Technological Process Chain - Mould Making

8/17/2019 Technological Process Chain - Mould Making

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© WZL/Fraunhofer IPT

Technologies for tool, die and mouldmaking –

Today and TomorrowUddeholm Automotive Tooling Seminar 2008

Sunne, Sweden

February 7th, 2008

Dipl.-Ing. Kristian Arntz

Fraunhofer-Institute for Production Technology IPT

Aachen, Germany


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Seite 2© WZL/Fraunhofer IPT

Contents

Summary and outlook

Tomorrow: Technological uniqueness

Excellence in tool and die making

Competence center aachener werkzeug- und formenbau

Today: Technology use in tool making


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Aachen’s Production Management Institutes

RWTH Aachen

founded 1870

30.000 students

5.000 students in engineering

Laboratory of Machine Tools and

Production Engineering WZL)

founded 1906 600 employees

(approx. 160 scientists)

Fraunhofer-Institute for Production

Technology IPT)

founded 1980

340 employees(approx. 60 scientists)

WZL Forum GmbH

in-house training and seminars (e.g. ExecutiveMBA)


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Our Topics

The competencies of the institutes in the tool, die and mold making field are concentrated in the joint

business segment „aachener werkzeug- und formenbau (awf, Aachen tool and die making)”.

Prof. F. Klocke

Manufacturing

technologies

Process

technology

Prof. C. Brecher

Machine

tools

Production

machines

Prof. G. Schuh

Production

management

Technology

management

Departments

Chairs

Metrology and

quality

Metrology and

quality management

Prof. R. Schmitt


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aachener werkzeug- und formenbau (awf) - Overview

Research for industry partners

Co-operative projects:

Largest EU scientific project in tool, die

and mold making: IP EuroTooling 21

Basic research

Research

Benchmarking

More than 128 international projects

Strategic Excellence

Effectiveness and efficient processes

Technological Excellence

Optimal use of technologies

Industry

Excellence-in-Production

Patron: BDI-President J. Thumann

Partner: VDI, VDMA, VDA, Federal Ministry

of Economic Affairs and Employment

Most challenging contest for producingenterprises

Up to 300 involved companies per annum

Toolmaker of the year

Colloquium

Most significant tool makers meeting in

Germany: 8th International Conference

„Tool and Die making for the Future“,

30.9. / 1.10., 2008 in Aachen Tool Shop Academy:

In-house training for both management

and employees

Education


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Integrated Benchmarking

...learn from the best!

Our Service for Tool Shops

Strategy development

& implementation

Market & Competition analyses

Cost & Lead time reduction

Global purchase & Tool supply

Supply Management

Calculation

Premium wage

Selection of technology

& optimization

Process chain design

Automation & Handling

Simulation & CAD/CAM

PPS & PDM selection

Metrology & Quality

Strategic Excellence Technological Excellence

Successful in tool making!


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Contents

Summary and outlook




European tool makers have to differentiate!

Strategic alternatives through technology

Measures for future success



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European Tool and Die Industry – Under Pressure from China

+ 44%

Germany China

- 91%

China

Work time* Personnel costs*

+ 61%

China

- 91%

China

Work time*

Source: WZL study „Tooling in China – Chance or Threat?“

Tool design

Tool production

1.714 h

2.471 h

1.915 h

3.083 h

*)Ø annualaverage

66.160 €

5.875 €

58.407 €

4.801 €

Germany

Germany Germany

*)Ø annualaverage

Personnel costs*


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Focusing in Strategy and Technology

Differentiation through technological uniqueness

Q u a n

t i t y o f p o t e n t i a

l c o m p e t i t o r s

Price competitionAdded value through increased

customer’s benefitTechnologicaluniqueness

Technological uniqueness reduces competition in a globalised market environment offers new possibilities to the customers enhances the added value for the company

Extension of the business model by introducing additional servicesto the customer such as availability, short lead times etc.


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No design changes

Last changes

Tool concept design Tool detailed design

Tool manufacturing

Latest finalisationof tool

Product development

Technological process chain has a huge »indirect influence« on leadtime and costs

In this period, only the tool maker isresponsible for Time-to-Market!

Only necessary work related to complexgeometries shall be performed here

All other parts of the tool can bestandardised and manufactured before

Frames, Pre-machining, Hardening,

Cooling channels, … Need for high performance processes for

hard machining with highest precision


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»EuroTooling 21«Selected case studies – relevant to create uniqueness!

CS1:Moulds for advancedinjection moulded parts

CS2: Tools for precisionand micro tooling

Product:Optical lens system

produced by plasticinjection moulding andprecision glass pressing

CS3: Moulds for small batchesof high variety IM products

Product:Toolboth machine cover

Product:New mould architecture

for injection-mouldedinterior car door panels


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Contents

Summary and outlook




Technological comparability of different branches

Technologies worldwide

IT and NC process chains



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Mold and die types and technology use

Injection molding anddie casting

Specific attributes

Surface

Accuracy

Filigree parts

Massive forming

Specific attributes

Material(temperature)

Surface zone

Accuracy

Deep-drawing

Specific attributes

Surface

Accuracy

Geometry

Punching und Bending

Specific attributes

Material

Accuracy

Surface

Focus machining of freeform surfacesPrismatic components

of tools

Importance

Milling

Turning

Grinding

Sinker EDM

Wire EDM

Machining operation

Importance Importance Importance

Machining operation Machining operation Machining operation

Milling

Turning

Grinding

Sinker EDM

Wire EDM

Milling

Turning

Grinding

Sinker EDM

Wire EDM

Milling

Turning

Grinding

Sinker EDM

Wire EDM


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Copy milling Eroding with

copper electrodes

Technological change of the mold and die making industry(mainly valid for free form surface machining)

P r o d u c t i v i t y / e c o n o m

i c e f f i c i e n c y

Automated processcombination

5-axis-simultaneous-milling

Presetting of workpieces

Handling system

Hard machining

Eroding withgraphit electrodes

HSC milling

CNC-machining Increasing share of

milling

Grade of development


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Employment of Machinery in the Mold and Die IndustryA comparative study of selected countries

A total of 164 interviews

Contacts to associations and universities

Analysis of literary sources

Brazil

USA

India

Japan

Taiwan

China Southkorea

CzechRepublic

Italy

Germany


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Typical factory equipment in the mold and die making industry -International comparision

High

Middle

Low

Portion ofproductivemachines

Germany

Italy

Czech Republic

USA

Brazil

China

Korea

Taiwan

HSC 5 axis

milling

HSC

milling

Machining

center

NC-machines

»white«

NC-machines

»green«

Manual

machines

Increasing importance of 5-axis- and HSC machines


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Importance of the CAx-process chain in mold and die making

NC-codesimulation

NC-codeoptimizing

Post processing

Simulation ofthe tool paths in CAM

CAM programming

Optimizing of the

CAD models

Machining AssemblyNC-

programmingDesign of

CAD model

Substantial steps for mold and die making:

P o s s i b l e s t e p s t o

g e n e r a t e N C - p

r o g r a m s :

- closing of surface areas- burnishing of transitions

- milling strategies- tool selection l- tool path calculation- process parameters

- tool collision- removal performance- theoretical processing

time

- translation of CAM-codes in NC-codes

- target: optimizedmachine behaviour

- collision control- machine behaviour

- real processing time

- adjustment of programheaders

- start up of cutting tools

Perception of CAx-chain Mold and die makers predominantly deal with

construction, machining and assembling of tools

Programming of NC programs often has smallshare of the whole process chain

(Estimation: 5-10%)

Only few mold and die makers perceive thepotentials of optimisation in NC-programming.

The relevance of individual process steps is notuniversal. An isolated observation is always

necessary.

Implementation ofprograms on the

machine


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Contents

Summary and outlook



High precision five axis hard milling Ceramic form inserts for sheet metal forming

Laser structuring of surfaces




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Technological competencies in entrepreneurial environment

T e c h n o l o g i c a l n e e d s

Process ability

„Needs are

exceeding

abilities“

Technology

leader

Low cost,

low quality

„Abilities are

exceeding

needs“

P r o c e s s a b i l i t y

Machine tool ability

Need for

investment

High

competence

Process with

potential for

external

sourcing

Process

optimisation

potential

Technological competencies Positioning of single technologies

Positioning the company inconsistence with the owntechnological abilities

Focus on core competencies andcontinuous innovation in thesefields


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NC-Milling in tool making – former perspective

100 % of total machining effort

75

50

25

2000199019801970 1996

Copy Milling

Simultaneous 5-axis

1 0

0 % C

N C - P e n e t r a t i o n

3- axis HSC(Finishing)

3-axis-milling(Roughing/Finishing)

2010


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NC-Milling in tool making – perspective ten years later

100 % of total machining effort

75

50

25

2000199019801970

Copy Milling

Simultaneous 5-axis

1 0

0 % C

N C - P e n e t r a t i o n

3- axis HSC(Finishing)

3-axis-milling(Roughing/Finishing)

Sim. 5-axisHSC

20102006


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Simultaneous 5-axis machiningAdvantages for tool making?

Obstacles for the introduction of simultaneous 5-axis machining

HSC-machining provides capable approaches for most of themachining tasks

High effort of CAM- programming

Limited availability of capable CAM- modules

Complex NC-process chain impairs process stability

Lessons learned in aerospace industry

Keeping tools under constant engagement conditions createsreliability even under extreme conditions

Exceeding existing limits!

Simultaneous 5-axis machining is successfully applied by the aerospace

industry These developments should be transferred to the tool- and die making

industry


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Targets Optimization of the milling process for complex geometries

in high hard tool steel up to 68 HRC Focus on complex five axis milling Integration of the whole process chain for hard milling

Procedure Further development of a fully hydrostatic milling machine Optimization of the milling tool and coating technology as

well as peripheral systems Development of novel milling tool concepts and milling

strategies following technological requirements

Results Drastic reduction of programming and machining times and

shortening of process chains Ameliorated milling tool life time and part quality

(Ra < 0,2 μm; Deviations < 5 μm)

Project information Funded by the European Commission 12/05 until 12/07

»HardPrecision«High precision five axis hard milling


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CAM and NC strategies

»HardPrecision«Holistic system optimization to reliably run process at its limit

Machine tool design

Economical evaluation

Process technologyDamped workpiece holder

Milling tools and coatings

AE process monitoringIn-machine measurement

Approach-Path

NURBS-Curveon Tool tip

NURBS-Curve –

Tool orientation

Surface to bemilled withu,v-Pathes


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Advanced process layout needs advanced tool path design!NC data analysis and optimization: NC-Profiler

current position

Software for NC- dataanalysis and optimization

B-Spline- module based onG01- programs

open XML- format for the

definition of kinematics,process, and NC-parameters

Analysis functions , graphplot, 3D- plot

3D-plot: tool path,measuring of point distance,referencing with NC- sets

Post Processing and NC-data-conversion

NCProfiler Copyright © 1999-2006 Fraunhofer IPT

d i i


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»HardPrecision«Potential of optimized tool path in roughing – circular roughing

40

80

120

160

200240 µm land wear VB

0 10 20 30 40 50 60Machined volume [cm³]

40

80

120

160

200

240 µm land wear VB

0 10 20 30 40 50 60Machined volume[cm³]

Material1.2379

S 6-5-2

S 6-5-3 PM

200 μm

200 μm

Conventional

Circular

H dP i i


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»HardPrecision«CBN for hard machining of complex moulds

CBN without edge rounding

500 μm 200 μm

CBN with edge rounding (ca. r c = 20 µm)

200 μm 100 μm

3000 6000 9000 12000Tool life [mm]

120 μm land wear VB

90

60

30

MaterialBöhler S600 (S 6-5-2)64,3 HRCToolSeco Tools; CBN200

D = 16 mm; R =4 mmParametersae =4 mmap = 0,1 mmvc = 150 m/minfz = 0,1 mm

0,4 μm roughness Ra

0,3

0,2

0,1

0

Coated carbide

i

t

h

e

o

n

i

t

h

e

o

n

K f


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»Keraform«Freeform ceramic inserts for deep drawing of hard to form materials

Quelle: IFUM

Motivation Coating of tools mostly not feasible

Significant increase of tool life by the useof Silicon Nitride Ceramic

No lubricants due to favourable tribological properties

Objective

Qualification of freeform ceramic inserts for economicdeep drawing of advanced sheet metals

Approach

Adaped tool design Optimized joining concepts for ceramic inserts

Developing of process chain for insert production basedon jig grinding, US-assisted grinding as well as laser-assisted milling

Econimical evaluation

Keraform


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Abweichung von

der Sollkontur

0,018 mm

0,012 mm

0,006 mm

0 mm

-0,006 mm

-0,012 mm

-0,018 mm

-0,024 mm

Abweichung von

der Sollkontur

0,009 mm

0,006 mm

0,003 mm

0 mm

-0,003 mm

-0,006 mm

-0,009 mm

-0,012 mm

CAD/CAMNC

5-axismachining

Machiningstrategy

Parameters

Highremoval

rates

High surfacefinish and form

accuracy

»Keraform«Process chain for 5-axis grinding of ceramic inserts

n

s

a

ep

v

f

1

2

»FlexOStruk«


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BMW AG

»FlexOStruk«Flexible and Near Net Shape 3D Laser Beam Structuring

Low flexibility High time and

costs efforts

Initial situation in theautomotive industry:

Increasing demand forsurfaces with haptic oroptical properties

At present fabrication ofdies through chemicaletching or leather linedmodels and galvaniccasting

BMW

3D Structure Design Injection Mold or 3D-Part

Digital Structure Mapping

NC Data Generation

Manufacturing Process

Structured Product

Quality Control

Measured Reference Structure CAD-based Structure 3D Part (Free-Form Surface)

Deformation free mapping of thestructures on the surface(part specifical adjustments possible)

Full generation of process para-meters by CAD/CAM-technology;laser modul control by NCProfiler

full automated 3D laser beamstructuring

direct control of thetool quality in themachine

»FlexOStruk«


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BMW AG

»FlexOStruk«5+3-Axis Laser Structuring Machine and First Test Samples (molds)

Highlights of the machine 3-axis laser system modular integrated into a 5-axisHSC milling machine: manufacturing in one clamping

NC-data in ISO-NC-code, using normal CAM-software main control unit is Heidenhain iTNC 530 motion

control linked with special software modul (NCProfiler) high ablation rate and surface quality by short pulsed

laser wide material range: steel, alu, ceramics, glass and plastic

Regular structure

Natural leather grain

Irregular structure

Synthetic loop structure»FlexOStruk«-Machine

»FlexOStruk«


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Synthetic 3Dstructures

»FlexOStruk«Application: Designed plastic surfaces of freeform interieur parts

Partoptimisation

Free formsurface

Source: IED University Essen

First test parts successfully injected

Application

Reduced struc-ture height

Source: Fraunhofer IPT


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Contents

Summary and outlook




Differentiation through technological uniqueness

…it is still worth to start tooling business in Europe!


Technology is one key success factor in future tooling business in


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Technology is one key success factor in future tooling business inhigh wage countries!

Tool making shifts from handcraft to industrial manufacturing

Manufacturing technologies are developing fast

Tool makers can differentiate through unique and focussed technology application

Technological uniqueness supports you in being a succesful toolmaker!

T e c h n o l o g i c a l n e e d s

Process ability

„Needs are

exceeding

abilities“

Technology

leader

Low cost,low quality

„Abilities are

exceedingneeds“

Focusing in Strategy and Technology

Q u a n t i t y

o f p o t e n t i a l c o m p e t i t o r

s

Price competitionAdded value through increased

customer’s benefitTechnologicaluniqueness

Extension of the business model by introducing additional servicesto the customer such as availability, short lead times etc.


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Spheres and aspheres Convex/concave Diameter 0,5-80 mm Num. aperture l/6 (@l632 nm,

15 nm RMS) Radius accuracy >1-2 μm Surface finish >2 nm RMS

Cylinder lenses Single lenses / arrays Length 10 nmRMS

10 mm

5 mm

10 mm10 mm

Aspherical micro mould Spherical macro mould

Aspherical cx/cv mould Aspherical cylinder lens array

2 mm

… it is still worth to start tooling business!


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© WZL/Fraunhofer IPT

Thank you for your attention!Dipl.-Ing. Kristian Arntz

Competence centeraachener werkzeug- und formenbau awf

Fraunhofer-Institute for Production Technology IPT

Tel: +49 (0)241 / 8904-121Fax: +49 (0)241 / 8904-6121Mail to: [email protected]

Web: www.ipt.fraunhofer.dewww.werkzeugbau-aachen.de

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Technological Process Chain - Mould Making