Machining Accessories - Vogel Communications Group
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
November 2012
NOV 12
Volume XIV | Issue 9 | November 2012 | ISSN 2194-7589 | €11 www.etmm-online.com
europeaN tool & mould makiNg
Machining Accessories
volume Xvii issue 9 • 70475
Industry News EDM Europe Supplement EuroMold Preview
Germany chooses its The Annual Buyer's Guide A report on partner
'Toolmaker of the Year' 14 Issue for 2013 41 country Austria 16
counting is one thing.
monitoring is another.
evolved visibility
When a tooling program begins, intended maintenance points and cycle
times are determined. However, actual performance may deviate over the
life of the mould. Progressive’s new CVe Monitor provides:
• Cycle time monitoring to verify consistent part quality and cost
• Maintenance activity tracking to reduce unscheduled mould stoppages
• Dimensional compatibility with Progressive’s mechanical CounterView
More than viewing counts on a mould, a tool’s efficiency and activity can be
accessed from across town or around the world. Call (44)0161-669-6191 to
discuss how your production goals can now remain in sight.
LEARN HOW yOu cAN tRAck it ALL
At www.procomps.com/ cve
See Progressive at the following events: Euromold | Eurostampi | Chinaplas | Amerimold | PDM 2013 | K 2013
Editor’s MEssagE
rising tool demand AHX FACE MILLS
with declining output? FOR CAST IRON,
I was fortunate enough to at- CARBON STEELS
tend this year's award ceremo-
ny for the Toolmaker of the
Year in Aachen, Germany
AND STAINLESS
(p.14). It was a great night for
the winners, but even the also-
rans seemed happy to have
come so close. One could feel
the passion these companies
have for their products, and
their businesses.
On the Town Hall balcony before the ceremony, I was
NE W
speaking with the owner of a shop under consideration for
an award – he failed to win but was still ecstatic – when I
noted that manufacturing output was on the decline in
AHX640-S series:
Europe, bad news for toolmakers. His quick and confident
AHX640-S - Ø63 ~ Ø200
standard and fine pitch for stainless and
response was that it didn't matter if production was falling
carbon steels
because OEMs need moulds regardless of the total number
and AHX640-W - Ø80 ~ Ø315
of parts they make. I was about to retort that economic
fine and super fine pitch for cast iron
contraction is rarely a good thing when he predicted that a
rise in product variants will likely increase tool orders.
The dinner bell rang before we could take the subject
any further, but it's one worth revisiting. I had heard a sim-
ilar discussion of the topic at a mould making seminar in
Frankfurt earlier this year. The argument focused on per-
sonalised automotive interiors; in this case on a hypotheti-
cal customer who wanted "Hello Kitty" knobs and buttons.
The point was this car buyer might start out with white
cartoon cats littering the inside of the cockpit, but later
grow bored with them and desire a change. Smart carmak-
ers would have a plan to meet that need and supply new
parts embossed with something for customers' current
tastes. And new parts come from new moulds.
One can consider the pros and cons of offering custom-
ers tailored products, but filling demand is what business is
all about. And until everyone has a 3D printer in their
house, OEMs will need mould makers to serve that de- NE W
mand, even if they are selling fewer cars, televisions or New MP7030 insert grade with optimised MM breaker
iPhones. for hig
h performance stainless steel cutting.
Complete series, AHX640-S for steels, AHX640-W for cast iron.
Unique heptagonal double sided inserts with 14 cutting egdes.
MP multipurpose chip breaker for steels and cast iron.
High performance MC5020 insert grade for cast iron milling.
MMC Hartmetall GmbH, GROUP COMPANY of
Eric Culp
EDITOR-IN-CHIEF
Comeniusstraße 2, 40670 Meerbusch.
Tel 02159 91890 Email: marketing@mmchg.de
www.etmm-online.com | November 2012 | European Tool & Mould Making
www.mitsubishicarbide.com
Table of ConTenTs
Cover Story
CaSE STudy
Source: Culp
How a supplier's tool-holding
technology has helped a tool
manufacturer reduce expenses and
production time while increasing the
quality of its products 24
ProduCT foCuS
a series of articles highlighting the
latest advancements and products in
the machining accessory sector 26
SourCiNg gridS
our easy-to-use table of companies
that supply machining accessories to
die, tool and mould making industries
Industry News
in Europe 30
EdiTor'S MESSagE
are product variants a chance for toolmakers to garner new business
even when manufacturing output is on the decline? ................................................... 3
iNduSTry NEwS
Business confidence wavers among Europe's tool and mould shops ............................ 6
European Commission calls for steps to reverse decline of manufacturing .................. 6
Source: Hexagon
Haas announces price for 5-axis uMC in Europe ........................................................ 10
Ceratizit to buy 50% stake of günther wirth ............................................................. 10
SPECial rEPorT
german research institutes for toolmaking announce awards ................................... 14
EuroMold PrEviEw
austria selected as partner country for Europe's biggest exhibition
for tool and mould making ...................................................................................... 16
iNTErviEw: ETMM talks to Eberhard döring, managing director
Cover photo courtesy of Hexagon Metrology. of EuroMold organiser demat, about what visitors can expect this year .................... 18
4 European Tool & Mould Making | November 2012 | www.etmm-online.com
Table of ConTenTs
EDM Europe Buyer's Guide
CasE sTudy
Photo: xxxxxxxxxxxxxxxxxxxxxxxxxx
sector diversity leads to success
for Bavarian toolmaker 42
ProduCTs aNd
sourCING GrIds
1 software 44
2 Materials 46
3 EdM Equipment 47
4 EdM accessories 51
5 automation 55
6 Machining Equipment 57
7 Machining accessories 60
8 Quality Control 63
CasE sTudy
a range of various hot runners helps a processor realise a four-component part........ 20
INTErvIEw
The founder of south Korean cutting-tool supplier yG-1
discusses the company's strategy in Europe ............................................................. 22
CasE sTudy
Measuring systems check both parts and moulds for quality..................................... 32
ProduCTs & sErvICEs
recently introduced equipment and services from around the world ........................ 34
CoMPaNy INdE x
a listing of the industry suppliers who supported this issue
with articles and advertisements .............................................................................. 65
NE xT IssuE
a brief rundown of our EuroMold issue ..................................................................... 66
www.etmm-online.com | November 2012 | European Tool & Mould Making
Industry news
News iN Brief Moods swing in europe's tool and mould
Swiss orders continue slide
countries on macroeconomic concerns
Swiss mechanical and electri- environments, companies
source: Culp
cal engineering orders have polled are asked to rate their
fallen for more than five quar- current levels of and expec-
ters, industrial association tations for quoting, ship-
Swissmem said. Sales have ments, order backlogs, prof-
stagnated, while pressure on its, employment, investment
prices and margins has persist- and selling prices. Istma be-
ed, the association noted. gan giving ETMM the data
"There is no recovery in sight." earlier this year.
When answering about
Plastics winning over paper the first half, respondents
in Europe's battle for labels said their businesses had im-
While the end-use applications proved. Business conditions
are relatively mature in Europe, for mould makers were said
plastic labels converters are to be "very good" in a
taking market share from pa- Whether prospects for tool and mould industries are looking up or number of countries, a rat-
per at an increasing rate, ac- down is a matter of national perspective. ing much better than report-
cording to a report from indus- ed in the poll for the last half
try consultants, AMI Consult- The latest report on business falling investments, declin- of 2011 released earlier this
ing, Bristol, UK. Despite recent conditions in Europe's tool ing order backlogs and slip- year. However, shops in a
economic hardships, plastic la- and die industries shows the ping profits. However, a few number of countries also re-
bel demand grew on average first half of the year turned countries said their shops ported "poor" conditions,
by 6% per year since 2008, the out better than expected, expect investment, order the worst possible rating.
report said. but many shops predict backlogs and even sector Die makers were more up-
waning prospects in the cur- employment to rise during beat, with a number of
Workshop for polishing tool rent six months ending on the period. shops in two countries not-
steel in Aachen, Germany 31 December. For the report, Istma com- ing the first half was "excel-
On November 19 and 20, While most of the shops piles information from lent", the best rating. The
2012, the Fraunhofer Institute polled for Istma's semi-an- mould and die makers sup- number of die makers not-
for Production Technology IPT, nual business conditions re- plied to national associa- ing "very good" conditions
Halmstad University (Sweden) port said they expect little tions in the Czech Republic, had also risen from the last
and the steel manufacturers change in the majority of Estonia, Finland, Germany, half of 2011.
Uddeholms AB Sweden and measures of business com- Hungary, Italy, Portugal,
Uddeholm Deutschland GmbH pared to the first half, a Slovenia, Spain, Switzerland » Istma,
will be holding a two-day number of national associa- and Turkey. To measure the Marinha Grande, Portugal.
workshop on tool steel polish- tions reported concerns of current and future business www.istma-europe.com
ing. Industrial and scientific ex-
perts are scheduled to speak,
and the workshop is in English.
european Commission says 'immediate action'
Swiss tooling systems firm
selects UK agency
should boost industry's role in europe economy
Tooling systems manufactured Brussels has warned that Eu- liver growth and can create
source: federation of finnish Technology industries
by Swiss firm Heinz Kaiser are rope 'needs to reverse the de- employment. Today we ta-
available in the UK through clining role of industry" and bled the conditions for the
NCMT, Thames Ditton, under a said "immediate action" sustainable reindustrialisa-
new sole agency agreement, should counter the down- tion of Europe."
the company said. The boring ward trend and raise the in- The Commission pro-
bars cover a wide diameter dustry's contribution to EU posed up to €15 billion in
range from 0.4 mm to three GDP from the current 15.6% additional public lending for
metres. NCMT Director Dave to as much as 20% by 2020. SMEs and called for the
Burley, said, "Existing users of Commission Vice Presi- elimination of obstacles to
the tooling can continue to dent Antonio Tajani said, private venture capital.
deal with their current regional "We cannot continue to let
resellers, which from now on our industry leave Europe. » The European Commission, Swift steps are needed to stop
will be supported by NCMT." Our figures are crystal clear: Brussels, Belgium. Europe's industrial decline, the
European industry can de- ec.europa.eu European Commission says.
6 european Tool & Mould Making | November 2012 | www.etmm-online.com
Industry news
Appointment expected to increase co-operation
Source: ARRK
within ArrK tool and moulding group
ARRK has announced the Russia, India and China, Lowe said part of his role
appointment of Tony Lowe provide tooling and mould- will be to ensure ARRK com-
as managing director of the ing services to automotive panies in Europe work more
Shapers Group in a move de- OEMs, Tier 1 and Tier 2 sup- closely together to offer cus-
signed to further integrate pliers. The group, which in- tomers "joined-up" services.
the company's operations. cludes the companies Sermo
Shapers, an ARRK-owned and Zimmerman, has a turn- » ARRK, Tony Lowe said his writ is to help
operation with sites in over of €85 million and em- Quedgeley, UK. Shapers' European shops work
France, Germany, Poland, ploys around 900 people. www.arrkeurope.comm better together.
entegris opens
production,
sales facility
Entegris said it has opened a
new facility to provide spe-
cialized silicon and dia-
mond-like coatings to Euro-
pean industry. Located in
the Techlid economic hub in
Lyon, France, the facility is
said to expand company ca-
pabilities in the US and Asia
for high-purity silicon and
diamond-like carbon (Ul-
traC) families of coatings.
Entegris said the silicon
coatings are high-purity,
dense and microconformal
with very low residual stress.
The UltraC coatings are ex-
tremely smooth, highly lu-
bricious, and are harder
than tool steel and chrome.
Both families of coatings are
highly resistant to corrosion.
To make them, the facility
will use a proprietary Plasma
Enhanced Chemical Vapor
Deposition (PECVD) process
that ensures no change to
the hardness of the sub-
strate, even to those proc-
essed at low temperatures,
the company said.
The company said the
new facility will also house
the European office to sup-
port the sale of Poco graph-
ite and Supersic products.
» Entegris,
Moirans, France.
www.entegris.com
Industry news
More than 100,000 visitors roam halls at IMts
for a record show-to-show increase
educational event, and only
Source: IMTS
turned into a buying/selling
forum after World War II,”
Eelman explained.
Along with a main con-
ference that featured 72 ses-
sions and more than 500
participants, the show co-lo-
cated six conference pro-
grammes. According to or-
ganisers, the hosts of the
conferences agreed that the
education component was
well-received. Across the
board, the quality of speak-
ers and presentations gar-
nered high marks from par-
ticipants, organisers said.
Along with the healthy
traffic on the show floor,
other highlights included
the ETC featuring a Local
The teeming fairgrounds in Chicago indicated the high number of visitors at this year's IMTS exhibition Motors Rally Fighter model
at a time when US manufacturing is on the rise. car, built live on the show
floor, as part of the collabo-
The recent International duction process, according fered solutions to manufac- rative manufacturing sec-
Manufacturing Technology to organisers, who said the turers seeking increased pro- tion of the ETC. The team
Show provided an indica- technology is the next major ductivity and lower costs. making the car compressed
tion of American manufac- manufacturing break- Fair organisers said they five weeks of work into five
turing growth as organisers through and can reduce pro- teamed up with exhibition days with the Rally Fighter
have reported the strongest totype and part develop- company Deutsche Messe to being unveiled before a large
results in over a decade. ment as well as help elimi- co-host the first-ever Indus- crowd. Local Motors is an
Hosting exhibitors and nate waste. trial Automation North upstart US automaker, the
visitors from 119 countries, “The energy level among America with IMTS. Indus- first to enter the market in
IMTS 2012, which ran 10 - 15 visitors and exhibitors was trial Automation North decades, and relies on the
Sept. at Chicago’s McCor- at an all-time high,” accord- America showcased products the principle of collabora-
mick Place, covered nearly ing to Peter Eelman, IMTS and solutions for production tive manufacturing. The de-
116,000 m² of exhibition vice president for exhibi- automation, complement- signs for its cars come from
space with 1,909 exhibiting tions and communications. ing the focus of IMTS on an open source community.
companies, organisers said. “The most exciting take- manufacturing technology, The next installment of
They quoted registration for away from IMTS 2012 is metalworking and precision IMTS is scheduled for 8-13
the six-day event at 100,200, what it says about the pros- manufacturing. Organisers September 2014. “An enor-
which is a 21.6% increase pects for manufacturing noted that exhibit space mous amount of strategic
over 2010, marking the larg- over the next year. The over- sales for that part of the fair thinking, talent and energy
est show-to-show increase all activity and buzz indicate exceeded expectations, and went into making IMTS a
ever for IMTS. that we are entering a period as part of the agreement to major success,” said Eelman.
The highlights of the of sustained growth that will extend the partnership to “As we look forward to 2014,
show focused on additive fuel economic prosperity IMTS 2014, Industrial Auto- we will move ahead with in-
manufacturing, multi-spin- and job creation." mation North America will novation and technology
dle machines and multi- The show is said to pre- occupy additional space. advances that will keep
tasking machines, organisers sented have a remarkable IMTS answered the indus- manufacturing technology
noted. Spotlighted both in display of new and emerging try call for education by re- growing and vibrant for gen-
the IMTS Emerging Technol- technologies that will con- turning to its roots with an erations to come.”
ogy Center (ETC) and in sev- tinue to revolutionise the increased offering of oppor-
eral exhibitor booths, addi- manufacturing world. These tunities. “We’ve come full » IMTS,
tive manufacturing contin- innovations, coupled with circle because in the early Chicago, USA.
ued to gain traction as a pro- traditional equipment, of- years IMTS was actually an www.imts.com
8 European Tool & Mould Making | November 2012 | www.etmm-online.com
Haas www.HaasCNC.com 100%
VISIT US!
DO YOU KNOW? HALL 9 • STAND C67
HAAS IS THE ONLY MACHINE TOOL
BUILDER TO OPENLY PUBLISH
PRICES FOR MACHINES AND OPTIONS.
Haas Automation, Europe | HaasCNC.com +32 2-522-99 05 | Made in the USA
Find your local Distributor at www.HaasCNC.com
Industry news
Haas 5-axis uMC to cost below €100,000 in europe;
Company expects record sales in 2012
Haas Automation said it will chine has an inline direct- When asked about the
Source: Culp
be selling its UMC-750 3+2 drive 40-taper spindle (8,000 low price tag, Murray ex-
simultaneous 5-axis univer- or 12,000 rpm), and comes plained it resulted partially
sal machining centre in Eu- standard with a 40+1 tool from streamlining at both
rope for under €100,000. side-mount tool changer. the factory and the compa-
The company also an- The company said the trun- ny. “Two years ago, I said:
nounced at its press confer- nion can position parts to ‘Let’s stop and focus on sim-
ence at the German metal- nearly any angle for 5-sided plicity.’” Increased automa-
working show AMB 2012 (3+2) machining, or provide tion at the Oxnard plant
that the unit, based on a simultaneous 5-axis motion combined with the decision
prototype first shown at last for contouring and complex to employ existing technolo-
year’s EMO exhibition, will machining. The machine gy has reduced costs.
be sold for less than provides +35° and -110° of Murray’s prognosis for
$130,000 in the US. tilt and 360° of rotation, ac- Europe was positive. “I think
Bob Murray, general man- cording to the supplier. there is a lot of opportunity
ager of the Oxnard, Califor- Haas General Manager Bob Mur- Talking about the ma- in Europe,” he said. When
nia-based machine tool sup- ray said he was upbeat about his chining centre, Murray said, asked to specify the areas in
plier, said he was optimistic company's growth in Europe. “I think it’s going to be a which he expected growth,
about both the new centre's home run.” He noted that Murray pointed to small and
prospects and the compa- Haas said the UMC-750 is only 21 parts on the unit, medium-sized vertical ma-
ny’s performance in Europe, a 5-axis universal machining mainly castings and sheet chines as “strong markets”.
and he predicted that Haas centre with travels of 762 metal components, are new-
will tally record sales this mm x 559 mm x 508 mm ly designed, with the rest » Haas Automation Europe,
year of between $960 mil- and an integrated dual-axis taken off the shelf from Zaventem, Belgium.
lion and $1 billion. trunnion table. The ma- available Haas technology. www.haascnc.com
Ceratizit announces intent to purchase a 50% stake
in German toolmaker Günther wirth
The Luxembourg-based Cer- that it and shareholders of
Source: Günther Wirth
atizit Group said it will in- Günther Wirth will each re-
vest in a 50% share of the tain equal control of compa-
German tool manufacturer ny once the transaction is
Günther Wirth as a way to complete. The companies
complement its product line declined to disclose finan-
with round tools made of cial details of the deal.
hard metal. A spokesman for Ceratizit makes hard ma-
Ceratizit explained to ETMM terial products for wear pro-
that the deal foresees a two- tection and cutting tools
person board at the German and has a presence in more
company which will com- than 50 countries. Günther
prise a representative from Wirth manufactures rotary
Günter Wirth as well as one cutting tools from hard met-
from Ceratizit, al. Founded in 1981, the
According to a statement Ceratizit says its purchase of a 50% stake in tool maker Günther Wirth family-owned company's
from Ceratizit, "In the fu- should be completed by the end of the year. parent plant is based in
ture, Günther Wirth will be Balzheim, Germany. It also
incorporated into the Cera- quisition, we will be able to The transaction is expect- has production sites in
tizit Group as a global busi- cover the whole value chain ed to be completed, subject France, India, the United
ness unit, and will remain as in hard metal production – to the finalisation of due dil- States and Italy.
a brand." from powder, to tool blanks igence and the approval by
Jacques Lanners, a mem- to custom-made and coated the anti-trust authorities, by » Ceratizit,
ber of the Ceratizit executive round tools such as drills the end of 2012, according Mamer, Luxembourg.
board, said, "With this ac- and end mills." to Ceratizit. The buyer noted www.ceratizit.com
10 European Tool & Mould Making | November 2012 | www.etmm-online.comIndustry news
German machine tool maker sees steady
Source: IMTS
demand through strong orders at AMB, IMts
Gildemeister said it was ture DMG/Mori Seiki un- BIMU in Milan and the
"pleased" with recent trade veiled eight world premieres, JIMTOF in Japan. The au-
shows in Germany and the and at IMTS, DMG/Mori tumn fairs confirm business
United States and recorded a Seiki showed 45 high-tech development is in line with
combined order intake of machines designed for the plans, it said.
€93.7 million and 377 ma- American market.
chines sold at AMB in Stutt- The company said it ex- » Gildemeister, The IMTS exhibition in Chicago
gart and IMTS in Chicago. pects a further boost from Bielefeld, Germany. proved a boon for orders of Gilde-
At AMB, Gildemeister ven- other fairs, including the www.gildemeister.com meister machine tools.
Cumsa opens
branch office
near detroit
Spain's Cumsa has an-
nounced the establishment
of an office in Troy, Michi-
gan, the fifth foreign branch
to be opened in recent years,
following Portugal, Italy,
China and Hong Kong.
The company said it se-
lected the city near Detroit
to take advantage of an area
that is one of the main cen-
tres for the US mould indus-
try. It noted that some of the
office's tasks will be to pro-
vide knowledge of the com-
pany’s innovations and to
promote its range of prod-
ucts as well as offer informa-
tion and support.
Cumsa noted that the
American market is one of
the company's largest and
represents approximately
11% of annual turnover. "In
the past, Cumsa has been on
the American market
through different distribu-
tors," the company said,
noting that it was time for a
change. "Now we have de-
cided to go one step further
and deal directly with our
American customers. Cur-
rent customers can continue
to purchase Cumsa products
through our distributors."
» Cumsa,
Barcelona, Spain.
www.cumsa.comIndustry news
Machine tool supplier Fritz studer bestows research
prize for examination of temperature sensitivity
Josef Mayr from the institute cially in hard fine machin-
Source: Fritz Studer
for machine tools and man- ing, such as grinding, hard
ufacturing at Switzerland's turning, etc.
Zurich Technical University Studer said the key as-
has won the most recent pects of Mayr's research
Fritz Studer Award and the work form the basis for con-
corresponding sum of CHF sidering the temperature
10,000 for his study of the sensitivity of machine tools
assessment and compensa- through measurement, as-
tion of the temperature sen- sessment, calculation and
sitivity of machine tools. compensation. He devel-
Swiss grinding equipment oped the finite difference el-
manufacturer Fritz Studer ement method (FDEM), a
said this was the third time combination of the finite
it has awarded the research difference method (FDM)
prize, which is given to Fred Gaegauf (r.), managing director of Fritz Studer, presents the and the finite element
scholars and graduates (indi- company's research award to Josef Mayr from the EHT Zürich. method (FEM), during his
viduals or research groups) dissertation which allows for
from universities, technical company noted that topics struction; simulation mod- efficient calculation and
institutes and technical col- submitted for this award els for dynamic and thermal evaluation of the thermal ef-
leges in Europe who have were to be dedicated to one behaviour of machine tools; fects on machine tools.
studied scientific topics or of the following fields: Inno- control and sensor concepts
produced results from their vative machine concepts for machine tools; and new » Fritz Studer,
student projects or bachelor/ and components; alternative or further-developed manu- Thun, Switzerland.
master diploma studies. The materials in machine con- facturing techniques, espe- www.studer.com
delcam announces joint Cutting-tool maker Greenleaf
venture in denmark adds distribution in uK
customers, including LEGO, Greenleaf said Peter Camp-
Source: Delcam
Source: Greenleaf
ECCO, Siemens Wind Pow- bell (Sales) Ltd. and Matrix
er, Vestas and Danfoss, along Tooling Services have been
with many smaller subcon- added to the US company's
tract manufacturers as well distribution network to
as toolmakers. "strengthen its position in
The Danish office will the United Kingdom."
support Delcam’s complete Peter Campbell (Sales)
Søren Friis has been selected as line of software products, Ltd., founded in 1982 and The US-based manufacturer said
the director of the new Delcam but the company said the located in North Lanark- it has distribution in over 30 coun-
Danmark joint venture. main focus in the beginning shire, Scotland, supplies a tries worldwide.
will be on the range of CAM wide range of industrial cut-
Delcam said it has estab- software, in particular Pow- ting tools and related prod- terials, Matrix’s collabora-
lished a new joint-venture erMILL for high-speed and ucts to the engineering in- tion with Greenleaf and WG
company in Denmark called five-axis machining, the Fea- dustry, Greenleaf said. whisker-reinforced ceramic
Delcam Danmark. The firm tureCAM feature-based sys- Sandiacre-based Matrix technology makes for a
will be a partnership with lo- tem, and the Delcam for Tooling Services was formed strong solutions team,
cal CAD/CAM specialist SolidWorks integrated ma- in 1987, according to Green- Greenleaf said, adding that
Søren Friis, also the compa- chining software. The com- leaf. The company provides it will continue to expand
ny director. pany will be based in Vam- cutting tools for numerous distribution globally.
Delcam said it has been drup near Kolding. applications, including solu-
active for many years in tions for aerospace and auto- » Greenleaf,
Denmark through resellers » Delcam, motive components. With a Saegertown, Pennsylvania.
and has a number of large Birmingham, UK. specialty for machining www.greenleafcorpora-
international companies as www.delcam.com nickel-based aerospace ma- tion.com
12 European Tool & Mould Making | November 2012 | www.etmm-online.comDO YOU WANT TO IMPROVE THE QUALITY OF YOUR PLASTIC PART?
Vacuumjet System
DO YOU WANT TO REDUCE YOUR CYCLE TIME?
Old problems...NEW SOLUTIONS!
Why we need to vacuum the cavity?
Before injecting the plastic, there is air trapped inside the
cavity. If we can remove this air, the plastic is free to fill the
whole cavity and will not find any counter-pressure slowing
down its flow.
Application example with Vacuumjet Valve (VV) and Automatic Vacuumjet (VK)
The vacuum is produced through the valve, the ejectors and sleeves maintain it.
CUMSA has created a series of products that removes this air,
and give many benefits when molding the plastic parts. These
benefits are (among others):
- Lower injection temperature and pressure
- Reduced cycle time
Application example with Vacuum Control (VM) and 3 Vacuumjet + (VG) units. - Increase in production
The vacuum is produced through the ejectors and sleeves.
- Superior visual appearance (less sink marks)
- Dimensional stability (invisible weld lines)
Visit us! - Uniform color
Hall 9.0 - Stand D29
- High mechanical resistance due to perfect plastic flow
Contact us, and we will find the best solution for your mold!
INNOVATIVE SOLUTIONS FOR MOLDSSpecial RepoRt | GeRman toolmakinG
toolmaking researchers in
Germany select top shop
Hundreds of tool and mould makers from throughout German-speaking Europe were vying
to be the region's best, but there could only be one.
In the end, ZF Friedrichshafen, Sch-
Source: Culp
weinfurt, Germany, came out on top.
Herbert Johann, the head of the com-
pany's tool shop, which supplies cutting
and forming tools for the driveline and
vehicle chassis manufacturer, said he was
"overwhelmed" by the win. As he hefted
the award to display it to the room, Jo-
hann drew on an oft-repeated statement
from a German footballing great who
raised a trophy to a crowd gathered at the
Munich Town Hall: "Like Oliver Kahn
said on the balcony: 'Here it is.'"
This wasn't the shop's first attempt at
the ultimate prize in German tool and
mould making – the company was near
the top in 2004, 2006 and 2008 – and one
could hear the relief and joy in his voice
as Johann thanked his co-workers, the
jury and the other toolmakers at the cer-
emony. "We've been trying for so long,"
he explained to the applauding crowd.
a new tactic: instituting takt
times in the tool room
According to Fraunhofer IPT, the shop
Herbert Johann (centre), the head of the tool shop at ZF Friedrichshafen, Schweinfurt, Germany, was a cut above the rest for a number of
proudly holds this year's award. reasons, but one stood out. The company
has shifted to cyclic production, which
has enabled the shop to remain com-
T he tension was palpable enough to
silence the nearly 300 guests assem-
bled in the Coronation Room of the
tion Awards to the winners of the com-
petition's four divisions. Now, one shop
would walk away with the trophy.
petitive as an internal supplier. The deci-
sion to industrialise tooling manufactur-
ing has made the company "a beacon"
Town Hall in Aachen, Germany. They for the sector, and the jury lauded the
waited impatiently as Michael Breme, Winnowing nearly 300 shop's life-cycle management, its weekly
the director of tooling at carmaker Audi, discussions with managers on the pro-
listed the accomplishments of another
entrants down to a victor duction line and its close work with ex-
German shop. Breme had been on that It had already been a close race, accord- ternal partners.
stage before: His company won the 2011 ing to the organisers. Fraunhofer IPT and The choice of location suited the hon-
Toolmaker of the Year Award, which is the WZL had to first whittle down the our, according to Professor Günther
presented by the Fraunhofer Institute for 297 entrants. The 14 tool shops that Schuh, the head of the WZL. In his open-
Production Technology and the WZL passed the initial muster then faced a ing remarks, Schuh told tables filled with
tooling laboratory at RWTH Aachen Uni- jury of eight industry experts. Breme told workers from the country's leading shops
versity. The audience didn't know ex- the audience that choosing the best of that the hall had played host to the cor-
actly who Breme was describing, but the best had weighed heavily on the or- onation of German kings for some 600
they had an idea: The organisers had al- ganisers. "This was a Herculean task for years. "This is the right place to crown
ready presented Excellence in Produc- the jury." the best German toolmaker," he said.
14 European Tool & Mould Making | Oktober 2012 | www.etmm-online.comSource: Culp
Special RepoRt | GeRman toolmakinG
Professor Günther Schuh, the head of the WZL, said Aachen's Coronation Hall "is the right place
to crown the best German toolmaker."
The competition had been tough, Siemens division Gigaset Communica-
Schuh noted. He said the contest had tions, Bocholt, Germany, which pro-
produced "a very close field" and half- duces telephones. Overall winner ZF
joked that the points winners had ac- Friedrichshafen topped the competition
crued in the past would not have been among internal tool shops with more
enough to secure an award this year. than 50 employees, Christian Karl Sie-
The inter-divisional competition was benwurst Modellfabrik und Formenbau,
also intense, according to jury member Dietfurt, Germany, won the award for
Rolf-Albrecht Schmidt. He noted that best external shop with over 50 employ-
"only a few points" separated the top ees, and W. Faßnacht Werkzeug- und
three companies vying for the award for Formenbau, Bobingen, Germany, col-
the best internal tool shop with 50 em- lected the award for best external shop
ployees or less. The winner was former with fewer than 50 employees.
German politician underscores
Source: Culp
importance of manufacturing
The award ceremony drew not only tool-
makers, it also attracted a top-level Ger-
man politician. Werner Ressing, the di-
rector general of German industrial
policy, made the trip from Berlin for the
event, and he underlined the importance
of tool and mould making for the coun-
try's future success. "Germany is a lead-
ing industrial country, and it should stay
that way," Ressing said. He pointed out
that 20% of German GDP comes from
manufacturing, and the sector helped
pull Europe's biggest economy out of the
last economic downturn. Ressing added
that toolmaking plays a "key role" in
Germany's status as a high-tech indus-
trial country.
Werner Ressing, the director general of Ger- » Fraunhofer IPT,
man industrial policy, talked of manufactur- Aachen, Germany.
ing's importance to Germany. www.ipt.fraunhofer.de
www.etmm-online.com | Oktober 2012 | European Tool & Mould Making 15Special RepoRt | euRoMold pReview
austrian companies move north
to partner with euroMold
The ties between Austria and Germany, home of EuroMold, have a long history and remain
close. This is one reason the Alpine country has been selected as the partner country for
Europe's biggest show for tool and mould making.
tion. Demat underscored Austria's "im-
Source: Culp
portance for the German economy, es-
pecially for product development in tool
and mould making". It added that along
with the machine tool industry, plastics
play a major role in Austria with sales of
€13 billion. Austria is also home to one
of the world's largest injection moulding
machine producers, Engel.
Germany serves as test market
for europe, beyond
For Austrian companies, Germany pro-
vides a proving ground for their goods
and services, according to Mario Haidl-
mar, managing director of toolmaker
Haidlmar Werkzeugbau, Nussbach, Aus-
tria. His family's firm is said to be one of
the world's leading producers of injec-
tion moulds for bottle carriers such as
Austrian toolmaker Mario Haidlmar says, "You have to be successful in Germany before you can be beer cases, and in the last fiscal year its
successful in the world." sales grew more than 40% to €38 million.
Haidlmar – the son of the company
founder – took charge of the business
W hen one examines Austria's im-
ports and exports, one country
stands out: Germany. "More than 30%
fact, manufacturing of machinery and
metalwares leads Austrian industrial pro-
duction by far; output in 2008 was more
earlier this year, and he knows the im-
portance of Germany for his company
and others trying to secure experience in
of our exports go to Germany," said than double the second-place sector, and knowledge of international produc-
Christoph Sturm from the Austrian chemical production. In addition, some tion. "You have to be successful in Ger-
Trade Commission. He noted that Ger- two-thirds of that machinery and those many before you can be successful in the
many is also the source of more than metal products were exported. Finally, world."
40% of Austria's imports. machinery and plant construction con-
tinues to serve as Austria's most impor- austrian toolmaker recipient
Similar economies, languages tant industrial employer, according to
data from the country's trade commis-
of Germany's top award
form strong bond sion. This primacy for the sector mirrors Haidlmar's shop has proven its skills and
In Austria, much like the economy of its the situation in Germany's industrial job acumen to the German market in an
gigantic neighbour to the north, heavy market, the largest in Europe. number of ways. Back in 2006, the com-
machinery plays a major role for the pany received the Toolmaker of the Year
well-being of the nation where German tooling, mould development Award from toolmaking research insti-
is the official language but spoken with tutes in Aachen, Germany.(See p.14 for
a slight accent. The heavy machinery
plays role in choosing austria this year's winners.)
sector comprises nearly 18% of Austrian Considering the close bonds btween the
exports, making it the largest industry countries, it is no wonder EuroMold or- » EuroMold,
for international sales, followed by elec- ganiser Demat has selected Austria as the Frankfurt/Main, Germany
trical engineering and automotive. In partner country for this year's exhibi- www.euromold.com
16 European Tool & Mould Making | November 2012 | www.etmm-online.comDesign today...
...build
tomorrow
at:
See us nkfur t
old, Fra
EuroM 130
1 1 .0 , stand E
Hall
Unlock the potential for Additive Manufacturing
Renishaw’s laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD,
which has the power to unlock the potential for additive manufacturing.
From tooling inserts featuring conformal cooling, to lightweight structures for aerospace and high technology applications, laser
melting gives designers more freedom, resulting in structures and shapes that would otherwise be constrained by conventional
processes or the tooling requirements of volume production. It is also complementary to conventional machining technologies,
and directly contributes to reduced lead times, tooling costs and material waste.
• Shorten development timescales - be first to market
• Reduce waste product and cost - build only what you need
• Enjoy increased design freedom - create complex structures and hidden features
Find out more at www.renishaw.com/additive
Renishaw plc Whitebridge Way, Whitebridge Park, Stone, Staffs ST15 8LQ United Kingdom
T +44 (0)1785 815651 F +44 (0)1785 812115 E additive@renishaw.com
www.renishaw.comIntervIew | euroMold PrevIew
euroMold faces the changing
world by drawing from its past
Even though regional fairs for mould making have been popping up throughout Europe, the
annual Frankfurt exhibition still reigns supreme by continuing to feature cutting-edge appli-
cations. Demat Managing Director Eberhard Döring explains why.
Source: Culp
Speaking with ETMM at his Frankfurt office, Demat Managing Director Eberhard Döring summed up his motivation for organising trade fairs
around the world: "It's wonderful bringing people together."
ETMM: Tool shops have a main goal, which there. Here, we are focusing more and to it later. That's what toolmakers are do-
is to sell their goods to manufacturers. more on product development. ing today, they are changing their phi-
What's your view on the number of interna- losophy. They are front loading. They are
tional OEMs that visit the EuroMold to find ETMM: How does that focus represent learning these soft skills.
mould makers? changes in the industry?
Eberhard Döring: It's pretty high. We Döring: As one expert noted recently, ETMM: EuroMold continues to feature what
have a very good OEM database. Unfor- toolmakers can no longer react, they some in the industry would consider fledg-
tunately in 2009 and 2010, there was a have to act. This means 'front-loading'. ling technologies. What is the reasoning
big drop because the car industry, and They must understand much more about behind that?
other OEMs, were not allowed to come the products, they need design capabili- Döring: I come from product develop-
during the crisis. Now it's picking up sig- ties and all kinds of activities such as ment. We have created this meeting
nificantly. And just like the Americans, materials selection for the product, and place also for when technologies
OEMs here are focusing on reshoring, for they have to advise their customers. In emerged or just started, like additive
sourcing out of Germany and out of Eu- the old days, you got a drawing and you manufacturing. These technologies are
rope, so this year we expect higher par- made the mould. But this is changing. really progressing very fast and they have
ticipation from OEM visitors. This is It's a complex business. The designer has growth rates well above any of the exist-
what a product development fair should demands, the production manager has ing conventional technologies, and they
provide. We always have development demands, toolmakers have demands and are there, and we are the biggest fair for
engineering people and skilled workers the marketing department has another them. My exhibitor board is always ask-
and owners. The production people go view. But, to make the product, you have ing, 'Aren't we overshooting in this di-
to metal working or plastics processing to bring all this together and face this rection?' but it's a fact. Additive manu-
shows and they can find what they need complexity in the beginning, not react facturing is developing fast, and we are
18 European Tool & Mould Making | November 2012 | www.etmm-online.comIntervIew | euroMold PrevIew
in this process chain and moving more circle around Stuttgart, and probably
and more in this direction and moving 75% of all metal in Germany is processed
ahead of mould making, per se. This year there. But, you of course have big OEMs
we have the jewellery section, which is in the north like Volkswagen, Mercedes
very interesting because it also includes in Bremen, and you have the old histor-
the additive manufacturing technolo- ical places around Ludenscheid. And the
gies along with the old cast technologies. industrial revolution in Germany started
in the Wattenscheid in the Ruhr Valley.
ETMM: Visitor generally expect some nov- So, in terms of mould making and tool-
elty at each instalment of a trade fair. ing, you have a centre in the south, you
What's new at EuroMold this year? have a centre in the middle of Germany,
Döring: We are improving the efficiency and of course you now have Chemnitz
that we think is important for the B2B in eastern Germany, originally a highly
situation. We have installed matchmak- established industrial area which is now
ing software that people can use. For picking up again.
example, you are in the tractor business,
and you want to find a design company ETMM: Considering the history, It sounds
or a designer that has experience with like Frankfurt makes sense for a German tool
tractors and you want to find a company and mould fair. Why is it suited for a Euro-
that has experience with mould making. pean show?
Or, you want to find someone capable of Döring: The best thing is probably the
making a 15-tonne mould. This means infrastructure access. You can access
you don't have to run around – especial- Frankfurt from any town in Europe in
ly the international visitors – and you two hours, more or less. If you are in Mi-
can make a match and meet the relevant lan, for example, it takes less than two
people. If you are the expert in tractor hours. Our visitors are divided into the
tooling, and you are there on Friday end users – the OEMs – the kind of orig-
morning, then you make this appoint- inators for mould making and tooling
ment. We have a B2B area where people sourcing. Plus, to quite a large extent,
can meet, even visitor to visitor. visitors are tool makers or people from
the process chain who want to see what
ETMM: With this range of fairs in the mar- is available in the specific areas. It's sim-
ket, how does EuroMold differentiate itself ilar to a plastics processing fair. Take Fa-
from the regional shows? kuma; a lot of processors go there, but a
Döring: Our target is to create the opti- lot of processors also exhibit. A good ex-
mum marketplace for this industry. We hibition depends the most on visitors,
have to represent the international situ- not the numbers, but the quality of visi-
ation, and Frankfurt is probably the best tors. At EuroMold, the quality of visitors
place to have this global fair or this lead- is very high. You can ask any exhibitor.
ing fair for this industry. We are now But he has to be international. AMB in
reinforced by our international activi- Stuttgart had 10% foreign visitors. Right
ties. From this activity outside Germany, now, our rate is above 23%, so nearly
we get a lot of feedback and reinforce- one-fourth of our visitors are from
ment for our own exhibition. That's very abroad. That's what makes it so interna-
important because this is a way to attract tional. The thing is, we aren't having an
visitors and exhibitors from all over. For exhibition just for the German toolmak-
example, EuroMold Brazil had about 110 er. Even back in 1995, we had high par-
exhibitors... We will now have a delega- ticipation from Portugal's toolmakers.
tion of 80 companies and their repre- That's when Portugal made the decision
sentatives visiting EuroMold for the first to create a toolmaking industry. Our goal
time. They are buyers and perhaps po- is to remain the leading fair for such busi-
tential exhibitors. At least we see the ness. People ask us, 'How many more
world is becoming smaller, and Frankfurt exhibitors will you have this year?' They
is the meeting place. should be asking, 'How many good ex-
hibitors do you have this year?' or 'How
ETMM: What makes Frankfurt the right city many companies will show a product for
to host this exhibition? this first time this year?'
Döring: In Germany, you have this
north-south situation. north of the Main » Demat,
River – there's not much left for metal Frankfurt/Main, Germany.
processing. You can draw a 100 kilometre www.demat.com
www.etmm-online.com | November 2012 | European Tool & Mould MakingCase study | Hot RunneRs
Four components for injection
moulding include an elastomer
A range of hot runners designed by Günther Heisskanaltechnik allows a processor to make
producing a complicated everyday item look easy.
product in three steps. The first step is
Source: Günther Heisskanaltechnik
the injection of the red and white but-
tons. For this, Oechsler explained, two
injection systems are combined in one
station. According to the company, these
work indirectly via balanced TEP-S T-
runners and two 5SMT120H nozzles
with anti-wear tips, which is to say via
an intermediate sprue. The shot volume
per nozzle is 2 cm³. This part of the solid
mould half is designed as a three-panel
tool, in order to be able to remove the
sprues, the company said.
The second component with a 50%
glass fibre content for the housing is in-
jected directly via a NHDP4B H-runner
and four slim-line 8NLT150-type needle-
valve hot runner nozzles. According to
Oechsler, this station works with a pneu-
matically activated feed mechanism; 6
cm³ of material is injected per nozzle.
A schematic of the hot half of the mould, which features 10 hot runners. It is used to produce re- The third and final stage is the injec-
mote controls for cars. tion of the elastomer component, the
TPU. The same hot runner technology is
said to be used as in the previous step:
M ould maker and plastic processor
Oechsler, Ansbach, Germany, has
created a complex tool – with a total of
automotive industry, it has to be pro-
duced inexpensively with a high stand-
ard of quality, the company said. The
the H-runner and the four needle valve
nozzles activated via a feed mechanism
provide the material-saving direct gating
ten hot runner nozzles of varying con- main component of the housing consists with a volume of 0.95 cm³ each.
struction and different runners from of black PA66 and PA6T/6I GF50.
Günther – for vehicle remote control According to Ochsler, this extremely out of sight, but still
housing shells from four materials. rigid material provides robustness and
good mechanical characteristics, which
not out of mind
a product that must be are required for, among other things, the Although the injection points of all the
basis for the turning mechanism of the components are in places that are not
simple, durable and reliable key. The buttons and/or symbols consist visible on the completed product, they
The remote looks unspectacular at first of a PA6 GF10. These buttons are coated must nevertheless satisfy relatively de-
glance but has perform reliably for a car's with a TPU; the membranes created in manding requirements to guarantee
whole life. Moreover, it must be able to this way are permanently elastic, provide problem-free assembly, Oechsler said.
cope with unfavourable environmental a pleasant sensation when pressed and For example, electronic components in-
conditions and withstand the buttons seal the whole unit, the supplier said. corporated into the key, such as the cir-
being pressed thousands of times during cuit boards, demand supporting points
the service life of the vehicle, safely and Moulding four materials in within narrow tolerances, without any
without any mistakes. unevenness, let alone stringing.
Oechsler supplies several versions to
three production steps
the General Motors Group, and the Oechsler and the specialists from » Günther Heisskanaltechnik,
whole housing must be robust in con- Günther developed and designed a quad- Frankenberg/Eder, Germany.
struction, but because it is for the the ruple tool, which creates the finished www.guenther-heisskanal.de
20 European Tool & Mould Making | November 2012 | www.etmm-online.com 3 Helical cutting edges for 90 degree milling
Internal coolant supply
Cutter bodies do not require modification for insert mounting
with corner radius
High relief for ramp-down application
Unique angled screw clamping gives increased insert stability 6 Helical cutting edges for 90 degree cutting
Dovetail mechanism clamping provides increased security
and insert clamping
Internal coolant supply
TaeguTec Ltd. World Headquarters
304 Yonggye 4-ri, Gachang-myeon, Dalseong-gun, Daegu 711-864, KOREA
Tel: +82-53-760-7640 Fax: +82-53-768-8055
Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Egypt _ Finland
France _ Germany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Malaysia _ The Netherlands _ New Zealand
Norway _ Pakistan _ Philippines _ Poland _ Portugal _ Romania _ Russia _ Serbia _ Singapore _ Slovakia _ Slovenia _ South Africa
Spain _ Sweden _ Taiwan _ Thailand _ Turkey _ Ukraine _ United Arab Emirates _ United Kingdom _ U.S.A _ VietnamSpecial RepoRt | inteRview
Slicing into the european
market for cutting tools
YG-1 is one of the world's five largest manufacturers of cutting tools. The South Korean
producer has long been a major OEM supplier in the German market, but only began selling
there under its own brand two years ago.
D uring a visit to YG-1's South Korean Song: In the last three years we have in-
Source: Fouhy
production facilities, ETMM Pub- vested heavily in all of our production
lisher Ken Fouhy spoke with company facilities, particularly in China and in
founder and CEO Hokeun Song about Korea. In China, the first factory already
global challenges facing the manufac- has 75,000 m² of production area. We
turer and the success of the YG-1 brand have installed all the machines and the
introduction in Germany. office, and that is in the Free Trade Zone.
In Qingdao we are erecting more build-
ETMM: Of all the markets in Europe, which ings that are to provide products for the
ones are the most successful for you today? Chinese market. The site covers 120,000
Song: Germany is the biggest market and m² and right now we are building a new
the most important one for us. Today, 33,000 m² factory. This year, we will erect
overall, our business in Germany is at two more buildings, and it could be
about €35 million in OEM business and more. One of the issues is that product
almost €5 million with the YG-1 brand, demand in China is so high that we need
so we are in a very strong position. local production. In addition, the land
prices there are only about 10% of those
ETMM: Looking ahead for the next three in our headquarters area in Korea, so our
years, what is your company's goal for the factories in China are single-story build-
German market? YG-1's CEO Hokeun Song says shows like AMB ings. In our main plant in Incheon you
Song: Within three years our YG-1 brand are important exhibitions for Germany, the saw that our production facilities are five
should be worth a minimum of €10 mil- company's most important market in Europe. or sixt stories high, which brings a logis-
lion. And I am sure that the OEM busi- tical challenge.
ness will also grow during this period.
ETMM: Is all of this new capacity you are
ETMM: What’s the YG-1 value-proposition not know much about us even though pointing out for the Chinese market, or is the
for cutting-tool users in Germany; aren’t they are already using our products. But Chinese production also exported?
there already enough cutting tool suppliers that is changing. And, as we win more Song: The first plant is in the Qingdao
in Germany? clients and offer more service, as we plan Free Trade Zone. And in that plant we
Song: Our quality and reliability is very to do, the acceptance will increase. manufacture finished products, for ex-
high and prices are reasonably low, so we port. The second factory is for the Chi-
can offer a lot of savings to the customer. ETMM: What were your expectations for the nese market, where we sold products
Our Motto is: "If it’s not perfect, it’s not AMB metalworking show in Stuttgart? worth $33 million last year. But a lot of
a YG-1.” German customers are already Song: For the German market, AMB is the items for the Chinese market come from
using almost €40 million worth of our best show this year. In the past, I went to Korea, too. To meet the booming de-
cutting tools, which shows that our AMB just to talk about the OEM business, mand, we have to make huge invest-
products are well-suited to the market. but it was not very important as an outlet ments in production capacity – this year
In Germany, service is also very impor- to talk to end-users. Now, it has become we will invest $60 million. So you can see
tant, which is an area in which we are the most important place to build brand why we are building so many factories.
increasing our capability. Also, for YG-1’s recognition for YG-1. And we look for-
global success it is a very important to ward to meeting many users to discuss ETMM: How much of the $60 million invest-
win acceptance in high-end applications their application needs and provide ap- ment is in land and construction and how
in Germany, as the users there are among propriate solutions. much in production technology?
the most demanding in the world. If we Song: This year we have spent almost $20
are successful in Germany, we can trans- ETMM: Why have you have focused much million on land and construction. The
fer this to other markets. But it all takes of your investment on China over the past remainder was investment in machinery
time. For now, the German end-users do few years? and production technology.
22 European Tool & Mould Making | Oktober 2012 | www.etmm-online.comYou can also read
