MCG tooling 2015

Company presentation

2015

MCG site

Manuel Conceição Graça, Lda.

Family Owned Private Company

Located in Carregado, PORTUGAL

Over 60 years experience

Steel parts and assemblies, tool an die development and manufacturing

MCG plants

Total area= 96.000 m²Covered = 34.000 m²

Metal1 – Stamping, welding, assembling, surface treatment

Metal 2 – Tool shop, machining

Metal 3 – Laser, bending, welding

Metal 4 – Stamping

Metal 5 – Assembling

Employees MCG

Business Areas

Prototyping and rapid manufacturingDesign, production and assembly of metal assemblies Metal assemblies

and components for the automotive industry

Development and manufacturing of stamping tools & dies for the automotive industry

R&D projects

Turnover

Destinations / Shipments

2014

• 46.000.000 shipped parts

• 30.000 shipments

• 130 clients/destinations all business units

MCG @ GM

General Motors' Supplier

Quality Excellence Award

2013/2014

Opel’s Live Auditorium

Rüsselsheim, Germany

September 30, 2014.

MCG ToolingBusiness Unit

MCG tooling supplies automotive industry tier 1 suppliers and OEMs that manage large scale outsourcing programs for stamping tools (progressive and automatic transfer tools) in order to achieve simple and competitive solutions for complex situations, succeeding

in their industrialization programs.Unlike low-cost, unqualified companies and with little or none

experience in analyzing and implementing serial production processes, MCG provides qualified and competitive personnel,

focused on optimizing customers total cost.With work based on its solid experience in stamped parts production, always under the highest automotive industry

standards (ISO9001, ISO/TS16949), MCG manages to get the best integrated solution (one stop shop), consisting in a reliable and

flexible partner as shown by several implemented programs with costumers like GM/Opel and VW (Body-in-White), Faurecia (Seat

Structures), CBI (DrumBreaks).

MCG Tooling Value Proposition

what we offer

MCG Tooling

our focus

MCG is a manufacturer for Stamping Tooling such as:

Progressive Stamping Tools up to 4500mm

Automatic Transfer Stamping Tools up to 6500mm

Tandem Transfer Stamping Tools

Hybrid (Progressive + Automatic Transfer) Stamping Tools

Checking Fixtures

Stamping tools with special features (in-die ops and automation)

MCG is equipped for Big Volume Tooling

MCG is able to validate in real conditions serial life conditions in most of the cases

MCG Tooling

project management driven

MCG is working on a project management logic

Periodic full detail reporting, conf calls

Centralized communication channels by the PM, or

Decentralized communication peer to peer according to clients needs

English as our official language

MCG Tooling Partners


our partners for materials and heat treatments

Material and Heat Treatment from Thyssen:

Thyssen Steel Center at 2Km from MCG. Total flexibility.

The heat treatments are made by Thyssen in Marinha Grande

Material and Heat Treatment from Bohler:

Representative from Bohler in Portugal called UniversalAfir.

Material and Heat Treatment from Uddeholm:

Representative from Uddeholm in Portugal called Ramada.


our partners for standard components

Standard Components from Fibro:

Representative from Fibro in Portugal called Ferrometal

Also direct contact to Fibro Germany

Volker Rupprecht – International Sales

Standard Components from Voestalpine:

Direct Contact to Germany

Frank Amede, Andreas Gayer – International Sales

Standard Components from Stack Normalien:

Direct Contact to Germany

Bernhard Reichl – International Sales


our partners for coatings

Coatings from Oerlikon Balzers:

Experience with Balinit Lumena and Futura Nano

Direct supplying in Portugal, Leiria

Coatings from Prirev:

Portuguese Supplier

Experience with TiN, CrN, TiCN, ZrN, AITiN and WS2 solid lub

Coatings TEandM:

Portuguese Supplier


our academic R&D partner

Since its creation in 1911, InstitutoSuperior Técnico is the largest and most reputed school of Engineering, Science and Technology and Architecture in Portugal.

It has three camps, all located in the Greater Lisbon area (Alameda in Lisbon, Taguspark in Oeiras and Tecnológico e Nuclear Campus in Loures),

http://tecnico.ulisboa.pt/en/

http://upload.wikimedia.org/wikipedia/commons/5/55/Instituto_Superior_T%C3%A9cnico_8894.jpg

http://upload.wikimedia.org/wikipedia/commons/5/55/Instituto_Superior_T%C3%A9cnico_8894.jpg


our academic R&D partner

MCG works in cooperation with IST and PhD Paulo Martins on several projects that led to several paper publications and magazine covers


MCG sponsors manufacturing labs at IST (NOF)

Tooling RelatedSoftware and

Personnel@ MCG

CAD/CAE/CAM UNIGRAPHICS-NX SIEMENS

CAD/CAE CATIA DASSAULT SYSTEMES

CAM TEBIS

CAD SOLIDEDGE SIEMENS

CAE AUTOFORM

CAQ PC-DMIS AND GEOMAGIC

LIQUID PLANNER

MCG Tooling

engineering and management software list

7 Tooling Engineers (up to 40 years in experience)

10 Assembly/Try-Out workers (up to 30 years in experience)

2 Project Managers + 2 Progress Monitors

5 Process Engineers/Machining Programmers

On tool shop we are able to work 3 shifts

MCG Tooling

engineering and management personnel list

Tooling RelatedNew Investments

@ MCG

MCG Tooling new investments

catia


autoform


tebis


precision universal tester

Shimadzu | AG-Xplus Series 50 KN


laser scanning arm

Quality reporting

Reverse Engineering

Tooling and Part checking

2,7m spherical working volume

Related softwares:

Cam 2

Polyworks Inspector

Geomagic

faro edge 2.7m


5 axis machining center

DMG DMU 60 eVo linear

New Plant Metal 4 | New 3.300 ton press

Machineryfor Big Tooling

MCG Tooling

specific machinery for big tooling

Milling Machine 4500*2600*1000

MCG Tooling


Laser Machine 4000*2000

MCG Tooling


Small to medium machines for smaller components

MCG Tooling


Transfer Mechanical Press 800Ton (4500*2100)

MCG Tooling


Progressive Mechanical Press 800Ton (4500*2100)

MCG Tooling


Mechanical Press 3300Ton (1500*2500 + 6400*2500)

Tooling RelatedR&D activities and projects

@ MCG

R&D Projects

TUBE FORMING

R&D Projects

Multi parts assembling and mechanical coupling systems

Challenge:To replace the welding

connections by others with the same mechanical characteristics

Conventional approachConventional welding

MCG Approach:Replacing conventional welding

by mechanical connection based on tube forming operations

SPIF

R&D Projects

SINGLE POINT INCREMENTAL FORMINGSmall batch production, prototypes and more diversity of productsPart production directly from the CAD design using CNC CNC machine with no need for stamping tools.

Challenge:Produce functional prototypes without

tooling investment.

Conventional approachProduction of conventional tools for

prototypes production.

MCG Approach:Depending on part geometry we have

the two options:SPIF and laser-cutSPIF, laser cutting and conventional stamping tools.

MouldCork

R&D Projects

Challenge:Optimize thermal, acoustic and

damping characteristics on structural metal components

Conventional approachUse of insulators and damping

materials applied after assembling operations

MCG Approach:Optimize a composite cork base

polymer for conventional stamping process, taking advantage of three characteristics associated with cork:

Low weightHigh acoustic and damping performanceHigh thermal performance

LaTch 1 | Lightweight Thermoplastic Composites

R&D Projects

ObjectiveDevelop and integrate new composite materials based on unidirectional thermoplastic and its processing techs.

ImplementationBuild a prototype of a structural automotive component taht is currently made out of steel

HowTest new materials and processes to try and reduce weight, matching the original strutural performance

CalendarStart - Jan 2014; End – Jul 2015

LaTch 2

R&D Projects

Project aiming to develop, build and test a hybrid automotive seat demonstrator (recliner and back/bottom sections only)The carbon reinforced polyamide part and additional metal inserts are then join together in a overmouldingprocess

Development of know-how on different hybrid joining processes (bonding, etc)

Improvement on tooling (LATCH 1) design and manufacturing; demo manufacturing on pre-industrialization environment.

MaxNesting

R&D ProjectsChallenge:Reduce raw material consumption to theTheoretical minimum with no additionalblanking operation.

Conventional approach:Reduce raw material consumption withblankingoperation

MCG Approach:MCG MaxNesting synthesizes blanking+ stamping in one operation

Customer Benefits:Lower piece cost

Raw material optimizationLess operationsOptimized machine occupation

Same industrialization cost

MCG Tooling

Tooling Case Studies

MCG Tooling – Case Studies

extrusions

3mm thick material, 18mm final extrusion

in-die tapping

push out force of more than 12 tons

in an m12 tap

85mm

18


stamping of big parts with material optimization

870 800

200

1.7mm thick sheet metal

1740mm*1000mm initial blank

special nesting and stamping position meant a real saving of 1kg per two parts, meaning more than 40.000€/year saving, when compared to similar

processes in same customer


safety products – drum brakes

highly precision and stable 3mm thick part

from prototyping to tooling development for tandem line presses.

550mm

275


safety products – hand break lever arm

high complexity parts, with high precision for final assembly.

550mm

280


safety products – motor housing

deep draw on aluminium, with high precision requirements

.

550mm

80mm

60mm (90º vertical)

3100mm


tooling in-die operations

Integrated processes allows us to meet capacity demands, still maintaining affordable and competitive prices

in-die tapping

in-die piercing


other products

450

copper parts

spring steel precision parts

hss steel parts

Portfolio MCG automotive

Teams & Plants

Quality Department

Quality Department

Recent acquisitions: FARO ARM

- 3D measurement anywhere;- Quick check when it comes to tools;- 100% comparison to a 3D Model.

Project Management

Stamping

Auto-Transfer max 8 m | 3.300 ton

Progressive max 4.5 m | 800 ton

Transfer max5.0 m | 1250 ton

Materials:

Mild steel & HSS steel

Aluminium

Stainless Steel

fully automated conveyors for scrap recovery with steel/aluminium segregation

Plant | Metal 1+4

Stamping

Plant | Metal 1+4

Welding, assembling, surface treatment

Welding and Joining capabilities

Robot & Manual welding

Arc Welding

Resistance / Drawn Arc

Tapping / Riveting / Clinching (in die & stand alone)

Materials: Sheet Metal & Tube, Bolts / Nuts / Rivets / Studs, Springs

Surface treatment

KTL Line

Epoxy Line

Annealing Line

Degrease/Washing

Capable to manage large scale programs for stamping tools (progressive and automatic transfer tools), up to 4,5 M€/year

Stamping Tooling such as:

Progressive Stamping Tools up to 4500mmAutomatic Transfer Stamping Tools up to 6500mmTandem Transfer Stamping ToolsHybrid (Progressive + Automatic Transfer) Stamping ToolsChecking FixturesStamping tools with special features (in-die ops and automation)

Able to validate in real conditions serial life conditionsin most of the cases

CAD/CAE/CAM UNIGRAPHICS-NX SIEMENSCAD/CAE CATIA DASSAULT SYSTEMESCAM TEBISCAD SOLIDEDGE SIEMENSCAE AUTOFORMCAQ PC-DMIS AND GEOMAGIC

Plant | Metal 2

Tool shop

Plant | Metal 2

Tool shop

Project management driven

Experienced team

7 Tooling Engineers (up to 40 years in experience)

10 Assembly/Try-Out workers (up to 30 years in experience)

2 Project Managers + 2 Progress Monitors

5 Process Engineers/Machining Programmers

On tool shop we are able to work 3 shifts

Production

Machining Centers

CNC Milling Machines

Turning Centre and Lathes

Grinding Machines

Wire Erosion Machines

Spark Erosion Machines

Try-Out Hydraulic Press

3D CMM machine

max 1000 x 500 x 500

max 4500 x 2500 x 950

max Diam 300

max 1000 x 500

max 700 x 500

max 700 x 500

1000 Ton

max 1000 x 800

Plant | Metal 3Prototype and

rapid manufacturing

Laser cutting equipment |Trumpf

Work area: 4000 x 2000 mm

Cutting speed (max): 300 m/min

Laser Power (max): 6000 w (Truflow6000)

Maximum sheet thickness:

Mild steel: 25mm, Stainless steel: 25 mm, Aluminium: 15 mm

Together with a bending equipment, also Trumpf, MCG offers a complete solution for prototyping and low series production

Plant | Metal 5

Assembling area

New investment (2015)

12.000 m2

Area dedicated to

assembly operations

MCG tooling 2015

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