die and mold industry richard chen - ses3000ses-3000.com/haberler/ycm recent technology developments...

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Recent technology developments for

Die and Mold industry

Richard ChenChairman


Outline

Company profile

Latest machine tool technology for

mold & die industry

Future trends


Foundry

Assembly 3

Assembly 2

Assembly 4

Machine Shop

Administration building

Technology

Center

Warehouse

Logistics Assembly 1

Year of founded : Since 1954

Total land : 164,160 m2

Factory facility ：98,063 m²

Assembly No.4：8,333 m²

Company profile


More than 50 distribution partners

Assembly Plant in Shanghai, China

Oversea technical center in USA and Malaysia

Building global brand through quality and value

World Wide Networks

Company profile

YCM in Turkey

In Turkish market since 1994 and partnered with SES3000 CNC

Sold more than 2500 sets YCM Machines in Turkish market


VM

C

FP FP55LX FP66A/G FP100A

NXV NXV560A NXV1020A/AM NXV1380A NXV1680A/B

TV TV116B TV146A/B TV158B TV188B TV2110B TV2610B

NTV NTV158A/B

MV NMV76A NMV106A

WV WV108A/B

FX NFX 380A NFX500A

NSV NSV66A NSV85A NSV102A/AM NSV156A

NDV NDV66A NDV85A NDV102A NDV156A

TCV TCV2000A TCV3000A TCV3000A-5AX

DCV

DCV2012A/B DCV3016B DCV4016B

DCV3021B DCV4021B DCV5021B DCV6021B

DCV3025B DCV4025B DCV5025B

DCV2018A-5AX DCV4030B/B-5AX/B-5AF DCV5030B/B-5AX DCV6030B/B-5AX

DCV4035B DCV5035B DCV6035B

NDC NDC2016B NDC3016B NDC4016B NDC3018B-AHC

YCM product line


HMCH H500A/B

NH NH450A NH630B NH800B

CNC

Lathes

GTGT-200A/B GT-250A/B

GT-300A/B/LA/LB

GT-380A/B/LA/LB

GT-200MA GT-250MA/MBGT-

300MA/MB/LMA/LMB

NT NT-2000Y/S/SY NT-2500Y/S/SY NT-2000SY2

TCTC-16A/B/LA.LB TC-26 TC-36 TC-46

TC-16MA/MB/LMA/LMB TC-26L TC-36W TC-46M

HBM BMP BMP1416P

YCM product line


Latest machine tool technology for

mold & die industry


Die & Mold

Industry

Machine Tool

X-Factor

CAD

/CAM

Strategies

Tooling Technology

Critical Factors for Die Mold Machining


Critical Factors for Die Mold Machining Center

Machine tool

Cycle Time

Surface Finish

Thermal Growth

Tool Life


Center shaft

cooling

Stator

cooling

Bearing

quill

cooling

Updated on NFP series

With bearing quill cooling design

With Stator cooling

With Center shaft cooling

Spindle Heat Removal


Through thermal compensation, the

machine only require 10 minutes to

stabilize in all axes.

Z axis thermal growth is drastically

reduced through offset.

Without

offset

With

offset

X axis 6 um 6 um

Y axis 3 um 3 um

Z axis 37 um 5 um

Without Offset

With Offset

Run spindle on 24,000rpm for 10

minutes.

After 10 minutes (24K rpm ),

the thermal changing become

stable.

Test on NFP-24K spindle in AC room

Spindle Thermal Compensation


Axial Heat Removal Design

Axial Heat Removal



Without nut cooling With nut cooling

Ballscrew Nut cooling system

to stabilize temperature

Axes heat removal


Axial Heat Removal Design


Nuts

cooling

Front

bearing

cooling

Rear

bearing

cooling

STC

function

Optical

scale

Heat

isolation

design

Construction

symmetry

design

Motor

flange

cooling

Center /Stator/

Bearing cooling

Overview for Thermal Solutions



Process Optimization


Process 1 - Spindle & lobe chart (Vibration optimization)

Spindle & Tool Lobe Chart

Determine optimal spindle speed



Process 2 - Program optimizationOriginal Program

Cutting Feedrate 15m/min.

Corner speed is reduced due to vibration

and tool marks

Identify optimal spindle and cutting speed

for best machining efficiency.

After optimizing program



Process 3 - High speed & High Accuracy parameters adjustment

NG Ok

High speed & High Accuracy

parameters adjustment

(Std. function in YCM Fanuc)

Overcut



Result

Original Cycling Time 160min/pcs

Final Cycling Time 110min/pcs

31%

Cycling Time

Reference

only


+Improved Tool Life


Future trends


Revitalizing MFG Policies (1/2)

USA AMP

Mass Customization

• Initiated in 2011

• Production technologies and

innovation

• Create re-shoring

manufacturing opportunities

Smart Factory


• Improve labor skill

• CPS implementation

• Smart factory

Germany

Industry 4.0

Smart Factory


Revitalizing MFG Policies (2/2)

China

2025 Plan

Intelligent production


• Intelligent equipment development

• New material application i.e. Nano

Technology

• Green energy development and

application

Japan

New Robot

Human-Robot Co-existence


• Humanized robot development

• Robots with multiple function

sensors

Smart Factory


What is Industry 4.0?

Smart Factory


Industry 4.0

Why Industry 4.0?

Mass

Production

Customization

Labor

Shortage

Shorter

Product Life

Cycle

Re-shore

MFG


Industry 4.0

Labor Shortage

Source: Mckinsey Global Institute,2012

1. Manufacturing employment in advanced economies is decreasing every year gradually.

2. Manufacturing employment in advanced economies could fall from 45 million jobs today to fewer than 40 million by 2030.


Industry 4.0

Mass Production Customization



Industry 4.0

Shorter Product Life Cycle



Industry 4.0

Advanced Economies want to re-shore manufacturing

Source: Roland Berger Strategy Consultant 2014


IOT (Internet of

Things)• Install sensors

to collect all

data through

internet

Robotic

• Automation

Big Data

(real-time)• Analysis system

• Cost MGMT

• Shorten lead time

• Supply chain

MGMT

Industry 4.0

Smart Factory(Robot+IOT+Big Data)

Industry 4.0

What is Industry 4.0?


2. Adaptive chip removal function

A. Intelligent Spindle1. Intelligent detection devices and black boxes

2. Spindle and motor temperature monitoring

3. Spindle vibration control

4. Deterioration monitoring of spindle motor coil

5. Tool life Management

E. Intelligent Feed Axes1. Ballscrew / motor temperature monitoring

2. Axial thermal compensation

3. Preventive maintenance motor coil

4. Machine collision protection

D. Remote Diagnosis &

Management

Intelligent Machining ModuleC.

1. Optimizing axial servo parameters

2. Adaptive cutting function

1. Production management

2. Tool life management

3. Machine status record

4. Plant / Machine monitoring

B. Thermal Solution1. Thermal Suppression

2. Thermal Removal

3. Spindle Thermal Compensation

Existing

2015

2016

2017

1. Tool management (list/ lifetime/ loading)

2. Big/ standard tool function

3. Heavy tool function

4. Fixed tool pot function

5. Tool pot locking function

6. Tool breakage detection

Intelligent ATC J.

1. CTS level detection

1. Automatic infrared sensor

2. Warning lights control

1. Automatic switch of safety door

2. Anti-layering protection mechanism

Energy-saving control

Safety/ Automatic Door SystemF.

Hydraulic System G.

Coolant/Chip Removal SystemH.

Lighting System I.

5. Energy monitoring

6. Production control

6. Spindle bearing wear/ lubrication monitoring

5. Preload monitoring

6. Lubrication monitoring

Smart Factory


i-Direct Website Design

Design and build website that can monitor plant from remote location and connect with ERP.

www

Database

INTERNET

Website Design

ERP

Smart Factory

http://www.mysql.com/

http://www.mysql.com/


i-Direct (Remote Monitoring)

Smart Factory

http://idirect.ycmcnc.com/YCM_RemotingSystem/

http://idirect.ycmcnc.com/YCM_RemotingSystem/


i-Direct (Remote Monitoring)

Smart Factory


i-Direct (Capacity utilization monitoring & Mgmt)

Smart Factory


Use of Four-/Five-Axis Machines

Use of Four-/Five-Axis MachinesTop Shops Other Shops

Four-axis positioning 56% 24%

Four-axis contouring 59% 37%

Five-axis positioning 44% 18%

Five-axis contouring 44% 22%

Benefits:

Minimize setups

Improves accuracy

Improves surface finish

Improves tool life


Machining at an angle

extends the tool life &

increase the surface finish.

Reduce the machining time,

increase the surface accuracy.

Advantages of 5 axes


Save fixture, work piece

install & machining time,

increasing the accuracy

Reduce interference, cost of

tool & time of machining



Avoid Center Cut - Improves Accuracy & Finish

Ａ

10,000 rpm

2.6

V=50m/min

3.26 times

0.8

φ6

0°15°

60° Ｂ V=163m/min



DCV4030B-5AX – Mold machining (Invar)



DCV6030B-5AX – Mold for sheet metal



High-pressure coolant

Trends in High-pressure coolant Use

Benefits:

More heat can be removed from

the cut zone.

helps break up chips and

remove them from the cutting

area more efficiently

the cutting tool spends less time

re-cutting chips.


Thank you!!

die and mold industry richard chen - ses3000ses-3000.com/haberler/ycm recent technology developments...

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