Results Today - GFMS · Results Today 8 It is no exaggeration to say that Sarwant Singh wrote the...

8Results Today

It is no exaggeration to say that Sarwant Singh wrote the book on megatrends, “the transformative, global forces that define the future world with their far-reaching impact on business, societies, economies, cultures and personal lives.”

Global megatrendstransforming the world

GF Machining Solutions

Milling technology | 12 Laser technology | 13 EDM technology | 13 Market Region Americas | 3

Milling solutionsfor productivityand precision

Automotivemanufacturersturn to Laser

EDM powersyour precisionand output

Putting you onthe path to thefuture—today

+ AMI | 4-5Colorado company aimsfor incomparable quality

+ LTTS | 8-9 Speed, reliability, expertisekeep customers coming back

+ TZZ | 10-11 Bringing ideas to lifewith Laser texturing

+ Spindles | 12 New HPC190 spindle platformdelivers very high flexibility

+ Automation | 14 TRANSFORMER growswith your business needs

+3Customersuccesses

+Productnews

Expert insights

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FACTORY OF THE FUTURE

The global customer newspaper — English edition

A globally renowned futurist and a senior partner with global growth consulting firm Frost & Sullivan, London-based Singh pioneered the macro-to-micro methodol-ogy for translating megatrends to micro level implications. His 2012 book, Mega Trends: Implications for Our Future Lives, has been sold in more than 30 countries and a Chinese translation will be avail-able this fall.

Singh joined Frost & Sullivan in 1999 and today leads two of its businesses: the Visionary Research Group focusing on megatrends research, and the global Automotive Transportation Practice. It was in 2008—with the global economy facing the worst financial crisis since the Great Depression—that Singh’s mega-trends were born. Committed to telling clients “something new, something they did not know,” he bravely told the world’s leading automotive company that it was not in the business of making cars but, instead, in the personal mobility business. His advice: Look seriously at car sharing, the personal mobility business model of the future.

“I was almost thrown out of the gates,” he has said.

A year later, in Detroit, Michigan—Motor City and birthplace of the modern automobile industry—he presented to Ford, GM and Chrysler about the future of mo-bility. He left Motor City with three, six-digit contracts. Today, many automakers have embraced car sharing, a business that Frost & Sullivan predicts will generate revenues of $3 billion by 2016.

Macro to micro: identifying implications

Under Singh’s leadership, Frost & Sullivan’s Visionary Research Group in 2009–2010 identified a handful of key global megatrends cutting across multiple industries, businesses, diverse careers and individuals. The megatrends are urbanization; smart is the new green; social trends; connectiv-

ity and convergence; bricks and clicks; innovating to zero; new business models (value for many); beyond BRIC (the new game changers); future infrastructure development; health, wellness and well being; future of mobility; and future of industry.

“Take urbanization, for example: 60 percent of the people in the world will live in urban areas in 2025 and subtrends—the devel-opment of mega regions, mega corridors and smart sustainable cities— will drive urbanization in the future,” he explained. “Most car companies today are devel-oping megacity cars and putting

megacity technologies into them; these technologies are very dif-ferent from the technologies in existing cars.”

Frost & Sullivan’s macro-to-micro approach allows business people to deep dive into the megatrends and come up with opportunities and growth strategies.

“What do these megatrends and subtrends mean for your busi-ness, your products, your cus-tomers?” Singh said. “What new technologies can you offer to augment your products? What are the unmet needs of your current customers?”

Innovating to zero: the factory of the future

Though manufacturers can expect to be impacted by all of the mega-trends, the “innovating to zero” trend describes a future enabled by the convergence of manufac-turing and information technol-ogy: zero defects, errors, waste, latency and turnaround time. Singh believes the factory floor in 2020 “will have made an evolu-tionary leap,” and he cites Honda, ABB and Mitsubishi as examples of manufacturers that have paved the way to new forms of modern manufacturing. The factory of the future is a vision of efficiency.

“It is intelligent, super-fast, IT-inclined and devoid of defects,” said Singh, adding that machines building machines will advance factory productivity and, while requiring less manpower, allow manufacturers to assign their hu-man resources to tasks for which humans are essential.

What does the future beyond 2025 hold? Singh is betting on a world that is increasingly smarter, fast-er, and connected as convergence of trends and industries continues at a blazing pace. An updated ver-sion of his Mega Trends: Implica-tions for Our Future Lives will be published next year.

« [The factory of the future] is intelligent, super-fast, IT-inclined and devoid of defects. »Sarwant Singh, futurist, author, and senior partner, Frost & Sullivan

Dear readers,

Welcome to the eighth edition of Results Today ! Our customer publication is all about you. You will discover the wide range of Milling, EDM, Laser, Spindle, Automation, Tooling, and Customer Services solutions we deliver to accelerate your success. Plus, you will get expert insights about the megatrends that are shaping our world and get a glimpse into the manufacturing environment of the future.

In these pages, you will read some of our successful customers’ stories in Market Regions Americas, Europe and Asia and learn why they partner with us to resolve their unique manufacturing challenges. We hope you will be just as inspired by their successes as we are proud to be part of those successes.

Wherever you are in the world, GF Machining Solutions is close to you and your concerns. Whatever your manufacturing segment and specialty, we have the expertise to help you seize new opportunities and outpace your competitors. In today’s increasingly complex global manufacturing environment, one thing remains simple: We put you first.

Pascal Boillat,President, GF Machining Solutions

EDITORIAL

GF Machining Solutions Results Today 082 Expert insights

“The factory of the future will have only two employees: a man and a dog. The man will be there to feed the dog. The dog will be there to keep the man from touching the equipment.”

When American organizational consultant Warren G. Bennis made that often-quoted prediction about the factory of the future, it was likely done tongue in cheek. But GF Machining Solutions’ Glynn Fletcher, Head of Market Region Americas,says it has proven insightful.

“Factory Automation solves two problems: Labor costs are increas-ing worldwide, and the skilled labor needed to apply traditional manufacturing techniques is hard to find,” said Fletcher. “We have the products, experience and expertise to help our customers move be-yond these challenges.”

Driving customers’ success with Automation

Fletcher said GF Machining Solu-tions’ collaboration with its own Automation unit, System 3R, is key to driving customers’ success with factory Automation.

“For example, we helped Pratt & Whitney Canada develop automat-ed electrical discharge machining (EDM) of turbine disks, and we sup-ported Toyota Racing Development in implementing automated race-car engine component Milling,” Fletcher said. “For a Brazilian door lock manufacturer, we helped com-bine Milling and EDM in a stamp-ing tool manufacturing facility.”

Those successes demonstrate GF Machining Solutions’ keen focus on helping customers prepare today for a manufacturing future that will be highly digitized and automated.

“We are already enabling the manufacturing environment of the future, where decisions can be made remotely and automatically so that processes can be improved in real time,” he said.

In the US, Fletcher said, there is a trend in manufacturing toward MTConnect, an open architecture, royalty-free protocol linking mul-tiple shop floor technologies and equipment in pursuit of seamless manufacturing and heightened productivity. The plug-and-play protocol allows a shop’s machine

performance to be automatically gathered and analyzed in real time.

“Government and larger aero-space and automotive companies are insisting on the MTConnect feature because it allows them to use data to make decisions intel-ligently, quickly and in real time,” Fletcher explained.

eTracking allows essential traceability

A good example of GF Machining Solutions’ pioneering, future-oriented technologies is eTrack-ing, linked to MTConnect, which provides a level of traceability essential in risk-averse manufac-turing sectors like aerospace

and medtech. With eTracking, the complete machining process becomes transparent, from part preparation to monitoring ma-chining parameters in real time to post-machining reporting.

“Pratt & Whitney is already using our eTracking technology on their GF Machining Solutions CUT 200 Dedicated wire EDM machines,” Fletcher said. “Our eTracking monitors their machines in real time, maintains their processes within predefined parameters, and ensures a perfect end product.”

That technology leadership is proof that GF Machining Solutions is uniquely positioned to provide the products, experience and

expertise to help our customers move beyond the challenges of increasing labor costs and short-ages of skilled labor.”

Paving the way to the futureGF Machining Solutions, with its own System 3R Automation solutions, is uniquely positioned with the products, experience and expertise to put you on the path to the factory of the future, today.

Glynn Fletcher,

Head of Market Region Americas

« Our eTracking monitors their machines in real time, maintains their processes within predefined parameters, and ensures a perfect end product. »Glynn Fletcher, Head of Market Region Americas

Market Region Americas, GF Machining Solutions

GF Machining Solutions Results Today 08 3

Tuck, president of AMI, bought the business with two of his brothers—Clint and Court—and a nephew, Joe Chughtai, in 1998. The broth-ers were all working at the Rocky Flats nuclear plant near Denver; with the plant’s impending decom-missioning, the brothers put their heads together to come up with a plan for their futures.

“We knew that in five years we would be out of jobs, so the three of us met at my house, brought our ideas, and—based on our backgrounds and knowledge—brainstormed,” Tuck explained. “None of us were machinists, but a brother and a nephew were working at a machine shop, we had a sheet metal worker, and an-other brother and I were in nuclear waste management.”

Meeting the market’s needs

Tuck, his brothers and nephew identified an unmet need.

“Longmont and Colorado were growing with the influx of technolo-gy businesses related to aerospace and there was room for a local ma-chining shop with a focus on high-est quality,” he explained. As luck would have it, a local businessman was selling his machine shop.

“We saw the growth potential. For example, Longmont has one of the biggest hard drive manufacturers in the US,” said Tuck who, with his brothers and nephew, bought that small machine shop and brought to it the same high level of quality and safety that they had practiced in the nuclear industry. Five years ago, AMI expanded its campus by add-ing a 12,000-square-foot building.

Today, AMI is a prototyping and production partner to manufactur-ers in aerospace, optics, energy, and electronic components.

Putting quality first

“We knew from the start that customers would appreciate our focus on providing them with high quality products. For example, we are ISO 9001:2008 certified for quality process management,” he said. The certifications are im-portant, he said, but AMI’s people and its partnerships are at the heart of the company’s success. He described GF Machining So-lutions’ attentiveness when AMI decided, just before Christmas 2006, to purchase its first five-axis Milling machine.

“A customer asked us whether we could make inducers and tur-bines, so we immediately began

Fulfilling a visionof incomparable quality

The Mikron HSM 400U’s integrated pallet system with fixtures for machining various

jobs that are set up concurrently

AMI’s Court Tuck (Production Manager),

Cleve Tuck (President), and Joe Chughtai

(Vice President)

If you ask Cleve Tuck what makes his business—Advanced Machining, Inc. (AMI) in Longmont, Colo., US—so successful, he’s quick to mention quality process management. And he’s just as quick to credit AMI’s highly skilled machinists and an eight-year relationship with GF Machining Solutions.

Advanced Machining, Inc.

GF Machining Solutions Results Today 084 Americas

Ramon Mosqueda enters tool data and validates a program that he has written.

Machinist Valentin Garcia (left) and AMI Vice President Joe Chughtai work on a

complicated setup for an aerospace part.

calling machine tool manufac-turers. We called GF Machining Solutions on Monday, and the next day, a regional vice president was here to talk with us,” Tuck recalled. “Just after he arrived, it started snowing and by the time he left, there was a foot of snow on the ground and Denver International Airport had closed. We literally got three feet of snow that day, but that didn’t deter GF Machining Solutions.”

That’s how AMI became the first business in a six-state area to own a Mikron five-axis Milling cen-ter—and the business has never looked back.

“A great thing about the Mikron HSM 600U is that it’s fully acces-sorized with touch probes and a pallet system, so there’s the advantage of one-stop shopping with GF Machining Solutions. A lot of competitors are upselling

accessories,” he explained. “Within the first month after installation, the business we did with that Mikron machine made the machine payment, the building payment, and the ma-chinist’s wage.”

On technology’s cutting edge

Tuck said GF Machining Solutions’ products are supported by friendly,

expert staff who help resolve ma-chine issues before they become problems. Those advantages spell success for AMI’s customers.

“Some prospective customers see all of our Mikron machines, and say, ‘I can’t afford to have my work done on that.’ I tell them, ‘You can’t afford not to,’” Tuck said. “Thanks to GF Machining Solutions, our equipment is al-ways up and running, and we have

the latest, greatest equipment and capabilities.”

“Our vision is to stay on the cut-ting edge and to continue working with GF Machining Solutions,” he added.

www.advancedmachining.biz

Advanced Machining, Inc.

1234 Sherman Dr.

Longmont, CO 80501

USA

Phone: +303-485-5256

Fax: +303-485-5257

Contact

Joe Chughtai, Vice President

[email protected]

Cleve Tuck, President

[email protected]

GF Machining Solutions machines

1 Mikron HEM 500U

1 Mikron HSM 600U

1 Mikron HSM 400U

1 Mikron VCE 800 Pro-X

1 AgieCharmilles CUT 20 P

AMI machinist Scott Miller validates a program he wrote and enters tool data for the job.

This nine-pound optical bench for the Geostationary

Operational Environmental Satellite (GOES) system

started as a 100-pound block of aluminum.

Inducer, made of 316 stainless steel,

for the oil and gas industry

Aluminum optical mount

for redirecting laser light

Aluminum aircraft structural component

for the aerospace industry

« Some prospective customers see all of our Mikron machines, and say, ‘I can’t afford to have my work done on that.’ I tell them, ‘You can’t afford not to.’ »Cleve Tuck, President, Advanced Machining, Inc.


Initiated in 2010 within the Eu-ropean Commission’s European Economic Recovery Plan, the FoFdation consortium is a public-private partnership researching the development and innovation of new, enabling technologies for the EU manufacturing sector. Consortium members are Airbus, Artis GmbH, CADCAMation, Cen-tro Ricerche Fiat, Delcam, École Centrale de Nantes, Swiss Fed-eral Institutes of Technology in Lausanne and Zurich, Fidia SpA, GF Machining Solutions, IK4-Tekniker, MECADTRON GmbH,

Paragon S.A., Pohang University of Science and Technology, Siemens, and the University of Patras.

Those heavy hitters are collabo-rating on solutions to the major challenges that manufacturers face today: managing global com-petition with multiple supply chain partners, achieving continuous, high-quality operations under productivity and environmental constrains, and tracking and man-aging information in order to meet new requirements like traceabil-ity, security and sustainability.

The FoFdation also addresses the need for a universal manufactur-ing information system based on a data exchange standard that can seamlessly share data in a com-mon format.

Knowledge-based manufacturing

“Factories must continue to meet the highest standards of lean, agile, flexible and sustainable pro-duction,” said Van Khai Nguyen, founder of CADCAMation. The Onex, Switzerland-based firm was

chosen as technical coordinator of the FoFdation’s work packages to ensure their best integration toward a coherent manufacturing solution. CADCAMAtion, founded in 1993, is a CAD/CAM thought leader and a key partner in four large manufacturing integrated projects (IP) funded by the Euro-pean Commission.

“Today’s manufacturing environ-ment is very influenced by software and will be dramatically impacted by information technology (IT),” he said. “The factories of the future

will be knowledge based, human welfare oriented, sustainable, and globally competitive.”

Nguyen does not need a crystal ball to foresee the factory of the future. His insights are informed by nearly 40 years of consulting for global companies, manufacturing research and his firm’s product lifecycle management (PLM) and building information modeling (BIM) business.

“Knowledge based means smart automation will be implemented

Shaping the sustainablefactory of the futureThe factory of the future will be smart, connected, automated and green, and the nine-nation Foundation for the Sustainable Factory of the Future (FoFdation) is at the forefront of research to make it happen.

FoFdation

GF Machining Solutions Results Today 086 Expert insights

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« Smart automation will be implemented throughout manufacturing sites and processes. This will improve surface quality, precision, productivity, and predictability. »Van Khai Nguyen, CADCAMation and FoFdation

throughout manufacturing sites and processes. This will im-prove surface quality, precision, productivity, and predictability,” Nguyen explained. “The key en-ablers are IT and the Internet of

Things. These will provide the capability to monitor machines, like machine tools, more soft-ware capabilities to deal with live data, and then close the optimi-zation loop.”

Capturing data, connecting the dots

Today, he said, manufacturers can capture a lot of machine tool data once lost on the shop floor.

New challenges come with that capability.

“The difficulty is to turn that cap-tured data into comprehensive and valuable data to improve the machines’ performance and use it for predictive analysis,” he said. “Thanks to IT, manufacturers will be aware of their machines’ daily execution, understand it, and use it to predict and optimize their processes in order to better meet their customers’ expectations.”

To make that happen, manufactur-ers need solutions, Nguyen said.

“Today, manufacturers use dif-ferent manufacturing processes, but these are not all integrated. A manufacturer may know one step in the process, but have no idea of the global solution process,” he explained. “Integration makes all processes interoperable and compatible and that has high value in the global manufactur-ing process while meeting today’s practical needs.”

Traceability is an example of how integration of machine tools into overall processes can help manufacturers’ meet their cus-tomers’ needs.

“Manufacturers need to know which machine is doing what. When accidents occur, they need to understand where the cause was a mismatch of processes or a pro-cess defect,” he said. “Traceability will give the machine operator ac-cess to all of the data and he or she can then stand back and see how all of the dots are connected.”

Human role will change

Three decades ago, machine tools were 30 to 40 percent driven by mechanical components and 30 to 40 percent by electronics. Today, machine tools are 30 to 40 percent driven by IT.

“That changes the paradigm and even the user’s role. Electronics and embedded IT are completely integrated,” said Nguyen. “In the early 90s, when we talked about the numerical control (NC) being based on a personal computer, no one be-lieved us. Now it’s the reality.”

Even with the emergence of IT’s key role in manufacturing, hu-mans will have a valuable role in the factory of the future, he said.

“One cannot afford to run a mold and die shop without a CAD/CAM system and NC machines. But artisanal mold, die and parts making skills will remain impor-tant by adding value to modern tools like CAD, 3D cameras and 3D printing,” he said. “The manu-facturing workforce of the future will be technology fluent but they need to understand how to use these skills to make real, physi-cal things. Manufacturers today can begin building the foundation for their factories of the future by transferring valuable skills to the next generation of tool, mold and precision parts makers.”

For more information, please visit: www.fofdation-project.eu.

FoFdation members

EuropeAirbus (1)Artis GmbH (2)CADCAMation (3)Centro Ricerche FIAT (4)Delcam (5)ECN (6)EPFL (7)

ETH-Zurich (8)Fidia SpA (9)GF Machining Solutions (10)IK4-Tekniker (11)Mecadtron (12)PARAGON (13)SIEMENS (14)University of Patras (15)

Asia (Korea)POSTECH

« The factories of the future will be knowledge based, human welfare oriented, sustainable, and globally competitive. »Van Khai Nguyen, CADCAMation and FoFdation


« The innovative use of System 3R CellManager to control the EDM has enabled more time for erosion of the seal slots. »Frank Nash, Project Engineer, Lufthansa Technik Turbine Shannon

Speed, reliability, expertise keep customers coming backIt’s no accident that Ireland’s Lufthansa Technik Turbine Shannon (LTTS) is a model of efficiency, speed and consistent process optimization. When LTTS decided to semi-automate its high-pressure turbine (HPT) seal slot repair operation, it turned to GF Machining Solutions for a bespoke solution.

Lufthansa Technik Turbine Shannon

GF Machining Solutions Results Today 088 Europe

www.ltts.ie

Lufthansa Technik Turbine Shannon

World Aviation Park, Shannon, County Clare, Ireland

Phone: +353 61 360512

Fax: +353 61 360513


20 die-sinking EDM

1 wire-cutting EDM

2 high-performance Milling

4 System 3R Automation systems

GF Machining Solutions helped Lufthansa Technik Turbine Shannon semi-automate its high-pressure turbine (HPT)

seal slot repair operation.

“Absolute quality and consis-tency are expected in the repair of shrouds and vanes for high- and low-pressure turbines,” said LTTS Project Engineer Frank Nash. “Similar to the medical industry, there is a gold standard for what must be achieved. Our job is to have the equipment and processes in place to meet the original equip-ment manufacturer (OEM) and regulatory (i.e., Federal Aviation Administration) requirements”.

In addition, the company’s cus-tomer engine shops are getting faster and more efficient at over-hauling engines, so the pressure on LTTS to more quickly return repaired components to those customers is increasing.

Lean, efficient and focused on TAT

“The focus of our production teams and customers is on turn-around time (TAT). As we are a repair service, we have to provide a very lean and efficient repair process to return those repaired components to the customer en-gine shops within the contracted TAT,” Nash explained. At the same time, reliability and expertise are paramount, as LTTS customers expect a premium level of repair, an assurance they have with the LTTS name on the release-to-service documentation.

GF Machining Solutions supported LTTS with a die-sinking EDM solu-tion that simplifies the repair of HPT shrouds—the seals between the tips of rotating HPT blades. During engine service, those blades wear into the shroud’s gas flow path rub coat. The LTTS repair process entails machining off the old rub coat. The rub coat is replaced with a sintered thermally densified coat-ing (TDC) by vacuum brazing.

LTTS then uses GF Machining Solutions Milling to machine the shroud back to nominal dimen-sions and die-sinking EDM to re-establish the seal slots.

“Die-sinking EDM is the OEM-pre-ferred method for re-establishing seal slots. Previously, we used ‘old but reliable’ Agie Mondo die sinkers to re-establish the seal slots. This process was not au-tomated and it relied heavily on the machine operator’s expertise to line up the seal slot position,” said Nash.

To help LTTS improve the desired time between units of production output synchronized to customer demand, a key in lean manufac-turing, GF Machining Solutions’ UK application team configured cells of FO 350 SP EDM machines with System 3R WorkShop Man-ager software.

“Basically, I configured the System 3R software to think that the Rotary Tool Changer (RTC) is a ro-bot so that the software takes full control of the RTC for auto scan-ning and inputting the position of the part into the program,” said GF Machining Solutions Applica-tion Engineer Jim Lewis. “When the machine is in operation, the CellManager screen even shows the part loaded in the machine.”

That programming feat took six months to accomplish. More than a year later, the bespoke solution continues to prove its value to LTTS.

“The innovative use of System 3R CellManager to control the EDM has enabled more time for ero-sion of the seal slots”. Nash said. “Chip identification of shroud fixtures and electrodes and er-ror proofing the shroud fixtures has eliminated potential human errors. The system recognizes which shrouds are available and which electrodes are available. If there is no system match, the System 3R CellManager cannot create a job.”

Nash added that the initial erosion parameters developed for re-es-tablishing the seal slots has since been further refined to optimize electrode use.

“Since the successful introduction of GF Machining Solutions EDM and Mikron Milling machines we have actively considered Automa-tion as an option for other product repairs,” he said.

« We have to provide a very lean and efficient repair process to return those repaired components to the customer engine shops within the contracted TAT. »Frank Nash, Project Engineer, Lufthansa Technik Turbine Shannon

High-pressure turbine (HPT) shrouds

for a CFM56-7B engine


Suzhou, China’s culturally historic Mudu Town is a testament to the rich textures of both natural and human creation: the clear waters of the Xiangxi and Xujiang rivers and crisscrossing water lanes to the surrounding hills, and stone carving, calligraphy and garden centers. Against that backdrop of nature, art and history, TZZ is using state-of-the-art Laser technology to reproduce an infinite variety of textures derived from nature and imagination.

Founded by Jian Weiping, TZZ is a professional mold etching technology company with dozens of years experience in produc-ing decorative patterns across a broad range of market segments. TZZ brings its Laser texturing expertise to automotive interiors, steering wheel covers, engine covers, sliding bearings, con-necting rods, piston pins and tire molds. In information and com-munications technology (ICT) and electronics, TZZ’s know-how can

be seen on mobile phone covers, TV shells, notebook computers, loudspeakers and camera cases, for example. The company’s tex-turing prowess also can be seen on jewelry and watches, and con-sumer goods like sports equip-ment, cosmetics cases and toys.

“We invest in the world’s most ad-vanced Laser texturing processing equipment from Switzerland: GF Machining Solutions’ LASER products,” Weiping explained.

“With our professional designers and this globally recognized Laser texturing technology, we can ef-ficiently texture, engrave, mark or apply fine structure to any surface, concave or convex.”

Since TZZ’s initial purchase of a LASER 1000 5Ax in October 2012, the company has expanded its LASER fleet to a total of seven machines, including another LASER 1200 5Ax, two LASER 600 5Ax, and three LASER 1000 5Ax ma-

chines. Weiping said GF Machining Solutions’ Laser technology en-ables TZZ’s processing ability to lay the foundation for product de-signers’ ideas to be transformed into innovative products.

More accurate, delicate, high end

“Our processing ability allows us to go beyond the limitations of traditional texturing to be more accurate, delicate and high end,”

Bringing customers’ ideasto life with Laser texturingCloseness to customers, extreme precision, just-in-time delivery and an eager embrace of GF Machining Solutions’ leading edge Laser texturing technology drive success at Suzhou Tian Zhi Zun Mould Technology Co., Ltd. (TZZ).

« We invest in the world’s most advanced Laser texturing processing equipment from Switzerland: GF Machining Solutions’ LASER products, »Jian Weiping, General Manager, Tian Zhi Zun Mould Tech Co., Ltd.

TZZ

GF Machining Solutions Results Today 0810 Asia

he said. “We are able to truly achieve our customers’ visions.”

Thanks to the fully digitized textur-ing process, TZZ’s customers can provide their 2D and 3D textures in a wide range of digital formats. The technology makes it easy to reproduce those detailed textures to five microns of precision on mold surfaces over an infinite number of iterations at the same high level of quality.

“Chemical etching and computer numerical control (CNC) machining cannot meet customers’ require-ments for hyper-fine patterns of 3D curved surfaces, and our LASER machines fill this gap,” Weiping said. “Any design our customers need can be processed efficiently, cleanly and at highest quality.”

High-quality products, high-tech support

But Weiping said the LASER prod-ucts are only part of the formula for success. He credits the appli-cation experts behind the technol-ogy for helping his staff get up and running with Laser texturing.

“When we began using our LASER machines to process textures, we were perhaps not familiar enough with this new technology and we had a problem of splice lines on textures. We could not solve it ourselves,” Weiping ex-plained. “GF Machining Solutions sent four people to help us. The team worked day and night with no sleep and solved our problem. They are the best team workers we have ever met!”

As a partner to global brands, including Lenovo, Logitech, Sam-sung, Huawei, Dell, Acer, Asus, Foxconn and Opple, TZZ is com-mitted to delivering the extremely precise textures customers de-mand, while staying close to them and ensuring just-in-time delivery. GF Machining Solutions’ Laser technology helps the company honor those commitments and live the TZZ motto: “Technology changes the future. Quality de-rives from expertise.”

www.tzz-laser.com www.tzzjg.com

Suzhou Tian Zhi Zun

Mould Tech Co., Ltd.

1st floor, Building A-2,

Jinqiao Auto Parts Industrial Park,

No.1258 South

Jinfeng Road, Mudu Town,

Wuzhong District, Suzhou,

China 215101.

Phone: +86-512-6651 3618

Fax: +86-512-6651 3628

Contact

Jian Weiping, General Manager

Xing Feng, Vice-General Manager

Email: [email protected]


2 AgieCharmilles LASER 1200 5Ax



TZZ’s expertise enables accurate, delicate, high-end texturing across a wide range of industries.

Laser texturing workshop at TZZ

TZZ’s specially designed “fingerprint texture” created with Laser texturing brings a

3D effect to 2D mold surfaces.

Leather texture samples

Electroplated geometrical texture samples

With GF Machining Solutions’ fully digitized texturing process,

TZZ’s designers see customers’ requirements onscreen.


Mikron HEM 500U Mikron HSM 200U LP Mikron HEM 700U Mikron HPM 600U Mikron HPM 800U

GF Machining Solutions puts the “high-efficiency” in high-efficiency machining with its newest HEM 500U/700U. The machine’s new options include a 20,000 rpm Step-Tec HPC190 Spindle; a simultane-ous, torque-driven rotary tilting table; and a highly competitive CT60 tool magazine with capacity for up to 60 tools.

The torque drive of the rotary tilting table extends your applica-tion horizons and lets you quickly

adapt to market changes. The new HPC190 motor Spindle is designed with an induction motor and an HSK-A63 interface, allowing you to fully leverage the Spindle’s strengths in tool and mold making and parts production.

Cutting oil preparation, precision machining

The latest version of the high-speed HSM 200U LP offers fea-tures that prepare you to use cut-

ting oil as a coolant and positions you for high-precision fields like mold-and-die production and in information and communications technology (ICT) and electronic components.

Machine preparation for working with cutting oil protects your cool-ing lubricant system’s plastics and seals. Features include a safety cabin for working with cutting oil, internal piping with a strainer for mist extraction, a soil protection

tray, a nozzle ring with six flush-ing nozzles, and a pressure relief damper with flame arrester.

Opening new application horizons

Siemens’ premium-class SINU-MERIK 840D sl control (CNC) is now available for the HPM 600U/800U. The drive-based, modular CNC opens the door to new applications, including air-craft engine parts, molds for auto-

motive and housings for printers, televisions and other electronics. Step-Tec’s 20,000 min-1 HPC 190 motor Spindle is now standard to the HPM 600U/800U. Furthermore, the available Machine and Spindle Protection (MSP) protects your ma-chine and spindle against crash.

Our latest-generation Milling solutions—the Mikron HEM 500U/700U, HSM 200U LP, and HPM 600U/800U—boast new features to boost your productivity and open new application horizons.

Milling solutions accelerate productivity and open new application horizons

The HPC190, part of Step-Tec’s new 6063 series, has a 190 mm diameter, and answers machine tool users’ concerns including high flexibility, installation length, light-weight construction, and energy efficiency, and boasts a package of options unique in the market.

A new standard in GF Machining Solutions’ Spindle portfolio

The new, state-of-the-art motor Spindle replaces sizes HM170, HVC212, and HVC230 used on Mikron high-performance ma-chining (HPM) centers and the Liechti go-Mill 350, closing the gap between the existing 150 mm and 240 mm sizes by one single Spindle dimension. Powered by an induction motor, and with an HSK-A63 interface, the strengths of the HPC190 can be fully exploited in

tool and mold making and stan-dard production applications.

Options such as an HSK-A80 in-terface, Spindle shaft interlock for turning applications, high-perfor-mance synchronous motor and three front bearings (instead of the standard two) make this Spindle ready for future GF Machining Solutions machine developments. Some of these developments are already available today on special request for Mikron HPM-line ma-chining centers, or are standard on the LiechtiTurbomill 800i/1400i.

Making strides in energy conservation

By appreciably reducing com-pressed air consumption (the most expensive form of energy in ma-chine tools) in comparison to other spindles, the new platform dem-

onstrates a clear understanding of the European Commission’s Ener-gy-using Products (EuP) Directive.

The area of active stator cooling is expanded toward the very front of the Spindle nose, based on the successful Opticool Spindle prin-ciple. The additional cooling of the front bearings right next to the tool interface has the effect of an addi-tional cooling barrier against heat transfer. The result is reduced thermal expansion of the Spindle nose and tool; this has a positive effect on the manufactured parts’ surface finish and precision.

GF Machining Solutions’ own Spindle manufacturer, Step-Tec AG, is marking an important milestone: the launch of its new, highly flexible HPC190 Spindle platform.

A new standard: HPC190 Spindle platform

Spindle platform HPC190:

High performance, high speed and lightweight design with additional options

GF Machining Solutions Results Today 0812 News, GF Machining Solutions

AgieCharmilles CUT 2000 S AgieCharmilles FORM 300

AgieCharmilles LASER 4000 5AX

AgieCharmilles CUT 3000 S AgieCharmilles FORM 200 with RTC AgieCharmilles FORM 20 iRTC

Integrated technologies engineered specifically to boost your productiv-ity are among the reasons the CUT 2000 S/3000 S, FORM 200/300/400, and FORM 20/30 are setting new standards for electrical discharge machining (EDM).

Thanks to their revolutionary gen-erator architecture, the high-end, wire-cutting CUT 2000 S/CUT 3000 S are becoming the machine tool industry’s benchmark for cutting speed and surface integrity. They are the fastest wire EDM solutions on the market, thanks to the new Intelligent Power Generator (IPG) with Direct Power Supply module.

They can reduce machining time by 30 percent and produce high quality Ra ≤ 0.05µm surface finishes.

The available Automatic Wire Changer (AWC) allows use of wires of different diameters and materi-als, and the IVU Advance optical-based measurement system al-lows comparison of the machined and theoretical (DXF) contours to achieve perfect results, thanks to program correction.

Forming the future

The new FORM 200/300/400 die-sinking EDM solutions are form-

ing the future with a wide range of technologies to help you more eas-ily execute complex applications.

The AC FORM human-machine interface (HMI) with wear parti-tioning puts process control at the touch of your finger, and its iGAP technology yields astonish-ing rib machining performance. The IPG generator performance ensures highest productivity. Moreover, the customized ma-chine configuration, including Rotary Tool Changer, C axis, and Automation, allows you to extend your capabilities.

Utmost capability, versatility

With its Integrated Rotary Tool Changer (iRTC), the FORM 20/FORM 30 die-sinking EDM ma-chines have productivity-enhanc-ing characteristics that make it a market favorite in terms of price/performance ratio.

The FORM 20/FORM 30 machines feature easy setup, the ergonomic and intuitive AC FORM HMI for a new level of logic, speed and safety, and built-in technology to eliminate electrode wear. At the heart of the FORM 20/FORM 30

is the high-end, IPG generator with embedded TECFORM expert system to enhance quality and save costs.

Developed in direct response to the automotive industry’s product design needs, the LASER 4000 5Ax has enormous (4 x 3 x 1.5 meter) capacity, making it an especially attractive solution for texturing large molds for bumpers, instru-ment panels, door panels, central consoles, airbag covers and front car lights.

It’s no wonder that leading auto-motive suppliers like J & F Krüth, Custom Etch, and Pel Plastic choose the LASER 4000 5Ax to texture oversize molds.

J. & F. Krüth in Soligen, Germany, today owns six Laser machines including two LASER 4000 5Ax and uses them during the design

phase for texture design and development, virtual parts for acceptance, and texture prototyp-ing. The machines are also used during design analysis and error testing. GF Machining Solutions’ Laser texturing technology allows the firm to apply textures directly onto molds and parts that cannot be textured using conventional methods. In fact, J. & F. Krüth’s main customers, including pre-mium German automakers, are using Laser textured interiors in their new car models.

Custom Etch in New Castle, Pa., US., already owned a LASER 1000 5Ax and a LASER 1200 5Ax, and bought a LASER 4000 5Ax a few months ago to texture over-size molds.

The LASER 4000 5Ax is also in use at Pel Plastic in Vimercate, Italy along with a LASER 1000 and LASER 1200. Pel Plastic is a refer-ence supplier for International car and motorcycle makers.

Just as it has seen impressive uptake as a fully digitized, environ-

mentally friendly texturing solution in the automotive industry, the Laser 4000 5Ax also appeals to producers of big consumer goods like refriger-ators, big-screen TVs, and chairs. Its large capacity makes it attrac-tive, as well, to makers of casting molds, forging tools, and aircraft and luxury yacht interiors.

GF Machining Solutions’ electrical discharge machining (EDM) technology positions you for the future with high precision, best productivity, and utmost versatility.

The new kid on the street just two years ago, GF Machining Solutions’ LASER 4000 5Ax Laser texturing machine today is the go-to texturing solution for automotive manufacturers and their suppliers worldwide.

Powering your precision, forming the future with EDM

LASER 4000 5Ax reachestipping point in automotive


The TRANSFORMER, a scalable Automation system based on standardized modules, allows you to begin with one or two machines and later add machines and mag-azine capacity. The solution can ultimately be extended to include up to 12 machines in a single cell.

High flexibility comes into play as well with the system’s con-figurability. A TRANSFORMER cell can link machines of the same make and type, or the cell can just as easily incorporate different machining technologies and ma-chines from various manufactur-ers. Open architecture—one of the core characteristics of the sustain-able factory of the future—is one of the TRANSFORMER’s clear advan-tages. You choose the machine or machines that best fit your specific manufacturing requirements, and we’ll tailor the TRANSFORMER accordingly, keeping your flexibil-ity and productivity in sharp and constant focus.

Tooling solutions for customer-specific applications

The TRANSFORMER Automation system handles your workpieces and/or electrodes that are mount-ed on pallets (i.e., based on a refer-ence system, commonly known as tooling). System 3R, GF Machining Solutions’ own Automation unit, also offers a variety of tooling systems. That means you are as-sured of the perfect solutions to palletize workpieces from small to

large, or by using chuck adapters, a combination of different systems in the same Automation cell. Plus, the TRANSFORMER can handle different tooling systems, so even if you already have a tooling sys-tem in place in your workshop, the TRANSFORMER can ramp up your productivity. Tooling solutions for customer-specific applications are easily implemented.

To further accelerate the TRANS-FORMER’s flexibility, additional in-process accessories can be

integrated into a cell. Whatever your needs, the TRANSFORMER provides a solution. A multiple loading station can be used with-out stopping production, and a draining station is available for post-machining emptying of work-piece cavities. A washing machine can be incorporated to clean your workpieces, and a coordinate measuring machining (CMM) can be integrated for pre-setting and/or parts inspection.

Easy-to-use software for consistency assurance

The TRANSFORMER’s user-friendly cell management software guar-antees the consistency essential to your processes. All production data is entered in a structured manner or imported through a data exchange interface for ma-jor enterprise resource planning (ERP) systems. The System 3R CellManager handles everything in the cell, from automatically loading the jobs into the machines

to recording the machining time of each job. At the heart of the sys-tem is an efficient database that uses chip identification of the pal-lets to ensure that the correct data is used for the correct parts.

You can count on the System 3R TRANSFORMER to stay ahead of your competition and transform your business from conventional tool making to modern tool production.

Extreme flexibility is engineered into GF Machining Solutions’ new System 3R TRANSFORMER. This Automation system is designed to grow with your business needs and—ultimately—ensure a greater return on your capital equipment investment.

System 3R TRANSFORMER grows with your needs

GF Machining Solutions Results Today 0814 News, GF Machining Solutions

System 3R’s Matrix system ensures fast setup, reduces machine idle time, and optimizes mounting stability. These advantages mean increased productivity and competitiveness for your manufacturing operation.

New System 3R pallet systemgreatly increases stability

The AC CUT VS package for the CUT 20/30 combines GF Machin-ing Solutions technology, certified consumables and the machine to help customers take advantage of machining speed increases and save costs.

To help CUT 20/30 owners experi-ence the specific benefits of the solution, Customer Services offers a free package that includes a test spool of AC CUT VS 900 certified wire and a technology dedicated to your CUT 20/30 wire-cutting EDM machine. The latest generation coated brass wire is proven to yield greater productivity and reduce part costs.

Certified wire: Fast track to success

The AC CUT VS 900 certified wire, used with the AC CUT VS technology for the CUT 20/30, increases machining speed and parts production up to 25 percent compared to standard brass wire. At the same time, the solution re-duces part costs up to 30 percent in comparison to standard brass wire. That means you can produce more parts per year.

Moreover, the wire answers the demands of most mold, punch and die and general mechanical applications requiring precision

and productivity even under poor flushing conditions.

The AC CUT VS package includes a USB key containing the tech-nology developed to support the complete solution. You simply connect the USB key to your ma-chine, save the technologies file in your working files, then select the “your technology” file for the part height you want to cut. You’re quickly on the road to machining your part and experiencing the im-proved productivity afforded by the AC CUT VS solution.

The AC CUT VS package proves that GF Machining Solutions un-

derstands that production costs, machine productivity and agility in reducing delivery times are key success factors in today’s highly competitive manufactur-ing environment.

You can order the AC CUT VS package through your local con-tact person, or request it via: ecat.gfms.com.

Rather than trying to save seconds in the machining of components, it is far easier and smarter to reduce machine idle time. However, this requires access to an interface that ensures fast setups.

System 3R’s Matrix system is just such an interface. Tool up beside the machine while it is running and then, in a matter of seconds, set up in the temporarily idle ma-chine. This is an important advan-tage in long production series and absolutely critical in short series and one-offs.

The system’s design has been optimized for stock removal op-erations. Furthermore, it is ideal when machining forces are high.

Engineered for optimal stability

Matrix’s main feature is the hole all the way through the drawbar. This allows much of any high or long workpiece to be “sunk” into the chuck. The distance between the connection’s reference sur-faces and the part of the work-piece to be machined is thereby reduced. This optimizes the sta-bility of the mounting.

Matrix offers five different pallet sizes (Ø110, Ø142, Ø185, Ø220 and Ø260 mm) and locking forces of up to 24,000 N.

Matrix is extremely flexible and, thanks to its fast setup times, stable mounting and precise po-sitioning, it rewards you with in-creased productivity.

Matrix is yet another addition to System 3R’s comprehensive pro-gram of quality tools and pallet

and Automation systems that generate considerable added val-ue for manufacturers all around the world and across a wide range of manufacturing segments.

A technology unit of GF Machining Solutions, System 3R is the world’s leading supplier for productivity-enhancing tools and methods for the manufacturing industry. For further details, please e-mail us at [email protected].

A complete solution dedicated to helping you get the most out of your CUT 20/30 machines has been developed by GF Machining Solutions Customer Services in collaboration with Research and Development.

AC CUT VS for CUT 20/30:Experience improved productivity

Imprint

Publisher GF Machining Solutions Management SA, Geneva, SwitzerlandEditor in chief: Rolph LucassenManaging editor: Melody M. Corrieri

© 2014 – GF Machining Solutions Management SA. Illustrations and specifications do not necessarily apply to products and services offered in each local market. Technical specifications are subject to change without prior notice. All other trademarks are the property of their respective owners.

Editorial board Rolph Lucassen, Elke P. Magnin, Melody M. CorrieriLayout: David Hirsbrunner

PhotographyMarinus van Breugel, Christina Kiffney Photography, Jiefeng Fan, Lufthansa Technik Turbine Shannon, Suzhou Tian Zhi Zun Mould Technology Co., Ltd., Frost & Sullivan

Translation (DE) Karsten U. Timmer

Print Nastro & Nastro SrlCirculation : 10,000 copies

The Matrix system aids

precision production in

the medical industry.

Here, the workpiece

(a knee joint) is mounted

onto the Matrix pallet.

Matrix chucks Pallet/holder, drawbar, and chuck

Here, the workpiece

(a hip joint) is mounted

into the Matrix pallet for

stable fixation.

AC CUT VS 900 AC CUT Brass

Speed

Precision

Surface finish

Machining complexity

Wire cost


GF Machining Solutions

All about you Empowering you is our commitment. We serve you cutting-edge solutions, created to provide outstanding long-term accuracy, and perfectly adapted to your needs—wherever you are.

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