MEN PHILIPPINES 2018 by Eastern Trade Media

THE MACRO ECONOMICS OF

OPTIMAL MATERIAL REMOVAL p10

MEN

ANTI-VIBRATION TOOLS:

A QUIET REVOLUTION p22

PUNCHING MACHINE

ADAPTABILITY p26

PUBLICATION BY ASIA PACIFIC METALWORKING EQUIPMENT NEWS www.equipment-news.com

WELCOME MESSAGE

MEN PHILIPPINES 2018

RODRIGO ROA DUTERTE THE PRESIDENT OF THE PHILIPPINES My warmest greetings to the organisers, participants and guests of the International Metalworking Philippines (IMTP 2018). I laud the Vision Exhibition Services Co., Ltd. and the Die and Mould Association of the Philippines for their efforts to create platforms like the IMTP 2018, which showcases the latest trends, techniques and technologies in the metalworking and manufacturing industries. May your partnership further strengthen as you hold the Smart Tech Manufacturing Philippines 2018 and discuss more innovative ways to advance your enterprises. It is also my hope that our business relations with other participating companies from various countries will be more meaningful and that it will lead to the continued growth and development of our respective economies. I trust that this event will promote the quality of the products and services of the Philippines and sustain our peopleâ&#x20AC;&#x2122;s distinction among the most competitive and professional workers in the world. I wish you all a successful IMTP 2018.

WELCOME MESSAGE

MEN PHILIPPINES 2018

RAMON M. LOPEZ SECRETARY OF DEPARTMENT OF TRADE AND INDUSTRY PHILIPPINES (DTI) Greetings to the organizers and participants of the International Metalworking Philippines (IMTP 2018)! We wish to offer our sincerest congratulations to Vision Exhibition Services, Inc. and the Die and Mould Association of the Philippines for holding this four-day exhibition and conference. The metalworking industry is an integral element of the manufacturing sector, which is the biggest driver of Philippine economic growth. As such, we are grateful for the efforts of the industry to keep itself globally competitive and fully abreast of the trends and movements of the 4th Industrial Revolution (4IR). To prepare the Philippines for 4IR, the Department of Trade and Industry (DTI) is spearheading the Inclusive Innovation-led Industrial strateg y (i3s), wherein the academe, industr y, and government sectors collaborate to solve business innovation challenges. With this strategy, the government aims to help local industries as well as its Filipino workers take advantage of Artificial Intelligence and all other advancements that 4IR will bring forth. Through the combined efforts and continued partnership of the government and the private sector, we are confident that we can achieve not only this objective, but also our overall goal of building a nation powered by inclusive growth and shared prosperity for all. Mabuhay!

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WELCOME MESSAGE

MEN PHILIPPINES 2018

MR JIMMY CHAN • FOUNDER OF PDMA AND PDMA INC. BOARD OF TRUSTEE • PHILIPPINE EXPORTERS CONFEDERATION, INC. (PHILEXPORT) • BOARD OF TRUSTEE OF METAL SECTOR • MIRDC GOVERNING COUNCIL—PRIVATE SECTOR • PHILIPPINE IRON S TEEL INS TIT UTE—BOARD OF TRUS TEE (WAY AND MEANS) Asia Pacific Metalworking Equipment News is pleased to conduct an interview with Mr Jimmy Chan on the future of the manufacturing landscape in the Philippines. 1. What do you foresee to be future developments in the metalworking industry in the next 2 to 3 years? JIMMY CHAN: The metal industry in the Philippines is predominantly focused towards construction. In as much as the Government is geared with its Build Build Build direction, basic steel related products and activities which cater to the building and infrastructure activities will experience double digit growth. Other manufacturing-related export activity faces much uncertainty due to tariff issues. 2. Which are the regional hotspots where we can expect to see these changes? JIMMY CHAN: Domestic inflation of 4.6 percent has affected prices and will trigger some slowdown but overall growth will still be swinging towards position growth though dismal interest rates increase will somewhat dampen private investments. But government investments in various infrastructure and foreign aired projects will lead activities. Areas of interest will still be in public transport, power & energy, and Consumer goods sectors. 3. Being an extremely competitive and complexed environment, what are some of the current challenges the mold and die industry is facing in the Philippines? JIMMY CHAN: The mold and die industry will still be a lucrative but technologically challenging industry. Shortages of skilled and dedicated human resource still remain a challenge. Foreign dependence is still the norm unless there is strong government support to invest in higher level of manpower skills. 4. What are the steps the industry is taking to become more locally-dominant and self-sustaining? JIMMY CHAN: PDMA is pouring its weight and focus for training and looking for grants to fund qualified youth development and to find careers in this field. 5. What are the short-term goals of the Philippine industry in terms of manufacturing? JIMMY CHAN: Resurgence programme in manufacturing industries is a new focus for government programmes and hopefully growth will ensue with it.

WELCOME MESSAGE

MEN PHILIPPINES 2018

HECTOR U. VILLANUEVA JR.

PRESIDENT, PDMA INC. (THE DIE AND MOULD ASSOCIATION OF THE PHILIPPINES)

MESSAGE

Warmest congratulations to Vision Exhibition Services Co., Ltd in organizing International Metalworking Philippines (IMTP) 2018.

Warmest congratulations to Vision Exhibition Services Co., organizing International Metalworking PDMA Inc.– The Die Ltd and in Mould Association of the Philippines’ Board of Directors and Officers would like to express our deepest appreciation for Philippines 2018 (IMTP)! choosing and making us your industrial partner. PDMA Inc. and Vision Exhibition Services Co., Ltd’s business relationship have grown over the PDMA Inc. -‐ the die and mould association of the Philippines' Board of Directors and Officers would like to years since Philippine Die and Mould & Machinery Tools and Accessories express our deepest appreciation for choosing and (PDMEX) making started. us your industrial partner. PDMA Inc. and Exhibition Vision Exhibition Services Co., Ltd business relationship have grown over the years since Philippine Die and As we continue working together Mould, Machinery Tools and Accessories Exhibition (PDMEX) started. in building a much stronger business relationship, we are both positioning our foundation for a new generation of comprehensive economic development, expand economic opportunities As we continue working together in building and a much stronger business relationship, we are both positioning ensure the innovative businesses which will eventually providing our foundation for a new generation of support comprehensive economic development, expand to the industry needs, to thrive and grow in the eventseconomic to come. opportunities and ensure the innovative businesses which will eventually providing support to the industry Organising IMTP 2018 and making it an alternate event with PDMEX, needs, to thrive and grow in the events to come. is something that will push the industry towards achieving our objective which is to boost the industry, as there will be a yearly industry event that Organizing IMTP 2018 and making it an alternate event with PDMEX, is something that will push the we will look up to. industry towards achieving our objective which is to boost the industry, as there will be a yearly industry Bringing the local and international experts in one venue through Smart event that we will look up to. Manufacturing Philippines Conference (SMTP 2018) themed as Empowering The Philippine Manufacturing Industry, it is another excellent Bringing the local and international experts iGrowth n one vFor enue thru Smart Manufacturing Philippines Conference move to provide us the industry insights and updates, learn more about (SMTP 2018) themed as Empowering Growth For Manufacturing Industry another industry 4.0 The and itsPhilippine effects, be aware of how to optimise industryis processing excellent move to provide us the industry with insights and updates, learn more about industry 4.0 and are its internet of things and listen to some industry leaders on how they adopting to industries’ new trends. effects, be aware of how to optimize industry processing with internet of things and listen to some industry leaders on how they are adopting to industries' new trends. For the above mentioned initiative in organising IMTP 2018 and SMTP 2018, it will help us in expanding and reaching out to the manufacturing sectors. For the above mentioned initiative in organizing 2018 and SMTP 2018 it will elp us in Vision expanding and PDMAIMTP Inc. will continuously step forward in h supporting Exhibition reaching out to the manufacturing sectors. PDMA Inc. will continuously step forward in supporting Vision Services Co., Ltd as your industrial partner on events to come. Exhibition Services Co., Ltd as your industrial partner on the events to come. As closing, PDMA Inc. wishes the best to all exhibitors, visitors and participants at IMTP 2018 and SMTP 2018. As closing, PDMA Inc. wishes the best to all exhibitors, visitors and participants at IMTP 2018 and SMTP 2018.

EDITOR’S NOTE & CONTENTS

EDITOR’S

NOTE

Forging Ahead In The Face Of Challenges

speedily growing A SE AN e co n o m y s in ce 2 0 16 , t h e Philippines is expected by the International Monetary Fund to sustain its GDP growth on the raft of constant demands and modest fiscal stimulus programmes that have the backing of the local administration. The Philippines manufacturing sector continually faces unending market trials and dynamic technological developments at a pace swifter than ever before. To stay abreast with the market in order to secure competitive advantages, local manufacturers need to ascertain that their plants stay up to date in these fastchanging times. Having said that , the IMTP 2018 conference affords a proverbial stage of vibrancy and education where industry leaders, technical experts, government officials convene to partake of their critical knowledge and expertise revolving around the manufacturing industry of today and the future.

MEN PHILIPPINES 2018

CONTENTS Metrology

CNC Machines

The Macro Economics Of Optimal Material Removal Many CNC parts manufacturers as well as production and job shops could reduce their overall production costs 15 percent or more by leveraging existing CAM technology that is readily available. By Stas Mylek, applications advisor, CNC Software

Productive Mould Construction With Modern CNC Technology Machine tools and controls from bring higher quality and shorter machining times in the production of stretch blow moulds. Contributed by DMG Mori

Cutting Tools

Anti-Vibration Tools: A Quiet Revolution Development in anti-vibration tools is able to reduce or even eliminate problematic vibrations. By Rafi Ravoach, Iscar ISO turn product manager Jessminder Kaur Assistant Editor

01 02 04 05

Message From The President Of The Philippines Message From Secretary of DTI Message From Founder of PDMA Message From President of PDMA

How Can Portable CMMs Help Improve Machine Shop Workflow? Innovations in the compact metrology space are changing the way machine shop inspection works for the better. By Bernard Chou, regional product line manager (portable), APAC at Hexagon Manufacturing Intelligence

Sheet Metal

Punching Machine Adaptability: Room To Grow An entry-level segment punching machine that can gradually be expanded into a fully-fledged combination machine has caught industry attention with a host of innovative features from punching holes to bends flanges and forms threads. By Trumpf

Increasing Speed And Productivity With The X-Definition Plasma Cutting System If you have not looked at plasma in the past few years, you should. Contributed by Hypertherm

Software

Smart Machines Need Smart Engineering Mirko Bäcker, marketing director EMEA, manufacturing engineering, Siemens PLM Software, explains how the machine-making industry needs new ways to work that are more collaborative, versatile and flexible.

07 08 16 32

Show Information Conference Programme

Exhibition Floor Plan Subscription

SMART TECH MANUFACTURING PHILIPPINES CONFERENCE Empowering Growth For The Philippines Manufacturing Industry World Trade Centre Metro Manila, Philippines

The Smart Tech Manufacturing Philippines Conference is proud to present international speakers from Asia & Europe to share their critical knowledge and experience on Industr y 4.0, Smar t Tech Manufacturing, Automation & Robotics and other disruptive technologies facing the manufacturing industry today and in the near future. Don't miss your chance to hear from the best and learn from the finest at Smart Tech Manufacturing Philippines Conference!

PROGRAMME DAY 1 22 August 2018 13:20 – 14:00 PHILIPPINES MANUFACTURING INDUSTRY UPDATES AND INSIGHTS Mr Robert O. Dizon Executive Director Department of Science and Technology Metals Industry Research & Development Center

14:00 – 14:45 WHAT IS INDUSTRY 4.0 & ITS EFFECTS ON SMES? Mr Willson Deng Founding CEO Arcstone Group, Singapore Chairman Singapore Manufacturing Consortium, Singapore

15:30 – 16:15 OPTIMIZATION INDUSTRY PROCESSING WITH INTERNET OF THINGS Mr Lionel Anciaux IOT Expert / Consultant IOT Factory, Brussels and Moscow President Information & Communication Technologies Cluster (Brussels, Belgium)

16:15 – 17:00 PANEL DISCUSSION WITH KEY INDUSTRY ASSOCIATIONS ON: Philippines Perspective And Engagement Interests Towards Industry 4.0, Smart Factory & IOT • Aerospace Industries Association Of The Philippines • The Die And Mould Association Of The Philippines • Metalworking Industries Association Of The Philippines Mr Willson Deng Founding CEO Arcstone Group, Singapore Chairman Singapore Manufacturing Consortium, Singapore

DAY 2 23 August 2018 10:00 – 10:45

DIGITAL TWIN – WHAT IS IT AND WHY IS IT IMPORTANT? Mr Suryanarayana Tumuluri Head of Digital Factory Manufacturing Design Siemens Singapore

10:45 – 11:30

MACHINE TOOLS INDUSTRY & DEVELOPMENT IN APAC Mr Tarun Roy Consulting Analyst, Industrial Automation & Process Control, Asia-Pacific Frost & Sullivan, Malaysia

TAITRA REDEFINITION OF MANUFACTURING WITH TAIWAN MACHINERY 13:00 – 13:30

EMBRACING INDUSTRY4.0 OPPORTUNITIES Mr Elvin Ng ASEAN Region, IIOT Sector General Manager Advantech Co., Ltd.

13:30 – 14:00

THE ROLE FOR PHILIPPINES’ MANUFACTURING TRANSFORMATION Mr Joe Allan Angara Regis Philippines Sales Manager Chain Headway Machine Tools Corporation

14:00 – 14:30

SMART MANUFACTURE LEADS INNOVATION OF KEY COMPONENTS DEVELOPMENT & APPLICATION Mr Taddy Chen Managing Director Hiwin Singapore Pte Ltd

15:00 – 15:45

COLLABORATIVE ROBOTS IN THE MANUFACTURING PROCESS – THE IMPORTANCE OF THE ECOSYSTEM Mr Darrell Adams Regional Commercial Manager for Southeast Asia & Oceania Universal Robots

15:45 – 16:30

OPERATIONAL EXCELLENCE VIA SMART MANUFACTURING Mr Louis LOH Tze Wei Regional Manufacturing Business Leader Dassault Systèmes, Asia Pacific South

N.B. The programme is conducted in English, and it is provisional and subject to change by organizer without prior notice. Organizer

Conference sponsor

Knowledge Partner

CNC MACHINES

MEN PHILIPPINES 2018

Machine time cycles can be greatly reduced with the right CAM technology.

CNC Software

THE MACRO ECONOMICS OF OPTIMAL MATERIAL REMOVAL

Many CNC parts manufacturers as well as production and job shops could reduce their overall production costs 15 percent or more by leveraging existing CAM technology that is readily available. By Stas Mylek, applications advisor, CNC Software

Stas Mylek believes the right tools are essential in increasing revenue for manufacturers.

y p i c a l l y, p r o d u c t i o n c o s t centres are of ten evaluated independently, whether they be tool costs, raw materials, capital equipment, manpower, or production costs. However, incremental savings in each typically do not add up to significant gains overall. Our contention is that the areas of cutting tools, CAM, and production,

par t icular ly t he newer toolpat h technologies, along with machine capabilities and investment, be looked at concurrently with the goal of optimisation as they relate to each other. What we are looking for is hitting the optimised sweet spot of all three, referred to as machining effectiveness, to gain significant production cost savings. MACHINING EFFECTIVENESS Adoption of this approach pursues a very simple formula:

Selec t optimal cut ting tools for the part. This will often be high quality carbide, but can be ceramic, insert tooling, or any other

type of tool. The key is optimising to the chosen tool(s).

Based on the cutting tool manufacturerâ&#x20AC;&#x2122;s recommendations, import the correct parameters for consistent chip load machining into toolpaths having this capability.

3 4

Optimise the cut parameters, if necessary, to match the full capabilities of the machine the job is running on.

Rep e at for e ver y t o olp at h process you create using CAD/ CAM software where the same tools, material, and machine are used.

True automated process control with Equator™ and IPC software Manufacturing process control can be achieved with real-time data feedback using the Equator gauging system and IPC software (Intelligence Process Control) from Renishaw. The gauging results from Equator is read automatically by IPC, which connects to modern machine tool controls for real-time offset values to be updated. Equator and IPC updates allows one-to-many (Equator system to various CNC machines) updating, offers offset and compensates for common causes of process instability, and yet boosts production efficiency. • Automatic gauging data updates reduce human intervention • Accurate data update – errors recoded over several parts are averaged • One-to-many (Equator to several CNC machine) updating

For more information visit www.renishaw.com/ipc Singapore Thailand Malaysia Indonesia Vietnam

T +65 6897 5466 T +66 2 746 9811 T +60 3 5631 4420 T +62 21 25504567 T +84 432 818 999

www.renishaw.com

F +65 6897 5467 F +66 2 746 9816 F +60 3 5631 5407 F +62 21 25502555 F +84 432 818 998

E singapore@renishaw.com E thailand@renishaw.com E malaysia@renishaw.com E indonesia@renishaw.com E vietnam@renishaw.com

CNC MACHINES

Everything begins with the tool, and the calibre and quality of carbide, advances in new ceramics, new grades, coatings, tool geometries, and the design engineering going into today’s tools are far different and more capable today than what was available just five years ago. Full slotting tools capable of going up to four times deeper in not only hardened steels and stainless, but super alloys was unheard of even a short time ago. Today, it is much more prevalent. These tools promise huge material removal gains, yet also require exact adherence t o re commende d c u t conditions and chip load to gain optimal performance and predictable tool life to address machining effectiveness. NEW TOOLPATH STRATEGIES Optimal material removal and cutting tool per formance occur when CNC machines are programmed using newer, readily available CAD/CAM software technolog y (Mastercam’s Dynamic Motion technology is one example). This technology continually maintains t he c u t t ing t o ol manu f ac t urer ’s recommended cut conditions and chip load, regardless of par t geometr y. Significantly higher material removal rates, with more predic t able and ex tended tool life, translates into the higher reductions in cycles times and production costs necessary for achieving machining effectiveness. And the machining effectiveness of the newer toolpath strategies are not limited to just the new breed of cutting tools; improved material removal rates and tool life can be realised with virtually any tool, since these newer toolpath s trategies are based on consistent cut conditions. Over the better part of a decade, since these new toolpath strategies have been available, manufacturers of all t ypes t ypically repor t CNC machine cycle time reductions for their roughing operations of between 25 to 70 percent—sometimes much more. Recently, a manufacturer repor ted that a part with a machine cycle of 32 minutes had been reduced to 12

MEN PHILIPPINES 2018

minutes by implementing a machining effectiveness mindset. MATCHING MACHINING CAPABILITIES Machining effectiveness gets another cost savings boost when you begin to match machine capabilities to cutting tool performance potential and toolpath strategy. With a toolpath that always keeps the tool in a safe, cutting condition and does not violate the tool manufacturer’s recommended chip load specs, CNC programmers can apply dif ferent methodologies. On faster machines where workholding might be lighter and cutting tool selection more traditional, users might opt for a higher feed rate and small step-over approach to maximise material removal rate and to lower cycle time. If set up is on a higher horsepower machine, that tops out on feed rate yet where the workholding can be locked down, a company might run the newer, full slotting-capable tools. Matching tool to machine to cutting tool capability, they could run heavy step-overs of 65 to 80 percent at 2x to 3xD or more and see material removal gains increase well beyond 70 to 75 percent over traditional toolpath strategies, resulting in a

Recently, a manufacturer reported that a part with a machine cycle of 32 minutes had been reduced to 12 minutes by implementing a machining effectiveness mindset. huge production cost savings. All this is feasible once companies put machining effectiveness into practice. TIME TO ADOPT However, adoption of these newer strategies and embracing a machining effectiveness mindset has been slow, yet there are signs they are finally beginning to take hold. Straw polls of CAD/CAM users and industry event attendees indicate that 30-40 percent of programmer/machinists are using these new toolpath strategies with increasing regularity. CUTTING CHUNKS OFF A CYCLE Once the process and strateg y is validated, the approach can be applied every time that tool is used to machine

Maximum Machine Efficiency

CNC Software

Manufacturers need to evaluate their tool efficiency to achieve maximum output.

CNC MACHINES

MEN PHILIPPINES 2018

a part made from that material. Benefits can be seen in everything from simple to ex tremely complex , aerospace and thin wall parts, and more easily machined materials to super-alloys. For example, a job shop recently took six hours off of a 24-hour cycle for an aerospace par t by adopting machining effectiveness methodology. This conver sion paid for it self immediately after the first part was produced. Better still, the company had a contract to make six more of them. So the benefits multiplied quickly. The bot tom line is t hat many manufac turers in many industries are operating far less efficiently than they could be and leaving money—lots of it—on the table by not optimising cutting tool, toolpath, and machine performance and viewing them in an integrated relationship. Cutting costs is necessary to compete and remain

A PORTFOLIO PERFECT FOR PROS.

prof itable. However, there’s a lost opportunity cost for companies, and possibly for entire manufac turing sectors, that don’t leverage everything t he y c an g e t f rom in t er-rel a t e d technologies. But what about the other 60 percent of CAD/CAM users? They frequently report not looking into it because, honestly, they have not had the time, nor given approval to do so. E xac tly how much time are we t alking about to implement a demons trably bet ter cos t cut ting methodolog y? Actually, ver y little. Tool manufacturers’ recommended cut parameters are often provided in available tool libraries and easily imp or t e d dire c t l y in t o t o ol p a t h operations of the CAD/CAM system when selecting a tool and material. Adjustments are made based on tool capabilities such as whether to use a

small or large step-over approach and what limits need to be applied to depth cuts based on the type of tool. UTILISING YOUR MACHINE’S POTENTIAL Machine limit s relative to spindle speed, feed rate, and horsepower are also considered prior to processing the program. Using toolpaths that maintain consistent chip load and safe cutting conditions, it is simply a matter of taking the program out onto the machine. Machine performance is validated relative to holding the programmed feed rate, ensuring the right workholding setup is in place for strategy, and that spindle load is maintained under the set requirements. Once the program is running on the machine, it may be necessary to make some minor adjustment s to toolpath parameters to make sure the

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CNC MACHINES

software is taking full advantage of the machine’s capabilities. Conver sely, some machine controller set tings may need adjustment to take full advantage of the toolpath. Very often, cutting tool vendors, CAD/CAM resellers, and technical specialists are happy to help you maximise performance and prove out the application. SIGNIFICANT GAINS By aiming at that optimised sweet spot called machining effectiveness, the gains company-wide or even for an industry, can be significant. By that, I mean millions. This seems like a pretty outrageous claim. Can it be justified? I think so. Cutting tool manufacturers are very confident that their best route to justify the benefit of higher quality and cutting tool performance is to show new users improved productivity. For example, Tom Raun, national milling produc t manager of Iscar Cutting Tools, maintains that the cost of the tool is really insignificant compared to the benefit of improved machine cycles. Cutting tools amount to about three percent of a typical CNC shop’s total costs. If tool life can be doubled, then that ROI amounts to less than 1.5 percent of the shop’s total costs for cutting tools. Even so, if a shop realises it can reduce its tooling costs by a million dollars by making a simple purchasing decision, it will jump on that opportunity in a heartbeat. On the other hand, experience has Raun convinced that a 20 percent improvement in material removal ef f icienc y can yield a 15 percent improvement in manufacturing costs per unit. Think about it: A shop with US$100 million in sales could realise a US$15 million gain by making an average 20 percent across-the-board improvement in machine cycles using mostly existing equipment and sof t ware. If par t s manufacturers in just the automotive, aerospace, and energ y industries embraced this idea, the savings would easily be billions.

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EMBRACING THE EFFECTIVE VIEWPOINT So why are we not doing it? It all comes down to a change in viewpoint, finding the time to save time, and making a commitment to get better. Production deadlines are always looming and we all get comfortable with current processes, whether we’re managers or programmers. It takes valuable time and resources to test and evaluate new technologies and methods, or to experiment with the outer boundaries of what is possible. Yet, with the potential payback and production costs savings of 15 to 25 percent or more, isn’t it worth it? The pressure of a tight deadline could be loosened by the opportunity of getting jobs done faster and with fewer issues or setbacks. What is needed is a little bit of planning and optimisation targeting

better machining effectiveness upfront. This can lessen the impact of tight deadlines as well as down time incurred due to lack of efficiency. It is not uncommon to find initiatives of this sort yielding total manufacturing process cost reductions of 15 to 25 percent or more. Savings of this magnitude could be us ed to achieve such wor t hy obje c t i ve s a s improv ing prof i t s , capturing more business, and doing t h e m o d e s t a m o un t o f t r ainin g required for more robust workforce development and continuous improvement. People who are in charge of the day-to-day operations at machine shops are frequently under too many pressures to take the lead in initiating the sort of changes that are required. That sense of urgency also needs to come from the top.

CNC Software

Cost breakdown of the manufacturing process.

QUALITY DRIVES PRODUCTIVITY

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EXHIBITION FLOOR PLAN

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EXHIBITION FLOOR PLAN

CNC MACHINES

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The company produces blow moulds with volumes up to 30 litres.

PRODUCTIVE MOULD CONSTRUCTION WITH

MODERN CNC TECHNOLOGY

Machine controls can bring higher quality and shorter machining times in the production of stretch blow moulds. Contributed by DMG Mori

ince 1989, the Austrian company Kosme Gesellschaft, based in Sollenau near Vienna, has been active in the field of labelling and filling technology. With the advance of polyethylene terephthalate (PET) bottles, the company expanded its portfolio in the 1990s to include stretch blow machines, which has become its main focus today. The company also produces the blow moulds it needs for both its own stretch blow machines and those of its parent company, Krones. Of the total 135 employees, 25 are charged with the construction, programming, manufacturing and quality control in mould construction.

MINIMISING THROUGHPUT TIMES Over 3,000 blow moulds a year and small batch sizes of maximum 25 pieces are typical for mould construction at the company. Productive operation is essential if a company is to remain competitive. Andreas Steidl, head of mould construction, reveals part of the solution, saying, “Our machines are in operation round the clock.” They normally work in a single shift, but Mr Steidl added that automation solutions and machining times of several hours enable produc tion to run at high capacity. T he company ’s consis tent machining and control philosophy also contributes to productivity. Amongst

other s , the company ’s machining centres consist of DMU eVo linear series which are all equipped with similar controls; in this case, most use Heidenhain’s iTNC 530, with a DMU 95 monoBlock using the more recent TNC 640. Mr Steidl said that this means they could setup on one machine and then continue machining on the identically equipped machines in parallel in order to minimise throughput times. He added that the newer control had familiar dialog programming in plain text on one hand and a significantly expanded range of functions on the other that could be integrated in their work. The enhanced programme

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ZONE3®

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CNC MACHINES

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simulation was a also benef it for workshop-orientated programming. IMPROVED SURFACE QUALITIES The machine control is suitable for 5-axis machining with a swivel head and rotary table. With its Advanced Dynamic Prediction (ADP) feature, the optimised motion control applies particularly in the case of NC programmes generated on CAM systems. It happens often that only 3D models of poor data quality are available. This results in reduced data resolution or fluctuating distribution of points in the NC programme. The ADP feature expands the conventional l o o k- a h e a d o f t h e p e r m i s s i b l e ma ximum feed rate and permit s optimised motion control of the feed axes. This enables further optimisation of axis speed and acceleration in 3- and 5-axis milling, and eliminates feed fluctuations arising from uneven distribution of points. The results are cleaner surfaces and contours with shorter machining times. REDUCED SUBSEQUENT MACHINING Not only limited to large workpieces, the company al so manufac tures blow moulds for PET bottles down to volumes of 0.05 litres. The runtimes of the different blow moulds var y according to size and complexity of the future bottles from 60 minutes to over 10 hours. Mr Steidl said that in combination with the high-speed cutting spindles, the high dynamics of the linear drives also prove beneficial where such diversity is concerned. He also added that all moulds undergo f inal polishing , but wit h milling speeds of 40,000 rpm they are able to significantly reduce the time and effort required for subsequent machining. A technolog ic ally up-to-date approach entails regular investments in modern CNC machines as well as the use of innovative control technologies. Mr Steidl said that it is the only way for the company to keep up with the positive development on the market for PET bottles.

Machine controls can provide improved programme simulation and optimised motion control.

The true-to-detail 3D simulation graphics make it possible to check the manufacturing result before the actual start of machining.

The colour marking of the material removal clarifies the work steps and simplifies the allocation of the tools used.

The manufacturing process of the blow moulds starts with the CAD construction and CAM programming.

CUTTING TOOLS

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Situated inside these tools is a damping mechanism that consists of a heavy mass that is supported by a rubber spring element containing oil to increase the required dampening effect.

ANTI-VIBRATION TOOLS:

A QUIET REVOLUTION

Development in anti-vibration tools is able to reduce or even eliminate problematic vibrations. By Rafi Ravoach, Iscar ISO turn product manager

hroughout the world, machinists have to deal with the presence of problematic vibrations on a daily basis. Most recently, the design and development of anti-vibration tools, otherwise known as tuned or damped tools, has been applied to the boring bar. One of the most common turning applications is the boring of components, a function also known as internal turning. The most widespread tools used for this type of machining operation are boring bars. Boring bars’ shapes enable them to operate through previously drilled holes, and to efficiently enlarge and accurately profile holes according to their specific requirements. BORING BARS The correct application of a boring bar enables a bore’s internal profile to be

machined according to specification, an accurate hole diameter to be achieved and the required surface finish quality to be realised. There are three common t ypes of boring bars offered: solid steel, solid carbide and anti-vibration. The maximum overhang for solid steel boring bars is up to 4xBD. This limitation is due to the fact that machining with a longer length of steel shank (more than 4xBD) can induce unwelcome vibrations due to the elasticity and characteristics of the steel. In order to limit the vibration on a higher overhang of more than 4xBD and up to 6xBD, the use of solid carbide boring bars is recommended. Solid carbide boring bars represent an excellent, highly efficient option for boring applications of up to six times the tool’s machining depth. This capability is attributable to solid

carbide possessing a coefficient of elasticity that is three times higher than that of steel. However, when the machining of hig h over hang s of more t han 6xBD is required, even the use of a s olid c ar bide shank c an c aus e vibrations. Therefore, in these cases t he us e of s olid c ar bide c an b e somewhat limited. DEEP TURNING Deep turning solutions for machining hig h dep t h t o diame t er in t er nal applications include special antivibration boring bar systems with a ‘live’ vibration dampening system located inside the tool body. Recent development s by Iscar have seen the release of Whisperline anti-vibration boring bars, which have been designed to significantly reduce vibrations when working with a high overhang from 7xBD to 10xBD. Situated inside these tools is a damping mechanism that consists of a heavy mass that is supported by a rubber spring element containing oil to increase the required dampening effect. In addition, the system contains other elements which help to further reduce vibrations. The reactive damping mechanism comes into action during machining with high overhang work dept hs and ac t s a s a counter to vibrations. The anti-vibration damper effect is applicable for large depth of cut and high feed rates, allowing for continuous, efficient machining. Coolant supply is also available direct to the cutting edge, increasing t he inser t ’s tool life by reducing temperature and also improving chip control and chip evacuation. These factors enable meaningful increases in productivity to be achieved, improvements in surface quality on high overhangs to be attained, scrap levels to be reduced and users’ profitability to be enhanced. INSERT GEOMETRY Correc t inser t geometr y is a ver y impor tant fac tor when using anti-

CUTTING TOOLS

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Machine controls can provide improved programme simulation and optimised motion control.

v ibr at ion b or ing bar s . T he mos t recommended inser t geometr y for successful anti-vibration use is a positive geometry insert with a positive rake angle, as this shape exer ts a lower tangential cutting force when machining. Choosing the appropriate nose radius of the insert is also a vitally impor t ant consideration. A lower nose radius is recommended as this configuration significantly reduces the cutting forces, due to the lower cont ac t b e t we en t he ins er t and workpiece, which helps to limit and reduce vibrat ion. A greater nose radius creates much larger radial and tangential cutting forces that can produce unwelcome vibrations.

Anti-vibration boring bars are designed to significantly reduce vibrations when working with a high overhang from 7xBD to 10xBD.

CHIP BREAKERS & SECURE CLAMPING Inserts with the benefit of appropriate chip breakers are recommended for improved chip evacuation, as the production of long and curled chips can cause a range of problems when working with long overhang tools. In addition to increasing vibration during machining, long and curled chips are liable to spoil or damage the surface quality of the workpiece.

Appropriate chip breakers ensure excellent chip control and the creation of small chips which can be evacuated more easily with the help of the coolant supply. An additional, ver y impor tant f ac tor in reducing vibr at ions is ensuring the clamping stability of the anti-vibration boring bar. Secure clamping helps users to achieve

the correc t workpiece dimension, which results in excellent workpiece surface quantity and assists in avoiding vibrations; clamping length should be 4xBD. Using anti-vibration turning tools in conjunction with the appropriate ap p r o ac h c an p r o v id e e f f e c t i v e solutions for reduc tion and even elimination of vibrations.

METROLOGY

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HOW CAN PORTABLE CMMS HELP

IMPROVE MACHINE SHOP WORKFLOW? Innovations in the compact metrology space are changing the way machine shop inspection works for the better. By Bernard Chou, regional product line manager (portable), APAC at Hexagon Manufacturing Intelligence

ew hardware, advanced 3D mea surement c apabilit ie s and int e g r at ion wi t h C A D and enterprise metrolog y sof tware packages is opening a range of new opportunities for greater inspection p r o du c t i v i t y an d manu f ac t ur in g process optimisation. Today’s portable device alternatives include portable measuring arms, laser trackers and scanning systems, making

it convenient to move a level of quality assurance directly onto the shop floor. Depending on the system, it’s possible to provide accurate measurements within a range of 15-100 microns. While still not yet at the level of the highprecision work done by stationar y CMMs in the lab, this degree of accuracy is entirely suitable for many of the measurement tasks typically found on the shop floor.

SPEED OF PRODUCTION On the shop f loor, uptime is what matters most, and any tool that best maximises metal cutting time rules the day. Using portable devices for making in-process checks or f irstpiece inspections (if accuracy permits) can be the difference when it comes to maximising uptime, as no effort is wasted getting parts to a remote measurement location and then waiting for inspection results to come back. The key to getting fast measurement results from a portable device at or near a machine tool is preparation. For the latest generation of armtype instruments, this means simply knowing what features to measure, selecting them using a graphic user interface and following the prompts. Users can even perform complex evaluations on the shop floor using portable arms equipped with the same software found on stationary CMMs. This type of software uses a CAD model to generate efficient probe paths and allows for the generation of as much as 90 percent of a measurement programme offline before even taking the portable measurement device to the part. What’s more, if a first-piece CMM inspection programme already exists for measuring a part, users can import all or par t of the programme into the portable software package with minimal changes, eliminating most of the required programming and saving time. All that needs to be done at this point is taking the portable device to the part, orienting the part to the device and performing the required measurements. In a guided inspection routine, the user interface that uses the CAD model as a reference will show the operator where to probe the par t and then immediately display the measurement result s. Colour-coding (green/red) on the CAD model view of the part will indicate where it is in or out of tolerance. This kind of instant feedback is a win-win for the manufacturing and quality departments; portable users

METROLOGY

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on the shop floor obtain measurement results immediately, and they do so without t ying up the CMMs in the quality laboratory, which often have a heavy workload on other tasks. FITTING CONCLUSIONS Even when a part on a machine has a problem, it is not always necessary t o s cr ap i t . T ho s e f amil iar w i t h CMMs already know how to use their sof t ware’s best-f it capabilities to answer a wide range of questions about a part: • The casting is malformed, but is there enough material available to make a good part from it anyway? • I s t h e r e e n o u g h m a t e r i a l available on this bad par t t o re -machine i t and make a good one? • By reorienting this rejected part in three dimensions within the measurement programme, can I match up the critical features more closely to the CAD model and avoid rejecting it? Answering these questions and others like them presents opportunities for salvaging valuable parts with many resources and hours of work already invested in them. Additionally, moving the answers from the quality lab to the shop floor is a sure-f ire route to signif icant

efficiency savings, whether that be from the reduced time spent assessing errant par t s , or the increased numb er of p ar t s repur p o s e d by eliminating the guess work involved in deciding which par t s are wor th fully assessing. PROCESS PROBLEM SOLVING Good manufac turing people are ingenious when i t come s t o devising on-the-spot solutions to dimensional problems that materialise une x p e c t e dly. T he s e impromp t u adaptations may include the use of shims, special fixtures and ad hoc machine tool of fsets, allowing the machinist to ship good parts out the door without having to double back and find the root cause of and correct every problem immediately. Portable measurement systems are an excellent aid in making such improvisations, allowing experienced machinists to work faster and with greater accurac y as t hey correc t mistakes on the fly. And once the immediate problem is solved, the portable measurement system becomes a vital tool in tracing the out-of-spec condition back through the various manufacturing operations to identify and fix the root cause of the problem. The operator will be able to follow this problem solving process using defined measurement knowledge rather than guess work, ultimately accelerating the entire process of unwinding the problem.

Portable measurement systems can aid experienced machinists to work faster and with greater accuracy.

FROM BASIC TO ADVANCED Us abili t y is alw ay s imp or t ant for portable measuring devices, and while eas y to under s t and and use, they actually support a broad range of user capabilities. For novice operators, a simple, intuitive user interface is presented for checking basic characteristics of parts or using pre-programmed measurement routines written by CMM experts to check more complicated geometry. This makes it a quick and easy process for operators to learn to perform in-process checks or do pass/fail inspections of their own parts. Users at the more sophisticated end of the scale most likely have working knowledge of CAD and CAM. They will have little trouble using advanced portable devices and software to expedite setups or troubleshoot manufacturing process problems. And quality assurance staff will be able to deploy portable measurement approaches to get measurement results faster and closer to the process while eliminating bottlenecks at the CMM in the laborator y, allowing produc t development work to avoid continuous interruptions for the sake of keeping manufacturing on schedule. This flexibility in allowing users at different levels to handle tasks of varying complexity with the same tools has obvious benefits. In terms of cost effectiveness, purchasing and training on a single tool presents a clear opportunity to avoid unnecessary spending. THE ROAD TO EFFICIENCY IS PORTABLE The field of industrial metrology has now reached the point where portable devices with CAD-based measurement software are no longer specialty items, but mainstream tools that can be used to detect the causes of dimensional problems when and where they occur. By measuring at or near the machine, measurement-related time wasters can be minimised and measurement backlogs at stationary CMM sites can be cut significantly, both of which are key factors in improving new programme delivery cycles.

SHEET METAL

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Trumpf

PUNCHING MACHINE ADAPTABILITY:

ROOM TO GROW An entry-level segment punching machine that can gradually be expanded into a fully-fledged combination machine has caught industry attention with a host of innovative features from punching holes to bends flanges and forms threads. By Trumpf

he search for an economical, comp ac t and au t omat ionfriendly punching machine that is specifically designed to grow with their business will be unveiled by Trumpf at this year’s Euroblech. The TruPunch 1000 can be expanded into an equally space-saving TruMatic 1000 fibre punch laser machine, allowing sheet metal processors to upgrade their machine to keep pace with their growing business. SOLID-STATE LASER With its expandable functionality, the TruPunch 1000 provides the perfect entry point into the world of professional punching . It can handle sheets up to 6.4 mm thick at rates of up to 600 strokes a minute, yet is remarkably compact. With a footprint of just 6.5 x 4.9 metres, the TruPunch 1000 stand-alone machine is around 15 percent smaller than its predecessor. “ T he space we have here is limited, but the compact TruPunch 1000 slotted into the same space

previously occupied by a Trumatic 200,” said Thomas Herberger, managing director of Herberger Metallwaren, a company that participates in the product testing program. “Now we can process medium-format sheets without having to reposition them and that really speeds up our production process.” As their business evolves, sheet metal processors sometimes yearn for the greater variety of parts that can be manufactured by a combination system – and with the TruPunch 1000 there’s no need to buy a second machine. Thanks to its novel modular design, the TruPunch1000 can be retrofitted with a laser cutting system, a laser evacuation unit and a beam guard system. A 3 kilowatt TruDisk solid-state laser can be connected up to convert the TruPunch 1000 punching machine into a punch laser machine. This configuration precisely matches the other recent addition to the product range of Trumpf: the TruMatic 1000 fibre.

A FIRST This is the f irst time that Trumpf has offered a combination machine in the entry-level segment, a move that makes it easier for customers to make the switch from purely 2D laser processing to punch laser technology. Customers who already have a TruDisk solid-state laser can also use this to operate the TruMatic 1000 fibre via the Trumpf laser network. The price of the new machine is undoubtedly appealing, and – with the TruMatic 1000 fibre’s specifications matching those of the previous TruMatic 3000 fibre model – customers don’t need to sacrifice anything in the way of performance. Both the new models in the 1000 range offer completely redesigned drive technology, which is crucial to the success of the modular concept. The patented “Delta Drive” literally marks a new movement in the world of industrial punching technology. The advanced engineering team of Trumpf came up with the new drive to facilitate the construction of smaller machines and open up new methods of material handling. The secret of the Delta Drive is that it eliminates the need to move the sheet and work table in the y-axis – normally an integral requirement of sheet metal processing. It achieves this

SHEET METAL

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by making the punching head quickly manoeuvre in that direction. This new approach involves a drive system that is powered by two servomotors. When the servomotors move in the same direction, they allow the punching head to move back and forth in the y-axis. And when the ball screws rotate in opposite directions, this activates the punching stroke. The y-axis can be accelerated far faster in this arrangement, because the punch drive is also used for travel motion, eliminating the need to move the sheet or work table. As a result, the punching process is more dynamic and the machine is more productive. Fur thermore, the lower relative movement between the machine table and the metal sheet reduces the risk of jamming and collisions, making the process more reliable overall. Finally, the stationary machine table significantly reduces the size of the machine’s footprint.

RIGHT FIT Trumpf was also determined to make the TruMatic 1000 fibre as compact as possible. One way the company achieved this was by developing a special space-saving beam guard system that is compatible with the machine’s modular concept . This protective housing is gathered closely

Trumpf

AUTOMATIC SORTING Bot h t he TruPunch 1000 and t he TruMatic 1000 fibre can automatically sort finished parts measuring up to 180 mm × 180 mm. All processed parts are sent down a chute into a sorting unit which moves in a linear direction. From there they can be sorted into a series of boxes (up to 4 different 400 mm × 300 mm boxes). The boxes are positioned below the machine, which provides for easy removal by the operator.

Due to the innovative movement of the punching head, the machine also of fers an alternative way to remove the parts. This second method comprises an additional big flexible parts flap, which is available as an optional extra for the TruPunch 1000 and fitted as standard in the TruMatic 1000 fibre. The flap can be equipped with a sensor that detects whether all the parts have been properly ejected from the machine’s working area. Designed with relatively generous proportions, this parts flap can also be used to eject long and wide parts into containers or onto conveyors or pallets during both punching and laser operations. “Often we fill sheets with just four to six parts, and in the past we had to remove and sort them manually,” Trumpf testing partner Herberger of explained. “But with the TruPunch 1000 nobody has to keep watch over the process because the machine simply ejects the parts through the generously sized flap and places them straight in the crate for us.”

Delta-Drive eliminates the need to move the metal sheet and machine table in the y-axis by moving the punching head in this axis instead.

As their business evolves, sheet metal processors sometimes yearn for the greater variety of parts that can be manufactured by a combination system. around the machine table in a skirting manner. In punching mode it moves downwards, giving the operator a direct and unobstructed view of the process. But as soon as the program switches to laser processing, the protective skirt rises and a hood is lowered over the Delta Drive, to which the laser processing unit is attached. This protective screen effectively intercept s t he small amount of scat tered that could potentially escape at a shallow angle below the work table brushes during production. There are al so t wo laser safet y screens that allow visual monitoring of the ongoing process. Even in their automated versions, these two machines from the 1000 product series are more compact than any other comparable machines on the market. Both of them can also be connected to the new SheetMaster Compact. This automation system loads small and medium-format sheets and blanks and unloads micro joint sheets and scrap skeletons. Thanks to its optimised loading cycles, it can reliably complete most of these tasks while the machine is in operation. Both machines are equipped with an intuitive touchscreen to make life easier for operators. The MobileControl app can also be used to operate the machines from a tablet. The TruTops Boost Punch software is required for programming, and both the license and maintenance agreement already come with the machines as standard.

SHEET METAL

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cuts rusty or “dirty” metal, with which fibre laser cutting systems could have issues. The system mounted on a highquality cutting machine is capable of cutting 25 mm at speeds of more than 1,900 mm/min.

Plasma systems have become much more adept at marking workpieces with bend marks, hole locations, or part numbers.

INCREASING SPEED AND PRODUCTIVITY WITH THE X-DEFINITION PLASMA CUTTING SYSTEM

If you have not looked at plasma in the past few years, you should. Manufacturers have made huge strides in terms of cut quality, cut speed, operating cost, and ease of use leading to better productivity and profitability. Contributed by Hypertherm

ue to the high speed and precision cuts combined with low cost, plasma cutting sees widespread use, and is of ten used in f abr ic at ion shops , automot i ve repair and restoration, and industrial construction. With the capability to work faster and more precisely than older machinery, it is easy to see why the popularity of plasma cutting is on the rise, and why machine shops are opting for plasma cutters instead of traditional CNC milling and turning machines. Another advantage of CNC plasma cutting is that it can be used for a wide range of metals of varying thicknesses. The cutter can be used for cutting both ferrous as well as non-ferrous metals. Whether a metal is 3 inches (7.6 cm) thick or it is of gauge thickness, plasma systems can cut through them effectively and effortlessly. SMOOTH SURFACE EDGES When looking for cut ting systems, machine shops need a cutting system which produces smooth surface edges. One example is the X-Definition plasma cutting system by Hypertherm which is capable of cutting material thicker

than 10 mm, and it produces parts with edges that are smoother than fibre laser cut parts. In addition to smoother cut edges, when the plasma cutting system is used on a high-quality cutting machine, it is capable of ISO 9013 Class 1 and 2 tolerances and ISO 9013 Range 2 and 3 cut quality for tolerances of around 0.5 mm. Additionally, there isn’t a need for a separate marking system. Plasma systems have become much more adept at marking workpieces with bend marks, hole locations, or part numbers. Users can even mark with the same consumables used to cut. By varying the torch speed and current level, shallow and deep marks can be alternated. CUT SPEEDS THAT BEAT LASER CUTTING SYSTEMS At 170 amps, the X-Definition plasma system can cut 10 mm material two times faster than a 4 kW fibre laser. Increase the amperage and material thickness and this gap gets even wider. The system is also capable of cutting mild steel, stainless steel, aluminium, brass, copper and additionally, it easily

BOLT READY HOLES Hole quality is one of the most frequently discussed topics in regards to CNC plasma cutting. When it comes to hole cutting, plasma systems have always had two big issues. A severe taper is always created in which the bottom of the hole is much smaller than the top. In addition, plasma systems leave notches inside the hole that has been cut called a ding or divot. Both issues arise when dropping a bolt through a plasma cut hole becomes impossible. However, these issues can be rectified with “True Hole” technology for mild steel which produces significantly better hole quality than what has been previously possible, for use in conjunction with Hypertherm’s auto gas plasma systems. The technology allows today’s plasma to cut bolt-ready holes with 1:1 and 2:1 diameter to thickness ratios. SMART FEATURES With the X-Definition plasma system, machine shops are able to rely on its WiFi capability, which enables connectivity to desktops, tablets, or smartphones for convenient system monitoring, process setup, and multiple system tracking. Sensors in the power supply deliver refined diagnostic codes and significantly enhanced system information to reduce t roubleshoot ing t ime and provide proac t ive dat a to improve over all optimisation. Moreover, better integration between the software and plasma makes the days of trial and error during bevel set-up a thing of the past. Plasma systems now do all the work, allowing users to both cut and make the most common bevel types right from the plasma table. IMPROVE PROFITABILITY WITH PLASMA A common thread in the technological advancement of plasma cutting since its invention is the continuous reduction in the cost per metre (or foot) of metal cut. This phenomenon is greatly accelerated with X-Definition plasma thanks to a combination of faster cut speeds, longer consumable life, improved cut quality, and greater cutting consistency. Due to the great precision and efficiency that can be achieved by using plasma cutting, it is little wonder that it has become popular and is being widely used in the manufacturing sectors.

PLM SOFTWARE

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SMART MACHINES NEED SMART ENGINEERING

It’s clear that we’re entering a new industrial revolution. In the industrial machinery market, the impact of new technology will see manufacturing computerised – with production lines featuring smarter, more connected and more complex machines. Mirko Bäcker, marketing director EMEA, manufacturing engineering, Siemens PLM Software, explains how this, and other trends, means that the industry needs new ways to work that are more collaborative, versatile and flexible.

CUSTOMERS DEMAND MORE Those of us who fondly remember the Terminator movie franchise will recall the scene from Terminator 2 when a designer from Cyberdyne Systems realises that machines have become self-aware.

While we’re not at t he point of “singularit y ” yet , machines are becoming more intelligent with the ability to do more things automatically. Take a per f ume produc t ion line. Machines are available now that can work autonomously and continuously,

changing the contents of bottles, and their labels, based on digital work instructions. In t he f u t ur e , mac hine s w ill also become part of an integrated produc t ion line – using sensor s , connec ted over the internet – to

PLM SOFTWARE

provide real-time data on production p r o g r e s s an d t h e s t a t u s o f t h e machines themselves. For example, machines will be able to monitor their status, including variables such as temperature, hydraulic performance and pressure levels. They will auto-f lag anomalies to engineers who can remedy the problem before it becomes a major, and expensive, malfunction. Data collected from machines will be part of a wider data ecosystem with technology such as actuators, sensors, wireless video cameras and RFID readers in plants providing continuous information from the production line. This data, analysed and processed in the cloud, will give better operational intelligence on which people – and machines – can take better decisions. While these development s are to be welcomed, for machine-building companies, they massively increase complexity. In particular, advanced software – with millions of lines of code – is required to control machines, with the amount of software content in machines having grown “by 45 percent between 1970 and 2010”. Complexity is increased, too, by demands from manufacturers. In key markets – from cars to consumer goods – people want ever more customised products. And customised products Virtual models are now capable of commissioning mechatronics so physical testing of the machines can be minimised.

MEN PHILIPPINES 2018

require customised machines to make them, with customers increasingly specif ying machines that demand bespoke design. Indeed, the days of designing, building and supplying a standard model of machine, with a long life cycle, are dwindling. O n t o p o f t h e s e i s su e s , t h e environmental agenda, coupled with changing safety standards, means that legislation is a moving target. To comply with demands, machine configurations need to be changed more often. In addition, the rise of machine makers in lower-cost economies means that globalisation is increasing margin pressure. With these issues in mind, as an industry, we need to find ways to do things differently. We need to cope with the ever growing rise in machine complexity, find efficiencies to cut costs, and be more flexible – designing, developing and engineering machines in more agile and accelerated ways. In short, we need to move to more advanced machine engineering. MACHINE-MAKING THE SMARTER WAY The cornerstone of advanced engineering is a digit al plat form that hosts all project work, enables collaboration between teams, and s t ore s and c at alo g ue s all wor k , ensuring that IP can be easily reused.

Moving to a unified system, designed for the project lifecycle of machine design, enables machine builders to take three key steps that enhance production processes: 1. Adopt mechatronic design: Using systems engineering principles, a customer’s requirements can be traced all the way through from initial discussions to f inished design. Importantly, software is enabling the creation of more adv anced f unc t ional model s . The model provides a common framework for mechanical , elec trical and automation disciplines to work together in parallel. For example, mechanical designers can use concept models for detailed design; elec trical designers can use model data to select the best sensors and actuators for each machine; and automation designers can apply cams and operational sequence data from the models to develop software. 2. Engineering to order: Digitising project management also supports a move to modular design – using s o f t w ar e t o b r e ak c u s t o m e r specifications into discrete parts that can be worked on separately.

TOUCHING MACHINES To date, machine controls and interfaces have been somewhat “clunky”. But as technology advances, customers are interested in interfaces that are much more intuitive, such as touch-screen systems that require minimal training and allow greater control over the machine. This requires the development of more advanced software – another factor that’s adding to the complexity of machine design.

PLM SOFTWARE

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Operator running a CNC program on Siemens controller.

These modules are likely to be reusable and therefore reduce the number of design cycles required to build a new machine. This approach also mitigates the cost and time issues that arise when customers specify a bespoke machine. 3. Virtual commissioning: Perhaps the most interesting area in the evolution of machine design is the creation of “virtual machines”. Complete, and detailed, 3D digital vir tual clones of machines can now be built to design, test and commission new products. Design concepts can be built quickly and the software has the capability to simulate the effect of variables such as gravity, friction and the performance of electrical systems, fluids and pneumatics. The model can also be connected to controllers in the physical world to bring hardware into the loop of the design process. Our software connects

with a wide range of controllers from different vendors and supports t he simul at ion of a shop f loor Programmable Logic Controller (PLC). The use of vir tual commissioning helps to make the development cycle more efficient by allowing testing to start before a machine has been built. It helps identify issues earlier in the process, so preventing unidentified problems causing expensive delays further down the line. ENGINEERING TIME SAVINGS Customers we speak to that are using Project Lifecycle Management (PLM) tools with the capabilities described above estimate that development time is cut by between 20 and 30 percent. The savings especially come from the reuse of IP and the use of virtual models that make it easier to design, tes t and commission machines. For instance, the team designing the PLC software can be given a conceptual design to kickstart their programming and they

can start to simulate their software’s per formance much earlier (in the conceptual phase) to avoid errors and greatly ease the software design process. PLM tools also provide the realtime digital collaboration framework that’s needed to coordinate global teams across different disciplines. It seamlessly integrates the work of different groups and creates alerts when a change to a design in one area may have implications elsewhere. This improved integration can also save considerable time. A s machines become more connec ted and autonomous, the designing and building of them will only increase in complexity. To create these advanced machines, advanced software is needed: software that’s dedicated to the task in the hand and which, through intuitive collaboration tools and interfaces, makes it easier, more cost-efficient and faster to build the customised machines of today and tomorrow.

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TRUMPF in Philippines As a market and technology leader in machine tools and lasers for industrial manufacturing, TRUMPF is committed to providing solutions to customers through our innovations. With that focus,TRUMPF Philippines is now an established subsidiary and continues to further improve in providing customers with the best services and products. For more information, visit us at www.trumpf.com. 2D Laser Cutting Machines

Punching Machines

Flexible cutting through thick and thin for medium or large formats.

Fast, complex, three dimensional punching tool with tool rotation.

Laser Tube Cutting Machines

Punch Laser Processing Machines

Cost-effective, precise and optimal tube and profile laser cutting.

Perfect combination of punching and laser cutting on one machine.

Bending Machines

Welding Machines

Simple to operate, efficient and accurate bending.

Ideal tool when it comes to welding metals or other materials.

Laser Marking Machines

3D Metal Printing Machines

Large selection of marking lasers in different power classes.

Offers complete solution including digitization, machines and services.

TRUMPF Philippines 24th Street Corner 7th Avenue, Unit 5S Twenty-Four Seven McKinley Building, Bonifacio Global City Taguig City 1634, Philippines. Telephone: +632 864 4100 Fax: +632 864 4101