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Recent technology developments for
Die and Mold industry
Richard ChenChairman
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Outline
Company profile
Latest machine tool technology for
mold & die industry
Future trends
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Foundry
Assembly 3
Assembly 2
Assembly 4
Machine Shop
Administration building
Technology
Center
Warehouse
Logistics Assembly 1
Year of founded : Since 1954
Total land : 164,160 m2
Factory facility :98,063 m²
Assembly No.4:8,333 m²
Company profile
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More than 50 distribution partners
Assembly Plant in Shanghai, China
Oversea technical center in USA and Malaysia
Building global brand through quality and value
World Wide Networks
Company profile
YCM in Turkey
In Turkish market since 1994 and partnered with SES3000 CNC
Sold more than 2500 sets YCM Machines in Turkish market
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VM
C
FP FP55LX FP66A/G FP100A
NXV NXV560A NXV1020A/AM NXV1380A NXV1680A/B
TV TV116B TV146A/B TV158B TV188B TV2110B TV2610B
NTV NTV158A/B
MV NMV76A NMV106A
WV WV108A/B
FX NFX 380A NFX500A
NSV NSV66A NSV85A NSV102A/AM NSV156A
NDV NDV66A NDV85A NDV102A NDV156A
TCV TCV2000A TCV3000A TCV3000A-5AX
DCV
DCV2012A/B DCV3016B DCV4016B
DCV3021B DCV4021B DCV5021B DCV6021B
DCV3025B DCV4025B DCV5025B
DCV2018A-5AX DCV4030B/B-5AX/B-5AF DCV5030B/B-5AX DCV6030B/B-5AX
DCV4035B DCV5035B DCV6035B
NDC NDC2016B NDC3016B NDC4016B NDC3018B-AHC
YCM product line
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HMCH H500A/B
NH NH450A NH630B NH800B
CNC
Lathes
GTGT-200A/B GT-250A/B
GT-300A/B/LA/LB
GT-380A/B/LA/LB
GT-200MA GT-250MA/MBGT-
300MA/MB/LMA/LMB
NT NT-2000Y/S/SY NT-2500Y/S/SY NT-2000SY2
TCTC-16A/B/LA.LB TC-26 TC-36 TC-46
TC-16MA/MB/LMA/LMB TC-26L TC-36W TC-46M
HBM BMP BMP1416P
YCM product line
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Latest machine tool technology for
mold & die industry
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Die & Mold
Industry
Machine Tool
X-Factor
CAD
/CAM
Strategies
Tooling Technology
Critical Factors for Die Mold Machining
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Critical Factors for Die Mold Machining Center
Machine tool
Cycle Time
Surface Finish
Thermal Growth
Tool Life
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Center shaft
cooling
Stator
cooling
Bearing
quill
cooling
Updated on NFP series
With bearing quill cooling design
With Stator cooling
With Center shaft cooling
Spindle Heat Removal
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Through thermal compensation, the
machine only require 10 minutes to
stabilize in all axes.
Z axis thermal growth is drastically
reduced through offset.
Without
offset
With
offset
X axis 6 um 6 um
Y axis 3 um 3 um
Z axis 37 um 5 um
Without Offset
With Offset
Run spindle on 24,000rpm for 10
minutes.
After 10 minutes (24K rpm ),
the thermal changing become
stable.
Test on NFP-24K spindle in AC room
Spindle Thermal Compensation
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Axial Heat Removal Design
Axial Heat Removal
Updated on NFP series
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Without nut cooling With nut cooling
Ballscrew Nut cooling system
to stabilize temperature
Axes heat removal
Updated on NFP series
Axial Heat Removal Design
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Nuts
cooling
Front
bearing
cooling
Rear
bearing
cooling
STC
function
Optical
scale
Heat
isolation
design
Construction
symmetry
design
Motor
flange
cooling
Center /Stator/
Bearing cooling
Overview for Thermal Solutions
Updated on NFP series
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Process Optimization
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Process 1 - Spindle & lobe chart (Vibration optimization)
Spindle & Tool Lobe Chart
Determine optimal spindle speed
Process Optimization
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Process 2 - Program optimizationOriginal Program
Cutting Feedrate 15m/min.
Corner speed is reduced due to vibration
and tool marks
Identify optimal spindle and cutting speed
for best machining efficiency.
After optimizing program
Process Optimization
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Process 3 - High speed & High Accuracy parameters adjustment
NG Ok
High speed & High Accuracy
parameters adjustment
(Std. function in YCM Fanuc)
Overcut
Process Optimization
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Result
Original Cycling Time 160min/pcs
Final Cycling Time 110min/pcs
31%
Cycling Time
Reference
only
Process Optimization
+Improved Tool Life
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Future trends
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Revitalizing MFG Policies (1/2)
USA AMP
Mass Customization
• Initiated in 2011
• Production technologies and
innovation
• Create re-shoring
manufacturing opportunities
Smart Factory
• Initiated in 2012
• Improve labor skill
• CPS implementation
• Smart factory
Germany
Industry 4.0
Smart Factory
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Revitalizing MFG Policies (2/2)
China
2025 Plan
Intelligent production
• Initiated in 2015
• Intelligent equipment development
• New material application i.e. Nano
Technology
• Green energy development and
application
Japan
New Robot
Human-Robot Co-existence
• Initiated in 2013
• Humanized robot development
• Robots with multiple function
sensors
Smart Factory
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What is Industry 4.0?
Smart Factory
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Industry 4.0
Why Industry 4.0?
Mass
Production
Customization
Labor
Shortage
Shorter
Product Life
Cycle
Re-shore
MFG
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Industry 4.0
Labor Shortage
Source: Mckinsey Global Institute,2012
1. Manufacturing employment in advanced economies is decreasing every year gradually.
2. Manufacturing employment in advanced economies could fall from 45 million jobs today to fewer than 40 million by 2030.
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Industry 4.0
Mass Production Customization
Source: Mckinsey Global Institute,2012
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Industry 4.0
Shorter Product Life Cycle
Source: Mckinsey Global Institute,2012
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Industry 4.0
Advanced Economies want to re-shore manufacturing
Source: Roland Berger Strategy Consultant 2014
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IOT (Internet of
Things)• Install sensors
to collect all
data through
internet
Robotic
• Automation
Big Data
(real-time)• Analysis system
• Cost MGMT
• Shorten lead time
• Supply chain
MGMT
Industry 4.0
Smart Factory(Robot+IOT+Big Data)
Industry 4.0
What is Industry 4.0?
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2. Adaptive chip removal function
A. Intelligent Spindle1. Intelligent detection devices and black boxes
2. Spindle and motor temperature monitoring
3. Spindle vibration control
4. Deterioration monitoring of spindle motor coil
5. Tool life Management
E. Intelligent Feed Axes1. Ballscrew / motor temperature monitoring
2. Axial thermal compensation
3. Preventive maintenance motor coil
4. Machine collision protection
D. Remote Diagnosis &
Management
Intelligent Machining ModuleC.
1. Optimizing axial servo parameters
2. Adaptive cutting function
1. Production management
2. Tool life management
3. Machine status record
4. Plant / Machine monitoring
B. Thermal Solution1. Thermal Suppression
2. Thermal Removal
3. Spindle Thermal Compensation
Existing
2015
2016
2017
1. Tool management (list/ lifetime/ loading)
2. Big/ standard tool function
3. Heavy tool function
4. Fixed tool pot function
5. Tool pot locking function
6. Tool breakage detection
Intelligent ATC J.
1. CTS level detection
1. Automatic infrared sensor
2. Warning lights control
1. Automatic switch of safety door
2. Anti-layering protection mechanism
Energy-saving control
Safety/ Automatic Door SystemF.
Hydraulic System G.
Coolant/Chip Removal SystemH.
Lighting System I.
5. Energy monitoring
6. Production control
6. Spindle bearing wear/ lubrication monitoring
5. Preload monitoring
6. Lubrication monitoring
Smart Factory
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i-Direct Website Design
Design and build website that can monitor plant from remote location and connect with ERP.
www
Database
INTERNET
Website Design
ERP
Smart Factory
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i-Direct (Remote Monitoring)
Smart Factory
http://idirect.ycmcnc.com/YCM_RemotingSystem/
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i-Direct (Remote Monitoring)
Smart Factory
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i-Direct (Capacity utilization monitoring & Mgmt)
Smart Factory
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Use of Four-/Five-Axis Machines
Use of Four-/Five-Axis MachinesTop Shops Other Shops
Four-axis positioning 56% 24%
Four-axis contouring 59% 37%
Five-axis positioning 44% 18%
Five-axis contouring 44% 22%
Benefits:
Minimize setups
Improves accuracy
Improves surface finish
Improves tool life
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Machining at an angle
extends the tool life &
increase the surface finish.
Reduce the machining time,
increase the surface accuracy.
Advantages of 5 axes
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Save fixture, work piece
install & machining time,
increasing the accuracy
Reduce interference, cost of
tool & time of machining
Advantages of 5 axes
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Avoid Center Cut - Improves Accuracy & Finish
A
10,000 rpm
2.6
V=50m/min
3.26 times
0.8
φ6
0°15°
60° B V=163m/min
Advantages of 5 axes
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DCV4030B-5AX – Mold machining (Invar)
Advantages of 5 axes
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DCV6030B-5AX – Mold for sheet metal
Advantages of 5 axes
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High-pressure coolant
Trends in High-pressure coolant Use
Benefits:
More heat can be removed from
the cut zone.
helps break up chips and
remove them from the cutting
area more efficiently
the cutting tool spends less time
re-cutting chips.
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Thank you!!
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