Technology Energy-efficient tool concepts

Transcription

1 Technology Energy-efficient tool concepts Save energy and costs with intelligent process management

2 MAPAL technology: Our contribution to energy efficiency You do not need to be a great prophet to predict that energy costs and, in particular, electricity prices will continue to rise. In Germany industry needs more than 40 % of the entire consumption of the electrical power produced. Approximately 60 % of this usage is down to the operation of production machines. In the case of machine tools the energy necessary for machining is very low in comparison to the total energy required by the machine. On these machines there are a number of possible ways of increasing the energy efficiency, for example by using regulators and controllers to suit the specific task, as well as by using energy-saving units. However, these approaches often involve large investments or even new machines. On the other hand, a significant energy saving and therefore cost saving can be achieved with intelligent process optimisation on existing machines. changes can be saved. On the other hand, higher feed rates and the related shorter machine running time bring significant energy savings. The conversion to minimum quantity lubrication (MQL) or dry machining offers even more potential. Energy savings from 0 to 30 % can be achieved, as the units necessary to supply the cooling lubricant are not required. MAPAL also offers complete solutions for MQL technology from the clamping tool to the cutting edge. MAPAL specialists optimise the process management Of particular importance for energy efficiency is reduced machine running time, that is shorter machining time. On the one hand this objective can be achieved with reduced non-productive times. MAPAL s complete machining tools combine the machining of various bores, chamfers and flat surfaces such that often four, five or more tool Less non-productive time Higher speeds Modern Technology MAPAL +++ A medium-size machine tool consumes approx. 65,000 kwh* per year in three-shift operation. This signifies carbon dioxide emissions of 95 t CO* and corresponds to the emissions from 66 small cars covering a mileage of,000 km each. Due to high performance tools and optimised machining processes, 5 to 0 % of the total energy required can be saved. The energy required can be reduced by a further 0 to 30 %, for example by converting to MQL or dry machining * Sources: Zäh, M.; Niehues, K.: Wie viel Energie verbraucht eine Werkzeugmaschine? fertigung journal 09/009 date , page 30ff. Umweltbundesamt, FG I.5., date March 00

3 Energy-efficient tool concepts

4 Less non-productive time shorter processes MAPAL the specialist for combination tools The usage of combination tools is particularly effective for reducing the energy required and at the same time increasing productivity. During process design, MAPAL specialists always pay attention to combining as many machining operations as possible in one tool. As a result tool changes and travels, that is non-productive times, are saved. Also the total manufacturing time is significantly reduced by the simultaneous machining of various bores, chamfers and flat surfaces. This method of working also brings higher accuracies in relation to the concentricity and angle requirements, as on combination tools an offset between the diameters cannot occur. A further positive effect on the usage of combination tools is that stations are freed up in the tool magazine. Lower consumption due to combination tools. Combination tool for machining bores and for circular milling (suspension arm AlSi0Mg) First the diameter (4 H8 ) is fine machined from the cored state using a premachining stage and fine machining stage. Then the flat surfaces and chamfers on both sides of the workpiece are circular milled. Due to the soft cut of the tangential inserts during circular milling and the support from the guide pads during the machining of the bore, it was possible to combine the original two machining tasks. Savings/year (80,000 parts) 89 hrs 6,358 kwh Emissions: 3.7 t CO *. Complete machining using tangential technology and solid carbide drill (actuator GG5) Three tools were necessary to machine a connection and bearing bore in a grey cast iron housing. All machining steps were combined into a three-piece combination tool. It was possible to save a total of 6 sec. in non-productive time and productive time solely by using this tool. Savings/year (5,000 parts) hrs,440 kwh Emissions:.4 t CO * *(=,800 km in a car) *(= 3,00 km in a car) 4

5 Energy-efficient tool concepts The largest effects in relation to energy efficiency and increasing productivity can be achieved during the design and optimisation of complete machining processes. It is during this process that the MAPAL Tool Expert Team defines and plans the optimum tools and aids for the machining. All the documents and studies necessary for perfect tool planning are prepared. On request, the MAPAL tool experts will also supply specific NC programs and provide support during the breaking-in of the tools. In this way it was possible during process optimisation to save of the 80 tools required originally for a gearbox housing. The machining time was shortened by 5 % as a result with a corresponding reduction in the total energy required by the machine. Examples for increased energy efficiency and productivity (gearbox housing Al). PCD-tipped precision drilling tool in lightweight design Four tools combined in one tool. Maximum diameter 50 mm and nevertheless a low weight of only 5.7 kg due to titanium tool body. Feed rate of 900 mm/min. Savings/year (40,000 parts) 7 hrs 3,76 kwh Emissions:. t CO * *(= 8,00 km in a car). Guided fine boring tool for bearing and location bores to the micron Complete machining of seven different features diameters, chamfers, front faces. Compliance with the tightest tolerances with high productivity. Combination with insertion tool for further machining positions. It was possible to replace three tools. Savings/year (00,000 parts) 388 hrs 8,536 kwh Emissions: 4.9 t CO * *(= 4,00 km in a car) Advantages: Complete machining tools for shorter machine running times Saving in additional tools, magazine stations and changing times due to machining at various position Significant reduction in the total energy requirement of the machine 0 to 5 % are possible Energy saving without investment in new units and machines 5

6 Higher speeds MAPAL the specialist for high performance tools Newly developed tools from MAPAL, for example the MEGA-Speed-Drill or the FeedPlus reamers, are able to reduce the machining times by up to 70 %. On the MEGA-Speed-Drill the new arrangement of the guiding chamfers provides the crucial increase in cutting speed. On the other hand, the innovative design of the FeedPlus reamer makes it possible to accommodate significantly more blades than on conventional reamers, and as a result enormously increase the feed rate. A large number of PCD blades are also the key for high speeds and short machining times on the HP-FaceMill face milling cutter. Together with the cutting edge geometries optimised for low cutting forces, the total energy requirement for a machine tool can be reduced by up to 5 %. Examples of energy-efficient MAPAL high performance tools 3. MEGA-Speed-Drill for drilling in an axle housing (GG30) Due to the considerably reduced load on the guiding chamfers, the machining speed can be significantly increased. As a result 3 sec. can be saved on the 3 bores per part compared to a conventional carbide drill. The MEGA- Speed-Drill also brought a 7 % longer tool life. Savings/year (00,000 parts) 889 hrs 9,558 kwh Emissions:. t CO * *(= 94,500 km in a car). FeedPlus reamer for highest feed rates 8 teeth instead of the conventional eight that is how the FeedPlus reamer realises such high feed rates. 66 % less productive time is the result on machining a bronze bush in a rocker arm. 3. HP-FaceMill provides energy saving due to more PCD blades in a valve gear casing (Al) Due to the increased number of teeth, the feed rate can be more than doubled, for example during milling on valve gear casings made of aluminium. Shortest payback time ensured due to increase in the productivity and energy efficiency. Savings/year (400,000 parts) 4 hrs 9,84 kwh Emissions: 5.4 t CO * *(= 44,000 km in a car) Advantages: Energy required by machine drops in parallel with the shortened productive times Higher power consumption due to the use of several inserts not relevant MAPAL high performance tools in standard versions and custom versions Competent advice from experienced specialists Savings/year (50,000 parts) 39 hrs 858 kwh Emissions: 0.5 t CO * *(= 4,00 km in a car) 3 6

7 Energy-efficient tool concepts Modern technology MAPAL the specialist for minimum quantity lubrication and dry machining Minimum Quantity Lubrication (MQL) and dry machining are particularly important features for the energy efficiency of a machine tool. The reason is the high power consumption of the high pressure pumps required for the cooling lubricant. Often these devices make up 0 30 % of the total energy required by the machine. By converting a cylinder head machining operation to MQL, it was possible, for example, to completely do without a pump that operates in the pressure range up to 50 bar and that has a motor power rating of kw. Example cylinder head MQL project. PCD precision boring tool for the blind bores for valve seat and valve guide Due to the exact matching of the channel cross-sections, medium is reliably and evenly supplied to all cutting edges. A special supply guarantees a response time of <0. sec.. Double edge PCD tools for the injector and spark plug bores Despite the large difference in diameter from 7 to 6 mm, on these tools the chips are reliably removed from the bore without high pressure. Even at an air pressure of only bar, machining is reliable. 3. Guided fine boring tool for fine machining the camshaft bore Guide pads made of PCD and MQL outlets designed to suit the bearings guarantee correct function during this machining operation. Possible savings 33,000 kwh Emissions: 9 t CO * Due to the removal of a high pressure pump on a medium-sized machine tool in three-shift operation and with 30 % of the total running time as productive time. *(= 60,000 km in a car) Advantages: MQL or dry machining possible for all machining methods and in all materials Special quality controls for the MQL tools Complete range of clamping tools available for single and two-channel MQL supplies Demonstration and sample machining in the MAPAL technology centre 3 7

8 MAPAL the major specialist Reaming and fine boring Boring Drilling Milling Turning Actuating Clamping Setting and measuring Services V.0.0 MAPAL Präzisionswerkzeuge Dr. Kress KG P.O. Box 50 D Aalen Phone +49 (0) Fax +49 (0) ENE-E WD Printed in Germany. Right of technical modifications reserved.