1403 Makino Newsletter3-low

03
CEO/President
Makino Asia
CONTENTS
07
08
Dear Readers,
22
15
25
18
03 FORERUNNER IN INNOVATIONS
04 MAKINO SINKER EDM
MACHINES MILESTONE
06 EDNC65W/EDNC85W
09 MAKINO EDcam
10 REWORKING ELIMINATED
12 FLYING HIGHER WITH EDBV3/EDBV8
14 DRILLING DEEPER AND STRAIGHTER
WITH FINE HOLE MACHINING
16 EFFECT OF MACHINING OIL PROPERTIES
17 THE EROWA ROBOT SYSTEM LINEAR
18 HARMONY WITHIN POWER,
ACCURACY AND SPEED
20 SUITABLE FOR HARD TO CUT MATERIAL
AND HEAVY CUTTING
22 HYPER-CUT
23 MAKINO TRAINING CENTRES
As a global leader in Sinker EDM, Makino
occupies the high-end segment of the market.
The Makino Sinker EDM machine has become
a symbol of sophisticated machining that
every mould maker strives to own. Very often,
owning a Makino Sinker EDM machine is
sufficient to convince customers of the
company’s capability and ability to do
high-end, high quality products. Many of our
new customers who bought our sinker
machine were able to move up the value
chain, allowing them to rise above
competition.
In this 3rd issue of INNOVATION DEFINED, we
report on one customer who shares our
passion for high performance and quality.
Hjernø Værktøjsfabrik A/S is a highly
specialised tool factory in Odense, Denmark,
that manufactures technically demanding
injection- moulding tools. Hjernø invested in
two machines, the Makino V33i vertical
machining centre and a Makino EDAF2 sinker
EDM machine to increase its machining
capacity. Their requirements have been
demanding: high milling speed and 2-3
micron precision to meet their customers’
quality specifications. Find out how stable
machines have eliminated the need for
reworking and brought other benefits on page
10 and 11.
This particular customer is a prime example of
how manufacturers can grow their businesses
and improve their performance by focusing on
what matters most. I hope the story will
inspire you to do the same.
Yours sincerely,
Dr Moh Chong Tau
+ FORERUNNER IN
INNOVATIONS
03
Makino has always been the forerunner in the sinker
EDM business. Since 1977, Makino has invented
numerous groundbreaking technologies that help to
shape the machining tool industry. Makino’s history of
innovation is one of the company’s success factors.
However, Makino is not alone in its glittering history of
innovation. Makino’s success comes from its strong
partnership with its clients.
NOTABLE ACHIEVEMENTS
Makino has introduced a wide range of major
innovations throughout the years. In 1987, Makino
developed the smokeless machining method and
adaptive control. This technology revolutionised the
Sinker EDM industry and became the basis for all
advanced EDM technology even until today. In 1996,
Makino invented the HQSF technology which is a
powder technology that is able to produce a superior
surface finish. Makino’s HQSF technology produced
unparalleled results and nothing else came close at
that time. 18 years on, HQSF still retains its crown in
producing the best surface. These innovations were
possible because of the voices from our partners.
They attest to Makino’s partnership philosophy.
INVENTIONS THAT CHANGED THE WORLD
Makino’s advancement has not only helped the machine
tool industry, but also created new machining
possibilities that eventually affect products we use
every day. Today, the Makino Sinker EDM is used in
industries ranging from medical, aerospace, automobile,
electronics, telecommunications, home appliances, etc.
While market trend changes, Makino continues to
quickly evolve and adapt. For example, the EDBV series
is our latest addition to our product line. EDBV allows
the aerospace industry to create cooling holes for
turbine blades at a fraction of current machining time
while making more complex profiles possible.
GLOBAL LEADER
As a global leader in Sinker EDM, Makino occupies the
high-end segment of the market. The Makino Sinker
EDM machine has become a symbol of sophisticated
machining that every mould maker strives to own. This
is because owning a Makino Sinker EDM machine is
sufficient to convince customers of the company’s
capability and ability to do high-end, high quality
products.
+
MAKINO SINKER EDM
MACHINES MILESTONE
1975
Makino introduces the
first commercially available
CNC EDM machine
1981
EDNC series
of CNC Sinker
EDM machine
04
1984
Develop large CNC Sinker
EDM machine
1986
First Intelligent Adaptive Control
1980
EDNC22 machine
2005
Super Spark III,
Super Surface,
Super Edge &
µ Cell EDM
2003
Super-Spark II
is released
2006
Ultra high
precision
EDM EDAC1
1987
Develops the smokeless
machine & the Dual-head
CNC Sinker EDM machine
1996
HQSF™ with patented
µSC additive
1992
2001
The Super-Spark
1998
Develops the Pallet
Magazine System
& Robotic Automation
Rib Head with linear
motor technology
2002
The EDCam™ offline software
solution for programming &
automating EDM machinery
2008
EDcam V.5 offline software
solution for programming
& automating EDM machinery
2010
2012
Super-Spark IV
is released
AF Control to prevent
the DC arcing
2013
EDNC65/85W,
HS-Rib
2010
EDAF
series EDM
05
+
The largest worktank in this class.
What we offer: EDNC65W/EDNC85W
Basic stroke with larger work tank
Value for money and
reduce machining time
06
With the technological innovations in our daily life, some parts such as those in automotive
and home appliance are becoming larger and more complex. This calls for larger mould
size with more deep reinforced ribs. Makino EDNC65W & EDNC85W feature larger
workpiece capacity and the latest cutting technology with enhanced electrode jump speed
and acceleration. It delivers optimum machining performance cost effectively on both
roughing and finishing cutting process.
Several parts combine into 1 single part
Cavity deeper as parts profile more complicated
More deep ribs needed for rigidity
1.7 times larger work tank volume than EDNC65/85
Inner Worktank Size
EDNC65
EDNC65W
EDNC85
EDNC85W
Width (mm)
1100
1400
(+300)
1400
1800
(+400)
Depth (mm)
750
900
(+150)
900
1200
(+300)
Height (mm)
450
500
(+50)
500
500
SERVING
CUSTOMERS
WITH WIDER
NEEDS
07
It is not speed, acceleration or sparking condition alone that matters.
It is the
of them that makes the difference.
Synergy
High acceleration jump
High accuracy jump
High speed jump
High performance jump
+
HS-Rib
New HS-Rib & new machining technology are able to machine
faster by 50% as compared to using Standard Head.
1.5G
*HS-Rib is offered as an option
1st process machining: MC depth vs. MC time
acceleration
Z-stablizer
accurate
Machining depth
08
20m/min
speed
50% Faster
HS-Rib
5m/min Standard
20m/min HS-Rib
0:00:00
2:00:00
4:00:00
6:00:00
8:00:00
10:00:00
Machining Time
12:00:00
14:00:00
spark condition
16:00:00
+
EDcam
Productivity tool that
makes the difference
The more electrodes you
use, the more productivity
improvement you gain by
using EDcam.
09
3D Model • EPX Data • Machining instructions
Machining program
With EDcam, generating of
machining programs can be
done on PC with much greater
ease and on-machine dry run
can be eliminated as well.
Without EDcam, generating EDM machining progrms,
machining positions, electrode dimension reduction
and other data have to be manually input on the
machine and this requires dry run checking on the
machine.
+
HJERNØ
Reworking
eliminated
Investment in Makino machines improves
Danish machine-tool factory’s margins
on high-precision injection mould making
Reworking injection moulds to achieve the precision
demanded by the medical technology and other high-tech
industries can eat up the slim margins on such jobs.
Hjernø’s investment in high-precision, thermally stable
machines from Makino has eliminated the need for
reworking – and brought other benefits as well.
Makino sinker EDM
machine EDAF2
10
www.hjerno.dk
Hjernø Værktøjsfabrik A/S, a highly specialised tool
factory in Odense, Denmark, manufactures technically
demanding injection-moulding tools. Founded in 1946,
Hjernø is now one of Northern Europe’s largest and oldest
tool factories with a current workforce of around 40. The
company, which has been specialising in injection moulds
since the 1970s, came through the economic and financial
crisis well and gained an AAA credit rating in 2011. “We
stayed in the black during the crisis,” explains Aage
Agergaard, the company’s managing director and
majority shareholder, “because we are at the top end of
the quality pyramid and an extremely well organised
company.” Hjernø’s customers are all from high-tech
indus-tries in Denmark, Norway, Sweden, Germany,
France and the UK. They include some of the world’s
leading hearing-aid manufacturers, e.g. GN Resound and
Widex. All of Hjernø’s customers have one thing in
common: “High demands on zero tolerance,” as Aage
puts it.
HIGH SPEED AND ULTRA-FINE PRECISION
Early in 2012 Hjernø invested in two Makino machines to
increase its machining capacity, particularly during peak
periods. Hjernø’s requirements have been demanding
high milling speed and 2-3 micron precision to meet their
customers’ quality specifications. After testing machines
from various manufacturers, Hjernø chose a Makino V33i
vertical machining centre and a Makino EDAF2 sinker EDM
machine. For over a year now, the two machines have
been producing ultra-high-precision injection moulds,
with the V33i operating day and night. Aage Agergaard:
“Since we were extremely happy with the two machines’
performance, we bought a Makino F3 vertical machining
centre a year ago, and we recently purchased a second
V33i for delivery in mid-March.” Aage explains why this
Makino machine is particularly suited to the production
conditions in his factory: “The temperature in our machine
hall varies quite considerably so the V33i’s Thermal
Stabilizer is vital to avoid thermal distortions and ensure
ultra-high precision over long periods of hardmilling.”
And those were not the only advantages Hjernø
discovered.
NO REWORKING – HIGHER MARGINS
Having to rework injection moulds to meet a customer’s
strict standards can turn a profitable job into a loss-maker.
Hjernø’s production manager Martin Riedel explains how
the V33i has saved the company money: “This machine
has eliminated the need for the reworking loops we had
on other machines. That saves us time, money and
frustration, and for the customer, it means no more
delayed deliveries.” Aage explains the economic
significance of eliminating reworking: “When we saw just
how precisely the V33i carries out hardmilling, we realised
it would enable us to eliminate reworking. That was one of
the reasons why we bought a second V33i. And since this
machine achieves great precision at high milling speeds,
we’ve also been able to reduce our lead times.” By
eliminating time- and money-consuming reworking and
shortening lead times, the Makino machines have proved
a good return on investment.
Aage Agergaard explaining the polishing experiment to
Makino agent Michael Balling-Petersen
VERY SATISFIED WITH SERVICE
As a coolly calculating businessman with a keen
eye for optimising in-company processes, Aage
Agergaard particularly appreciates the fact that the
Makino machines were delivered and installed
without any trouble. “The machines come on time,
the service is perfect and the people who install the
machines know what they’re doing. We can count on
Makino.” Martin Riedel adds. The service is provided
by technicians based at Makino’s Hamburg site, only
three hours drive from Odense. “Our operators are
also very happy with the V33i. They can go home in
the evening and sleep soundly at night because they
know it will run reliably day and night.”
POLISHING EXPERIMENT
Right now, Hjernø is experimenting with using the
Makino sinker EDM to polish injection moulds to
achieve a surface finish of 6 microns. Aage explains
the thinking behind this experiment: “Up to now,
we’ve had two men doing polishing work all day. If a
machine can take on this job, we’ll save a lot of
money.” Martin Riedel has discovered that “this
sinker EDM machine has excellent polishing qualities
and there are no black spots on the polished
surfaces”. If the polishing experiment works, and the
signs are very promising, it will prove to be yet
another cost-cutting feature of a Makino machine.
With margins so tight in the die & mould industry,
the money-saving benefits of eliminating reworking
and manual polishing and reducing lead times can
make a key contribution to staying in the black – as
Hjernø has done.
Typical mould
component produced
by Hjernø
11
+
12
FLYING HIGHER WITH
EASY AND FAST
HOLE DRILLING
6 seconds
Diffuser:24 seconds
Hole:
Staying cool
with EDBV3/8
DIFFUSER HOLE IN TURBINE BLADE
Diffuser holes are needed in turbine blades
for cooling purposes. EDBV is a specialised
machine designed to address this. Using
high speed water EDM drilling, EDBV is
able to create diffuser holes more easily
and faster than any other machine.
SUBMERGED MACHINING
Stable machining is accomplished even
at high speeds. Spark discharges never
become unstable even when the electrode
pierces the workpiece in through-hole
machining.
USES OFF-THE-SHELF PIPE
ELECTRODES
EDBV series can machine a wide
range of hole diameters without
any need to make new
electrodes. It easily machines
diffuser holes and a variety of
other hole shapes besides round
ones.
BREAK THROUGH
DETECTION FUNCTION
The sensor detects when the
electrode pierces the workpiece.
This function prevents defects
when machining the turbine blade
surface by avoiding contact
between the electrode and the
wing wall on the back side of the
workpiece.
13
m
10
0
m
m
100m
14
Ø80µm electrode 125hrs continuous
machining for 1000 finehole with
pitch accuracy ± 5µm
Work material
Electrode material
Work thickness
No. of electrodes used
:
:
:
:
Super Hard (G5)
Copper (Ø0.08mm)
0.5 mm
32
EASY SWITCH
MOUNT/DISMOUNT
Fine hole arm can easily be mounted
and dismounted so that user can switch
between normal EDM and Fine Hole
drilling easily.
DRILLING DEEPER
AND STRAIGHTER WITH
+
FINE
HOLE
MACHINING
ATC FOR FINE HOLE
Fine hole option also comes with
ATC for automation so that long hours
of machining is possible.
15
Effect of Machining Oil Properties on Die-sinking Electrical
Discharge Machining Idemitsu Kosan Co., Ltd
This report is reference of below information. Kitamura Tomohiko, Ryoichi Okuda, et al.:
Japan Society of Electrical Machining Engineers, Electrical Machining Technology, Vol32, No.102 (2008)
Testing of Oil Type Dielectric Fluid
1 Objective
The objective of this report is to clarify the factors
affecting machining characteristics of different dielectric
fluids of different physical properties – focusing on the
cooling characteristics (heat transfer coefficient) of each
fluid.
2 Test Method
Table 1 Machining oil properties
Kinematic
viscosity @40 ˚C
[mm2/s]
A
B
C
2.41
1.87
2.26
2.35 1.96
79
225
238
269
Heat Transfer
Coefficient
Integral
[104W/m2]
2 .1 Oil Samples
D
E
258
Test Oil A
Test Oil C
Table 1 shows the physical properties of each test oil. Test
oils A to E were varying heat transfer coefficient align with
their respective kinematic viscosity.
Figure 1 shows that the temperature depended on heat
transfer rate curve in the case of Oil C. This cooling
process was divided into vapour blanket stage, boiling
stage and convection stage. Boiling stage was where heat
transfer rate was the greatest when the oil was in a state
of nucleate boiling and the silver bar was cooled by
evaporation of the oil.
16
Table 1 shows the cooling curve of the heat transfer
characteristics of each test oil within the temperature
range of 100 to 800 °C. In Figure 1, shows the comparison
of a much higher coefficient heat transfer Oil C and the
inferior Oil A. Oil C, with higher heat transfer rate, had
excellent cooling which could cause nucleate boiling
strongly over a wide temperature range.
2 .2 Machining Parameters
Test had been carried out in die-sinking type machine with
4L capacity tank, without oil circulation. Table 2 shows the
machining conditions.
3. Analysis of Test Results
Silver Test Piece Temperature
Fig. 1 Heat transfer coefficient curve
Table 2 Test conditions
Roughing Condition
Peak Current (A)
Pulse (µ s)
I dle Time (µ s)
Machining Time (Min)
Electrode
Work Piece
Machine
Finishing Condition
15
5.5
256
16
256
16
5
10
Cu (10mm x 10mm )
S55C
die-sinking type
Oil E results were used as a benchmark for comparison.
Result:
1. Higher machining speed was achieved for both
roughing and finishing when the heat transfer rate
was high.
2. The machining speed becomes faster when cooling
performance of the oil is superior.
3. The effect of higher heat transfer rate on machining
speed was caused by nucleate boiling effect of oil
between electrodes (poles) had been intensified,
resulting in a greater discharge of machining waste
and a more stable machining condition.
Heat Transfer
Coefficient [×104W/m2]
Fig. 2 Effect of heat transfer on Cutting speed
EROWA AUTOMATION ROBOT SYSTEM LINEAR
Erowa Robot Gripper in Action
In the context of precision engineering, machines are only profitable
when they are fully utilised and producing. They should be operating
during the day, off-peak hours, weekends and at night. Achieving this
goal means combining all production requirements in a plan. This
plan is known as the “Flexible Manufacturing Concept” – or FMC in
short. The 4 steps of the Flexible Manufacturing Concept by Erowa
incorporates
(1) Standardisation,
(2) Measurement,
(3) Automation and
(4) Integration.
It is necessary to implement this plan and turn it into reality in
well-measured steps. The Erowa Flexible Automation System is the
key to enhancing productivity.
In today’s highly competitive environment, machine tools with
automatic placement are now the standard. Customers are
demanding for small batch production from small to large
workpieces, fast delivery and high quality parts. Rapid intermediate
inspections during production increases production reliability. With
an appropriate handling system, measuring machines, washing and
cleaning stations and a reliable Job Management Software JMS Pro,
Erowa offers a consistent solution to meet these requirements.
Erowa EWIS RFID Scanning
Workholding Pallet in Magazine
THE
The Erowa Robot System Linear (ERSL) offers the fl exibility of an
extendable modular rail which accommodates up to eight machines
of different technologies with tools, workpieces and electrodes
handling capabilities. The Erowa Robot System Linear (ERSL) is an
automated robot system that travels on a rack and pinion drive over
the entire linear axis which facilitates large acceleration and precise
positioning. The system is supplemented with loading stations,
gripper changer (depending on pallet size), rotary and rack magazines
as well as pallets for fixtures, workpieces and electrodes mounting.
In addition, an intelligent magazine concept allows precise and easy
identifi cation of all tools, workpieces and electrodes by way of an
EWIS RFID system. Tools, workpieces and electrodes which are
mounted onto the pallets can be arranged haphazardly in the
magazines to be scanned and picked up by the Robot for production
processes.
EROWA
ROBOT SYSTEM
LINEAR
17
+
HARMONY WITHIN POWER,
ACCURACY AND SPEED
In the competitive climate of
today’s metalworking industry,
highly flexible and productive
processes are essential – not
just for survival but also as
integrated solutions to sustain growth. Makino’s PS Series
vertical machining centres have been developed with these
challenges in mind.
Targeted at the high-mix, low-volume parts machining sector, the
PS Series stands out for its high material removal rate, high pitching
accuracy and multi-hour machining consistency. Add to that rigidity,
reliability and a favourable total cost of ownership and you have a
competitive solution to meet the requirements of precision metal-cutting
industries such as aerospace, medical, automotive, general engineering
and precision engineering.
18
Equipped with Makino’s
high performance spindle
technology used in
horizontal machining
centre, the PS spindle,
boasting of a front
spindle bearing of
85mm, is in a class
usually seen in #50
taper machine.
This ensures that
the metal removal
rates and spindle
performance of the
PS is unparalleled
amongst #40 taper
machines. It offers
efficient, highly
productive machining
characteristics to
address a wide
range of
materials
typical of the
production
environment.
19
FLEXIBILITY
With the increase in demand for automation
in the global market, automating production
processes to optimise the use of time, materials,
human resources, maintainence of the highest
possible quality standards and reduction of
costs are needed. The PS series is equipped
with optional interfaces for it to be ready for
automation systems available in the market.
These may include 4th axis tables, tool length
measurement, spindle probe, light curtain, auto
doors and a variety of other features.
Interface for hydraulic fixtures (option)
can be done either from top of
the splash guard or from the ports
on table casting. The maximum
numbers of ports available are
6 hydraulic, 6 pneumatic and 1
coolant.
+
SUITABLE FOR HARD
TO CUT MATERIAL
AND HEAVY CUTTING
ENHANCED RIGIDITY AND
MACHINING CAPABILITY
The enhanced rigidity of the a81nx delivers a
more stable and powerful machining
performance across all Y axis stroke.
Various
structural
modifications
have
strengthened the rigidity of the casting
structure, table and bed. The overall structure,
for example, is twice as rigid as its
predecessor.
20
EXCELLENT INDEXING ACCURACY
One of the strengths of the a81nx is its
high-precision bore-index-bore cutting. Three
factors play a significant role in this:
1) The highly rigid structure ensures stable
straightness and squareness even when the
machine
is
working
under
varying
conditions, e.g. with workpieces of different
weights.
2) The spindle/table (B-axis) run-out has been
minimised.
3) A thermally symmetrical structure, combined
with elimination of undesirable heat sources
through thermal insulation and heat removal
functions, ensures thermal stability, even
during lengthy machining operations.
REDUCED CYCLE TIMES
The shorter machining and non-cutting times
are
achieved
through
higher
spindle
acceleration and deceleration, improved axis
acceleration and jerk, and a quicker on/off
response
time
for
the
nozzle
and
through-spindle coolant. All these lead to
shorter continuous cutting feed times or a
significant reduction in the time required for
rigid tapping.
1,000 cm3/min MRR in cast iron
IMPROVED UTILISATION
OF MACHINING AREA
The maximum permissible length, diameter and weight
of the tools that can be used on an a81nx are 690 mm
(length), 356 mm (diameter) and 30 kg/45 Nm or 35
kg/50 Nm (depending on the tool carrier).
21
+HYPER-CUT
Better result with lesser cut
22
Hyper-Cut technology addresses the demanding need to
deliver superior finish while reducing trim cuts. Hyper-Cut
was initially designed for precision stamping die industry.
However, being able to deliver excellent surface finish
with lesser number of cuts, Hyper-Cut found itself
successful in much wider range of applications.
Machining Time
Conventional
4 Pass
1st
U6
1st
3 Pass
2nd
2nd
3rd 4th
3rd
18%
reduce
Wire size: dia. 0.30 mm, Work material: S50C,
Work thickness: 300mm
Wire Consumption
Conventional
U6
4 Pass
3 Pass
15%
reduce
Wire size: dia. 0.30 mm, Work material: S50C,
Work thickness: 300mm
Group photo with the 1st batch trainees of the Makino
Technical Training Centre, Bangalore (INDIA).
Bangalore Training Centre (INDIA).
+ MAKINO
Industrialisation plays a pivotal role when a nation is
transforming itself. Young and rapidly industrialising,
India needs a sea of trained manpower to run its
factories efficiently with today’s technology driven
equipment, including CNC machine tools.
Home to the world’s largest reclining jade Buddha,
Kunshan can now be proud of one more symbol of
beauty – the Makino Asia China Training Centre.
Beginning with a thorough grounding of engineering
basics, students progressively learn the in and outs of
operating a CNC machine. In addition, they go on to
master supporting areas such as Fixture Engineering
and PLC Programming. After the completion of a 1
year course certified by Makino experts, these
well-trained graduates get placement at various
customers of Makino including leading corporate and
overseas affi liates.
TRAINING CENTRES
Sitting on three acres of lush greenery, the Kunshan
Technical centre was completed in 2013. The
establishment of the new training centre stems from
our corporate vision to impart knowledge and skills to
maximise the human potential of our employees and
customers.
The training centre was specially designed to
accommodate product assembly and operation
training and thus, consists of offi ce space and
training facilities.
This training centre is poised to become the preferred
choice for precision engineering assembly, and
manufacturing education and training for Makino’s
business partners.
Operational since 2006, the Makino Technology
Training Centre (MTTC) in Bangalore is set to meet
these demands with its unique blend of Corporate
Social Responsibility and machine tool expertise.
Every year, 60 deserving students from top tier
polytechnics are trained on all major domains of CNC
operations, adding indispensable value for their
workplaces.
Mr. Matsubara
Fumiyoshi lighting
the lamp during
the inauguration
of the Makino
Technical Training
Centre in
Bangalore (2006)
Kunshan Training Centre (CHINA).
23
MAKINO ASIA PTE LTD
2, Gul Avenue, Singapore 629 649 Tel: +65-6861 5722 Fax: +65-6861 1600
Email: [email protected] Website: www.makino.com.sg
P rin t e d in Sin g a p o re , A E 0 0 1 E a 14/04/3 (L/D)