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MAKINO DIE MOLD EXPO A SUCCESS
*** Images available below for media use. ***
Makino Die Mold Expo a Success
Industry leaders attend three-day event
Auburn Hills, Michigan—September 2007—Makino’s fifth bi-annual Die Mold
Expo, held at Makino’s Die Mold Technology Center in Auburn Hills,
Michigan was a resounding success September 25 – 27, 2007. Leaders of
the die/mold industry were in attendance to learn about cutting-edge
technologies and techniques.
“By bringing together sought-after business speakers, Makino’s
machining experts, new technology demonstrations, and some of the
world’s best die/mold manufacturers, we are arming North American shops
with tools to compete against overseas competition,” said Andre Ey,
Makino’s Vice President of Die Mold Technologies.
“Many shops tell us that this event is the most important three days of
their year,” said Mark Rentschler, Makino’s marketing manager. “It’s an
invaluable opportunity for training and a way for shops to get a
first-hand look at some of the most advanced technology and
applications expertise.”
Day 1: Business Day (Sept 25)
On the first day of the event, Makino hosted several speakers on topics
such as diversification of your manufacturing business and industry
forecasts.
First to speak was Erich Merkle, Chief Economist & Director of
Forecasting for IRN. Merkle took the audience step-by-step through the
future of the automotive industry, including new insights and what it
means to the North American die/mold shop. He used charts comparing the
U.S. durable goods manufacturing, new car sales, GDP, and many other
variables to illustrate where he thinks potential areas of growth are
in manufacturing. Merkle’s predictions have come to be known as some of
the most accurate in the industry.
Next up was Jeffrey Fox, best-selling author of nine books, including
The Dollarization Discipline, which outlines how to move past a
low-cost selling strategy. Fox customized his presentation for the
die/mold industry, citing specific examples of shops who have found
ways to sell the value of their work, not just become another
lowest-cost provider. He also spoke on ways die/mold shops could market
themselves and stand out from everyone else. He also spoke about ways
to quantify the value of your work to potential customers, focusing on
the true cost of a mold or die, not just the price.
After the break, Jeffrey Mengel, CPA from Plante & Moran, spoke on
the results of Plante & Moran’s biannual North American Survey of
the Plastics Industry, including the benchmarks and statistical
analysis that went along with it. He shared insights on where the
automotive and manufacturing industries are headed, along with several
areas of manufacturing which mold shops need to beware. He also shared
the results of Plante & Moran’s survey of U.S. mold shops, showing
the financial characteristics of a shop that is growing. Throughout his
speech, Mengel emphasized the resilience and adaptability of die/mold
shops, and ways shops could improve their business by seeking business
in growth areas.
Next to speak was Jud McKinley, Executive Vice President of IRN. He
spoke on the topic of selling to new domestic automakers and their
suppliers via his three-phase approach, designed over 20-years of
selling. He used his own experience to share how North American
manufacturers have successfully sold to the new domestics after losing
contracts from domestic automakers, and in turn have grown their
business.
After McKinley finished, Thomas Klier, Senior Economist with the
Federal Reserve Bank of Chicago took the stage. Klier spoke on the
changing structure of the U.S. auto industry, and how this momentous
shift is affecting teir 1 suppliers in North America. He shared several
geographic studies, illustrating where assembly and parts production
plants have moved, and showed the difference between how domestic and
foreign auto makers have spread across North America.
Next up was Rena Pomaville of Tsunagari Services. Her presentation went
into detail on the techniques required to maneuver into the Japanese
business system and how North American shops can win business with
Japanese transplants. She went into detail on the long-term commitment
required by a North American company to establish itself as a potential
supplier to a Japanese firm, using examples of her own experience
working for a Japanese company in the U.S. She also spoke about ways to
interpret responses by Japanese companies, as well as the steps you
need to take in order to prepare yourself for a Japanese company’s
factory visit.
Finally, Steven Everson and Amy Forester from Plante & Moran
discussed how new IRS regulations can benefit North American die/mold
shops through R&D tax credits. They applied their industry
expertise and experience to tell the audience ways to expand their
technology and business assets, while cutting down the money owed to
Uncle Sam. Steven and Amy went into detail on how to decide if an
R&D Tax credit would benefit your business, what the qualifying
factors are, and how to go about getting the tax credit for your
business.
Day 2 & 3: Showroom and Theater Presentations (Sept 26-27)
For those in attendance, one of the most anticipated parts of the
Die/Mold Expo is always what topics are covered in Makino’s Die/Mold
Technology Center showroom and theater. This year was no
disappointment, as Makino’s Applications Engineers and Product Managers
presented on a wide variety of new technologies and machining
techniques.
Showroom demonstrations included a presentation on revolutionary cutter
technologies for stainless steels; the latest advancements in
high-volume roughing applications utilizing high-feed mills; sinker EDM
process technologies to backburn punches, speed up rib machining,
machine fine holes and obtain superior surface finishes; a shop-owner
showing off his job-shop running “lights-out” hardmilling via webcam;
and a case study of why a shop chose to switch to a Makino wire EDM.
Theater presentations included:
The Evolution of Hardmilling: Past, Present and Future, where a Makino
Applications engineer talked about how this process has changed over
the years, Makino’s role in its development, and how Makino is
currently machining materials at 70+ HRc.
Metrology: Does Your Part Measure Up, where Optical Gauging Products
(OGP) demonstrated some of the best and most practical measuring
processes for specific applications including laser, vision and probe.
HEAT and SurfaceWIZARD, where Makino’s EDM Product Manager spoke about
the new technologies, when combined eliminate witness lines in stepped
workpieces and dramatically increase speed and accuracy in poor
flushing conditions. This demonstration also included a live
demonstration in the showroom.
2+3 Machining: The Realities of 5-Axis Machining, where a Makino’s VMC
Product Manager talked about the advantages and disadvantages of 5-axis
in die/mold applications, including accuracy and programming concerns
related to this technique.
Shrinking Lead-Times in Medical Mold Manufacturing with Micro
Technology, where lead-time comparisons were presented between direct
milling and EDM, showing the technological advancements and challenges
during the build of a medical staple mold.
Cut to Zero, where an emSOLVE engineer shared processing techniques on
how to finish a machine cavity and core to net-zero stock. He also
discussed how CAM software plays a role in cutting to zero, and some of
the latest software, such as FF/CAM®, contributes to net-shape
machining.
Day 2 & 3: Machining Demonstrations (Sept 26-27)
Eighteen machines were under power on Makino’s showroom, demonstrating dozens of technologies and materials.
These included:
V22 vertical machining center, micromilling a medical mold with
extremely small tools. In this demonstration, tool-to-tool blends and
surface finish were critical. In addition, the machine was used to
demonstrate hardmilling of 70 HRc materials using coated carbide
tooling.
V99L vertical machining center, designed to handle large molds without
sacrificing speed or accuracy. The V99L demonstrated how a large-mold
machine could behave like a smaller vertical, creating polish-free
surfaces yet still having the horsepower and torque to rough at
high-speeds.
S56 vertical machining center, which was machining actual
part-production forging components for a customer in 52 HRc H13 to a
polish-free surface. These parts were said to go straight into
assembly, then to the press without any benching or polishing. The new
S56 was demonstrated with the optional graphite and automation
packages, making the machine more flexible for a mold shop environment.
V33-5XB, 5-axis vertical machining center that demonstrated practical
2+3 machining for die/mold. This machine demonstrated how 5-axis could
be applied to die/mold, without suffering from the accuracy problems
typically associated with this technique. This demonstration further
illustrated the theater presentation 2+3 Machining: The Realities of
5-Axis Machining.
V33 Graphite vertical machining center, which showed graphite and steel
machining on one machine with automation. This setup showed how a
production mind-set, with 24/7 unattended operation is being done using
palletized machines in die/mold shops. It also demonstrated how you can
use one machine to machine hardened steel (62 HRc was demonstrated) and
machine graphite electrodes for Ram EDM applications, all in one
machine using an unattended robot cell for part handling.
a61 horizontal machining center, demonstrated automated a new method of
multiple-sided machining of extrusion dies, offering process advantages
such as unattended machining.
MCC2516-VG horizontal machining center, designed to tackle large molds
with a 2+3 machining approach. This machine was milling an inner door
panel using it’s variable geometry spindle head and a 63mm 4-insert
shell mill with a 380mm extension for deep pocket rough machining.
U32j wire EDM, with a System 3R workpal robot showing how die/mold
shops can take advantage of automation to increase through-put and
implement unattended machining, while utilizing technologies such as
SurfaceWIZARD to eliminate hand-work.
Two SP43 wire EDMs were on display, one with a Pico Precision threading
and guide system, demonstrated how the threading of small holes (0.010
inches), even at high pitch distances is easily achieved using a Pico
Precision Guide System. It also illustrated how ultra-precision taper
angle machining can be achieved through a live demonstration.
The second SP43 demonstrated a completely new part production process,
utilizing a fully-integrated NC table for applications requiring
automatic part indexing. The machine also demonstrated a wire EDM
turning process, utilizing a high-speed, high-precision submersible
spinning unit. This process is perfect for round parts that are too
hard or brittle for conventional processing, or too small to withstand
normal cutting forces.
SP64 wire EDM showed HEAT, a revolutionary process to speed cutting in
poor flushing conditions. Various part geometries were machined,
representing the poorest flushing conditions possible, without
sacrificing part accuracy, straightness, or causing wire breaks.
UPJ2 wire EDM was on hand, showing the world’s only horizontal wire EDM
capable of automatically threading wire sizes down to 0.00078 inches.
This machine is capable of producing inside corner radii of 0.001
inches, and uses dielectric oil instead of de-ionized water, providing
excellent control of the spark gap and producing surface finishes down
to 0.3 microns Ry. The standard 0.05 micron scale resolution and
thermal chamber design allow positioning and repeatability of 1 micron,
even after extended hours of machining. With its vertically sliding
“drop tank” design and automatic work changer, the machine drew crowds
to see what it was capable of.
ENDC65S sinker EDM with HQSF™ burned large surface area cavities with
finishes twice as fine and 40 percent faster than a conventional EDM,
as demonstrated on two die cast cavities on display. This EDM permits
full unmanned operation from roughing through finishing with extended
tool life due to a reduction in the recast layer of the finished
workpiece.
EDGE2 Fine Hole sinker EDM was on hand, showing how to machine 0.003
inch diameter holes and simple automatic handling of very small pipe
electrodes. It also included an integrated wire EDM electrode dressing
option, providing automatic dressing capabilities for shaped holes.
EDAC1 sinker EDM was shown, regarded as the highest precision Ram EDM
in the world. An electronic indicator probe was used to measure the
accuracy of the X, Y and C-axes, showing positioning repeatability of
0.000006 to 0.000010 inches. Sample parts were on display to confirm
0.0002 inch (0.005mm) inside corner radii and machined positioning
accuracies of 0.000039 inches.
EDCAM Professional was demonstrated, showing how this offline
programming system permits the direct input of CAD/CAM part models and
develop an EDM program using the positioning data from the CAD model.
Full graphic simulations of the EDM job, prior to part setup, were
shown.
Exhibitors
A number of select manufacturers were invited to exhibit at the Die Mold Expo. The list of exhibitors included:
Blum Laser and ATLM Systems, Camtek CAM software for EDM,
Delcam CAD/CAM, EDM Sales & Supplies, emSOLVE CAM system solutions,
Erowa Technology Inc. workholding and automation solutions, Espirit CAM
software supplier, Hardmilling Solutions machining services, Hirschman
NC rotary tables for EDM, Hitachi Tool cutting tools, International
Mold Steel material and steel supplier, Lyndex Nikken tooling systems,
Matsumoto rotary tables for EDM, Millstar cutting tools, Mastercam,
MST-Tecnara toolholding, OGP/Clark Technical measuring equipment
supplier, OSG Tap & Die cutting tools, Remote Machining monitoring
systems, SST Tools die/mold consumable tooling supplier, System 3R
workholding and automation, Technitron NC rotary tables and integration
and Union Tool cutting tools.
Makino is a global provider of advanced machining technology and
application support, where new thinking takes shape for the
metalcutting and die/mold industries. Makino manufacturing and service
centers are located in the United States, Japan, Germany, Singapore,
Italy, France, Korea, Taiwan, Turkey, China, Mexico, Brazil and India,
and are supported by a worldwide distributor network. For more
information call 1.800.552.3288, or visit www.makino.com.
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Expo images: PDF contact sheet
Day 1: 1 2 3 4
Day 2 & 3: 1 2 3 4 5 6 7 8 9 10 11 12
***Editor’s
note: Images are high-res JPGs. Please allow some time for download. If
you have trouble getting an image, please contact brhoten@hsr.com and
we will send you the image directly in whatever format you need. Thank
you.
Visit www.makino.com/media for releases, images, and other media information.
Makino logo: JPG
Media Contact
Brandon Rhoten
HSR Business to Business
513.346.3588
brhoten@hsr.com
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