technological process chain - mould making
TRANSCRIPT
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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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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
Tomorrow: Technological uniqueness
Excellence in tool and die making
Competence center aachener werkzeug- und formenbau
European tool makers have to differentiate!
Strategic alternatives through technology
Measures for future success
Today: Technology use in tool making
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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
Tomorrow: Technological uniqueness
Today: Technology use in tool making
Competence center aachener werkzeug- und formenbau
Technological comparability of different branches
Technologies worldwide
IT and NC process chains
Excellence in tool and die making
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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
Excellence in tool and die making
Competence center aachener werkzeug- und formenbau
High precision five axis hard milling Ceramic form inserts for sheet metal forming
Laser structuring of surfaces
Tomorrow: Technological uniqueness
Today: Technology use in tool making
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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
Tomorrow: Technological uniqueness
Excellence in tool and die making
Competence center aachener werkzeug- und formenbau
Differentiation through technological uniqueness
…it is still worth to start tooling business in Europe!
Today: Technology use in tool making
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