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For more product information visit www.etmm-online.com
The large range of added-value standard mould components stocked by Meusburger has grown even larger.
40
Dynamics of 5-Axis Machine Ensure Accuracy, Fine SurfacesThe high-performance C 42 U dynamic from Hermle is suited for the five-side machining of complex workpieces in one setup.
IN THIS ISSUE
• Designing Plastic Products for Manufacturability
• Preview: Mould Eurasia in Turkey• Preview: Control 2010 in Stuttgart• Sourcing: Quality Control
35
VOLUME XII NUMBER 3 � AN ACCESS COMMUNICATIONS INC. PUBLICATION APRIL 2010
26
A tool shop that has standardized all of its machining centres on one Siemens CNC enjoys improved operations.
Precision is at the core of perfection. Machining centres from Hermle are precision powerhouses. We are the leaders in 5-axis technology. Our automation technologyand our reliable service makeus the ideal partner for milling applications.
Precision powerhouse
Maschinenfabrik Berthold Hermle AG, Gosheim · Phone: +49 7426/95-0 · [email protected]
www.hermle.de
We can show you our latest answers to performance and precision with the C 42 U, C 50 MT and C 60 U. Visit us at our in-house exhibition from 21 to 24 April 2010 here in Gosheim.
In-house exhibition
www.etmm-online.com
Editor’s Message
ISTMA World Conference: Out of Global Crisis Come Global Opportunities
“Global Opportunities for Special Tooling & Machin-
ing Companies” is the theme of the 13th ISTMA World
Tooling & Machining Conference, coming to Wind-
sor, Ontario, June 20–24. The Canadian Tooling &
Machining Association (CTMA), the host of the event,
has done a great job of putting together a lineup of
pertinent conference subjects. These range from ways
to speed up production and cut costs to evaluations of
worldwide industry trends and a host of methods for improving business.
The executive director of the CTMA, Les Payne, issued a statement inviting
all of the world’s tooling and machining industry to attend the conference. “It
is shaping up to be an excellent event for representatives from the world’s best
tool, die, mould, pattern and machining companies to connect with each other
and learn about new technologies and global opportunities,” he said.
Considering that the conditions brought about by the massive economic cri-
sis will probably be with us for a while to come, the ISTMA World 2010 confer-
ence could not be happening at a better time. Tool and mould makers around
the world are facing many challenges. The event in Windsor can really help
attendees by enabling them to compare their situations and responses with
those of some of the world leaders in the industry.
One of the most interesting offerings of every ISTMA conference or meeting
I have attended has been the company tours. These tours give you a chance to
see how other tool and mould makers run their shops. You get to observe facili-
ties in actual operation, and there is always something to learn.
The area around Windsor is a hotbed of tool and mould making industry.
The CTMA has arranged for an amazing number of tours during the event: at
least 15 companies are opening their doors to ISTMA World attendees.
I have never been disappointed by any ISTMA event I have attended, and I
am sure this year will be no exception. For more information about the June
conference and meeting, check on-line at www.ctma.com, where you will find a
brochure and registration form.
Douglas SellersMANAGING DIRECTOR/EDITOR-IN-CHIEF
Higher timing performance, more precise results, lower unit costs – increase your level of cost effi ciency by using laser system solutions in production processes.
Find out at Lasys how this specifi cally applies to you. Independent experts will be on hand in the “Solution Center” to answer your questions and point you in the right direction for advice.
Do you want to benefi t from better processing? Register now: www.lasys-messe.de
BETTER PROCESSING WITH LASER SYSTEM SOLUTIONS
4 European Tool & Mould Making � April 2010 www.etmm-online.com
April 2010
Industry News
7 Corporate, professional and educational events that define the direction of the industry
EuroMold News
12 World Market Leaders Have Signed Up to Exhibit at the First Amerimold in Cincinnati in May
13 Afrimold Trade Fair Premiering in August in Johannesburg Brings EuroMold Concept to Another Continent
ISTMA News
15 Full Schedule of Events and Activities for the Next ISTMA Conference in June Is Detailed
Special Reports
16 Turkey’s Leading Trade Fair for Mould Making and Related Industries, Mould Eurasia, Returns to Bursa in May
Table of Contents
18 Direct Part Production via the Software-Based Additive Manufacturing Technique Is Following a Growth Curve
Technology
20 Complexity versus Manufacturability: Plastic-Product Design in an Era of Sophisticated 3D CAD Systems
24 Innovative Solid-Carbide Drills with Special Geometries and In-House Coatings Shed Chips Easily, Allow Faster Work
Case Studies
26 ‘One for All’: Musketeers Aside, the Motto Serves for a Tool Shop That Standardizes All Machines on One CNC
28 Multimaterial 3D Models Help Company Save Product Development Costs through Early Feasibility Studies
29 Automotive Die Manufacturer Seeking Greater CAM Flexibility and Toolmaking Productivity Finds the Answer
Spotlight: Rapid Prototyping
30 Selective-Laser-Sintering System Makes Possible Time- and Cost-Saving Production of Large Components on Demand
32 Enhanced Desktop 3D Printer Offers Eight Material Colours, Two Resolution Options and a Generous Build Volume
Products & Services
34 Recently introduced equipment and services from all over
28 ���
Objet Geometries Ltd.Being able to make multimaterial 3D models in one quick process helps a
company cut development costs.
��� 7Rapid.Tech 2010The seventh rapid technology trade fair and associated congresses come to Erfurt in May.
20 ���
Vero Software plcPlastic-product design using 3D CAD
systems involves balancing product complexity with manufacturability.
37 ���
TaeguTec UK Ltd.Milling cutters with up to six small, close-pitch inserts answer demands for stability at high feed rates.
.
www.etmm-online.com
Türk+Hillinger GmbH78532 Tuttlingen Germany
Tel. +49 74 61 70 140 Fax +49 74 61 70 1410
www.tuerk-hillinger.de
since 1963
we are your best choice forheating elements
wide product range
large repertory of stock types
customer-specific executions
modern, rational manufacturing methods
over 30.000 heating elements daily
certified according to DIN ISO 9001:2000
high life span
500 qualified employees
over 240 patent applications
made in Germany
Volume XII Number 3
May 2010• Plastpol Special Section:
A product preview of Poland’s leading plastics trade fair
• Special Feature: The EuroMold Pavilion at RosMould, Moscow
• Product Focus: Hot Runners, Mould Components, Software and Materials
• Quick Sourcing Grid: Hot Runner Technology
www.etmm -online.com
NEXT ISSUE
Company Index
50 A listing of the industry suppliers who supported this issue with articles and advertisements
Krones AGA semiautomatic mould changeover system for stretch blow moulding machines reduces downtime significantly.
41 ���
29 ���
Delcam plcA flexible CAM system enables
a maker of large automotive dies to enjoy up to threefold
increases in productivity.
Tecnomagnete S.p.A.Magnetic milling chucks for alloyed-material workpieces remove the need for demagnetizing parts after machining.
42 ���
Control 2010
44 Measuring Technology in Web 2.0: Global, Internet-Based Metrology Discussions and Value-Added Services
44 Upgraded Software for Laser Scanner Has 64-Bit Architecture for More-Efficient Point-Cloud Handling
45 Systems Enhance Machine Automation, Process Control, Performance Assessment
46 Evolving Fibre Probe Provides High-Precision Measurement of 3D Microcomponent Structures
46 High-Accuracy Fixturing Systems for Measuring and Assembly Are Built via Laser-Sintering or Fused Deposition
Quick Sourcing Grid: Quality Control
47 A handy table of companies supplying quality control products to the tool and mould making industry, cross-indexed by category
6 European Tool & Mould Making � April 2010 www.etmm-online.com
VOLUME XII NUMBER 3 APRIL 2010
EUROPEAN TOOL & MOULD MAKINGAn Access Communications Inc. publication
Contract-published 9 times per year by SellersMedia
P U B L I S H E R
Clay [email protected]
E U R O P E A N A G E N C Y
SELLERSMEDIA*Otto-von-Guericke-Ring 3A, 65205 Wiesbaden, Germany
Tel: +49 6122 95590 • Fax: +49 6122 [email protected]
M A N A G I N G D I R E C TO R / E D I TO R - I N - C H I E F
Douglas Sellers*[email protected]
P R O D U C T I O N, C I R C U L AT I O N & I N F O R M AT I O N S E R V I C E S M A N A G E R
Sylvia Zwick*[email protected]
G R A P H I C D E S I G N E R S
Jason Sellers*[email protected]
Law Wai [email protected]
I N F O R M AT I O N T E C H N O L O G Y S P E C I A L I S T
Markus Müller*[email protected]
S A L E S M A N A G E R E U R O P E
Britta Solloway*[email protected]
A D V E RT I S I N G S A L E S F R A N C E
Evelyne Gisselbrecht33 Rue du Puy-de-Dôme, 63370 Lempdes, France
Tel: +33 473 619557 • Fax: +33 473 [email protected]
R E P R E S E N TAT I V E A G E N T F O R TA I W A N, C H I N A & H O N G KO N G
Robert Yu, Worldwide Services Co. Ltd.11F-B, No. 540 Wen Hsin Road, Section 1, Taichung 408, Taiwan
Tel: +886 4 23251784 • Fax: +886 4 [email protected]
N O RT H A M E R I C A C O R P O R AT E H E A D Q UA RT E R S30765 Pacific Coast Highway, PMB 351
Malibu, CA 90265-3643 USATel: +1 805 744-7924 • Fax: +1 310 507-2032
B U S I N E S S M A N A G E R
MiSook [email protected]
EDITORIAL CONTRIBUTIONS: Product/service information bulletins and press releases should be submitted in English and should be accompanied by a colour photograph or transparency. The publishers assume no responsibility for return of artwork, photographs or manuscripts. NOTICE: Every precaution is taken to ensure accuracy of contents; however, the publishers cannot accept responsibility for the correctness of the information supplied or advertised or for any opinion expressed herein.
SUBSCRIPTIONS: European Tool & Mould Making is published 9 times per year, plus the supplemental EDM Europe Buyer’s Guide, and is distributed free of charge to qualified readers in Europe.
Nonqualified readers in Europe: US$100 (1 year), US$175 (2 years)Readers outside Europe: US$150 (1 year), US$275 (2 years)Single copies: US$25. Payments to be made in US dollars.
Subscription inquiries, back issues, address changes: send your request to EUROPEAN TOOL & MOULD MAKING by e-mail to [email protected] or by fax to +49 6122 51090.
Circulation Audit: Member of the Informationsgemeinschaft zur Feststellung der Verbreitung von Werbeträgern e.V. (IVW), Berlin
Printed at: Kössinger AG, www.koessinger.de
Copyright © 2010 ACCESS COMMUNICATIONS INC. ALL RIGHTS RESERVED
www.etmm -online.com
6 European Tool & Mould Making � April 2010
CHOOSE JAPAN’S NO. 1
www.mitsubishicarbide.com
DRILLS FOR MOULDAND DIE WITH
ADVANCED COATINGS ANDGEOMETRIES FOR TODAYS
PRODUCTION NEEDS
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www.etmm-online.com April 2010 � European Tool & Mould Making 7
Generative manufacturing processes such as rapid prototyping (RP) and rapid manufacturing (RM) are in the spotlight at Rapid.Tech 2010, the sev-enth trade fair in the series, which will welcome the industry in Erfurt, Ger-many, May 18 and 19. The integrated event programme includes a user’s conference, a design engineer’s day, the Student Design Award competi-tion in RM, the 1st Medical Technol-ogy trade congress, and the 2nd CAD/CAM and Rapid Prototyping in Dental Technology congress.
The target audience for the user’s conference includes machine devel-opers, design engineers and users of generative processes, all of whom can profit from the immediate, practical and cross-sector exchange of knowl-edge that will take place. The user’s day provides a framework for the med-ical and dental technology congresses by giving potential users from all in-dustry sectors an opportunity to learn about materials and surfaces, qual-ity assurance and RP/RM machinery through specialist lectures and practi-cal case studies.
In contrast, the design engineer’s day focuses more on design, construc-tion and industrial practice.
Generative manufacturing proc-esses—RM in particular—are especial-ly relevant for the future of medical technology. Trends in RP-supported RM applications in that field are to be highlighted at the Medical Technolo-gy trade congress that is part of Rapid.Tech. Practising physicians and RM experts provide information about ap-plications and their potential.
Seventh Rapid Technology Trade Fair and Congresses Are Coming to Erfurt in May: Rapid.Tech 2010
Industry News
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These days, new scanning technol-ogy, CAD/CAM systems, processing machinery, materials and RP processes are driving change in dental technol-ogy and making dental laboratories more efficient and growth-conscious. The Dental Technology congress at Rapid.Tech 2010 offers dental techni-cians, dentists and dental market sup-pliers a critical and informative over-view of current trends.
Rapid.Tech 2010ERFURT, GERMANYwww.rapidtech.de
8 European Tool & Mould Making � April 2010 www.etmm-online.com
Industry News
Rofin-Baasel Lasertech has been recognized as one of 16 suppliers to receive Intel Corp.’s Preferred Quality Supplier (PQS) award for their performance in partnering with the processor manufacturing company in 2009. Rofin is ac-knowledged to have made a significant contribution by vir-tue of having providing Intel with laser-marking equipment that has been deemed essential to Intel’s success.
The PQS award is an element of Intel’s Supplier Con-tinuous Quality Improvement programme. To qualify for PQS status, suppliers have to achieve a score of 80% on a report card that assesses performance and ability to meet cost, quality, availability, delivery, technology and customer satisfaction goals, and also on a challenging improvement plan. In addition, they must demonstrate solid quality and business systems.
“It is a great honour for us to receive the Preferred Qual-ity Supplier award from Intel for the third consecutive year,” says Günther Braun, president and CEO of Rofin. “This award is the result of an excellent partnership and coopera-tion between both companies.”
Adds Ron Rinfret, Intel’s assembly capital equipment de-velopment director: “We were very pleased to see Rofin step up to numerous technical challenges in 2009 and make fur-ther improvements on their already world-class laser-mark performance. Intel is very appreciative of their demonstrat-ed excellence and their commitment to quality.”
At a March press conference hosted by the manufacturing technology association UCIMU-Sistemi per Produrre, it was announced that the Italian turnaround specialist Paritel Fi-nanziaria had added to its machine tool holding company IMT-Italian Machine Tools the grinding machine manufac-turer Tacchella Macchine. IMT now comprises that compa-ny, the grinding technology firm Morara, and De.Ci.Ma, a gear-cutting-machine company. It offers machines branded as Tacchella Macchine and Morara-De.Ci.Ma.
UCIMU chairman Giancarlo Losma emphasized the value of joining two prestigious Italian trademarks in the IMT project. “With the market’s globalization,” he said, “the way to do business has deeply changed. In this sense, the aggregation of companies proves a useful means of better guarding a position in the international marketplace, by im-proving the management of costs.”
Alberto Tacchella, vice chairman of IMT and immediate past chairman of UCIMU-Sistemi per Produrre, seconded Losma, saying that he was more than ever convinced that alliances are the right way to defend and enhance the excel-lence of Italian companies in the machine tool sector.
Luca Peli, chairman of IMT, also spoke at the press con-ference, explaining that “the IMT-Italian Machine Tools project is the realization of an industrial plan in support of development and profitability, allowing business consolida-tion and the defense of trademarks.”
Rofin-Baasel Receives Intel’s Preferred Quality Supplier Award for Third Time
UCIMU Hails Important Alliance of Machine Tool Names Tacchella and Morara
CGTech, the specialist in numerical control (NC/CNC) simulation, verifi-cation, optimization and analysis software technol-ogy, has released a partial 2010 schedule of European Vericut User’s Exchange (VUE) events at which at-tendees will learn about new Vericut® software fea-tures for improving CNC manufacturing efficiency. In addition, Vericut users at each VUE meeting will be able to make suggestions regarding possible fu-ture directions for the software.
The meeting locations and dates set so far are Worcester, UK, on April
CGTech Issues Schedule of Its First Interactive European Vericut User’s Exchange Events for 2010
on June 3; Sheffield, UK, on September 15; and Belfast, UK, on October 7. CGTech plans additional events for later in the year in Denmark, the Netherlands, the Czech Republic and Russia.
At each VUE event, the performance-improving en-hancements added in Veri-cut 7, many of them driven by customer requests, will be reviewed. Also part of each meeting is a workshop in
which CGTech engineers highlight spe-cific productivity features of Vericut.
22; Schkopau, Germany, on April 28; Jönköping, Sweden, on May 11; Glas-gow, UK, on May 12; Treviso, Italy, on May 25; Milan, Italy, on May 27; Brive, France, on June 1; Le Vésinet, France,
CGTech Ltd.HOVE, E SUSSEX, UKwww.cgtech.co.uk
Rofin-Baasel LasertechSTARNBERG, GERMANYwww.rofin.com
UCIMU-Sistemi per ProdurreCINISELLO BALSAMO (MI), ITALYwww.ucimu.it
Answers for industry.
Looking for a better way to machine the perfect mold?
When you make high-quality miniature plastic toy vehicles like BRUDER Spielwaren in Fuerth, Germany, your CNC system has already enabled you to master one decisive task: producing the perfect mold. And SINUMERIK® MDynamics does just that with its new Advanced Surface functionality – the new intelligent path control for perfect workpiece surfaces and significantly reduced machining times. www.siemens.com/sinumerik
SINUMERIK MDynamics: The expert milling package for perfect surfaces
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10 European Tool & Mould Making � April 2010 www.etmm-online.com
Industry News
Students at Sweden’s Royal Institute of Technology School of Architecture are using a ZPrinter® 650 multicolour 3D printer made by Z Corp. to produce a steady high volume of concept mod-els. The single printer supports more than 50 undergraduate and graduate students in the school’s design studio and technology seminar classes. The ZPrinter 650 was selected for its speed and low materials cost, because archi-tecture students need a constant flow of models to provide sensory feedback on their progress. The printer’s large build size contributes to its ability to keep pace with school requirements, even during finals when the machine is producing models around the clock.
Z Corp.’s ZPrinting technology also helps the school’s students learn the principles of fabrication technology, something often slighted in architec-ture education. Since the ZPrinter is so highly automated, students can han-
Swedish Architecture School Uses ZPrinting for Economical High-Volume Production of Student Concept Models
the school, notes that spatially ori-ented architects gain much more un-derstanding from seeing a design in three dimensions than from spinning around a virtual CAD model.
dle the entire printing process with minimal training. In addition, ZPrint-ing contributes to deepening their understanding of such academic con-cepts as performative design.
The biggest benefit, however, may be the value of holding a model in the hand. Daniel Norell, a lecturer at
Lüdenscheid Precision Mechanics Guild Meets at Strack NormaThe precision mechanics guild of Lüdenscheid, Germany, recently held a spring meeting hosted by Strack Norma GmbH, the producer of a wide range of standard parts for injection moulding and die-casting tools and for punching and forming tools. The guild consists of 51 member compa-nies from the district, whose repre-sentatives, before the meeting, were able to learn about Strack Norma’s comprehensive programme. Techni-cal manager Ludger Müller Strack told them about the new Power Max cam series and related punching tools, and the application engineer Klaus
Filthaut followed with a presentation on the in-house production of hot runner technology at Strack Norma, and applications for those products.
During a tour through the manifold production and logistics departments, the trade visitors gained an impression of Strack Norma’s production and de-livery capacity. Because short delivery times are important to its customers, the supplier faces daily the challenge of delivering some 130,000 stock arti-cles just in time.
Calendar of EventsMAY 2010 HIGHLIGHTS
May 4–7: Control 2010New Stuttgart Trade Fair Centre, Stuttgart, Germany 24th International Trade Fair for Quality Assurance www.control-messe.com
May 11–13: Amerimold 2010Duke Energy Center, Cincinnati, OH, USA Moldmaking and Tooling, Design and Application Development www.pdx-amerimold.com
Z Corp.BURLINGTON, MA, USAwww.zcorp.com
Strack Norma GmbH & Co. KGLÜDENSCHEID, GERMANYwww.strack.de
www.etmm-online.com April 2010 � European Tool & Mould Making 11www.etmm-online.com
Industry News
Specialist trade fair and user conference for rapid technology
ww
w.r
apid
tech
.de/
uk
18 + 19 May 2010
The annual venue for practitioners, developers and visionaries including:
· User conference
· Design engineer’s day
· Specialist conference “CAD/CAM and rapid proto- typing in dentistry”
· 1st specialist conference in medical engineering
Joint Stand on Trends in Metal-Working Technology Innovation at AMB 2010Survival in the turbulent and competi-tive metal-cutting technology business increasingly involves challenges relat-ing to rationalization and productivity maximization. Technology develop-ment, efficient use of energy, and lean machining are concepts that machine and tool manufacturers must consider in seeking to develop their potential. This is a theme that will be addressed at AMB 2010, the international exhi-bition for metalworking being held at the New Stuttgart Trade Fair Centre from September 28 to October 2. Un-der the motto “Trends of Tomorrow—Metal Working Innovation Tour,” the Institute for Production Management, Technology and Machine Tools (PTW) of the Technical University of Darm-stadt will be organizing a 540-m2 joint stand in Hall 5.
Along with about 25 exhibitors, the PTW will provide visitors with infor-mation on the five themes of energy-efficiency, lean machining, microcut-
Microsys Micro- and Nanotechnology Fair Set for September in StuttgartMicromechanics, micro–injection moulding, microelectronics, micro-optics, and microsystems technology—the Microsys trade fair for micro- and nanotechnology in R&D, production and applications engineering is an in-tegral platform for all of these manufac-turing applications. The next edition, Microsys 2010, takes place at the New Stuttgart Trade Fair Centre September 13–16.
With this, the 4th, Microsys, the organizer P.E. Schall GmbH has taken care to emphasize practical uses for micro- and nanotechnologies. This distinguishes Microsys from other events in this field that tend to be more theoretical and do not mediate between research and actual industri-al application. Schall has assembled a world-class advisory committee made up of representatives of research in-stitutes, industry associations and in-dustrial enterprises to ensure that the show will offer useful information for
ting, CAD/CAM and titanium cutting. The special stand will present the most important trends and the latest devel-opments in the world of cutting tech-nology. Innovative companies will ex-plain their latest research results and developments. In addition, in short talks given at the stand on all five fair days, exhibiting companies will sup-ply visitors with information about future-oriented metal-cutting trends.
Companies interested in participat-ing in “Trends of Tomorrow—Metal Working Innovation Tour” at AMB 2010 can now register. They should contact the PTW by e-mailing [email protected] or telephoning +49 6151 162156.
Messe Stuttgart anticipates that AMB 2010 will showcase some 1,200 exhibitors on 105,000 m2 and draw more than 75,000 trade visitors.
optimizing production and applica-tions engineering.
Microsys 2010 will be running concurrently with the 29th Motek international trade fair for assembly and handling technology and the 4th Bond expo trade fair for industrial bonding technology. P.E. Schall GmbH expects these co-located shows to pro-vide a context for presenting the proc-ess sequences for the production and application of micro- and nanotechni-cal products.
For several years, a microsystems technology theme park at the Motek fair has received a great deal of interna-tional attention. That field of technol-ogy is being seamlessly integrated into the 4th Microsys, providing exhibitors with the opportunity to act within their own target group setting and ex-pand their market position.
Microsys 2010STUTTGART, GERMANYwww.microsys-messe.com
AMB 2010STUTTGART, GERMANYwww.messe-stuttgart.de/amb
12 European Tool & Mould Making � April 2010 www.etmm-online.com
EuroMold News
In its premiere edition, the new Amerimold international trade fair for mould making and tooling, design, and appli-cation development already looks forward to showcasing numerous world market lead-ers by virtue of having regis-tered distinguished exhibitors from three continents. Ame-rimold 2010 is scheduled to take place in Cincinnati, Ohio, in the heart of the Unit-ed States, on May 11–13. Ac-cording to the show organizer, DEMAT GmbH, the creator of the industry-leading Euro-Mold trade fair, more than 120 exhibitors had signed up for the first Amerimold by the end of February. DEMAT foresees the eventual number of Amerimold 2010 exhibitors falling somewhere between 140 and 180.
Exhibition with ConferenceSuch renowned companies as Carl Zeiss, Buchem Chemie + Technik, Dassault Systèmes, EOS, Objet Ge-ometries, E. Zoller and Stratasys have already booked space in Cincinnati. Besides the United States, the home countries of participating exhibitors will include, among others, the indus-trial powerhouses Germany and Chi-na. DEMAT expects its new trade fair venture to attract from 4,000 to 6,000 professional visitors over the three days of the inaugural event.
Amerimold provides a compre-hensive framework programme that includes high-quality conference ses-sions that will cover the topics of rapid prototyping and manufacturing,
World Market Leaders Have Signed Up to Exhibit at the First Amerimold in Cincinnati in May
and has the objective of establishing the leading exhibition for mould mak-ing and tooling, design, and applica-tion development in the USA.
Amerimold presents the complete range of mould making and tooling and related technologies as a first pri-ority, but the show will focus also on additive technologies such as rapid manufacturing and rapid prototyping.
Being sited in Cincinnati, Ame-rimold draws attention to one of the most important centres of product de-velopment in the United States. Such notable companies as Procter & Gam-ble, Johnson & Johnson, Toyota and GE Aviation have their headquarters in Cincinnati and create a huge de-mand for the development of innova-tive products.
Valve Gate Solutionsmaximum flow
total controlultimate part
and industrial design. Further, the pro-gramme offers workshops in the areas of tools for injection moulding, tool-making innovations, and the globali-zation of mould making and tooling. In addition, at the first Amerimold the prestigious Leadtime Leaders Awards will be bestowed for the eighth time. These awards recognize outstanding innovations within the field of mould making and tooling.
The EuroMold ConceptWith its new Amerimold trade fair and conference, DEMAT exports its successful and well-established Euro-Mold concept to North America. The trade event organizer is putting on Amerimold in cooperation with Gard-ner Publications Inc., the Cincinnati-based publisher of industry magazines and producer of websites and events,
Amerimold 2010CINCINNATI, OH, USAwww.pdx-amerimold.com
www.etmm-online.com
EuroMold News
Afrimold Trade Fair Premiering in August in Johannesburg Brings EuroMold Concept to Another Continent
With the premiere of Afrimold, which will take place August 16–18, 2010, at the Sandton Convention Centre in Johannesburg, South Africa, DEMAT GmbH launches its successful Euro-Mold concept in an African setting. South Africa has made tremendous strides in product development, tool-ing and mould making in recent years. Afrimold 2010, the international trade fair for mould making and tool-ing, design, and application develop-ment, is an acknowledgment of this growth.
Many European companies have a presence in the Republic of South Af-rica, a country whose major industries are automobile manufacturing, metal processing and machinery produc-tion. Important South African trading partners are Germany, the USA, the UK and Japan. Intended to close the geographical gap between Africa and its far-flung suppliers, Afrimold will serve as a strategic platform for high-lighting mould making and tooling and enhancing product development throughout Africa and also for advanc-ing business, technology and design on the continent. The technology exhibition will be accompanied by a technical conference. Both offerings
afford networking opportunities for exhibitors and visitors alike.
Sandton Convention Centre is DE-MAT’s partner in this venture. In ad-dition, the Toolmaking Association of South Africa is lending assistance, guaranteeing a high level of industry support for the premiere. The exhibi-tion is scheduled during the European summer trade fair break, but interna-tional exhibitors should note that Au-gust is the South African high season.
South Africa now serves as a hub and trading centre for Asia and South America. The nation strongly pro-motes its domestic industry but still requires support from Europe and the United States. Afrimold is expected to exert an influence on neighbour states and strengthen South Africa’s supply markets.
Visitors to EuroMold from African countries had previously conveyed to DEMAT the strong need they felt for a local fair of their own. The result? In August, South African suppliers can meet their customers at home and en-deavour to open up markets that have been difficult to reach.
Our precision is the basis of your quality
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Unlimited innovationsThe product range “Solid carbide drills” of Inovatools includes the diameters starting from �0,5 mm - �20,0 mm, with coolant hole or without coolant hole and for drilling depths from 3xD - 15xD.
Top quality Top prices Made in Germany
Afrimold 2010JOHANNESBURG, SOUTH AFRICAhttp://afrimold.demat.com
14 European Tool & Mould Making � April 2010 www.etmm-online.com
ISTMA
The International Special Tooling & Machining Association (ISTMA) is a well-established international organi-zation representing more than 30 na-tions’ special tooling and machining organizations across three continents: North America, Europe and Asia.
ISTMA Europe represents the in-dustry in matters concerning indus-trial relations in the European Union. Among its many activities, it conducts
Directory of ISTMA Europe Member Associationsa dynamic schedule of exchanges on technical subjects in the special tool-ing and machining sector; promotes communication among its members on a wide variety of industry concerns; maintains an information pool on technical investigation subjects; trans-fers performing management actions among its member associations; and supports European fairs and exhibi-tions focusing on special tooling.
CZECH REPUBLICTool Factories AssociationSvaz [email protected] Armady 118156215 Usti nad OrliciTel.+420 465 557101 · Fax +420 465 525128www.svaz-nastrojaren.eu
ESTONIAEstonian Special Tooling AssociationMr. Andres [email protected] tee 1 · 74001 Viimsi vald, Harjumaa Tel. +372 620 5902 · Fax +372 620 5901www.emliit.ee
FINLANDTechnology Industries of FinlandMr. Veli Matti [email protected]äranta 10 · 00130 HelsinkiTel. +358 9 1923373 · Fax +358 9 624462www.techind.fi
FRANCEAFIM (Association Française des Industries du Moule, Modèle et Maquette)Mrs. Catherine [email protected]/41 Rue Louis Blanc · 92400 CourbevoieTel. +33 1 47176412 · Fax +33 1 47176360www.afim-france.com
GERMANYVDMA Die and MoldDr. Wolfgang [email protected] Strasse 18 · 60528 Frankfurt/MainTel. +49 69 66031251 · Fax +49 69 66032251www.vdma.org
HUNGARYSZMSZ (Hungarian Toolmakers Association)Dr. Sándor Markos · [email protected] u. 31/C · 1139 BudapestTel. +36 1 3402972 · Fax +36 1 3295425www.szmsz.hu
ITALYUCISAP (Unione Costruttori Italiani Stampi & Attrezzature Precisione)Mrs. Fausta Antinori · [email protected] Fulvio Testi, 12820092 Cinisello Balsamo (MI)Tel. +39 02 26255392 · Fax +39 02 26255214www.ucisap.it
LATVIALatvian Tool and Prototype Producer AssociationMrs. Natãlija Ivanova · [email protected] str. 2c · Riga 1046Tel. +371 678 07794 · Fax +371 678 07780www.lipra.lv
POLANDStowarzyszenie Techniczne - Tworzywa SztuczneMr. Maksymilian [email protected], ul. Graniczna 1005-816 MichalowiceTel. +48 22 7233812 · Fax +48 22 7235201www.stts.com.pl
PORTUGALCefamol (Associaçao Nacional da Industria de Moldes)Mr. Manuel Oliveira [email protected]. D. Dinis 17, Aptdo. 2572430-263 Marinha GrandeTel. +351 244 575150 · Fax +351 244 575159www.cefamol.pt
SLOVENIAChamber of Commerce and Industry of Slovenia (Metal Processing Association)Ms. Janja [email protected] 9 · 1504 LjubljanaTel. +386 158 98308 · Fax +386 158 98100www.posvet-orodjarstvo.com
SOUTH AFRICAToolmaking Association of South Africa (TASA)Mrs. Alet Balaam · [email protected] Alexander Road, WestmeadKwazulu Natal · P.O. Box 661 · 3600 PinetownTel. +27 31 7005563 · Fax +27 31 7005562www.tasaweb.co.za
SPAINFEAMM (Federación Española de Asociaciones Empresariales de Moldistas y Matriceros)Mr. Josep Font · [email protected] Tecnològic del Vallès, Ceramistes 208290 Cerdanyola del Vallès (Barcelona)Tel. +34 93 5944747 · Fax +34 93 5944737www.feamm.com
SWEDENSvensk Industriförening (SINF)Mr. Niklas Eidersjo · [email protected] 14, P.O. Box 22307104 22 StockholmTel. +46 8 4401170 · Fax +46 8 4401171www.sinf.se
SWITZERLANDSwissmem (Swiss Mechanical and Electrical Engineering Industries)Mr. Peter Vogel · [email protected] 4, 8032 ZürichTel. +41 44 3844811 · Fax +41 44 3844846www.swissmem.ch
TURKEYTool Manufacturers’ Association of Turkey (UKUB)Mrs. Solmaz Ugurlar [email protected] Karaer Cad. Cigdem 2 Sok.PK:41 DOSAB, BursaTel. +90 224 2615892 · Fax +90 224 2615893www.ukub.org.tr
UNITED KINGDOMGTMA (Gauge and Tool Makers Association)Mrs. Julia Moore · [email protected] Forge House, Summerleys RoadPrinces Risborough, Bucks HP27 9DTTel. +44 1844 274222 · Fax +44 1844 274227www.gtma.co.uk
For information, contact:Mr. Fausto RomagnaniSecretariat, ISTMA Europec/o Cefamol · Av. D. Dinis 17, Aptdo. 2572430-263 Marinha Grande, PortugalTel. +351 244 575150 · Fax +351 244 [email protected]
April 2010 � European Tool & Mould Making 15www.etmm-online.com
The 13th International Special Tool-ing & Machining Association World Conference (ISTMA World) will be held June 20–24, 2010, in Windsor, Ontario, Canada. The hosting organization for ISTMA World is the Canadian Tooling & Machining Association (CTMA). Taking place at the same time and place is the 11th International Pattern-Model Makers Congress, for which the Canadian Pattern-Modelmakers Asso-ciation serves as host. A four-page bro-chure and registration form is avail-able for the convenience of industry members interested in attending these important meetings, which occur only once every three years.
The theme of ISTMA World 2010 is “Global Opportunities for Special Tooling & Machining Companies.” On Wednesday, June 23, attendees have a chance to find out what these opportunities are by auditing the 16 technical sessions that fill the day. Ses-sion topics include practical ways to
ISTMA
get tools into production faster and at less cost; worldwide tooling trends and production; new CAD software that can reduce engineering time; de-velopments in tooling materials; ad-vanced tool surface treatments; EDM machining conditions; and injection mould engineering techniques. Other talks will focus on business improve-ments for tool shops; enhanced serv-ice provision in the tooling industry; international trends in workplace health and safety specific to the in-dustry; and the European Manufuture tooling platform.
Tuesday is the day set aside for plant tours. Fifteen mould and tool in-dustry–related companies in Windsor will open their doors to those in town for ISTMA World. These local opera-tions are all within a few minutes of each other as well as near to the con-ference site.
On June 20, the ISTMA World board meets. That Sunday culminates in the
Full Schedule of Events and Activities for the Next ISTMA World Conference in June Is Detailed
Welcome Dinner for all attendees. On Monday morning, the three ISTMA regional associations hold their meet-ings. The centrepiece of the week is the ISTMA annual meeting, which oc-cupies Monday afternoon.
Canadian Tooling & Machining Association (CTMA)WINDSOR, ON, CANADAwww.ctma.com
16 European Tool & Mould Making � April 2010 www.etmm-online.com
Special Report
The 4th Bursa Mould Technologies and Side Industry Fair, being organ-ized by Tuyap Bursa Fairs Organization Inc. in cooperation with Prestij Publi-cation and with the support of UKUB (the Tool Manufacturers’ Association of Turkey), Bursa Metropolitan Mu-nicipality and the Bursa Chamber of Commerce and Industry, takes place at the Tuyap Bursa International Fair and Congress Centre May 6–9, 2010. On those dates, Mould Eurasia 2010 will be accompanied by Packaging–Plastic 2010 (the 9th Packaging and Plastic Industry and Rubber Fair) and Bursa Autotechnic 2010 (the 3rd Automo-tive Side Industry, Garage and Serv-ice Equipment, Gas Station Equip-ment and LPG Sys-tems Fair).
Enterprises ex-hibiting at the Mould Eurasia fair will display the full range of mould making capabili-ties, along with mould processing and manufactur-
Turkey’s Leading Trade Fair for Mould Making and Related Industries, Mould Eurasia, Returns to Bursa in May
ing machines and equipment, mould care and repair services, standard mould components and technical hardware, raw materials and semifin-ished products, CAD, CAM and CAE applications, prototyping and rapid prototyping/manufacturing technol-ogies, mould and industrial product design services, and much more.
In addition to the exhibition, the event will include conference semi-nars in which foreign and domestic academics, industrialists, engineers and sector professionals will illumi-nate important aspects of the Turkish moulds sector for fair visitors.
Mould Eurasia 2009 and the co-located trade fairs hosted 15,621 visi-tors from 28 countries throughout Europe, Western Asia and Africa and from 30 Turkish cities with concen-trations of industrial enterprises that employ moulds in production opera-tions. A successful event despite the global economic conditions, last year’s
Mould Eurasia fair featured the partici-pation of 275 exhibiting companies who hailed from 20 nations.
Professional visitors to the 2009 edition of Mould Eurasia—those who identified themselves as consumers of the products and services on ex-hibit—mainly represented the moulds industry (40.6%), mould process-ing and manufacturing technology (29.1%), the plastics-processing indus-try (16.8%), the automotive industry and its suppliers (3.4%) and mould care and repair services (2.5%). On the basis of a survey, the event organ-izer determined that 32.5% of these visitors were responsible for corporate general management and 23.8% were the sole decision makers within their company. Ninety-one percent of the surveyed visitors in 2009 indicated that they intended to come to Mould Eurasia 2010.
Mould Eurasia is the most compre-hensive trade exhibition the burgeon-ing industrial nation of Turkey has to offer. Its location in Bursa, where Europe and Asia meet, symbolizes the strategic position of Turkey as a link between the mature high-technology industries of Europe and the energetic industrial development of the non-Western world.
UKUB: Turkey’s Voice in ISTMAEstablished eight years ago and headquartered in Bursa, the Tool Manufacturers’ Association of Turkey (UKUB), which supports the effort to present the Mould Eurasia fairs, is a member of the International Special Tooling & Machining Association (ISTMA). UKUB coordinates Turkish mould manufacturers in order to increase their global competitiveness, cooperates with other national associations in the same sector, and strives to elevate the quality of both management and employees working in the Turkish tool and mould industry. Of its 112 members, 96 are toolmaking companies and 12 are educational institutions.
Mould Eurasia 2010BURSA, TURKEYwww.tuyap.com.tr
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Special Report
Additive manufacturing (AM) technology is having a profound impact on the way some companies manu-facture products. These or-ganizations—some of them very small—are successfully applying the rapid proto-typing and manufacturing technology to the produc-tion of finished goods, carry-ing the technique’s range of applications beyond design review and validation, fit and function prototyping, pattern making and tooling construction. Wohlers As-sociates Inc., the US-based consulting firm that special-izes in analyzing the rapid product development and additive manufacturing market, be-lieves that this practice will grow and will eventually become the most sig-nificant application of the technology.
In the future, according to Wohlers Associates, many organizations will use AM technology to manufacture a
wide variety of custom and limited-edition products and replacement parts. Companies will employ the technology for short-run and series production in quantities ranging from a single part to thousands of units.
AM in the Consumer MarketRecently, an impressively large number of consumer items produced via AM have become available for purchase from multiple sources. For
Direct Part Production via the Software-Based Additive Manufacturing Technique Is Following a Growth Curve
example, FigurePrints, a company founded by former Microsoft vice president Ed Fries, manufactured 1,700 custom products by means of the additive technique for players of World of Warcraft in October 2008. This came only 10 months after the
company had launched the manufac-turing service.
Metaltec Innovations, a division of ProMetal, uses AM to produce custom pulls, knobs and knockers for doors. In addition, the company manufactures metal sculptures for homes and busi-nesses, as well as custom decorative tile that includes special themes and intricate detail.
The MGX division of Materialise in Belgium was launched in 2004. This group applies methods of additive
Expected growth of additive manufacturing technology for part production applications, in terms of current and estimated future percentage of business in AM. Source: Wohlers Associates Inc.
manufacturing in the production of limited-edition lighting designs, furniture and other home and office acces-sories. The complexity of most of the designs in the collection makes it infeasible to produce them economically any other way. MGX did about $2 million worth of business in 2009, most of it involving the selling of around 1,500 lamps. So far, about 10,000 MGX lamps have been sold worldwide.
Future ProspectsCompanies operating in the additive manufacturing field are optimistic about the future growth of AM for part production applications. Organi-zations representing thousands of AM technology users and customers around the world responded to a sur-
vey conducted by Wohlers Associates on the subject. They collectively believe that AM part production will represent 35.9% of their business in five years, as shown in the graph. In 10 years, say these same companies, manufacturing by means of the rapid tech-nique should constitute more than half (50.5%) of their business. The survey respondents reported that AM part production made
up 15.6% of their business in 2008.Much of the information in this
article was taken from Wohlers Report 2009, a timely 250-page global study that focuses on advances in additive manufacturing worldwide. A detailed overview of the report, along with ad-ditional information on the AM mar-ket and industry, is available at the Wohlers Associates website.
Wohlers Associates Inc.FORT COLLINS, CO USAwww.wohlersassociates.com
DESIGN
ERS WILLIAM
MCDO
NALD AN
D SULAN KO
LATAN O
F KOL/M
AC LLC
Exhibit with DEMAT worldwide!
www.demat.com
Fairs + ExhibitionsDEMAT
December 1 – 4, 2010Frankfurt /Main, Germany
May 11 – 13, 2010Cincinnati, USA
June 2 – 4, 2010Moscow, Russia
March 18 – 21, 2010Mumbai, India
August 16 – 18, 2010Johannesburg, South Africa
September 15 – 17, 2010Guangzhou, China
Partner Country Turkey
at EuroMold 2010
20 European Tool & Mould Making � April 2010 www.etmm-online.com
Technology
The rapid development of modern 3D CAD systems has facilitated the evolution of product design and has resulted in a move to more-organic product forms and ever-increasing ge-ometric complexity. Just think about the change in design from the con-ventional box-shaped vacuum clean-er to the modern Dyson. This article focuses on design fundamentals for plastic products in six basic areas and the impact of these on engineering and production processes.
Consistent Wall ThicknessDesign engineers need to try to maintain a consistent wall thickness throughout the entire product model. Any substantial variation in part thick-ness can cause major moulding issues to arise, such as internal voids, surface sink marks, unpredictable shrink rates and, ultimately, longer cycle times (Figure 1). If a change in wall thick-
Complexity versus Manufacturability: Plastic-Product Design in an Era of Sophisticated 3D CAD Systems
ness is necessary, the transition from one thickness to another should be smooth so as to ensure easy material flow and thus prevent the creation of critical stress points that could cause part failure during product testing and necessitate a revision of the part de-sign or the introduction of additional tooling costs.
Detecting manufacturability issues at the design stage prevents costly re-working and saves valuable time dur-ing later production stages.
Rib DesignIn creating rib patterns, it is important to remember that ribs are there only to increase part rigidity and should not be compromised for aesthetic reasons. If possible, a combination of thin and thick ribs should be avoided. Design engineers typically follow standard guidelines for rib design, the most com-mon of which include the following.
• Rib thickness should be 60 to 80% of the nominal wall thickness.
• Maximum rib height should not exceed three times the nominal wall thickness. (To increase prod-uct rigidity, it is better to increase the number of ribs rather than rib height.)
• Minimum spacing between ribs should be two times the nominal wall thickness.
• Fillet radii that are applied to ribs should be no greater than 50% of the rib thickness.
• Extra-thick ribs should be cored out.• Cross-ribbed patterns are preferred
(if the design allows), as they offer greater loading permutations and ensure uniform stress distribution.
BossesBosses are a fundamental element of plastic part design in that they offer strengthening properties and provide alignment during assembly. As in rib design, it is important to consider wall thickness when designing bosses. Ob-serving a few design guidelines will help prevent surface imperfections such as internal voids and surface sink marks, as well as unpredictable shrink rates. They are as follows.
• The boss thickness should be 60% of the nominal wall thickness unless the thickness of the part is greater than 4 mm, in which case boss thickness can be reduced to 40% of the nominal wall thickness.
• The boss height should not exceed 2.5 times the diameter of the hole in the boss.
• Corner bosses integral to side walls will result in excess material accu-mulation (Figure 2).
Fillet radii should be applied at the base of a rib or boss for better stress distribution. If no fillets are applied, high stress-concentration peaks oc-cur. This will often lead to cracking and part failure. Note, however, that if the fillet radii applied are too large, ex-cess material accumulation can occur, which may lead to voids or sink marks
Figure 1: Excess material accumulation where wall thickness changes may result in voids or sink marks.
Figure 2: Corner bosses integral to side walls will result in excess material accumulation (a), so bosses with orthogonal flanges are a preferred corner design (b).
a b
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www.etmm-online.com
Technology
Figure 3: Part thickness analysis enables designers to identify potential model problems and move more quickly to the prototyping and production stages.
during the moulding cycle. This same principle holds in places where a rib or boss meets the edge of the component.
Fortunately, CAD systems are beginning to introduce analytical tools to calculate and display the thickness of a CAD model and thus help identify potential problem zones (Figure 3). Two methods are typically available. The first is based on the largest sphere that can be placed within the model without intersecting any other face. The second is the more traditional shooting-ray method, which shoots a ray through the model along the surface normal until it hits a second face.
Draft AngleThe need to add draft angle to a model is well understood, but often ignored during the design stage. While this may seem like a trivial task, if the taper is not added at the right point within the history tree (if applicable), or if complex fillets are subsequently added, the task becomes consider-ably more complex.
Draft angle is an important feature of a moulded part that allows it to be extracted from a mould cavity without issues. The high pressures involved in injection moulding, along with material contraction, often make it difficult to remove the part. While it is possible to mould parts with zero draft (or even negative draft) by using side cores, lifters or two-stage ejection, these features dramatically increase the complexity and cost of the tool.
Although no formula for defining the correct draft angle for a certain part exists, there are many factors that have an impact on the optimum value. Draft angle analysis enables designers to identify potential moulding issues prior to core and cavity construction (Figure 4).
Thin-walled parts that undergo high-pressure injection moulding generally need more draft as the material is forced in, which results in a tighter grip on the cavity. Equally, parts that are subjected to lower-pressure moulding forces can have less draft.
For smooth surfaces, generally a minimum of 0.5° draft per side is recommended, although experience has shown that a draft angle of 1° per side provides easy ejection for most surfaces. Textured surfaces are slightly different, as the nonuniformity will result in dragging and scuffing, ruining the intended effect if the draft angle is insufficient. As a gen-eral guideline, a minimum of 1.5° per 0.025-mm depth of texture has to be allowed for in addition to the normal draft amount.
22 European Tool & Mould Making � April 2010 www.etmm-online.com
Technology
The depth of draw (as with deep ribs) is a very important considera-tion. This is because, on the one hand, ejection becomes easier as the distance of draft becomes greater, while, on the other hand, the thickness of the geom-etry becomes greater as well. As men-tioned earlier, dramatic changes in thickness from one part of the model to another may cause the appearance of internal voids or surface sink marks
and unpredictable occurrences of warpage. For example, a draft angle of 1° over a drop of 100 mm would in-crease part thickness by 1.75 mm per side (Figure 5).
Although the polymer from which the part is to be moulded may not be known yet at the design stage, that material, once chosen, can have a determinating effect on the draft an-gle required. For example, materials with fillers, such as glass-filled resins, tend to exhibit less shrinkage and will therefore not move away from the cavity wall. In this case, larger draft
angles are necessary.Holes are easy to produce in moulded parts and are typi-cally created using core pins. However, blind holes with zero draft can cause a vacuum
effect at the top of the core pin during ejection, most often in
parts with a polished finish. In such a case, a small draft angle will break the seal and improve ejection. Ultimately, the easier it is to remove the part from the mould, the fewer the number of ejector pins required.
Part RadiiA significant number of plastic parts fail because of sharp corners or insuf-ficient radius. Sharp corners create lo-calized stress concentrations that tend to promote crack initiation and cause premature part failure. The addition of fillet radii to all sharp corners will not only reduce stresses but also im-prove plastic flow. As a general rule, at
Figure 4: Draft angle analysis enables designers to identify potential moulding issues prior to core and cavity construction.
April 2010 � European Tool & Mould Making 23www.etmm-online.com
Technology
corners the inside radius is 0.5 times the material thickness, and the outside radius should amount to the material thickness plus the part thickness. A larger radius should be used if the part design allows it.
Injection Gate PositionIt is often preferable to gate onto the thickest section of the component in order to reduce the possibility of sink-
ing due to insufficient material pack-ing. Fixing the gate location ultimately determines the filling behaviour, weld lines, shrinkage, warpage and surface quality of the moulded part.
Weld lines are junctures where two plastic flow fronts meet and form a rel-atively weak bond. These are the areas most likely to fail when the part is un-der stress. Complex mouldings will al-ways contain weld lines. If the number of lines cannot be reduced, then they
should be moved to noncritical areas of the component. This is typically achieved by moving the gate location or, if the design allows, changing the part’s wall thickness.
ConclusionWhile the plastic-product design principles discussed in this article are generic and cannot all be applied to every scenario, they constitute a solid base from which to start any design process. A designer who is about to shell out a model or drop in some strengthening ribs should consider the impact these decisions will have on the production cycle.
In the engineering world, project success depends on continually mak-ing compromises between product design details and the imperatives of production feasibility.
This article is edited from a text written by Marc Freebrey and supplied by Vero Software plc.
Figure 5: The effect on part thickness when draft is added over the total length of a rib is clearly visible.
Vero Software plcCHELTENHAM, GLOS, UKwww.vero-software.com
24 European Tool & Mould Making � April 2010 www.etmm-online.com
Technology
A new drill programme from Inova-tools, the German tools group that is a business of Eckerle & Ertel GmbH, has been given a name that reflects the manufacturer’s conviction that the high-quality, aggressively priced drills should capture a good share of the metal-cutting market through their improved performance and efficiency. It is called the Drill Offensive 2010.
The Drill Offensive consists of sol-id-carbide drills with an innovative carbide substrate, special geometries and in-house-developed coatings, all of which have been engineered to make these tools more powerful and effective than their predecessors. An extensive assortment of both polished and coated solid-carbide drills is of-fered through the programme.
The new Inovatools range com-prises four tool families. First is a series of extra-short solid-carbide twist drills available in diameters ranging from 3.0 mm to 20.0 mm. Also available is a solid-carbide drill with integrated coolant holes. This drill comes in a wide range of diameters, from 1.0 mm up to 20.0 mm, and in shaft lengths extending from 3 times diameter to 15 times diameter. It is offered in universal and INOX designs.
The next tool in the Drill Offensive programme is a straight-fluted, right-hand-cutting, high-performance solid-carbide drill that features a TiAlN coat-ing. This drill has a cylindrical shaft and is avail-
Innovative Solid-Carbide Drills with Special Geometries and In-House Coatings Shed Chips Easily, Allow Faster Work
a special geometry de-signed to accommodate
drilling applications involv-ing ele vated feed rates. These
small drills have diameters be-tween 1.0 mm and 2.9 mm.All of these tool families are avail-
able in diameters scaled in increments of 0.1 mm.
The carbide substrate that Inova-tools uses to produce these drills was chosen to guarantee a long operation-al lifetime. The tools are manufactured in a brand-new production facility using state-of-the-art grinding ma-chines. Capable of extremely precise finishing, the grinders produce drills with optimum surfaces and close tol-erances. Among the beneficial results of this high level of production so-phistication is excellent runout accu-racy when the drills are used in ma-chining various types of steel and cast iron, INOX, aluminium alloys, copper, bronze and brass.
Drill performance is boosted by the special design geometry with a newly
developed chip space. This considera-tion makes for high cutting values and optimizes chip removal during the machining process.
The drills’ smooth special coatings make the chips flow off even faster, which dissipates heat from the con-tact area quickly; thus, the workpiece remains undamaged, even at high cutting speeds. In addition, the high-performance coatings minimize wear and increase cutting-edge stability and heat resistance.
Because Inovatools does all of its own tool coating, the full value chain, as well as all manufacturing processes and quality steps, is under in-house control.
Ultimately, the drills in the new Inovatools programme are designed to satisfy future production demands and perfectly translate the accuracy and efficiency of modern CNC ma-chines into chips.
able in diameters of 1.0 mm to 14.0
mm. It is suited for drilling materials as
hard as 65 HRc.Finally, there is the
Mini family of uncoated self-centring solid-carbide
twist drills manufactured ac-cording to factory standard. The
tools have a cylindrical shaft and
Jochen Eckerle manages production of the new drills.
InovatoolsKINDING/HAUNSTETTEN, GERMANYwww.eckerle-ertel.de
26 European Tool & Mould Making � April 2010 www.etmm-online.com
Wincor Nixdorf AG is one of the world’s most successful providers of information technology solutions for banks and commercial enterprises. Its commitment to innovation in every area means that the company is very well equipped to cope with difficult economic periods. For instance, as Michael Schönbeck, Wincor Nixdorf’s head of technology lines, points out, the company uses only the best tech-nology available. Not only is the plant machinery consistently optimized, but it is all controlled by the Sinumerik 840D sl CNC from Siemens AG.
Over the past few years, Schönbeck has restructured the tool shop, where 65 employees manufacture around 300 tools per year for in-house use. The company also performs machin-ing work for external customers and in return buys in the services of other mould manufacturers. This leads to a high degree of flexibility and opti-mum utilization.
Uniform Control ArchitectureToolmaking at Wincor Nixdorf is fo-cused on complex finish-machining. Prefabricated master dies are procured just in time and are then processed fur-ther with the same level of efficiency. Thus, more than 15 years ago, Schön-beck saw that milling would become the most-strategic production method in his tool shop. High-speed milling machines could be used to produce surfaces that require only a minimum of finishing. So, he thought, which control systems would be able to achieve the necessary speeds while also offering the functionality to proc-ess the required volumes of data?
“We used to deploy a variety of CNCs,” Schönbeck explains, “so we were able to compare different prod-ucts objectively based on experience. And of course we also took a close look at the current and future generations of controllers at the time.” Twelve years ago, the Wincor Nixdorf tech-nology manager made the decision to equip a milling machine with the Sinumerik 840D sl. He was extremely pleased with the results and soon es-
‘One for All’: Musketeers Aside, the Motto Serves for a Tool Shop That Standardizes All Machines on One CNC
tablished a uniform control archi-tecture throughout the entire shop. This was enormously beneficial for machine operators and also improved company logistics.
Machines Matched to TasksStandardization is important to Win-cor Nixdorf in selecting production machinery as well. Potential machine tool suppliers have to offer a wide range of products and provide a suit-able solution for every machining task. The company selected the DMG Group, whose high-quality HSC 75 linear machining centre with direct drives it uses for electrode production, to be its partner in this area.
“After all, the best control sys-tem on the market is useless to us if the machine cannot achieve the re-quired surface or is too slow,” remarks Schönbeck. He is delighted with both the machining times and the surface quality achieved on graphite and cop-per electrodes. The machine virtually eliminates finishing work, Schönbeck says. This positive experience encour-aged Wincor Nixdorf to purchase a larger, equally powerful machining centre for its shop.
The company opted for DMG’s HSC 105 linear, which is ideal for medium-sized 5-axis-machined parts. This machine has a very large work-ing area relative to its overall size. Not only does the fork head provide a high
The 5-axis HSC 105 linear milling centre, when it is equipped with the Sinumerik 840D sl CNC as at Wincor Nixdorf, is perfect for high-precision tasks and is also very easy to operate.
Case Studies
Siemens AGNUREMBERG, GERMANYwww.siemens.de/sinumerik
Cell phone, printed onan Objet 3D printer
3D Printing? It’s time to call Objet
To make the best choice for your business,
For more information: [email protected] www.objet.com
visit us atApril 19-23 2010, Hannover, Germany, Hall 17 Booth G58
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Case Studies
level of machining freedom, but the axes also achieve impressive accelera-tion and speeds. This is made possible in part through the use of 1FN3 linear motors, which offer significant ben-efits in terms of precision, dynamics and acceleration. In order to provide optimum compensation for thermal influences and ensure clean swarf re-moval, machine builder Deckel Maho uses vibration-reducing material and intricately designed machine geom-
etry. When machining times must be short, the interaction of this machine geometry, the linear motors and the Sinumerik CNC ensures very high axis acceleration and speeds.
Powerful, User-Friendly CNCMichael Schönbeck is certain that the Sinumerik CNC contributes sig-nificantly to the results obtained, pro-nouncing it the “fastest control sys-
tem both in terms of batch processing and cycle times.” Moreover, the con-figurable and programmable zero off-sets known as frames are simple and flexible to set and can be transferred to the machine at the touch of a button.
The more elaborate the programme, the more important these features are. Siemens provides a very user-friendly feature—the Shop-Mill graphical user interface—that offers a quick and easy way of creating programmes. Al-though of only limited importance at Wincor Nixdorf, where more than 90% of complex programmes are created on external CAD/CAM work-stations, this interface still provides valuable assistance to the machine operators: its setup and tool manage-ment functions are extremely useful in preparing workpieces for machining.
Siemens consultant Ingo Bartsch sums it up: “Our interface software is intuitive and features graphical ani-mations, making setup so simple that even untrained employees can pick it up within a few days.”
28 European Tool & Mould Making � April 2010 www.etmm-online.com
Case Studies
“When we started using the Con-nex500™ in our lab, it was a quantum leap for us.”
Hugo Arnold, head of prototype manufacturing at Geberit Group, a Swiss developer and manufacturer of sanitary technology products such as plumbing fittings and drainage and wastewater systems, was already familiar with the utility of 3D printing technology available from Objet Geometries Ltd., because Geberit had been using an Eden260™ printer to perform in-house prototyping since 2005. In-house 3D printing capabilities, replacing CNC machining of proto-types and the occasional outsourcing of prototypes needing to be built via 3D printing, had enabled Geberit to transform its product development process; feasibility testing and fit and function testing with high-pressure running water could all be undertaken on-site while still in the early product design stages. But when the company acquired the advanced Connex500 multimaterial 3D printing system in 2008, it gained a real competitive advantage by becoming the first en-terprise in its sector to have in-house multimaterial 3D printing capabilities.
Geberit purchased the Connnex500 because it wanted to reduce post-prototyping assembly requirements substantially and, ultimately, shorten time-to-market. The technology was quite new, but the company had con-fidence in Objet. “We are real fans of
Multimaterial 3D Models Help Company Save Product Development Costs through Early Feasibility Studies
Object, due to the model quality and, in particular, the superior surface qual-ity and fine features,” explains Arnold.
The Connex500 uses Objet’s PolyJet Matrix™ technology, which is the only method available for producing 3D parts and models from multiple ma-terials with different physical proper-ties in a single build. Intrinsic to the technology is the Digital Materials concept: composite model materials are generated on the fly to provide a very wide variety of properties.
Geberit considers the quality and smoothness of model surfaces, the large build-tray size, and the range of hardness values attainable with Digital Materials Pack2 to be key advantages of the Connex500. The new Tango-BlackPlus model material, which of-fers improved part strength, opens up a very nearly unlimited range of new
applications, according to Arnold.Significantly, Geberit can now con-
duct feasibility testing very early in the design process. Product design-ers use the Connex500 to print four or five different designs for any part, simultaneously, along with free-form rubber parts for sealants and gaskets. This enables them to figure out the optimal solution in terms of flow con-trol, water pressure and noise reduc-tion. By simulating the installation and removal of part assemblies, they can evaluate and optimize tight spaces in the design.
“We save considerable time and money in product development and hence reduce time-to-market, thanks to Objet,” says Hugo Arnold.
With their close resemblance to the end product in terms of look, feel and function, multimaterial parts pro-duced on the Connex500 provide val-uable support to Geberit’s internal and external marketing processes when used in all sorts of presentations. The 3D printer has also led to better com-munication between engineers, prod-uct designers and the rapid prototyp-ing department, and it has enhanced creativity at the firm in that it chal-lenges developers to test more design ideas for future products.
Objet Geometries Ltd.REHOVOT, ISRAELwww.objet.com
April 2010 � European Tool & Mould Making 29www.etmm-online.com
In order to achieve the company goal of boosting productivity and quality, NC programmers at the Canadian die manufacturing company EXCO Engi-neering have been phasing out several different brands of CAM software in favour of the flexibility and capability offered by the PowerMill CAM sys-tem developed by Delcam. The deci-sion followed a six-month evaluation of products available from six leading CAM developers.
EXCO, a world leader in large high-pressure die-casting dies and a major tooling supplier to the global automo-tive industry for more than 50 years, boasts considerable experience in the design of large dies for engine blocks, transmission cases and instrument panels. To ensure die accuracy and functionality, it makes extensive use of CNC equipment, including ma-chining centres, large boring mills and coordinate measuring machines.
In early tests with PowerMill, EXCO saw up to threefold productivity in-creases for some parts. Programming time for a large insert shrank from a week to one day in one case. The col-lision avoidance in PowerMill is a sig-nificant benefit that allows program-mers to cascade down with a shorter tool assembly; large areas can be cut
Automotive Die Manufacturer Seeking Greater CAM Flexibility and Toolmaking Productivity Finds the Answer
safely before moving to a longer tool. For all roughing strategies, PowerMill orders tool paths that greatly reduce air moves and make rest-roughing tool paths more efficient. Also, users can edit tool paths quickly, without the time-consuming recalculations the previous software required whenever changes were made in the programme.
A big change has been the addi-tion of semifinishing operations to the machining sequences. “Previ-ously, we did not semifinish because it greatly increased our programming time,” explains Mr. Gabor, the new-project engineer. “Now we can pro-gramme roughing, semifinishing and finishing fairly quickly, and run the programmes more smoothly. Power-Mill helps us control material removal rates at each stage.”
EXCO finds that PowerMill’s main advantages are its flexibility, its range of machining strategies and the many options for tackling a job. The com-pany was impressed that Delcam had been so willing to provide training during the evaluation of PowerMill, and says that customer support has been excellent.
Case Studies
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Delcam plcBIRMINGHAM, UKwww.delcam.com
30 European Tool & Mould Making � April 2010 www.etmm-online.com
Spotlight: Rapid Prototyping
Hofmann Innovation Group AG has developed what it calls the world’s largest selective-laser-sintering (SLS) system for plastics. With a usable x-y-z volume as large as 1,500 x 500 x 500 mm (375 l), the XXL-sized Hofmann Medea 1500 SLS system makes it pos-sible to sinter large plastic components in a genuinely sin-gle-step process. The result is one-piece components with no adhesive joints or welded seams. For the first time ever, with the use of this innovative machine, Hofmann is able to manufacture large components such as instrument pan-els and interior or exterior automotive parts, on demand, by means of an in-expensive sintering process.
The TechnologySelective laser-sintering allows com-plex, three-dimensional functional prototypes or moulds to be manufac-tured easily. An SLS system produces these quickly and fully automatically from the component’s computer-aided design (CAD) data. The Medea 1500 SLS system developed by Hof-
Selective-Laser-Sintering System Makes Possible Time- and Cost-Saving Production of Large Components on Demand
ing Technologies department of the Modellbau division to produce large prototypes in a very short time.
Hofmann Modellbau’s new XXL-sized SLS system is highly versatile. It can produce thousands of different components at one time, all in a sin-gle process. Also, the system allows for a greater variation in layer thick-
ness than conventional SLS systems can. The Medea 1500 system not only makes it possible for Hofmann to manufacture components in a wider range of sizes, but also enables tech-nicians to influence and configure the process to a much greater extent than
mann’s Modellbau division uses this design data (usually in STL format) to generate numerous layers, or “slices.” It is able to build up functional com-ponents in just a few hours because multiple lasers can be used at the same time. This enables the Rapid Prototyp-
A finished instrument-panel module with one-piece laser-sintered parts.
conventional sintering systems allow. By varying the layer thicknesses, users can achieve greater precision or, alter-natively, higher buildup speeds.
The breakthrough system can also act as a development platform for al-ternative materials that until now had been unsuitable for the SLS process. It therefore offers advantages with
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Spotlight: Rapid Prototyping
Our engineers had just three days to fi x an overheating brake rotor with a new cooling duct. We designed the duct in CAD, then used our Fortus 3D Production System to help:
� Quickly produce and test a series of design iterations� Test fi tment of functional prototypes on the race car� Produce a tooling buck for molding the fi nal part� Cut time and costs by 90% over traditional methods
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respect to the size, volume and geom-etry of the components that can be produced, and maximizes their overall quality.
Cost AdvantagesPrototype components have tradition-ally been produced by means of com-plex moulds made of aluminium or steel. These moulds represent a great deal of time-consuming construction, manufacturing and installation work. With such tooling, the costs of mak-ing changes in product geometry or of integrating extra functions during a development project are usually very high. When laser-sintering is used in-stead, the costs tend to be relatively higher, yet constant for each compo-nent produced.
The alternative mould costs depend to a large extent on the complexity of the component, whereas the costs of laser-sintering are influenced main-ly by the component’s volume and height. As a result, the costs for laser-sintering can easily be calculated from the CAD data. This in turn reduces the financial risks involved. Experience
shows that this effect is even more evi-dent when the components produced are large.
SLS allows additional functions to be integrated into a component dur-ing the development phase so as to increase its value. The result of this is a reduction in the production costs and economic risks involved.
A particular advantage of laser-sin-tering from an industrial point of view is that it enables reliable production on demand. Any product modifica-tions can be carried out quickly and with minimal outlay. For example, Hofmann Modellbau now has the op-tion of producing alternative versions or geometries for use as illustrative models alongside actual series com-ponents. More important, it can do so while incurring none of the costs and risks of prototype moulds.
The Service ProvisionIn the manufacturing of sintered plas-tic prototypes, Hofmann Modellbau offers customers a comprehensive range of services. These include the performance of installation work and
the enhancement of components by applying vapour-deposited, painted, or printed finishes. Hofmann is able to provide anything from large function-al parts to complete modules with the surface finish of a series component. As a result, its customers can obtain laser-sintered prototypes in sizes that have not previously been available on the market.
Hofmann Modellbau now offers not only XXL laser-sintering of large components but a variety of other XXL services also. These include XXL cusing and XXL injection moulding. The former offers customers what Hof-mann believes is currently the largest capacity for generative metal laser-melting. Through this cusing service, the service provider can produce very large metal prototypes at low cost. Its XXL injection moulding offer in-volves the use of a 16,000-kN mould-ing machine for making samples and prototypes. This machine is designed to meet all two-shot, embossing, and turntable requirements.
Hofmann Innovation Group AGLICHTENFELS, GERMANYwww.hig-ag.de
32 European Tool & Mould Making � April 2010 www.etmm-online.com
One year after introducing what the company says has become the world’s best-selling 3D printer—the Dimen-sion® uPrint®—Stratasys has expand-ed the market-leading product line with the new Dimension uPrint Plus enhanced 3D printer (photo below). The modified version of the uPrint per-sonal printer offers many new features, some of them developed in response to customer requests for expanded ca-pabilities. Despite the greater perform-ance range of the Dimension uPrint Plus, Stratasys has managed to keep the price surprisingly low.
Like the original uPrint 3D printer, the uPrint Plus has a small footprint that suits it for true desktop deploy-ment. It commands just 635 x 660 mm (25 x 26 in.) of surface area. Neverthe-less, the printer features a build enve-lope that measures a generous 203 x 203 x 152 mm (8 x 8 x 6 in.) These dimensions represent an increase in volume of 33% over Stratasys’ original uPrint, and enable users to build pro-portionally larger models.
Both of the Dimension uPrint print-ers build 3D models
Enhanced Desktop 3D Printer Offers Eight Material Colours, Two Resolution Options and a Generous Build Volume
using the manufacturer’s patented and proven fused deposition model-ling (FDM®) technology. The uPrint Plus offers the advantage of being able to print in eight colours of Stratasys’ proprietary ABSplus modelling mate-rial—red, blue, olive, black, dark gray, nectarine, fluorescent yellow and ivo-ry. This range of options is intended to make it easier for designers to differ-
entiate individual assembly compo-nents and thus create the most informative possible depiction of their product idea.
Further, the uPrint Plus of-fers a choice of two resolution settings, 0.254 mm (0.010 in.) and 0.330 mm (0.013 in.), to give users additional printing options.
Stratasys’ uPrint Plus per-sonal printer is distinguished additionally by two support-material enhancements devel-oped to reduce both material consumption and modelling time. The first of these is Smart Supports. This software en-hancement results in a reduc-
tion in material usage of 40%, which means a sig-nificant cost savings. The other enhancement is the introduction of SR-30, an improved soluble support
material that dissolves 69% faster than the material that
preceded it, and thus accelerates the modelling process. These support en-hancements are available for the ear-lier uPrint as well as for the uPrint Plus 3D printer.
The new 3D printer is now available for shipment through the manufactur-er’s authorized resellers.
US-headquartered Stratasys manu-factures additive fabrication machines for prototyping and manufacturing plastic parts under the brand names Fortus (3D production systems; photo above) and Dimension (3D printers). According to Wohlers Report 2009, Stratasys supplied 43% of all additive fabrication systems installed world-wide in 2008, making it the unit mar-ket leader for the seventh consecutive year. Via the FDM process, the systems create functional prototypes and man-ufactured goods directly from any 3D CAD programme, using high-perform-ance industrial thermoplastics.
Dimension-brand 3D printers of-fer CAD users a low-cost, networked alternative for building functional 3D models from the desktop, provid-ing a convenient means of evaluating design concepts and testing models for functionality, form and fit. They build models layer by layer from ABS thermoplastic, which is widely used in injection-moulded products today.
Stratasys GmbHFRANKFURT/MAIN, GERMANYwww.stratasys.com
Spotlight: Rapid Prototyping
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34 European Tool & Mould Making � April 2010 www.etmm-online.com
Products & Services
Upgraded CNC Machine Simulation and Optimization Software Features Many Customer-Driven EnhancementsVericut 7 CNC simulation, verifica-tion, optimization and analysis soft-ware, the latest version of the popu-lar CNC machining simulation tool available from CGTech Ltd., features significant performance improvement owing to enhancements that save time for manufacturing engineers en-gaged in developing, analyzing, in-specting and documenting the CNC
programming and machining process. With this update, instead of creating new features or add-on modules, the CGTech developers focused on diligent code optimization and the incorpora-tion of more than 500 customer-driven enhancements.
CGTech modified the user interface in Vericut 7 so as to provide a more natural and obvious sequence for the
most common user actions. A graphical tree layout gives the user interaction a top-down flow, with context-sensitive choices appearing as the user moves along in the NC programme simula-tion. System and graphics performance were both improved, resulting in a better, faster Vericut experience.
Vericut’s purpose is to eliminate the need to prove out NC programmes manually. It reduces scrap loss and re-work. The software also optimizes NC programmes in order to both save ma-chining time and produce a higher-quality workpiece surface finish.
Vericut simulates all types of CNC machine tools, including complex multiaxis machines. It runs stand-alone, but can also be integrated with such leading CAM systems as CATIA V5, Siemens NX, Pro/Engineer, Mas-tercam, Edgecam, GibbsCAM, Delcam PowerMill, Missler TopSolid’Cam and Open Mind hyperMill.
CGTech Ltd.HOVE, E SUSSEX, UKwww.cgtech.co.uk
The new Uni-Mill power-roughing cutters VHM .48W and VHM .49W have been developed by Jongen Werkzeugtechnik GmbH & Co. KG as a product line extension, supplement-ing the established VHM .46W and VHM .47W. The integration of coolant passages in these hard-metal rough-ing end mills ensures optimal cool-ing at the cutting edge and supports chip flow. Designed for rough-milling of all current steels—tool steel, high- and low-alloyed steel, and structural steel—the tools offer smooth func-tionality, maintain high chip-removal volumes and have long lifetimes, thus providing very high efficiency.
The availability of diameters of 4 to 20 mm, the choice of three to five teeth, and spiral-slot angles that vary with the diameter all contribute to the roughing cutters’ universal applicabil-ity and optimal adaptation to various
Roughing End Mills with Integrated Coolant Passages Are Versatile, Efficient and Long-Lived
machining methods and materials. Additional flexibility comes from the range of utility lengths: up to 40 mm for the VHM .48W and up to 53 mm for the VHM .49W.
These Uni-Mill end mills have a sta-ble core geometry, and their optimized micro- and macrogeometries also en-hance stability and tool life. Their symmetrical knurled profile is aligned optimally with the tool diameter and number of teeth to maximize produc-
tivity and operating lifetime. A central cutting edge makes them suitable for boring operations as well.
The TS35 cutting material, a fine-grained hard metal, offers outstanding tenacity and wear characteristics. The tools’ TiAlN-nanocomposite coating provides glazed surfaces, high thermal stability and oxidation resistance.
Jongen Werkzeugtechnik GmbH & Co. KGWILLICH, GERMANYwww.jongen.de
www.etmm-online.com April 2010 � European Tool & Mould Making 35
Products & Services
Krones AGNEUTRAUBLING, GERMANYwww.krones.com
Krones AG developed its semiautomatic Mould-Xpress Advanced sys-tem for blow-mould changeover in order to shorten significantly the time required for chang-ing over moulds used in Contiform stretch blow moulding machines of the S16 to S28 series and thus to improve the ma-chines’ availability lev-els. The system, which is integrated into the blowing wheel, reduces changeover time from about 3.5 minutes to less than 1 minute per blow moulding station.
The different mould sets to be substituted for each other are kept securely in a changing trolley of improved de-sign. By means of appro-
Semiautomatic Mould Changeover System for Stretch Blow Moulding Machines Shortens Downtime Significantly
priately designated compartments, the moulds are unambiguously identified, which minimizes the risk of installa-tion errors. Thanks to a rotating func-tion principle, the position for remov-al of each mould is always the same for the operator.
The MouldXpress Advanced system is used in the Contiform machines identified above for the standard proc-ess, and also for relax-type moulds with neck cooling. The system can reduce makeready time by as much as 75%, thus increasing overall equip-ment effectiveness.
Another advantage of the Mould-Xpress Advanced system is that mould changeovers are not only simplified but also carried out at a consistent high level of quality. Also, since no tools are required, operators will find changeovers to be less onerous and time-consuming.
Standard Mould Components Designed to Offer Tool Builders Added Value Are Stocked for Immediate Shipment
The Austrian standard moulds special-ist Meusburger Georg GmbH & Co. KG has expanded its product range to more than 41,000 items, as item-ized in the company’s new print and digital catalogues. The latest product novelties available from the full-range supplier include contour core pins, a support pillar with guide function, and USA-system auxiliaries for tem-perature regulation.
The precision, through-hardened
contour core pins are made from the cold-work steel 1.2210 and hot-work steel 1.2344 in many different dimen-sions. They feature protection against twisting at the head, and, since the en-tire surface is ground after tempering, there is no thickening at the shaft.
The space-saving combination of support pillar and parts for ejector plate guiding is available in various dimensions, matching the variety of riser heights, and with two different
guide bushes. This in-stock product is ready for immediate shipment.
With its new US-oriented auxiliary temperature-regulating equipment, Meusburger offers customers the benefit of an alternative to its well-established EU-system products. These items, too, are readily available from stock in all current dimensions and forms.
New from Meusburger (left to right): auxiliaries for temperature regulation (USA-system), contour core pins, and the support pillar with guide function.
Meusburger Georg GmbH & Co. KGWOLFURT, AUSTRIAwww.meusburger.com
36 European Tool & Mould Making � April 2010 www.etmm-online.com
Offered to Minimize Rejected Parts, Flexible Sealing Elements Optimize the Encapsulation of Mould InsertsA recent innovation from the producer of modular, interchange-able standard mould components Hasco Hasenclever GmbH + Co. KG is the A4200 series of flexible seal-ing elements, which represent a considera-ble advance in the en-capsulation of metal parts within a mould. By mounting these flexible sealing ele-ments in mould cavity plates, manufacturers can overmould insert-ed metal components without having to worry about flash-ing plastic or compression damage. The advantageous performance of the A4200 series is based on the MurSeal® sealing technology they embody.
The utility of the A4200-series seal-
where technology had seemed to reach its practical limits, most notably by allow-ing the reliable over-moulding of metal inserts without risk of damage or flashing. The sealing elements, which are particularly useful for sheet metal thicknesses of about 4 mm and greater, mini-mize the number of rejected parts.
Through the elimi-nation of rework costs and a reduction in the frequency of rejects,
users of Hasco’s A4200-series flexible sealing elements can expect to lower unit costs considerably.
Products & Services
ing elements has been proven in the moulding of both reinforced and unreinforced plastics. Standard cut-ting tools for steel can be used to ma-chine these sealing elements as well. The series opens up new possibilities
Hasco Hasenclever GmbH + Co. KGLÜDENSCHEID, GERMANYwww.hasco.com
Innovations in Enterprise Visualization Software Package Improve Document Collaboration across Company Sites
new iSDK software development kit. A new Work Offline mode is available, which enables users to view and mark up engineering docu-ments off-line. Also just introduced are 3D Walkthrough capabilities that al-low AutoVue users to perform detailed reviews of company facilities and to ex-plore buildings and structures digitally in a more natural way. In addition, new 3D features greatly enhance the use of 3D models.
AutoVue 20.0 has been optimized to drive process efficiency. Users can now load and work with large multi-page Word and 2D CAD documents, as well as large 3D models, much more quickly. The new AutoVue also deliv-
ers timely support for additional for-mats, including Pro/Engineer Wild-Fire 5, Unigraphics NX6, Mechanical Desktop 2010 and 2009, Adobe Acro-bat PDF 9.0, and others. A free test ver-sion of the programme is available for downloading.
DataCAD Software & Services GmbH, a supplier of technical software solu-tions to industrial customers, now offers AutoVue 20.0 Enterprise Visu-alization software from Oracle, the latest version of the industry-leading solution for viewing, reviewing and collaborating on asset and engineer-ing documents and information. The software can serve as a single platform for document visualization across the global enterprise, improving both per-sonal productivity at the desktop and team productivity spanning applica-tions and geographic areas. Oracle considers Version 20.0 one of its most important releases of AutoVue.
AutoVue 20.0 boasts a brand-new architecture that facilitates scaling the software along with the organization’s evolving enterprise requirements and that efficiently serves the visualization and document collaboration needs of users. The integration of AutoVue into any environment is easy with the
DataCAD Software & Services GmbHBAD KREUZNACH, GERMANYwww.datacad.de
www.etmm-online.com April 2010 � European Tool & Mould Making 37
Products & Services
For machining workpieces as com-pletely and economically as pos-sible, five-side machining in one clamping offers great advantages. Auxiliary processing is mini-mized, and reclamping errors are avoided. But optimizing produc-tivity in workpiece clamping also is important. For this, Erowa AG offers its 148 P/i centring vise as a precise and flex-ible interface between workpieces and the machine.
To safely absorb the changing forces gener-ated during chip cutting and to ensure that stability remains as high as possible, the pallet and the base body of this vise have been made from a single block. The centre of the vise can still be adjusted. The vise’s entire body is made of stainless hardened steel. With
Highly Stable Centring Vise Provides a Precise and Flexible Interface between Workpiece and Machine
the base body of a P pallet, the 148 P/i is compatible with all Erowa chucks of
the ITS PowerChuck P, PC210 Combi, and MTS/MTS+ single chuck types.
Erowa’s centring vise features user-friendly operation and is designed to guarantee optimal accessibility during the machin-
ing process. It comes with a wide range of jaws that can be positioned at grid distances of 15 mm. The entire clamp-ing range is suitable for handling workpieces sized from 5 to 155 mm. Clamping repeat-ability is ±0.01 mm. The spindle’s sealed design eliminates the need for its mainte-
nance and ensures that the vise re-mains in working order even when the level of contamination is high.
Erowa AGBÜRON, SWITZERLANDwww.erowa.com
TaeguTec has launched the Chase-PlusMill Mini line of milling cutters in answer to mould and die industry demands for higher productivity and shorter cycle times with stable cut-ting conditions. This new line com-plements the company’s established ChasePlusMill series. The flexible ChasePlusMill Mini cutters incorpo-rate small inserts that can be mounted so as to provide a close tooth pitch. This improves productivity and feed rates considerably. A range of econom-ical inserts is available, all with four cutting edges each.
Each ChasePlusMill Mini cutter can substitute for several cutters, being able to perform any operation from facing to shouldering, straight ramp-ing, helical ramping and cavity ma-chining. Further enhancing produc-tivity is the geometry of the cutter and its inserts, which optimizes chip evac-uation and keeps cutting forces low. Low cutting forces, combined with an
High-Productivity Milling Cutters Can Be Fitted with As Many As Six Inserts for a Close Tooth Pitch
TaeguTec UK Ltd.LEEDS, UKwww.taegutecuk.co.uk
internal coolant system, minimize in-sert chipping.
The ChasePlusMill Mini series of-fers shank diameters of 16, 20, 25 and 32 mm, with a choice of nine cutting diameters between 16 and 40 mm. There are anywhere from two to six inserts per cut-ter, depending on the diam-eter selected. Shanks with overall lengths of 100 to 220 mm connect with either a modular or a face mill–type cutting head.
The series is available with Taegu-Tec’s TT9080, TT8030 and TT7080 coated insert grades. Thus, the cut-ter can comfortably machine carbon steels, alloy steels, and prehardened, hardened, stainless and mould and die
steels with a hardness level beyond 50 HRc, as well as cast iron. ChasePlus-Mill Mini tools can cut at speeds of 80 to 220 m/min, with a 1-mm feed per tooth on depths of cut up to 1 mm.
38 European Tool & Mould Making � April 2010 www.etmm-online.com
Tool-price calculation software that was introduced two years ago by Schmale Werkzeug- und Formtech-nik GmbH especially for toolmak-ers and that is based on a relational database of mould costs and prices from completed projects offers users the benefits of enhanced cost trans-parency and better scope for project planning and the generation of per-formance indexes. Recently, Schmale introduced a docking station that links CAD data with the Schmale calculation software. It clarifies costs all the more, making them more pre-cise, and enables toolmakers to elimi-nate the “guesstimation factor” from the prices in their quotations.
Via an XML interface, the docking station transfers CAD data to systems such as Facton. Data exchange can be carried out with most CAD data formats. In addition, the station can implement company standards for components such as bolts, and can calculate them, too. These Schmale of-ferings can be adopted individually to increase the quality of a cost forecast.
Plugged-In Knowledge: A New Docking Station Enhances the Capabilities of Tool-Price Calculation Software
for tool-price calcula-tion that Schmale in-troduced to the mar-ket a couple of years ago (see the article in ETMM November/De-cember 2008, page 24), has been welcomed by early customers, who have employed it to improve their knowl-edge of their own data and to enhance the quality of their project planning.
Because both the Schmale database and the docking station increase cost transpar-ency and data consist-ency and thus make it possible to actually know what a tool cost to produce—as well as what price it had—they allow for the user to continually adapt pricing to current cir-cumstances. The sys-
tem also includes a cost-recalculation option that enables the operator to calculate the actual costs of jobs that have already been carried out, lead-ing to better and more-precise future offers. Therefore, it enables constant pricing optimization over the time the application is used.
Use of the Schmale knowledge da-tabase also has a direct implication for the production process itself, as the data can be used for production sched-uling and planning.
The finer-cut the CAD data are, the system’s inventor points out, the less the toolmaker has to deal with the tool-price calculation software. For instance, if the number of parts to be produced is known, a quick run will enable the software user to submit a price immediately. Thus, the Schmale software provides a high degree of flexibility and responsiveness for daily business.
At present, 276 companies in 29 countries are making routine use of the Schmale calculation tool.
Products & Services
Schmale Werkzeug- und FormtechnikGmbHBISCHOFFEN, GERMANYwww.schmale-gmbh.com
A Company and Product Are BornSchmale Werkzeug- und Formtechnik GmbH was founded by Lothar Schmale and his wife Helmtraud in 1997. Before that, Lothar had worked for more than 20 years as an executive of a medium-sized tool and mould construction company. In the early years of their own business, the couple were sales agents for companies involved with mould making, contract manufacturing, plant engineering, milling machines, and coated sheet metal parts and components. Lothar also advised automotive industry firms in matters of process optimization and tool design.
One day, an OEM suggested that Lothar Schmale develop and sell a software for calculating costs for tools and moulds. That he did.
Lothar Schmale: “Our software is the worldwide benchmark for calculating tools and moulds.”
The new docking station links CAD systems to the cost and pricing calculation software of Schmale.
The docking station, which is an add-on for the knowledge database
PHOTO: SCHM
ALE
www.etmm-online.com April 2010 � European Tool & Mould Making 39
High-Stability Gantry-Style Milling Machines Feature a Pallet Changer to Speed Processing of Big WorkpiecesDesigned by Matec Maschinenbau GmbH for single-part and series pro-duction of large and heavy workpieces in the fields of tool and mould mak-ing, mechanical engineering, and structural-steel engineering, Matec-30 PP and Matec-40 PP gantry-style milling machines are engineered to be able to fulfill the highest qual-ity demands. Their well-dimensioned gantry construction with a stable bridge ensures that deformation of the machine is trivial and, therefore, that the contour consistency and surface quality of the workpiece is optimized. In addition, the gantry format guaran-tees that accessibility to the workpiece is good from every side.
Among the machines’ special fea-tures is a 2-axis swivel head that is CNC controlled for 5-axis simultaneous ma-chining. It includes a c-axis that turns through the range of ±180° and a tilt-ing b-axis that swivels through ±95°. Application of the swivel head and
the 2-axis CNC motor-spindle milling head allows multilateral machining. A wide variety of spindle speed and spindle power options for all materi-
Products & Services
Matec Maschinenbau GmbHKÖNGEN, GERMANYwww.matec.de
als is available from Matec. The machines are distin-guished as well by a long 1,500 mm of z-axis travel.
The Matec-30 PP and Matec-40 PP milling ma-chines are equipped with a pallet changer that func-tions also as a machine table. This pallet changer moves along the x-axis.
Matec Maschinenbau’s new gantry series of mill-ing machines is completed by the Matec-30 PR and Matec-40 PR, whose ma-chine table is designed for rotary movement. This configuration makes pos-sible simultaneous turning and milling in the machin-
ing of workpieces.
Versatile, Quick-Setup 5-Axis Clamping Vise Supports Five-Side Machining of Workpieces of Nearly Any Type
of 250 x 250 mm. It allows simple saw cuts to be machined with the same high level of performance as complex cast parts. The user can choose among five clamping functions: vise, concen-tric, double-vise, concentric-plus-vise, or double-concentric.
Quadrok clamps with total flexibili-ty, from outside and from inside. Even mandrel or chuck clamping can be re-
alized with this 5-axis vise. Hainbuch has designed the device to enable us-ers to complete machining jobs more rapidly, more flexibly and more cost-effectively and thus ensure customer satisfaction through greater delivery reliability.
The innovative dou-ble-concentric Quad-rok 5-axis clamping vise from Hainbuch GmbH Spannende Technik brings to the market a clamping sys-tem that can save users of machining centres the trouble of com-plex and expensive customized solutions. The Quadrok offers strengths in the area of five-side machining. It can clamp workpieces of almost any type through a clamping repertoire that is essentially inexhaustible. Setup takes no more than 2 minutes.
Highlights of the practical all-around clamp include surrounding, four-side clamping; extremely shallow clamping; optimal material removal values through active pull-back; and a maximum acceptable workpiece size
Hainbuch GmbH Spannende TechnikMARBACH/NECKAR, GERMANYwww.hainbuch.com
40 European Tool & Mould Making � April 2010 www.etmm-online.com
Products & Services
High-Performance 5-Axis Machining Centre with Outstanding Dynamics Is Ready for Demanding Five-Sided ApplicationsThe completely redesigned C 42 U dy-namic all-purpose 5-axis CNC high-performance machining centre from Maschinenfabrik Berthold Hermle AG is the latest in the manufacturer’s C series of gantry-design universal and 5-axis machining centres. With x-y-z traverses of 800 x
for the y-axis; and an a-axis swivelling angle of ±130°. The space-saving ring-shaped tool magazine integrated into the machine body works according to the pickup principle, changes tools very quickly, and has room for 42 tools with an SK40 or HSK-A63 hold-er. Additional magazines with more pockets are available, making it pos-sible to machine completely, without any additional setup, highly complex workpieces, entire product families or a wide variety of individual parts.
Customers can choose from among three main spindle drives that of-fer up to 29 kW of power, torques to 200 Nm and speeds of 10,000, 18,000 and 25,000 rpm. They can also select from four table variants: a large rigid clamping table and three different ro-tary tables of varying sizes and load ca-pacities. Of course, a machining centre this sophisticated can be supplied with every kind of automation enhance-ment for unattended machining.
Maschinenfabrik Berthold Hermle AGGOSHEIM, GERMANYwww.hermle.de
800 x 550 mm optimally adjusted to the maximum tool size, and consist-ently designed for 5-axis applications, the C 42 U dynamic is well suited for machining applications requiring ex-treme accuracy, very close tolerances and the best workpiece surface quali-ties. These include work in tool and mould making, medical technology, aviation and aerospace, machine and
apparatus construction, and engine and auto-racing technology.
The C 42 U dynamic features 3 axes in the tool and 2 in the workpiece; a highly stable modi-
fied gantry design with excellent vi-bration-dampening properties and op-timum main-axis support; bearings on both sides of the NC swivelling ro-tary table with tan-dem drive; a quad-ruple-roller guide
system and centrally arranged main drive
To accommodate those seeking the advantages of a shrink-fit, semiperma-nent toolholder assembly for shank-style cutters but who have a low usage requirement, LMT has developed the economical, ready-to-run ISG 1000 benchtop shrink-fit toolholding system. Suitable for the tool spindles of machining centres and driven tool units on mill/turn centres, this assem-bly helps users overcome problems as-sociated with traditional collets and hydraulic chucks. The portable 390 x 310 x 640-mm unit is powered from a three-phase plug-in source and accom-modates straight-shank tools sized be-tween 3 and 16 mm in diameter and in lengths as great as 290 mm.
Shrink-fit technology provides not only a quick and simple way to mount milling cutters, drills and taps into a toolholder, but also significant advan-
Economical Shrink-Fit Toolholder Assembly for CNC Milling and Mill/Turning Provides Strong Machining Advantages
tages for machining. It creates a more-rigid setup between the machine spin-dle bearings and the tip of the cutting
tool, minimizes runout at the tool tip (important on small-diameter or long-series tools) and provides a longer cutting life with better accuracy and surface finish. Also, shrink-fit tool as-semblies cope better with the accelera-tion of modern spindles and the influ-ence of centrifugal force.
The ISG 1000 unit requires less than 20 seconds to heat the nose area of the toolholder through its 6.5-kW induc-tion heating coil. The cutting-tool’s shank is positioned in the holder and held there as a single unit as it contracts under cooling. A cooling adapter in-cluded in the ISG 1000 package speeds the cooling process by enabling the heat generated to dissipate rapidly via strategically positioned heat sink fins.
LMT Deutschland GmbHOBERKOCHEN, GERMANYwww.lmt-tools.com
www.etmm-online.com April 2010 � European Tool & Mould Making 41
Products & Services
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Production Software Suite and Associated Services Close the Gap between Machine Control, Operations PlanningThrough its new e-tekx soft-ware group, a networked initiative for transparency and tailored improvement measures, MAG is closing the software gap between machine control and opera-tions planning. The e-tekx portfolio comprises a variety of production software and controls, including CAM soft-ware for metal-cutting and composite-processing appli-cations, software for real-time acquisition of machine and process data, and reporting tools and analytics, as well as supplementary engineering services and application sup-port. For networked production, MAG provides many different interfaces to machine tools with a variety of con-trols, and also supplies components such as air compressors and other aux-iliary equipment.
The objective of all these applica-tions and support services is to achieve process optimization and complete transparency in production so that the customer will see measurable and du-rable productivity improvements. For
example, using the Freedom eLog software module, part of the Freedom eWare suite, a manufacturer of hydraulic and pneumatic components and a supplier to the oil and gas industry reportedly realized large savings. In both cases, in-creased levels of efficiency and productivity resulted in return on investment occurring in less than 12 months.
The recently introduced e-tekx product portfolio and complementary service capa-bilities will be showcased in June at an in-house exhibition at Corcom, the MAG facility in Rottenburg, Germany, where
several critical production assets have been equipped with the Freedom eWare suite.
MAG Europe GmbHSTUTTGART, GERMANYwww.mag-ias.com
Freedom software measures real-time machine-condition parameters and offers flexible options for analysis.
42 European Tool & Mould Making � April 2010 www.etmm-online.com
Products & Services
Magnetic Milling Chucks for Alloyed-Material Workpieces Eliminate Need for Postmachining Demagnetization
Use of a magnetic chuck for milling provides the advantages of quick work-piece clamping, five-sided machining in a single setup, high holding force, and no maintenance. On the other
materials, HN chucks activate the Nu-flux system on every demagnetization cycle to remove all residual magnet-ism from the workpiece. Demagnetiz-ers are no longer necessary.
As standard, HN chucks are fitted with special conical polar extensions designed to optimize the concentra-tion of magnetic flux. This doubles the specific force per square centime-tre of polar area in contact with the workpiece. The chucks are supplied in combination with the ST 210R control unit, available in voltages of 200 to 480 V, as well as with a power controller on eight levels for precise adjustment of the magnetic force in accordance with the characteristics of the piece to be clamped.
Enhanced Collaboration and Openness, Realistic Simulation Are among Many Features of PLM Platform UpgradeDassault Systèmes, which develops 3D and product lifecycle management (PLM) software solutions, has issued Release 20 of the collaborative V5 PLM portfolio, including CATIA®, En-ovia®, Simulia® and Delmia®. V5R20 includes enhancements to Enovia SmarTeam multi-CAD collaboration software, integration of Simulia’s non-linear and thermal realistic simulation capabilities into the V5 platform, and unique composites design and simula-tion capabilities in CATIA and Simulia. The latest release of the PLM software features additional enhancements across the entire product portfolio, including digital manufacturing, fur-thering its support of a variety of pro-duction deployments and improving overall usability.
V5’s openness is advanced in Re-lease 20 through updated multi-CAD integrations and a new 3D viewer available directly within Enovia SmarTeam. In addition, V5R20 intro-duces a new product, CATIA Extended STEP Interface, which enhances large-assembly archiving with nested assem-
tegration with PLM data and processes.
The list of enhancements appear-ing in Release 20 of the V5 PLM pack-age is long. In a nutshell, this upgrade promotes more-efficient collabora-tion, accelerates realistic simulation, improves digital production, shortens programming time for NC machining, and generally enriches the experience of collaborative innovation.
quarter update of the entire V5 port-folio will also include support for the Windows 7 operating system.
With the realistic simulation tech-nology from Simulia, V5R20 now enables customers to include nonlin-ear and thermal physics behaviour in their design while maintaining full in-
hand, when alloyed steel materials are being machined (typically in mould making), a “glue” effect may occur be-tween the workpiece and the magnet, making it difficult to remove the part
after processing without risking damage. Often, it is necessary
to place the workp i e ce in a demag-netizer to
remove halos of re-sidual magnetism. Tec-
nomagnete S.p.A. has solved these problems through its Quad
Extra HN70 milling chuck with the patented Nuflux system.
The Quad Extra HN70 is a special high-density polar version of the HN design. Its 70 x 70-mm poles are each able to generate a force of 3,500 N. De-signed for the machining of alloyed
Tecnomagnete S.p.A.LAINATE (MI), ITALYwww.tecnomagnete.com
Dassault SystèmesVÉLIZY-VILLACOUBLAY, FRANCEwww.3ds.com
bly support and, in the V5R20 update scheduled for the second quarter of 2010, will provide comprehensive support for composites design attributes and functional tol-erancing and annotation data. The second-
www.etmm-online.com April 2010 � European Tool & Mould Making 43
Clean-Machining Plug-Assist Material for PP Forming Resists High Temperatures
The Ultrix high-speed multipurpose vertical machining centre (VMC) from Breton S.p.A., which comes equipped with 4 or 5 continuous axes, is suited for the milling, hori-zontal or vertical turning, and grinding of medium-sized workpieces made of superalloys, steel, aluminium or com-posite material. Breton has designed this machine for high-level multitasking performance and maximum productiv-ity.In addition, it has provided the centre with ample scope for automation.
Capable of carrying out complex milling operations with 3, 4 or 5 interpolated axes, together with turning and grind-ing, on one workpiece, the Ultrix can in fact mill, bore, tap, turn and grind a part in just one positioning, thereby of-fering a potentially dramatic reduction in downtime. The VMC’s direct-drive technology and gantry drive ensure high dynamics and system rigidity, and thus the highest machin-ing quality. Automated systems for pallet changing and workpiece loading and unloading further increase produc-tivity and make it possible for users to schedule production cycles precisely.
High-Speed VMC Machines Parts Fully in One Positioning
The latest innovation in the field of plug-assist technology that is offered by the plastics-processing technology special-ist Kiefer Werkzeugbau GmbH is the resistant plug-assist material FORMLITE™, which has been designed to ensure a high level of quality in the polypropylene-forming appli-cation area. Kiefer considers the most important attributes of FORMLITE to be its high-temperature resistance, its dust-free machinability and its authorization by the US Food and Drug Administration for use in applications regulated by that agency.
The manufacturer keeps this new material permanently in inventory, along with all of the other well-established plug-assist materials in its portfolio.
With its up-to-date machining equipment and the excel-lent availability of goods, Kiefer Werkzeugbau is able to re-alize very short delivery times. Its integrated development department and manufacturing via CNC machines enable the company to produce plug assists of the optimum shape. Kiefer is always pursuing new plug-assist technology devel-opments and generating solutions tailored to the satisfac-tion of customer needs.
Products & Services
Breton S.p.A.CASTELLO DI GODEGO (TV), ITALYwww.breton.it
Kiefer Werkzeugbau GmbHSCHWAIGERN, GERMANYwww.kiefer-mold.de
44 European Tool & Mould Making � April 2010 www.etmm-online.com
Control 2010
Measuring Technology in Web 2.0: Global, Internet-Based Metrology Discussions and Value-Added Services
information for beginners and experts alike. Additional benefits available to customers who have a software sup-port agreement with Carl Zeiss include software updates, service patches and extensive product documentation.
Early users have reported that an-swers to metrology problems can be found quickly and that the exchange of knowledge among measuring tech-nicians enables new perspectives to appear. But not only do Carl Zeiss cus-tomers benefit by learning to use their machines more effectively; Carl Zeiss
itself benefits by in-tegrating customer experiences into its process of develop-ing training con-cepts, documents, and new software and hardware.
Also available at the Metrology Portal are extensive eLearning videos for self-study; short programmes, help scripts, macros for myCalypso entry-level measuring software, and other software add-ons; and glossaries and
other sources of basic information to ensure clear communication among site users and between Carl Zeiss and those users. Anyone can upload or ac-cess programmes and macros offered through the portal. Other users can enhance programmes and republish them. Carl Zeiss employees test these programmes and label them “Zeiss-verified” when proven to meet the company’s high quality standards.
To meet rising measurement de-mands, Carl Zeiss Industrial Metrol-ogy GmbH has created the Metrology Portal Internet-based community for users of measuring technology. This “Web 2.0” innovation consider-ably expands the company’s previous Internet offering of discussion forums and software download opportunities. Its purpose is to support customers in their daily measuring tasks and in planning for future projects, and to in-crease their productivity. The Web por-tal provides comprehensive metrology
Carl Zeiss Industrial Metrology GmbHOBERKOCHEN, GERMANYwww.zeiss.com/IMT
Faro Europe GmbH & Co. KGKORNTAL-MÜNCHINGEN, GERMANYwww.faro.com
Upgraded Software for Laser Scanner Has 64-Bit Architecture for More-Efficient Point-Cloud HandlingThe provider of portable measurement and imaging solutions Faro has re-leased Faro Scene 4.7 scan processing software for the Faro Laser Scanner. The latest version of the software fea-tures more-efficient point-cloud han-dling and visualization. This advance is the result of new 64-bit architecture that extends the system’s usable mem-ory. In addition, Faro Scene 4.7 incor-porates one-click Web-Share function-ality: through this built-in function, scanned images can now be put on the Internet, enabling companies us-ing Faro’s software to share scan infor-
mation with customers, suppliers and partners efficiently and without the need for additional software. Not only is it easy to share scan data, but Web-Share is secure as well.
Faro Scene 4.7 is being delivered with every new Laser Scanner starting in April 2010. Faro will sup-ply current users of a 4.x version of the scan processing software with an up-grade at no cost.
April 2010 � European Tool & Mould Making 45www.etmm-online.com
Control 2010
Systems Enhance Machine Automation, Process Control, Performance Assessment
Products for increasing machine tool automation and process control, a wireless device for assessing machine performance before starting to cut metal, and such motion control products as a true absolute optical encoder for ro-tary and linear applications are all new from Renishaw plc.
New touch probe systems that incorporate Renishaw’s unique frequency-hopping spread spectrum (FHSS) probe-signal radio transmission technology support automated job setup and in-process measurement on CNC machine tools of all sizes. The ultracompact RMP40 touch probe is well suited for multiaxis and mill/turn applications, while the RLP40 is specifically designed for more-hostile turning environments.
Also recently introduced is the successor to Renishaw’s widely used QC10 ballbar system for assessing machine tool positioning and servo-control performance, the QC20-W ballbar. The completely new design of the QC20-W features a Renishaw-developed linear sensor and Bluetooth® wireless technology, and allows testing in three orthogonal planes through a single reference point. A single simple hardware setup accelerates volumetric testing.
Finally, Renishaw’s new Resolute™ absolute optical en-coder system offers resolution of 1 nm at a speed of 100
m/sec for both linear- and angle-encoder applica-tions while also providing dirt immunity.
Absolute position is acquired immedi-ately at system switch-on, so the
exact orientation of axis and motor commutation angle are known without the need for a reference return. Large setup tolerances facilitate installa-
tion and ensure high re-liability, while low jitter and subdivisional error make the system com-patible with high-preci-sion stages.
Renishaw plcWOTTON-UNDER-EDGE, GLOS, UKwww.renishaw.com
46 European Tool & Mould Making � April 2010 www.etmm-online.com
Evolving Fibre Probe Provides High-Precision Measurement of 3D Microcomponent Structures
The patented Werth Fiber Probe (WFP) tactile sensor, which has been developed by Werth Messtechnik GmbH through a joint effort with the German National Metrology Institute (PTB), is a device that has been used worldwide to measure 3D microstruc-
ple, the sensor is also suitable for cali-brating optical measurements.
The fibre probe continues to be de-veloped by Werth and the PTB jointly as an ongoing project. In one variant of the probe, a laser diode is used as the light source. It generates a speckle pattern that can be used to determine the three-dimensional position of the contact sphere. Low probing uncer-tainties can be achieved by directly evaluating the contact element. Reso-lution is in the nano range and is ulti-mately dependent only on the optics that are used.
One advantage of the WFP is that direct measurement of the contact ele-ment means that any bending of the probe shank has no influence on the measurement result. The probe shank is also continuously kept in motion by a vibration generator in order to pre-vent stick-slip effects.
High-Accuracy Fixturing Systems for Measuring and Assembly Are Built via Laser-Sintering or Fused-DepositionThe Belgium-based additive manufacturing specialist Ma-terialise N.V. is dedicating its Control display to a pres-entation of patented RapidFit+ fixturing systems, which are engineered to uniquely fit the automotive or aerospace com-ponent to be inspected, meas-ured or assembled. RapidFit+ consists of a structural platform composed of locators (orange additive-manufactured parts) and beams. Using the layer-by-layer additive manufac-turing technology to create the platform, the RapidFit+ team de-signs and manufactures each locator such that the fit is always perfect.
As soon as the RapidFit+ team re-ceives CAD or STL data for the part, it designs the locators using CAD and Materialise software in combination. All RapidFit+ parts are fully 3D scanned
either delivers the complete structure intact or, if the customer has its own modular system, provides only the locators. In any case, the beams can be reused many times. This layer-
by-layer construction technique is a parallel process, so multiple locators can be built at one time for improved efficiency and cost savings. Because snap-fits and clamps can be integrated into the locator, users can mount and re-
lease parts quickly.The locators accurately
simulate the part’s real-life environment. For example, when a bumper is to be measured, the Rap-idFit+ modular system will create a precise on-car simulation. The result is very high accuracy and a quick, easy, repeatable process.
and CAD-compared. Contact points are assembled and fixed to 3D
adjustment blocks quickly and with-out hassle, significantly reducing lead times.
The combination of beam struc-tures and locators constitutes a part-specific support system. Depending on customer requirements, Materialise
tures and precision components in a wide range of industrial fields for more than 10 years. Typical applications for the WFP include gauges, spinning nozzles, miniature gears and compo-nents for fuel injectors. Owing to its low contact force and physical princi-
Control 2010
Materialise N.V.LEUVEN, BELGIUMwww.materialise.com
Werth Messtechnik GmbHGIEßEN, GERMANYwww.werthmesstechnik.de
Quality Control
COMPANY Advertisers are listed in bold type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 WEBSITEAberlink Ltd., Tetbury, Glos, UK, +44 1453 835737 1 2 5 6 9 12 www.aberlink.co.ukActiCM, Moirans, France, +33 476 913766 1 6 www.acticm.comAR Motif Makina Dis Ticaret Ltd. Sti., Istanbul, Turkey, +90 212 5678932 1 2 3 5 6 8 9 www.armotif.comBenteler Maschinenbau GmbH, Bielefeld, Germany, +49 521 5420 2 4 12 www.benteler.comBlum-Novotest Ltd., Lichfield, Staffs, UK, +44 1543 257111 5 www.blum-novotest.comBowers Metrology UK Ltd., Bordon, Hants, UK, +44 870 9509050 2 3 5 www.bowers.co.ukCadem CAD/CAM Destek Merkezi A.S., Istanbul, Turkey, +90 216 5576464 1 2 4 5 6 8 9 12 www.cadem.com.trCarl Zeiss Industrial Metrology, Oberkochen, Germany, +49 7364 202144 1 4 5 6 7 9 12 www.zeiss.com/IMTCMS S.p.A., Zogno (BG), Italy, +39 0345 64111 8 www.cms.itCoord3 S.p.A., Bruzolo (TO), Italy, +39 011 9635511 1 2 6 www.coord3.itCreaform EMEA, Lille, France, +33 872 843620 1 www.creaform3d.comDelcam plc, Birmingham, UK, +44 121 7665544 6 www.delcam.comDiebold Goldring-Werkzeuge, Jungingen, Germany, +49 7477 8710 5 14 www.hsk.comDimension, Eden Prairie, MN, USA, +1 952 906-2258 8 www.dimensionprinting.comDuwe 3D AG, Lindau, Germany, +49 8382 275900 6 www.duwe-3d.deE. Zoller GmbH & Co. KG, Pleidelsheim, Germany, +49 7144 89700 2 5 6 9 12 14 www.zoller.infoEuracon, Rotterdam, Netherlands, +31 10 7142633 3 www.euracon.netFaro Europe GmbH, Korntal-Münchingen, Germany, +49 7150 97970 1 2 4 5 6 12 www.faro.comHexagon Metrology S.p.A., Grugliasco (TO), Italy, +39 011 4025111 1 2 3 4 5 6 12 www.hexagonmetrology.comHorst Witte Gerätebau Barskamp KG, Bleckede, Germany, +49 5854 890 43 5 www.horst-witte.deKistler Instrumente AG, Winterthur, Switzerland, +41 52 2241111 5 6 10 www.kistler.comKreon Technologies, Limoges, France, +33 555 428040 1 4 6 12 www.kreon3d.comKubotek Europe S.r.l., Costabissara (VI), Italy, +39 0444 585556 6 www.kubotekeurope.comLeica Geosystems AG, Unterentfelden, Switzerland, +41 62 7376767 1 4 6 12 www.leica-geosystems.com/metrologyMetrol Co. Ltd., Tokyo, Japan, +81 42 5273278 3 5 14 www.toolsensor.comMillutensil S.r.l., Milan, Italy, +39 02 29404390 29 8 13 www.millutensil.comMitutoyo (UK) Ltd., Andover, Hants, UK, +44 1264 353123 1 2 3 4 5 6 7 8 9 12 www.mitutoyo.co.ukMitutoyo Messgeräte GmbH, Neuss, Germany, +49 2137 102406 1 5 6 7 www.mitutoyo.deMoldex3D, Chupei, Taiwan, +886 3 5600199 3 6 10 www.moldex3d.comNewall Measurement Systems Ltd., Leicester, UK, +44 116 2642730 5 www.newall.co.ukNikon Metrology N.V., Leuven, Belgium, +32 16 740100 1 2 3 4 5 6 12 www.nikonmetrology.comOGP UK Ltd., Foston, Derbyshire, UK, +44 1283 585933 1 2 3 4 5 7 9 12 www.ogpuk.comPANalytical B.V., Almelo, Netherlands, +31 546 534390 5 www.panalytical.comPlatit AG, Selzach, Switzerland, +41 32 5446200 5 www.platit.comRaytek GmbH, Berlin, Germany, +49 30 4780080 5 6 12 www.raytek.comRenishaw plc, Wotton-under-Edge, Glos, UK, +44 1453 524524 47 1 2 3 4 5 6 11 12 14 15 www.renishaw.comRJG Inc., Traverse City, MI, USA, +1 231 947-3111 5 6 10 www.rjginc.comSchmitt Europe Ltd., Coventry, UK, +44 2476 697192 4 5 www.schmitteurope.comSimpoe SAS, Torcy, France, +33 1 60332990 6 www.simpoe.comSolartron Metrology Ltd., Bognor Regis, W Sussex, UK, +44 1243 833333 2 3 5 www.solartronmetrology.comTaylor Hobson Ltd., Leicester, UK, +44 116 2763771 1 2 5 6 www.taylor-hobson.comVision Engineering Ltd., Woking, Surrey, UK, +44 1483 248300 2 5 7 www.visioneng.comWenzel Group GmbH & Co. KG, Wiesthal, Germany, +49 6020 2010 1 6 9 12 www.wenzel-cmm.comWerth Messtechnik GmbH, Gießen, Germany, +49 641 79380 1 2 3 4 5 6 7 9 12 14 15 www.werthmesstechnik.de
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www.renishaw.com/cmmretrofit
Advances in sensors, metrology software and controller technology can transform existing CMMs, providing greater accuracy, faster measurement, more automation and new capabilities.
April 2010 � European Tool & Mould Making 47www.etmm-online.com
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50 European Tool & Mould Making � April 2010 www.etmm-online.com
Company Index
Afrimold 2010 13
AMB 2010 11
Amerimold 2010 12
Asiamold 2010 21
Breton S.p.A. 43
Canadian Tooling & Machining Association (CTMA) 15
Carl Zeiss Industrial Metrology GmbH 44
CGTech Ltd. 8, 10, 34
CNC Software Inc. 7
Cumsa 25
Dassault Systèmes 17, 42
DataCAD Software & Services GmbH 36
Delcam plc 29
DEMAT GmbH 19
Deutsche Edelstahlwerke GmbH 15
Erowa AG 37
European Tool & Mould Making 22, 30
Faro Europe GmbH & Co. KG 44
Hainbuch GmbH Spannende Technik 39
Hasco Hasenclever GmbH + Co. KG 36
Hofmann Innovation Group AG 30
Horst Witte Gerätebau Barskamp KG 43
Husky Injection Molding Systems S.A. 52
Inovatools 13, 24
ISTMA Europe 48
Jongen Werkzeugtechnik GmbH & Co. KG 34
Kiefer Werkzeugbau GmbH 43
Krones AG 35
Lasys 2010 3
LMT Deutschland GmbH 40
MachineTools.com Inc. 41
MAG Europe GmbH 41
Maschinenfabrik Berthold Hermle AG 2, 40
Mastip Technology Ltd. 12
Matec Maschinenbau GmbH 39
Materialise N.V. 46
Meusburger Georg GmbH & Co. KG 35
Microsys 2010 11
Millutensil S.r.l. 29
Mitsubishi Carbide 6
Mould Eurasia 2010 16, 51
Objet Geometries GmbH 27, 28
Plastpol 2010 45
Progressive Components Europe Ltd. 33
Rapid.Tech 2010 7, 11
Renishaw plc 45, 47
Rofin-Baasel Lasertech 8
Schmale Werkzeug- und Formtechnik GmbH 38
Shun Chuan Machinery Ind. Co. Ltd. 23
Siemens AG 9, 26
Strack Norma GmbH & Co. KG 10
Stratasys GmbH 31, 32
TaeguTec UK Ltd. 37
Tecnomagnete S.p.A. 42
Türk + Hillinger GmbH 5
UCIMU-Sistemi per Produrre 8
Vero Software plc 20
Werth Messtechnik GmbH 46
Wohlers Associates Inc. 18
Z Corp. 10
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