Specialist journal from Mikron Nidau
for the Milling Technology
Issue 14
Selling price:
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Page 2 - 3: Mahle, car pistons,
Page 6: HSM 600U ProdMod, can
Page 7: Milling is his passion - the
Page 14: Trutron has made tool-
Page 16: Hallmark - the leading
production with high precision
be used in production
Mikron HSM 600U
ing for CV joints since the 1970s
greeting card publisher in the UK
Mikron – The Complete Package
From standard machines up to the most efficient high-speed machining centers,
and extensive know-how on the subject of milling.
The impressive product spectrum
of Mikron in Switzerland, the technological leader of milling centre
manufacturers, encompasses the
most modern high-speed and
high-efficiency machining centres
with 3, 4 and 5 axes. Over the last
few years, automatic loading and
unloading of components has been
consistently implemented. This
has resulted in today's range of
machines, which have a high degree of innovative characteristics.
use of torque motors for the rotary
table drive and for the swing movement of the swing head. This is the
only technology which allows high
levels of acceleration and speed in
rotary axes. The large clamping
table, with a diameter of 1600 mm,
and for loads of up to 3000 kg, can
be driven up to 30 rpm. The extremely high torque levels and the
The XSM 600U is the most dynamic machine produced by Mikron.
The HPM 1850U is presently the largest machine on offer from
Mikron. It has traverse movements of X 1850 mm and Y 1400 mm.
Jens Thing
The VCE 1000 Pro represents Mikron's well-proven vertical
machine range .
Mikron machines fulfil the highest demands concerning speed, accuracy and surface quality.
The demand-oriented design,
the high-quality components, the
digital drive technology and the
most modern control systems are
intended to provide maximum efficiency and functionality.
Today, Mikron has a high degree of competence and decades
of experience in the manufacture
of milling machines and machining centres. Mikron has achieved
this leading market position
through constructive dialogues
with customers, the qualified nature of their personnel, and by using the latest technology in both
development and production.
For years, the design and manufacture of innovative machining
centres has not only involved the
latest know-how, but also our own
research to guarantee that the
state of development at Mikron is
always up to date. This has resulted in the HSM range, for example,
which has set new standards in
high-speed machining. The surface
quality, contour accuracy and
process security achieved by these
machines are excellent. The
machining times for components
have been reduced markedly
can work out solutions with customers for complex manufacturing
problems. An extensive training
programme is designed for the
requirements of HSC and HPC.
The pleasing order income
levels received in the past year
have confirmed Mikron’s efforts.
Further market releases are
planned for 2005.
compared to conventional milling,
whilst increasing the quality at the
same time.
A special range of machines,
named HSM ProdMod, has been
developed from the HSM series,
which was originally conceived
for tool and die making. This new
range is designed to fulfil the
specific requirements of production machines.
The new HPM 1850U, the machining centre for 5-axis simultaneous machining of large compo-
nents, is based on a portal design
with a travelling table. This machine is designed for high output
at the highest level of precision machining in die making, machining
of castings, and in series production. The machine's sturdy construction means that it can be used
for both heavy duty material
removal and for the most accurate
final cut machining.
The latest technology has also
been used in the development of
the HPM 1850U. This involved the
achievable positional accuracy are
really impressive.
Know-how Transfer at Mikron
Mikron do not only produce machines, they also supply know-how
on the entire subject of milling from
their own HSM Competence Centres. These service centres advise
and inform on the subject of high
speed milling (HSC) and high performance milling (HPC). Amongst
other things, they also organize
seminars and training courses and
www.mikron-ac.com
Die-mold and tool-making
2
Editorial
Jens Thing
Brand Manager Mikron
HSM today Nr. 14
For Formula 1 the best is
just good enough
The automobile supplier MAHLE mills using Mikron
Technology high performance pistons for Formula 1
Dear reader,
Ever since Heraclitus (about
540 – 480 BC), many philosophers
have concerned themselves with
the subjects of change and modification. Today we consider it as
self-evident, and we have long accepted the fact that change is the
only thing that remains constant.
This also applies to business,
of course. And so, since January
2005, there have also been some
changes at Mikron. Michael
Hauser, the long-standing Managing Director of Mikron, now
leads the newly created business
sector "Marketing and Sales Support” as well as the "Milling" division of the Agie Charmilles
Group, which, in addition to
Mikron, also includes the motor
spindle manufacturer Step Tec.
His position as Managing Director
of Mikron is taken by Erich Bär,
who can also look back on a successful career in the Agie
Charmilles Group. I have personally been involved at Mikron for
over 15 years and now, as Brand
Manager, I lead the areas of Customer Service, Technical, Sales,
and Applications Support, and
Marketing.
Not only are there changes in
the Agie Charmilles Group, but also within the Georg Fischer Corporation. In future, the companies
within the Groups will present
themselves as a single entity.
HSMtoday has also been matched
to the new Corporate Design, in
order to underline the fact
that Mikron also belongs to
Georg Fischer.
I would like to take this opportunity of thanking our customers
and suppliers for the good partnership with Mikron. Your belief
and your trust have enabled us to
have a successful 2004. You have
chosen us as the supplier for 3-,
4- and 5-axis high-speed and highefficiency centres for the tool and
die-making industry, for production and manufacturing of highvalue components in the most varied industrial applications. The
continuous contact with you via our
sales and service network is the
best motivation to keep our product range at the highest level.
Your success is also our success.
Several thousand race car pistons
a year are produced by MAHLE in
its race motoring factory in Fellbach near Stuttgart, Germany. In
this factory, only three things
count: quality, quality, and again
quality.
Lothar Stehle
For several decades there has
hardly been a company involved in
car racing with such resounding
success as the automobile supplier MAHLE. The Stuttgart firm produces several thousands of high
performance pistons a year for
all racing series throughout the
world. MAHLE products are found
in Formula 1, Rally WM, the DTM,
the Indy races, Formula 3, the FIA
GT races, the Porsche Cup, the
Nascar races, or in LeMans as well
as in numerous other national car
racing series - basically everywhere where high performance engines are used.
Car racing is therefore an advertisement for the Stuttgart world
company with its more than 30,000
employees and a turnover of
3.2 billion euros for the year 2003.
MAHLE currently has over 60 production and development sites
worldwide and has production
lines with piston systems, filter
systems, valve gear systems, as
well as ventilation and fluid
systems. It covers an appreciable
part of the world market in passenger and utility vehicles.
MAHLE holds pole position on
the world market in piston systems.
Furthermore, MAHLE has enjoyed
an excellent reputation as a
supplier of these systems to the
motor vehicle industry for some
years. In fact, every second car
today includes products from the
80-year-old Stuttgart family firm
which, since the 1960’s, has been
managed as a limited company
foundation.
at a few more statistics to make the
point: almost 70 per cent of all 624
World Championship points given
in 2003 had decisive technological
support from MAHLE; at the same
time, over 80 per cent of all leading kilometers and pole positions.
Furthermore, almost 82 per
cent of the fastest laps in 2003 used
MAHLE pistons and motor sport
components. And if one calculates
all the kilometers driven by the 6
quality when dealing with its suppliers for machine tools. The technological package must make the
grade, which limits the number of
manufacturers for the equipping
of new machines in the Fellbach
motoring factory. "We had five
serious offers,” remembers Günter Mertz, production manager in
the MAHLE race motoring factory
during the selection process for
mid 2002. "What finally made us
best Formula 1 drivers in 2003, just
about 85 per cent used the knowhow from Fellbach.
These figures highlight the fact
that MAHLE is uncompromising in
decide on Mikron – once high performance quality had been set as
a priority – was the fact that the
HSM 400U and XSM 400U are two
machines which, with their Heidenhain control systems, are good
at adjusting to small series production, provide a pallet changer
which is ideal for us and guarantee multilateral accessibility. Besides, the Mikron machines are
very compact and therefore allow
greater installation flexibility on an
existing factory floor." The technical data of the Mikron Machines reflect the technical high performance as stipulated by Günter Mertz.
MAHLE became famous because of its reputation for producing pistons far superior to those of
its competitors. Such activities
have centered round filter and valve
gear systems in recent decades.
The company became especially
well known recently for its technological commitment to Formula 1,
in which five out of ten teams win
races through significant support
from MAHLE.
"Take the example of Ferrari",
says Fred Türk, head of MAHLE’s
racing parts factory, "Since 1996
no Ferrari has been taken out of a
race because of a defective part
from MAHLE. It’s really quite
simple: Our pistons cannot break
down – whatever happens and whoever is driving”.
Uncompromising quality
Fred Türk comes straight to the
point: "Our customers expect 100
per cent quality. And we deliver.
Without compromises." Let’s look
Precise, dynamic, automated, and
safe production
The HSM 400U and XSM 400U
were built for the highest precision
and maximum production safety.
The basic frame, moulded in monoblock in a bridge-type construction,
HSM today Nr. 14
Die-mold and tool-making
3
is the first prerequisite for the
rigidity and stability of the machine
required for HSM milling. Optimum
surface quality and minimal wear
on the workpiece are guaranteed
through the excellent damping
qualities and the very high thermal
stability of the polymer concrete
base.
Further criteria of the HSM
400U and the XSM 400U are the
automation with the pallet and tool
changer, suitability for wet and dry
runs and unique accessibility.
The axes and guides have been
fully designed with stability in
mind — a wide area for the guides
and optimally positioned guide
shoes in the flow of acceleration
forces.
High dynamic axes and feed
rates of maximum 80 m/min and
acceleration up to 2.5g give these
machines unique dynamics. The
feed spindles and the water-cooled
drive motors are thermally separated. Built-in length measuring
systems with permanent pneumatic overpressure assembled near
the machining process guarantee
an outstanding long-lasting precision and operating safety.
The Mikron motor spindles are,
naturally, state-of-the-art technology: liquid cooled with oil/air
lubricated ceramic alloy ball bearings and extremely short run-up
and brake times through vector
control. Spindles are available with
various characteristics (up to
54,000 min-1).
The central element of the XSM
400U is the high-speed swivel
table with torque direct drive in linear technology. With a speed up
to 1,500 º/sec and acceleration
up to 20,000 º/sec2 it enables an
ultra high speed even with the
five-axis simultaneous machining
processes.
Significantly reduced machining
time with Mikron machines
Technological high performance in MAHLE Motorsport Appli-
Car pistons made by Mahle.
Since all data concerning racing car pistons must be kept confidential, the newest MAHLE pistons cannot, unfortunately, be shown.
cations translates into both time
savings in production and exemplary milling quality. The blank pistons forged in the MAHLE factory
in Rottweil in southern Germany
are subsequently machined in Fell-
bach. The Mikron machines therefore take on an especially difficult
and time-consuming part of the
machining of the piston interior —
a milling process requiring several hours per piece, and clockmak-
ing precision. Narrow molding cutters with over 40,000 RPM relieve
the box-shaped piston undersides
of all excess material that needs to
be eliminated because of excess
weight, and can therefore be
removed after forging.
"We inspect each racing car piston 100 per cent. Even the smallest unevenness on the surface is
corrected. The better a milling machine works, the less waste there
is.” says Günter Mertz. The results
of the Mikron machines give great
satisfaction which, given MAHLE’s
quality philosophy, speaks for
itself. Three Mikron high-speed
machining centers for milling
are in the MAHLE race motoring
factory in Fellbach.
"If technology continues to
prove itself as it does now, then
The CNC millers Gülur Fatin
and Senner Sari operate the
three Mikron high-speed milling
machines in MAHLE‘s race motoring factory near Stuttgart.
nothing will keep us from setting
up in other factories,” comments
Adrian Edinger, responsible for
machine planning at MAHLE, with
regard to the cooperation with
Mikron up to now. Adrian Edinger
sums it up by saying: "We’ve got
what we wanted at a price we could
accept and with the service we
require,” . It’s a classic win-win
situation, and a result that can be
built upon.
www.mikron-ac.com
High-speed machining
4
At the 12th Austrian HSC Symposium
(28th - 30th September 2004), the winner,
Beat Leutwyler, applications engineer at the
HSM Competence Centre of
Mikron Comp-Tec AG in Nidau, Switzerland,
received the prize for the "Aluminium Reference Component”. The reference part was
milled on a Mikron XSM 400U.
The High Speed Machining
Award was announced for the
6th time. Under the technical
leadership of the Institute of
Production Management, Technology and Machine Tools (PTW)
at the Darmstadt University of
Technology, Germany, and Profactor Produktions-Forschungs
GmbH of Steyr, Austria, it has
developed into a top-class
competition that is recognised
throughout Europe.
In the meantime it is regarded
as the European benchmark
for high speed machining and
precision manufacturing in the
fields of tool and mould production,
and precision part and volume
production.
The newly-created "Aluminium
Reference Component” competition placed the highest demands
on the competitors. The capabilities of both the machine tool and
the cutting tools used were strenuously tested at the same time.
In any case, innovative solutions
and the best quality were necessary to come out as winner in this
competition. The requirement was
for the optimum machining to
drawing of the aluminium reference component. Included in
the evaluation were processing
HSM today Nr. 14
High-Speed-Machining
Award for
Mikron in Nidau
Fig. 1: The specified component not only places stringent demands on the precision of the machine;
the complex profile also requires excellent dynamics and an outstanding capacity for machining threedimensional surfaces.
time, quality achieved, performance, milling or processing strategies and, of course, the degree
of innovation.
Machine concept, ambient
conditions, a structured
procedure and know-how
are the key to success
Ralf Löttgen
High Speed Machining (HSM),
as an alternative or complement
to conventional milling or sink
erosion, has become firmly established in recent years as an
addition to traditional machining
methods. In order to achieve this
success, new machine concepts,
a thorough analysis of the application, new approaches to
solutions and an optimisation of
the manufacturing processes
were required to satisfy the technological requirements of the
HSM process.
Nowadays high speed machining is a standard machining process
not only in tool and mould produc-
Fig. 2:
With an XSM 400U Beat
Leutwyler milled the
component in aluminum.
The XSM 400U is the
most dynamic machine
from Mikron
tion, but increasingly also in the
production of complex components. In Mikron’s case, more than
half of the HSM centres manufactured are currently supplied for
production applications.
HSM Award 2004 – Reference
component
The theme of the HSM Award
2004 in the reference component
category was especially interesting for the reasons mentioned
above. The specified component
(Fig. 1) not only places stringent
demands on the precision of the
machine; the complex profile also
requires excellent dynamics and an
outstanding capacity for machining three-dimensional surfaces.
These demands can only be completely satisfied in an optimal manner by machine concepts that are
designed in accordance with the
requirements of the high speed
machining process (HSM).
High Speed Machining Centres
XSM 400 and HSM 600U ProdMod
The XSM 400U (Fig. 2) was
selected from the available range
of Mikron machining centres for
high speed and high performance
HSM today Nr. 14
machining as the most dynamic
machine for this task.
Meanwhile a special range,
designated HSM ProdMod (Fig. 3),
which was specially designed to
meet the requirements of production, was derived from this
machine, which was originally conceived for tool and mould manufacture. In particular it features
optimum reliability in three-shift
operation as well as a dramatic
reduction in idle time.
High speed machining centres
are characterised by high feed
rates and high spindle rotation
speeds. It is particularly important
that the inevitable generation of
heat and its resultant displacement
effects are continuously compensated by intelligent algorithms. ITC
(Intelligent Thermal Control) is
therefore an indispensable standard on all XSM and HSM machining centres and a prerequisite for
meeting the tolerances required for
the reference component.
In high speed machining, accuracy and surface quality are very
strongly dependent on the balance
of the combined milling tool and
tool holder and, in the case of a
large tool projection, also on the
presence of clattering. Both effects
result in vibration marks on the
surface of the workpiece or, in extreme cases, in premature failure
of the spindle. The APS (Advanced
Process Control) function makes
visible the appearance of spindle
vibrations and enables automatic
interruption of the machining
process or permits the operator to
make a specific optimisation, for
example by modifying the feed rate,
the spindle rotation speed, the selection of tool holder and milling
tool or the machining strategy.
CAM system, reference system,
milling tools and tool holders
With its variety of HSM-compatible machining cycles, the CAM
High-speed machining
5
Beat Leutwyler, applications engineer at the HSM Competence Centre of Mikron Comp-Tec AG in Nidau, Switzerland.
system used, hypermill from Open
Mind Technologies GmbH, supports the efficient and structured
creation of NC programs for 3 and
5 axis machining sequences.
The workpiece is clamped
directly to a 3R Macro Magnum
pallet system. Working with pallet
systems enables the machining
and checking of workpieces on
several machines without loss of
the machining reference. In the
case of the reference component,
the pallet is the prerequisite for
machining the component and inspecting it on the coordinate measuring machine.
Shrink-fit chucks are the optimum solution for precision machining with high speed spindles.
Particularly important in this respect are minimum concentricity
error and a shape matched to the
requirements of the machining
process, which enables the projection of the milling tool to be minimised. Stable chucks with a large
external diameter were therefore
selected for the readily accessible
areas; long, slim chucks were used
for the recessed areas. In this
instance, the use of the latter shape
together with a small tool projection is absolutely preferable,
compared to short, stable chucks
and a large tool projection. With regard to these requirements,
shrink-fit chucks and collet holders by Schaublin, and for light
machining, shrink-fit chucks by
MST were used.
With the exception of some special tools, fully-hardened tools by
Fraisa were used for the milling
and thread cutting operations.
Lubricants and cooling
lubricants used
Minimum quantity lubrication
was used for all machining steps
with the exception of the grinding
and thread cutting operations. The
reason lies in the long-known
effect that, when using cooling
lubricants in conjunction with high
spindle rotation speeds, adequate
lubrication of the cut is not guaranteed because of air turbulence
in its vicinity. The surface quality
typically suffers as a consequence.
Minimum quantity lubrication has
thus proved of great value as
a meaningful alternative in high
speed machining. This fact should
not be confused with the problem
of poor surface quality resulting
from inadequate chip removal
when using minimum quantity lubrication and the subsequent
crushing of chips into the surface
of the workpiece. The correct
adjustment of minimum quantity
lubrication is thus very important.
It often happens that too great
a volume of oil is used, with the
result that chips stick to the surface of the workpiece and during
Fig. 3:
HSM 600U ProdMod, machines
of this series are able to live up
to the demands of production.
subsequent operations find their
way once more into the active
cutting area of the milling tool,
where they can lead to impairments
in the surface quality. In the case
of machining aluminium, it is not
really possible to make a blanket
statement regarding the optimum
lubricating medium. The fact is that
the positive effect of cutting fluid
lies particularly in the controlled
chip removal. In contrast, minimum
quantity lubrication has clear
advantages on cost and environmental grounds, which nowadays
can certainly be used in conjunction with a machine concept designed for the optimum chip flow.
The grinding and thread cutting
operations were carried out
using coolant lubricants. In this
regard it can also be said that
tooling concepts and strategies
have been tried out in universities
and in industry to make even
these machining processes robust
when using minimum quantity
lubrication.
The machining of the reference
component was accomplished in
19 processing steps, using 15
different tools.
www.mikron-ac.com
High-speed machining
6
HSM today Nr. 14
HSM 600/600UProdMod
The machines which can
be used in production
High-speed machining has become a solid component
of 3 and 5-axis milling technology, until recently, however, almost
exclusively in mould and tool construction.
But with the new models HSM 600(U) ProdMod the technology
can also be used in production.
The new models, HSM 600(U)
ProdMod, are a further development of the successful Mikron
HSM machines for use in production. Even today, the machines in
the Mikron HSM range remain a
benchmark in this category.
The HSM 600(U) ProdMod is a highspeed machining centre with the
highest dynamic for the rational
machining of demanding precision
parts in medium to large-sized
series. It is equipped with highly
dynamic direct drives for the B and
C axis. The differences are in com-
ponents such as chip removers,
tool changers and cooling lubricant systems, which have been
developed in accordance with the
demands of production.
Christian Knuchel
The HSM 600(U) ProdMod are
constructed on the patent applied
for HSM monoblock machine base
in a portal construction made of
polymer concrete. This basis has
proved itself for several years, both
in the smaller HSM 400 and the
larger HSM600/800. Nothing is left
to be desired with regard to rigidity, damping behaviour, accessibility und compactness. Another contributing factor to the success of
this machine range are the highperformance motor spindles in different designs for varying speed
and torque ranges.
Increasingly more customers
have been opting for an automated Mikron HSM machine. This
means the setup times can be
completed parallel to the actual
machining time and the system’s
productive hours extended during
the unmanned hours. These are
two advantages that should not be
underestimated, especially in the
production of parts in medium and
larger batches.
This is where the further development of existing machine models starts up to the HSM ProdMod
designs.
Modular tool changer with up to
220 tools
In automated production, companies use different strategies with
regard to the management and implementation of tools. However, it
is in everyone’s interest to limit
the quantity of tools to an acceptable number. Nevertheless, in
order to achieve a maximum of flexibility, machines are deliberately
equipped with the whole tool set.
Such a machine must therefore be
provided with a large tool storage
device. The Mikron ProdMod designs can be adapted to individual
requirements and be equipped with
a modular tool changeover system.
120, 170 or even 220 storage spaces
are available for selection. There
are short changeover times due to
Perfectly integrated pallet
changer
5-axis version: standard with
3R (Dynafix)-, Mecatool (GPS)or Erowa (UPC) pallet/chuck
available.
The tool storage is constructed as a circularsu spended shelf.
As such it is scaleable in almost any way. In the standard version
there are 120, 170 and 220 tool positions.
the separation of the provisioning
mechanism and the transfer handling. By virtue of the "double tool
handling" changeover times as little as 3 seconds are achieved, the
chip to chip time is approximately
5 seconds. The tool changeover
time is, however, not the only decisive factor in the production of
parts in series. Just as important
is the provisioning time for the
next tool. This provisioning time
doesn’t even reach 10 seconds in
the modular Mikron changeover
system. This enables even using
tools with very short operating
times economically (e.g. when
drilling,
countersinking
and
threading) without waiting times
for the next tool.
Motor Spindle with HSK-A63
Tool Tolder
The new Mikron HSM ProdMod
machines now also include spindles with the HSK-A63 tool holder
and interior coolant supply. This addition to the existing spindle offer
allows the use of larger and hence
longer tools. By doing so, Mikron
closes a gap in the existing HSM
machine range and, at the same
time, responds to a new application segment i.e. the production of
parts in medium and large series.
Chip Removal and Cooling
Lubricant Systems
In order to respond better to the
demands made by production in
multi-shift operation, Mikron has
thoroughly analysed and newly
developed chip removal and lubricating coolant supply in the existing HSM machines. As such, we are
in a position to cope with the requirements of different machining
materials and strategies and to
equip the machines accordingly.
Thus in order to ensure the safe
removal of the incoming chips the
following is required: washing
nozzles in the working area, inner
coolant supply through the spindle
with adjustable pressure between
18 and 70 bar, as well as different
chip conveyers and filter systems
which reliably make allowances for
the workpiece material and the type
of chip such as needle chips, broken chips, light metal chips with a
tendency to float etc.
With the new HSM ProdMod
machines, Mikron offers a range of
highly dynamic machines capable
of facing up to the most demanding of 3 and 5-axis machining tasks
in extended multi-shift operation.
www.mikron-ac.com
High-speed machining
HSM today Nr. 14
7
Customers demand
ever tighter tolerances
Over the last 2 years, Martin Stürmer has been
operating with a Mikron HSM 600U
In the summer of 1984 the time
had finally arrived. Martin
Stürmer had his master craftsman
certificate in his pocket. Now
nothing could stop him from
fulfilling his wish to set up his
own company.
Jürgen Maurer
In an adjoining building to his
parental home, he found enough
space for his first machine. On the
basis of his excellent work, word
soon spread that, in Hösbach, in
Mr Stürmer, firstly may I thank you
for your friendly reception.
You have had two machines from
Mikron in Switzerland in your
factory for over three years.
How did you become aware of
the UCP 710 and especially the
HSM 600U?
I have been in close contact with
the representatives of Mikron, Och
GmbH in Nürnberg, for many years.
I have had a very close business relationship for many years with Mr.
Peter Paul in particular. He is responsible for the sales in our area.
The new HSM 600U ProdMod. It was developed particularly for
the production.
the Rottenberg area, there was a
new workshop which was undertaking commission work precisely
and reliably.
Slowly but continuously the
concern grew. Today "cnc turning
technology stürmer" employs 16
people. In order to be able to continue to employ qualified workers
in the future, Martin Stürmer
employed 4 trainees.
Today, "cnc-turning technology
stürmer" manufactures sample
components, prototypes and small
production runs in a building,
which was acquired in 1990. The
customers are mainly from the
fields of automobile manufacture,
medical technology and tooling and
die manufacture.
During our visit to Hösbach,
Rottenberg area, Martin Stürmer
gave us detailed answers to our
questions about his company and
the work he carries out.
He recommended Mikron to me as
a machine supplier.
The entry into high speed machining (HSM 600U) arose from the
experience with the UCP 710 and
the consequence that my customers now require more complex
components with tighter tolerances within ever shorter delivery
periods.
From which sectors do your
customers come?
The majority of my customers
come from the automotive industry, from medical technology and
from tooling and die manufacture.
What sort of parts and which
materials do you machine for
your customers?
Mainly batches of 5-20 parts,
but sometimes also just one-off
and more rarely batch sizes of 200.
Generally they are sample components or parts for prototype
manufacture. I machine aluminum,
hardened steel, (actually all steels
available in the marketplace), and
occasionally also plastic materials.
What experience has you or
your colleagues gained with high
speed machining in the recent
past?
So far we have had only good
experiences. My colleagues have
been very well trained by C-mill, a
company from Switzerland. HSM
machines require a different working strategy. After approximately 9
months they were in a position
where they could make optimum
Top photo: Martin Stürmer (right) with Michael Rickert,
foreman Manufacture.
Bottom photo: Palette changer on HSM 600U.
use of the possibilities offered by
HSM milling. This breaking-in
period, which many would view
Training and on-going learning
have high importance
at “cnc drehtechnik stürmer” in
Hösbach, Germany.
as being relatively long, has proved
to be well worth it. My customers
are extremely satisfied with the
milling results.
What tolerances are specified by
your customers?
In general, the tolerances are
between 10 – 15 µm. It seems improbable, but these days more and
more, tolerances less than 5 µm
are requested.
How do you find the Mikron
machines, are you satisfied
with, for example, the accuracy,
the reliability, the processsecurity etc.?
The accuracy that you can
achieve with Mikron machines is
really excellent. At the present
time, I know of no other machine
manufacturer who achieves the
same degree of accuracy with their
machines. The machines are reliable and the process-security is
good.
What is the situation in your company with regard to automation
and / or multiple shift working?
We have operated a multiple
shift system for several years now
and automation is definitely part of
our considerations. We need to become more and more flexible. Time
pressure plays an ever more important role, of course. Since the
Mikron machines are equipped with
an automatic palette and tool
changer, we can machine orders
through the night without any problems. This means that we can
deliver very quickly.
You mentioned that you are in the
process of purchasing a ProdMod
from Mikron. What are your reasons for this?
The ProdMod was developed
from the HSM-series, very dynamic machines which were initially
conceived for tooling and die manufacture. The ProdMod is now
especially capable of meeting the
requirements of a production environment. It is fitted with a tool
changer with up to 220 tools. In
addition, spindles with HSK-A 63
tool mounting and internal coolant
feed are available.
With this machine we have the
required flexibility to complete orders which require a large number
of tools. We can only satisfy our
customers these days with reliability, flexibility, and service.
Our co-operation with Mikron
helps us to do this.
www.mikron-ac.com
HPM 1850U
for large parts
5-axis simultaneous machining
10
High End Performance
with High Precision
The HPM 1850U is based on the
portal design in table-type construction. The machine is prepared for high performance machining in mold making, casting
machining and series production.
Its stable assembly means its use
extends from heavy roughing work
to precise finishing work. The HPM
1850U allows highly precise 5axis simultaneous machining.
Stefan Fahrni
Just as le Corbusier said: The
foundations form the basis of the
base. This quote accurately describes the development of the new
Mikron HPM 1850U. Mikron’s experience of over 100 years of mechanical engineering and the construction of thousands of machine
tools has provided the basis for the
development of the HPM 1850U.
Year long experience combined
with state-of-the-art technology
As early as in the construction
phase, the most modern techniques were used to optimize the
machine with regard to rigidity
and dynamics. For a machine of
such dimensions, calculations have
shown that in order to meet high
demands with regard to milling
performance on the work piece,
only a strong ribbed cast base from
one piece can be the right
basis. In addition to this, the portal forms the rock solid yoke for the
Y and Z slides. The 23 tons forming the basic machine therefore
guarantee work piece precision and
a long tool service life.
Weight reduction: A lesson from
nature
What makes a bird fly? Or what
gives a leopard its immense flexibility and speed? – The minimum
weight of the body frame while
maintaining maximum stability.
This is the first time that an innovative process has been used for
HSM today Nr. 14
The new Mikron HPM 1850U,
the machining center
for the 5-axis simultaneous
machining of large work
pieces.
the structure of a considerable part
of the Mikron HPM 1850U moving
masses. Metal foam is used to connect the exterior shell to the interior shell. This type of construction
has the advantage that the Z slide
alone has been made 300 kg lighter
than a conventional cast slide,
while still maintaining the same
rigidity. This reduction in weight
has had a significant effect on the
axis movements. This enables the
contour accuracy to be read directly at the work piece surface and
from measuring results.
Flexible Milling Head
With the HPM 1850U it is easy
to carry out undercuts on the work
piece when machining simultaneously with 5 axes. The milling head
can be used to simultaneously
swivel the tool spindle 140°. Furthermore, the swivel axis can be
clamped in order to efficiently
use the motor spindle’s highest
torques. The clamp is so powerfully designed that it doesn’t
require any indexing. Thus the
spindle can be held in every conceivable angle position. The switching time from the vertical to
the horizontal machining process
takes less than one second. This
provides machining options that
previously couldn’t be considered.
The varied application possibilities
of the new Mikron HPM1850U
are almost never-ending, ranging
from rough cutting, 5-sided
complete machining up to the
5-axis simultaneous machining of
turbine vanes.
Consistent implementation of
High Speed Milling experience
The swivel axis is moved using
a direct drive, a so-called torque
motor. This drive is based on the
linear motor principle and has
proved to be the best option for this
application. The great advantage of
this type of drive is that between
generating the torsional force and
the moving part (in this case the
spindle’s swiveling movement) neither belts nor gears are used. The
spindle housing is tightly attached
to the rotor. Gear clearance or signs
of wear and tear are therefore practically ruled out.
Directly driven rotary table
New challenges facing machining performance require new solutions and technologies in order
to implement it effectively. That’s
why, in the case of the Mikron HPM
HSM today Nr. 14
5-axis simultaneous machining
The big pallets of the HPM 1850U for the heaviest loading up to
3000 kg can be turned with up to 30 min-1
11
The HPM 1850U is prepared for high performance machining in mould making, engine manufacturing,
casting machining and series production. Its stable assembly means its use extends from heavy roughing
work to precise finishing work.
1850U, a linear motor has been
used as a rotary table drive. High
accelerations and speeds can only
be achieved using this technology.
The large worktable with a diameter of up to 1600 mm for the heaviest loading up to 3000 kg can
be operated with up to 30 min-1.
Its enormous torque and the positioning accuracies achieved are
impressive and constitute two
characteristics of paramount importance to Mikron with regard to
this machine.
Powerful Motor Spindles
The HPM 1850U can use motor
spindles optionally with 15,000
min-1 and 191Nm torque as well
as 24,000 min-1. The modern and
widely distributed HSK63 is used
as the tool interface. It enables the
machine to offer sufficient output
and reserves to smoothly overcome
the most demanding of cutting
tasks.
Pallet changer with direct access
Large machines are typically
surrounded by a platform to provide the machine operators with
access for loading the machine.
Mikron believes that this is very
awkward for the operator. As such,
this type of platform was deliberately left out. Instead, the machine
is equipped with lifting apparatus
which lifts the pallet to the height
of the working table. The HPM
1850U is the only machine of its
size with ground-level access to
both loading stations. Additionally,
both loading stations are equipped
with manual turning equipment.
This is extremely useful for securing large work pieces on the
reverse side as well. Likewise, this
also makes the loading and unloading of mounting towers considerably easier.
The new 5-axis Mikron HPM
1850U machining center opens new
ways to the modern and economic
production of large parts up to a
part volume of 1.6 m3.
Both loading stations are provided with manual turning equipment.
The minimize of downtime by equipping on a total of two stations while the machine is in operation.
The automation increases productivity during unmanned evening and weekend hours.
www.mikron-ac.com
The HPM 1850U allows highly precise 5-axis simultaneous machining. It opens new ways to the modern and economic production of large
parts up to a part volume of 1.6 m3
12
Universal machining
Vario - Flexible
Production
is the Future
Rising wage costs and fierce competition demand new production
strategies, particularly from
small and medium-sized manufacturers. Improving the utilization ratio of production resources
by unmanned night and weekend
shifts can give a decisive advantage over rivals.
Urs Hänni
Flexible production is the future
Given the short shelf-life of
today's products and consumer
goods, inflexible production equipment can no longer be installed and
then used almost unchanged year
after year. Automated production
solutions such as Mikron's UCP 600
Vario are thus of increasingly vital
importance when planning production for small and medium-sized
batches.
The Vario is also well-equipped
to deal with other forward-looking
production features such as mixed
production, operating through
lunch- and tea-breaks, and shifts
with minimum operating personnel. It is vital that a high-performance machining centre has a reliable palette changer, a scaleable
tool changer, a monitoring system
and built-in measuring capabilities. Finally, the fallen chips
also have to be disposed of cleanly and reliably.
Solution - the Vario System
With its UCP 600 Vario, Mikron
has a convincing five-axis solution
for automated production. As well
as the compact basic machine itself, the Vario system has: a multitude of high-performance milling
spindles; a scaleable, modular tool
changer system, the best known
palette changer from other Mikron
machines; and the right disposal
or cleaning solution for every chip
and coolant situation. The customers themselves can decide how
variable their UCP 600 is to be.
HSM today Nr. 14
The UCP 600 Vario constitutes an economic solution
to the demands of
automated production.
However, one thing is guaranteed
to stay the same: access to the machine and peripheral devices is
wonderful!
High-Performance Unit made up
of dependable components
The Vario system builds on a
stable, compact basic machine
that has surprisingly large traverse paths on the smallest possible base space. With one of the
three high-performance spindles
provided and the circular swiveling
table, the UCP 600 Vario masters
all milling processes. The palette
of possible spindles goes from the
12,000 min-1 spindle for conventional machine tool technologies,
to the 20,000 min-1 spindle for machining a wide variety of materials
using strategies from HSC technology, to the 42,000 min-1 spindle,
which when used in combination
with the powerful Heidenhain iTNC
530 control system, gives access to
HSC technology. The basic UCP 600
Vario has everything required to be
used successfully for, for example,
tool and mould making, medical
technology and the entire machining process for frame components.
The various modules in Mikron's
"smart machine" product ensure
that the future of modern production is also incorporated into a
UCP 600 Vario. Depending on
their requirements, the customer
can choose such differing modules
as the RNS (Remote Notification
System), the APS (Advanced
UCP 600 Vario:
Heavy workpieces can be easily
loaded by crane.
Process System) or the ITC (Intelligent Thermal Control).
Scaleable tool changer meets all
needs
When machining multi-functional components (complex cast
iron casings, valve blocks, cylinder
heads), there is a need for multiple operations that require a wide
variety of tools to be readied, e.g.
to make tap holes, drill seats or
boring functions, in the shortest
possible time.
Mikron meets these needs with
a new, modular, scaleable tool
changer whose most significant
features are its small installation
space, the sizes of the tool capacity that can be matched to the customer's needs, and a very short tool
set up time. The modular-designed
tool changer has space for 120 to
220 tools, depending on the size of
each tool. Taking up very little space
and fitting optimally into the compact machine layout, this new tool
changer is the ideal complement
to make the UCP 600 Vario into a
highly productive and flexible production unit.
A palette changer to be proud of
The UCP 600 Vario ensures automated production by the costeffective integrating of a palette
changing system. In the smallest
possible space, work pieces with a
surface area of up to 320x320 mm,
a height of 350 mm and a maximum
weight of 80 Kg can be automatically changed and five-axis
machined (with manual machine
loading: Ø 450mm x height 450mm,
200kg). Aligned in the best possible way with the machine and the
circular swiveling table, the palette
HSM today Nr. 14
changer can be supplied for use
with Dynafix palettes from Mikron's
system partner System 3R or for
the GPS (Mecatool) or UPC (Erowa)
palette types, according to the customer's wishes.
Chips all under control
When it comes to chip management, Mikron does everything to
ensure that the chips end up going
where they should: namely, in the
chips container. To achieve this objective, any build up of chips in the
workspace should really be avoided. Mikron has thought through the
detail of the cabin's construction
so that such chip nests cannot be
formed. The 400mm wide chip conveyor takes care of disposal itself,
as an edge filter clearly separates
Universal machining
13
coolant from chips. Sedimentary
material is collected in the bottom
of a small, easily accessible adjacent basin, so that the important
cleaning of the equipment becomes
a simple, routine task. The chips
disposal unit is, of course, fitted
with overflow protection. Where
there is a chip jam, the scratching
device automatically goes into reverse. The chip jam is unblocked
or notification of the breakdown is
appropriately displayed on the control console screen. The fact that
the ejection position of the chip
conveyor can be selected on a
TheUCP 600 Vario - best
suited for 5-sided, 5-axis
positioning and up to 5-axis
contour machining
Machine model UCP 600 Vario
Working range
Longitudinal
X mm
Cross
Y mm
Vertical
Z mm
Swivelling
B°
Turning
C°
High speed motor spindle
Maximum speed
min
Spindle performence at 40% ED/S6
Toolholder
Feed drive
Feed - rapid speed X/Y/Z m/min
Tool changer
Magazine positions
quantity
-1
Rotary swivel table
Table dimension
Max. workpiece weight
(5-axis operation)
Table versions
mm
kg
Pallet versions
Control
CNC
Construction
kg
Pallet changer (Optional)
Number of pallets
Units
Pallet surface
mm x mm
UCP 600 Vario with palette changer illustrates just how seriously
Mikron treats the subject of chip
disposal. Above and beyond this already high standard, variants such
as even more high-performance
chip conveyors and mini-strip filters can be provided that guarantee the effective removal of chips
UCP 600 Vario tool changer:
Tool changer, scaleable with
optionally 120, 170 or 220 tool
positions.
600
450
450
-115 / +30
n x 360
12'000 / 20'000 / 42’000
kW 15 / 16 / 14
ISO 40 / HSK A63 / HSK E40
max. 22
30-220, (configuration
upon request)
450
200
table Ø 450 mm,
with starshaped or parallel .
arrangement of the T-slots
3R (Dynafix), Erowa (UPC),
Mecatool (GPS)
(others upon request)
Heidenhain iTNC 530
7700
7 (Dynafix, UPC), 10 (GPS)
3R (Dynafix) 280x280,
Erowa (UPC) 320x320.
Mecatool (GPS) 240x240,
(others upon request)
with particular properties, such as
needle and swarf chips, and floating chips. Thorough chip disposal
is the last feature of a series of important production factors that
make the UCP 600 Vario a successful high-performance machining
centre for automated production
and flexible manufacturing.
www.mikron-ac.com
High-speed machining
14
HSM today Nr. 14
Automation
brings competitive
advantage
If you’re machining families of
parts, you need to take full advantage of the features that the parts
have in common to minimize programming, setup and machining
times. That’s part of the thinking
that guided Trutron Corp., a CNC
machining firm located in Troy,
Michigan, as it sought to become
more efficient in the production of
a particular type of automotive
tooling for which it is noted-punches and dies for front-wheeldrive constant velocity joints.
Leo Rakowski
Trutron has made tooling for CV
joints since the early 1970s. The
main components of the tooling are
a punch and die, both made from
high speed steel bar stock. The
punches are typically 10 to 12 inches long by 4 inches in diameter. The
dies are typically 8 inches long by
6 inches in diameter, with a 4-inch
cavity. Originally, after initial sizing
and heat treating of the blanks, the
punch and die details were burned
in by the EDM process, in keeping
with the fact that the company
started as an EDM company.
As the company grew, its machining capabilities expanded. It also started diversifying into aerospace work, which involved having
to machine parts made of many different metals. In order to process
the aerospace work more efficient-
ly, the company added machining
centers. Then, when high speed
machining came on the scene, the
company began considering the advantages of high speed machining
centers for the production of
graphite electrodes for its sinker
EDM machines and as an alternative to EDMing some jobs.
Trutron officials made the
rounds of the machine tool builders
and distributors that exhibited high
speed machining centers at the
1998 International Manufacturing
Technology Show in Chicago. They
were most impressed by the
machining centers exhibited by
Mikron, Holliston, Massachusetts,
which offered spindle speeds up
to 42,000 rpm. Some time later, the
company purchased a Mikron
HSM 700, three-axis, machining
center - to which it added a fourth
axis - intending to use it for high
speed machining of graphite electrodes as well as for high-speed
machining of heat treated metals
up to 65 Rockwell C.
"The first time that we used the
high speed mill to machine parts
instead of EDMing them, we were
able to eliminate four hours of
operations on each part,” explains
Tim Griswold, Trutron’s vice
president of manufacturing. "That
opened our eyes to the potential
benefits of switching more work to
the high speed machine.”
The high speed mill is pro-
The machining center’s
20-pallet carousel allows up
to 20 punch or die blanks to be
loaded at a time for machining,
enabling the machine to run
unattended for long periods.
grammed off-line by Mark Cohrs,
Trutron’s engineering manager,
using Esprit software from DP
Technology (Camarillo, California).
Building a knowledge base
To take advantage of the similarities of the Trutron CV-joint
punches and dies, Mr. Cohrs began
building a machining knowledge
base that would allow him to copy
pieces of existing programs and
paste them into machining programs for similar punches and
dies. "There are 20 to 30 different
values that we keep track of in
our machining knowledge base,”
he explains.
"For example, if I need to program a new relief area for a punch,
I don’t have to re-specify those
values for every new punch,” he
continues. "I simply call up the
Punch Relief file from the data base
and plug it into my program.
As Trutron became more proficient at machining the high speed
steel CV-joint punches and dies, so
much work was transferred from
the EDM machines that the company invested in a second high
speed machine, this one a Mikron
Close-up of a typical CV-joint punch being machined on the 5-axis
machining center HSM 400U.
HSM 400U 5-axis vertical machining center with an integral 20position pallet changer.
According to Mr. Griswold, 90 to
95 percent of the company’s high
speed steel parts now go across
the two Mikron machines. He
stresses that the parts are not
only produced faster by high speed
machining, but that they are more
accurate and more consistent
as well.
They work weekends
The high speed machines also
require minimal supervision—one
operator tends both machines—
and they can be operated for long
periods in an unattended mode.
For example, the HSM 700 4-axis
machining center is frequently set
up with a fixture that holds multiple parts for machining, each of
which can require an hour or more
of machining time. Typically, parts
will be loaded in a fixture before
the last shift leaves on Friday night,
and as many as 15 fully machined
parts will be waiting when the first
shift comes back on Monday.
Trutron’s second high speed
vertical machining center, the
5-axis Model HSM 400U, with its
Operator Joe Adamski (holding
punch) confers with Trutron
vice president Tim Griswold
(left), company president
Dennis Carlson, Jr. (blue shirt)
and Mark Cohrs.
integral 20-position pallet changer, also permits unattended machining of multiple large components,
Dennis Carlson, Jr., president
of Trutron, puts his company’s newly added high speed machining
capability in perspective: "We view
high speed machining as a more
efficient tool for machining M2, M4,
M50 and other high speed steels,
therefore we have moved most of
that work to the high speed machines. However, we also process
a lot of tungsten carbide, all of
which goes on our EDM machines,
which explains our recent addition
of a new CNC sinker EDM with a
25-position tool changer.
"We’re in a very competitive
business, and we need to be
able to provide our customers with
the most efficient process for producing their parts,” he continues.
"With our EDM and high speed
machining capabilities, we’re can
provide the best process, or combination of processes, for getting
the customer’s job done. On the
software side, our programming
software and machining knowledge
base help us ensure that we do
the job efficiently and get it right
the first time.”
Reprint from the April 2004 issue of
MODERN MACHINE SHOP Magazine.
Copyright 2004 Gardner Publications, Inc.,
Cincinnati, Ohio USA.
Used with permission
www.mikron-ac.com
smart machine
HSM today Nr. 14
"smart machine”
The Mikron Modular
System for
Process Optimisation
Mikron has embraced different modules (software und hardware) under the term "smart machine”. Each module has a special
function for optimising the milling
process.
Christian Knuchel
The objective of the "smart machine” modules is to make the
milling process more transparent
and easier to control for the user.
In order to do so, the first thing to
be achieved is communication between the user and the machine. It
is only in this way that the user is
provided with the comprehensive
information he needs regarding the
milling process in order to make
proper judgements. Secondly, the
user must get support during the
optimisation of the different milling
processes, as a result of which performance is significantly improved.
Thirdly, the machine controls and
optimises the milling process independently, thus improving
process safety and the quality of
the workpiece, especially during
automated operation.
It is at this point that the "smart
machine” functions begin to make
their presence felt.
Use of the different "Smart
Machine” modules
• Greater accuracy at short processing times
• Improvement in the workpiece
finish as well as molding
accuracy
• Detection of critical processing
strategies
• Improvement in process safety
• Reduction in the machine rate
resulting in an increase in
machine service life
15
Intelligent functions
support the
milling process
• Increase in availability
• Increase in operation
comfort even during automated
operation
• Considerable increase in
reliability during automated
operation
• Overall economic budget improved through optimisation in
all process areas.
The Smart Machine Modules
Mikron Advanced Process System
(APS)
The APS module is a monitoring system which opens up new
possibilities to the user to observe
and control the milling process.
This system was specially developed for high performance and high
speed cutting. However, it can be
perfectly adapted to other milling
machining systems.
With the help of an acceleration
sensor integrated in the spindle,
the vibrations during the milling
process are detected and displayed
to the user via the control. By
doing so, it is intended that the necessary measures can be taken in
the process to optimise this.
Remote Notification System (RNS)
A new era in communication
and flexibility is achieved using this
module. By using this system, it is
now possible to receive information regarding the operating conditions in the Mikron machining
centre regardless of the location as
well as regarding the milling
process itself. Via SMS on a mobile
telephone the user can be informed
of the operating conditions or the
machine programme status. This
is a way of enabling the extensive
and flexible involvement of the
Siemens press picture
Remote Notification System (RNS): A new era in communication.
By using RNS it is now possible to receive information regarding the operating conditions in the Mikron
machining centre regardless of the location as well as regarding the milling process itself via SMS on a
mobile telephone.
user since with this module a
stand-by organisation can be
easily achieved.
The unique, worldwide first
intelligent Operator Support
System (OSS)
OSS optimises the machining
process in accordance with the
structure and requirements of the
workpiece. By using an easily understandable user interface, the
target sizes, speed, accuracy and
finish, as well as the workpiece
weight and the complexity of the
machining, can be specifically set
and changed at any time. This
process-oriented way of working
guarantees maximum use of the
Mikron machine.
Intelligent Thermal Control (ITC)
By using the ITC the machine
operator no longer has to maintain
the machine’s thermal steadystate. He can concentrate fully
on the requirements specific to
the workpiece. The Mikron machine
already possesses "thermal
process knowledge”.
For all Mikron machines with a
Heidenhain control system
The "smart machine" modules
can be used on all Mikron machines
with current Heidenhain control
systems. Some of the modules
already form part of the standard
machine equipment. Others are
optional.
Each of the "smart machine”
modules fulfils a specific function.
As in the modular system, the user
can pick out the modules that he
feels are most suitable for improving his milling process. This means
that workpieces can be produced
more in line with processes and
more accurately. Reliability during
automated operation is increased,
the service life of machines is
extended and production costs are
significantly reduced.
It is Mikron’s objective to provide the user with even more information "straight from the machine”. That’s why Mikron is already
developing more "smart machine”
modules.
"Smart machine” is a modular
system and new modules are continuously being developed. The currently available combinations,
Mikron-Machines and modules can
be found on Mikron’s home page at
www.mikron-ac.com.
Impressum
HSMtodayTM
is published by Mikron Nidau
Mikron AG Nidau,
Ipsachstrasse 16, CH-2560 Nidau
Tel. +41 32 366 11 11,
Fax +41 32 366 11 66,
E-Mail: [email protected]
Brand Manager: Jens Thing
Managing and Design Editor:
Jürgen Maurer
Photo adaptation: Vik Furer
Circulation: 45’000
Published in German, French,
English, Italian, Polish, Spanish and
Chinese
Photos: Hallmark, Mahle, Mikron Nidau,
Siemens, Trutron
Print: Stämpfli AG, CH-3001 Bern
Issue 14, February 2005
© Mikron AG Nidau 2005
www.mikron-ac.com
High-speed machining
16
HSM today Nr. 14
Mikron HSM
technology is definitely on the cards
for Hallmark
Congratulations, celebrations
and even commiserations. If there
is an important date coming up in
the diary for members of your
family or your friends – the
chances are that you will send
them a card to help commemorate
the occasion.
The greeting card industry is
truly global and Hallmark Cards is
one of the world’s largest and bestknown greeting card producers. It
has 50% market share in the US
and is the leading greeting card
publisher in the UK.
Established in 1910 the company operates in more than 100 countries worldwide - publishing and
producing cards in more than 30
languages. Such a market presence means that whether you are
browsing through card racks in
Antigua or Zimbabwe…or any country in between… there’s a good
chance that you will ultimately
choose a Hallmark product.
One of the company’s biggest
and most successful operations is
in the UK. With over 3,100 employees, Hallmark UK accounted for
over 70% of the whole of Hallmark
International’s turnover in 2001.
The company boasts an impressive
product range with over 8,000
different products being available
in the UK at any one time – enough
to satisfy the £1.07bn annual UK
market.
To maintain Hallmark’s market
dominance requires a combination
Did you know?
Hallmark’s UK businesses currently produce
2 billion cards per year.
Hallmark’s UK businesses 120 million metres
of gift wrap per year – enough to wrap around the
world three times over.
The UK has the world’s largest per capita
consumption of greeting cards – 55 cards are
bought per person per year.
of excellent design and creative
skills, an effective and focused
network of wholly-owned subsidiaries, licensees, distributors
and agents, state-of-the-art production facilities and investment in
the latest advanced manufacturing
technologies.
The manufacturing operation at
Hallmark UK’s Bradford-based
facility is a case in point.
The company has recently invested in two Mikron HSM 800 highspeed vertical machining centres.
The Mikron machines, installed
within the company’s CNC machining facility, are used to produce
brass and aluminium foil (fluted,
textured and flat) and embossing
dies used extensively in the manufacture of greeting cards.
Because the greeting card in-
dustry is highly-competitive and
because success is often dependent on getting new, competitivelypriced and distinctive selections of
products to market quickly – it is
critical that all manufacturing operations are efficient and highlyproductive.
The greeting card industry is in
effect a fast moving consumer
goods market (FMCG) – and as
such, labour intensive production
processes have been replaced by
advanced manufacturing technologies as a route to reducing lead
times and controlling costs.
The manufacture of dies is no
exception especially when one considers that at Hallmark some
25,000 individual dies are required
and produced each year!
To meet such a high demand
the Mikron machines operate on a
24/7 basis and, since their installation, have had a significant impact on the company’s productivity
(reduced lead times, reduced production costs etc.). The company
estimates that with over 60% of die
manufacture now taking place on
the Mikron HSM 800 machines –
productivity increases approaching
40% have been realised.
Says Dave Sowden, technology
director at Hallmark:
‘We operate and work in a demanding production environment.
We not only have to work to high
accuracy (+/- 2 microns) and surface finish – we have to be fast
and ultra-efficient too. The HSM
800’s are great machines – both
Since their installation - over
60% of the production of foil and
embossing dies now take place
on the two Mikron machines.
Intricate and accurate - the HSM 800's are used to
produce complex dies.
have been supplied with 8.5kW
60,000rpm spindles that enable us
to perform intricate and precise
2 and 3-D machining operations
at high speed.
This plus the machines’
40m/min rapid rates and 17m/s2
acceleration/deceleration give us
all the speed we require.’
The decision to select the
60,000rpm spindle speed option,
not only enables Hallmark to machine at high-speed using exceptionally small diameter cutting
tools – it also represents a first
for Mikron too. The HSM 800’s
were Mikron’s first high-speed
60,000rpm spindle machines to be
installed within the UK.
The HSM 800’s are incredibly
versatile. A generous working
envelope ( X = 800mm, Y = 600mm,
Z = 500mm) means that large workpieces can be easily accommodated. In the production of caption
dies – some 200 individual captions
can be produced on a workpiece in
just one machining operation using the Mikron machines! This is
incredibly productive.
The Mikron machines are both
equipped with a 20 position ATC
capability and automated 4 station
pallet changers for round-theclock unmanned operations – again
another key determining factor for
Hallmark and critical to the company’s ability to cut lead times and
reduce costs.
Since their installation, the
HSM 800’s have delivered reliable
and consistently high levels of performance. This is emphasised by
Hallmark’s digital technology manager, Vanessa Redshaw:
‘We are delighted with our investment in Mikron technology. Because our production schedules
and deadlines are so tight - we have
to have complete confidence in our
new technologies. They have to deliver from day one. We are pleased
to say that the Mikron machines
have never let us down.’
Such customer endorsements
not only reflect the high-performance and reliability of Mikron’s advanced manufacturing technologies – they also highlight the
significant effort and resources
that go into creating and maintaining productivity partnerships between Mikron and its customers.
Technical and applications support, comprehensive operator
training and first-class after sales
and service all ensure that customers are able to fully-exploit the
potential of their investment in
Mikron technology.
Also in the year 2005 it will give
opportunities to consider the production and manufacturing challenges that have been met in ensuring that we are able to have
ready access to such a rich diversity of greeting cards – day in…day
out. Year in …year out!
www.mikron-ac.com