1403 Makino Newsletter3-low
Transcription
1403 Makino Newsletter3-low
03 CEO/President Makino Asia CONTENTS 07 08 Dear Readers, 22 15 25 18 03 FORERUNNER IN INNOVATIONS 04 MAKINO SINKER EDM MACHINES MILESTONE 06 EDNC65W/EDNC85W 09 MAKINO EDcam 10 REWORKING ELIMINATED 12 FLYING HIGHER WITH EDBV3/EDBV8 14 DRILLING DEEPER AND STRAIGHTER WITH FINE HOLE MACHINING 16 EFFECT OF MACHINING OIL PROPERTIES 17 THE EROWA ROBOT SYSTEM LINEAR 18 HARMONY WITHIN POWER, ACCURACY AND SPEED 20 SUITABLE FOR HARD TO CUT MATERIAL AND HEAVY CUTTING 22 HYPER-CUT 23 MAKINO TRAINING CENTRES As a global leader in Sinker EDM, Makino occupies the high-end segment of the market. The Makino Sinker EDM machine has become a symbol of sophisticated machining that every mould maker strives to own. Very often, owning a Makino Sinker EDM machine is sufficient to convince customers of the company’s capability and ability to do high-end, high quality products. Many of our new customers who bought our sinker machine were able to move up the value chain, allowing them to rise above competition. In this 3rd issue of INNOVATION DEFINED, we report on one customer who shares our passion for high performance and quality. Hjernø Værktøjsfabrik A/S is a highly specialised tool factory in Odense, Denmark, that manufactures technically demanding injection- moulding tools. Hjernø invested in two machines, the Makino V33i vertical machining centre and a Makino EDAF2 sinker EDM machine to increase its machining capacity. Their requirements have been demanding: high milling speed and 2-3 micron precision to meet their customers’ quality specifications. Find out how stable machines have eliminated the need for reworking and brought other benefits on page 10 and 11. This particular customer is a prime example of how manufacturers can grow their businesses and improve their performance by focusing on what matters most. I hope the story will inspire you to do the same. Yours sincerely, Dr Moh Chong Tau + FORERUNNER IN INNOVATIONS 03 Makino has always been the forerunner in the sinker EDM business. Since 1977, Makino has invented numerous groundbreaking technologies that help to shape the machining tool industry. Makino’s history of innovation is one of the company’s success factors. However, Makino is not alone in its glittering history of innovation. Makino’s success comes from its strong partnership with its clients. NOTABLE ACHIEVEMENTS Makino has introduced a wide range of major innovations throughout the years. In 1987, Makino developed the smokeless machining method and adaptive control. This technology revolutionised the Sinker EDM industry and became the basis for all advanced EDM technology even until today. In 1996, Makino invented the HQSF technology which is a powder technology that is able to produce a superior surface finish. Makino’s HQSF technology produced unparalleled results and nothing else came close at that time. 18 years on, HQSF still retains its crown in producing the best surface. These innovations were possible because of the voices from our partners. They attest to Makino’s partnership philosophy. INVENTIONS THAT CHANGED THE WORLD Makino’s advancement has not only helped the machine tool industry, but also created new machining possibilities that eventually affect products we use every day. Today, the Makino Sinker EDM is used in industries ranging from medical, aerospace, automobile, electronics, telecommunications, home appliances, etc. While market trend changes, Makino continues to quickly evolve and adapt. For example, the EDBV series is our latest addition to our product line. EDBV allows the aerospace industry to create cooling holes for turbine blades at a fraction of current machining time while making more complex profiles possible. GLOBAL LEADER As a global leader in Sinker EDM, Makino occupies the high-end segment of the market. The Makino Sinker EDM machine has become a symbol of sophisticated machining that every mould maker strives to own. This is because owning a Makino Sinker EDM machine is sufficient to convince customers of the company’s capability and ability to do high-end, high quality products. + MAKINO SINKER EDM MACHINES MILESTONE 1975 Makino introduces the first commercially available CNC EDM machine 1981 EDNC series of CNC Sinker EDM machine 04 1984 Develop large CNC Sinker EDM machine 1986 First Intelligent Adaptive Control 1980 EDNC22 machine 2005 Super Spark III, Super Surface, Super Edge & µ Cell EDM 2003 Super-Spark II is released 2006 Ultra high precision EDM EDAC1 1987 Develops the smokeless machine & the Dual-head CNC Sinker EDM machine 1996 HQSF™ with patented µSC additive 1992 2001 The Super-Spark 1998 Develops the Pallet Magazine System & Robotic Automation Rib Head with linear motor technology 2002 The EDCam™ offline software solution for programming & automating EDM machinery 2008 EDcam V.5 offline software solution for programming & automating EDM machinery 2010 2012 Super-Spark IV is released AF Control to prevent the DC arcing 2013 EDNC65/85W, HS-Rib 2010 EDAF series EDM 05 + The largest worktank in this class. What we offer: EDNC65W/EDNC85W Basic stroke with larger work tank Value for money and reduce machining time 06 With the technological innovations in our daily life, some parts such as those in automotive and home appliance are becoming larger and more complex. This calls for larger mould size with more deep reinforced ribs. Makino EDNC65W & EDNC85W feature larger workpiece capacity and the latest cutting technology with enhanced electrode jump speed and acceleration. It delivers optimum machining performance cost effectively on both roughing and finishing cutting process. Several parts combine into 1 single part Cavity deeper as parts profile more complicated More deep ribs needed for rigidity 1.7 times larger work tank volume than EDNC65/85 Inner Worktank Size EDNC65 EDNC65W EDNC85 EDNC85W Width (mm) 1100 1400 (+300) 1400 1800 (+400) Depth (mm) 750 900 (+150) 900 1200 (+300) Height (mm) 450 500 (+50) 500 500 SERVING CUSTOMERS WITH WIDER NEEDS 07 It is not speed, acceleration or sparking condition alone that matters. It is the of them that makes the difference. Synergy High acceleration jump High accuracy jump High speed jump High performance jump + HS-Rib New HS-Rib & new machining technology are able to machine faster by 50% as compared to using Standard Head. 1.5G *HS-Rib is offered as an option 1st process machining: MC depth vs. MC time acceleration Z-stablizer accurate Machining depth 08 20m/min speed 50% Faster HS-Rib 5m/min Standard 20m/min HS-Rib 0:00:00 2:00:00 4:00:00 6:00:00 8:00:00 10:00:00 Machining Time 12:00:00 14:00:00 spark condition 16:00:00 + EDcam Productivity tool that makes the difference The more electrodes you use, the more productivity improvement you gain by using EDcam. 09 3D Model • EPX Data • Machining instructions Machining program With EDcam, generating of machining programs can be done on PC with much greater ease and on-machine dry run can be eliminated as well. Without EDcam, generating EDM machining progrms, machining positions, electrode dimension reduction and other data have to be manually input on the machine and this requires dry run checking on the machine. + HJERNØ Reworking eliminated Investment in Makino machines improves Danish machine-tool factory’s margins on high-precision injection mould making Reworking injection moulds to achieve the precision demanded by the medical technology and other high-tech industries can eat up the slim margins on such jobs. Hjernø’s investment in high-precision, thermally stable machines from Makino has eliminated the need for reworking – and brought other benefits as well. Makino sinker EDM machine EDAF2 10 www.hjerno.dk Hjernø Værktøjsfabrik A/S, a highly specialised tool factory in Odense, Denmark, manufactures technically demanding injection-moulding tools. Founded in 1946, Hjernø is now one of Northern Europe’s largest and oldest tool factories with a current workforce of around 40. The company, which has been specialising in injection moulds since the 1970s, came through the economic and financial crisis well and gained an AAA credit rating in 2011. “We stayed in the black during the crisis,” explains Aage Agergaard, the company’s managing director and majority shareholder, “because we are at the top end of the quality pyramid and an extremely well organised company.” Hjernø’s customers are all from high-tech indus-tries in Denmark, Norway, Sweden, Germany, France and the UK. They include some of the world’s leading hearing-aid manufacturers, e.g. GN Resound and Widex. All of Hjernø’s customers have one thing in common: “High demands on zero tolerance,” as Aage puts it. HIGH SPEED AND ULTRA-FINE PRECISION Early in 2012 Hjernø invested in two Makino machines to increase its machining capacity, particularly during peak periods. Hjernø’s requirements have been demanding high milling speed and 2-3 micron precision to meet their customers’ quality specifications. After testing machines from various manufacturers, Hjernø chose a Makino V33i vertical machining centre and a Makino EDAF2 sinker EDM machine. For over a year now, the two machines have been producing ultra-high-precision injection moulds, with the V33i operating day and night. Aage Agergaard: “Since we were extremely happy with the two machines’ performance, we bought a Makino F3 vertical machining centre a year ago, and we recently purchased a second V33i for delivery in mid-March.” Aage explains why this Makino machine is particularly suited to the production conditions in his factory: “The temperature in our machine hall varies quite considerably so the V33i’s Thermal Stabilizer is vital to avoid thermal distortions and ensure ultra-high precision over long periods of hardmilling.” And those were not the only advantages Hjernø discovered. NO REWORKING – HIGHER MARGINS Having to rework injection moulds to meet a customer’s strict standards can turn a profitable job into a loss-maker. Hjernø’s production manager Martin Riedel explains how the V33i has saved the company money: “This machine has eliminated the need for the reworking loops we had on other machines. That saves us time, money and frustration, and for the customer, it means no more delayed deliveries.” Aage explains the economic significance of eliminating reworking: “When we saw just how precisely the V33i carries out hardmilling, we realised it would enable us to eliminate reworking. That was one of the reasons why we bought a second V33i. And since this machine achieves great precision at high milling speeds, we’ve also been able to reduce our lead times.” By eliminating time- and money-consuming reworking and shortening lead times, the Makino machines have proved a good return on investment. Aage Agergaard explaining the polishing experiment to Makino agent Michael Balling-Petersen VERY SATISFIED WITH SERVICE As a coolly calculating businessman with a keen eye for optimising in-company processes, Aage Agergaard particularly appreciates the fact that the Makino machines were delivered and installed without any trouble. “The machines come on time, the service is perfect and the people who install the machines know what they’re doing. We can count on Makino.” Martin Riedel adds. The service is provided by technicians based at Makino’s Hamburg site, only three hours drive from Odense. “Our operators are also very happy with the V33i. They can go home in the evening and sleep soundly at night because they know it will run reliably day and night.” POLISHING EXPERIMENT Right now, Hjernø is experimenting with using the Makino sinker EDM to polish injection moulds to achieve a surface finish of 6 microns. Aage explains the thinking behind this experiment: “Up to now, we’ve had two men doing polishing work all day. If a machine can take on this job, we’ll save a lot of money.” Martin Riedel has discovered that “this sinker EDM machine has excellent polishing qualities and there are no black spots on the polished surfaces”. If the polishing experiment works, and the signs are very promising, it will prove to be yet another cost-cutting feature of a Makino machine. With margins so tight in the die & mould industry, the money-saving benefits of eliminating reworking and manual polishing and reducing lead times can make a key contribution to staying in the black – as Hjernø has done. Typical mould component produced by Hjernø 11 + 12 FLYING HIGHER WITH EASY AND FAST HOLE DRILLING 6 seconds Diffuser:24 seconds Hole: Staying cool with EDBV3/8 DIFFUSER HOLE IN TURBINE BLADE Diffuser holes are needed in turbine blades for cooling purposes. EDBV is a specialised machine designed to address this. Using high speed water EDM drilling, EDBV is able to create diffuser holes more easily and faster than any other machine. SUBMERGED MACHINING Stable machining is accomplished even at high speeds. Spark discharges never become unstable even when the electrode pierces the workpiece in through-hole machining. USES OFF-THE-SHELF PIPE ELECTRODES EDBV series can machine a wide range of hole diameters without any need to make new electrodes. It easily machines diffuser holes and a variety of other hole shapes besides round ones. BREAK THROUGH DETECTION FUNCTION The sensor detects when the electrode pierces the workpiece. This function prevents defects when machining the turbine blade surface by avoiding contact between the electrode and the wing wall on the back side of the workpiece. 13 m 10 0 m m 100m 14 Ø80µm electrode 125hrs continuous machining for 1000 finehole with pitch accuracy ± 5µm Work material Electrode material Work thickness No. of electrodes used : : : : Super Hard (G5) Copper (Ø0.08mm) 0.5 mm 32 EASY SWITCH MOUNT/DISMOUNT Fine hole arm can easily be mounted and dismounted so that user can switch between normal EDM and Fine Hole drilling easily. DRILLING DEEPER AND STRAIGHTER WITH + FINE HOLE MACHINING ATC FOR FINE HOLE Fine hole option also comes with ATC for automation so that long hours of machining is possible. 15 Effect of Machining Oil Properties on Die-sinking Electrical Discharge Machining Idemitsu Kosan Co., Ltd This report is reference of below information. Kitamura Tomohiko, Ryoichi Okuda, et al.: Japan Society of Electrical Machining Engineers, Electrical Machining Technology, Vol32, No.102 (2008) Testing of Oil Type Dielectric Fluid 1 Objective The objective of this report is to clarify the factors affecting machining characteristics of different dielectric fluids of different physical properties – focusing on the cooling characteristics (heat transfer coefficient) of each fluid. 2 Test Method Table 1 Machining oil properties Kinematic viscosity @40 ˚C [mm2/s] A B C 2.41 1.87 2.26 2.35 1.96 79 225 238 269 Heat Transfer Coefficient Integral [104W/m2] 2 .1 Oil Samples D E 258 Test Oil A Test Oil C Table 1 shows the physical properties of each test oil. Test oils A to E were varying heat transfer coefficient align with their respective kinematic viscosity. Figure 1 shows that the temperature depended on heat transfer rate curve in the case of Oil C. This cooling process was divided into vapour blanket stage, boiling stage and convection stage. Boiling stage was where heat transfer rate was the greatest when the oil was in a state of nucleate boiling and the silver bar was cooled by evaporation of the oil. 16 Table 1 shows the cooling curve of the heat transfer characteristics of each test oil within the temperature range of 100 to 800 °C. In Figure 1, shows the comparison of a much higher coefficient heat transfer Oil C and the inferior Oil A. Oil C, with higher heat transfer rate, had excellent cooling which could cause nucleate boiling strongly over a wide temperature range. 2 .2 Machining Parameters Test had been carried out in die-sinking type machine with 4L capacity tank, without oil circulation. Table 2 shows the machining conditions. 3. Analysis of Test Results Silver Test Piece Temperature Fig. 1 Heat transfer coefficient curve Table 2 Test conditions Roughing Condition Peak Current (A) Pulse (µ s) I dle Time (µ s) Machining Time (Min) Electrode Work Piece Machine Finishing Condition 15 5.5 256 16 256 16 5 10 Cu (10mm x 10mm ) S55C die-sinking type Oil E results were used as a benchmark for comparison. Result: 1. Higher machining speed was achieved for both roughing and finishing when the heat transfer rate was high. 2. The machining speed becomes faster when cooling performance of the oil is superior. 3. The effect of higher heat transfer rate on machining speed was caused by nucleate boiling effect of oil between electrodes (poles) had been intensified, resulting in a greater discharge of machining waste and a more stable machining condition. Heat Transfer Coefficient [×104W/m2] Fig. 2 Effect of heat transfer on Cutting speed EROWA AUTOMATION ROBOT SYSTEM LINEAR Erowa Robot Gripper in Action In the context of precision engineering, machines are only profitable when they are fully utilised and producing. They should be operating during the day, off-peak hours, weekends and at night. Achieving this goal means combining all production requirements in a plan. This plan is known as the “Flexible Manufacturing Concept” – or FMC in short. The 4 steps of the Flexible Manufacturing Concept by Erowa incorporates (1) Standardisation, (2) Measurement, (3) Automation and (4) Integration. It is necessary to implement this plan and turn it into reality in well-measured steps. The Erowa Flexible Automation System is the key to enhancing productivity. In today’s highly competitive environment, machine tools with automatic placement are now the standard. Customers are demanding for small batch production from small to large workpieces, fast delivery and high quality parts. Rapid intermediate inspections during production increases production reliability. With an appropriate handling system, measuring machines, washing and cleaning stations and a reliable Job Management Software JMS Pro, Erowa offers a consistent solution to meet these requirements. Erowa EWIS RFID Scanning Workholding Pallet in Magazine THE The Erowa Robot System Linear (ERSL) offers the fl exibility of an extendable modular rail which accommodates up to eight machines of different technologies with tools, workpieces and electrodes handling capabilities. The Erowa Robot System Linear (ERSL) is an automated robot system that travels on a rack and pinion drive over the entire linear axis which facilitates large acceleration and precise positioning. The system is supplemented with loading stations, gripper changer (depending on pallet size), rotary and rack magazines as well as pallets for fixtures, workpieces and electrodes mounting. In addition, an intelligent magazine concept allows precise and easy identifi cation of all tools, workpieces and electrodes by way of an EWIS RFID system. Tools, workpieces and electrodes which are mounted onto the pallets can be arranged haphazardly in the magazines to be scanned and picked up by the Robot for production processes. EROWA ROBOT SYSTEM LINEAR 17 + HARMONY WITHIN POWER, ACCURACY AND SPEED In the competitive climate of today’s metalworking industry, highly flexible and productive processes are essential – not just for survival but also as integrated solutions to sustain growth. Makino’s PS Series vertical machining centres have been developed with these challenges in mind. Targeted at the high-mix, low-volume parts machining sector, the PS Series stands out for its high material removal rate, high pitching accuracy and multi-hour machining consistency. Add to that rigidity, reliability and a favourable total cost of ownership and you have a competitive solution to meet the requirements of precision metal-cutting industries such as aerospace, medical, automotive, general engineering and precision engineering. 18 Equipped with Makino’s high performance spindle technology used in horizontal machining centre, the PS spindle, boasting of a front spindle bearing of 85mm, is in a class usually seen in #50 taper machine. This ensures that the metal removal rates and spindle performance of the PS is unparalleled amongst #40 taper machines. It offers efficient, highly productive machining characteristics to address a wide range of materials typical of the production environment. 19 FLEXIBILITY With the increase in demand for automation in the global market, automating production processes to optimise the use of time, materials, human resources, maintainence of the highest possible quality standards and reduction of costs are needed. The PS series is equipped with optional interfaces for it to be ready for automation systems available in the market. These may include 4th axis tables, tool length measurement, spindle probe, light curtain, auto doors and a variety of other features. Interface for hydraulic fixtures (option) can be done either from top of the splash guard or from the ports on table casting. The maximum numbers of ports available are 6 hydraulic, 6 pneumatic and 1 coolant. + SUITABLE FOR HARD TO CUT MATERIAL AND HEAVY CUTTING ENHANCED RIGIDITY AND MACHINING CAPABILITY The enhanced rigidity of the a81nx delivers a more stable and powerful machining performance across all Y axis stroke. Various structural modifications have strengthened the rigidity of the casting structure, table and bed. The overall structure, for example, is twice as rigid as its predecessor. 20 EXCELLENT INDEXING ACCURACY One of the strengths of the a81nx is its high-precision bore-index-bore cutting. Three factors play a significant role in this: 1) The highly rigid structure ensures stable straightness and squareness even when the machine is working under varying conditions, e.g. with workpieces of different weights. 2) The spindle/table (B-axis) run-out has been minimised. 3) A thermally symmetrical structure, combined with elimination of undesirable heat sources through thermal insulation and heat removal functions, ensures thermal stability, even during lengthy machining operations. REDUCED CYCLE TIMES The shorter machining and non-cutting times are achieved through higher spindle acceleration and deceleration, improved axis acceleration and jerk, and a quicker on/off response time for the nozzle and through-spindle coolant. All these lead to shorter continuous cutting feed times or a significant reduction in the time required for rigid tapping. 1,000 cm3/min MRR in cast iron IMPROVED UTILISATION OF MACHINING AREA The maximum permissible length, diameter and weight of the tools that can be used on an a81nx are 690 mm (length), 356 mm (diameter) and 30 kg/45 Nm or 35 kg/50 Nm (depending on the tool carrier). 21 +HYPER-CUT Better result with lesser cut 22 Hyper-Cut technology addresses the demanding need to deliver superior finish while reducing trim cuts. Hyper-Cut was initially designed for precision stamping die industry. However, being able to deliver excellent surface finish with lesser number of cuts, Hyper-Cut found itself successful in much wider range of applications. Machining Time Conventional 4 Pass 1st U6 1st 3 Pass 2nd 2nd 3rd 4th 3rd 18% reduce Wire size: dia. 0.30 mm, Work material: S50C, Work thickness: 300mm Wire Consumption Conventional U6 4 Pass 3 Pass 15% reduce Wire size: dia. 0.30 mm, Work material: S50C, Work thickness: 300mm Group photo with the 1st batch trainees of the Makino Technical Training Centre, Bangalore (INDIA). Bangalore Training Centre (INDIA). + MAKINO Industrialisation plays a pivotal role when a nation is transforming itself. Young and rapidly industrialising, India needs a sea of trained manpower to run its factories efficiently with today’s technology driven equipment, including CNC machine tools. Home to the world’s largest reclining jade Buddha, Kunshan can now be proud of one more symbol of beauty – the Makino Asia China Training Centre. Beginning with a thorough grounding of engineering basics, students progressively learn the in and outs of operating a CNC machine. In addition, they go on to master supporting areas such as Fixture Engineering and PLC Programming. After the completion of a 1 year course certified by Makino experts, these well-trained graduates get placement at various customers of Makino including leading corporate and overseas affi liates. TRAINING CENTRES Sitting on three acres of lush greenery, the Kunshan Technical centre was completed in 2013. The establishment of the new training centre stems from our corporate vision to impart knowledge and skills to maximise the human potential of our employees and customers. The training centre was specially designed to accommodate product assembly and operation training and thus, consists of offi ce space and training facilities. This training centre is poised to become the preferred choice for precision engineering assembly, and manufacturing education and training for Makino’s business partners. Operational since 2006, the Makino Technology Training Centre (MTTC) in Bangalore is set to meet these demands with its unique blend of Corporate Social Responsibility and machine tool expertise. Every year, 60 deserving students from top tier polytechnics are trained on all major domains of CNC operations, adding indispensable value for their workplaces. Mr. Matsubara Fumiyoshi lighting the lamp during the inauguration of the Makino Technical Training Centre in Bangalore (2006) Kunshan Training Centre (CHINA). 23 MAKINO ASIA PTE LTD 2, Gul Avenue, Singapore 629 649 Tel: +65-6861 5722 Fax: +65-6861 1600 Email: sales@makino.com.sg Website: www.makino.com.sg P rin t e d in Sin g a p o re , A E 0 0 1 E a 14/04/3 (L/D)