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.
Reliable thread turning in tight spaces
Walter AG is completing its range of MX grooving inserts with the A60 and AG60 geometries for small to medium pitches. Just like the existing MX geometries (CF5 and GD8 for all grooving and parting off tasks, RF5 for grooving and copy turning), the A60/AG60 inserts are also designed with four cutting edges.
The geometries are made for creating 60° partial-profile external threads in a wide range of pitches (0.5–3.0 mm) and are particularly suited to thread turning in tight spaces, like near a shoulder or counter spindle. In addition, the system offers general advantages like excellent cost-effectiveness or the ability to use all inserts universally with one toolholder on the left and right.
The MX system is suitable for all materials and enables insert widths between 0.8 and 3.25 mm and cutting depths of up to 6 mm. One special feature is the design of the insert seat: Due to the self-aligning tangential clamping, the insert is pressed against the contact points when the screw is tightened. A special dowel pin helps with accuracy of fit and simultaneously makes it impossible to mount the insert incorrectly. That results in a high degree of dimensional stability and repeat accuracy. The fact that the insert contact surface is not ground when creating the cutting edge width, and the entire insert thickness is therefore maintained, also contributes to the high stability of the MX system. Special profiles outside the standard range are offered by Walter from ten pieces and are available via the Walter Xpress service within four weeks.
ANDRITZ to supply a 20-high cold rolling mill to Harada Metal Industry
International technology group ANDRITZ has received an order from the private enterprise Harada Metal Industry Co., Ltd., Japan, to supply a 20-high cold rolling mill in four-column design to produce high-precision quality coils of phosphor bronze with a final strip thickness of 20 microns for its Sendai plant, Miyagi Prefecture, Japan.
The cold rolling mill will be designed with particular focus on production level, strip shape, and strip thickness tolerances to produce top-quality coils of phosphor bronze. Production of the first coil is scheduled for the first quarter of 2020.
The ANDRITZ scope of supply includes the engineering and supply of tension reels, the main drive gear box and mechanical drive line, the mill stand, the hydraulic and media systems, and the automation and electrical equipment.
This order is now the fifth cold rolling mill to be delivered to Harada, thus confirming the long-term and successful cooperation, dating back to 1983, between Harada Metal and ANDRITZ.
Harada Metal, founded in 1952, is a renowned Japanese manufacturer of phosphor bronze sheets and strip.
ANDRITZ is a globally leading supplier of plants, equipment, and services for hydropower stations, the pulp and paper industry, the metal working and steel industries, and for solid/liquid separation in the municipal and industrial segments. Other important fields of business are animal feed and biomass pelleting, as well as automation, where ANDRITZ offers a wide range of innovative products and services in the IIoT (Industrial Internet of Things) sector under the brand name of Metris. In addition, the international technology Group is active in power generation (steam boiler plants, biomass power plants, recovery boilers, and gasification plants) and environmental technology (flue gas cleaning plants) and offers equipment for the production of nonwovens, dissolving pulp, and panelboard, as well as recycling plants.
ANDRITZ Metals is the technology and global market leader in forming equipment through the Schuler Group, in which ANDRITZ has a stake of more than 95 percent. Schuler offers presses, automation solutions, dies, process know-how, and services for the entire metal forming industry. Its customers include car manufacturers and their suppliers, as well as companies in the forging, household appliance, packaging, energy, and electrical industries. Schuler is also the market leader in coin minting technology and offers system solutions for the aerospace industry, rail transport, and manufacture of large pipes.
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.
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