This is how the German machine tool and metal forming industries are doing
VDMA Laser Working Group elects new board of directors
European plastics industry braces for increased instability
Arburg Denmark celebrates 25th anniversary
“Smart Bratwurst” wins Industry 4.0 talents competition
Design & Make challenge returns to raise manufacturing’s profile with young people
Why Portugal makes sense when it comes to tool and mould making
Metav succeeded under challenging conditions
Sprung core in a new design — precision angled holes no longer required
Unique guiding concept for low production volumes
Slanted slide as a standardised compact unit
Set-up cost reduction through faster clamping
Latest Articles in "Additive Manufacturing "
Creaform releases tenth version of VX elements 3D measurement software
ITT acquires AM technology capabilities with investment in CRP
Desktop Metal introduces expandable 3D printable resin for foam part production
Bofa and Würth announce AM industry collaboration
Latest Articles in "Machining Equipment "
Milling, EDM, measuring and cleaning in one cell
All-round check for sintered parts
Mazak strengthens UK sales team with new sales engineer
Can high-speed machining achieve the quality demanded for medical products?
New 3MF example code available for Polygonica
Arburg implements 5G test field for networked production
Digital transformation: latest Industry 4.0 and metrology trends
How self-learning automation makes your production more intelligent
Latest Articles in "Hot Runners"
Hot runners: Advanced HMI makes control easier and more flexible
Mold-Masters extends capabilities of E-Multi Auxiliary Injection Platform
Portuguese moulding industry discusses hot-runner innovations
New RMTP system enables circularity of PET for injection moulders
Wire EDM catapults German manufacturer into XXL machining
Winbro relies on PP C&A for strategic outsourcing of machine assembly
Model railway manufacturer fast-tracks another EDM machine
EU counters dumped imports of graphite electrodes from China
Latest Articles in "Quality Control"
Digital transformation: latest Industry 4.0 and metrology trends
LK Metrology to exhibit new CMM and metrology solutions at IMTS
New duo complements series of portable metrology-grade 3D scanners
Learn more about surface roughness, texture and tribology
Latest Articles in "Machining Accessories "
Studer grinding machine elevates daily grind for Mazak
New control software for intuitive and fast grinding
Latest Articles in "Surface Treatment & Repair "
Protect your tools: coatings for almost every application
Safe and easy deburring and deflashing with new ceramic tools
New products for workshop equipment
Compact and effective laser cleaning of workpieces
Cannon Ergos collaborates with Boeing
Thermoplastic composite aircraft sidewall panels made of recycled carbon fibre
Vedanta launches first low carbon aluminium from India
Plastics processors report sales growth beset by uncertainties
Collaborative project: New approach to the production of thin-walled packaging
In mould and die making, individual machining processes are increasingly being combined into automated production cells with integrated handling. The main advantage is a higher degree of machine utilisation, as the systems can operate unattended 24/7. Two prerequisites for realisation of such autonomous systems are more intensive digitalisation of the processes consistent with Industry 4.0 and an increased level of investment.
One company that has followed the route of automation is German power tool manufacturer Festool, which produces complex die casting mould tools and plastic injection moulds for producing its products at a factory in Neidlingen. The toolmaking department has installed a robotic production cell based on machining centres manufactured by German firm, Roeders. Similar technology is available in the UK and Ireland through the latter's sole agent, Hurco Europe, High Wycombe.
Jürgen Kopsieker, head of tool and mould making in Neidlingen explained that his department has to compete with other toolmakers to win business from within the group, while it is also free to offer its services on the open market. The department therefore has no option but to organise itself as a profit centre to ensure it keeps up with market demands in terms of quality, technology and price.
About three years ago the manufacturer still had an old-style toolmaking department with five individual machines, three machining centres including a 5-axis model plus a wire and a die-sink EDM machine. “All were constantly supervised by operators who, in addition to monitoring the machining processes, were responsible for fixturing workpieces, loading and unloading the machines, and setting and changing tools. In addition, supervisors took care of quality assurance,” Manufacturing team coordinator Tomislav Jurisa remembers. Utilisation of the machines was therefore unsatisfactory so at this point, in mid-2019, the company decided to comprehensively upgrade the shop. “We wanted an automated manufacturing cell in which milling, EDM, coordinate measuring and aqueous cleaning were fully integrated”, says Jurisa.
The core of the automated toolmaking cell at Festool's Neidlingen facility are two Roeders RXP machining centres and a handling robot on a linear rail. (Source: Hurco )
Additionally, to ensure completely unattended operation, the firm was keen to add storage facilities for milling cutters and electrodes, as well as for workpieces mounted on Erowa pallets, with all transport tasks performed by a handling robot. The idea was that operators would simply supply the cell with workpieces and tools and create the NC programs.
Realisation of this goal became the responsibility of Roeders, which was chosen for the project for two reasons. First, other companies within the Festool group had many years of experience operating Roeders machining centres and reported that they are reliable and precise. Second, the supplier could point to numerous successful installations of complete solutions based on automated manufacturing cells, including the integration of third-party products from a range of different sources.
To implement the installation, Roeders supplied two of its RXP 5-axis machining centres and RMS Main job manager software, which is linked to Festool's IK Office enterprise resource planning system. It also supplied a Fanuc R-2000iC handling robot running on a linear rail. Located within the cell also are a Hexagon coordinate measuring machine, an Exeron die-sink EDM machine and an automatic washing system from Mafac.
In addition, a storage room accommodates 110 palletised workpieces and 258 tools, which is supplemented by the capacity of the tool magazines in the machining centres themselves.
Within the cell, a Roeders RXP 601 DSH is used mainly for hard machining. Materials include 1.2343 hot work tool steel and sometimes 1.2379 cold work tool steel.
Raw material is rough machined in the hardened condition (54 — 60 HRC) and subsequently finished while still in the same fixture. Compared with the previous procedure of roughing in the soft state, then hardening and finally finishing in a second operation, the new method is significantly faster and less expensive. Cost savings are principally the result of significant reductions in manual operations.
Kopsieker enthused, “I am thrilled about how well the individual elements in the cell work together. The RMS Main job manager is an open system with interfaces for communication with our own IT system as well as other machine manufacturers' software. Cooperation was excellent between the Roeders engineers and those at Hexagon, Exeron and Mafac. All systems in the cell worked together without any problems and the projected productivity increase and component quality were reliably achieved right from the start.”
By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy.
Naturally, we always handle your personal data responsibly. Any personal data we receive from you is processed in accordance with applicable data protection legislation. For detailed information please see our privacy policy.
I hereby consent to Vogel Communications Group GmbH & Co. KG, Max-Planckstr. 7-9, 97082 Würzburg including any affiliated companies according to §§ 15 et seq. AktG (hereafter: Vogel Communications Group) using my e-mail address to send editorial newsletters. A list of all affiliated companies can be found here
Newsletter content may include all products and services of any companies mentioned above, including for example specialist journals and books, events and fairs as well as event-related products and services, print and digital media offers and services such as additional (editorial) newsletters, raffles, lead campaigns, market research both online and offline, specialist webportals and e-learning offers. In case my personal telephone number has also been collected, it may be used for offers of aforementioned products, for services of the companies mentioned above, and market research purposes.
In case I access protected data on Internet portals of Vogel Communications Group including any affiliated companies according to §§ 15 et seq. AktG, I need to provide further data in order to register for the access to such content. In return for this free access to editorial content, my data may be used in accordance with this consent for the purposes stated here.
I understand that I can revoke my consent at will. My revocation does not change the lawfulness of data processing that was conducted based on my consent leading up to my revocation. One option to declare my revocation is to use the contact form found at https://support.vogel.de. In case I no longer wish to receive certain newsletters, I have subscribed to, I can also click on the unsubscribe link included at the end of a newsletter. Further information regarding my right of revocation and the implementation of it as well as the consequences of my revocation can be found in the data protection declaration, section editorial newsletter.
He added that Festool's staff was fully on-board with the project, not only accepting the necessity and advantages but actively committed, even in stressful situations when ongoing production had to be maintained in the midst of the changeover.
The fact that the Roeders software is based on the Windows operating system made it comparatively easy to learn, which proved to be an advantage. The structure and handling of the programming for the machine controls and the RMS Main job manager were also well adapted to a machine shop, so the training needed was minimal.
Graphite electrode production: When the robot takes over the night shift
How hybrid manufacturing processes increase your competitiveness
Cookie-Manager Imprint About Media Privacy General Terms and Conditions Help
Copyright © 2022 Vogel Communications Group
This portal is a brand of Vogel Communications Group. You will find our complete range of products and services on www.vogel.com
Hurco; Hufschmied Zerspanungssysteme ; Walter Maschinenbau; Ametek GmbH Division Creaform Deutschland; VDW / U. Nölke; VDMA; Desatis; GKV/Tecpart; Arburg; Allianz Industrie 4.0 BW; Manufacturing Assembly Network; Poolnet; Constanze Tillmann/ Messe Düsseldorf; Cumsa; Strack Norma; Knarr; Creaform; Victory Motorsports Team; Desktop Metal; Public Domain; SMC/ Roboworker; Yamazaki Mazak; GF Machining Solutions; Polygonica; Wenzel; BBG; Oerlikon HRSflow; Moldmasters; Onair Solutions/ Hasco; Brian Pieters/ Husky; Ralf M. Haaßengier; Winbro; Nick Matthews; LK Metrology; Michigan Metrology; Kellenberger; Zeller + Gmelin; Pero; KIMW-F; Boride; HSB Normalien; Emag; Cannon Group; Business Wire; Polymerfan; Christophe Brissiaud , Collomb Mécanique