105432-FEB 2013.pdf

FEBRUARY 2013

VolUmE 16 / NUmBER 2

DEsigN / BU ilD / REpAiR

Improve Input Quality With the Right Tool Inspection and Monitoring System PG 26.

FEATURES / ViDEos

Taking Advantage of Carbide Material for Your Mold Designs PG 33.

Its Time to Reevaluate Co-Injection Technology PG 38.

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M A C H I N I N G C E N T E R S T U R N I N G C E N T E R S 5 - A X I S D O U B L E C O L U M N S U P E R I O R C O N T R O L S

achinists

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D O U B L E C O LC O U M NM N S U P E R I OR I O R CR C O N TT R OR O L S

Machines shown with options. Information may change without notice.

C O LC U MU M N SS U P EU P E R I O R C O NO N T R O LO L S

PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856-854-1715 / [email protected]

Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513-527-8808 / [email protected]

Editorial

Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . .800-579-8809 / [email protected]

Senior WriterSherry L. Baranek . . . . . . . . . . . . . . . . . . . . .908-537-6406 / [email protected]

Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . 413-772-6436 / [email protected]

Contributing Writer, Special Projects Jan Bottiglieri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847-923-5729 / [email protected]

art/Production

Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

MarkEting

Senior Marketing ManagerDave Necessary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Reprint SalesScott Clifton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

circulation

Circulation DirectorP. Ross Jacobs, CCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

ExPositions

Senior Events ManagerAllison Miller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513-527-8800 / [email protected]

amerimold Event ManagerDave Necessary. . . . . . . . . . . . . . . . . . . . . . . . . . 513-527-8800 / [email protected]

corPoratE

President Richard G. Kline, CBC . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Executive Vice President Steven R. Kline, CBC . . . . . . . . . . . [email protected]

Chief Operating Officer Melissa K. Skavlem . . . . . . . . . . . [email protected]

Group Publisher Richard G. Kline, Jr. . . . . . . . . . . . . . . . . . . . . [email protected]

Executive Vice President, Content Tom Beard . . . . . . . . . . . [email protected]

Director of Information Technology Jason Fisher . . . . . . . . [email protected]

Director of Finance Ernest C. Brubaker . . . . . . . . . . . . . . . . . . [email protected]

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MoldMaking Technology magazine (ISSN #1098-3198) is published monthly by Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. 800-950-8020, 513-527-8800, Fax: 513-527-8801, gardnerweb.com. Canadian Agreement #40012278.Nonqualied subscription rates per year are $89.00 in the United States, $99.00 in Canada and

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without written permission from the publisher.Views expressed by the bylined contributors should not be construed as a reflection of the opinion

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magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Periodicals postage at Cincinnati, Ohio and at additional mailing offices.

PRINTED IN THE U.S.A.

2 MoldMaking Technology February 2013

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Contents


Features

26 Inspection/MeasurementImprove Input Quality with the Right Tool Inspection And Monitoring SystemIntegrating efficient tool inspection before and after the cut with opti-mized tool performance in the cut improves efficiency and profitability.

29 Inspection/MeasurementInspection/Measurement Advances Yield Better Molds FasterA roundtable discussion of the latest trends and developments in mold inspection and measurement technology.

33 Cutting Tools Taking Advantage of Carbide Material for Your Mold DesignsEnd mills that cut 3D features into carbide demonstrate how moldmak-ers can reap the benefits of carbide material for their mold designs.

38 Hot Runners Its Time to Reevaluate Co-Injection TechnologyAdvances in resins, hot runners and controls technology enable co-injection to move from a niche application to mainstream acceptance.

42 Global Competition Reshoring Efforts Conquer Time-to-Market Crunch

Challenges in time compression, complexity, communication and cost call for U.S. manufacturing.

Departments

6 From the Editor: Broadening the Board

6 Whats New on MMT Online: Additive Manufacturing

8 New Business Opportunities: Expand Your Niche

10 Your Business: Structured Training

12 Mold Business Index

14 Profile: Advanced Manufacturing Consortium

18 Case Study: Automation/Machining

23 Case Study: Machining

46 Product Focus: Mold Components

54 End Market Reports: Medical and Consumer Products

55 Ad Index

56 TIP: Cutting Tools

On ThE COvERImage courtesy of Marposs (Auburn Hills, MI).A Marposs OP32 optical spindle probe used with Marposs 3DSI measurement software allows moldmakers to turn their machining center or milling/boring machine into a virtual CMM. This enables in-process measurement and verification of the accuracy of the machined shape without removing it from the machine. Here a thermoplastic mold is checked after machining on a Hermle C 800 U machining center. The OP32 probe has optimum spatial isotropy and unidirectional repeatability of 1 /0.00004 (2Sigma). See article on page 26.

Images courtesy of (left to right) U.S. Union Tool, Mold-Masters Ltd. and Mack Molding.

1. Laser Sharp A laser can measure a tool rotating at virtually any practical cutting speed, which means that speed- and temperature-related spindle variations can be detected along with out- of-balance conditions. PG. 26.

2. Powerful Combo The right combination of geometry design and coating properties can enable an end mill to physically cut carbide into small chips, making a clean and burr-free surface on the workpiece. PG. 33.

3 Its in the Details When it comes to mold design for co-injection you need to adapt to the gate detail for the co-injection nozzle, which is typically different than standard monolayer gate details. PG. 38.

4 Team Effort An OEM, molder and moldmaker collaboration developed eight high-volume, steel production molds for high-pressure injection molding. PG. 42.

5 Meeting Demands When mold applications demand hard milling of materials up to 66 HRC, using the right end mills, cutting parameters and machining methods is critical for success. PG. 56.

February 2013 Volume 16 / Number 2

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This MonTh on moldmakingtechnology.com

From the Editor


Wayne Hertlein is a Program Manager for Wilbert

Plastics Servicesa supplier of plastics injection mold-

ing and heavy gauge thermoform products and assem-

blies in Belmont, NC. His responsibilities include pro-

gram management of automotive plastics components

and their assemblies. Previously, Wayne worked at

MMI Engineered Solutions, International Automotive

Components, Collins and Aikman Global Tooling

Company, and others in the Midwest. With more than 35 years in the plastics

industry, Wayne has served on committees to advance the plastics and tooling

industries. He is an Honored Service Member and SPE member since 1981.

David Hirt is a Tooling Engineer for Ventra Plastics in Sandusky, OHa

molding/manufacturing plant specializing in automotive exterior light-

ing. Dave holds a B.S. degree in Manufacturing Technology from Bowling

Green State University; a journeymans card in Tool & Die, and has an A.S. in

Mechanical Engineering from Terra Technical College.

Dan Mishek is the Managing Director and Co-Owner of Vista Technologies

LLC (VistaTek)a full-service custom U.S. manufacturer with in-house mold-

making, injection molding, inspection and secondary operationsin Vadnais

Heights, MN. He has been published and has presented around the world.

Dan is a third generation manufacturer, President of the SPE Upper Midwest

Section 22 and a proud member of the AMBA.

Tim Peterson is Vice President at Industrial Molds Group in Rockford,

ILhis familys company. After graduating from high school, he began the

moldmaking apprenticeship for four years then went to work for Mold Design

for eight years before returning to Industrial as a toolmaker. After becoming

lead toolmaker, he spent two years in the Quality Department then in 2006 he

moved into management as an account manager in sales to Vice President. He

is a board member of the AMBA.

Mike Walter is President of MET Plastics in Elk Grove Village, ILa cus-

tom mold builder and injection molder specializing in low-volume molds

and molding for aerospace, medical, business equipment and food services.

He holds a B.S. in marketing and management from DePaul University and

attended Northern Illinois University for Plastics Technology. Mike currently

serves on the board of directors of the AMBA, is Secretary of the Chicago

Chapter of the AMBA, and is Vice President of the Manufacturers Association

for Plastics Processors.

Welcome to our new members! View our full board of advisors on page 55.

Broadening the BoardNew members round out the variety of business types, job

functions, specialties and end markets represented, so

the content we provide can be all the

more relevant for you.

MMT Zone: Additive Manufacturingwww.moldmakingtechnologycom/zones/additiveAdditive Manufacturing is a supplement to MoldMaking Technology magazine. It reports on the growing use of addi-tive technology as an option for manufacturing functional parts. You can subscribe using MMTs online subscription page, and can also read current or past issues in the AM library online.

Browse Past Additive Manufacturing Articles: Embracing Both Additive and Subtractive Manufacturing:

Additive manufacturing can complement your subtractive manufacturing processes, establishing you as a modern mold shop.

Molten Spray Moldmaking: Rapid solidification creates mold and die tooling that is harder than heat-treated com-ponents, within build times that are faster than machining.

3D Printing for Better Customer Communication: Additive technology helps a mold manufacturer establish better customer communication and create a more productive design process.

Conformal Cooling: Another Tool in the Toolbox to Build a Better Mold: Moldmakers are just starting to scratch the surface of what can be done with conformal cooling, which involves an additive approach.

Search Additive Manufacturing Products: 3D Metal Printer Offers Increased Volume Output,

Ex One Company Additive and Subtractive Together, GF AgieCharmilles Partners Create Medical Products Using DMLS, EOS Rapid Product Development Adds SLA System, 3D Systems Multi Material 3D Printing, Objet

Find a Supplier Via the Following Categories: 3D Printing Equipment 3D Scanning Systems Product Design and Development Services Prototype Tooling Services Prototype/Short-run/Injection Molding Services Rapid Manufacturing Equipment Rapid Manufacturing Services Rapid Prototyping Equipment Rapid Prototyping Services Rapid Tooling Equipment Rapid Tooling Services Reverse Engineering Services RP Materials, Metallic RP Materials, Non-metallic Stereolithography Equipment

Webinars Additive Manufacturing Solutions: Materials and

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New Business Opportunities

for its customers in the automotive/transportation industry,

hardware, consumer products and packaging.

This opportunity demonstrates how a great relationship can

develop into a partnership with customers, as weve become

very much a value-added supplier to them, Peterson says.

Were co-located with them and that strategy lends itself to

other OEMs looking for similar relationships.

Peterson adds Pyramid Plastics San Antonio will be adding

two-shot and lower tonnage presses over the next yearas low

as 150 tonsto accommodate a wider range of part sizes. We

have room for future expansion and were currently evaluating

some additional services there such as mold repair and main-

tenance, and secondary operations in the future, but for now

the mold engineering and technology will remain in Rockford,

offering full support services to San Antonio, he comments.

Obviously, decisions to add capabilities and equipment will be

driven by customer requirements.

As OEMs look to more regional suppliers to help mitigate

risk, Peterson says that it will most likely drive Tier 2 and Tier

3 suppliers such as Industrial Molds Group to look at other

strategic opportunities. Obviously we cant site a facility every-

where we have customers, he states. These strategic decisions

need to make good business sense for both Industrial Molds

and for our customers throughout the U.S., to establish a pres-

ence in regions where we can maximize our growth and be a

supplier of excellence for our customers.

A Run for the Border Expands

Transportation Market Niche

Sometimes the opportunity to capture new business requires

taking a big leap. For Industrial Molds Group (Rockford, IL)

MoldMaking Technologys 2012 Leadtime Leader Award win-

nera chance to expand business for a Tier 1 customer in the

transportation industry meant making a run for the border.

Later this month, Industrial Molds Group and sister company

Pyramid Plastics, a custom injection molding firm, will hold the

grand opening of its newest molding facility, Pyramid Plastics

San Antoniolocated in San Antonio, TXin a free trade zone.

Industrial Mold Groups customer assembles its products at

plants in Mexico and the Southwest, so it needed Industrial to

be closer to those facilities to shorten the supply chain. The new

facility comprises 21,000 square feet of production and office

space; however, Industrial Molds Group has a commitment to

expand into 30,000-square feet during the next few years as

business in the region grows. It currently houses five injection

molding machines with 500 to 800-ton capacity to accommo-

date large-part molding. There are nine employees with two

shifts currently.

According to Industrial Molds Group Vice President Tim

Peterson, This opportunity came to us because we have grown

the company into a full-service supplier for mold design and

engineering, molding process development and production

molding through our sister firm, Pyramid Plastics. Being a

full-service provider has given us a lot of new business over the

past few years, and we always strive to meet the value-added

requirements of our customers.

Industrial Molds Group has added more than $1 million in

new equipment, including machine tool automation and robot-

ics in the companys mold manufacturing division, MoldEx 3D

mold filling analysis software to optimize mold design, and

state-of-the-art 3D modeling.

Recent investments in Pyramid Plastics capabilities include

the addition of a 700-ton press and a 1,000-ton press, bringing

the tonnage ranges from 20 to 1,000 tons. The company has

also added two-shot molding to accommodate requirements

FoR moRe inFoRmation:

Industrial Molds Group / (815) 397-2971

[email protected] / industrialmolds.com

This opportunity demonstrates how a great

relationship can develop into a partnership with

customers, as weve become very much a value-added

supplier to them. Were co-located with them and

that strategy lends itself to other OEMs looking for

similar relationships.

The opening of a Texas facility has allowed Industrial Molds Group to

solidify a niche as a full-service provider from art-to-part.

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Your Business / Structured Training


Finding, Training and Retaining Employees I Part 2 of a Series

By Ryan Pohl

Once you have implemented some of the strategies discussed

in Part 1 of this series (December, 2012 issue), you should be

able to find quality, entry-level candidates. Now you need to

know how to handle these people once you hire them. So lets

discuss training.

First, I would like to establish the fact that structured train-

ing is a proven way to increase retention. So when we are dis-

cussing training, we are also discussing higher retention rates.

All of the training techniques and ideas suggested will increase

the likelihood that the people you have worked so hard to find

will stay with your company for the long-haul.

Training is a minute-one strategy. In the first minute a new

employee is with your company, he/she is learning. Learning

with whom to speak to get information, learning where and

how to clock in, learning the layout of the shop, learning

where to keep their lunch, learning what their responsibilities

are going to be, learning what the moods of their co-workers

are like at 6:00 a.m., and on and on.

All of this learning is immediately establishing habits (good

or bad) and leaving impressions about the company and its

expectations. This learning should not be left to chance.

Every company should estab-

lish a structured orientation

training plan that controls

the experience of all new

employees.

From the moment every new

employee begins their job they

should be made to feel like

a valuable assetnot like an

unfortunate liability. Your new

employee should know exactly

where to go and who to report

to upon arrival on their first day. The person they are looking

for does not have to be their direct supervisor. The person

they report to should be a person that will greet them with a

smile. Maybe it is one of your employees with a particularly

positive attitude, or someone from Human Resources. This

person can act not only as a trainer on the first day, but also

as a mentor throughout their early employment. This mentor

should take them around the shop and introduce them to the

other employees, give them an in-depth tour and help them

begin to feel at home in their new environment.

All of their training should be guided by check-sheets with

clearly defined objectives. The check-sheet should include a

place for the employee and the trainer to sign-off when they

have mastered the task. This could include everything from

safety training to learning about company history and who

your main customers are. Some examples of first day training

objectives could be as follows:

Traineehasdemonstratedabilitytopunch-inproperly.

Traineeunderstandswhenandwherebreakscanbetaken.

Traineecandescribetheprimaryproductsandservices

provided by the company.

Traineecanexplainthehistoryofthecompany.

TraineehaspassedtheOSHAOverheadCrane

certification test.

It is critical that orientation training is controlled and

designed to make the new employee feel like a valued team-

member. Orientation training may last one or several days,

but either way, it should set a very positive tone and high

expectations for the weeks, months and years of learning that

they are about to embark upon. Give your new employees all

the reasons they need to give you the best that they have to

offer, right from the start!

contRIButoR

Ryan Pohl is President of Expert Tech. He is a journeyman CNC machinist with

years of experience in high-speed and multi-axis machining. He is also a State

of Michigan certied manufacturing teacher, and has taught at both high

school and college levels. He holds an Associates degree in Manufacturing

Tooling, a Bachelors degree in Technical Education and a Masters degree in

Industrial Training and Development. Ryan is motivated to raise awareness

in our industry about the coming skilled-labor shortage and how it has the

potential to dramatically hinder future sustainability and growth. He believes

that with a renewal of pride in workmanship and an updated training format,

Americans can secure their future as leaders in the industry.

FoR moRE inFoRmaTion:

Expert tech / (616) 785-5733

[email protected] / expert-technical.com

Every company should

establish a structured

orientation training plan

that controls the

experience of all new

employees.

Simple. Innovation.

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Vertical Edition

Mold Business Index


The New Orders component is 41.8 in the latest month.

The trend of declining new orders over the past few months

continues to result in diminishing Backlogs. The Backlog

sub-index is 36.0 for December. The Production sub-index

of 42.8 is still below the breakeven mark of 50, but it is sig-

nificantly better than the previous month. The Employment

component is 46.4, which means that payrolls decreased for

the second straight month.

Prices received are suffering a gradual decline over the last

four months. The Prices Received sub-index for December is

49.6. The sub-index for Materials Prices exhibited a jump this

month to 64.4. The Supplier Delivery Times component is a

mostly steady 51.4. There was a significant decline in offshore

orders last month, as the Exports sub-index is 43.4.

The Moldmaking Index is 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 indicates business

activity expanded when compared with the previous month,

and a value below 50.0 means business levels declined.

Total Moldmaking Index for December 2012: 43.6

From its inception, the focus of this column has been the

Mold Builders Index, which reported business conditions of

mold builders only. However, since December 2011 Gardner

Business Media, publisher of MoldMaking Technology, has been

surveying its entire readership of durable goods manufactur-

ers. With this expanded survey, Gardner is providing data on

business trends for

all of the markets it

serves. The expanded

survey and additional

data means that this

column can enhance

its reporting from the

business trends for

mold builders to the

business trends for

the entire moldmak-

ing industry, which

is the focus of this

magazine. Now, this

column will report on

the Moldmaking Index.

However, because of

the enhanced data

collection, indices can

be created for specific

parts of the moldmaking industry, including mold builders,

mold buyers, regions of the country and plant sizes. While

the column will highlight some of these specifics, most of the

information will be found online (we will let you know when

that website is ready). We think you will find the enhanced

survey and expanded data helpful in managing your business.

For the sixth straight month, a survey of the North

American moldmaking industry indicates that overall activ-

ity levels continue to decline. The Moldmaking Index for

December 2012 is 43.6 (a value under 50.0 indicates a decrease

in business levels for the month). The latest index value is a

2.4-point increase from the November value of 41.2, but it is an

11.9-point decrease from the 55.5 posted in December 2011.

A drop was reported in the New Orders category for the

fifth straight month. Supply conditions, as measured by

the Supplier Delivery Times and Materials Prices compo-

nents, were mixed when compared with the previous month.

Supplier delivery times were steady but there was a significant

rise in materials prices. Prices Received was steady, though

the gains in prices received are still not keeping pace with the

increases in costs for materials. Future Expectations rebound-

ed from a sharp drop in November.

The overall downward trend in the Moldmaking Index that started at the beginning

of last year appeared to accelerate in the fourth quarter. The best explanation of

this disconcerting end-of-year performance is the uncertainty that was generated

by rst the election and then the scal cliff drama. Some of the uncertainty was

nally alleviated by the 11th-hour agreement in Washington, but much of that was

not. Because of this, overall activity levels will likely remain sluggish during the

rst half of 2013, but the momentum should pick up noticeably in the second half

of the year. The economic fundamentals that drive manufacturing activity in the

U.S. are steadily improving, and barring some cataclysmic screw-up in Washington

during the next few months, these improving fundamentals will generate increas-

ing demand for new molds this year.

Moldmaking Index December 2012

Sub-Index

New Orders 41.8

Production 42.8

Employment 46.4

Backlog 36.0

Exports 43.4

Supplier Deliveries 51.4

Materials Prices 64.4

Prices Received 49.6

Future Expectations 63.9

The total Moldmaking Index is a weighted

average of the sub-indices for new orders,

production, employment, backlog, exports, and

supplier deliveries.

Moldmaking Index

12/1

1

1/12

2/12

3/12

4/12

5/12

6/12

7/12

8/12

9/12

10/1

2

11/1

212

/12

55

50

45

40

60

Prole


Advanced Manufacturing

Consortium:

Addressing The Skilled

Labor Shortage

By Sherry L. Baranek

In 2011, Kalamazoo Community College/Groves Center (KVCC;

Kalamazoo, MI) reached out to a number of local companies

and service provider organizations to help the college develop

an integrated model to attract, screen and train qualified can-

didates for current and future Advanced Manufacturing career

opportunities in Southwest Michigan.

According to Trish Schroeder, Director of Corporate Training

at Groves Center, after a series of meetings the Advanced

Manufacturing Consortium formed four workgroups:

1. Recruitmentwith a focus on how to recruit more poten-

tial candidates into manufacturing

2. Screeningwith a focus on key elements needed for a

community-wide, talent-based screening tool

3. Trainingwith a focus on the key elements of a compe-

tency-based assessment and training model for Advanced

Manufacturing

4. Implementationwith a focus on how all pieces of the

program are fitting together, and next steps necessary to

launch the project

The manufacturing sector needs skilled workers, Schroeder

states. As the nation recovers from the Great Recession, manu-

facturers are leading the way in job growth. Technological

advances, which have enabled companies to compete with low-

cost manufacturers around the world have also created challeng-

es. Workers in Advanced Manufacturing are required to possess

specific abilities and characteristics. Unlike many other entry-

level employment opportunities, manufacturing continues to be

a leader in providing on-the-job training, sponsorship of appren-

ticeships, and payment for continued education and career

advancement. Manufacturing employers in the Kalamazoo and

St. Joseph county area have worked together as the Advanced

Manufacturing Career Consortium in an effort to address their

need to recruit, train and hire new workers.

A direct result of the consortiums work is the formation of

the Production Technician Academysix-week, fast-track train-

ing designed to provide people with an easy way to gain entry-

level skills for careers in moldmaking and manufacturing. Dave

Martin, President of Portage, MI-based Accu-Mold, Inc. and a

member of the consortium, believes it is an innovative approach

to address the skilled labor shortage. Employers want soft

skills in their employeeslike being problem solvers, having a

sense of urgency, intelligence and knowing what is right and

Consortium Participants

The following companies and service support organizations comprise

the Advanced Manufacturing Consortium.

AccroSeal / accroseal.com

Accu-Mold / accu-moldinc.com

American Axle / aam.com

Chemlink / chemlink.com

Dimplex Thermal / dimplexthermal.com

Eliason Corporation / eliasoncorp.com

Fabri-Kal / fabri-kal.com

Fab-Masters / aluminum-fabrication-welding.com

Flowserve / owserve.com

Graphic Packaging / graphicpkg.com

Humphrey Products / humphrey-products.com

Hydro Aluminum / hydro.com

Kadant Johnson / kadant.com

Kaiser Aluminum / kaiseraluminum.com

Landscape Forms / landscapeforms.com

Mall City Containers / mallcitycontainers.com

MANN+HUMMEL / mannhummel.com

Marshall Plastic Film / marshallplastic.com

Micro Machine / micromachineco.com

Parker Hannin / parker.com

Perrigo / perrigo.com

Pzer / pzer.com

Schupan & Sons / schupan.com

Stryker Instruments / stryker.com/en-us/products/instruments/index.htm

Stryker Medical / stryker.com

Sturgis Molded Products / smpco.com

Tru-Tech Industries / trutechsystems.com

Unifab / unifabcages.com

Service Support Organizations:

Glen Oaks / glenoaks.edu

HRM Innovations / hrminnovationsllc.com

KRESA / kresa.org

KVCC / kvcc.edu

MI Works! / mitalent.org

Southwest MI First /southwestmichiganrst.com

St Joseph ISD / sjcisd.org

Sturgis EDC /sturgisdevelopment.com

wrong before they get hired, Martin states. Just showing up

for work does not impress anymore. We live in a world economy

and compete with people and technology. No more hiring and

hoping they show up for work, and have drive and intelligence.

Schroeder notes that the programs goal is to deliver acceler-

ated training programs in the form of corporate training (target

company incumbent workers) and academies (target individuals

seeking skill certifications to prepare them for employment).

Participants attend class Monday through Friday for four-

and-a-half weeks with an average class size of 16. Students who

complete a class receive a certificate of completion and a tran-

script of competencies, which Schroeder explains is a descrip-

At Plastic Engineering & Technical Services, we will.

We defne performance. Our engineering team is Expert

Gold certifed and the recognized industry leader in the use of

leading-edge analytical tools. We bring more than 25 years of hot

runner design, manufacturing and plastic processing experience

into every analysis we do. No one else in the industry has the

tools in their arsenal that we have. We ofer mold flling, mold

cooling, shrink & warp analysis, gas assist analysis, injection

compression, co-injection and more.

Once the frst analysis is completed, we re-analyze it, utilizing a

diferent sofware to cross check the results, to ensure accuracy.

We help you increase your efciency, reduce costs and improve

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We deliver value. We were the frst hot runner manufacturer to

use Mold flling sofware as part of our daily business and more

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mold flling analysis and your manifold build, and we will do

whatever it takes to make sure our hot runner/manifold

system works to your complete satisfaction, and stand behind

its performance.

Call us today at 248.373.0800 or visit us at www.petsinc.net.

WHO STANDS BEHIND THE PERFORMANCE OF YOUR HOT RUNNER/MANIFOLD SYSTEM?

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tion of skill sets signed by instructors that can serve as a

reference to prospective employers.

The units of study that make up each training module are

presented in a sequence, which assures a theoretical founda-

tion and an opportunity to practice or observe the technology

in use in the learning lab, Schroeder states. The program

combines lecture, demonstration and laboratory exercises to

facilitate learning. Safe work practices are stressed and con-

For more inFormation:

Accu-Mold, Inc. / (269) 323-0388

[email protected]

accu-moldinc.com

Kalamazoo Valley Community College

(269) 353-1253 / [email protected]

kvcc.edu

Tool Dynamic TD 2009 Comfort Plus

Application Balancing of cutting tools, tool holders

Operation Brilliantly simple via Control Terminal

Indexing of balancing position Automatically

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The more HAIMER, the better.

sistently practiced. Industry leaders will guide and direct the

entrance criteria and curriculum, which adjusts constantly to

keep up with changes in technology.

The following are the courses in the program: Advanced

Manufacturing Industry Introduction, Safety Training, Lean

Manufacturing, Team Workgroup Participation, Applied

Math Fundamentals, Industrial Blueprint Reading, Precision

Measurement, Quality Management, Statistical Process

Control, Root Cause Analysis/

Problem Solving, Mechanical Concepts,

Electrical Fundamentals, Introduction

to Programmable Logic Control, Basic

Industrial Fluid Power, Job Search and

Interviewing and Computer Usage

Integration.

Martin of Accu-Mold is confident

that the consortiums efforts with the

Production Technician Academy will

be fruitful. Programs like these are

working on rebranding manufacturing

into a more computerized and clean

environmentand most important

jobs that will lead to other careers, such

as designing, supervision, quality and/

or leadership, he emphasizes. Todays

world of manufacturing is a career

not a job!

Students and two instructors from the Production Technician Academya fast-track training program devel-

oped by the Advanced Manufacturing Consortium to address the skilled labor shortage.

Pho

to c

our

tesy

of

KV

CC

.


Case Study / Automation / Machining

Automated Hard Milling Expands Capacity,

Capability

Streamlining a die/mold manufacturing process

can be accomplished through automation, enabling

companies to increase throughput without adding

real estate. However, as workpiece designs continue

to grow in complexity, manufacturers must support

these automated systems with accurate, repeatable

and reliable machining technologies. For North American

manufacturers, this combination has proven to offer a com-

petitive advantage against many low-labor-cost countries.

The benefits of work cells are no longer exclusive to part

production environments. In fact, the influence of todays

global marketplace has made these capabilities essential to the

competitiveness of North American mold manufacturers, says

Scott Matenaer, tool-room operations manager at MGS Mfg.

Group (Germantown, WI). By

embracing this level of technol-

ogy and focusing our efforts on

the engineering and production

of complex tools, we are able

to offer our customers unprec-

edented flexibility, quality and

delivery at an affordable price.

MGS was recently ranked as

one of the top 15 moldmakers

in North America by Plastics

News, based on tooling sales. In the last year, the company has

produced and sold over 400 molds for a broad customer base,

including consumer products, medical, electronics and auto-

motive. Based on the diversity of MGSs one-off production,

automation systems have been a key component to the shops

flexibility and scheduling management.

The one commonality that exists between the applications

produced at MGS is the level of complexity. According to MGS,

recent designs have included 64 HRc steels with required

tolerances of plus or minus 0.0003 inches with repeatability

within 0.0002 inches.

In nearly all cases, designing and building the style of pro-

duction molds that move through this facility involves a great

deal of development and prototypingengineering the part for

manufacture, says Matenaer. To accomplish this in a lights-

The key to investing in

new machinery is to get

more work done with the

same amount of people,

not the same amount of

work with fewer people.

Reliability was a key factor in MGS hard milling investments in order to

ensure that no single element of the work cell would limit other components

from reaching their full potential.

moldmakingtechnology.com 19

out environment requires access to reliable,

accurate and efficient machining technologies.

When faced with hard milling limitations

in 2011, we decided to update our machining

technologies with investments in two Makino

V33i vertical machining centers, Matenaer

continues. The investment has proven to be a

sound business decision that has enabled us to

get the most out of our automated work cells,

improving workflow and adding new capabili-

ties to build on our history of innovation.

Up for a Challenge

Founded in 1982 by CEO Mark G. Sellers, who happened to

be a state of Wisconsin journeyman toolmaker, MGS began

its operations as an injection-mold tool shop. While molding

operations now make up over 60 percent of the companys

revenue, its ability to successfully engineer, design and build

plastic injection molds remains the foundation.

MGS believes that an injection mold is more than simply

one of the required components of part manufacturing. It is

an investment in productivity. The company strives to work

with customers that put a premium on the productivity, effi-

ciency and longevity of their molds. While MGS evaluates and

quotes every tooling opportunity using standard

factors (i.e., leadtime commitment, workpiece

size, budgets, etc.), it pays particular attention

to more challenging applications, such as higher

cavitations, multi-shot, thin wall, living hinge,

stack systems, rotary stack and spindle systems,

that enable the tool shop to demonstrate its true

capabilities.

Engineers at MGS understand the impact that

technology has in overcoming challenges, and

they have high expectations for time-sensitive

delivery of consistent and repeatable workpieces.

In the case of automation, the company bases

its investments on output per square foot of

floor space, output per employee and output per

machine.

We first began implementing automated capa-

bilities in 2000, starting with simple pairing of

individual machines with robots, which we knew

would improve productivity simply by reducing

downtimes incurred by manual setups and tear-

downs, notes Matenaer. In the following years,

we applied simple work cells into several different process

environments, which ultimately led us to build more complex

automated systems that combine various machine processes

into a single cell.

MGS applied this experience to its recent V33i investments,

which have been integrated into two robot-tended work

cells that share a common coordinate measurement machine

(CMM). MGS attests that the speed, accuracy and consistency

afforded by this configuration have dramatically enhanced

prove-out processes and overall workflow of its precision hard

milling applications.

The key to investing in new machinery is to get more work

done with the same amount of people, not the same amount

of work with fewer people. To accomplish this, you need

automated machining capabilities that are both flexible and

reliable, says Jeff Kolbow, COO of MGS. Our goal in hard

milling applications is to maximize our spindle time. The per-

formance and reliability of the V33i machines have enabled us

to routinely exceed this goal with up to 20 hours of operation

per day in certain applications.

Reliable Hard Milling Solutions

The V33i investments were a natural next step for MGS,

following more than a decade of experience with Makino

(Mason, OH) milling and EDM equipment. In 2001, the com-

pany invested in a Makino SNC64 vertical machining center,

which has been deployed as both a graphite and hard milling

machine. With approximately 50,000 hours of machine time

logged, the SNC64 remains a workhorse for one of the tool

shops neighboring MGS facilities.

MGS has streamlined its hard milling processes by integrat-

ing dual-operating machining cells featuring two Makino

V33i vertical machining centers and System 3R robots which

share a common CMM.

Phot

os c

ourt

esy

of M

GS

Mfg

. Gro

up

MGS pays particular attention to more challenging applications that enable the tool shop to

demonstrate its true capabilities and remain globally competitive.



In 2009, the company scoured the market for high-precision

graphite machining solutions that could meet increasing

demands for accuracy and repeatability. Among the potential

investments identified was the V33i graphite machining center.

When our toolmakers recognize a need for new equipment,

we organize a group together to determine exact needs, such

as size, horsepower, accuracy and spindle speed, in order to

narrow down a list of equipment to evaluate, states Matenaer.

In our recent graphite machining selection, we designed five

test pieces featuring geometries common to our EDM applica-

tions. Results were judged on speed, accuracy and repeatability.

The V33i graphite machine was one of the only technologies to

meet and exceed our expectations across all criteria, producing

accuracies as precise as 0.0001 inches.

Based on these experiences, MGS was quick to identify

the V33i as a potential investment for its precision hard mill-

ing applications. This addition would

also enable the company to combine its

graphite and hard milling operators based

on their familiarity with the control sys-

tem. In addition, the predominant use

of automation had further increased the

companys needs for machine reliability

and serviceability.

While any machine process can ben-

efit from automation, work cells as a

whole are only as efficient and reliable as

their individual components will allow,

says Kolbow. Weve been troubled in the

past by machines with high maintenance

costs and frequent inaccuracies that have

dramatically increased our total invest-

ment costs. Comparatively, maintenance

upkeep on our V33i investments has been

among the best on our shop floor. The

end result is a highly accurate, repeatable

and cost-effective solution.

Accurate, Repeatable Hard Milling

According to MGS, the accuracy and reli-

ability of a machine is not just important

to meeting specifications but also in

maintaining consistent workflow.

Due to the volume and variety of

workpieces, the company must operate

under a tight timeline that cannot afford

recutting of workpieces. All jobs are

scheduled and stacked up, waiting to be

loaded into the hard milling work cells.

If one job is delayed, four other jobs

must be expedited in order to maintain

deadlines. In the worst-case scenario, this

could mean a cut in profit margins as a

result of outsourcing.

There are a lot of machines available

on the market that can produce the tol-

erances we require, but few with the level

of repeatability to feel confident running

them fully unattended overnight, com-

ments Don Rafko, toolmaker at MGS.

The moment you realize that new requirements

do not require new equipment.

This is the moment we work for.

Having both contact and optical scanning technology

allows the new O-INSPECT 322 to do the work of a CMM,

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While hard milling capabilities have enabled MGS to reduce its EDM pro-

cesses, the company still relies on high-performance EDM machines for complex

features that cannot be milled.

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In our razor-blade molds, were expected

to machine five identical seats that hold

each blade at a precise pitch and distance.

These have to be repeated anywhere from

24 to 64 times, oftentimes in multi-shot

molds with zero tolerance. On many

machine platforms, this would be a con-

cern for us, but not the V33i.

Rafko attests that no matter what level

of accuracy a machine can provide, the

overall performance can only be as good as

the cutters allow. The company addresses

these considerations in its hard milling

work cells by incorporating laser-tool-

monitoring systems that interface with

the machine controls to check and verify

tool diameters, dimensions and sizes. By

ensuring consistency among tooling, MGS

is repeatedly achieving tolerances within

plus or minus 0.0003 inches.

A secondary benefit that MGS has experienced as a result

of its newfound hard milling accuracy is the ability to reduce

or eliminate EDM operations. This capability has enabled the



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makino.com

company to trim leadtimes while removing manual handwork

and improving the surface integrity of its molds.

Weve been slowly reducing EDM processes over the

last decade due to higher spindle speeds and better tooling

options, says Matenaer. In some cases our hard milling

machines are now producing better quality, consistency

and accuracy straight out of the machine than what can be

accomplished through EDM processes.

Our ability to substitute hard milling in place of EDM pro-

cesses has influenced the way that we design blocks, cavities

and cores, Matenaer continues. Corner radii that once would

have remained sharp for EDM processing are now designed

into the milling process. Parting lines are cut directly in the

mill, which not only saves us time, but graphite production

and expenses as well. And while there are still features that

require EDM processing, it remains our goal to continue elimi-

nating as much EDM time as possible.

expanding opportunities

According to the engineering team at

MGS, current applications are only

scratching the surface of what they can

potentially accomplish within precision

hard milling. The company anticipates

that further optimization of these

technologies is likely to enable MGS

to expand into more complex markets,

such as micromachining.

As a North American mold manu-

facturer, you must continually seek

out new challenges and opportunities

to remain competitive, says Kolbow.

This is why proper machining invest-

ments are critical to the expansion of

your business. Its not enough to just

replace equipment. Technology has to

add capabilities and remain a catalyst

for engineering leadership.

Streamlining and improving our

hard milling processes has enabled us

to simplify the complex. We put raw

materials into the cell, and finished

parts come out, Kolbow adds. Theres

no rework, and labor time is dramati-

cally less than what is required by EDM

processes. We can spend more time and

energy focusing on the engineering of

complex applications while simultane-

ously improving cycle times, workpiece

quality, unattended capabilities and

overall cost per part.

Case Study / Machining


The Right Machine Eases Moldmakers

Transition to

Five-Axis

By Sherry L. Baranek

North Vernon, IN-based Injection Mold, Inc. is a full-service

shop providing a range of injection molds and specializing

in rapid prototyping molds (i.e., additive manufacturing-based

tooling)everything from simple prototypes to high-volume,

hot runner production tools for industries such as medical,

electronics, safety, baby products, appliance and plumbing. A

desire to reduce set-up times and increase accuracy led the

company to upgrade from three to five-axis machines with the

help of Hurco Companies, Inc. (Indianapolis, IN).

According to Vawter, the company has a stellar reputation

when it comes to speed. We have made a commitment to stay

on top of technology, Vawter says. We have newer equip-

mentlike high-speed machining centers and now five-axis

capabilitiesto shorten the time it takes to go from design to

putting parts in our customers hands. This new technology

allows us to be more efficient, which in turn means we can

take on more work and also meet the short turnaround times

our customers need.

This need for speed led Injection Mold to consider upgrad-

ing from three-axis to five-axis technology. A lot of our work

involves multiple setups on three-axis machines, and with the

short deliveries we do, we needed to find a way to speed up

our times, Vawter notes. Using five-axis technology would

allow us to eliminate a lot of set-ups.

Vawter looked at a number of different machines, but all

roads led to Hurco. One of the reasons we went with Hurco

is that they are right down the road from us, he says. We

also owned Hurcos in the past and have been very happy with

them. We found that the VMX30U was exactly what we were

looking for.

Three- to Five-Axis Transition

The VMX30U that Injection Mold purchased last year has

X/Y/Z travels of 30 x 20 x 20.5 inches and rapids of 1,181 in

X and Y, and 1,378 per minute in Z, notes Hurco Marketing

Director Phil Fassnacht. Fassnacht says the mechanical team

considered rigidity during each design decision. We use

larger linear rails that are mounted to a machined shoulder

to increase rigidity, he notes. Additionally, the rails are

wedge-locked to the frame to reduce vibration instead of

simply being face milled. All of the Hurco five-axis trunnion

style (U-Series) machines provide more clearance in the Z-axis

because they have been designed with an integrated trun-

nion table instead of simply attaching a table on a three-axis

machine. And, the mechanical design team added a four-inch

riser on the Z-axis column.

According to Fassnacht, Hurco decided to make five-axis

a priority 10 years ago and has dedicated resources to the

development of features that make the transition easy for

three-axis shops like Injection Mold and others that are new

to five-axis machining.

Vawter notes that the Hurco control makes the five-sided

process easier with features like Transform Plane and NC/

Conversational Merge. With Transform Plane, you just need

to locate one part zero and the remaining part zero locations

can be defined as incremental measurements from the origi-

nal location, he says.

It basically changes programming on a five-axis mill back

to 2.5D programming that you do on a three-axis mill. You

dont need to worry about the tilting and the rotating. The

technology does the work for you so you can start making

chips faster.

Vawter sent one of his employees to the Hurco facility for

training before having the machine installed on the shop floor.

Injection Mold, Inc. has reduced the number of set-ups with this Hurco

machinesaving time and improving accuracy.

Phot

o co

urte

sy o

f In

ject

ion

Mol

d, I

nc.


Case Study / Machining

Multiple Advantages

Injection Mold bought the machine solely for the purpose of

eliminating multiple set-ups, but Vawter notes the more they

use the VMX30U, the more they find they can do with it.

For example, we had a four-cavity production tool with three

slides per part, and they have angled holes through them on

20 degrees, he elaborates. Theres a 25-degree angle on the

back with tapped holes. To machine these in the past, we

would have a set-up for each operation

on a manual mill. The way we would

have done it would have taken probably

five set-ups; and we probably would

have an hour to an hour and a half

on each block. When we do it on the

VMX30U, it is one set-up and 20 min-

utes in each piece. We set-up our block

of steel, it machines it from the top,

then the machine rotates the table so

we can machine the sideswhich in a

three-axis machine would require

an addition set-up for each side. Then

the machine will rotate 20 degree so we

can drill the hole.

Another payoff is higher accuracy.

Each time you have to take the piece

out of the machine to put in another

set-up, you take a chance of everything

not blending out, Vawter explains.

Now we just pick it up one time and we

will cut from the top and the machine

will rotate and cut the piece from the

sideso accuracy is better. We maintain

.005 micron accuracy on our work.

Vawter is very pleased with the

VMX30U. Once we made the leap, we

continue to find more benefitsthings

we didnt even consider are now pos-

sible. We have had it a little over a year

and we feel like we are just starting

to scratch the surface of what we can

utilize it for. We will definitely consider

another five-axis purchase by years

end.

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Hurco Companies, Inc. / (800) 634-2416

[email protected] / hurco.com

FiveAxisMachining.com

Then, a Hurco technician followed up with some additional

on-the-floor training with Injection Mold employees.

Five-axis was a brand new area for us, Vawter recalls.

Since we have always had three-axis, we grew accustomed

to working in three planes. Then, all of a sudden, there were

five. While he says it took the employees several months to

get completely comfortable with the machine, Hurco was

always readily available to field questions.

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Inspection/Measurement


Improve Input Quality with

The Right Tool Inspection and

Monitoring System

By Sharad Mundra and Jorge Pea-Mena

There is a maxim in the computer industry

known as GIGO, which is an acronym for

Garbage In Garbage Out. It simply means

that if one does not provide quality inputs to a

process, one will not get quality outputs from that

process.

The GIGO law also applies to moldmaking

where the inputs are power and tools, and the out-

put is either a usable mold or a chunk of expensive

scrap metal depending on how well the inputs

perform. Since the process is performed on the

machine tool, it makes perfect sense to measure

and check the results on the machine tool as well.

Tools typically are inspected before and after

the cut using one of several available technolo-

gies. The choice of technologies is determined to a

great extent by the sophistication of the machin-

ing operation involved and the physical size of the

tools and the machine tool.

Contact

At the low end of the technology spectrum is a touch-type tool

setting system. These are commonly used to detect tool pres-

ence and/or breakage and to measure the length and diameter

of rotary tools.

Touch systems are relatively inexpensive, very compact, and

can be wired or wireless. Some, in fact, can be mounted to

the machine table with a magnetic base, making them a good

choice for smaller machines or machines with large parts,

where space is at a premium. They can also often share radio

frequency or optical communication hardware with spindle

probes, further reducing their total installed cost.

Since they literally touch the tool, speeds and feeds can-

not be very high. This limits their ability to detect unbalanced

tools, most speed- and temperature-related spindle variations

and a whole range of other characteristics including broken

inserts on multi-insert cutters. Touch systems are also rela-

tively slow, often requiring precious seconds to perform a tool

breakage and tool measurement cycle.

Integrating efficient tool inspection before and after the cut with

optimized tool performance in the cut improves mold manufacturers

efficiency and profitability.

A probing system with radio transmission includes (from top to bottom) a

bore plug gauge, tool setter, spindle touch probe, receiver and remote control

for programming. The system has an applied transmission frequency band of

2.4 GHz, permitting this single system to be used in applications in most parts

of the world.

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While typically not used for tool inspection, spindle probes

and wireless bore plugs are also touch devices that often are

used to inspect features of the workpiece while its on the

machine. When coupled with powerful, modern SPC and 3D

analytical software, a spindle probe or a bore plug can reduce,

or in some cases even eliminate, the need to do in-process

inspections on a CMM. Wireless bore plugs can be a very criti-

cal tool for providing in-process bore size data in microns for

use by self-adjusting boring bars.

Feedback from the spindle probe and the bore plugs can be

combined with dimensional data from the toolsetter to gener-

ate wear-based tool offset adjustments. Even at the most basic

level, such a system can significantly reduce the incidence of

out-of-spec features requiring re-machining after the final

CMM inspection.

Non-Contact

The other option for tool inspection is a non-contact system,

which today almost always means a laser-based device. A laser

can measure a tool rotating at virtually any practical cutting

speed, which means that speed- and temperature-related

spindle variations can be detected along with out-of-balance

conditions. And unlike last-generation systems, todays lasers

are virtually unaffected by the presence of coolant mists or

droplets on the tool or in the air.

Lasers also are very fast. A modern system can perform a

breakage check; map the full dimensional profile of the tool;

and check each individual insert profile in a multi-insert tool in

a matter of few seconds. Moreover, the laser system can perform

these checks while the tool is spinning at full cutting speed and

moving at rapid traverse velocity.

Lasers are the only practical choice for very large machines,

with systems available for distances up to 15 meters (50 feet)

between the transmitter and receiver. Even with that range,

such systems can make measurements to a repeatability of 1

micron or less.

At the other end of the size spectrum, a high-precision laser

system can measure to 10 microns on a spinning tool, but only

has a maximum range of 32 millimeters. These find application

on small, ultra-precision machine tools often found in mold

shops serving the electronic and medical industries.

Inspecting tools before and after they are in the cut provides

size information that can be used to check tool presence and

compensate for wear, but it provides no data about what is

actually happening during the cut. That is the function of a

tool monitoring system, which fills the vital information gap and

makes it possible to bring the whole process under real-time

control.

These systems use sensors to detect operational conditions

including strain and force; power consumption; acoustic emis-

sions; vibration and acceleration; torque and force; and, coolant

temperature and flow. The sensors can be integrated into com-

ponents like drives and spindles on new machines, or added on

as external devices on existing machines.

In either case, sensor data is processed to create a real-time

signature for the operation. Obviously, the sensors will detect

potentially catastrophic eventssuch as crashes or tool break-

ageand provide feedback to minimize any damage to the

machine or workpiece.

This capability alone makes a monitoring system worthwhile

given the high-value of machines, tools and workpieces in the

moldmaking industry. Of even greater potential value, however,

is the ability to use the data to optimize a tools performance in

the cut via an adaptive control strategy.

A radio spindle probe used in conjunction with analytical software on a

double-column VMC for on-machine part measurement.

A new non-contact laser tool

setting system featuring a

reduced size laser beam down

to 20 microns diameter, making

it ideal for checking tools as

small as 10 microns diameter.

It has a rounded laser beam

suitable for making isotropic tool

measurements. It is ideal for

5-axis machining centers where

different measurement approach

directions are needed.

A new optical touch probe

system for use on large 3- and

5-axis machining centers. The

multi-channel system consists

of a receiver with integrated

interface and a transmitter

unit that is compatible with

the full range of touch-trigger

probes, and is available in

a compact version or a modular

version allowing wide range

application exibility.



A new process monitoring and control system for machine tools that

increases the process safety of machine tools, fully automatically and without

complex and tedious setting.

Real-time data on what is happening in the cut allows the

control system to adjust cutting parameters on-the-fly to

achieve optimal metal removal rates, optimal tool life or any

combination of the two that will result in optimal profitability

for the operation. Tool monitoring alone has demonstrated

cycle time reductions of up to 20 percent in a range of milling

and drilling applications in the auto industry.

contrIbutorS

Sharad Mundra is Mida Probes Product Manager at Marposs Corp. and Jorge

Pea-Mena is General Manager and Director of Application Engineering for

the Artis division of Marposs.

FoR MoRe INFoRMaTIoN:

Marposs / (888) 627-7677 / marposs.com

Summary

The net result of integrating efficient tool inspec-

tion before and after the cut with optimized tool

performance in the cut is the reduction to near zero

of Garbage In for mold manufacturing applications.

And, the assurance of quality inputs made possible

by inspection and monitoring moves the industry

one step closer to the total elimination of Garbage

Out, while improving both productivity and profit-

ability.

800-243-8253 / 562-903-1929www.ChevalierUSA.com

We do mean FULLY automatic.The FSG-2040ADIII series features a new PLC controller that includes a grind cycle with rough and fine grinding, spark-out passes and an automatic over-wheel dresser with compensation that can be added to a fully automatic grinding process. After the cycle is finished, the table will park either left or right, wheel head will park at safety position to facilitate unloading and loading.

The fully automatic grinding feature consists of rough- and fine-grinding cycles, switching from rough-grinding down-feed increments to fine- grinding down-feed increments at preset points

during the cycle. This crossfeed also switches from a rough to fine cross-feed increment, which results in a finer surface finish and finer accuracy.

Its friendly too. The FSG-2040ADIIIs new user-friendly touch-screen control has standard surface grinding programs and a plunge grinding cycle. There are also optional crisscross or zigzag cycles and a CBN dressing cycle. So simple and user-friendly, all skill levels can operate this series of ADIII controllers.

Call your local dealer to see the new ADIII and our comprehensive product line for all your machining needs.

SEE US AT HOUSTEX IN BOOTH 1365


Inspection/Measurement By Sherry L. Baranek

Laser scanning allows the user to transition seamlessly between

probing and scanning.

Advancements in inspection and measurement technol-

ogies are focused on helping moldmakers produce the

highest quality molds in the shortest timeframes

which involves gathering accurate surface data through a

number of methods. Reducing cycle times and rejection rates

while improving accuracy are areas that manufacturers, sup-

pliers and service providers continue to address as they intro-

duce the latest in products, equipment and offerings.

Several leading inspection/measurement suppliers discuss

common inquiries they field as well as reveal the newest

packages, products and services on the market.

Challenges

Over at Renishaw Inc. (Hoffman Estates, IL)a company that

specializes in measurement, motion control and spectroscopy

technologiesquestions relate to reducing cycle times and

accuracy, notes Jeff Seliga, Manager of Marketing Services. A

common question is, Weve shifted to five-axis machining to

reduce cycle times for chip cutting, but our CMM inspection

times have not been similarly shortened. We often hit a bottle-

neck there. What are our alternatives to correct this? Secondly,

Seliga points out that Renishaws customers want to know what

they can do to improve the speed and accuracy of on-machine

probing once they have upgraded to five-axis machine tools.

Greg Richards, Supervisor, Public Relations and Events at

FARO Technologies, Inc. (Lake Mary, FL)a producer of comput-

er-aided coordinate measurement and imaging devices and soft-

warenotes that the companys most common questions relate

to how moldmakers can improve efficiency and lower their costs

by reducing rework time and expediting measurement functions.

Customers want to know how they can reduce waste through

better measurement; techniques to enable users to measure bet-

ter, faster and more accurately; and why precise measurement is

so important to reducing cost, he says.

According to David Olson, Director of Sales & Marketing for

Anaheim, CA-based Verisurf Software, Inc.a metrology software

development company that delivers computer-aided inspection

and manufacturing solutionshe fields questions such as:

How can we speed up the inspection and buy-off of our molds?

How can we reduce or eliminate paper drawings?

How can we speed up profile inspection?

What are the pros and cons of non-contact inspection?

Where can we find skilled inspectors?

At Geomagic (Morrisville, NC)a provider of 3D technology

through 3D digital reality, touch-enabled design and product

verificationSenior Sales Manager Nick Chwalek points out that

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A roundtable discussion of the

latest trends and developments in

mold inspection and measurement

technology highlights the cycle time

reduction, accuracy improvement

and cost decrease benefits.

Inspection/Measurement Advances

Yield Better Molds Faster



moldmakers want to reduce reject rates and still get the prod-

ucts manufactured faster. The main mission is to avoid warp-

age, twist, voids and other errors in a production part, and we

are always asked questions about how to identify specific part

areas that are out of spec, he says.

Kamal Khan, also a Senior Sales Manager at Geomagic, adds

that often moldmakers want to be able to measure a mold,

measure a resulting part, and then compare all that to the

engineering CAD data. As per usual in manufacturing, it is

never quite that simple, he notes. CAD data never matches

the tool because the tool is designed to compensate for mate-

rial shrinkage and warpage in order to match the desired

output. Moldmakers are constantly asking about go/no-go sce-

narios, how to achieve lower reject rates, and how to identify

potential defects like weld area problems and air trap issues.

According to Peter Dickin, International Marketing Manager

for Delcam (Birmingham, UK)a supplier of CAD/CAM solu-

tions for the manufacturing industry, including inspection soft-

waredevelopments that shorten delivery times are something

that every shop in manufacturing asks about. However, due to

the complexity and size of the parts that moldmakers usually

have to deal with, especially in the automotive industry, quality

and safety is a major priority, he notes. Delivery of a part fast

is nothing if it is not correct.

Dennis Morical, CMM Sales Engineer at Mitutoyo America

Corporation (Aurora, IL)a provider of precision measur-

ing tools, instruments and equipmentnotes the company is

approached with both software and hardware related ques-

tions. Software-related questions are: What CAD formats will

your software work with? Will your software work with solid

models? Can you create graphic reports from your software?

Can your software measure exact points that are placed on the

model by our customer? Can you reverse engineer a mold with

your system? Hardware-related questions include: Will highly

reflective surfaces cause issues? Does your software create a

On-machine verication allows the user to check the machined parts

to be carried out on any CNC machine toolrather than having to transfer them

to CMMs for inspection.

surface from the point cloud? How long does it take to

scan a mold with your laser scanner? What is the standoff

distance required for the laser scanner? What file format

will your software output the data in?

Jesse Garant, President of JG&A Metrology Center

(Windsor, ON)a provider of industrial CT scanning

servicesadds that the number one question he gets

asked is, How quickly can you get me the part-to-print

results?

Advancements

FAROs Richards notes that he expects advancements in

non-contact measurement/laser measurement technolo-

gies to continue to evolve. While very accurate, most

laser scanning solutions fall just short of the accuracies achieved

by their hard probing counterparts, he elaborates. But, because

they are easy to use, accurate enough for the majority of mold-

making applications and can capture point cloud data of very con-

toured molds, laser scanners have become the preferred method

of measurement for manufacturers.

We expect the blurring of lines between contact and non-

contact measurement to continue, Richards continues. We also

expect the accuracy of laser scanning solutions to improve to

where, someday, there may be no difference between contact and

non-contact measurement accuracy.

Richards points out a developing trend toward more portable,

easier to use and more robust 3D measurement technologies.

FARO continues to develop 3D measurement solutions that allow

our customers to improve the quality of their products, reduce

work time and lower cost, he states. Our focus is on improving

the portability of our products, the ease with which they can be

implemented and the accuracy at which they measure.

Morical of Mitutoyo also predicts laser technology will continue

to advance, Laser technology will come closer to the accuracy of

tactile measurement on a CMM, and laser-based technology will

3D metrology and inspection software provides robust and accurate

comparison of nished part data to existing reference data.

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105432-FEB 2013.pdf

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Transcript of 105432-FEB 2013.pdf