DECO-Go No 1/99a

«WELCOME TO THE SHOW»

81/ 99

F E B R U A R Y

IMPRESSUMDECO-MAGAZINE 1/99

Industrial magazine dedicatedto turned parts:

TORNOS-BECHLER SARue Industrielle 111CH-2740 Moutier, SwitzerlandInternet: http://www.tornos.chE-mail: [email protected] +41 (32) 494 44 44Fax +41 (32) 494 49 07

Editing Supervisor:Francis Koller, Sales Director

Editing Manager:Pierre-Yves KohlerCommunication Manager

Graphic & Desktop Publishing:Georges RapinCH-2603 PéryPhone +41 (32) 485 14 27

Printer:Roos SA, CH-2746 CréminesPhone +41 (32) 499 99 65

FEditorial 3

Doughty Hanson & Co acquiert TORNOS-BECHLER S.A. 4

Expositions 1999 5

Changement fondamental 7

Voici la seconde utilisation de la fonction interpolation en coordonnées polaires (fonction TRANSMIT): 10

MULTIDECO 26/6 12

A la découverte des options 14

L’historique de MUL-T-LOCK: 16

DEditorial 19

Doughty Hanson & Co übernimmt TORNOS-BECHLER S.A. 20

Ausstellung 1999 21

Eine tiefgreifende Veränderung 23

Hier folgt die zweite Anwendungsmöglichkeit der Interpolationsfunktion in Polarkoordinaten (Funktion TRANSMIT) 26

MULTIDECO 26/6 28

Die Geschichte von MUL-T-LOCK: 30

Den Optionen auf den Zahn gefühlt 32

EEditorial 35

Doughty Hanson & Co acquires TORNOS-BECHLER S.A. 36

«Welcome to the show» 38

Fundamental change 39

Now for the second use of the polar co-ordinate interpolation function (TRANSMIT function): 42

MULTIDECO 26/6 44

The story of MUL-T-LOCK: 46

Discovering options 48

IEditoriale 50

Cambiamento fondamentale 51

Cronistoria di MUL-T-LOCK: 54

Doughty Hanson & Co acquisisce TORNOS-BECHLER S.A. 56

Esposizioni 1999 57

Ecco la seconda utilizzazione della funzione di interpolazione in coordinate polari (funzione TANSMIT). 58

MULTIDECO 26/6 60

Alla scoperta delle opzioni 62

36

MAGAZINE

8 / DECO-MAGAZINE 1/99

TORNOS-BECHLER SA,head-quartered in Moutier, is a world-wide leading manufacturer of highperformance automatic lathes forthe production of precision turnedparts.

The company had turnover ofSFr280m in 1998,representing anapproximately 35 % gain over 1997figures.

As with other Doughty Hansoncompanies, it is intended thatexisting management will stay inplace and participate in the ac-quisition and that the new com-pany will go public through an ini-tial public offering in three to fiveyears.

Dr. Anton Menth, President andCEO of TORNOS Holding SA,said:

“Doughty,Hanson has a reputationfor investing in market leadingcompanies and helping those com-panies fulfil their total potential.Doughty Hanson’s backing willgive us the opportunity to continueour rapid and sustained growth.Furthermore, the company willbe in a strong position to conti-nue with the development of new,technologically innovative pro-ducts.”

ABOUT DOUGHTY HANSON & CO

Doughty Hanson & Co is an in-dependent fund managementcompany with offices in London,Chicago, New York, Frankfurt,Milan, Stockholm and Warsaw.Doughty Hanson & Co’s partnershave many years’ experience in thesuccessful management of inter-national private equity funds andhave led and arranged a numberof the largest European acquisi-tions.

Doughty Hanson’s latest fund wassuccessfully launched in Septem-ber 1997, raising US$2.5 billion.Investors in the fund include ma-jor pension funds, insurance com-panies, banks and state fundsworldwide.

Doughty Hanson differentiates it-self both by the size and com-plexity of its transactions as wellas its consistent record of innova-tion. Recent examples include:

◆ Dunlop Standard AerospaceGroup, acquired from BTR plc,is a market leading businesswithin various niches within theaerospace industry;

Doughty Hanson & Co acquires TORNOS-BECHLER SADoughty Hanson & Co (“Doughty Hanson”), Europe’s leading independentprivate equity company, announces today that it has signed an agreementto acquire TORNOS-BECHLER SA of Switzerland.

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◆ Geberit, one of the largest suchtransactions in Europe and thefirst to use a non US dollar de-nominated high yield financing;

◆ Impress Metal Packaging, inwhich Doughty Hanson simul-taneously acquired and mergedtwo European metal packagingbusinesses to form a new com-pany which is now one of thelargest metal packaging pro-ducers in Europe;

◆ Elexis, a German holding com-pany for nine engineering busi-nesses, formed from the rumpbusinesses of Daimler Benz/A-EG AG. The business was heav-ily loss-making when acquiredin December 1995 but has sincebecome profitable. The com-pany is now planned for a Frank-furt Stock Exchange Listing du-ring 1999.

Investment Strategy

The objective of Doughty Hanson& Co is to grow each investmentin partnership with management,through investment where ap-propriate. Typically,Doughty Han-son & Co looks to arrange an ini-tial public offering for the com-panies it acquires within 3-5 yearsof acquisition.

Doughty Hanson & Co is alwaysrepresented on the supervisoryboard of the company and activelyassists the management of the

company in the preparation andexecution of strategic and finan-cial objectives.,

Examples of Doughty Hanson’sEuropean IPO portfolio include:

◆ Tarkett AG, Europe’s largestmanufacturer of resilient andhardwood flooring, listed on theFrankfurt Stock Exchange in1995;

◆ Tag Heuer International SA,oneof the world’s premier produc-ers of prestige ,sports watches,listed on the Zurich and NewYork Stock Exchanges in 1996;

◆ PowderJect Pharmaceuticals plc,the innovative manufacturer ofneedleless injection systems,list-ed on the London Stock Ex-change in 1997;

◆ Winkler & Diinnebeir AG, theworld market leader in produc-tion of machines for printingand folding paper envelopes,listed on the Frankfurt StockExchange in May 1998.

Reputation as a good owner

Doughty Hanson is committed todeveloping the companies it ac-quires in preparation for a stockmarket listing. It has pioneeredthe use of bond finance in struc-turing a number of its larger Eu-ropean acquisitions, thereby es-

tablishing rated paper and researchon investee companies from theoutset of its involvement. It hasfound these techniques to be anexcellent preparation for achiev-ing a full listing of the investee com-pany’s shares on the public mar-ket.

Doughty Hanson seeks to workwith experienced professionalmanagement teams in the busi-nesses it acquires and to developshared strategic goals. In this wayDoughty Hanson has establisheda reputation as an entrepreneur-ial shareholder that works withmanagement.

www.doughtyhanson.com

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NEWS

What the market has to offer takesplace in a restricted geographicalarea, with all visitors, companyclients, competitors and other ex-hibitors being available and inte-rested in obtaining useful and per-tinent information.

The above information was correctat the time of publication. How-ever,changes are possible and onlythe invitations to these events willfeature the exact dates.

All customers will be invited tothese events. If you are not amongthe group of people regularly in-vited to attend, but would likesome information and be sent in-vitations,then we would be pleasedto put your name on our privilegednotification list.

Trade fairs

in 1999

«Welcome to the show»In our field of activities, the « trade fair » is vital for meeting

new people.

The following table is a provisional schedule:

As the meeting point betweencompanies and clients, this com-munication vehicle is a vital ele-ment to both parties.

Being an EMO year, the countriesof Cecimo (Europe) will be some-what neglected by this event –owing to restrictive regulations.

We are anxious to present sever-al new high-quality products, soit has been decided that ‘OpenHouses’ will be organised for oursubsidiaries.

Comments: I may, at any time, request that the above information be deleted by calling (++41 32 494 44 34).

REPLY COUPONto be returned by fax to DECO magazine on number ++41 32 494 49 07

EXHIBITION COUNTRY OPENING DATE CLOSING DATEMach-Tech Hungary 2.3.1999 5.3.1999Amtex Australia 22.3.1999 26.3.1999Tornos-Bechler Switzerland 12.4.1999 17.4.1999Maribor Slovenia 21.4.1999 23.4.1999Feimafe 99 Brazil MayLinkage Hong kong MayEmo France 5.5.1999 12.5.1999Balttechnika Lithuania 18.5.1999 21.5.1999Nitra Slovakia 25.5.1999 28.5.1999Open House TTUK United Kingdom 25.5.1999 27.5.1999Open House TB Switzerland To be agreedOpen House Tecnocontrol Italy 10.6.1999 13.6.1999Poznan Poland 14.6.1999 18.6.1999Open House Martini Italy 18.6.1999 20.6.1999Tel Aviv Israel 21.6.1999 24.6.1999Open House TTD Germany To be agreedTatev 99 Turkey SeptemberCimt 99 P. R. of China SeptemberBrno Czech Republic 13.9.1999 15.9.1999Open House Denmark 20.9.1999 25.9.1999Open House Czech Republic OctoberOpen House Netherlands OctoberTIB Rumania 11.10.1999 14.10.1999Open House Japan To be agreedINDEX Greece November

USA LOCATION OPENING DATE CLOSING DATEOrlando Orlando, FL 19.1.1999 21.1.1999South-Tec Greenville/Spartanburg 26.1.1999 28.1.1999WESTEC Los Angeles, CA 22.3.1999 25.3.1999Fort Wayne Show Ft. Wayne, IN 14.4.1999 14.4.1999Zimco Open House St. Louis, MO 20.4.1999 22.4.1999Pennco Open House Philadelphia, PA 22.4.1999 29.4.1999Denver Tool Show Denver, CO 27.4.1999 29.4.1999Minneapolis Minneapolis, MN 4.5.1999 6.5.1999Cleveland Cleveland Fairgrounds 11.5.1999 13.5.1999Indiana Ind. Prod. Show Indianapolis, IN 25.5.1999 26.5.1999EASTEC Springfield, MA 25.5.1999 27.5.1999Detroit Detroit, MI 14.9.1999 16.9.1999Rochester Tool Show Rochester, NY 21.9.1999 23.9.1999MidAtlantic Fort Washington, PA 28.9.1999 30.9.1999Cleveland Cleveland (IX Center) 19.10.1999 21.10.1999Southeast Florida Ft. Lauderdale, FL 20.10.1999 21.10.1999Dallas Dallas, TX 2.11.1999 4.11.1999Chicago Ind. Prod. Show Villa Park, IL 9.11.1999 10.11.1999Pacific Coast Ind. Show Santa Clara, CA 16.11.1999 18.11.1999Houstex Houston, TX 25.1.2000 27.1.2000South-Tec Charlotte, NC 29.2.2000 2.3.2000IMTS 2000 Chicago, IL 6.9.2000 13.9.2000

Hall 5Stand B16

� I do not know TORNOS-BECHLER and would like to be added to the «privileged» list� Moutier � F � UK � I � E � USA � D

Surname & first name Company

Address

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INTERVIEW


Fundamental changeIf you had visited the company more than 6 months ago, the changes made

since then mean that you would no longer recognise it!

The renewal of TORNOS-BECHLER S.A. is well underway and thisproject has enabled the company to meet stringent marketrequirements.Whilst undergoing continuous improvement, the process entailswidescale change on a daily basis throughout the company.Boththe processes and places of work are changing.In order to provide a full explanation on the full details of therestructuring of the company,we arranged to interview Mr.RolandBreitschmid,production manager and initiator of these changes.

DM: Hello Mr. Breitschmid!We are talking a lot about majorchanges in TORNOS-BECHLERbut what exactly are they?

RB: We have completely rebuiltthe company over the last 15months, especially the machineshop.

All production means and process-es, the flow of goods and infor-mation, are new or in the processof being so!

DM:Why exactly did you proceedwith these changes?

RB: The success of the DECO2000 and the quantities producedwere considerable. As this was inline with our aim of continuousimprovement, it was essential toact quickly to relieve the pressureon production.

DM: If I understand things cor-rectly, the company was restruc-tured to face rapid growth.Wouldsuch reactions not entail any risk,especially in a highly volatile mar-ket such as machine tools?

RB: Of course! We accounted forthis in our strategy with produc-tion being re-structured to workin 2 shifts. The flexi-hour systemhelps when faced with peaks or

troughs and we have the facilityto go from 1 to 3 shifts to meetshort or medium term cyclic fluc-tuations.

DM: In concrete terms, what ex-actly are the changes in produc-tion?

RB: The whole of production hasbeen broken down into « islands ».An island is the concept of a mini-shop being constructed around afamily of parts.

These islands resemble auto-nomous divisions operating with-in the company along « client-supplier » lines.

Each islands is responsible for itsown quality and meeting deadlinesand costs.

DM: Did this change take placewithout problem?

RB: Yes.We were impressed withthe calibre of all the professionalswithin the company.There was, awillingness to improve, whilst thesuccess of the DECO and need toreact quickly has enabled us to im-plement this new system and trans-formation.

DM: How did your colleaguesregard these changes?

RB: As far as our colleagues wereconcerned, the major change wasthe re-appraisal of jobs – from be-ing an operative to someone withresponsibility. The degree of re-sponsibility obviously depends onthe job, but everyone is responsi-ble for the quality of their work.

DM: And was this change inattitude straightforward?

RB: think that change is never sim-ple, but it has been a positivemove. This can be discussed withMr.Heizmann,who is head of theboard of the company (see framebelow).

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EDITORIAL


At a time when all the talk isabout globalisation, high-speedcommunication networks, theInternet, information technologyand how we launched a comput-er-controlled automatic lathe, thelaunch of a magazine in hard copy,dedicated to the DECO 2000,could appear presumptuous.

After 7 editions and distributionof more than 78,000 magazines,with an ever-growing number ofinterested parties and faithfuladvertisers, we can state that thissystem is a success !

With the aim of providing evenbetter information to our clientsand interested parties, this formof back up has hit the target. Wemay decide to merge the DECOMagazine and the MultispindleMagazine (currently on stand-by),and supplement these with CD,Web site and video information.

Like all other means of commu-nication, our magazine has with-stood many problems associatedwith translation,formatting,dead-lines and so on, but generallyspeaking, we are very satisfied.

However, it is not our satisfactionwhich is of importance – whatreally counts is our readers’ satis-faction!

This is why we are inviting you tosend us your comments on theDECO magazine, its articles, ouractivities in the market,our prod-ucts or even on the global com-petitive environment.

DECO magazine wants to createan objective tool for informationand exchange and not merely beyet another run-of-the mill ad-vertising vehicle.

This year, the last year of the mil-lennium,will see the last EMO ofthe millennium. We shall issue 4editions of DECO magazine witha vast series of innovations, spe-cial editions, and errata (hopeful-ly few if any) etc.

I would like to thank all our read-ers for their interest and wouldreally like to invite you to expressyour comments as to how we canimprove.We look forward to meet-ing you in ten or so magazines’time with a view to re-appraisingthe situation.

Pierre-Yves KohlerChief editor

n the press, the editorial is often a separate section where the editoradopts a position or addresses subjects which are not necessarily inkeeping with the magazine. To date, DECO Magazine has managed to

avoid this phenomenon – we have always remained very “technical” evenwithin these columns.After eight editions, including many technical articles I need to take stockand see how we can improve. Any suggestions?

I

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INTERVIEW


DM: What were the aims of suchre-organisation?

RB: The main aim was to meetmarket demands and become morecompetitive – in other words:

◆ reduce the number of parts inthe process of manufacture.

◆ reduce machine change-overtimes.

◆ allow the run to take place withflow drawn downstream.

The ideal ratio between flow timeand actual machining is 3:1 andwe are actively working to achievethis aim.

According to the old methods oforganisation, this factor could bewithin the region of 50:1 to 100:1,if not more!

DM:Does flow drawn from down-stream mean reduced stock?

RB: Ideally it goes without sayingthat the stocks should be as smallas possible commensurate withcustomer requirments so as to re-duce capital tie-up to a minimum.

At the moment, the stocks atTORNOS-BECHLER are down to

DM:Hello Mr.Heizmann! Did thechange go well as far as the em-ployees were concerned?

DH: The change went well, but itis quite clear that this particularprocess requires a complete changein the attitude of our colleagues,those who have been involved inthe change-over, changing fromoperatives to managers.

In all, we can say that two cate-gories of people emerged:

the young employees who clear-ly understood the benefits of thesystem right from the outset.

the older employees who had tomake a lot of effort to adapt, fol-lowing several decades of condi-tioning.

DM: And what about the hier-archy ?

DH: All levels of the companywere affected, both managementand staff had to undergo change.

All staff were involved from theoutset with the emphasis placedon versatility and increased abili-ty, also leading to the overall useof ability scales which aims at im-proving knowledge and skills.

DM: So all employees are in-volved in the process?

DH: Absolutely. Several motiva-tion levels came to the fore, butin all events the decisive factorswere the communication and at-titude of the leaders and the inter-face between top managementand staff.

DM: In concrete terms then, whatwas your own investment in timefor this project?

DH: Despite a general positive at-titude, much time was still need-ed explaining the targets and meansof achieving then.

Personally, I spent more than60 % of my working hours – whichstarted on the lathe – in meetings,seminars and organisation, as wellas still working on my lathe.

DM: As a conclusion and purelyat staff level,do you really believethat there has been an improve-ment in working conditions?

DH: Absolutely. We are nowlooking to introduce the conceptof versatility for all members ofstaff, by on-going training. Im-provement and learning are en-couraged and jobs have been re-evaluated. This provides an ex-cellent opportunity for everyone.

Re-evaluation and responsibilityhave been beneficial to the com-pany climate (hence its produc-tion!).

DM: Mr. Heizmann, thank youvery much.

Views of Mr. Daniel Heizmann,employees representative, on this major change.

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INTERVIEW


a minimised and controlled level.As the drawing on production flowtightens,the stock will decrease un-til it reaches its optimum level,thusproviding the best service for pro-duct assembly.

DM: In concrete terms, is thiscreation of islands associatedwith other actions?

RB: Of course. This restructuringalso involved the renovation ofbuildings and means of production,amounting to several tens of mil-lions of francs, resulting in:

◆ a new environment

◆ a new organisation

◆ a new attitude amongst ourcolleagues

All workstations are more er-gonomic in design and a «mana-gement of order» concept hasemerged!

DM:What do you understand by«management of order»?

RB: The basic idea is that in aworkstation everything must be inits proper place. Each colleague isresponsible for the order, care andcleanliness of his work place.

This would lead to improved work-ing conditions and pleasure in exe-cuting the work,since it is now pos-sible to concentrate on what is es-sential.

DM: Which brings us back to theworkforce.They really seem to bethe key element of this reorgani-sation – what do you think?

RB:Absolutely.Whatever it takes,we are striving to uphold the highdegree of know-how throughoutthe company, and are looking atways of increasing the added va-lue provided by our colleagues toour products.

Based on this context, we are alsoincreasing the «man-machine»ratio by continuing to improveour know-how and added value.

DM: So if I understood correctly,production at Moutier, the his-toric centre for producing auto-matic lathes in the world, is on-going?

RB: More than ever before. Theknow-how of our colleagues is oneof our reasons for being success-ful in the market.

DM: In terms of staff, could theycope with this rapid growth?

RB: We have taken on more than150 people over the year. In thiscontext, I would like to say thatwe have set up a permanenttraining system which will allowoutside professionals to work atTORNOS-BECHLER and com-plete their training, whilst at thesame time allowing our employ-ees to acquire new knowledge.

DM: What reasons led you toadopt this measure?

RB: There are several reasons butas a company priority it is to in-crease its own added value anddevelop the strategic know-howof its employees!

Obviously, the saturation of thelabour market in precision engi-neering has also had an effect.

This personalised form of trainingat the professional Tornos centreis extremely successful and hasallowed us to plug a few gaps inour means of production.

At present, 5 people are trainedeach month!

DM: What are the benefits to aclient purchasing a DECO 2000machine (or other)?

RB: I am well aware that talk oflong lead times is very unpopular.The periods encountered overthese past months have not beengood publicity for TORNOS-BECHLER,but without this com-plete re-organisation, the compa-ny’s position would have been ab-solutely catastrophic. We wouldnever have been able to supplymore than 1000 DECO machineswithin 18 months!

The fact that we have colleaguesresponsible for costs,delivery datesand quality at all levels of the pro-duction process, guarantees thereliability of our machines. Eachpart is certified as being correct bythe skilled worker who has pro-duced it.

DM: I would like to thank you,Mr. Breitschmid, for this inter-view. To conclude, what do youhave to say to such a change?

RB: The reorganisation of thecompany actually makes the re-gion stand out. At TORNOS-BECHLER,the entire productionwas revolutionised by the DECO2000 and customer requirements.

I would like to take this opportu-nity to thank all our workforce, se-nior management,employee com-mittees and trade unions for theirinvolvement in this project whichwill allow us to face up to the fu-ture with confidence.

DM: Production at TORNOS-BECHLER has shown theway to renewal, let us en-sure that the entire compa-ny will adopt this processwhich is destined to lead tothe on-going improvement ofits products... E

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TRICKS OF THETRADE


Now for the second use of the polar co-ordinate interpolation function

(TRANSMIT function):

Reminder:

The operation line containing thecode M198 D-1 to execute ma-chining in polar co-ordinates,musthave axis X as master 1, axis C asmaster 2 and the third axis ( e.g.Z ) as slave.

The first master axis must,as a mat-ter of course, be a diametral axis( X2, X3 or X4 ).

Following presentation of milling a square with T31 and end-milling, we shallnow discuss milling a square with a circular Ø 80 miller mounted on the poly-gon unit in position T24 (example taken from the DECO-2000 26 mm)

Programming with millingradius correction

For easier programming, it wouldbe useful to use the milling radiuscorrection using functions G41 orG42.

Graphic representation of theapproach:

Where the miller has a diameterwhich is far greater than that ofthe bar being machined,and wherethe path of axis X2 is limited (seefigure below), programming theapproach (engaging G41 or G42)is extremely important. It is noteasy to explain programming offunctions G42 and G40 in detail,because these functions requirespecial programming. Nonethe-less, the example we are going todescribe,(which is frequently usedat TORNOS-BECHLER) is agood starting basis if one wantsto mill any shape in polar co-or-dinates using a polygoning unit andthe functions G42/G40.

The square shape will be machinedwith a polygoning unit fitted witha circular miller of Ø 80 mmmounted in position T24. Theprogrammed shape will be ob-tained by combining the move-ments X2 and C1.

From the tool catalogue, intro-duce the geometry of the millerin X at the centre of the miller.For example, miller with a Ø 80(size recommended for the DECO2000, 20 and 26 mm capacity):D = 80, geometry in X = -80

Please refer to the previous DECO MAGAZINE edition for information on the principles of pro-gramming polar co-ordinates.

Max. position of X2 = 80

Milling cutterdiameter 80

Add Tool to Catalogue

T24/T29 support 24Circular milling cutter

Previous Next

Circular milling cutter mounted on the polygoning attachment

CancelSelect Correctors OK

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TRICKS OF THETRADE


Comments:

Path 1 - 2 - 3 = programming the approach

Path 1 - 2’ - 3’ = path resulting from the approach ( G42 engaged )

Erratum

The last issue in 1998was the first to containerrors in its tricks ofthe trade articles.

Logically, this meansthat this is the firstedition to contain anerratum…

These minor errorswere due to unfortu-nate technical prob-lems. Please acceptour apologies. Weshall publish the cor-rections here.

ISO code for the milling operation:

1. G1 X2=160 Z1=-4 G100 T24 G942. M198 D-13. (APPROACH AND PREPARATION OF CONTOURING G42)4. G1 X2=70 C1=-55 G100 T24 G425. G1 X2=14 C1=7 F5006. G1 X2=-14 C1=77. G1 X2=-14 C1=-78. G1 X2=14 C1=-79. G1 X2=14 C1=710. (OUTPUT PREPARATION)11. G1 X2=0 C1=1012. G3 X2=0 C1=-10 G100 R1013. G3 X2=20 C1=0 G100 R1014. (CONTOUR OUTLET)15. G1 X2=160 C1=0 G100 G4016. M199

X

43

2 1

X-

C

C-

1; 11

6

7 8

4 3

109

5

3'

3

2

2'1

The fictitious point 2 which isprogrammed on line No. 4 of theISO code above, must be deter-mined as a graph. This is only ofuse for executing the approach, ir-respective of material. Its precisionis therefore, not critical.

Engaging milling correction mustalso be carried out with the samedegree of care given to program-ming the approach.The axes mustbe at the same points (machineposition) when engaging M 199polar co-ordinate interpolation as

when engaging M198 D-1. Con-sequently, it is necessary to turnaround the part before proceed-ing with the function G40 (lines11 to 13).

To conclude, why should you usethis method rather than the onedemonstrated in our previousedition (milling a square with T31and end milling, Ø 10 mm) or theother way round?

To be found

in our next issue:

◆ Constant cutting

speed when cutting

parts with a G904

◆ Saving time with

the long part devi-

ce!

The choice for the customer isbased on the machine that theyhave. In terms of quality, the re-sult obtained is a better solutionwith the «circular miller with poly-goning unit» !

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TRICKS OF THETRADE


DECO 20/26 DECO 103/97 Incorporated assistance Standard Standard3/97 Much quicker programming Standard Standard1/98 Compensation for wear Standard Standard2/98 Cross-tapping with threading miller on the T24 tool Standard No.1500

6 3/98 Deburring a cross drilled hole No. 1500using axis C No. 0916 No. 0916

7 4/98 Macro G903 (indexing) Standard Standard7 4/98 Milling a square in T31 with an No. 0916 No. 0916

end miller. Transmitted function No. 0917 No. 09178 1/99 Milling a square with a circular No.0916 No.0916

miller on the polygoning unit No.0917 No.0917Transmitted function No.1700 No.1700

New table summarising the various hints and equipment

No. DECO Mag Hints Option required

TECHNICAL

MULTIDECO 26/6Let us examine the characteristics in detail.

Applying the DECO 2000 con-cept to multi-spindles is likely tocreate a new standard in terms ofhigh, flexible productivity.

The purpose of this section is todiscover some new elements of theMULTIDECO which have not yetcome to light.

Based on the com-ments or questionsalready receivedwe shall look atthe information ingreater detail.

In this edition, weshall be present-ing the spindlesand their variousfacilities.

The design of the MULTIDECO26/6 spindles (irrespective oftype) hinges on the ISO dimen-sional quality roller bearings.

The spindle nose is supported ina 3 bearing assembly using preloaded bearings, thus guaranteeingthat the machining stability re-quired for high precision, largeproduction runs is maintained.

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TECHNICAL


This is ideal for obtaining the bestsuited cutting speed, especiallyduring hobbing and sliding opera-tions at different stations. Its ratioof 1:2 is a good compromise whichdispenses with spindle waitingtimes during different operationsat 2 working positions.

The different versions

Apart from the single speed spindle, several types of spindle considerably increases the range of operations available on the MULTIDECO 26/6.

Single speed spindlewith single stop

Is only available for position 4.Thecross-machining functions suchas drilling, boring and tapping areensured within specific, angulartolerances.

This spindle therefore enables theMULTIDECO 26/6 to execute veryprecise parts with positioned holes.

In a future edition we shalldiscuss

the conceptof

combiningcam

shafts andPNCs.

The cutting is always executed athigh speed. The choice of highor low speeds is completely op-tional on all the other workstations.

This option is also well suited forpolygon and threading operations!

The spindle with posi-tioned stop

Two-speed spindle withstop

This is designed for cross-machi-ning operations such as drilling,boring and tapping,with the maxi-mum speed of this version being4000 rpm.This option is availablefor one or more spindles runningat the same time.

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MAGAZINE


The story of MUL-T-LOCK:

In 1973, two young men set out to realize a dream.Avraham Bahry and Moshe Dolevestablished in Israel, were to become one of the world’s foremost manufacturersof High Security products, MUL-T-LOCK.Today, Millions of people worldwide are MUL-T-LOCK users.

Q: What are the typical productsproduced in the factory?

A: The products machined in thefactory are cylinder lock bodies(stators),plugs (rotors),keys,pins,sub assemblies and other cylindersand locks components. The mostchallenging are plugs and bodies,since they are of various shapesand designs and high precisioncomponents. Any market has itsown types of bodies and plugs, fit-ted to local standards.As we servearound 100 different markets,andconstantly expand the applica-tions, new designs are frequent,which demands fast responses tothe setting of machines.

Q: How did the factory grow?

A: In the beginning, with a verysmall range of products, we startedwith special purpose single oper-ation machines.The products hadto go through a long route, caus-ing long production cycles andoperator dependent quality. Lat-er,when quantities increased,came

the rotary transfers. At this pointwe had developed a solid infra-structure for future growth. Thiswas good preparation for the 90’s.

The Cylinders Division is one offive major divisions. The divisionemploys 270 staff,and it producescylinder locks,padlocks and manyother types.The machining plant,spreads over 4500 sq. meters andoccupies 90 employees using awide range of machining tech-nologies: «Esco» screw machines,mechanical cam lathes, 2-axesCNC lathes,turning centers (seve-rall of them are DECO 2000),

mechanical rotary transfers,CNCrobot loaded rotary transfer, Hor-izontal machiningcenters, vertical ma-chining centers, plas-tic injection moldingmachines, broaches, aheat treatment line, aproduction line forkeys, and many othermachines.Most of themachines in the fac-tory are workinground the clock, withthe operators beinghighly skilled. Theplant produces in to-tal about 30,000 dif-ferent parts, in a concept of justin time and short delivery times,which causes very complicatedlogistics and very dynamic at-mosphere.

MUL-T-LOCK was born of aningenious 4 way locking system,developed and expanded intoworldwide activity, providing awide range of High Security pro-ducts for the protection of pro-perty. MUL-T-LOCK is a proudowner of hundreds of registeredpatents and patent pending ap-plications.MUL-T-LOCK enjoyed

a growth rate that isextraordinary high for

its type of industry: Fromsales of $1,000,000 in 1973, to

nearly $100,000,000 today.

MUL-T-LOCK nurtures its em-ployees and encourages them torealize their own individual po-tential in conjunction with theattainment of MUL-T-LOCK’sgoals.

MUL-T-LOCK products are soldin over 100 countries, by 4 sub-sidiaries and more than 150 dis-tributors and some 15,000 salesand service dealers.

MUL-T-LOCK’s subsidiariesmarket and distribute their prod-ucts in the US , Canada, Franceand the U.K,with production linesare spread over some 35,000square meters.

Interview with

David Ellenbogen,

Project managerin

MUL-T-LOCK’scylinders division,

and Izik Vaxman,

Technical manager

of the division.

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Recently, as markets developedand different products were addedto our product catalogue, we hadto look for more flexible solu-tions.

Q: What flexible solutions didyou find?

A: First step were horizontal ma-chining centers. The flexibility ofthose machines is almost unlimi-ted,but a long set up must be donebefore first component is pro-duced on the machine.The blankmust be cut off a profile or turnedfrom round bar, then a jig and aprogram must be produced. Inoptimal conditions this processmay last 2 weeks.

Next came the CNC rotary trans-fer. This machine has enormousoutput, but involves huge invest-ment and a long preparation timefor a new product.

The next generation was that ofthe turning centers,producing fin-ished parts directly from raw ma-terial and eliminating the needfor second operations. In 1994 wepurchased 2 CNC machines.Thosemachines reduced the time be-tween the finishing of design, andthe production of the first part,and were an excellent starter fornew technology.

Q: Then came the DECO revolu-tion?

A: Yes, indeed, with all of its ben-efits. We were following the de-velopment of the DECO 2000,waiting for the day TORNOS-BECHLER will meet our needs

for bar capacity and number ofpower driven tools. We came toMoutier on the very first day ofshowing the 20 mm DECO 2000,with a purchase order for one ma-chine and option for another. Wehave used the option to order a25 mm 6 months after the first.Today,we have 2 DECO 2000 ma-chines running and we know thatthey will not be the last DECOmachines we will buy.

Q: What, by your opinion, arethe major advantages of DECO2000 machines?

A: In one word, efficiency!

1. Low cycle time due to 4 toolsmachining simultaneously, shortchip to chip time because no timepneumatics or hydraulics is in-volved in tool change,and smoothand continuous movements, sav-ing dwell caused on traditionalCNC controls.

2. Saving precious machine timedue to the simple off-line pro-gramming and simulation on theTB DECO program. This featureallows loading of a proven andoptimized program before the firstproduct is cut, instead of opti-

mizing after the first part has beenproduced, as on other machines.

3. Excellent investment comparedto productivity.

4. Excellent floor space to pro-duction ratio.

5. Very simple maintenance andgood access to machine’s systems.

6. Finally, top Swiss precision dueto rigid construction and Swiss-type turning.

Q: What about the future?

A: As far as we can see, the trendis for increased flexibility.No longercan we rely on old designs and con-quer markets with them. Marketsare thirsty for innovations, fastresponse and top quality. There-fore we worked very hard to de-velop flexible production capa-bilities as part of our plant. OurR&D is working continuously tobring innovations according to themarkets demands.All activities ofthe company are controlled by aleading ERP software, «SAP», andthe division is ISO 9001 qualifiedsince 1998 (ISO 9002 since 1995).

We feel that today, based on thelatest technologies, innovationsand quality, we are a leading com-pany in the field of High Securi-ty products.

All this together gives us the pow-er to grow and expand in the sat-urated and competitive market oflocking products.

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THE PRESENT


Option 1910 – Milling head andtool centring system (withoutcutters)

Number of cutters required: 3

Regrinding ~40 times

Option 5250 – Coolant pump,20 bar (ex-works)

Left or right hand treads are con-trolled by the setting of the angleof the unit.

Discovering optionsAfter presenting the principle of thread whirling in the edition (1/98),

we now look at the tooling used.

First of all, the external whirl cutter fitted to the DECO2000, 20 mm capacity:

Option 1900 – High-speed external thread millingdevice (high capacity whirl cutting)

(Uses 2 positions - T24 and T25 on X2-Y2)(Requires options 1910 and 5250)(Incompatible with emulsion based coolant)

Characteristics:

Max. part rpm: 8,000 rpm.

Max. drive power: 1.5 kW

Max. machining diameter: 11 mm

Max. whirl cutting length: 200 mm

M204

M103x°

M204

M104

x°

Comments on the direction of threads:

A) Unit inclined upwards: Programming in X -Geometry in X = - 6Rotation C + = (M 103)

B) Unit inclined downwards: Programming in X -Geometry in X = - 6Rotation C - = (M 104)

Comments:

The geometry is calculated in relation to the machine kinematics andthe part to be produced. If necessary, please do not hesitate to contact ourspecialists for further information...

The inclination of the unit is cal-culated as follows:

(mean diameter)

➜ 6° incline

= 6.0027°5,35 x π

(pitch) 2.8

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THE PRESENT


Option Designation DECO Mag. no 10 20/26

5430 Oil mist and emulsion suction device 7 (4/98) x

4900 Long parts extractor 7 (4/98) x

0940 Spindle lock

3800 Internal thread miller, for counter-operation 8 (1/99) x

3810 Fixing system for the whirl cutter spindle 8 (1/99) x

4400 Internal thread miller, for operation 8 (1/99) x

4410 Fixing system for the whirl cutter spindle 8 (1/99) x

1650 Revolving spindle unit for ESX 25 chuck 4 (1/98) x

2100 HF drilling spindle 15,000 rpm 4 (1/98) x

3240 Triple end tool holder 4 (1/98) x

5010 High pressure drilling device 5 (2/98) x

1800 Generation cutting device 5 (2/98) x

3300 Long revolving drilling/milling spindle for ESX 25 chuck 6 (3/98) x

4550 S5 longitudinal motorisation to drive therevolving units to positions T41-T44 6 (3/98) x

3350 Differential spindle 6 (3/98) x

0940 Spindle lock 7 (4/98) x

1900 High speed external thread miller 8 (1/99) x

1910 Milling head with tool centring system 8 (1/99) x

5250 Coolant pump, 20 bar 8 (1/99) x

Table summarising the novel features DECO

Second option put forward:

Internal whirl cutting on theDECO 2000, 10 mm capacity

Option 3800 – Option 4400

High speed internal thread millingdevice

(whirl cutting with air spindle)

(including lubrication system)Ex-works

Characteristics:

Can be mounted in the followingpositions:

T31, T32 or T33 (option 3800)

T41, T42, T43 or T44 (option 4400)

Max. tool rpm: 30,000 rpm

Max. torque: 0.01 Nm

Max. machinable diameter: M4

Min. diameter possible: 1.4 mm

Depth:More than 2 x the diameter

Main material worked:Titanium or stainless steel

Fixing the spindle requires thefollowing option:

3810 (for 3800) – System forfixing the internal whirl cutterspindle

4410 (for 4400) – for counter-operation

It is possible to mount two inter-nal thread millers per machine (ifrequired), for example, one formain spindle and one for counter-operation!

Option 3800

Option 4400

DECO-Go No 1/99a

Documents

Transcript of DECO-Go No 1/99a