines and productionquality, says that the resultingfine surfaces provide optimaldemouldability and are alsomuch easier to polish to amir-ror surface finish, when com-pared to milled surfaces.ops-ingersoll.de
Sou
rce:
OPSInge
rsoll
OPS says its Eagle G5 PrecisionEDM machine is the answer formulti-cavity applications.
document875548913946439350.indd 59 19.10.2018 13:06:03
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Quick Sourcing Grid:Automation
ADonpag
e
ElectrodeMan
agem
entTe
chno
logy
Han
dlin
gSys
tems,
Automated
Robots
ToolC
hang
ers,
Automatic
Toolin
gSys
tems,
Integrated
Work
Cells,C
omplete
Company | Contact
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de58,63
Matsuura Europe GmbH, Wiesbaden, DE | www.matsuura.de 21
BES Funkenerosion GmbH, Fluorn-Winzeln, DE | www.bes-edm.de
Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen, DE | www.zeiss.de/imt
Charlyrobot S.A., Cernex, FR | www.charlyrobot.com
DP Technology Corp., Camarillo, CA, USA | www.dptechnology.com
EDM Service, Jouy-le-Mouier, FR | www.edmservice.com
Erowa AG, Büron, CH | www.erowa.com
Exeron GmbH, Oberndorf am Neckar, DE | www.exeron.de
GF Machining Solutions, Genf, CH | www.gfms.com
Hermann Schmidt Co., South Windsor, USA | www.hschmidt.com
Hirschmann Engineering UK Ltd., Denbigh, UK | www.hirschmannengineering.co.uk
Hirschmann GmbH, Fluorn-Winzeln, DE | www.hirschmanngmbh.com
HK Holdings, Rugby, Warks, UK | www.hkholdings.co.uk
Husky Injection Moulding Systems SA, Dudelange, LU | www.husky.ca
J. Schüchl Vakuum - Maschinen, Brunnen, DE | www.schuechl.de
JS GmbH, Fluorn-Winzeln, DE | www.jauchschmider.com
Makino Europe, Kirchheim unter Teck, DE | www.makino.eu
Matra-Werke GmbH, Hainburg, DE | www.matra.de
Mazak Machine Tools, Worcester, UK | www.mazak.com
Millutensil s.r.l., Milano, IT | www.millutensil.com
Misumi UK Ltd., Staines, Middx, UK | www.misumi-europe.com
Mitsubishi Electric Europe B.V. Factory Automation, Ratingen, DE | eu3a.mitsubishielectric.com
Motoman robotec GmbH, Allershausen, DE | www.motoman.eu
NCMT Ltd., Thames Ditton, Surrey, UK | www.ncmt.co.uk
Ona Electroerosion, S.A., Durango, Bizkaia, ES | www.onaedm.com
OPS - Ingersoll Funkenerosion GmbH, Burbach, DE | www.ops-ingersoll.de
Pennine Machine Tools Ltd., Halifax, W.Yorksh., UK | www.pennineuk.com
PeyerConsult S.A., Cadenazzo, CH | www.pcam.com
Rapitypes Ltd, Leicester, UK | www.rapitypes.com
SMS Elotherm GmbH, Remscheid, DE | www.elotherm.de
Stäubli Faverges SCA, Faverges, FR | www.staubli.com
Streuli technologies AG, Birmensdorf, CH | www.streuli-techno.ch
Syndal S.p.A., Trezzano sul Naviglio (MI), IT | www.syndal.it
System 3R (UK) Ltd., Princes Risborough, Bucks, UK | www.system3r.com
System 3R Europe GmbH, Groß-Gerau, DE | www.system3r.com
System 3R Nordic, Vällingby, SE | www.system3r.com
System 3R Schweiz AG Spannsysteme u. Automation, Flawil, CH | www.system3r.com
Vista Développement International, Sonthonnax, FR | www.vista-plasturgie.com
Zimmer&Kreim GmbH&Co KG, Brensbach, DE | www.zk-systems.com
document9216357825628836776.indd 60 19.10.2018 14:33:52
SUPPLIERS DIRECTORY
6111/12-2018
Dahlienweg 8 · 56281 Emmelshausen/Germany
Quick Sourcing Grid:EDM Equipment
Adonpag
e
ECM
Electroch
emical
Mac
hine
s
EDG
Electrica
lDisch
argeGrind
ing
Micro
EDM
Mac
hine
s
Ram
(Die-S
inking
)Mac
hine
s,CNC
Ram
(Die-S
inking
)Mac
hine
s,Man
ual
Small-Hole
Drilling
Mac
hine
s,CNC
Small-Hole
Drilling
Mac
hine
s,Man
ual
Wire
-Cut
Mac
hine
s,Flush
ing
Wire
-Cut
Mac
hine
s,Auto-W
ire-Threa
ding
Wire
-Cut
Mac
hine
s,Open
-Tan
k
Wire
-Cut
Mac
hine
s,Sub
merged
Wire
EDM
Company | Contact
EDM-Tec OHG, Kaisersesch, DE | www.edm-tec.de58,63
Mac Tec e.K., Emmelshausen, DE | www.mac-tec.de61,63
Sarix SA, S. Antonino, CH | www.sarix.com 51
BES Funkenerosion GmbH, Fluorn-Winzeln, DE | www.bes-edm.deBunol EDM Supplies, Wermelskirchen, DE | www.bunol.com
Desktop Engineering Ltd., Long Hanborough, Oxon, UK | www.dte.co.uk
Easymetal GmbH, Wolkersdorf, AT | www.easymetal.com
EDM Service, Jouy-le-Mouier, FR | www.edmservice.comExeron GmbH, Oberndorf am Neckar, DE | www.exeron.de
GF Machining Solutions, Genf, CH | www.gfms.comH.G. Hassfurther GmbH&Co. KG, Lüdenscheid, DE | www.hgh-luedenscheid.de
Harig Manufacturing Corp., Niles, IL, USA | www.harigmfg.com
HK Holdings, Rugby, Warks, UK | www.hkholdings.co.ukIC-Hungary Kft., Sziget-Szentmiklós, HU | www.ichungary.hu
JS GmbH, Fluorn-Winzeln, DE | www.jauchschmider.comMachineTools.com Inc., West Bloomfield, USA | www.machinetools.com
Makino Europe, Kirchheim unter Teck, DE | www.makino.eu
Matra-Werke GmbH, Hainburg, DE | www.matra.deMitsubishi Electric Europe B.V. Factory Automation, Ratingen, DE |eu3a.mitsubishielectric.com
NCMT Ltd., Thames Ditton, Surrey, UK | www.ncmt.co.ukOna Electroerosion, S.A., Durango, Bizkaia, ES | www.onaedm.com
OPS – Ingersoll Funkenerosion GmbH, Burbach, DE | www.ops-ingersoll.de
SMS Elotherm GmbH, Remscheid, DE | www.elotherm.deSodick Europe Ltd., Coventry, UK | www.sodick.org
Sommen-edm B.V., Waalre, NL | www.sommen-edm.nlSyndal S.p.A., Trezzano sul Naviglio (MI), IT | www.syndal.it
System 3R Schweiz AG Spannsysteme u. Automation, Flawil, CH |www.system3r.com
Tokai Carbon Italia S.r.l., Trezzano Rosa (MI), IT | www.tokaicarbon.co.jp
Vista Développement International, Sonthonnax, FR | www.vista-plasturgie.comZimmer&Kreim GmbH&Co KG, Brensbach, DE | www.zk-systems.com
document3400836793298827756.indd 61 19.10.2018 16:10:40
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Quick Sourcing Grid:Machining Equipment
AD
onpag
e
Cuttin
gTo
ol
Grind
ers
Eng
raving
Equip-
men
t(Nonlas
er)
Graphite-E
lectrode
Mac
hining
Cen
tres
Grind
ingMac
hine
s
High-Spee
dMac
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Cen
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Micro
Mac
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Cen
tres
Lase
rEng
raving
Equipmen
t
Lase
rsforCuttin
gMetal
Sha
rpen
ing
Equipmen
t
Company | Contact
Mac-Tec e.K., Emmelshausen, DE | www.mac-tec.de61,63
Matsuura Europe GmbH, Wiesbaden, DE | www.matsuura.de 21
Mersen France Gennevilliers SAS S.A.S., Gennevilliers, FR |www.mersen.com 57
Sarix SA, S. Antonino, CH | www.sarix.com 51
Alltec GmbH Foba Laser Marking + Engraving, Selmsdorf, DE | www.foba.deBaublys Laser GmbH, Ludwigsburg, DE | www.baublys.deBreton, SpA, Castello di Godego, IT | www.breton.itCTL-Centreline, Coventry, UK | www.ctl-centreline.comCyba Manufacturing Technology Ltd., Hyde, Cheshire, UK | www.cybamantech.co.ukDME Europe, Mechelen, BE | www.dmeeu.com
DMG Mori Seiki AG, Bielefeld, DE | www.dmgmoriseiki.comEmag GmbH&Co.KG, Salach, DE | www.emag.comEmco GmbH, Hallein, AT | www.emco-world.comExeron GmbH, Oberndorf am Neckar, DE | www.exeron.deFehlmann AG, Seon, CH | www.fehlmann.com
Fidia, SpA, San Mauro Torinese (TO), IT | www.fidia.itFMS-Tools Oy AB, Helsinki, FI | www.fms-tools.comFPT-Industrie, SpA, Santa Maria di Sala (VE), IT | www.fptindustrie.comHaas Automation Europe, Zaventem, BE | www.haascnc.comHardinge Machine Tools Ltd., Whetstone, UK | www.hardinge.co.uk
Heinisch Werkzeugmaschinen- vertriebs GmbH&Co. KG, Engelskirchen, DE |www.heinisch-machines.comHK Holdings, Rugby, Warks, UK | www.hkholdings.co.ukHurco Europe Ltd., High Wycombe, Bucks, UK | www.hurco.co.ukImes-icore GmbH, Eiterfeld, DE | www.imes-icore.deJobs, SpA, Piacenza, IT | www.jobs.it
Kondia Urbano Conde S, A., Elgoibar, ES | www.kondia.comLeader Chuck Systems Ltd., Tamworth, UK | www.leaderchuck.co.ukLMT Tool Systems GmbH, Oberkochen, DE | www.lmt-tools.comLTA Lufttechnik GmbH, Nordrach, DE | www.lta.deMakino Europe GmbH, Hamburg, DE | www.makino.de
Mandelli, SpA, Piacenza, IT | www.mandelli.comMaschinenfabrik Berthold Hermle AG, Gosheim, DE | www.hermle.deMatec Maschinenbau GmbH, Köngen, DE | www.matec.deMazak Machine Tools, Worcester, UK | www.mazak.comMoliporex Lda, Marinha Grande Codex, PT | www.moliporex.pt
NCMT Ltd., Thames Ditton, Surrey, UK | www.ncmt.co.ukOKK Europe GmbH, Neuss, DE | www.okkeurope.comOkuma Europe GmbH, Krefeld, DE | www.okuma.deOtto Suhner AG, Brugg, CH | www.suhner.comParpas Spa, Cadoneghe, IT | www.gruppoparpas.com
Pibomulti SA, Le Locle, CH | www.pibomulti.comRofin-Baasel Lasertech GmbH&Co. KG, Starnberg, DE | www.rofin.com/selectRosa Ermando, SpA, Rescaldina Z.I., Milan, IT | www.rosa.itSachman Jobs, Reggio Emilia, IT | www.sachmann.itSandvik Coromant UK, Halesowen, UK | www.coromant.sandvik.com
Sauer GmbH, Stipshausen, DE | www.gildemeister.comSiemens S.p.A., Milano, IT | www.siemens.itStreuli technologies AG, Birmensdorf, CH | www.streuli-techno.chSuhner Abrasive Expert AG, Brugg AG, CH | www.suhner.comVollmer Werke Maschinenfabrik GmbH, Biberach an der Riß, DE | www.vollmer.de
document6214208463655711464.indd 62 19.10.2018 13:42:30
11/12-2018 63
PRODUCT FOCUS
C O M P A N Y S H O W C A S E
EDM-TEC, an expert in EDMmachineaccessories since 1999, emphasizeshigh quality, short delivery time andcustomer support.Its product range consists of brasswires, all types of coatedwires(Xwire, special wires andGAMMAwires), filters, resin, spare parts, copper,tungsten copper, graphite, tubes andother usual and special accessories forEDMmachines. These are supplied tomany satisfied customers all overEurope. To learnmore about thewiderange of products offered by EDM-TEC,visit www.edm-tec.de.Telephone +49-2653-91516-0.
» EDM-TEC oHG,Kaisersesch, Germany.www.edm-tec.de
C O M P A N Y S H O W C A S E
MAC-TEC e.K.: Your partner for EDMerosion machines and milling machines.The company MAC-TEC is for more than20 years your competent partner for usederosion machines. Our philosophy is tooffer a first class quality for a fair price toour customers.MAC-TECoffers a big choiceof used metal working machines and isalways interested in buying such machin-ery. To learnmore please visit our websitewww.mac-tec.de
» MAC-TEC e.K.,Emmelshausen, Germany.www.mac-tec.de
From batch size 1 to volume production
Mircomachining – Sarix offers a powerfulrange ofmicro-erosionmachining systemswith solutions for all production environ-ments and volumes – from simple ta-ble-top machines for one-off productionto fully automated cells with robotic load-ing.At AMB 2018, EDM specialist Sarix pre-
sented the SX80model, a table-top erosionmachine of the latest generation. The SX80is very compact and available in variousconfigurations. According to the company,it is suitable for drilling micro-start holesfor wire-cutting applications aswell as formicro-erosion milling in mould and tool-making.With the Sarix CNC control, a touch-
screen, a Wizard-operator guidance, ero-
sion power electronics of the fifth gener-ation, high rigidity and stability, themod-el is simple, powerful and precise, asSarix announced.sarix.com
Sou
rce:
Sarix
The SX80 is atable-top eroisionmachine by Sarix.
Cutting-edge control on machines forIndustry 4.0 requirements
The innovative MVR1200RConnect with a new control andsimplified operation.
Sou
rce:
Mitsub
ishi
Electri
Controls – Last year, Mitsubishi Electricpremiered two of the company’s high-per-formancewire-cuttingmachines from theMV-R Connect series, the MV1200R andtheMV2400Rwith a new control and sim-plified operation.According to the company, these EDM
machines now display the output of nu-meric values as easy-to-read graphics. Thenewmanual control box features a bright,user-configurable display and has a free-ly rotating and pivoting 48cm-multitouchdisplay for the operator’s ease of use. Thebuilt-in cost and performance monitorenables the user to analysemachine prof-itability and make adjustments to opti-mise processes and boost efficiency. Dia-grams are available, which depict operat-ing costs and output. All operatingmaterial statuses andmaintenance cycles
can be called up at a touch, and can evenbe read out. The machine comes with anetwork connection as well as USB, FTP,DNC and open data interfaces, and can belinked up to existing production planningand analysis systems.In line with Industry 4.0 requirements,
the processable data available with thesemachines ensures transparency in all pro-duction stages. Intel Security is alsopre-integrated to provide data security.The new Job Plannermakes it possible tobring forward urgent jobs, with automat-ic storage of the parameters of interrupt-ed jobs. This allows for the continuationof these jobs at another time from thepoint of interruption. The control alsoguides less experienced users through thecutting process step by step.mitsubishi-edm.de
document7079576755920572348.indd 63 19.10.2018 13:06:38
SUPPLIERS DIRECTORY
64 11/12-2018
Quick Sourcing Grid:Quality Control
CoordinateMea
suring
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ageDetec
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Company | Contact
3D Scanners (U.K.) Ltd., Coventry, UK | www.3dscanners.co.uk
Aberlink Ltd., Tetbury, UK | www.aberlink.co.uk
ACI (UK) Ltd, Newport Pagnell MK16 9PS, UK | www.acieurope.co.uk
Bowers Metrology UK Ltd., Bordon, Hants, UK | www.bowers.co.uk
Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen, DE |www.zeiss.de/imt
Carl Zeiss Optotechnik GmbH, Neubeuern, DE | optotechnik.zeiss.com
Cirtes, Saint-Dié-des-Vosges, FR | www.cirtes.fr
Coord3 Industries S.r.l., Bruzolo (TO), IT | www.coord3.it
CRDM Ltd., High Wycombe, Bucks, UK | www.crdm.co.uk
Dreier Lasermeßtechnik GmbH, Horb am Neckar, DE |www.dreier-lasermesstechnik.de
Duwe-3d AG, Lindau (Bodensee), DE | www.duwe-3d.de
E. Zoller GmbH&Co. KG Einstell- und Messgeräte, Pleidelsheim, DE |www.zoller.info
Easymetal GmbH, Wolkersdorf, AT | www.easymetal.com
Erowa AG, Büron, CH | www.erowa.com
Faro Europe GmbH + Co KG, Korntal-Münchingen, DE | www.faro.com
Fratelli Rotondi, Legnano (MI), IT | www.rotondi.it
Haimer GmbH, Hollenbach, DE | www.haimer.de
Hexagon Metrology S.p.A., Grugliasco (TO), IT | www.dea.it
Imes-icore GmbH, Eiterfeld, DE | www.imes-icore.de
Imtech Design Ltd., Chislehurst, Kent, UK | www.imtechdesign.com
Kreon Technologies, Limoges Cedex, FR | www.kreon3d.com
Kubotek Europe S.r.l., Costabissara, IT | www.kubotekeurope.com
Leica Geosystems AG, Unterentfelden, CH |www.leica-geosystems.com/metrology
Mapal Fabrik für Präzisionswerkzeuge Dr. Kress KG, Aalen, DE |www.mapal.com
Metris UK Ltd., Derby, UK | www.metris.com
Metrol Co. Ltd., Tokyo, JP | www.toolsensor.com
Millutensil s.r.l., Milano, IT | www.millutensil.com
Mitutoyo (UK) Ltd., Andover, Hants, UK | www.mitutoyo.co.uk
Mitutoyo Deutschland GmbH, Neuss, DE | www.mitutoyo.de
Moliporex Lda, Marinha Grande Codex, PT | www.moliporex.pt
Nikon Metrology NV, Leuven, BE | www.nikonmetrology.com
OGP UK Ltd. Faraday House, Foston, Derbyshire, UK | www.ogpuk.com
Raytek GmbH, Berlin, DE | www.raytek.com
RJG Inc., Traverse City, USA | www.rjginc.com
Scan Technology (Scantech) ApS, Ringsted, DK | www.scantech.dk
Schmitt Europe Ltd., Coventry, UK | www.schmitteurope.com
Solartron Metrology, Bognor Regis, UK | www.solartronmetrology.com
Vision Engineering Ltd., Woking, UK | www.visioneng.com
Wenzel Group GmbH&Co. KG, Wiesthal, DE | www.wenzel-group.com
Werth Messtechnik GmbH, Gießen, DE | www.werth.de
Witte Barskamp KG, Bleckede, DE | www.witte-barskamp.de
document476295064582510410.indd 64 19.10.2018 13:06:57
PRODUCT FOCUS
6511/12-2018
Grinding and eroding for toolsup to 380 mm longTwo new multi-axis Walter Helitronic tool grinding/eroding machines havebeen announced byWalter Ewag UK, a member of the United GrindingGroup. The machines for the production of carbide as well as PCD toolinghave extended traverses to enable tools up to 380 mm long to be processed.
New from the ground up – the two-in-one grinder/eroder WalterHelitronic Power Diamond 400.
Sou
rce:
WalterE
wag
UK
For the Power 400 grinder and the two-in-onePower Diamond 400 grinding-erodingmachine,the extended roommeans an increase ofmore
than 35 percent compared to the previous limit of280mm. Tools of 3 mm to 315 mm in diameter canbe accommodated on machines with X, Y and Zaxes travels of 650 mm, 350 mm and 720 mm, re-spectively.Both have been completely redesigned and fea-
ture, for example, a very rigid cast-iron bed – up to70 percent more rigid – to ensure improved damp-ing characteristics, which in turn facilitate greaterprecision and higher surface quality. In addition,they come with a 26 kW (10,500 revs/min) spindleas standard,while an extremely accurate, low-main-tenance torquemotor is available for themachines’C axis, which, on standard versions, is driven byworm drive.Walter engineers have also replicatedthe Visionmachines’ pneumatically driven steadyrests and tailstocks – devices that are less prone toleaks, require lessmaintenance and aremuch clean-er. They also absorb less heat than components thatuse hydraulic oil, thus ensuring even greater pre-cision. In addition to having a grindingwheel/elec-trode changer (four-station as standard; eight-sta-tion optional) for increased automation and un-manned operation, both machines can utilise arange of robot loading solutions - the Top Loaderfor up to 500 tools, a Robot Loader for up to 7,500tools or a Robot Loader 25, which has a capacity fortools weighing 25 kg including grippers.The new machines incorporate the Helitronic
Tool Studio grinding and eroding software withintegrated wizard technology for fast tool produc-tion simulation, parameter changes and machineoperation. The latest version (3) of the softwareincludes an erosion function option for the fast andeasy programming of ‘what you see you can grindand erode’.For example, the new erosion functionality allows
for:W The design and programming of complex toolgeometries, including individual tooth geometriesand tool parameter scaling
W Fast 3D live simulation routinesW Automatic collision controlThe system offers a simulation mode as standardwhere parameters can be quickly and easilychanged before tool production starts. Tool Studio3 also has a grinding wheel data interface for theHeliset tool measuringmachine tomeasurewheel/wheelsets and then send/import that data to theTool Studio.
Fast tool production
Like all of Walter’s two-in-one grinding-erodingmachines, the new erodingmachine uses Fine PulseTechnology for better PCD tool surfaces and qual-ity, as well as process reliability. Fine Pulse Tech-nology is the result of progressive improvementsto the machines’ generator as well as the erosionsoftware. Marked differences to PCD tools of 10microns grain type that have been eroded by othermachines can be seen with the naked eye – thesurface finish is like that of a polished (ground) tool– and even coarse-grained PCD types can befine-finished with perfect surface qualities.walter-machines.com
document651652785430605401.indd 65 19.10.2018 13:07:26
EUROPE
66 11/12-2018
ISTMA Europe MeetingThe next ISTMA Europe Fall Meeting willtake place in Milan (Italy) on November, 7and 8, 2018. The programme will be organ-ised in close co-operation with the UCISAP– Italian Mould & Die Association, and willgather European representatives from themould and die, special tooling and machin-ing industries.
Attendees will have the opportunity to meet and visit local com-panies as well as enjoy networking opportunities with counterpartsfrom different countries. The last European meeting was held a yearago in Celje, Slovenia.istma.org
Mexico joins ISTMAMexico was formally recognisedas ISTMA member in October2018. The Asociación Mexicanade Manufactura de Moldes yTroqueles (AMMMT) based in thecity of Queretaro has been ac-knowledged as the newest IST-
MA member. AMMMT was founded in 2014 and is the sole nation-wide organisation in the die and mould industry in Mexico, aiming topromote sector's technological and commercial development. It's anon-profit organization with 63 member's companies from differentregions of the country.ammmt.mx
More than 1,100 attendees in PortugalJointly organised by Cefamol, thePortuguese Association for MouldIndustry, Centimfe, the Techno-logical Center for the Mouldmak-ing, Special Tooling and PlasticsIndustries, and Pool-Net, thePortuguese Tooling and PlasticsNetwork, the “Moulds Event2018” was a full success. Comprising several seminars, conferenc-es and workshops, the event included analysis and discussions oftechnological and market trends affecting the tool-making industryworldwide. Challenges and opportunities towards the edification ofan environment prone to innovativeness and development of newR&D projects or businesses were main topics at this year's edition.cefamol.pt
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
Sou
rce:
AMMMT
Sou
rce:
ISTM
A
Sou
rce:
ISTM
A
EVENTS
Compamed 2018
W The trade show presenting high-tech solutions for medical tech-nology will be held from 12 to 15 November in Düsseldorf, Germany.
Formext 2018
W Besides additive manufacturing, Formnext promises to show thenext generation of manufacturing technologies. Some 470 exhibitorswill present their products and solutions from 13 to 16 November inFrankfurt, Germany.
SPS IPC Drives
W SPS IPC Drives will be held from 27 to 29 November 2018 inNuremberg, Germany. Focus of the trade show is on smart anddigital automation.
NEWS
document4808468075634807930.indd 66 19.10.2018 13:07:42
MASTHEAD/COMPANY INDEX
6711/12-2018
Company Index
AAgathon AG Normalien . . . . . . . . . . . . . . 36AMT The Association For ManufacturingTechnology . . . . . . . . . . . . . . . . . . . . . . . 10Anca Pty Ltd . . . . . . . . . . . . . . . . . . . . . . 12Arburg GmbH & Co . KG . . . . . . . . . . . . . 32BBitkom e .V . . . . . . . . . . . . . . . . . . . . . . . . . 8BKL-lasertechnik . . . . . . . . . . . . . . . . . . . 18Boride Engineered Abrasives . . . . . . . 59Bystronic Laser AG . . . . . . . . . . . . . . . . . 14Bühler AG . . . . . . . . . . . . . . . . . . . . . . . . 31CCNC Software Inc . . . . . . . . . . . . . . . . 7, 8Cumsa . . . . . . . . . . . . . . . . . . . . . . . . . . . 9DDormer Pramet . . . . . . . . . . . . . . . . . . . . 42EEDM-Tec OHG . . . . . . . . . . . . . . 58, 59, 63FFormlabs GmbH . . . . . . . . . . . . . . . . . . . 18Fraunhofer-Institut für Werkzeug-maschinen und Umformtechnik IWU . . . . 14GGebr . Becker GmbH . . . . . . . . . . . . . . . . 33GF Machining Solutions Management S 55Günther Heisskanaltechnik GmbH . . . . . 16HHabeck Matthias Hasecke e .K . . . . . . . . . 14Haimer GmbH . . . . . . . . . . . . . . . . . . . . . . 8
Hasco Hasenclever GmbH + Co . KG . . . 37HBI Helga Bailey GmbH . . . . . . . . . . . . . 31HIG Handel mit Industriegütern ‘Gesellschaft m .b .H . . . . . . . . . . . . . . . . 55IIncoe International Europe . . . . . . . . . . . 10Incus Head Office . . . . . . . . . . . . . . . . . . 18InovaTools Eckerle & Ertel GmbH . . . . 43Iscar Ltd . . . . . . . . . . . . . . . . . . . . 1, 11, 40LLandesmesse Stuttgart GmbH . . . . . . 15Leibniz Universität Inst . für Umformtechnikund Umformmaschinen (IFUM) . . . . . . . . 14LEO Lane Ltd . . . . . . . . . . . . . . . . . . . . . . 33MMac Tec e .K . . . . . . . . . . . . . . . . . . . 61, 63Makino Europe GmbH . . . . . . . . . . . . . . 57Matsuura Europe GmbH . . . . . . . . . . . 21Mecadat CAD/CAM ComputersystemeGmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Mersen France Gennevilliers SAS . . . . 57MesagoMesse Frankfurt GmbH . . . . . . 17, 22, 24Meusburger Georg GmbH & Co . KG . . 37Mitsubishi Electric Europe . . . . . . . . . . . . 63Mitsubishi Materials . . . . . . . . . . . . . . . . 3OOkuma Europe GmbH . . . . . . . . . . . . . . 48OPS - Ingersoll Funkenerosion GmbH . . 59PProgressive Components . . . . . . . . . 2, 37
Proto Labs Ltd . . . . . . . . . . . . . . . . . . . . 31RRenishaw plc . . . . . . . . . . . . . . . . . . . 7, 23SSarix SA . . . . . . . . . . . . . . . . . . . . . . 51, 63Shanghai International ExhibitionCo Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . 25Strack Norma GmbH & Co . KG . . . . . . . . 36Synventive Molding Solutions GmbH . . . 12TTaeguTec Ltd . . . . . . . . . . . . . . . . . . . . . 13Trumpf GmbH + Co . KG . . . . . . . . . . . . . 32Trumpf WerkzeugmaschinenGmbH + Co . KG . . . . . . . . . . . . . . . . . . . 14Türk+Hillinger GmbH . . . . . . . . . . . . . . . 5VVerein Deutscher Werkzeugmaschinen-fabriken e . V . (VDW) . . . . . . . . . . . . . . . . . 7Vero Software Limited . . . . . . . . . . . . . . . 45ViscoTec Pumpen- und DosiertechnikGmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . 33WWagner Tooling SystemsBaublies GmbH . . . . . . . . . . . . . . . . . . . . 36Walter Maschinenbau GmbH . . . . . . . . . 65Wissenschaftliche Gesellschaft fürProduktionstechnik e . V . – WGP . . . . . . . 14
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