Technologies for tool, die and mould making â€“ Today and Tomorrow

© WZL/Fraunhofer IPT

Technologies for tool, die and mould making –Today and Tomorrow

Uddeholm Automotive Tooling Seminar 2008

Sunne, Sweden

February 7th, 2008

Dipl.-Ing. Kristian Arntz

Fraunhofer-Institute for Production Technology IPT

Aachen, Germany

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


Aachen’s Production Management Institutes

RWTH Aachenfounded 187030.000 students 5.000 students in engineering

Laboratory of Machine Tools andProduction Engineering (WZL)

founded 1906 600 employees (approx. 160 scientists)

Fraunhofer-Institute for ProductionTechnology (IPT)

founded 1980340 employees (approx. 60 scientists)

WZL Forum GmbHin-house training and seminars (e.g. Executive MBA)


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

Manufacturingtechnologies

Processtechnology

Prof. C. Brecher

Machine tools

Productionmachines

Prof. G. Schuh

Productionmanagement

Technologymanagement

Departments

Chairs

Metrology and quality

Metrology andquality management

Prof. R. Schmitt


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 ExcellenceEffectiveness and efficient processes

Technological ExcellenceOptimal use of technologies

Industry

Excellence-in-ProductionPatron: BDI-President J. ThumannPartner: VDI, VDMA, VDA, Federal Ministryof Economic Affairs and Employment

Most challenging contest for producing enterprises

Up to 300 involved companies per annum

Toolmaker of the year

ColloquiumMost 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


Integrated Benchmarking...learn from the best!

Our Service for Tool Shops

Strategy development & implementationMarket & Competition analysesCost & Lead time reductionGlobal purchase & Tool supplySupply ManagementCalculationPremium wage

Selection of technology & optimizationProcess chain designAutomation & HandlingSimulation & CAD/CAMPPS & PDM selectionMetrology & Quality

Strategic Excellence Technological Excellence

Successful in tool making!


Contents

Summary and outlook




European tool makers have to differentiate!

Strategic alternatives through technology

Measures for future success



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 annual average

66.160 €

5.875 €

58.407 €

4.801 €

Germany

Germany Germany

*)Ø annual average

Personnel costs*


Focusing in Strategy and Technology

Differentiation through technological uniquenessQ

uan

tity

of

po

ten

tial

co

mp

etit

ors

Price competitionAdded value through increased

customer’s benefitTechnologicaluniqueness

Technological uniqueness reduces competition in a globalised market environmentoffers new possibilities to the customersenhances the added value for the company

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


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 hereAll other parts of the tool can bestandardised and manufactured before

Frames, Pre-machining, Hardening, Cooling channels, …

Need for high performance processes forhard machining with highest precision


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

CS1:Moulds for advanced injection moulded parts

CS2: Tools for precision and micro tooling

Product:Optical lens system produced by plastic injection moulding and precision glass pressing

CS3: Moulds for small batches of high variety IM products

Product:Toolboth machine cover

Product:New mould architecture for injection-mouldedinterior car door panels


Contents

Summary and outlook




Technological comparability of different branches

Technologies worldwide

IT and NC process chains



Mold and die types and technology use

Injection molding and die casting

Specific attributesSurfaceAccuracyFiligree parts

Massive forming

Specific attributesMaterial (temperature)Surface zoneAccuracy

Deep-drawing

Specific attributesSurfaceAccuracyGeometry

Punching und Bending

Specific attributesMaterialAccuracySurface

Focus machining of freeform surfaces Prismatic componentsof tools

Importance

MillingTurning

GrindingSinker EDM

Wire EDM

Machining operation

Importance Importance Importance

Machining operation Machining operation Machining operation

MillingTurning

GrindingSinker EDM

Wire EDM

MillingTurning

GrindingSinker EDM

Wire EDM

MillingTurning

GrindingSinker EDM

Wire EDM


Copy millingEroding withcopper electrodes

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

Pro

du

ctiv

ity/

eco

no

mic

effi

cien

cy

Automated processcombination5-axis-simultaneous-milling

Presetting of workpiecesHandling systemHard machining

Eroding withgraphit electrodesHSC milling

CNC-machiningIncreasing share of milling

Grade of development


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

A total of 164 interviewsContacts to associations and universitiesAnalysis of literary sources

Brazil

USA

India

Japan

Taiwan

ChinaSouthkorea

Czech Republic

Italy

Germany


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

millingHSC

millingMachining

centerNC-machines

»white«NC-machines

»green«Manual

machines

Increasing importance of 5-axis- and HSC machines


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

NC-codesimulation

NC-codeoptimizing

Post processing

Simulation of the tool paths in CAM

CAM programming

Optimizing of theCAD models

Machining AssemblyNC-

programmingDesign of

CAD model

Substantial steps for mold and die making:

Poss

ible

step

sto

g

ener

ate

NC

-pro

gra

ms:

- 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: optimized machine behaviour

- collision control- machine behaviour- real processing time

- adjustment of program headers

- 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 small share of the whole process chain(Estimation: 5-10%)

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

The relevance of individual process steps is not universal. An isolated observation is always necessary.

Implementation ofprograms on the

machine


Contents

Summary and outlook



High precision five axis hard milling

Ceramic form inserts for sheet metal forming

Laser structuring of surfaces




Technological competencies in entrepreneurial environmentTe

chno

logi

caln

eeds

Process ability

„Needs areexceeding

abilities“

Technology leader

Low cost, low quality

„Abilities areexceeding

needs“

Pro

cess

abili

ty

Machine tool ability

Need forinvestment

Highcompetence

Process withpotential for

externalsourcing

Processoptimisation

potential

Technological competencies Positioning of single technologies

Positioning the company in consistence with the owntechnological abilities

Focus on core competencies and continuous innovation in thesefields


NC-Milling in tool making – former perspective

100 % of total machining effort

75

50

25

2000199019801970 1996

Copy Milling

Simultaneous 5-axis

100

% C

NC

-Pen

etra

tion

3- axis HSC(Finishing)

3-axis-milling(Roughing/Finishing)

2010


NC-Milling in tool making – perspective ten years later

100 % of total machining effort

75

50

25

2000199019801970

Copy Milling

Simultaneous 5-axis

100

% C

NC

-Pen

etra

tion

3- axis HSC(Finishing)

3-axis-milling(Roughing/Finishing)

Sim. 5-axisHSC

20102006


Simultaneous 5-axis machiningAdvantages for tool making?

Obstacles for the introduction of simultaneous 5-axis machining

HSC-machining provides capable approaches for most of the machining 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 creates reliability 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


TargetsOptimization of the milling process for complex geometries in high hard tool steel up to 68 HRCFocus on complex five axis millingIntegration of the whole process chain for hard milling

ProcedureFurther development of a fully hydrostatic milling machineOptimization of the milling tool and coating technology as well as peripheral systemsDevelopment of novel milling tool concepts and milling strategies following technological requirements

ResultsDrastic reduction of programming and machining times and shortening of process chainsAmeliorated milling tool life time and part quality (Ra < 0,2 μm; Deviations < 5 μm)

Project informationFunded by the European Commission12/05 until 12/07

»HardPrecision«High precision five axis hard milling


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-Curve on Tool tip

NURBS-Curve –Tool orientation

Surface to be milled with u,v-Pathes


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

current position

Software for NC- data analysis and optimization

B-Spline- module based on G01- programs

open XML- format for the definition of kinematics, process, and NC-parameters

Analysis functions , graph plot, 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


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

40

80120

160200

240 µm land wear VB

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

40

80120

160200

240 µm land wear VB

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

Material1.2379S 6-5-2S 6-5-3 PM200 μm

200 μm

Conventional

Circular


»HardPrecision«CBN for hard machining of complex moulds

CBN without edge rounding500 μm 200 μm

CBN with edge rounding (ca. rc = 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; CBN200D = 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

Wit

ho

ut

edg

ero

un

din

g

Wit

hed

ge

rou

nd

ing


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

Quelle: IFUM

MotivationCoating of tools mostly not feasibleSignificant increase of tool life by the useof Silicon Nitride CeramicNo lubricants due to favourable tribological properties

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

ApproachAdaped tool designOptimized joining concepts for ceramic insertsDeveloping of process chain for insert production basedon jig grinding, US-assisted grinding as well as laser-assisted millingEconimical evaluation


Abweichung von der Sollkontur

0,018 mm0,012 mm0,006 mm0 mm

-0,006 mm-0,012 mm-0,018 mm-0,024 mm

Abweichung von der Sollkontur

0,009 mm0,006 mm0,003 mm0 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

ns

aeap

vf

ϕ1

ϕ2


BMW AG

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

Low flexibilityHigh time and costs efforts

Initial situation in the automotive industry:

Increasing demand for surfaces with haptic or optical propertiesAt present fabrication of dies through chemical etching or leather lined models and galvanic casting

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 the structures 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 beam structuring

direct control of the tool quality in the machine


BMW AG

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

Highlights of the machine3-axis laser system modular integrated into a 5-axis HSC milling machine: manufacturing in one clampingNC-data in ISO-NC-code, using normal CAM-softwaremain control unit is Heidenhain iTNC 530 motion control linked with special software modul (NCProfiler)high ablation rate and surface quality by short pulsed laserwide material range: steel, alu, ceramics, glass and plastic

Regular structure

Natural leather grain

Irregular structure

Synthetic loop structure»FlexOStruk«-Machine


Synthetic 3D structures

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

Part optimisation

Free formsurface

Source: IED University Essen

First test parts successfully injected

Application

Reduced struc-ture height

Source: Fraunhofer IPT


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 high 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!

Tech

nolo

gica

lnee

ds

Process ability

„Needs areexceeding

abilities“

Technology leader

Low cost, low quality

„Abilities areexceeding

needs“

Focusing in Strategy and Technology

Qu

anti

ty o

f p

ote

nti

al c

om

pet

ito

rs

Price competitionAdded value through increased

customer’s benefitTechnologicaluniqueness

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


Spheres and aspheresConvex/concaveDiameter 0,5-80 mmNum. aperture <0,9Accuracy >l/6 (@l632 nm, 15 nm RMS)Radius accuracy >1-2 μmSurface finish >2 nm RMS

Cylinder lensesSingle lenses / arraysLength <100 mmOpt. aperture <0,85Accuracy >l (@l632 nm)Surface finish >10 nm RMS

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!

© 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 / 8904-6121 Mail to: [email protected]

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

Documents

Technologies for tool, die and mould making â€“ Today and Tomorrow