232608-JAN 2014.pdf
Transcript of 232608-JAN 2014.pdf
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JANUARY 2014
VolUme 17 / NUmbeR 1
DesigN / bU ilD / RepAiR
What Machine
Consolidation Can
Mean for You PG 27.
FEATURES
Soft Wired: Cutting High Taper
Angles with Wire EDM PG 29.
Chasing the Perfect
Feed Rate PG 32.
CASE STUDY
CAM Can Help You Do
More with Less PG 22.
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reset past practices.
Companies dedicated to continuous improvement are embracing
new capabilities of the CVe Monitor system. Maintain your feet of
molds by accessing these recently added features:
Store PM points and view deviation alerts to PM targets
Access disassembly/assembly PDFs on internal fash drive
Non-resettable lifetime count, plus resettable interval count
Begin a change for the better. Visit procomps.com/CVe to learn of
new ways to maximize your tooling investment for the years ahead.
a new years revolution
See Progressive at: PLASTEC West | PLASTEC South | ANTEC 2014 | AMBA Annual Convention | Amerimold
0114 Progressive Components.indd 1 12/13/13 3:39 PM
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Machines shown with options. Information may change without notice.
TURNING CENTERS MACHINING CENTERS 5 -AXIS DOUBLE COLUMN HORIZONTAL
Take The Leap
www.HURCO.com | 800.634.2416
Is speed more important than accuracy? Can you have both? With
Hurco, you can. Our HSi High Speed Machining mills are built from
the ground up to achieve speed and accuracy. Take the HSM leap
see, hear, and feel the difference with Hurco HSi machining centers.
HIGH SPEEDMACHINING HURCO.COM/SPEED
1113 Hurco.indd 1 10/2/13 11:30 AM
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PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Senior EditorMatthew Danford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Managing Editor El McKenzie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Moldmaking Technology (ISSN 1098-3198) is published monthly and copyright 2014 by Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and additional mailing offces. All rights reserved.
POSTMASTer: Send address changes to Moldmaking Technology Magazine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If undeliverable, send Form 3579.
CANAdA POST: Canada returns to be sent to IMeX Global Solutions, P.O. Box 25542, London, ON N6C 6B2. Publications Mail Agreement #40612608.
The information presented in this edition of Moldmaking Technology is believed to be accurate. In applying recommendations, however, you should exercise care and normal pre-cautions to prevent personal injury and damage to facilities or products. In no case can the authors or the publisher accept responsibility for personal injury or damages which may occur in working with methods and/or materials presented herein, nor can the publisher assume responsibility for the validity of claims or performance of items appearing in editorial pre-sentations or advertisements in this publication. Contact information is provided to enable interested parties to conduct further inquiry into specifc products or services.
2 MoldMaking Technology January 2014
6915 Valley Avenue Cincinnati OH 45244-3029P 513-527-8800Fax 513-527-8801 gardnerweb.com moldmakingtechnology.com
Richard G. Kline, CBC | President
Melissa Kline Skavlem | COO
Richard G. Kline, Jr. | Group Publisher
Tom Beard | Senior V.P., Content
Steve Kline, Jr. | Director of Market Intelligence
Ernest C. Brubaker | Treasurer
William Caldwell | Advertising Manager
Ross Jacobs | Circulation Director
Jason Fisher | Director of Information Services
Kate Hand | Senior Managing Editor
Jeff Norgord | Creative Director
Rhonda Weaver | Creative Department Manager
Dave Necessary | Senior Marketing Manager
Allison Kline Miller | Director of Events
ALSO PUBLISHER OF
Modern Machine Shop IMTS Directory Products Finishing Products Finishing Directory Plastics Technology / PT Handbook NPE Offcial Show Directory Production Machining Automotive Design & Production High-Performance Composites Composites Technology
Production Sourcing
Technical Education
Business Networking
Knowledge Centers
Technology Displays
Facility Tours
Live Demonstrations
The Industrys Largest Mold Manufacturing Event
PRESENTED BY
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0114 MMT DEPT--Masthead.indd 2 12/18/2013 12:58:28 PM
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0114 Iscar.indd 1 12/11/13 10:30 AM
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Great Tips from This Issue5TRICKS OF THE TRADE
Contents
4 MoldMaking Technology January 2014
Features
27 Machining What Machine Consolidation Can Mean for You
How to expand your production and profits in milling and high-speed cutting.
29 EDMSoft Wired: Cutting High Taper Angles with Wire EDM
Examine the wires properties to determine the right wire for achieving the best cut.
32 Software Chasing the Perfect Feed Rate
Get more than just reduced machining time with NC program feed rate optimization software.
35 Surface TreatmentPlating and Maintaining Textured Surfaces
Communication with your texturing and plating sources is key to properly maintaining the mold surface.
38 Mold Maintenance/RepairIn the Trenches: The Trouble with Troubleshooting
A look at the obstacles to effective troubleshooting.
Departments
6 From the Editor: Resolve to Get to Know Your Market
6 Whats New on MMT Online: Research
8 New Business Opportunities: Molding Capabilities
10 Your Business: Employee Retention
12 By the Numbers: MoldMaking Business Index
14 Profile: OESA Tooling Forum
18 Where Are They Now?: B A Die Mold
22 Case Study: Software
24 Case Study: Software/Automotive
40 Product Focus
45 MoldMaking Marketplace
46 End Market Report: Aerospace and Automotive
47 Ad Index
48 TIP: Marketing
On THE COvER
Image courtesy of DMG Mori Seiki.
Advanced, multi-axis machines, such as this DMG Mori HSC 55
Linear, showcase more consolidated moldmaking processes.
Their multifunctional capabilities help them perform
start-to-finish operations for the most challenging molds
decreasing cycle times, improving precision and cutting costs.
See related story on page 27.
Images above courtesy of (L to R) Harbec Inc., Sable Engineering and Wisconsin Engraving.
1. Do More with LessOne of the main driving forces behind today's technology advancements is consolidation. Everyone is trying to do more with less. PG. 27.
2. The Softer SideA better solution for cutting high tapers is soft wire. Low-tensile-strength soft wire easily bends to follow the correct path determined by the CNC controller to provide more accurate cuts. PG. 29.
3. Critical ConditionWith advances in cutting tools, tool materials and CAM software, it is increasingly critical to use the right feed rate for each and every cut. PG. 32.
4. Mold ReadyAreas that need textur-ing can be spotted and then gloss levels can be re-established, so every-thing looks brand new. After texture and gloss level requirements are re-established, the mold is ready to be plated again. PG. 35.
5. Closing the SaleSales and marketing training should include a program that targets the sales cycleprospect, interested, objections, commitment and close and how to effectively manage customer objec-tions and expectations. PG. 48.
January 2014 Volume 17 / Number 1
352422
vIDEO ACCESS
0114 MMT DEPT--Contents.indd 4 12/18/2013 12:58:56 PM
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0114 Doosan.indd 1 12/11/13 1:14 PM
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This MonTh on moldmakingtechnology.com
From the Editor
6 MoldMaking Technology January 2014
Resolve to Get to Know
Your Market Better
As we kick off 2014, we welcome a new team member with
experience in gathering market intelligence.
Christina M. Fuges
Editorial Director
And right now that intelligence is projecting a busy
2014. In addition to reshoring, high levels of indus-
trial production, and strong and improving capacity
utilization at durable goods manufacturers has led to
increased investment in molds and the equipment to
make molds.
We are thrilled to have Steve Kline Jr. join the
MMT team. Steve is part of the fourth-generation
ownership of Cincinnati-based Gardner Business
Media, which publishes media for the durable goods
manufacturing industries, including MoldMaking Technology magazine. He is
currently Gardners director of market intelligence and has produced forecasts
for his familys business, and for the plastics and metalworking industries. He
also has been working on Gardners Capital Spending Survey for more than
five years. Steve travels the country presenting the results of his research to
a variety of organizations at numerous events. He graduated from Vanderbilt
University with a bachelor of science in civil engineering and earned an MBA
with an emphasis in finance from the University of Cincinnati.
Reports and analysis from Steve that we will publish in MMT throughout
the year will examine more than just dollars spent; his research will also high-
light trends within various industry segments that affect mold manufacturing.
Keep in mind that MoldMaking Technologys audience falls within both
the metalworking and plastics markets, and comprises more than just mold
builders. It also includes those individuals at OEM and molding facilities
who specify, purchase, design, build, maintain or repair molds. Therefore, to
capture more data and deliver better intelligence, Steve has been surveying
Gardners entire readership of durable goods manufacturers since December
2011. This expanded survey and additional data mean enhanced reporting on
the business trends for mold builders as well as those for the entire moldmak-
ing industry, which is the focus of this magazine. We think you will find the
enhanced survey and expanded data helpful in managing your business.
Understanding industry trends will help you become a more informed deci-
sion maker. It will alert you to what your competition and customers are doing
so you can then plan strategically and identify potential growth markets.
For more information, feel free to contact Steve at skline2@gardnerweb.
com, 513-527-8800 or gardnerweb.com/economics/blog. He will be contribut-
ing relevant market and economic information regularly to MMT through
By the Numbers: MoldMaking Business Index, End Market Reports and the
MMT Blog.
Follow MMT on: Follow @MMTMag
MMT Zone: Gardner Research gardnerweb.comGardner Business Media provides research and reports that forecast and analyze the plastics and metalworking industries.
BRoWSe ReSeARCH RePoRTS gardnerweb.com/articles/list/223
2014 Metalworking Capital Spending Reports: Gardners Capital Spending Survey is the largest, most comprehensive survey detailing future spending in the durable goods manufacturing industries.
2014 Metalworking Capital Spending Presentation: View Gardner Research Director of Market Intelligence Steve Klines annual Metalworking Capital Spending presentation.
2013 World Machine-Tool Output and Consumption Survey: The World Machine Tool Output and Consumption Survey collects global statistics country by country and compares them in U.S. dollars.
2013 Tooling Equipment Report: Gardners Tooling Equipment Report projects spending of $3.6 billion in 2013.
eConoMIC BLoGgardnerweb.com/economics/blog
Household Debt Flow Increases Most Since December 2007
Capital Goods New Orders Contract Slightly in October
American Manufacturing on the Rise
MMT RePoRTS AnD InDUSTRY CoVeRAGemoldmakingtechnology.com/articles
end Market Reports: Forecasts and trends specific to a variety of end markets, including automotive, consumer products, packaging, medical, electronics and more.
MoldMaking Business Index: Based on a monthly survey of subscribers to MoldMaking Technology magazine. Using the data from this survey, Gardner Research calculates a diffusion index based on 50.0. A value above 50.0 for the index indicates that business activity expanded when compared with the previous month, and a value below 50.0 means that business levels declined.
2013 Automotive Vendor Tooling Study: The results of this industry survey set the stage for suggested practices and strategies that could help the entire vendor tooling value stream be more competitive, have adequate capacity and reach its desired success.
Signs of Growth: If online surveys could capture facial expressions, a recent survey of tool shop executives would probably show a good number of smiling faces, albeit cautiously optimistic ones.
0114 MMT DEPT--Editorial.indd 6 12/18/2013 12:59:36 PM
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0412 Ingersoll.indd 1 3/12/12 11:00 AM
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8 MoldMaking Technology January 2014
New Business Opportunities
Close Relationship with Molder Pays Dividends
By Matthew Danford
When asked about the relationship between Industrial Molds
Group and Pyramid Plastics, the first words out of Kerry
Smiths mouth are that the two companies operate indepen-
dently, with separate sales forces and customer bases. With
that out of the way, however, the account supervisor at
Industrial Molds has plenty to say about the advantages of
having tool manufacturing and production molding under
the same ownership umbrella. Although this situation natu-
rally results in a level of collaboration that might be atypical,
any moldmaker that works to build a close relationship with
its customers could potentially realize similar benefits.
The most obvious of these is a direct source of new work.
When a potential customer comes to Pyramid with an idea
for a molded part, chances are good that Industrial Molds
Group will have the opportunity to make the tool. The
organizations respective markets can sometimes limit these
opportunities, as Pyramid
targets mostly hardware,
HVAC and food dispens-
ing, while Industrial focuses
mostly on automotive, medi-
cal, consumer goods and
lighting. Still, Pyramid com-
monly enlists the services
and expertise of its parent
company for engineering
changes and repair work. In
any case, Smith emphasizes
that the company is careful
to ensure this collabora-
tion only works one way. As he puts it, We sell Industrial
Molds through Pyramid, but we dont sell Pyramid through
Industrial Molds.
Despite this arrangement, any visitor to Pyramids
Rockford, Ill., plant will likely encounter at least a few freshly
machined molds shipped from Industrials facility just a few
miles down the road. This tooling isnt there for production
purposes, but for sampling. Although many tool shops work
with a molder for sampling, Pyramids status as a division
of the same company ensures this work can be done at the
drop of a hat, Smith says. In contrast, an unrelated molder
would have its own set of scheduling constraints and priori-
ties, and it might be farther away.
Having a close, full-service injection molding operation
readily available for sampling also eliminates the need for
Industrial to invest in its own in-house presses. More than
one or two of these machines wouldnt make much sense,
but a limited number could also limit the tooling that could
be tested. Pyramid, on the other hand, has presses ranging
from 40 to 1,000 tons. Industrial can also focus on what it
does best rather than working to keep injection presses busy
beyond just sampling.
Pyramid also provides a source of frank but construc-
tive criticism. A fresh set of eyes can often spot flaws that
people who designed and built a tool might overlook because
of their attachment to their own work, Smith says. This
feedback can provide valuable lessons about what molders
look for in a toollessons that can translate to interactions
with other customers. For example, working with Pyramid
has prompted Industrial to pay more attention to things
like access to fittings and how easily tools can be loaded or
unloaded from presses. We try to make our molds more
user-friendly, he says.
Whether under the same ownership or not, both toolmakers
and molders can benefit significantly from closer relationships,
Smith concludes. Molders who do sampling have the oppor-
tunity to learn by seeing more tools and more types of tools.
From our standpoint, we can learn more about the molding
process and how things work on that end.
For More inForMation:
Industrial Molds Group / 815-397-2971 / industrialmolds.com
Molders who do sampling
have the opportunity to
learn by seeing more tools
and more types of tools.
From our standpoint, we
can learn more about the
molding process and how
things work on that end.
The markings on this tool identify fttings for water hookups. A push to
make molds more user-friendly is one result of feedback from Pyramid.
Phot
o co
urte
sy o
f In
dust
rial
Mol
ds G
roup
.
0114 MMT DEPT--New Business Opportunities.indd 8 12/18/2013 1:00:00 PM
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Your Business
10 MoldMaking Technology January 2014
By Kevin LaMont
As a business owner, you know the most valu-
able resource your company has is its employ-
ees. And in todays business environment,
employees not only expect a proper salary for
a job well done, they expect to be provided
with benefits, not only for themselves but for
their families as well.
Competitive benefit packages generally
include health, dental and life insurance, and
some form of a retirement plan. Here, we
focus on retirement plans (specifically the
401(k) plan) and how this simple tool may help
you not only recruit better employees but
retain them as well.
So, what is a 401(k)? As defined by the IRS,
it is a qualified deferred compensation plan
in which an employee can elect to have the
employer contribute a portion of his or her
cash wages to the plan on a pretax basis. For
2013, the maximum amount an employee
could contribute to a 401(k) was $17,500. The
maximum contribution between employee
and employer was $51,000.
There are several compelling reasons to establish a 401(k).
For one thing, such a plan is a tax break for your business. Any
company costs associated with operating a 401(k) plan can
be deducted at tax time,
including any contribu-
tions. Second, its a great
tool for attracting and
retaining employees
through vesting schedules.
In a recent survey pub-
lished by online media site
Business News Daily, 40
percent of employees said
they would leave their
current employer for a similar job if it offered a 401(k) plan.
The survey also concluded that most employees work harder
and stay on the job longer once a 401(k) is introduced.
In addition 401(k) plans are one of the most flexible types
of retirement plans available today. As the plan trustee, the
company can determine whos eligible to participate, whether
it will match employee contributions and how long before
employees become vested in the plan, and it can tie company
goals to 401(k) incentives. In other words, the more profitable
the company is, the greater the employees benefit.
A business owner also may wish to combine a profit sharing
plan with a 401(k) in order to enhance the effectiveness and/
or flexibility of the plan(s). Profit sharing plans dont require a
formula that ties the contributions to company profits.
No matter what type of plan you choose to help recruit or
retain top employees, it seems obvious that retirement plans
are here to stay. Their popularity has gained traction in the
past few years, and there appears to be no slowing down in the
near future. Regardless of the type retirement plan that you
elect to implement, make sure you check with your financial
advisor or CPA to ensure you understand any and all tax
ramifications that these plans may have, not only for you, but
for your company as well.
contriButor
Kevin W. LaMont, ChFC, is director of advance planning and investments for RB Capital Management LLC.
For more inFormation:
rB capital Management LLc / 949-861-4362
A business owner may wish
to combine a proft sharing
plan along with a 401(k)
in order to enhance the
effectiveness and/or fexibility
of the plan(s).
the High cost of employee retention
0114 MMT DEPT--Your Business.indd 10 12/18/2013 1:00:26 PM
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0114 Haas.indd 1 12/3/13 11:25 AM
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By the Numbers
12 MoldMaking Technology January 2014
strong, and supplier deliveries shortened
for the second time in four months
to 48.5. Material prices continued to
increase to 57.4, although at their slow-
est rate since November 2012. Prices
received, at 49.6, contracted for the
fourth month in a row, putting pressure
on profits. Future business expectations
improved for the second consecutive
month, reaching 76.2, their highest level
since March 2012.
Manufacturing facilities that subscribe
to MMT are classified according to
NAICS codes. Two important classifica-
tions for the moldmaking industry are
custom processors and metalcutting job
shops. In general terms, custom proces-
sors are analogous to molders while
metalcutting job shops are analogous to moldmakers. Custom
processors have been growing throughout 2013, but metal-
cutting job shops grew in November for the first time since
September 2012their fastest rate of growth since June 2012.
This improvement at metalcutting job shops was a significant
reason for the faster growth in the overall MBI.
Moldmaking business in the East North Central region of
the U.S. grew at a faster rate for the third consecutive month,
but the fastest rate of growth in November was in the South
Atlantic region. The Middle Atlantic region also grew, while
the West North Central and Pacific regions contracted.
Future capital spending plans are at the highest level in
the history of the index, which dates back to December 2011.
Novembers planned spending was roughly 30 percent above
the next highest month, and this months future capital
spending plans were 92.1 percent higher than they were in
November 2012. In fact, future capital spending plans have
increased month over month in every month but one since the
index was established.
MoldMaking Business Index for November 2013: 52.5
By Steve Kline Jr.
With a reading of 52.5, the MBI showed that the moldmaking
industry grew in November for the second month in a row and
at the fastest rate since July 2012. The index also was 27.4 per-
cent higher than it was in November 2012.
New orders grew for the second consecutive month to
59.6, also hitting their fastest rate of growth since July 2012.
Production grew for the 10th time in 11 months to 59.2, its fast-
est rate of growth since June 2012. Backlogs increased for the
first time since April 2012 to 50.4. The improvement in recent
months in backlog indicates that capacity utilization should
also rise in upcoming months. Employment also expanded
for the second month in a row to 53.4. Exports, at 46.8, have
been contracting for some time as the dollar remains relatively
Sub-Indices Nov Oct Change Direction Rate Trend
New Orders 56.9 50.7 6.2 Growing Faster 2
Production 59.2 54.1 5.1 Growing Faster 3
Backlog 50.4 45.9 4.5 Growing From Contracting 1
Employment 53.4 50.7 2.7 Growing Faster 2
Exports 46.8 47.1 -0.3 Contracting Faster 18
Supplier Deliveries 48.5 54.8 -6.3 Shortening From Lengthening 1
Material Prices 57.4 62.3 -4.9 Increasing Less 24
Prices Received 49.6 49.0 0.6 Decreasing Less 4
Future Expectations 76.2 69.2 7.0 Improving More 24
MoldMaking Business Index 52.5 50.6 1.9 Growing Faster 2
55
50
45
40
60
12/12
9/12
6/12
3/12
12/11
MoldMaking Business Index
3/13
6/13
12/13
9/13
For More INForMatIoN:
[email protected] / gardnerweb.com/economics/blog
ABout the Author
Steve Kline Jr. is the director of market intelligence for
Gardner Business Media Inc., which publishes MoldMaking
Technology magazine.
0114 MMT DEPT--By The Numbers.indd 12 12/18/2013 1:00:47 PM
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14 MoldMaking Technology January 2014
Driving Change
from the Bottom Up
By Matthew Danford
Although some challenges are beyond the capacity of any indi-
vidual company to address, teaming up with like-minded orga-
nizations can provide a means to effect real change. For evi-
dence of that, look no further than an event this past October
that attracted more than 200 people representing the entire
automotive supply chain, including most major OEMS as well
as a number of Tier 1 suppliers. The big draw? A new study that
identifies and proposes solutions to a projected vendor tooling
capacity shortage amounting to nearly $6 billion. By the time
the results were unveiled, the scope of this study had expanded
to cover the interests of the entire value stream. However, it
was initially conceived in response to concerns raised by com-
panies occupying the lowest rungrelatively small, indepen-
dent tool shops that, until recently, didnt have a collective voice.
The Original Equipment Supplier Association (OESA)
Tooling Forum aims to provide that voice. Open to indepen-
dent companies that manufacture automotive molds, stamp-
ing dies, gages and fixtures in North America, the forum has
provided toolmakers with a means to discuss common prob-
lems, share best practices and gain market intelligence since
September 2012. Cash flow and other problems resulting from
the unpredictable payment schedules associated with PPAP
(production part approval process) terms were among the chief
topics of discussion at the groups initial meetings, says Margaret
Baxter, OESAs senior vice president, operations and interna-
tional affairs. These discussions led directly to efforts that cul-
minated in the 2013 Vendor Tooling Study, conducted by con-
sulting firm Harbour Results in partnership with the OESA and
officially unveiled during the October gathering in Novi, Mich.
(To view an article on the study from MMTs December issue,
visit short.moldmakingtechnology.com/toolstudy.)
In addition to demonstrating the power of working together
to attract attention to a critical issue, the study is just one of
many examples of the sort of concrete deliverables that drive
the success of the tooling forum, Baxter says. In many cases,
these action items arise not from any specific effort like the
study, but from open roundtable discussions, which often
result in the drafting of best practice guidelines. Talking
about what keeps everyone up at night can be cathartic, and
members appreciate that, she says. But when a topic like
online auctions comes up, and someone can offer a concrete
example of how their company has turned those auctions to
its advantage, thats where the real value lies.
This type of sharing didnt come easily at first, says Shaun
Karn, co-chair of the forum and executive vice president
and chief financial officer at Hi-Tech Mold & Engineering
(Rochester Hills, Mich.). Although many of the companies the
OESA consulted about forming the group in summer of 2012
participate in other industry advocacy organizations, none
knew of any focused solely on automotive tool manufacturers.
All agreed that such a group would be valuable. Still, attendees
were apprehensive at first, and many seemed more interested
in just seeing what this was all about than really opening up
and participating, Karn says.
That apprehension is still common among companies that
audit the peer groups quarterly meetings to gauge their inter-
est in joining. However, just as the original members did, they
soon find that the risk of losing any competitive advantage
is minimal at best. Indeed, the now 25-company group has
added at least one new member after each meeting, Baxter
says. One reason she and Karn cite for the increased comfort
level is that the group is not designed to discuss competitive
secrets or technical information about the shops manufac-
turing processes. Rather, discussions revolve around broad,
strategic topics that affect all members, such as staffing
and workforce development, diversification, benchmarking,
supplier audits, capacity constraints, OEM product launch
The tooling forum is just one of many peer groups administered by the
OESA. Others focus on legal and regulatory issues, supplier technology, human
resources and public relations, among other topics. This shot depicts a meeting
of the CEO Council, a group designed specifcally for chief executives of auto-
motive supplier companies.
Pho
to c
our
tesy
of
OES
A.
The OESA Tooling Forum enables
automotive vendor tool suppliers
to discuss common problems, share
strategies, and promote business
practices that improve the entire
supply chain.
0114 MMT DEPT--Profile.indd 14 12/18/2013 1:01:12 PM
-
In its 12th year, the Leadtime Leader Awards,
presented by MoldMaking Technology, honors
those outstanding North American mold
manufacturers who best demonstrate overall
innovation, effciency, quality and commitment
within their moldmaking operations while
raising the bar in terms of mold engineering,
building, repair and management.
Nominate Your Shop Today!
Often we are so focused on the day-to-day activities of running
a business that we dont think much about all of the things that
weve done over the years to create and sustain a successful
business. In retrospect, flling out the Leadtime Leader Award
questionnaire forced us to consider all the various components
of our success including the adoption and implementation of new
technologies, customer service, continual education, training
and cross-training of employees, our sales/marketing efforts, and
involvement in our industry in ways that help to make it better
and stronger. We believe that receipt of the Leadtime Leader
Award is recognition from our peers of a job well done and we
want to thank everyone involved in the process.
Jerry Seidelman, Tech Mold, Inc. 2013 Leadtime Leader Winner
For complete information, eligibility requirements and nomination forms,
please visit: short.moldmakingtechnology.com/LLA
or contact Editorial Director Christina Fuges at [email protected] or (800) 579-8809
Innovative / Effcient / Quality-Driven / CommittedIf this describes your shop, then you have what it takes to be a leader.
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Attract new customers
Boost morale in the shop
Distinguish your shop as an industry leader
Leadtime Leader.indd 1 9/13/13 12:42 PM
-
Profle
16 MoldMaking Technology January 2014
cadence, scheduling, and industry forecasting, among others.
The fact that these topics are chosen by members themselves
has also proven critical to the groups effectiveness, Karn adds.
He emphasizes that the OESA supports and facilitates, and it
provides valuable resources for items such as the tooling study
and detailed forecasting that might otherwise be unavailable to
individual shops. Nonetheless, he says, The bottom line is that
for this forum to work, it has to be driven by the members.
To that end, the board of governors that guides the groups
interactions consists solely of representatives from member
companies. Meetings last about five hours, which includes
lunch, an overview of antitrust guidelines, announcements,
member introductions and chosen discussion points. Thats
followed by a formal presentation, whether from members
themselves or guests. In one instance, the group brought
in speakers from the Center for Automotive Research and
Ferris State Universitys Engineering
Technology program to discuss the
state of employment in the automotive
industry and educational initiatives,
respectively. Following that, a panel of
group members shared their own best
practices for finding, hiring, training
and retaining employees, and an OESA
representative shared information on
potential state- and local-level train-
ing resources. In another, more recent
example, representatives from Nissan
addressed the group about the com-
panys tooling strategy and expectations
for suppliers. Proceedings conclude
with a roundtable discussion, typically
regarding an issue previously agreed
upon by the board, and refreshments.
This March, the OESA Tooling
Forum will reach a critical milestone.
At its inception, the peer group was set
up to operate for a period of 18 months,
at which time members could opt to
disband or renew it for another 18
months. Both Baxter and Karns expect
that members will be eager to renew.
My sense is that, in the long run, these
companies would like to see this
industry remain competitive in North
America, and they recognize the poten-
tial of the forum for helping to do that,
Baxter says. It provides an opportunity
for peers to discuss issues they all face
and promote sound business practices
that improve the performance of the
entire supply chain.
For more inFormation:
OESA / 248-952-6401 / oesa.org
Harbour Results Inc.
248-629-9331 / harbourresults.com
0114 MMT DEPT--Profile.indd 16 12/18/2013 1:01:27 PM
-
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Where Are They Now?
18 MoldMaking Technology January 2014
Leveraging Limited
Resources
By Matthew Danford
In some ways, MoldMaking Technologys 1998 profile of B A Die
Mold reads as if it were written yesterday. Among the chief
challenges facing the Chicago-area mold manufacturer, com-
pany founder Alan Petrucci cited a shortage of skilled workers
and low-cost, overseas competition, topics that remain very
much in vogue. Then, as now, the shops success depended on
its willingness to adapt to new realities, its drive to keep up
with technology, and its flair for creative problem-solving.
Yet beyond these broad strokes, B A Die Mold is a very
different company than it was 15 years ago. Petrucci remains
quite active in the business, but his daughter, Francine, has
taken the reins as president. The facilities are larger and
more modern, and the equipment is more sophisticated.
The staff is leaner, the skill sets of individual employees are
broader, and more work than ever before runs lights-out.
Finally, B A Die Mold has parlayed a core competency into a
new product line that serves as a direct source of revenue.
Peak to Valley
After Petrucci founded B A Die Mold in 1968, the com-
pany outgrew three different facilities before settling into
a 10,000-square-foot plant in Lisle, Ill., in 1975. By the time
MMT profiled the shop in 1998, it had built a solid reputation
as a supplier of plastic injection molds, particularly complicat-
ed multi-action tooling and molds for threaded parts. B A Die
Mold was doing well by any measure, Francine Petrucci recalls
well enough, in fact, to begin planning yet another expansion.
Fed up with low ceilings, insufficient power and other prob-
lems with its aging plant, the business moved into its current
16,000-square-foot facility in Aurora, Ill., in 2000. By that
point, however, the shop was down to a fraction of its former
staffing levels. A significant cause of this decline was a major
exodus of mold machining work to low-cost overseas suppliers,
a development that seemed to happen overnight, she says.
More With Less
Work once viewed as an art form had become commoditized,
and attempting to compete on price alone would be futile for
a shop committed to quality and reliability. So B A Die Mold
began to shift its customer base from various custom molders
to larger OEMs that appreciated what the shop had to offer.
Having shed their own tooling and engineering departments
in many cases, these companies needed not just a supplier, but
a problem-solving partner. Although these customers hailed
from different industries, the work itself didnt change much,
Petrucci says. The company could continue to thrive on qual-
ity and precision. However, it would also have to meet tighter
delivery schedules and provide additional services like proto-
typing, all with a significantly leaner staff.
The shops success in this endeavor is evidenced by the fact
that sales are higher than at any point during the 90s, yet
costs are lower. In part, thats because each member of its
leaner staff wears many hats, says General Manager Michael
Duquette, who instituted a formal cross-training program
about six years ago to empower shopfloor operators. Enabling,
say, quality-control personnel to also operate EDM machines
not only keeps work flowing when team members are on
vacation or otherwise unavailable, but also helps alleviate
bottlenecks when certain areas become busier than others.
Employees also have more to offer when it comes to solv-
ing problems. Anyone might have valuable input on the big
picture of how a job might flow through the shop, Petrucci
explains. Theres more of an I can do that mindset, as
opposed to a They can do that attitude.
An example of the shops
standardized workholding, a critical
factor in reducing setup time for
operators running multiple machines or
programming lights-out work. The shop
machines most electrodes from copper
rather than graphite to avoid the mess,
reduce part surface faws caused by
DC arcing and improve surface fnish.
Pho
tos
cour
tesy
of
B A
Die
Mo
ld.
This moldmaker credits cross-training,
unattended machining and a knack for
problem-solving for its ability to survive
and thrive through tough times.
0114 MMT DEPT--Where Are They Now.indd 18 12/18/2013 1:01:52 PM
-
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Another important change is that a single operator typically
programs and runs multiple machines. Unattended machining
during the night shift has also been critical. In fact, Duquette
says the share of lights-out work has increased from about 10
percent of total production to about 30 percent within the past
10 years. Again, much of that improvement can be attributed
to efforts to empower the people on the shop floor. Moving
from offline to conversational programming, for example, has
enabled employees to use their own knowledge and experience
to schedule and program this work, which typically involves
repetitive machining routines, lengthy cycle times, and open
geometry that doesnt require fine, difficult cuts.
Of course, raw technological improvements cant be dis-
counted. For example, software that enables extracting EDM
electrodes directly from 3D solid models of the corresponding
part geometry was critical to getting electrode development
out of engineering and onto the shop floor, Duquette says.
Likewise, custom fixture plates that accept standardized hold-
ers from Erowa ensure location repeatability from workpiece
to workpiece and from machine to machine without re-refer-
encing. This system was a major factor in enabling operators to
run multiple machines and prepare lights-out work more effi-
ciently. He also credits advancements in machine tools, CNCs
and cutting tools for faster, more reliable production.
Idea to Opportunity
In the short term, the shop aims to continue doing more with
less by implementing pallet systems, and, eventually, robotics.
These sorts of investments will be critical to future competi-
tiveness, but Duquette cautions that the shop cant rely on
technology alone. It would be great to replace our equipment
every year, but the reality of business dictates otherwise.
For that reason, management agrees that the future success
of both B A Die Mold and the U.S. industry as a whole will
depend not just on technology, but also on knowledge and
ingenuity. In fact, the shop has already capitalized on one par-
ticular area of expertise. The PERC (Programmable Electric
Rotating Cores) system was originally developed for in-house
use, but it now brings in a steady stream of revenue on the
open market. Molds for threaded components require rotat-
ing cores to unscrew and eject parts without damaging the
threads. Rather than hydraulic racks that can become long
and unwieldy for parts with many threads, the PERC system
employs programmable servomotors to ease setup and
enable the use of smaller presses, among other advantages.
We realized that wed come up with a great idea, and we
decided to patent it, Ms. Petrucci says. But were constantly
solving problems creatively, and that really goes for all mold-
makersits just what we do.
0114 MMT DEPT--Where Are They Now.indd 20 12/18/2013 1:02:01 PM
-
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0114 UBM.indd 1 11/6/13 3:41 PM
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22 MoldMaking Technology January 2014
Case Study / Software
At any given time during a 24-hour workday, moldmakers
at Harbec Inc. can be found sitting elbow to elbow in a CAM
room crammed with 16 computers equipped with Mastercam
CAM software from CNC Software Inc., writing CNC pro-
grams to manufacture mold plates for current jobs. Meanwhile,
the 36 three-, four- and five-axis mills, lathes and EDMs for
which they are responsible are churning out components that
will be used by other moldmakers to assemble their molds.
Harbec is a vertically integrated company with three core
profit centers: CNC manufacturing of 3D prototype parts,
design and manufacture of molds and injection-molded proto-
types, and production molding. Half of the companys income
is derived from molding, and the other half from the manufac-
ture of precision prototypes and tooling.
Harbecs president, Bob Bechtold, explains how this break-
down bucks the current trend of molders trying to reduce
toolroom operations because they mistakenly consider it a cost
factor rather than a profit center.
All of the toolmakers at Harbec are profcient CNC
programmers who use Mastercam software.
CAM Can Help You
Do More with Less
By keeping it all in one place, we can truly manage quality
and product, he says. We own the queue. Rather than managing
the relationships, we manage the customers work. We cant blame
it on anyone but ourselves if things dont work out well. We hope
to find enough customers who appreciate that level of detail.
So far, this strategy has been working, and the company has
been heavily booked with work, particularly from the medical
device, aerospace and energy industries.
Skills and CAM Confidence
Bechtold credits the companys success to the tremendous con-
fidence it has in the skills of its people and its CAM technology.
This has always been our strategy, he says. Since the first
Mac-based version of Mastercam was introduced, I have been
infatuated with this programs ability to give us strength as
moldmakers. In CAMs early days, the industry buzz was that
these computers were going to put us all out of business, but in
actuality CAM is the greatest tool that the toolmaker will ever
have, particularly for one-of-a-kind, highly complex tools.
Harbec has maintenance licenses for its Mastercam software
and leans on its reseller for early releases. This enables Harbec
to evaluate new features that could impact productivity and
implement them as soon as possible. The company also makes an
extensive investment in training by encouraging in-staff mentor-
ing, formal in-house training and training provided by its CAM
reseller. Bechtold says Harbec has about 40 moldmakers who are
CAM users, and about 30 of them are very proficient. The others
know enough to get by and are working to improve their skills.
CAM Builds Business
Harbec President Bob Bechtold values the role CAM has played in his familys
businesses. With Bob as a toolmaker and his brother Mike as a machine tool
repairman, they have been able to start several thriving companies over the
years, including:
1. OptiPro, a state-of-the-art optical grinding and polishing equipment manu-facturer, and Mastercam reseller.
2. OptiMax, a custom aerospace optics manufacturer.3. Harbec, a provider of tightly toleranced prototypes, tooling, machined
components and injection-molded parts.
Each one is a substantial business serving major OEMs and other manufac-
turers worldwide while providing hundreds of well-paying jobs to skilled em-
ployees in upstate New York. The family believes its CAM expertise has been
a common thread that runs through all of its businesses.
One moldmaker makes significant
advances in programming and
machining productivity while
reducing cutting tool costs.
0114 MMT DEPT--Case Study 1--mastercam.indd 22 12/18/2013 1:02:45 PM
-
moldmakingtechnology.com 23
According to Harbec, these and other improvements have
translated into greater confidence in unattended CNC machine
operation; the ability for the same staff to create one-third more
programs; the capability to keep 40 machining spindles in near-
ly continuous operation, 20 hours a day, five days a week; dra-
matic reductions in tooling costs per unit of production; faster
turnaround on tooling projects; and the ability to produce more
without a proportional increase in capital equipment.
CAM Sophistication Leads to New Mold Developments
Increasing CAM sophistication has enabled Harbec to develop
a new, lower-cost, fast-turn Quick Mold Solution (QMS) con-
cept that has become very popular with its customers. While
the company still prides itself on its ability to produce Class A
tools guaranteed for a million cycles, most customers dont have
those needs or requirements. QMS tools are made of aluminum
instead of hardened steel, and may be guaranteed for thou-
sands or tens of thousands of parts. They also can be produced
with far shorter lead times and at a fraction of the cost, so the
customer is able to get its products to market faster. With this
concept, Bechtolds vision of toolmakers using CAM to produce
fast-turn tools for complex, short-run products has come to
fruition.
Imag
es c
ourt
esy
of M
aste
rcam
/CN
C So
ftw
are.
For More iNForMAtioN:
Harbec Inc. / 585-265-0010 / [email protected] / harbec.com
Mastercam/CNC Software / 800-228-2877 / mastercam.com
Each year, the company fully expects that its CAM software
will enable it to do more with less. For example, during the past
several years, Mastercams dynamic tool pathswhich allow
for machining at the highest safe speeds with minimal engage-
menthave enabled the company to make significant leaps
forward in programming and machining productivity, as well as
reduce cutting tool costs.
Bechtold believes that it is counterproductive to focus on
how much the company is saving from one year to the next.
What do I care how much time we took out of typical jobs
last year? What I want to know is how we are going to drive 10
more hours out of a job that we are doing today, and do it with
more precision.
Toolmaker Peter Knapp is forthcoming about the quality
and productivity benefits of recent CAM improvements as
well. He believes that he and his fellow moldmakers are at least
30 percent more productive across the board with the latest
version of Mastercam than they were several versions ago.
Dynamic tool paths are first among the improvements he cites,
and he also mentions features such as:
STL Compare, which facilitates a direct comparison
between the CAD model and the CAM program to assure
that the machining program is complete.
Simulation, which enables verification of appropriate
material removal along with tool movement backplots
that make it possible to detect potential tool crashes.
Geometry Manipulation, which makes it easy for the
toolmaker to generate additional geometry that will
enable him to create fillets and other features that assure
precise mating of mold halves.
Hybrid Toolpath, which combines contouring and
finishing tool paths into a single operation with finely
blended transition areas to improve throughput and
reduce subsequent polishing time.
The reliability of the programs enables CNC equipment to run unattended
while Harbec moldmakers are back in the CAM room writing programs for the
manufacture of other components.
Effcient, material-aware dynamic and hybrid tool paths enable even
complex parts to be manufactured at high speeds with minimal stress on the
tool or the part. Hybrid tool paths combine both roughing and fnishing with
a single tool to optimize productivity and blend transition areas for improved
surface fnish. This means molds can be assembled faster because fewer
secondary grinding or polishing operations are required.
0114 MMT DEPT--Case Study 1--mastercam.indd 23 12/18/2013 1:02:55 PM
-
24 MoldMaking Technology January 2014
Case Study / Software / Automotive
Sable Engineering of Port Huron, Mich., got its start in 1999
within the medical field when an orthopedic doctor urged
owner Andreas Batz to buy the right equipment to produce
his own line of medical devices. Over time, market demand
pushed Sable Engineering into the automotive industry. Early
work involved using CMM and mold flow data to unwarp and
reverse-engineer 30- to 40-percent glass-filled parts. Today,
most of this ISO 9001:2008-certified companys jobs are
focused on prototype and production blow molds, fixturing,
and product design. With this transition to the automotive
industry came new challenges. Designs became more com-
plex and assembly jobs more frequent, and the software Sable
Engineering was using was not
up to the task. One of my best
customers advised me to get
software that could better handle
large assemblies, Batz says.
Thats when I realized I needed
Cimatron.
Making Complex Jobs Easy
Working long hours to get the
job done and delivering exactly
what was promised has helped the
company build a loyal customer
base of automotive suppliers. According to Batz, before Sable
Engineering started using Cimatron, a lot of time was spent
on labor-intensive design work, including redrawing standard
components in the companys previous 3D CAD software,
which resulted in lengthy projects and eroded profit margins.
Moving to Cimatron was quick and easy for my designers,
Batz says. The software gives the designer a great level of
freedom to go back and forth between solids and surfaces,
making complex jobs easy. When we need help, the team at
Cimatron has been extremely responsive, and their tooling
knowledge is second to none.
The mold design and NC machining data for this two-cavity, cowl-side
prototype were generated using Cimatron software. The prototype was
machined on an Awea 1250 CNC machine.
Completing complex
mold designs faster
without lowering our
margins is something
that we wouldnt have
accomplished if it
wasnt for Cimatron.
Cimatron prepared the machining data and 3D rib curves for NC for this slider
on a prototype air box door tool. The part was machined on a Kitamura CNC machine.
CAD/CAM Answers New Automotive Challenges
For this blow mold manufacturer,
the right CAD/CAM software yielded
time savings, productivity gains and
streamlined customer communication.
Imag
es c
our
tesy
of
Cim
atro
n an
d Sa
ble
Engi
neer
ing.
0114 MMT DEPT--Case Study 2--cimatron.indd 24 12/18/2013 1:03:21 PM
-
moldmakingtechnology.com 25
Cimatron using advanced
surfacing and solid cut created
this production secondary fxture.
According to Batz, Sable Engineering now can save a lot
of time by using catalog parts and assemblies, and with just
a few clicks at the end of the project, it can generate the
complete bill of material. Overall, we can now do things
five times faster compared to what we did prior to using
Cimatron, Batz says.
Gaining More Business
Batz realizes value in his purchase of Cimatron software
every day. Completing complex mold designs faster without
lowering our margins is something that we wouldnt have
accomplished if it wasnt for Cimatron, he says.
Cimatron enables multiple designers to work on one
project, dramatically speeding up delivery time. Additionally,
Batz says that nearly every component the designers add to the
job has a cut body, and Cimatron creates the hole/pocket and
then automatically updates it if that component is moved.
The time savings and productivity gains are not the only
benefits of the software that Batz and his team value; its
Cimatron with Mold Wizard was used to design this production four-cavity
fller tube, including the use of full catalogs, 2D drawings and bill of materials.
Challenges Meeting customer requests for short delivery time on complex mold designs.
Delivering assembly-based 3D designs for concurrent manufacturing processes.
Maintaining proftability with effcient design methods.
Solution Sable Engineering uses Cimatron to get complicated jobs done faster,
thanks to the softwares greater fexibility working in solids/surfaces,
effcient use of assemblies and catalog parts, and better communication
with customers.
Results Increased design productivity as much as fvefold compared with
previously used software.
Streamlined collaboration with customers. Cultivated a growing and loyal customer base.
0114 MMT DEPT--Case Study 2--cimatron.indd 25 12/18/2013 1:03:30 PM
-
26 MoldMaking Technology January 2014
Case Study / Software / Automotive
For more inFormation:
Sable Engineering Inc. / 810-689-9399 / sableengineering.com
Cimatron / 248-596-9700 / cimatrontech.com
also the streamlined customer communication and collabo-
ration. Batz finds these capabilities especially helpful when
dealing with design and engineering changes.
Handling modifications quickly and effectively is critical to
keeping projects on time and on budget, he says. Most of our
customers use Cimatron, which makes communication and
changes much simpler. If the customer needs to modify some-
thing quickly, they can do it on their end in a seamless fashion.
Regardless of who makes the changes, this software enables us to
implement them seamlessly, because everything is associative.
taking on more
Additional work has been another benefit from Sable
Engineerings move to Cimatron. Just recently we received a
job outsourced from a large progressive stamping company,
which is not using Cimatron and needed assistance with the
surfacing work, Batz says. Even though the designs were
correct, the software they were using created poor surfaces,
even after spending more than 45 hours working on the part.
With Cimatron, we were able to help them get the job done
in a matter of hours. They were able to deliver the project on
time and, most importantly, to the complete satisfaction of
the customer.
Production mold design prepared for Cimatron motion analysis.
0114 MMT DEPT--Case Study 2--cimatron.indd 26 12/18/2013 1:03:37 PM
-
moldmakingtechnology.com 27
What Machine Consolidation
Can Mean for You
By Dr. Greg Hyatt
One of the main driving forces behind
technology advancements in manu-
facturing today is consolidation.
Everyone is trying to do more with less, and
faster cycle time is more important than ever
across many industries. With new products
coming to market every dayand increasing
competition and demandsmore efficient
production methods are crucial.
Milling is a particularly challenging pro-
cess to optimize for fast-production applica-
tions because of the complex geometries and
time-intensive programming that is often
necessary. In addition, few milling machines
can offer increased volume capabilities and
decreased downtime. For this reason, address-
ing this issue has been an important emphasis
for technology developments.
The Multitasking Option
The machine tool industry needs high-speed, high-volume
machines that can provide accurate, capable milling and high-
speed cutting. Cost is a consideration, however, as many shops
historically have avoided offering these capabilities because
it was just too expensive. How can you combine the milling
power of a VMC and the ultra-high speed of a drill-tap center?
Done right, many of the downfalls of drill-tap machines on the
market can be addressed, including subpar rigidity, slow tool-
change times and less accurate finishing.
One way to answer these challenges is with a multitask-
ing machine. These types of machines offer more advanced
machining capabilities and enable manufacturers to combine
several processes and cutting techniques on a single unit,
often with standard, off-the-shelf tooling. The time and cost
savings are significant.
Multitasking is an area of interest for those in mold
manufacturing because it can greatly reduce or eliminate
benchwork time. The multitasking machines real value is in
the precise finishing applications it provides. The appropri-
How to expand your
production and profits
in milling and high-
speed cutting.
Mutlitasking machines can offer increased performance in machining
molds, large or small. These machines offer smaller tools and higher spindle
speeds for small-depth milling, yet a large work area.
Video
Access video
at end of article.
Imag
es c
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esy
of D
MG
Mor
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iki.
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Machining
28 MoldMaking Technology January 2014
Another important feature for a multitasking machines
spindle is whether it offers almost the same torque at low
speed that the standard spindle offers. This results in little
compromise in roughing while reducing cycle time in finish-
ing. Add to that a high-speed toolchanger, and you should be
able to achieve chip-to-chip times of less than 1.5 seconds.
A spindle that drives the turret of the toolchanger is not
unique, but the way in which it drives the turret can befor
example, inside the spindle stock instead of running up a
gear reel on the spindle nose, which brings a lot of imbalance
and noise. This design eliminates the rotating gears, greatly
increasing the life of the spindle.
Also consider a 33-hp spindle designed to push the limits of
a typical drill and that has built-in water-cooling capabilities,
because these unique features allow for continuous machining
at maximum speeds. Both a water-cooled spindle and water-
cooled motor enable manufacturers to use the machine at
maximum speed 100 percent of the time.
Because high-performance multitasking machines are built
for high-volume production or automated machining, chip
disposal is another factor to consider. When you purchase
a machine to make a lot of chips, you dont want to stop the
machine because of those chips. The secret to better chip
flow and superior accuracy is optimized table construction.
A triangle-shaped table and thermal stability both help with
this chip flow.
Summary
In order to optimize production and profits in milling and
high-speed cutting operations, mold manufacturers should
consider a multitasking, high-speed mill. New technologies
have eliminated barriers and significantly improved the pro-
cess, and operations stand to get even more accurate, faster
and less expensive in the future.
contributor
Dr. Greg Hyatt is the chief technical offcer at DMG Mori Seiki.
For more inFormation:
DMG Mori Seiki / 847-593-5400 / dmgmori-usa.com
Video: High-Productivity milling and Boring http://short.moldmakingtechnology.com/ multidm
Look for a multitasking machine that has a superior high-speed toolchanger.
Some multitasking machines can offer chip-to-chip times of 1.5 seconds.
ate machine can be an ideal solution for those who are more
concerned with finishing applications than with roughing and
with having those applications completed quickly.
machine Considerations
Look for a machine that combines speed, rigidity and high
dynamics in one concept. Consider one with a C-frame design,
a traveling X axis with a 700-mm stroke, a 5.4-foot-wide foot-
print and a table that can load as much as 880 pounds without
any speed restriction. Most other cross-table concepts typi-
cally cannot handle large workpieces at high speed and still
maintain accuracy. The right design concept will lend itself to
high-speed moldmaking because it offers the rigidity and size
accommodation needed for large injection molds.
Because it plays an essential role in the machines productiv-
ity and accuracy, a higher-end control also is necessary. Such
a control that enables the operator to switch the dynamics of
the machine easily and quickly through roughing, semi-finish-
ing and finishing is particularly useful for moldmaking. The
control should also be extremely user-friendly and make it easy
to optimize each tool for its specific operations.
Optimal rigidity is determined by whether the machine
can produce more cubic centimeters/inches of cut metal per
minute than another machine. Increased machine rigidity also
means more accuracy and less vibration, which results in bet-
ter surface finish and longer tool life.
A particularly important factor in reducing benchwork time
is the spindle. While most will associate a high-speed spindle
with aluminum cutting (or bottle molds), a 24,000-rpm spindle
is essential in ferrous applications of mold manufacturing as
well. Complex mold cavities require small-diameter tools, and
achieving 800 square feet per minute with a tool 0.125 inch in
diameter requires 24,000 rpm.
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moldmakingtechnology.com 29
By Steve Bond
This injection mold was machined on
a wire EDM machine using soft brass
wire and tapering to 30 degrees. The
machine uses optional large-opening
fush nozzles that prevent the wire
from curling over the opening of the
nozzle during the machining of the
large taper sections.
When conventional machining processes cannot
successfully cut high taper angles, wire EDM can.
However, mold manufacturers using wire EDM
technology face some challenges when cutting such angles,
which can range from 10 to 45 degrees. Oftentimes, EDM
machines have the axis movement necessary to achieve the
desired angle, but the physical properties of the wire and relat-
ed machine technology may not be adequate. Examining the
wires properties is useful in determining the right wire
for achieving the best cut.
Hard vs. Soft Wire
Hard wire is stronger, straighter and more resistant to break-
age during cutting than soft wire. High-tensile-strength,
harder wire can also better fight deflection during cutting,
but very hard wire with little elongation can cause vibrations
during taper cutting as the wire travels between the upper
and lower wire guides. In addition, hard
wires memory resists the true pro-
grammed wire path during high-
taper cutting, which bends the
wire and can lead to reduced
accuracy, poor surface finish
or wire breakage. This will
leave intolerable marks on the
workpiece and waste material
and production time.
A better solution for cut-
ting high tapers is soft wire.
Low-tensile-strength, soft
Examine the wires properties to determine the
right one for achieving the best cut.
Soft Wired: Cutting High
Taper Angles with Wire EDM
wire easily bends to follow the correct path determined by the
CNC controller and provide more accurate cuts. However,
soft wire has less memory than hard wire and is prone to
breakage in aggressive cutting conditions. It is also sensitive
to the voltages and tension applied to it by the EDM machine
during the AWF cutting cycle. If not handled properly, the
result is a malformed wire tip that is curved and prevents the
wire from being able to be inserted into the wire guides. In
these instances, the machine is unable to thread or re-thread
the wire, so the erosion process is stopped and production
time is lost. The operator is required to manually intervene
before cutting can begin again.
Overcoming Obstacles
To overcome the challenges of soft-wire threading, consider
EDM equipment that provides improved wire processing during
the AWF cutting cycle. Technology should include a way to pre-
Imag
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esy
of M
etho
ds M
achi
ne T
ools
Inc
.
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EDM
30 MoldMaking Technology January 2014
Figure 1
Soft Wire AWF
Figure 2
Soft Wire
Figure 3
Soft Wire AWF
Figure 4
Soft Wire
cisely control the wire tension and energy used to cut the wire.
The ideal AWF situation is one where the wire heats and
stretches until it breaks in two without melting. Using the
ideal voltage needed to cut the wire and form a bullet point
can enhance soft wire threading performance, improving the
straightness of the wire and decreasing electrode wear (see
Figure 1).
It is not just the hardness or softness of the wire that needs
to be considered, however. Factors such as wire diameter, cut-
ting and anneal tension, and voltage need to be fine-tuned
based on the wire selection in order to preserve the shape
of the wire tip, minimize damage to the face and maximize
straightness (see Figure 2).
The small discharges used in wire EDM can result in elec-
trode and wire tip damage, wire chip buildup and reduced
AWF reliability (see Figure 3). Some EDM machines offer an
air blow system that directs cool air to the wire cut point. This
keeps the wire tip as cool as possible and also prevents a mol-
ten tip from being produced during thermal wire cutting.
To optimize the threading cutting cycle, a relay on a timer
is used to open an air solenoid to gently blow cool air onto the
wire cutting electrode and keep the wire tip from heating up
to a melting stage. This prohibits wire chip buildup, extends
electrode life and provides reliable threading and cutting per-
formance (see Figure 4).
During the cutting phase, accurately controlling wire tension
is critical (especially with soft wire), so an AWF system with
a wire tension monitoring device that provides continuous
observation is important. EDM systems that include an AC
motor and encoder wire drive system working in tandem
enable the tension motor and drive roller to communicate
energy usage to the controller, and will allow the operator to
better maintain wire tension throughout the cutting process.
There are also some measures the operator can take to
improve cutting performance. When working with soft wire,
its important to use a die guide designed for large-taper cut-
Why you should use soft wire on big taper (10 - 45 degree) cutting.
0114 MMT -- FEATURE 2 -- methods.indd 30 12/18/2013 1:05:06 PM
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moldmakingtechnology.com 31
and alignment of components in the mold. The more accurate
and smooth the finish, the less additional, time-consuming,
manual fitment and polishing is required by the moldmaker.
Another benefit of wire EDM in moldmaking is the abil-
ity to quickly manufacture prototype molds. This identifies
problems that may occur during actual production and helps
to prove out the efficiencies of the tooling and the viability
of the part prior to building costly hard tooling, saving time,
money and frustration.
Mold manufacturers who want to take advantage of todays
EDM technologies and strategies need to consider their wire
options as well as appropriate EDM equipment features.
contributor
Steve Bond is national sales manager for FANUC RoboDrill, RoboCut and EDM
products at Methods Machine Tools Inc.
For more inFormation:
Methods Machine tools inc. / methodsmachine.com
ting, especially if you are going to skim-cut the large tapers to
improve surface finish and accuracy. These guides have a much
larger support to help the wire transition through large angles.
To ensure accu-
racy, also use the
features in the CNC
that compensate
for the changing
position in Z-axis
direction so that
the taper angles are
precise. Finally, if
the cutting technol-
ogy being used was developed for hard brass wire, the wire
tension will have to be reduced on the rough cut.
opportunities and applications
Technology developments in EDM have affected machining
across many industries. The ability to accurately and efficiently
machine taper cuts using soft wire has opened up new areas of
opportunity for the technology. For instance, mold manufac-
turing regularly requires parts with steep angles. Mold builders
depend on the accuracy of the angle to ensure proper location
Learn moreVisit our EDM Zone for more information
about electrodes and wire, sinker and
small-hole EDM.
Go to moldmakingtechnology.com/zones
for a complete list.
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0114 MMT -- FEATURE 2 -- methods.indd 31 12/18/2013 1:05:12 PM
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Software
32 MoldMaking Technology January 2014
By Bryan Jacobs
Most moldmakers will agree that
reducing NC machining time is
one of the best ways to improve
efficiency and increase profitability.
Understanding the need for feed rate opti-
mization is relatively simple, but it can be
difficult to achieve without good informa-
tion about the current cutting conditions.
CAM systems have no concrete way to
determine the volume or the amount of
material removed by each cut. Therefore,
programmers are forced into the difficult
task of visualizing the material removed in
order to get in-process information.
Determining optimum feed rates
traditionally has presented NC program-
mers and machinists with a number of
problems. Typically, the selected feed
rate represents a compromise between
tool life, cycle time and the worst-case
cutting condition encountered. This rate
may end up being the ideal feed rate for
the part where the most material is being
removed or where the worst cutting con-
ditions are encountered. Unfortunately, it
may also waste time and even create poor
cutting conditions elsewhere.
Feed rates can be adjusted by hand dur-
ing the machining process. Experienced
machinists listen for the telltale signs of excess cutter load
and then manually alter the feed rates at the machine accord-
ingly. The only override adjustments the machine tool opera-
tor typically makes is to slow down the feed rates as needed.
And most CNC controls have very limited capabilities for
speeding up feed rates when conditions permit.
With advances in cutting tools, tool materials and CAM
software, it is increasingly critical to use the right feed rate for
each and every cut. However, many CAM systems use machin-
ing strategies and cut patterns that are not efficient for com-
mon operations such as open boundaries, roughing cuts on
complex shapes, complex pocketing or planar roughing.
Get more than just reduced machining time with
NC program feed rate optimization software.
Chasing the Perfect Feed Rate
Imag
es c
ourt
esy
of C
GTe
ch.
Video
Access video
at end of article.
Some software packages can detect and machine excess
material, unmachined areas and surface blend areas, but
for this useful automation, efficiency is usually sacrificed.
Therefore, a lot of time is wasted cutting air and feeding
slowly across the parts surface. Additionally, the tool path may
plunge the cutter into material at an incorrect or inefficient
angle. Poor feed rates contribute to excessive cycle times, bad
workpiece finishes, increased cutter wear and broken tools.
Powerful, Intuitive Productivity Tool
Software that enables programmers to automatically optimize
NC toolpath programs is essential. This software can read the
Adjust, test and fne-tune the NC program optimization setti