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Machine tools | Standards | EDM technology | Accessories | 85088
mold & die journal
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18International magazine Issue 3/2018
The
The HSC machine - combining the best of the best:
The new HSC MP7.
The new HSC MP7. If better, then at its best.“
When we are talking about proper further development, we are thinking in many different directions – instead of just one. This is why we did not just equip our new HSC machine with a linear drive, but developed a completely optimised machine concept: the HSC MP7. “Micro Precision” for maximum precision, a greater variety of applications, minimum downtime and the-refore, higher efficiency and profitability. Do you want to know more? We are happy to provide information on all questions regarding HSC and EDM. www.exeron.de
exer
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Cover 3-2018.indd 1 16.05.18 09:06
Manifold block Z 920 /. . .For simple configuration of flexible cooling circuits. The clear arrangement of cooling lines ensures greater safety at the workplace and more reliable production.
– Clear arrangement of feed and return lines– Hoses connected via fixed screw connections or nipple / coupling combinations– Central inflow/outflow enables shorter hose lengths and energy savings www.hasco.com
AMERIMOLD
Novi /MI, booth 217
June 13 - 14, 2018
I distribute reliably.
Anz_Z920_A4_EN.indd 1 04.05.18 12:04
www.fachverlag-moeller.de The mold & die journal 3/2018
EDITORIAL
3
mould maker these days. Since the achievable sales price for moulds and tools has dropped considerably over the last years, the costs and time margin for eventual corrective measures at mould maker’s expense has shrunk as well. Extensive reworking on moulds or on items produced with them may infl ict severe economic hardship on the tool making companies. A close cooperation between the customer and the mould maker from the design phase right up to mould construction for the items to be produced is of course the best way to create optimal equipment. “Simultaneous Engi-neering” is the buzzword for such cooperation .It is especially helpful if prior to the mould making, a prototype of the item to be produced is pre-pared through Rapid-Prototyping technique.
Dipl.-Ing. K.-H. Möllerpublisher
The mold & die journal
About risks and side effects inmould making…
Mass production equipment like injection- , press- and foaming moulds etc. are – with the excep-tion of progressive tools – always-single unit productions. Therefore, these may as well be classifi ed as special machines which have to be newly constructed and pro-duced for every single item to be manufactured with them.Since mould making is one of the most complex fi elds of metal technology, the mould producer has to live with the constant risk that the tool produced matches fully with the sample or the technical drawing and that it will function optimally in mass production. Like the sword of Damocles hanging over him, the mould maker suff ers constantly from the impending danger that the sampling of tools may reveal shortcomings for which he has to take responsibility, rework them and in case of failure, he may be held liable for the side eff ects. As is common knowledge, this can become expensive.
How can one avoid such risks?
Generally, in the mould making business, risks and side eff ects cannot be avoided fully.Painstakingly installed safeguard measures against customer’s notice of defects and warranty claims are essential for every
Along with a technical drawing describing the item to be produ-ced precisely, such a prototype is best suited in avoiding misunder-standings. Further, in many cases, the customer and the mould maker can easily identify as to which function related dimensions must have tight tolerances for cost optimised mould production. Prototypes also allow advance installation and functional tests thus avoiding cost and time inten-sive reworking.So far so good. Every professional knows however that the optimum cooperation described up to this point is relatively rare. This means for the mould maker that he has to safeguard himself in any case through appropriate business terms and conditions in such a way that the risks and their side eff ects are calculable and thus can be limited to a manageable degree.
S. 3 Kommentar engl. aus 3/2013.indd 3 16.05.18 09:10
The mold & die journal 3/2018 www.fachverlag-moeller.de4
TABLE OF CONTENTS
About risks and side effects in mould making ........... 3
Breaking down barriers in additive tooling ................. 6
Side-mounted operating cylinder for hot runner needle valve nozzles................................................... 8
Increasing market of packaging made of plastic ..... 10
Valve gate systems for small mould dimensions...... 11
REHAU trainees take off ........................................... 12
Needle opening control in cascade injection molding ..................................................................... 16
Water-miscible coolant for drilling and milling operations ................................................................ 20
New vacuumjet devices ........................................... 22
Build-in cylinder with flange ..................................... 23
Evaluation unit for easy and reliable measurement .. 24
Increasing part quality and time efficiency via Autonomous Optimization ........................................ 26
Innovative solutions for efficient temperature control ...................................................................... 27
Machining centers with scalable automation advance manufacturers' agility and autonomy ........ 28
Large-scale machining center delivers maximum versatility .................................................................. 31
Perfect combination for structural parts .................. 32
Solid carbide finishing mills with diameters from 2 mm (0.0787") ......................................................... 35
Fully screwed together and wired hot runner systems .................................................................... 36
The dovetail pin allows flat workpieces to be clamped directly ....................................................... 37
Innovative machinery and processes at the Plast .... 38
New stack mould components ................................ 41
formnext on track for further success ...................... 42
High-performance bandsaw halves cutting times.... 44
New die-sinking EDM machines .............................. 48
Tablet instead of an oil can ....................................... 50
NEWS ....................................................................... 55
Advertising Companies & Order Card ...................... 58
Publisher:Dipl.-Ing. Karl-H. Möller
Publishing house and advertising:Technischer Fachverlag MöllerP.O.Box 10 07 7242507 Velbert, Germany Neustraße 16342553 Velbert, Germany
Telephone: Operator: +49 / 20 53 / 981 25-0Editing: +49 / 20 53 / 981 25-17Ads department: +49 / 20 53 / 981 25-13Telefax: +49 / 20 53 / 981 25-6
Published bimonthly: six times a year www.koessingerag.de
Purchase prices: Annual subscription (six issues) EUR 30.-- plus postage (foreign countries)
Price per issue: EUR 10.-- plus postage (foreign countries)
imPrinT
registry court: Municipal Court: Wuppertal, GermanyTrade Register No.: HRA 21087Owner: Dipl.-ing. Karl-Heinz möller VelbertBank details:Deutsche Bank AG:BIC-Code: DEUTDEDBWUP IBAN-Nr.: DE52 3307 0024 0462 1694 00Commerzbank:BIC-Code: DRESDEFF332 IBAN-Nr.: DE65 3308 0030 4592 7948 00Postbank Essen:BIC-Code: PBNKDEFF360IBAN-No.: DE58 3601 0043 0168 6354 35UBS Bank: BIC-Code: UBSWCHZH80A IBAN-No.: CH64 0023 3233 8029 74J1 FBeneficiary:K.-H. Möller
Member of German Audit Bureau of Circulations
S. 04 Table of contents 3/18.indd 4 16.05.18 10:38
Magazin: The Mold & Die Magazin Sprache: EN Format: 210x297 + 3 mm Thema: Hydraulik AS: 21.03.2018
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The mold & die journal 3/2018 www.fachverlag-moeller.de6
FAIR REPORT
Breaking down barriers in additive toolingTools, Mould and Fixture Making forum on 5 June to highlight current developments in additive tooling
Dynamically tempered tools help improve the quality of injection moulded components. Channels fi lled with hot or cold liquid directly under the tool surface are proving to be the most eff ective. Selective laser melting is particularly well suited to the manufacture of such channels. It can also be used to produce hybrid tools, where complex struc-tures are additively constructed with conformal tempering on classic tool base plates or inserts. Researchers from the Zurich University of Applied Sciences will report their re-sults in this fi eld at the Tools, Mould and Fixture Making forum on 5 June 2018 at Rapid.Tech + FabCon 3.D in Erfurt.
Hybrid processes will also be the subject of a presentation by Gefertec, a mechanical engi-neering and process developer for additive manufacturing. The presentation will illustrate how the capacity of arc-based additive manufacturing can be signifi cantly expanded with the 3DMP pro-cess using integrated subtractive machining units. “These issues also demonstrate a trend in addi-tive tooling – combining various procedures into hybrid processes in order to generate further per-formance improvements through-out the entire production chain”, emphasised Holger Löffl er from Vorwerk Elektrowerke GmbH & Co. KG. He is jointly responsi-ble for the content of the forum alongside Dietmar Frank of EOS GmbH. Another current trend is size. “We are breaking down barriers in additive tooling thanks to ever-more sophisticated processes and technology. We can now manufacture larger components, which then also allows us to tap into new applications”, said Holger Löffl er in reference to the eff ects of this development. The Thuringia-based research group “Temperierte Großwerkzeuge” (Tempered Industrial Tools) will present an example of this. They
Breaking down barriers in additive tooling.indd 6 16.05.18 09:13
The mold & die journal 3/2018 www.fachverlag-moeller.de www.fachverlag-moeller.de The mold & die journal 3/2018
FAIR REPORT
7
design additive processes such as arc welding and diff usion bonding in such a way that they can make geometrically large moulds with complex tempering channel structures. The forum topics also demon-strate that additive tooling has already achieved a high level of maturity in many areas and that it leads to economic benefi ts. Stratasys will show that FDM-manufactured plastic devices are already profi table thanks to low manufacturing costs and short production times. Swiss company Avonisys will provide information on the 3D printing of tyre moulds using liquid jet laser technology and mould design. RWTH Aachen University will present research on material choices for the additive manufacturing of polymer tools. A presentation by Kunststoff -Institut Lüdenscheid will cover meth-ods for the 3D printing of plastic mould inserts to make prototypes that are virtually market ready. The Tools, Mould and Fixture Making forum is part of the Rapid.Tech + FabCon 3.D international trade show and conference for additive technologies, which will take place from 5 to 7 June 2018 at Messe Erfurt. The event is celebrating its 15th anniversary this year. It has been held in Erfurt since 2004, and is a pioneer of 3D printing technologies at interna-tional level. Its comprehensive conference programme, the only (Pictures: Messe Erfurt GmbH, Erfurt, Germany)(Pictures: Messe Erfurt GmbH, Erfurt, Germany)
one of its kind, also includes the Users Conference and AM Sci-ence forum being held on 6 and 7 June, respectively. New this year, held across both days, will be the Medical, Dental and Orthopaedic technology forum. Another new forum on Law will be held on 5 June, alongside the Additive Contract Manufacturing, Design and Automotive Industry forums. The 3D-Printed Electronics & Functionality and 3D Metal Print-ing forums will follow on 6 June, with the Aviation forum on 7 June closing the three-day long fair. The 3D printing community will once again come together on all three days for the 3D Printing Conference. As well as discuss-ing current issues and technical innovations, speakers will give
behind-the-scenes insights into their research and development activities and selected competi-tions. Talks will cover everything from start-up fi nancing to digital fabrication to education. Messe Erfurt is once again looking for the most innovative company found-ers for its Start-Up Award and the best design ideas for its 3D Pioneers Challenge. More than 200 exhibitors will be presenting the latest develop-ments, products and services in additive manufacturing at the sold-out trade fair. In 2017, 4,800 (2016: 4,500) trade visitors and conference partici-pants, and 207 exhibitors (2016: 176) from 13 countries attended Rapid.Tech + FabCon 3.D in Erfurt.
Breaking down barriers in additive tooling.indd 7 16.05.18 09:14
The mold & die journal 3/2018 www.fachverlag-moeller.de8
TECHNICAL ESSAYS
With its new side-mounted cylinder, Italian hot runner spe-cialist HRSfl ow has developed a constructional solution in which the hydraulically or pneumatically driven operating cylinder for the needle valve nozzle is positioned on the outside of the mold. This confi guration provides time and cost benefi ts in repair and main-tenance work, and also makes it possible to dispense with the otherwise necessary cooling facilities – without making any compromises in terms of perfor-mance and reliability. The new development involves keeping the cylinder away from the hot runner. As a result, the components of the overall sys-tem can be accessed more eas-ily and conveniently. Work can be carried out on the cylinder without having to disassemble the mold. Conversely, the opera-tor can carry out maintenance work on the hot runner system by simply removing the mani-
Side-mounted operating cylinder for hot runner needle valve nozzles
folds from the levers and leaving the cylinders mounted on the mold plate. The second big advantage of the side-mounted cylinder comes from it being placed far away from the manifold area. As a result, uncooled operation of the hydraulic or pneumatic cylinder is possible. The fact that there is no need for cooling lines or respective connections makes it possible to signifi cantly simplify the confi guration of the hot run-ner system and thus also of the connections in the mold.
Suitable for the innovative FLEXfl ow technology
The cylinder positioned on the side of the mold for operating the needle valve can be con-verted without much work from a hydraulic or pneumatic drive system to a servo-electric sys-tem of the FLEXfl ow hot runner needle valve solutions developed
by HRSfl ow because the levers and extensions used to move the pins are the same. The innovative FLEXfl ow tech-nology is a signifi cant step forward in sequential injection molding because, thanks to the integrated servo-electric needle drive, it off ers a variety of pos-sibilities for setting the process parameters. For example, the individual pins of a hot runner system can be controlled inde-pendently of one another with regard to their stroke, velocity and force. As a result, users can control the pressures and fl ow rates accurately, easily and fl ex-ibly during the entire mold-fi lling process and thus optimize the quality of their injection-molded parts. The advantages attainable in this way over conventional needle valve systems make it possible not only to manufacture large Class A surfaces but also to re-duce warpage. The products are also suitable for cleanroom ap-plications thanks to the dry and clean method of working. Other benefi ts include the maintenance and user friendliness, and the possibility of lowering the clamp-ing force by around 20 % and the weight of the part by up to 5 % - with outstandingly high reproducibility.
Side-mounted cylinder: The maintenance-friendly operating cylinder mounted on the side of the mold is suitable for hydraulic or pneumatic drive systems and can be easily converted to the servo-electric drive of the FLEXfl ow hot runner systems from HRSfl ow(Picture: HRSfl ow, San Polo di Piave (TV), Italy)
Side-mounted operating cylinder for hot runner needle valve nozzles .indd 8 16.05.18 09:14
The mold & die journal 3/2018 www.fachverlag-moeller.de8
TECHNICAL ESSAYS
With its new side-mounted cylinder, Italian hot runner spe-cialist HRSfl ow has developed a constructional solution in which the hydraulically or pneumatically driven operating cylinder for the needle valve nozzle is positioned on the outside of the mold. This confi guration provides time and cost benefi ts in repair and main-tenance work, and also makes it possible to dispense with the otherwise necessary cooling facilities – without making any compromises in terms of perfor-mance and reliability. The new development involves keeping the cylinder away from the hot runner. As a result, the components of the overall sys-tem can be accessed more eas-ily and conveniently. Work can be carried out on the cylinder without having to disassemble the mold. Conversely, the opera-tor can carry out maintenance work on the hot runner system by simply removing the mani-
Side-mounted operating cylinder for hot runner needle valve nozzles
folds from the levers and leaving the cylinders mounted on the mold plate. The second big advantage of the side-mounted cylinder comes from it being placed far away from the manifold area. As a result, uncooled operation of the hydraulic or pneumatic cylinder is possible. The fact that there is no need for cooling lines or respective connections makes it possible to signifi cantly simplify the confi guration of the hot run-ner system and thus also of the connections in the mold.
Suitable for the innovative FLEXfl ow technology
The cylinder positioned on the side of the mold for operating the needle valve can be con-verted without much work from a hydraulic or pneumatic drive system to a servo-electric sys-tem of the FLEXfl ow hot runner needle valve solutions developed
by HRSfl ow because the levers and extensions used to move the pins are the same. The innovative FLEXfl ow tech-nology is a signifi cant step forward in sequential injection molding because, thanks to the integrated servo-electric needle drive, it off ers a variety of pos-sibilities for setting the process parameters. For example, the individual pins of a hot runner system can be controlled inde-pendently of one another with regard to their stroke, velocity and force. As a result, users can control the pressures and fl ow rates accurately, easily and fl ex-ibly during the entire mold-fi lling process and thus optimize the quality of their injection-molded parts. The advantages attainable in this way over conventional needle valve systems make it possible not only to manufacture large Class A surfaces but also to re-duce warpage. The products are also suitable for cleanroom ap-plications thanks to the dry and clean method of working. Other benefi ts include the maintenance and user friendliness, and the possibility of lowering the clamp-ing force by around 20 % and the weight of the part by up to 5 % - with outstandingly high reproducibility.
Side-mounted cylinder: The maintenance-friendly operating cylinder mounted on the side of the mold is suitable for hydraulic or pneumatic drive systems and can be easily converted to the servo-electric drive of the FLEXfl ow hot runner systems from HRSfl ow(Picture: HRSfl ow, San Polo di Piave (TV), Italy)
Side-mounted operating cylinder for hot runner needle valve nozzles .indd 8 16.05.18 09:14
1.1730
1.1730 1.2312 1.1730 1.2312 1.2311
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Anz. Milacron 3-18.indd 1 16.05.18 09:15
The mold & die journal 3/2018 www.fachverlag-moeller.de10
TECHNICAL ESSAYS
Over the past 30 years, KIEFER Werkzeugbau GmbH has devel-oped into a specialist in the fi eld of toolmaking for plastics process-ing. With more than 100 employ-ees worldwide at the Schwaigern headquarters and three other
Increasing market of packaging made of plastic
locations, toolmaking has devel-oped to become a globally active group of companies. KIEFER's range of services today includes thermoforming and injection mold-ing tools, as well as stretch blow molds. The heart of the KIEFER Werkzeugbau GmbH is still ther-moforming molds. Large food groups and their suppliers are now part of the customer base and they order molds for bowls, lids, cups and the associated steel rule dies, match metal dies and stack-ing units. But also medical prod-ucts, pills, shavers, toothbrushes or dressings are to be packed for the customer in an interesting, hygienic and ultimately sales-promoting way. KIEFER supplies the tools for the production of all conceivable forms, creative per-formance of the KIEFER company included. Industry 4.0 is currently of very big interest. Communica-tion between machines, parts of machines and tools is increasing and is increasingly part of modern production processes. This also applies to the multi-layered pro-
(Pictures: KIEFER Werkzeugbau GmbH, Schwaigern, Germany)
cess of thermoforming also which is increasingly monitored, evalu-ated and ultimately optimized by electronic components / sensors. Considering sustainability with ever-increasing raw material and energy prices, of course, always require new, economical concepts in the area of thermoforming tools. New solutions are also constantly being developed in this area. KIEFER has long established itself fi rmly in the market of thermo-formers and is one of the top ten addresses of the industry world-wide. As modern tool and mold making, KIEFER is fast and eff ec-tive. Design paired with decades of product know-how is used to the advantage of the customers and very much appreciated by them. Technologies such as laser processing and 5-axis CNC milling up to 3 m machining size support this. In order to maintain this posi-tion, investment in qualifi ing young people is becoming increasingly important. The training rate at KIEFER is 10-15 %. The aim is to gain a skilled and versatile training to attract qualifi ed specialists for the future. A technology center for test runs of new tools also belongs to the KIEFER Group for several years. In addition, some patents and utility models are fi led every year. The need to always be a step ahead of the competition has not become smaller even after 30 years. Innovation, precision and experience continue to form the foundation and success for the future.
Increasing market of packaging made of plastic.indd 10 16.05.18 09:15
www.fachverlag-moeller.de The mold & die journal 3/2018
TECHNICAL ESSAYS
11
Valve gate systems for small mould dimensions
2/ The sliding mechanism of the 16-drop valve gate system shown here enables pre-cisely synchronized opening and closing of the needles thanks to its mechanical coupling(Pictures: GÜNTHER Heisskanaltechnik GmbH, Frankenberg, Germany)
GÜNTHER Hot Runner Technol-ogy off ers its valve gate systems for small mould dimensions as an outstanding solution for precisely these kinds of high-quality appli-cations. As these drive concepts for valve gate technology can be controlled with a high degree of precision, they are ideal for pro-ducing items which require con-sistently high gate point quality. Innovative needle guide and shut-off needle design geometries result in low-wear operation and a long needle guide service life. The sliding mechanism used on systems with a greater number of drops enables tight cavity spac-ing of 9 millimetres or more and
Modern plastics are subject to a host of diff erent requirements. Customers in the con-sumer goods and packaging fi elds want an attractive design and perfect surfaces with a pleasant feel. Medical technology and electrical engineering require moulded parts with complex geometries, often with minimal wall thicknesses. Items which meet these needs can only be created using very stable processes which guarantee maximum precision.
1/ Specially coated sliding components provide optimum wear protection and can also be replaced by the customer
precisely synchronised opening and closing of the needles thanks to its mechanical coupling. Valve gate systems with up to eight needles are optimally outfi tted with a lifting plate system. The drive can be either pneumatic or hydraulic as desired. Hot runner nozzles with melt channel diam-eters from 4 to 12 millimetres are used with both system versions. Adjustment of the needle position can optionally be carried out while installed. Special openings in the mould clamping plate and the needle suspension with adjust-ment thread and adjustment nut enable individual position setting of the shut-off needle from the outside. Thanks to front instal-lation of the NTT nozzles, they
FRÄSEN + BOHRENThis technical magazine serves a reader-ship engaged in the milling and drilling business. Topics include CNC milling, HSC milling, milling machines, milling tools, drilling machines, drill bits, cooling lubricants etc.
For a sample magazine and further infor-mation please contact:
Fachverlag Möller • Neustraße 163 • 42553 Velbert, GermanyPhone: +49 (0 )20 53/98 12 5-11 • Fax: +49 (0 )20 53/98 12 56www.fachverlag-moeller.de • e-mail: [email protected]
Maschinen Werkzeuge Anwenderberichte Interviews Messeberichte 79223
FRÄSEN BOHREN BOHREN+
www.fachverlag-moeller.de Ausgabe 6/2014
www.iscar .de
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FRÄSEN + BOHRENThis technical magazine serves a readership engaged in the milling and drilling business. Topics include CNC milling, HSC milling, milling machines, milling tools, drilling machines, drill bits, cooling lubricants etc.
For a sample magazine and further information please contact:Fachverlag Möller • Neustraße 163 • 42553 Velbert, Germany • www.fraesen24.comPhone: +49 (0 )20 53/98 12 5-11 • Fax: +49 (0 )20 53/98 12 56 • e-mail: [email protected]
Maschinen Werkzeuge Anwenderberichte Interviews Messeberichte 79223
FRÄSEN BOHREN BOHREN+
www.fachverlag-moeller.de Ausgabe 6/2014
www.iscar .de
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can be easily replaced for mould separation. Easy replacement of all wear parts makes GÜNTHER valve gate systems even more at-tractive to use.
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The mold & die journal 3/2018 www.fachverlag-moeller.de12
USER REPORT
Author: Dr. Michael Thielen, freelance editor
REHAU trainees take off Training project: Four injection moulding tools with HASCO standard mould components
REHAU sees itself as a premium brand for polymer-based solu-tions in the fi elds of construction, automotive and industry. The company's tool-making depart-ment and its training workshops use standard mould units from HASCO, and frequently rely on HASCO's expertise. In close co-operation with this Lüdenscheid/Germany-based manufacturer of standard mould components, four trainees have produced, as part of a comprehensive training project, four injection moulding tools for a miniature rocket – the object chosen to symbolise change at REHAU. 1/ The REHAU trainees Julian Rießbeck, Robert Baumann, Sven Thiede, Simon Korta with
Christian Beer (technical instructor, REHAU) and Matthias Popp (technical sales engineer, HASCO) from left to right
Inspire
Smartify Focus
Simplify
Vision
Mission
Company Values
2/ REHAU takes off
In 2010, the fi rm REHAU AG + Co, headquartered in Rehau in south-ern Germany, built a large training centre in a historical building in the town to give young people specialist training in combination
with their technical training at the company's production plant. "As in practice, as in real life," says Christian Beer, a technical instructor at REHAU. In total, the REHAU Group supports around 600 young people at nine training centres, with 200 of them current-ly employed by Rehau. Alongside commercial courses, the com-pany also off ers various technical courses leading to qualifi cations in eight professions. At present some 100 young people are reg-istered, with many of them taking dual training courses with studies at Hof University.
REHAU 2020
Like many industrial companies, REHAU is in the process of un-dergoing change to make itself fi t for the future and strengthen its position as the technology leader in their respective industries. The
"Rocket" symbolises this change with the concept: "REHAU takes off ". The symbol was chosen by a team of trainees for their fi nal project in their last training year. With the support of the instruc-tors and HASCO, they produced the moulds for manufacturing a miniature rocket. Because the possibilities of the 150 kN Arburg injection mould-ing machine in the training work-shop are limited, the length of the rocket was fi xed at 100 mm. The project was then placed internally within the company and carried out by four tool mechan-ics. The production of various sections of the moulds consti-tuted part of the fi nal examination for the trainees. At the end of the project, the complete moulds – apart from the nitriding of the ejector pins – were produced in-house at REHAU. Overall, four injection moulding
REHAU trainees take off.indd 12 16.05.18 10:50
