Makino Europe’s Customer Magazine

Precisely!www.makino.eu

01|2016

ACCURER

Accurate by name. Accurate by natureSTERCH INTERNATIONAL

Where the design matters!BERGS Precise in volumetric accuracy, dynamic along contourINTERNATIONAL AEROSPACE AND DIE & MOULD FORUM The first event in the house of extremesINDUSTRIE 4.0 AWARD Production of the Industrie 4.0 Award

Welcometo the House of Extremes

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Makino Europe’s Customer MagazinePrecisely! 01|20162 3

Towards the end of last year, Makino invited customers and partners to a series of Technology Days at some of our major Technology Centres across Europe (Kirchheim Teck, Cavenago di Brianza, Bratislava). The basic idea behind this series was to allow customers in the die&mould, aerospace and auto- motive industries to gain a deeper insight into high-performance, high-quality processes and technologies than can usually be demonstrated at exhibitions. Such focused events also provide us at Makino with opportunities to learn more about custom- ers’ expectations today and for the future, and have an active and fruitful exchange as to how their expectations can be met – or even exceeded!

The International Aerospace and Die & Mould Forums in late November 2015 were most certainly a highlight as they attracted more than 600 participants. They were staged in the newly opened extension to our Kirchheim facility, which is now Makino’s largest Technology Centre in Europe. And it is in this 2,000 m2 showroom that we are planning a new series of technology workshops on selected topics of particu- lar interest in the coming months. We will keep you informed.

The Makino Technology Days were also an opportunity to reveal a number of new technologies. I should like to draw your attention to two software innovations first presented. The first one, the Makino PRO6 CNC controller, makes previ-ously unattained levels of machine performance possible in the milling sector. Developed to meet our customers’ need for enhanced machining processes, it achieves this goal by reducing the risk of collision, streamlining and facilitating operability, and improving machine performance. The second innovation, Makino’s new-generation Hyper i CNC controller, now brings clear benefits in both wire and sinker EDM opera- tions. Since Hyper i is easier and more intuitive to operate, even less experienced operators can profit from the know-how of Makino’s application engineers and rapidly achieve outstanding results. Two additional innovations products are worth mentioning, too: the Makino U86 high-precision wire EDM has been enhanced to deliver even more versatile and accurate machining of large parts in non-stop working opera- tions; and Makino’s ultra-high-precision vertical micro- machining centre, the iQ300, now offers a mirror surface option for manufacturing optical surfaces of the highest possible quality.

In this edition of PRECISELY we feature three outstanding stories from Makino customers. Two are successfully oper- ating in the aerospace segment, Accurer in Spain (pp. 4-6) and Sterch in the Czech Republic (pp. 7-9), and one is a die&mould customer from Austria, Bergs Kunststofftechnik (pp. 10-12). That story, in particular, provides impressive evidence of Makino’s 5-axis competence, as did our milling of the Industrie 4.0 Award for the German trade magazine Produktion. That trophy was milled to perfection on a Makino 5-axis machine at our 5AX Competence Centre in Cavenago. Finally, it goes without saying that, in between all exhibitions, technology days and customer workshops, we are pleased to welcome you at any of our Technology Centres for an in-dividual demonstration of our various technologies and their performance. You may expect the extraordinary!

Yours sincerely,

P. Anders IngemarssonPresident & CEO Makino Europe

Dear Reader, 4 ACCURER Accurate by name. Accurate by nature 7 STERCH INTERNATIONAL Where the design matters! 10 BERGS Precise in volumetric accuracy, dynamic along contour 13 INTERNATIONAL AEROSPACE AND DIE & MOULD FORUM The first event in the house of extremes – Makino’s largest technology centre in Europe

16 Makino Europe News 18 INDUSTRIE 4.0 AWARD Production of the Industrie 4.0 Award

Contents

For detailed information and registration, please go to www.makino.eu. We are looking forward to your visit!

Events2016

We kindly invite you to join us at the following events: Technology Days in Makino Technology Centre, Cavenago di Brianza, Italy 23 - 24 June 2016

Die & Mould trip to Japan 27 June - 2 July 2016

mav Workshop “Reduction of manual rework” in Makino Technology Centre, Kirchheim unter Teck, Germany 5 July 2016

Farnborough International Airshow, United Kingdom 11 - 15 July 2016

AMB – International exhibition for metal working, Stuttgart, Germany 13 - 17 September 2016

MSV – International Engineering Fair, Brno, Czech Republic 3 - 7 October 2016

BIMU, Milan, Italy 4 - 8 October 2016

PRODEX – International Trade Fair for machine tools, tooling and manufacturing technology, Basel, Switzerland 15 - 18 November 2016

EMAF – International Exhibition of Machine Tools and Accessories, Porto, Portugal 23 - 26 November 2016

Makino Europe’s Customer MagazinePrecisely! 01|20164

Accurate by name. Accurate by nature.

A husband and wife business, a homely atmosphere, a passion for accuracy: Nomen est omen at Accurer, a small family firm in San Fernando de Henares, just outside Madrid. In less than ten years, Luis Alberto Álvarez and his wife Yolanda de Gea have built up a thriving and unusually family-like precision engineering business centred on machining parts of the highest accuracy and quality. The first Makino a61nx-5E to be installed in Spain is playing a key role in Accurer’s on-going success.

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ACCURER

5

An unusual family firmWalk into the Accurer premises and you’d be forgiven for thinking you’ve come to the wrong address. The first things you see are a chesterfield chair and a beautifully crafted carpenter’s bench. Potted plants adorn the upper floor. The impression is more living room than high-tech metal-working. A thought crosses your mind: “Isn’t this a woman’s touch?“ And you’re right. Yolanda de Gea, the female half of Accurer’s management duo, is an IT specialist who is also responsible for quality controls and accounts at Accurer. But her most eye-catching contribution to the business is undoubtedly the unusually family-like ambience she has created. Everyone at Accurer finds this highly motivating.

Her husband, Luis Alberto Álvarez, talks about their reasons for setting up their own business in 2006: “I’m the third generation of my family to be in machining. My father still crafted models from wood – he crafted the carpenter’s bench – and I worked in my family’s business for over 20 years before we decided to set-up shop on our own. That was because we wanted to do things differently.“ Luis and Yolanda certainly have – and not just in the look and feel of their firm.

The heart, soul, and brain behind Accurer

“We wanted to dothings differently. “a61nx-5E" 80 kw high power spindle 24,000 rpm

" Direct driven B and C axis – no backlash or wear out

" 5-axis horizontal machining centre with pallet changer –

designed with Aluminium structural parts in mind

" Structural rigidity with 3 levelling points

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ACCURER STERCH INTERNATIONAL

Where the design matters!

A passion for accuracyAccurer has a workforce of eight peo-ple. Their main customers are, among others, RYMSA, Indra, Thales Alenia Space, Lockheed Martin, DMAC, Iberespacio, CESA, Tecnobit and SENER. The precision parts Accurer produces go to companies from the aerospace, telecommunications, electrical, pharmaceuticals and food industries. Luis explains what the success of the past ten years has been based on: “We are passionate about the accuracy and quality of the parts we machine. And we firmly believe that it is vital to design good processes to ensure the quality of our final products.“ Just how accu-rate Accurer’s high-quality parts are is illustrated by the fact that in the past three years, the company had only two cases of non-conformity with customers’ strict requirements. Needless to say, Yolanda’s quality-control process spotted those parts before they were shipped to the customer.

An accurate assessmentLuis and Yolanda are delighted with the performance of the 5-axis a61nx-5E in machining all kinds of complex parts. Luis explains why: “Makino really is a top-end machine with an excellent set-up, rigid base as well as good controls and drives. There are a lot of good machines on the market but it’s the details that have impressed me most about this a61nx-5E – and I particularly like the Professional 5 control software.“ But the final comment on this family firm has to come from Yolanda: “What you see at our factory is exactly what we will do for a customer’s parts.“ Meticulous accuracy and outstanding quality in high-tech parts that look just as good as the premises they are machined in.

A look inside the Accurer factory

A dream comes trueIn 2014 Luis and Yolanda decided to step up to 5-axis machining. The choice fell on a Makino a61nx-5E with a 14,000 rpm/240 Nm spindle. “For 5-axis work we prefer horizontal machining centres – and one of the key reasons why we chose the a61nx-5E was because there are not many small-sized 5-axis horizontal machin-ing centres which normally start with a pallet size of 800 mm. Besides, I’ve always wanted a Makino – it’s my dream machine!“ When the Makino machine arrived in March 2015, Luis had no time to waste: “We needed to get the a61nx-5E operational very fast because we had an extremely urgent job to do on it.“ So Luis put his pro-gramming skills to good use and had the machine up and running in less than four days – on his own! Needless to say, the customer was extremely pleased with the parts completed so quickly.

Design is a key criterion at STERCH International,

a parts production company located in the Czech city of Olomouc. All the fixtures and parts STERCH produces look as good

as they perform. But it wasn’t design that led STERCH to invest in the first-ever Makino

EDBV8 sinker EDM machine to be installed in Europe. It was the machine’s performance

potential in ultra-fast and accurate drilling.

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Marek Roskol, STERCH Production Manager, has an unusual perspective for an engineer: “Design is very important to me so we pay attention to the look and feel of every part we pro- duce.“ And you can’t help noticing the parts’ pleasing design. But Marek naturally knows that design alone is not enough, which is why STERCH’s other key parameters are top quality and outstanding accuracy. Established back in 1996, the company was renamed STERCH International in January 2015 and generates an annual turnover of Kč 100 million (€ 3.7 million) with its 20 employees. Its customers mainly come from the energy and aerospace sectors. For example, STERCH produces electrical servo-drivers (actuators) for nuclear power stations, a highly demanding application with extreme working conditions, and fixtures or engine parts made of Inconel®, titanium or Hastelloy® for aerospace cus-tomers such as Honeywell and GE Aviation Czech. Since STERCH covers the entire value chain from in-house design and engineering to final testing and quality control inspections, it can offer customers all-in solutions in parts production – as the company’s motto says: “Born to bring solutions.“

DUO 64: First excitementMarek Roskol first came into contact with a Makino DUO 64 when his friend Svatopluk Daněk recommended this wire EDM machine. Since Svatopluk Daněk enjoys an almost unparalleled reputation as a wire EDM expert, his evaluation counted for a lot. Marek’s conclusion: “Why should I buy outsourced parts when I can make them myself?“

The crucial function on the DUO 64, he discovered, was H.E.A.T. “Working with the DUO 64, the cycle time was 30% faster than on other manufacturers’ machines.“ The DUO 64 was purchased to machine Inconel® engine parts and Marek has been highly satisfied with its performance: “We’ve only had the best experiences with this machine.“

EDBV8: “5X as a minimum“ The complex parts STERCH produces place the highest demands on machines. “Everything here is a minimum of 5X,“ Marek says with pride. The excellent performance of the DUO 64 and the fact that the EDBV8 is one of the first sinker EDM machine to offer 5-axis technology led STERCH to invest in the first-ever Makino machine of this kind to be installed in Europe. That was back in August 2014. Since then, the EDBV8 has been drilling cooling holes and diffuser holes in aircraft engine parts and blades. STERCH has been extremely satisfied with its performance. “This machine drills very, very fast,“ Marek says with a big smile. “We are extremely happy with how the machine works and the intelli-gence of its software. The EDBV8 also works very economi-cally and accurately, and produces no scrap.“ Both Makino machines have provided an outstanding solution for a company that expects the best in design, quality and accuracy.

U6 H.E.A.T.: Ideal wire EDM solutionTo produce enough Inconel diffuser blades to meet the Czech aviation industry’s growing demand for parts, STERCH has purchased two Makino U6 H.E.A.T. wire EDM machines. Marek outlines the relevant criteria: “Cycle times, accuracy, stable machining process and reliable 24/7 operating capability are the parameters that matter to us.“ These are precisely the qualities the U6 H.E.A.T. can offer.

Though first impressions count and design can sell a product, Marek Roskol knows that, in the final analysis, it is quality and accuracy that matter most to STERCH’s energy and aviation customers, while productivity in machining is of vital importance for the company’s own bottom line. And he knows that the Makino machines are making a key contribu-tion to keeping STERCH in great shape. The first EDBV8 5-axis sinker EDM

to be installed in Europe

Accuracy and quality – top priorities at STERCH

Marek Roskol talking to Makino's sales manager Petr Pavka

“Design can sell a product. “

Makino Europe’s Customer Magazine8

U6 H.E.A.T." Fixed table design ensures consistent cutting result" Using H.E.A.T. technology increases cutting

speed by up to 80 % and achieves the best cutting performance, even in difficult flushing situations.

" Easy maintenance – only 1 hour of maintenance for 100 hours of machining

EDBV8" Submerged and electrode flushing – fas

t break-

through with upto 50% shorter machining time

" Good safety in production using

‘Through-hole’ detection

" Freedom in position, angle, diameter

using ‘Hole-by-Hole’ method

" Fast electrode change with the combined holder

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Makino Europe’s Customer MagazinePrecisely! 01|201610 11

Precise in volumetric accuracy,dynamic along contour.

Finishing is 30 % faster, because the roughing stock could be reduced to 0.3 mm. Instead of a whole day – die-spotting takes merely two hours, so an entire mould can be finished only in four hours. This was made possible in the tool production facility at Bergs Kunststofftechnik in Ennsdorf, Austria with the Makino machining centres F8, and D500. The precision of the machining centres played a significant role in the vast time savings. The relevant issues were high speeds at the contour and

precision in volumetric accuracy. The objective was to reduce processing times, create high-quality surfaces and conse- quently reduce manual-rework. So the requirements of the new 5-axis machining centre were clearly specified at Bergs Kunststofftechnik KG, along with the goal to identify savings potential. The service costs were exploding and the various malfunctions, and weaknesses of the existing 5-axis machin- ing centre – operating for the last three years – had never really been thoroughly remedied. The investment in the Makino 5-axis machining centre D500 was intended to change all of this, for better. Although the machine has only been in operation since May 2015 and is still being investigated and tried out, the successes so far are impressive. For a variety of reasons, Andreas Bergs, Managing Director of Bergs Kunststofftechnik KG, views the investment as a logical deci- sion in providing for the future: “We have been manufacturing with the Makino F8 machining centre for three years. Since we mill so many 3D contours, the concept is literally tailor-made for us. The machine has the speed required for the contour, it is stable, and works with the highest precision. Unlike our previous 5-axis machining centre, Makino required no service during this period. We called the hotline twice, but only because our operator was on vacation, and both times we received help immediately. This investment also marked the beginning of the future for us: We are planning to automate in the near future. The D500 is prepared for the combination of electrodes and mould insert machining, just like I imag-ined.“

Substantial savings in post-treatment Normally one would rely on Heidenhain controls when invest- ing in a machining centre – particularly for die&mould making. Christian Fröschl, the man at the machine – explains why the decision was made – to go with Makino and the Professional 5 controller: “ First of all, we worked on a different machine with a kind of 'faux Fanuc’ for a few years, and the controller wasn't bad at all. Just different. Also, we program less than two percent on the machine. All of the programs, with the exception of drilling, are prepared via the post-processor. Aside from that, of what use is the best machine with a bad controller, or vice versa? With Makino the combination is just right.“

The objective in Ennsdorf, with its two machining centres, was to save time – in regards to both the processing times and post-treatment, and that vision has become reality. For example, nowadays it takes only four hours to finish a mould whereas spotting alone used to take a whole day. With post-treatment of inserts, and sliders there used to be blending errors as large as 0.02 mm and 0.03 mm amongst different tools. With the D500 on the other hand, if there is any differ-ence after the tool change, it is evident only by a very minute difference in the surface texture. This means that the machin- ing centre is absolutely precise, and thermally stable, along with being powerful and dynamic. Thus the processing time for roughing has been reduced by 50 %, and for finishing it

BERGS

Makino F8 and D500 are a strong team: Filing time was reduced by 50 %, and finishing by 30 %. Improved process, substantially, improved surface qua-lity, and less wear on the tools were some of the highlights.

With the D500 on the other hand, if there is any difference after the tool change, it is evident only by a minute difference in the surface texture. This means that the machining centre is absolutely precise and thermally stable.

" Unique and stable A&C Trunnion table" Low vibration spindle technology – longer tool life, better surface roughness, higher accuracy" Direct Drive motor on every rotary axis – no backlash – smooth, precise and dynamic motion" Superior rigidity and outstanding accuracy" Core cooled ball-screw and rotary axis motor cool-ing maintains best-in-class dynamic accuracy

D500

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BERGS INTERNATIONAL AEROSPACE AND DIE & MOULD FORUM

The first event in theHouse of Extremes –

Makino’s largest technology centre in Europe

has been reduced by up to 30 %, depending on the contour. The Bergs Kunststofftechnik managers estimate that the overall process is 70 % faster now. This estimate does not, however, take into consideration the additional potential that might result from an upcoming training by Makino. The objec- tive of the training is to convey new and valuable knowledge on CAD programming, 5-axis simultaneous milling or new strategies. One new strategy is the combination of a low cutting-depth with a high feed rate, as Makino has introduced on the Japanese market under the name FF (Flush Fine). All in all, the decision to invest in the D500 was the logical consequence of the positive experiences with the Makino F8. An intensive benchmark never occurred, explains Andreas Berg: “ We knew what Makino could do. The dimensions of the machining centre – we mill very long components, 1,000 mm x 400 mm – were ideal for our needs. And the difference in price compared to similar machines was not as exorbitant as one might expect from the premium segment.“ Looking at it from this perspective, this was the right choice for the future in Ennsdorf. After all, the dimensions of the moulds as well as the complexity have been growing steadily for the specialists of the plastic industry over the last few years. And this has inevitably led to the demand for better equipment quality.

A closer look at the heart of precision

More than 600 attendees from all over Europe visited the International Aerospace and Die & Mould Forum in late November 2015, staged in the newly opened extension to our Kirchheim facility, which is now Makino’s largest Technology Centre in Europe.

Andreas Bergs (left) and Christian Fröschl (right): The Makino machining centres not only saved huge amount of time, our precision in the 5-axis field is at least ten times higher than with the previous machine.

Bergs Kunststofftechnik at a glanceThe company was founded in 1955 and is now being run by Andreas Bergs, the third generation at the helm. Customers from the furniture, automotive, and sporting goods industries buy injection mould-ed parts ranging in weight from 1 g to 1.5 kg. Bergs Kunststofftechnik is also a major supplier of ski tips made of two-component parts and of ski binding plates to Fischer and Blizzard. The staff now in-cludes 30 plastics’ technicians and toolmakers, and the company has 20 injection moulding machines possessing 400-500 tons of clamping force.

And by the wayAndreas Bergs: "We manufacture high quality tools and cannot invest in special deals. Precision and the highest process reliability are essential topics which have never been questioned, with Makino."

Of interest in AustriaSteindl Vertriebs GmbH has been Makino’s partner for component manufacturing for years. The company has been representing Makino’s die&mould solutions, selling the 5-axis and 3-axis machining centres, series F and D, as well as the EDM machines since April 1, 2015.

www.steindl.at

High speed, high definition, and low heat machining

process pioneered by Makino.

" It combines high spindle speeds with precisely controlled,

high pressure coolant or forced air to blast away chips and

prevent heat buildup, either in the workpiece or the tool

" It permits high speed machining with

greater thermal stability, and chip control

" It results in a superior accuracy and finish, as well

as high metal removal-rate and longer tool life

Flush Fine

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Makino Europe’s Customer MagazinePrecisely! 01|201614 15

INTERNATIONAL AEROSPACE AND DIE & MOULD FORUM

The three-day forum from 24th to 26th November, 2015, offered ex-clusive presenta-tions, live machine demonstrations, and challenging state-of-the-art production technolo-gies focussing on Aerospace and Die & Mould applications. As goes the saying that it all begins at home; the forum started with Makino unveiling the latest software innovation – PRO6 CNC controllers. The Makino PRO6 CNC controller, improves the machining performance manifold. It ensures enhanced safety with features like Collision Safeguard (CSG), stream-lines and facilitates operability with simplified operation flow, and a lot of new features like super high-speed finishing, which increases the speed upto 4 times while maintaining the surface quality level. Also,with the new set-up panel setting can be done intuitively new features.

The forum showcased leading industry developments from both Aerospace, and Die & Mould, presented by esteemed

speakers like Prof. Seul from VDWF, and others from companies like Dassault Systems, Alicona, Leroxid, GLN Moulds. The presentation of next- generation technology, and industry spear-heading trends were not re- stricted to companies; Dr.-Ing. Andreas Zabel from TU Dortmund, and Dipl.-Ing. Stefan Steinbach from TU Hamburg-- Harburg presented 'Latest Developments in Manufacturing of Aerospace Parts', and 'Chip Removal of Sintered Carbide: Challenges and Perspectives' respectively. The forum was also supported by partners like Haimer and Sandvik, who set-up their booths and provided demonstrations of their products. The focus of the forum was innovation, sustainability, and co-opera- tion. There were 22 machines run-ning demonstra-tions with application engineers engaging in interesting discussions to exemplify not only in-

The forum was not only about machines and machining, two celebrity guest-speakers added some entertainment and motivation quotient during the evenings of the first two days. On 24th evening, ESA-Astronaut Dr. Ulf Merbold graced the evening with his presence – sharing inspirational accounts of his space journeys, recollecting the surreal moment of watching the moon and the Earth in the same frame.

For the second evening, on 25th, the celebrity guest was ESA-Astronaut Patrick Baudry, who is also a UNESCO Goodwill Ambassador. It was the perfect balance between inspirational and entertainment where guests were awe-struck by his re-collections from numerous space journeys and also entertained with lighter accounts of effects of anti-gravity. The evening events not only lightened-up the mood and revitalized everyone for the fol-lowing day’s program, it also allowed ample room for networking and con-necting with each other.

novations like the new controller, but also sustainability topics like reduction of manual re-work, and overall machin-ing time.

On one hand, there were mammoth machining centre like the Makino T1 – one of the most versatile and power- ful horizontal machining centre dedi- cated to Titanium structural parts. On the other hand in the micro-machining section, there were machines like the UPN-01 achieving sub-micron level accuracy with the machine’s Pneumatic Static Pressure Guideways, and Linear Motor motion technology. Indeed, it was the 'House of Extremes'. The pneumatic guideway system, which is similar to high-accuracy co-ordinate measuring machines (CMMs), minimizes mechanical friction and ensures consistent high-precision movement for fine feeds, while elimi-nating the need for oil lubrication.

The forum finally concluded on 26th afternoon, after numerous presenta-tions, demonstrations, and countless interactions, with sumptuous lunch and exuberance all over the Kirchheim facility. It was not only the confluence of people from all over the world that made this event so special, it was also the zeal which was not allusive in its contribution in making the event – a success.

There is probably only one way to summarize those three days in the house of extremes – Makino is at the heart of precision.

Engaging product demonstration by the application engineer

Up and close with the samples Ongoing sample demonstration

Inspirational evening speaker – Patrick Baudry

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NewsMakino Europe

STERCH-INTERNATIONAL s.r.o., Czech Republic, was founded in 1996 as a subsidiary of SCHIEBEL GmbH, Vienna. The company specializes in CNC milling, mainly catering to the Aerospace industry. In 2015, STERCH invested in two Makino U6 H.E.A.T. Wire EDM machine.

www.sterch.com

EMMEPI STAMPI, Italy, was es- tablished in 1996 and is nowadays a leading company in the design, construction, maintenance, and modification of moulds for plastic, thermosets and die-casting alloys. In 2015, they invested in a Makino U6 Wire EDM machine.

www.emmepistampi.it

STAMPI 2F S.r.l, a Die & Mould company based in Terno D’Isola, Italy, focussing mainly on plastic and rubber moulds, invested in a special edition F5 vertical machining centre in 2015.

MATEC CNC – Technik S.R.L., a parts’ manufacturer from Romania invested in two a51nx horizontal machining centres in 2015.

www.matec.ro

Camuna Stampi S.r.l, ItalyThe company “Camuna Stampi” was born in 2000 and deals with the design and the production of moulds for rubber, plastics, iron, silicon as well as the production of shears, matrix and con-struction of electrodes made of copper and graphite. In 2015, they bought a F5 vertical machining centre.

www.camunastampi.it

Ebel Werkzeugbau GmbH, a Die & Mould company based in Arnsberg, Germany designs and manufactures progressive dies for sheet metal processing, injection moulding, die-casting tools, and deburring tools. In 2015, they pur-chased a Makino U6 H.E.A.T. Wire EDM machine.

www.ebelwzb.de

FRANZ PAULI GMBH & CO. KG As a medium-sized company based in Ense, Germany, Franz Pauli Gmbh & Co. KG has been involved in the production of metal and plastic components since 1956. In 2016, they invested in a Makino U6 H.E.A.T. Wire EDM machine.

www.pauliense.de

Stanform, from Warsaw, Poland, has purchased its first Makino F5 vertical machining centre in 2015, with a view to use it in the production of injection moulds. The company also specialises in the production of tooling and fixture components and the production of tools for plastic forming of metals (punching & stamping dies) while focusing on providing innovative and comprehensive solutions for its customers.

www.stanform.pl

Mariborska livarna Maribor d.d., SloveniaCombining the knowledge about metals and tools Mariborska livarna Maribor successfully fulfils the ex-pectation of their customers in the automotive, and electrical industry, in the industry of white goods in many enterprises that need semi products made of copper and its compounds and also in the modern world – the indispensable metal – aluminium.Mariborska livarna Maribor invested in a Makino a51nx horizontal machin-ing centre, in 2015.

www.mlmmb.si

LIOR d.o.o., Slovenia, is a family business having more than 40-year tradition producing high-quality tools for die-casting, and injection mould-ing with materials like Zamak, and Aluminium. LIOR d.o.o. invested in a Makino EDAF 3 in 2015.

www.lior.si

BEKOMOLD Werkzeugbau GmbH, a Die&Mould company from Hungary purchased a Makino V56i 5XB vertical machining centre in 2015.

www.bekomold.hu

LABARA s.r.o., based at Velká Bíteš, Czech Republic caters to the electro-technical industry. In 2015 LABARA invested in a Makino PS95 for its requirements.

www.labara.cz

It takes3daysto become a maintenance expert with our Basic Training Course. It is the first step towards service expertise.

If you would like to find out more about the Makino portfolio, a specific product or anything else mentioned in this magazine, or if you have any other questions or enquiries, please get in touch with: Andreas Walbert, Marketingprecisely@makino.eu

Publisher: MAKINO Europe GmbHEssener Bogen 5, 22419 Hamburg, Germany +49 (40) 29809-0Director of publication: P. Anders IngemarssonPhotos: Makino

The iQ300 uses linear scales with a resolution of

0.005 µm and achieves accuracies in the nanometer range.

4.279 were part of the Makino family in 2015. people

11%of Makino employees are dedicated to research and development. Only this allows us to provide the latest cutting-edge technologies.

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19Makino Europe’s Customer MagazinePrecisely! 01|201618

In December 2015, for the third time, the

German magazine Produktion and ROI

Management Consulting AG presented the

Industrie 4.0 Award to companies that had success-

fully implemented the Industrie 4.0 principles in

their manufacturing or value creation processes.

All three recipients of the award had their Industrie 4.0

solutions inspected by a specialist jury and assessed in

terms of their levels of innovation, economic efficiency,

feasibility in practice, and customer benefit.

INDUSTRIE 4.0 AWARD

The top prize was given to the Robert Bosch GmbH plant in Blaichach, Bavaria, for a solution that connects all relevant operational resources within production and logistics. As a result, the company could connect more than 5,000 production equipments both vertically and horizontally.

However, apart from the brilliant achievement of Robert Bosch GmbH, it was the award itself which was special in every way – it was produced on a Makino D800z, at Makino, Italy.

The award was milled out of high-strength Ergal aluminum, with the foot being made of stainless steel. “The biggest challenge in the processing of the Industrie 4.0 Award was its dimension – it was actually too small for the vertical 5-axis machining centre. There was a chance of interference between the spindle and table, especially at the 90 degree position of the table” commented Andreas Walbert, Head of Marketing & Product Planning, Makino Europe. For this reason, a special clamping extension had to be created, to setup the workpiece far apart from the palette in order to avoid the interference. In the process of this production one of the main features of Makino D800z was once again highlighted – rigidity of the machine. Along with smooth movement of the axes, the D800z table driven by Direct Drive motors enables smooth rotation regardless of the payload, which might go up to 1.2 tons. The Makino D800z was developed keeping in mind both high-precision parts production, and medium to large-size moulds, along with accuracy within the contours and a high surface quality. All these factors reduced the overall cycle time drastically, especially due to reduced off-line operation required for manual polishing.

Since in this case, the workpiece was relatively thinner than the base – the vibration was higher and this contrib-uted to un-stability and chattering. Hence the application engineer had to produce this award in several steps, checking the momentum with NC-simulation and collision check so as not to destroy the award.

To sum it up, it was an interesting ex-perience for our application engineer to make a test cut not guided by toler-ances or other hard facts as usual, but by the demands of a designer.

PRODUCTION OF THE INDUSTRIE 4.0 AWARD

D800Z in actionDefining the milling strategy

The winners proudly accepted the award during the Industrie 4.0 congress, which took place in Saarbrücken last December.

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