The mold & die journal

Machine tools | Standards | EDM technology | Accessories | 85088

mold & die journal

Fach

verla

g M

öller

• Ne

ustr.

163

• D-

4255

3 Ve

lber

t • P

hone

: +49

/205

3/98

1250

• ww

w.fa

chve

rlag-

moe

ller.d

e • 7

th Y

ear •

Mar

ch/A

pril 2

019

International magazine Issue 2/2019

The

#MEX2019Messe Stuttgart, Germany

www.moulding-expo.com/tickets

21 – 24 May 2019

The countdown s on!

Already got your admission ticket

s?

-

Cover 2-2019.indd 1 18.04.19 11:08

Moulding Expo D-Stuttgart

21 - 24 May 2019

hall 7, booth C58

I set standards.

H 1280 /. . . Multi-zone control unit

The new HASCO multi-zone control unit H 1280 /. . . offers a high functionality, individually displayed process values, comprehensive diagnostics and outstanding operating comfort.

– Intuitive touch user interface – 7“ touch display, swivellable – Integrated help function – Quick Links– Troubleshooting agent – Individual pin assignment– Special start-up routine– Integrated communication interfaces– Ready for operation without instructions

www.hasco.com

Anz_H1280_A4_EN.indd 1 08.04.19 12:26Unbenannt-2 1 18.04.19 11:08

www.fachverlag-moeller.de The mold & die journal 2/2019

EDITORIAL

3

A producer of large-size molds recently announced that he had noted a considerable shift in the expenses for design and manu-facture in his company over the last few years.About ten years ago, the extent of manual work in said company was some 70 percent of the total amount of work needed for the production of a mold. This per-centage had decreased step by step to initally 50 percent and is approx. 30 percent nowadays. It must be pointed out that this concerns the labor input in the workshop. A major part of the activities performed there is now done in the preparation depart-ment.

What are the causes of this development?

Well, the reasons are the growing use of computers, remote data transmission and the application of CAD/CAM systems. In addi-tion, most of the remachining work that had been performed manually so far, for instance part of the polishing work, could be substantially decreased by using state-of-the-art machines. The above mentioned precent-ages can, of course, not be transferred to all tool and mold making sectors, as they are fac-ing diff erent conditions. This is especially true for mold making departments that are integrated in manufacturing companies. But the fi gures represent a clearly perceptible trend in the mold

and die making industry: It is the reduction in manual work and in personnel expenditure. It should be mentioned that the personnel expenses include labor costs as such plus high payroll- related costs that are beyond the infl uence of the companies. In view of the ever stronger compe-tetion with producers in low-wage countries, these problems are ranking high and can only be solved by using state-of-the-art machine tools, by reducing the level of vertical integration, for example through the use of standard components, by com-puter-aided design and manu-facturing as well as by applying, whereever possible, labor-saving handling devices and appliances. Stereolithography and rapid prototyping are further factors contributing to the optimization of staff costs in the mold and die making industry. Another in-novation potential is off ered by high-speed milling (HSC) which considerably cuts manufactur-ing times and improves surface quality. For some workshops it is not easy to tell whether such mod-ernisation or rationalization measures, i.e. reducing the staff expenses, have been success-ful. To independent moldmakers the ratio of per capita sales to per capita expenses is a clear indicator of success or fail-ure. Of course, all employees participating in the design and manufacture of the mold must be included in this calculation. The

Personnel expenditure - the most important cost factor in the mold and die industry

success of rationalization meas-ures is refl ected by a rise in sales at constant personnel expenses or by a decrease of the share in personnel expenses at constant sales.For mold making departments that are integrated in manu-facturing companies, fl low-up calculation and subsequent cost computing are more diffi cult. Frequently, the mold makers employed there have to carry out additional maintenance and repair work. Hence, it is necessary to meticulously record the times needed for manufacturing a new mold. And this is the reason why many large mold and die making departments, for example in the automotive industry, separate the repair department from the new constructions sector to enable better planning and follow-up calculation. When the follow-up fi gures and per-capita sales fi g-ures are available, many a manu-facturing and injection molding or die casting workshop will have to check whether they would be better off if they had their molds or dies be made by an independ-ent mold and die manufacturer.

Dipl.-Ing. K.-H. MöllerPublisher

"The mold & die journal"

S. 3 Editorial 2/19 aus 2/14.indd 3 18.04.19 11:08

The mold & die journal 2/2019 www.fachverlag-moeller.de4

TABLE OF CONTENTS

Personnel expanditure - the most important cost factor in the mold and die industry .................................................................... 3

Moulding Expo 2019 - International participation higher than ever ................................................................................................ 6

Precise temperature control .......................................................... 8

Clamping fixture minimises start-up times and boosts productivity .................................................................................. 10

Simulation captures more details ................................................ 13

Mass production with amorphous metals ................................... 14

Improved part properties via virtual DoE ..................................... 16

A new thermal sensor with short response time ......................... 18

Smart Factory set-up for SMEs ................................................... 20

A software solution for process optimisation in wire erosion ...... 22

New laser texturing solution ........................................................ 26

New identification stamp ............................................................. 27

A hot runner mold in five minutes................................................ 28

New embossing elements for die making ................................... 29

Fully automatic production of large molded parts ...................... 30

The series of double-acting clamping vises is growing .............. 32

Specification for injection moulds ............................................... 33

Improved NC accuracy for better milling quality ......................... 34

Hot runner controller with three new pin assignments ................ 36

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 25-13Ads department: +49 / 20 53 / 981 25-14Telefax: +49 / 20 53 / 981 25-6

[email protected]

Published bimonthly: six times a year www.koessingerag.de

Purchase prices: Annual subscription (six issues) EUR 30.-- 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

Flexible single clamping module for individual palletizing .......... 37

Robust systems for greater accuracy and reliability ................... 38

Self-locking wedge clamping element with spring force ............ 39

Universal die set monitoring ........................................................ 40

New solution enables hot runner systems with uncooled cylinder ........................................................................................ 41

5-axis milling of precision parts for the tool construction industry ........................................................................................ 42

K 2019 Düsseldorf ....................................................................... 44

Innovative tool for designers ....................................................... 45

A Tradition of CAM Innovation..................................................... 46

Expanded hose range ................................................................. 47

Formnext continues at record speed .......................................... 48

Tools and molds in the die casting technology ........................... 50

Tool, pattern and mould making in all its diversity ...................... 52

Formnext + PM South China to premiere in September 2020 .... 55

Simultaneous holding of five events focused on instrumental mechanics ................................................................................... 56

Advertising Companies & Order Card ......................................... 58

S. 04 Table of contents 2/19.indd 4 18.04.19 12:54

www.meusburger.com/hot-runner-moulds

YOUR HOT RUNNER MOULD IS JUST A

FEW CLICKS AWAY

Unbenannt-2 1 18.04.19 11:10


FAIR REPORT

A trade fair for exchanges with colleagues from all over the world

The trade fair created in a joint venture with the four German partner associations - German Association of Model and Mould Manufacturers (BVMF), German Engineering Federation (VDMA), German Machine Tool Builders' Association (VDW) and Associa-tion of German Tool and Mould Makers (VDWF) – has been designed by the industry for the industry. "Moulding Expo has now become one of the most impor-tant business platforms for the tool, pattern and mould making industry and its suppliers," said Ulrich Kromer von Baerle, CEO of Landesmesse Stuttgart GmbH. "Moulding Expo is the market-place for mutual exchanges be-tween the players in the industry. In particular, the wide range and expertise of the Moulding Expo exhibitors are responsible for the international success of the trade fair. Practically no other trade fair features such a comparably high proportion of tool, pattern and mould making companies.A successful trade fair like Moulding Expo brings the right people together so that they can talk to one another, think together

Moulding Expo 2019 - International participation higher than everAround 700 exhibitors in Stuttgart

Tool, pattern and mould making companies, as well as their customers and technology suppliers from Germany, Europe and the entire world have a must-attend event in Stutt-gart in spring 2019: the industry will meet at MOULDING EXPO, International Trade Fair for Tool, Pattern and Mould Making, from 21 to 24 May 2019. This year, around 700 ex-hibitors are expected to attend this event in the middle of the strongest industrial region in Europe. Compared with the previous event, the proportion of international exhibitors has now already risen by 5 per cent to a new record figure of 36 per cent. Most of the international exhibitors come from Portugal, Italy and Turkey.

1/ Ulrich Kromer von Baerle, CEO of Landesmesse Stuttgart GmbH, is keen to emphasise how Moulding Expo has already become one of the most important business platforms for the tool, pattern and mould making industry and its suppliers after three editions. Born in Fulda in 1952, the trade fair professional held the position of Managing Director of Blenheim Sch-weiz AG and Blenheim Int. Deutschland GmbH between 1989 and 1994. Between 1996 and 2001 Ulrich Kromer von Baerle was President of Messe Leipzig before he moved to Messe Stuttgart in the same position in 2001

and ultimately develop new prod-ucts, ideas or projects together.“ This industry event offers very high value-added due to the extensive accompanying programme which contains talks, podium discus-sions, special shows and re-nowned parallel events such as the Automotive Shows of UKi Media & Events Ltd. The location of the trade fair centre right next door to Stuttgart International Airport and the A8 motorway makes it very easy to attend Moulding Expo.This is also the reason why Mould-ing Expo is no longer a secret tip

outside Germany. "The trade fair is the most important industry event for Slovenian tool makers. It is a must-attend event, especially for the injection moulding sector in Europe," said Dr. Aleš Hančič from Celje. He is the Managing Director of Tecos, the Slovenian Tool and Die Development Cen-tre. 65 firms or 35 per cent of all companies in the industry are represented by Tecos. "Slovenian companies will also naturally at-tend Moulding Expo as exhibitors, for example on the joint stand of Spirit Slovenia with seven partici-pating companies. Anyone not exhibiting will come to the trade fair as a visitor," said Hančič.The Slovenes are looking for new customers or partners for long-term cooperation agreements. "Companies in Europe are grow-ing together. Some German tool

Moulding Expo 2019 - International participation higher than ever 6 18.04.19 11:11

The mold & die journal 2/2019 www.fachverlag-moeller.de www.fachverlag-moeller.de The mold & die journal 2/2019

FAIR REPORT

7

3/ Bob Williamson, President of ISTMA, is very familiar with the tool, pattern and mould making industry: after emigrating in the early 1970s, the British native and natu-ralised South African mechanical engineer worked for a short time as a plant techni-cian in the automotive industry before starting his tool and mould making career with the development and production of high-tech systems. With a workforce of 150 employees, his company Quad Precision Engineering is one of the leading suppliers of high-precision fixtures and measuring systems both for the South African aviation industry and internationally with narrowest tolerance test gauges for the automotive industry (Pictures: Landesmesse Stuttgart GmbH, Stuttgart, Germany)

makers have workpieces manu-factured in Slovenia, and others entire moulds. In the last few years tool makers have become more communicative. "We are talking more intensively with one another, also across national bor-ders. Moulding Expo is an ideal location in this respect." Hančič is convinced: "Only if European tool makers exchange informa-tion on production processes and their experiences in adapting new technologies or on the market will they be able to compete against low-wage countries."

No successful national economy without valid tools

Bob Williamson, President of the International Special Tooling and Machining Association (ISTMA), underlined the relevance of Moulding Expo as an international

2/ Looking for new partners for long-term cooperation agreements: Dr. Aleš Hančič, Managing Director of Tecos, the Slovenian Tool and Die Development Centre, during MOULDING EXPO with an Association delegation. Around 35 per cent of all Slove-nian tool, pattern and mould making com-panies are organised under the umbrella of Tecos. However, the members also include customers of the tool making industry and scientific institutes

meeting point: "Not only German tool, pattern and mould makers meet here in Stuttgart, but also entrepreneurs from throughout the world. Anyone wanting to en-joy success in the industry must communicate - also with potential competitors on the market."Trade fairs such as Moulding Expo show the industry the importance of tool, pattern and mould making. "There is no production without our industry! Zero! Well over 60 per cent of potential cost efficiency, irre-spective of the product, depend directly on the choice of the right tools and moulds for the produc-tion process," said the South African mechanical engineer and entrepreneur. "Valid means of production are the essential basis for effective industrial produc-tion in every national economy. As an international marketplace, Moulding Expo is exactly the right platform to obtain information as a buyer, tool maker or pattern manufacturer.“

The High Performance Coated EDM Wire

STARCUT TM

HI-TECH Qua l i tyEDM Wires for AllYour Cutting Jobs

HI -TECH Qua l i tyEDM Wires for AllYour Cutting Jobs

The Premium JAPANESE Quality Brass Wire

HIG Handel mit IndustriegüternGesellschaft m.b.HP.O.Box 7, Eisenbahnstr. 71, A-1195 VIENNAPhone +43.1.370 22 33 0, Fax +43.1.370 31 0 [email protected] www.hig.at

The Authentic People Since1973

Available from central stock in VIENNA/Austria or from authorized distributors across Europe

Pyroelectic the ADVANCED Coating of Wire CuZn40

High-Performance EDM Wire New Developed, Patent DE202017106956

Special EDM coated wire

ELECTROPLATED

www.hig.at

GAMMA

A.HIG_1_deutsch.engl.Stahlf.2019_HIG engl. Anz. 1-3 qxd5 14.11.

Moulding Expo 2019 - International participation higher than ever 7 18.04.19 11:12


TECHNICAL ESSAYS

Simple controller connection

THYPO can be linked via the communication module CI to a large number of PLCs and controllers from all leading sup-pliers. Profinet IO and Modbus TCP are available as standard, other connections are in prepa-ration. In addition, THYPO can also be used as an output mod-ule with the PSG temperature control system flexotemp.

Modular and expandable

The heart of the system is the communication module CI. This communicates via the system bus with the TP power control-ler modules, which are available in different versions. Due to the modular design, the system can be flexibly adjusted to customer requirements. Up to 1,512 out-lets can be controlled individu-ally. This way the heat can be placed and timed precisely.

Exceptionally flexible

THYPO covers a wide perfor-

Precise temperature controlWith THYPO, PSG offers a service-friendly, modular multi loop power controller for resistive loads which is used, for example, in the plastic and packaging industry, the glass industry or in air conditioning and heating technol-ogy. THYPO is robust, space-saving and ideally suited for heating, melting, drying, hardening, or annealing in a variety of industrial processes.

mance range. The TP power controller modules are avail-able in three different versions. In addition to a version with 24 outlets at 8A/230VAC and 9 outlets at 16A/230VAC, there is also a version with 9 outlets at 16 A/480 VAC. This covers a wide range of electrical heaters.

Integrated innovation

A number of innovative and intelligent functions ensure pro-cess reliability and optimal prod-uct quality. For example, the heating current measurement is carried out virtually reaction-free using a summation current transformer. The mains volt-age compensation guarantees constant output even if there are fluctuations of the input voltage.

Fast and intelligent current measurement

The heating currents are record-ed continuously in the process and therefore without retroactive effect. With the help of the heat-ing current recording, failures of thyristors or fuses and line breaks or partial load failures are quickly signalled. Disruptions can then be quickly localised.

Small, robust and quick to assemble

The compact modules offer

significant space saving in the control cabinet. Everything is integrated in the power con-troller modules. A side by side installation is guaranteed. The installation work is thus reduced to a minimum.

No mains feedback

By default, the power semicon-ductors switch to the TP in zero crossing. Full-wave or half-wave operation can be preset. This way the power semicon-ductors are protected and the mains feedback is reduced to a minimum. Depending on the function, the heating output is operated in phase control mode.

Two mounting variants

THYPO is designed for indus-trial use. The housings have a robust design. Depending on the control cabinet design, there are two mounting variants: directly mounted on the control cabinet or on a line bar system.

Easy to service

The design of the module is extremely service-friendly. All cards and connectors can be easily removed and mounted again when service is required. The fuses are easily accessible and simple to replace.

Precise temperature control with the PSG THYPO power controller(Picture: PSG Plastic Service GmbH, Viernheim, Germany)

Precise temperature control 8 18.04.19 11:12

MOULD BASES

STANDARD PARTS

SPECIAL PARTS

KNARR.com Your powerful partner for tool and mould making.

at our booth

demoulding via

collapsible core!

Hall 7 | B39

LIVE

Unbenannt-2 1 18.04.19 11:13


USER REPORT

In April 1996, Wilfried Emde, a trained agricultural machinery mechanic, began recycling re-jects, sprues and similar single-sort industrial plastics waste in Diemelsee-Adorf, Germany. Some of the regrind from the plants, which have an overall capacity of approximately one tonne per hour, goes back to the supplier com-panies, while the rest is sold to plastics processing or granulation companies. When his 26-year-old son Swen

Author: Dr. Michael Thielen, Freelance editor

Clamping fixture minimises start-up times and boosts productivity For a good twenty years, Wilfried Emde has been recycling primarily production waste from the plastics processing, injection moulding and extrusion sectors in his recycling plant in Diemelsee. When his son Swen joined the company, they took the decision to build up a further mainstay. The new mouldmaking division relies consistently on components and support from HASCO, the Lüdenscheid/Germany-based standard component manufacturer.

1/ HASCO’s A8001/... clamping fixture in use on the machining center

joined the company, a good three years ago, after training as a toolmaker and passing his mas-ter’s examination as a precision mechanic, they had the idea of expanding the company and add-ing a mouldmaking division.On board, right from the start, was machining mechanic Benjamin Finck, who Swen Emde had already worked with in a mouldmaking company. Both brought the necessary know-how and experience with them.

The centrepiece of the mould-making unit, a five-axis simultane-ous milling machine, was rapidly supplemented by three milling machines, two eroding machines and a deep-hole drilling machine. A further three employees were also added to the team. Today, the Emde mouldmaking division can supply complete injection moulds, including a hot runner with the corresponding service, right from the initial stag-es. “Customers frequently arrive

Clamping fixture minimises start-up times and boosts productivity 10 18.04.19 11:13

The mold & die journal 2/2019 www.fachverlag-moeller.de www.fachverlag-moeller.de The mold & die journal 2/2019

USER REPORT

11

with just a hand-drawn sketch of the plastic part to be produced,” explains Swen Emde. “We then design the article, have it printed on a 3D printer, and design and manu-facture the injection mould."Working with an exter-nal designer, Benjamin Finck takes charge of the design work at a Solid-Works 3D-CAD workplace.

HASCO support right from the start

In his design work, B. Finck appreciates the innovative options of-fered by the software link to the HASCO portal, where paramet-ric data has become available, making his job considerably easier. The HASCO portal not only provides sup-port in confi guring the mould – the integrated calculator also en-ables rapid and reliable determination of the overall mould costs.The fi rst customers of

Emde's mouldmaking division also include a number of the compa-nies who are Emde's recycling customers. Technical support for mouldmaking is pro-vided by Klaus Meier, a technical sales engi-neer in HASCO’s Team West Germany. He has also been able to fi nd a number of custom-ers for the company. “It’s good if you know the size and needs of the diff erent compa-nies. You can then see who would fi t together well and promote synergies”, says Klaus Meier, “and this ulti-mately leads to win-win situations.”The young company also manufactures bending tools and con-structs fi xtures. Preci-sion steel plates from HASCO are the pre-ferred material for this, which are delivered with or without deep bores. Emde then mills any holes or pockets required for the cavity insert and slideways or attaches threads

2/ Klaus Meier/Technical Sales Engineer at HASCO, Swen Emde/Managing Director of Emde Werkzeugbau (from left to right)

Messe Düsseldorf GmbH

P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany

Tel. +49 211 4560-01 _ Fax +49 211 4560-668

www.messe-duesseldorf.de

gifa.de newcast.detbwom.de

worldwideworldwide

EFFICIENT PROCESS SOLUTIONS

Metals

Innovation engine –foundryGIFA and NEWCAST 2019 – the world champions across the entire value creation chain.

GIFA: Plants, machinery and technologies for all production stages of the foundry. With the special show Additive Manufacturing.

NEWCAST: Precision in casting - from precision casting in medical technology to large components for machine and plant engineering.

Welcome to Düsseldorf!

2019

The Bright World

of Metals25– 29 JUNE

DÜSSELDORF/GERMANY

gif1902_GifNew_100x297+3_INT.indd 1 29.01.19 13:25



USER REPORT

for the connections. The end customer then simply places their cavity insert in this “mould blank” and can start producing straightaway.Swen Emde particularly likes the HASCO clamping fixture A8001/…, three of which are deployed on the available milling and eroding machines.The clamping fixture permits cost-efficient clamping of the system plates (K and ejec-tor plates and plates for the K3600/... small-series mould). Set-up times can be considera-bly shortened during the clamp-ing process, while productivity on the processing machines is substantially boosted. The precisely bored positioning

holes permit rapid and reliable variable clamping of different mould sizes with a repeat accu-racy to the nearest 10 µm. Hori-zontal and vertical machining of all common mould dimensions is possible without any problems.Locking washers with a special expansion technique form posi-tive and non-positive connec-tions with the system bores and, even during the most intensive machining operations with high loading limits, ensure secure positioning of the plate being machined. Using the spacer blocks, developed especially for the purpose, it is possible to conduct five-sided machin-ing with just a single clamping operation.

Sealing plugs prevent chips from entering the empty system holes and thus avoid costly clean-ing operations during retooling. Coloured sealing plugs mark the spacing positions for the sys-tem plates and separately fitted ancillary plug-in modules, sorted according to system diameters, permit user-friendly handling. Corrosion-resistant base plates in 1.2099HASCO.M and DLC-coat-ed functional elements guaran-tee minimised wear and system durability. “Using the HASCO clamping fixture, I can achieve consider-able time savings,” says Swen Emde. “Each time a workpiece is removed and then clamped on again, it is precisely positioned.” HASCO offers the sealing plugs in six different colours to ensure that users can find their way around rapidly and easily, given the large number of clamping options available with the A8001. Swen Emde: “A sixty percent saving on set-up times is easy to achieve.” In addition, time is saved on reclamping, since five surfaces of a plate are acces-sible for machining with a single clamping operation.The start-up company’s cus-tomer base is exceedingly broad – matching the range of plastics applications. These extend from technical household articles to plastic parts for the automotive industry. And the close proximity to his father’s recycling company, with its high-quality secondary raw materials, also opens up a number of interesting synergy options.

3/ Designer Benjamin Finck/Emde at the CAD workplace

4/ Accessory plug-in modules for the HASCO A8001/... clamping fixture(Pictures: HASCO Hasenclever GmbH + Co + KG, Lüdenscheid, Germany)


The mold & die journal

Documents

Transcript of The mold & die journal