Large-scale mold maker relies on HAIMER technology
Schweiger Formenbau (Schweiger Mold Making) relies on automation to produce high-precision injection molds at competitive costs in Germany. In order to achieve the required, high process reliability, the large-scale mold manufacturer does not make any compromises. For tooling they rely on tool holders, shrinking, balancing and tool presetting technology from the system supplier HAIMER.
The owner-managed Schweiger GmbH & Co. KG from Uffing at Staffelsee in Bavaria specializes in one of the most demanding industries: the automotive industry. For Managing Director Anton Schweiger and his approximately 75 employees, this means having to meet the highest standards of precision and quality with every injection mold produced. Additionally, they are competing in a global market, which, among other things, is subject to enormous cost pressure.
However, facing the strain of global competition, the qualified toolmaker and his team have adjusted and positioned themselves accordingly. They rely on an automated process chain which ensures absolute security and ends with injection molds that meet all requirements. In 2016, for example, the company built a new production hall and invested in two DMC 210U and 270U 5-axis DMG Mori machining centers, which are capable of processing even XXL components in one clamping operation. Equipped with an appropriate pallet automation, the machines run around the clock seven days a week – and all with just one-person shifts. On the weekends they run completely unmanned. This requires highest process reliability across all relevant components and functions.
In this respect, Anton Schweiger has also focused on tool clamping technology, the often overlooked interface between spindle and tool. It bears great responsibility for the quality of the machining, the service life of the spindle and the tool life.
The milling specialists at Schweiger swear in this respect by the support and counsel of HAIMER GmbH, Igenhausen. In 40 years, the family-owned company has become the market leader for tool clamping technology in Europe and is considered to be the world leader in tool shrinking and balancing technology.
Quality makes the difference
For Andreas Orterer, production manager at Schweiger, the main argument for this strong partnership is the quality delivered by HAIMER, “With Haimer products, we can be sure we will always receive the quality that meets our high standards.”
Schweiger currently uses in the thousands of HAIMER tool holders with shrink fit technology. In addition, there are two Power Clamp shrinking devices and a Tool Dynamic balancing device in the production.
Andreas Orterer adds, “From Haimer, we get all tooling from a single source, which suits us very well. In addition, you notice the shrinking and balancing devices have been developed by machinists. They are easy to use and lead to fast results. “
This is also true for the Microset presetter UNO autofocus 20 | 70, which has its place between the shrinking and the balancing devices at Schweiger.
This machine has become a “HAIMER” product since the Bavarian company took over Microset Tool Presetting Technology in Bielefeld at the beginning of 2017. Compared to the manual version, the UNO autofocus is able to automatically focus the cutting edge for measurement of the C-axis. Especially when it comes to tools with several cutting edges on the circumference, this option proves to be enormously time-saving. All in all, the device allows set-up time reductions of up to 70 percent just from presetting outside of the machine.
Andreas Haimer, Managing Director of Haimer GmbH, explains, “With the acquisition of Microset Tool Presetting Technology we have become a system supplier for tool management. Microset perfectly complements our existing portfolio of high-precision tooling, clamping, shrinking and balancing technology, in such a way as to enable us to provide even greater support to our customers. “
Automatically highest runout accuracy
The level of satisfaction Anton Schweiger, Vice President of the Association of German Tool and Mold Makers (VDWF), has in his partnership with HAIMER and his tool holders can be measured by the fact that he has been using them for more than two decades.
When the toolmaker bought the first HSC machine about 20 years ago, he switched from mechanical collet chucks to HAIMER shrink fit chucks because of the improved runout accuracy. Compared to the products of other suppliers, the HAIMER shrink fit chucks won him over with its superior quality, “a company goal that HAIMER and ourselves have in common.» »If you take the example of the shrink fit chucks, this can be seen in the runout accuracy, which is, by default, below 3 μm.”
This is an important prerequisite for the tool makers from Uffing. After all, they do not produce injection molds for cheap consumables, they create highly sophisticated molds used in premium vehicles – for example used to make headlight end plates in 2-component injection molding. These customers place high demands on the end products and do not accept the slightest blemish. Accordingly, the injection molds have to meet similar requirements: as a rule, surfaces should be smooth as glass and tolerances of less than 2/100 mm must be maintained.
One of Schweiger’s main areas of focus in production is the milling of large complex molds, whereby individual workpieces can weigh up to nine tons. The cavities are often very deep. Typically between 300 to 400 mm, sometimes even up to 500 or 600 mm deep. This requires slim shrink fit tool holders, the use of shrink fit extensions as well as tools with extremely long shanks. “Another strength of Haimer. The company offers a large variety of tool holders standard. If required, however, we can always order a wide range of special designs,” emphasizes production manager Orterer. He points again to the extremely good runout accuracy properties, which apply equally to standard and special tool holder designs. Not only do they contribute to excellent machining results, they also spare the spindle and the tools.
A long tool life enables unmanned operation
In general, a longer spindle life means considerable costs savings, but the tool live is even more important in automated production. “In order to work unmanned, I need an absolutely reliable, long-lasting system of spindle, tool holder and tool,” explains Anton Schweiger.
Schweiger machines many large injection molds automatically in one clamping operation – for 40 to 50, sometimes even 100 hours, non-stop. A broken tool or even a spindle damage during unmanned operation would be fatal. In addition, a rigid and stable connection is important to achieve the requested surface quality. “A key to this is the Haimer tool holders,” adds the company owner, “they enable process-reliable machining.”
Not every requirement of the toolmaker can be optimally fulfilled with standard tool holders. Anton Schweiger especially appreciates the close cooperation with the HAIMER specialists and the flexibility of the company in Igenhausen. “For us it is important that Haimer listens to the users,” emphasizes the entrepreneur. His HAIMER contact, Oliver Lechner, sales manager for Southern Germany, always responds quickly to inquiries. Lechner comments, “After that, we supply Schweiger with the required custom-made products, such as special, conically shaped face mill arbors that allow the machining of cavities up to 360 mm depth.” Anton Schweiger adds, “These tool holders are perfectly adapted to the tool diameter and the respective cavities. That is how I can, without any concerns, let the machines work without supervision – even for roughing.”
Specialist for complex large-scale molds
The tool and mold making company, Schweiger, was founded in 1962 by Erich Schweiger. Today, under the management of his son Anton Schweiger, it has around 75 employees and generates around 10 million Euros in sales each year. Their core business consists of complex injection molds weighing between 5 and 30 tons, 99 percent of which are supplied to the automotive industry. They are mainly used for the production of headlight covers, optical and visual components. Customers include German premium manufacturers, as well as their 1st tiers. In addition to automated production with standardized processes, Schweiger sees its strength in turn-key solutions. The services range from support in product development to series production and aftersales services.
Sandvik Coromant showcasing new paths to success in Stuttgart
At this year’s AMB exhibition (Stuttgart, 18-22 September), Sandvik Coromant intends to show how customers and partners can achieve significantly higher productivity levels, more flexible machining processes and more sustainable production under the strapline ‘Shaping the future together’. For instance, the global specialist in cutting tools and tooling systems will be revealing how it is revolutionizing the world of turning, improving the entire manufacturing process with digital connectivity solutions and offering fascinating possibilities for the automotive and aerospace industries.
On Stand E50 in Hall 1, Sandvik Coromant will present digital solutions designed for smarter machining and greater manufacturing efficiency. These innovations will include CoroPlus® ToolGuide, which provides fast and precise tool recommendations for the specific operation and material type, as well as CoroPlus® ToolLibrary, which enables users to integrate tool assemblies directly into their digital machining environment. Along with software that helps improve design and production planning, the company will showcase networked tool and process-control solutions.
Trade visitors can also discover the latest technologies in the fields of turning, milling and drilling at the 375 m2 stand. Included will be turning solutions such as CoroCut® QD for cutting with the Y axis. CoroCut® QD uses the potential of modern turning centres and multi-tasking machines to guide the tool in the Y direction, positioning the upper side of the indexable insert parallel to the end of the blade. This capability enables faster feed speeds and the machining of longer overhangs without loss of stability.
Also being promoted at the show will be the PrimeTurning™ process for turning in all directions. Manufacturers in the automotive and aerospace industries, in particular, can benefit since PrimeTurning™ is extremely versatile. Indeed, the process is suitable for turning short, compact components, for longitudinal turning, and for machining contours and front-end geometries.
“We are looking forward to another great AMB because this trade show always offers an excellent opportunity to meet customers and partners personally in order to optimize future co-operation,” says Josse Coudré, General Manager Sales Area Central Europe at Sandvik Coromant. “We are proud to present our high-end solutions in Stuttgart, all of which are designed to help manufacturers become more efficient, productive and profitable.”
Thanks to numerous co-operations with machine manufacturers, including being a co-exhibitor on the DMG Mori stand, solutions from Sandvik Coromant will be on display in many places around the exhibition. Sandvik Coromant is also one of the sponsors and speakers at the special two-day AMB show ‘Digital Way 2018 – Digital Paths in Production’.
The Sandvik Coromant service team will again support and advise customers before and during AMB. A five-man technical crew will be available one week before the start of the trade fair in Hall 5, Room 5.3.
STUDER introduces a new machine to the market
STUDER expands its product portfolio and introduces a new machine to the market – the favorit with a centre distance of 1600mm (63”).
If you believe that a large STUDER machine will exceed your budget, we recommend you have a look at the favorit. This machine, top in price and performance, can be used universally and thanks to the centre distance of 1600mm (63”) can also handle long workpieces.
favorit – for big demands and small budgets
This CNC universal cylindrical grinding machine is designed for grinding both single part and series production and can be fitted with automation. With various options such as measuring control, balancing system, contact detection and longitudinal positioning, it can be subsequently adapted to other grinding tasks.
The favorit is a very reasonably priced machine. As with all STUDER cylindrical grinding machines, the proven machine bed made of solid Granitan® ensures maximum precision, performance and safety. The full enclosure provides an optimal view of the grinding process. The wheelhead, which can be automatically positioned every 3 °, can accommodate a belt-driven external and internal grinding spindle.
Thanks to the practice-oriented STUDER grinding software, with its proven Studer- pictogramming, even less experienced users can program grinding and dressing cycles quickly and efficiently. With the optionally available StuderGRIND software, special applications, such as profiling the grinding wheel for complex workpiece shapes, can be efficiently programmed. Development, production, assembly and testing of the STUDER products are process-oriented and comply with the strict guidelines of VDA 6.4 and ISO 9001.
Another novelty awaits you at the AMB in Stuttgart from September 18 – 22. Come to the unveiling event on September 18 at 12:00 in hall 5, booth 5C12.
Gleason – Total Gear Solutions at IMTEX 2017
Gleason will present solutions in advanced gear manufacturing technology in Hall 4 Booth B116 at IMTEX 2017, covering a wide array of processes for the complete production and inspection of all types of bevel and cylindrical gears and tools.
Advanced Gear Manufacturing Tools
Gleason will present its latest gear manufacturing tools including advanced carbides as well as innovative coatings.
For bevel gears Gleason will show new cutter head systems like the PENTAC® RT Plus and the PENTAC® Mono RT, for fast and easy assembly and inspection, and superior cutting results. Gleason will also present its latest line of hard finishing tools including dressing tools for cylindrical grinding and honing applications.
For cylindrical gears we show high-quality hobs, shaving cutters, shaper cutters, power skiving tools, master gears, as well as grinding and dressing tools. Our hobs and shaving cutters for cost-efficient manufacturing are supported by local sharpening service. Gleason gear technology experts will be present at the booth to consult you regarding your specific application.
Innovative Workholding Solutions
Quik-Flex® Plus, Gleason’s next generation of modular, quick-change workholding systems requires a one single tool for changeover, less time and minimal operator experience, now available for cylindrical and bevel gear applications. Gleason will also present its line of hydraulic workholding solutions. The holding force, extreme accuracy and contamination-free designs are well suited for dry gear processing applications. The new Gleason Stir-Able Modular Workholding designs allow off-spindle assembly and truing, reducing changeover time as well as the amount of total run-out in the fixture. Gleason India produces Gleason Workholding solutions locally.
Gleason Global Services
Gleason Global Services is the leading source of gear technology knowhow and education. Gleason trainers will be promoting the full range of training classes ranging from beginner levels to the most advanced expert topics. Gleason Global Services will present its range of performance upgrades, modernization programs and tooling services, including practical examples.
Manufacturing Solutions for Hobbing and Shaving Applications, as well as workholding and bevel cutting tools, made in India
Gleason is manufacturing gear hobbing and shaving machines as well a workholding solutions and bevel cutting tools in its plant at Bangalore, made to the same high quality standard as in all other global Gleason operations. Meet our experts at the Gleason Booth at IMTEX and get to know the advantages of Gleason machines made in India.
New Gleason Facility in Bangalore
Join us on August 17th and 18th as we celebrate the opening of our new state-of-the-art facility in Bangalore. Visit our booth at IMTEX to learn more about this event and reserve your place to attend technology demonstrations and informative seminars presented by international gear technology experts. This event is a unique opportunity, giving visitors an unusually in-depth look at many advanced new technologies for gear manufacturing.
Gleason is a leader in the development, manufacture and sale of gear production machinery and related equipment and automation solutions. The Company’s products are used by customers in automotive, truck, aircraft, agriculture, mining, energy, construction, power tool and marine industries and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in the United States, Brazil, Germany, Switzerland, India, China and Japan, and has sales and service offices throughout North and South America, Europe and in the Asia-Pacific region.
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