Recent technology developments for Die and Mold industry Richard Chen Chairman P. 1 of 43
Outline Company profile Latest machine tool technology for mold & die industry Future trends P. 2 of 43
Company profile Assembly 2 Assembly 3 Foundry Year of founded : Since 1954 Total land : 164,160 m 2 Factory facility :98,063 m² Assembly No.4:8,333 m² Machine Shop Logistics Assembly 1 Warehouse Technology Center Assembly 4 Administration building P. 3 of 43
Company profile World Wide Networks More than 50 distribution partners Assembly Plant in Shanghai, China Oversea technical center in USA and Malaysia Building global brand through quality and value YCM in Turkey In Turkish market since 1994 and partnered with SES3000 CNC Sold more than 2500 sets YCM Machines in Turkish market P. 4 of 43
VMC YCM product line 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 DCV2012A/B DCV3016B DCV4016B DCV3021B DCV4021B DCV5021B DCV6021B DCV 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 P. 5 of 43
YCM product line HMC CNC Lathes H H500A/B NH NH450A NH630B NH800B GT GT-200A/B GT-200MA GT-250A/B GT-250MA/MB GT- 300A/B/LA/LB GT- 300MA/MB/LMA/LMB NT NT-2000Y/S/SY NT-2500Y/S/SY NT-2000SY2 TC GT- 380A/B/LA/LB TC-16A/B/LA.LB TC-26 TC-36 TC-46 TC- 16MA/MB/LMA/LMB TC-26L TC-36W TC-46M HBM BMP BMP1416P P. 6 of 43
Latest machine tool technology for mold & die industry P. 7 of 43
Critical Factors for Die Mold Machining Tooling Technology Machine Tool Die & Mold Industry CAD /CAM Strategies X-Factor P. 8 of 43
Critical Factors for Die Mold Machining Center Thermal Growth Surface Finish Tool Life Machine tool Cycle Time P. 9 of 43
Spindle Heat Removal With bearing quill cooling design With Stator cooling With Center shaft cooling Center shaft cooling Stator cooling Updated on NFP series Bearing quill cooling P. 10 of 43
Spindle Thermal Compensation Through thermal compensation, the machine only require 10 minutes to stabilize in all axes. Z axis thermal growth is drastically reduced through offset. Run spindle on 24,000rpm for 10 minutes. Without Offset With Offset Without offset With offset X axis 6 um 6 um Y axis 3 um 3 um Z axis 37 um 5 um After 10 minutes (24K rpm ), the thermal changing become stable. Test on NFP-24K spindle in AC room P. 11 of 43
Axial Heat Removal Axial Heat Removal Design Updated on NFP series P. 12 of 43
Axes heat removal Axial Heat Removal Design Ballscrew Nut cooling system to stabilize temperature Updated on NFP series Without nut cooling With nut cooling P. 13 of 43
Overview for Thermal Solutions Center /Stator/ Bearing cooling Construction symmetry design Heat isolation design STC function Optical scale Front bearing cooling Motor flange cooling Nuts cooling Updated on NFP series Rear bearing cooling P. 14 of 43
Process Optimization P. 15 of 43
Process Optimization Process 1 - Spindle & lobe chart (Vibration optimization) Spindle & Tool Lobe Chart Determine optimal spindle speed P. 16 of 43
Process 2 - Program optimization Original Program Process Optimization Cutting Feedrate 15m/min. Corner speed is reduced due to vibration and tool marks After optimizing program Identify optimal spindle and cutting speed for best machining efficiency. P. 17 of 43
Process Optimization Process 3 - High speed & High Accuracy parameters adjustment Overcut NG Ok High speed & High Accuracy parameters adjustment (Std. function in YCM Fanuc) P. 18 of 43
Process Optimization Result Cycling Time 31% Reference only Original Cycling Time Final Cycling Time + Improved Tool Life 160min/pcs 110min/pcs P. 19 of 43
Future trends P. 20 of 43
Revitalizing MFG Policies (1/2) Smart Factory USA AMP Germany Industry 4.0 Mass Customization Initiated in 2011 Production technologies and innovation Create re-shoring manufacturing opportunities Smart Factory Initiated in 2012 Improve labor skill CPS implementation Smart factory P. 21 of 43
Revitalizing MFG Policies (2/2) Smart Factory Japan New Robot China 2025 Plan Human-Robot Co-existence Initiated in 2013 Humanized robot development Robots with multiple function sensors Intelligent production Initiated in 2015 Intelligent equipment development New material application i.e. Nano Technology Green energy development and application P. 22 of 43
Smart Factory What is Industry 4.0? P. 23 of 43
Industry 4.0 Why Industry 4.0? Mass Production Customization Labor Shortage Re-shore MFG Shorter Product Life Cycle P. 24 of 43
Industry 4.0 Labor Shortage 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. Source: Mckinsey Global Institute,2012 P. 25 of 43
Industry 4.0 Mass Production Customization Source: Mckinsey Global Institute,2012 P. 26 of 43
Shorter Product Life Cycle Industry 4.0 Source: Mckinsey Global Institute,2012 P. 27 of 43
Industry 4.0 Advanced Economies want to re-shore manufacturing Source: Roland Berger Strategy Consultant 2014 P. 28 of 43
Industry 4.0 What is Industry 4.0? Industry 4.0 Smart Factory (Robot+IOT+Big Data) Robotic Automation IOT (Internet of Things) Install sensors to collect all data through internet Big Data (real-time) Analysis system Cost MGMT Shorten lead time Supply chain MGMT P. 29 of 43
Smart Factory J. H. Existing 2015 2016 2017 Intelligent ATC 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 I.Lighting System 1. Automatic infrared sensor 2. Warning lights control Coolant/Chip Removal System 1. CTS level detection 2. Adaptive chip removal function A. Intelligent Spindle 1. 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 6. Spindle bearing wear/ lubrication monitoring B. Thermal Solution 1. Thermal Suppression 2. Thermal Removal 3. Spindle Thermal Compensation C. Intelligent Machining Module 1. Optimizing axial servo parameters 2. Adaptive cutting function D. Remote Diagnosis & Management 1. Production management 2. Tool life management 3. Machine status record 4. Plant / Machine monitoring 5. Energy monitoring 6. Production control G. Hydraulic System Energy-saving control F. Safety/ Automatic Door System 1. Automatic switch of safety door 2. Anti-layering protection mechanism E. Intelligent Feed Axes 1. Ballscrew / motor temperature monitoring 2. Axial thermal compensation 3. Preventive maintenance motor coil 4. Machine collision protection 5. Preload monitoring 6. Lubrication monitoring P. 30 of 43
i-direct Website Design Smart Factory Design and build website that can monitor plant from remote location and connect with ERP. www Website Design INTERNET ERP Database P. 31 of 43
Smart Factory i-direct (Remote Monitoring) http://idirect.ycmcnc.com /YCM_RemotingSystem/ P. 32 of 43
i-direct (Remote Monitoring) Smart Factory P. 33 of 43
Smart Factory i-direct (Capacity utilization monitoring & Mgmt) P. 34 of 43
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Use of Four-/Five-Axis Machines Use of Four-/Five-Axis Machines Top 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 P. 36 of 43
Advantages of 5 axes Machining at an angle extends the tool life & increase the surface finish. Reduce the machining time, increase the surface accuracy. P. 37 of 43
Advantages of 5 axes Save fixture, work piece install & machining time, increasing the accuracy Reduce interference, cost of tool & time of machining P. 38 of 43
Advantages of 5 axes Avoid Center Cut - Improves Accuracy & Finish φ6 10,000 rpm 2.6 0.8 60 B V=163m/min 0 15 A V=50m/min 3.26 times P. 39 of 43
Advantages of 5 axes DCV4030B-5AX Mold machining (Invar) P. 40 of 43
Advantages of 5 axes DCV6030B-5AX Mold for sheet metal P. 41 of 43
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. P. 42 of 43
Thank you!! P. 43 of 43