Auto Parts and the Future Industries: Aerospace, Electric Vehicle, and Intelligent System 9-10 August 2017 Bangkok, Thailand Machines for Aerospace and Automobile Parts Manufacturing Kenichi Harashima
Company Information Company Name Representatives Founding Capital Number of Employees Headoffice Chairman : Yoshihiro Sugino President : Takara Sugino March 1, 1936 JPY 2,324 million 1,590 (for the entire group) Uozu City, Toyama Prefecture, Japan 2
Manufacturing Plants Total 5 manufacturing plants in Japan, China and Germany 3
Sales Network 14 sales locations and distributors in over 40 countries worldwide 4
SUGINO Philosophy Founding Spirit since 1936 All SUGINO employees shall work together to provide the latest and best products to customers in return for a fair profit, so that the company and its employees may prosper and thus fulfill their social responsibilities. SUGINO s Original Tube Cleaner in 1936 5
Five core and ultra technologies Wet Pulverizing and dispersing Equipment Dry type atomization Nano fiber Ultra Fine High pressure pump High pressure washing machine Water jet cutting machine Pressurization testing machine washing deburring cutting High pressurization dispersing emulsification pulverizing surface reforming Superoll Dimple forming tool Skive roller Ultra High Pressure Surface property modification 5-axis control machining center Water jet and laser machine Compact machining center Ultra Precision drilling tapping Ultra Finishing Machining center High speed spindle motor High precision drilling unit High precision tapping unit Ultra High Speed 6
Ultra High Pressure Hayatsuki Plant Washing, Deburring, Cutting, Pressure It consists of the next elements High-Pressure Pump High-Pressure Water Jet Cleaner High-Pressure Water Cutting Equipment High-Pressure Fatigue Test Equipment High-Pressure Test Equipment 7
Ultra Fine Hayatsuki Plant Wet Jet Dispersion Unit Nano material production Biomass Nano-Fiber 8
Ultra High Precision Namerikawa Plant Metal Cutting Simultaneous 5-axis Control Compact Machining Center 9
Ultra High Speed Namerikawa Plant High Speed Spindle Motor High Precision Drilling Unit Precision Tapping Unit 10
Ultra Finishing Kakegawa Plant Roller Burnishing tools Plastic working of metal surface Improved Surface Hardness and Finish Increased Life of Part Workpiece Fatigue test 11
SUGINO Water Jet Technologies Water Jet Technologies 12
SUGINO Water Jet Technologies Usage of Water Jet (The relation between the pressure and the flow rate) Flow rate(l/min) 8 0 0 1 0 0 the water jet cutting much more in detail 3 0 cleaning washing 2 0 1 0 deburring dispersion atomization cutting high pressurization 0 1 0 0 0 2 0 0 0 3 0 0 0 4 0 0 0 5 0 0 0 6 0 0 0 100 200 300 400 500 600 Discharge pressure(mpa) 13
SUGINO Water Jet Technologies Water jet cutter This is a device to cut any materials with ultra high speed jetting water from a small diameter nozzle. Cutting of wave sheet Cutting of stainless 14
SUGINO Water Jet Technologies Feature and effect of water jet cutting Why water jet cutting is used? 1 Heat is not generated. 2 Any cutting material. 3 The dust is not generated. 4 The precision sawing is possible. 5 The plank cutting is easy. 15
SUGINO Water Jet Technologies Sugino Machine has 2 types of water jet cutting procedures 1 Aqua jet cutter cutting with only high pressure water 2 Abrasive jet cutter cutting with high pressure water and abrasive Target Suitable Soft materials Rubber, Cloth,Sponge, etc. Target Hard materials Metals, Non metals, Ceramic,CFRP, Special steel, Glass, etc. 16
SUGINO Water Jet Technologies The structure of abrasive jet cutting head Abrasives IN High pressure water OUT Abrasive nozzle Water nozzle High pressure water IN We put the abrasives into the high speed water-jet and accelerate its speed. Accelerated abrasive water jet is discharged from the abrasive nozzle. 17
SUGINO Water Jet Technologies Water jet cutting system Abrasive supply device Ultra high pressure pump Control unit Cutting machine Water supply unit 18
Water Jet Cutting Utilization to Aircraft Industries Cutting samples at 350MPa Ti-6Al-4V t120 [mm] 350 [MPa] 2 [mm/min] 304 Stainless Steel t120 [mm] 350 [MPa] 2 [mm/min] CFRP t60 [mm] 350 [MPa] 30 [mm/min] 19
Water Jet Cutting Utilization to Aircraft Industries Cutting samples at 500MPa Ti-6Al-4V t100 [mm] 500 [MPa] Cut section Cutting speed 5 [mm/min] 10 [mm/min] 20
Water Jet Cutting 150mm of Titanium at 500MPa (2mm/min) 21
Line Up of Water Jet Cutter Useful for 3 dimensional cutting such as cubic or curved shape because of 5-Axis control. Ultra high-pressure water jet cutting equipment /5-axis control system 22
Abrasive jet cutting 20mm of Aluminum at 450MPa (150mm/min) 23
Surface Treatment by high pressure water jet Pressurized water from 100 through 245MPa is discharged on the objects, and it removes surface coating or linings without damage the object s body itself. Removal Jet Rotary Nozzle Unit built in robotic system Painted bolt and nut of the bridge structure Pressure :200MPa Flow rate:2.1l/min 24
Hand removing (Hi-Rotary Gun) For manual handling of cleaning with Rotary Gun. It can be used for cleaning and chipping at Maximum pressure 245MPa. 25
Drilling Unit for Aerospace Industries Drilling Technologies 26
Development Background of Drilling Unit Recently CFRP material (Carbon Fiber Reinforced Plastics) has been using for airplane parts to save the fuel consumption. <http://www.carbonfiber.gr.jp/field/images/ plane01_b.jpg> The Japan Carbon Fiber Manufacting Association <http://www.carbonfiber.gr.jp/field/images/ plane02_b.jpg> 27
Development Background of Drilling Unit 2. The problem of the conventional technologies (Mechanical Feed Drilling Unit) (1) Conventional drilling units cannot change feed rate during the process because they are driven by air and mechanical screw feed. Delamination and burr generate at the exit of the drill bit. In case of complex laminated material, drilling time takes longer. 28
Development Background of Drilling Unit 2. The problem of the conventional technologies (Mechanical Feed Drilling Unit) (2) Spindles do not have rigidity. Running cost is very high. Repair takes long time. Long-awaited Japan-made drilling units 29
Pneuconfeeder Outline All Air-Driven By Air Rotation and Air Feed PAT. Sugino Machine has developed the all air driven drilling units. We use air motor for rotation and air cylinder for feed. Air Cylinder Air Motor 30
Pneuconfeeder Compact Lightweight Durable high torque Air motor Capable of Drilling Titanium:Max. Φ13mm Weight:3.5kg 31
Pneuconfeeder Video The Pneuconfeeder is drilling into CFRP plate. 32
Pneuconfeeder Feature1 Control Delamination and Burr Generation Two-step feed system Control by 1+2 Control by 1 Origin 2 Hydro-Speed Regulator are used for 2 different feed speed 1 Control main cutting feed rate 2 Control crawl feed at the through hole exit Crawl feed Main cutting feed Rapid feed Minimize delamination and burr when drill penetrates. 33
Pneuconfeeder Feature１ Control Delamination and Burr Generation Two-step feed system Burr conditions Minimized burr conditions Without Two-step feed system With Two-step feed system 34
Pneuconfeeder Feature 2 Less Workpiece damage and deflection Adjust thrust per tool condition. To prevent workpiece damage and deflection caused by too much thrust. (PAT.) Thrust Adjustment Knob Air Pressure Gauge 35
Pneuconfeeder Feature 2 Less Workpiece damage, deflection Workpiece deflection occurs Burr and Delamination is generated in gap. Too much thrust No workpiece deflection Air pressure is adjusted to have appropriate thrust. Proper thrust 36
Pneuconfeeder Option 1. Collecting duct collects the Cutting Chips To collecting Unit Cutting Chips Collecting Duct Especially drilling CFRP material creates very fine chips. So you can get improved working environments. 37
Eleconfeeder Compact High-performance High-powered motor and control Eleconfeeder is all electric driven drilling units. PAT. Capable of Drilling Titanium:Max. Φ16mm Weight:12kg 38
Eleconfeeder Feature 1 High rigidity, High accuracy and High reliability High precision ball screw, Bearing, Linear guide High performance electric motors 39
Eleconfeeder Feature 2 Easy optimal program setup by Touch Panel in case of 3 different material layered like this, the panel has cutting parameter table for each Touch Panel Screen material. Layer0(Rapid feed) CFRP Titanium Aluminum Layer1 Layer2 Layer3 Layer4(Crawl feed) Utilized cutting parameters for each material 40
Eleconfeeder Feature 3 Most airplane parts consists of different materials like this, outside layer is titanium, and inside layer is aluminum. And also the materials thickness is not constant. Stroke free system Titanium Aluminum Then Eleconfeeder can automatically programmed without inputting the conditions. Not required to set cutting start point Not required to set workpiece thickness Not required to set cutting end point 41
Eleconfeeder Video 42
Jet Clean Center:JCC Washing & Deburring Jet Clean Center :JCC Sugino CNC turret type high-pressure washing and deburring machine 43
JCC 102 Wide Superb Performance machine in Compact size Special Features: 1. User friendly Compact machine L: 4,275mm, W: 1,500mm, H: 2,640mm Rapid Feed Rate (X, Y, Z axes): 48m/min 2. High Accuracy Level: 0.08mm positioning 3. 6 Types of Nozzles can be attached for chips and burr removal 4. Applicable to any type of a work piece Cylinder head, Cylinder block, Crankshaft, Stator for EV, Transmission parts and etc. 44
JCC 102 Wide 6 Type Nozzles based can be attached to CNC character 6 Types of Nozzles for Chips and Burr Removal One of the most important technologies for deburring and washing machine is Nozzle function. We offer 7 types of Nozzles that can be wisely selected in accordance with work piece s requirements. Direct Type Spray Nozzle Flat Type Spray Nozzle Rotating Lance Nozzle L-Type Angle Nozzle Multi-Nozzle Manifold Dual Rotating Nozzles Offset Nozzle Out of 7 types, the 6 Nozzles can be attached to CNC Turret. 45
Deburring Treatment by JCC Crankshaft application Material: Ductile cast iron Deburring Pressure: 50MPa Before After 46
JCC 402 U-Jet U-Jet means under water washing. Best Suited for Complex-shaped workpieces 1. Submerged washing method made possible to effectively wash complex shaped work pieces such as cylinder head, cylinder block, valve body and etc. 2. High pressure jet and Cavitation in water remove residual chips completely inside of complex shaped workpiece. 3. Horn nozzle designed for submerged washing process generate cavitation bubbles. 4. 0.08 mm positioning accuracy level for washing efficiency. 47
JCC 402 U-Jet Perfect Washing Performance for Complex-shaped Holes The vortex cleans the internal of the complex shaped parts. Submerged Water pushes water. High speed camera : 1 sec.=30 sec. Open-Air Water is drained from nearby hole, unable to reach corners. 48
JCC 503 Robo 1. Introduction JCC 503 Robo was developed as the world s first CNC controlled workpiece handling type washing machine. We provide our customers with washing quality that you have never experienced and superior flexibility. 49
JCC 503 Robo Video 50
JCC 503 Robo 2. Proposal of Optimal Washing Conditions (1) We can provide optimal conditions per application based on our experience and research Washing conditions: nozzle type, pressure, flow rate, etc. (2) Special nozzles are made by Sugino per application such as washing and deburring processes. (3) Nozzle selector automatically changes washing line. (Developed by Sugino) (4) We can respond against quality requests from customers which are getting stricter in recent years. High Pressure Washing No.4 Direct Nozzle High Pressure Washing No.3 Direct Nozzle Low Pressure Washing Flat Spray Nozzle Lay out of nozzles 51
JCC 503 Robo 3. General Flexibility Self Loading & Unloading System Robot hand grabs a workpiece by the machine itself. Loading unit is not necessary. Grabs a workpiece by itself. => Perform washing and air blow while handling the workpiece! 52
JCC 603 Robo JCC603ROBO JCC 603 ROBO (Same concept machine as JCC 503 ROBO) 53
JCC 603 Robo Ultrahigh-pressure Deburring can be done at maximum 245MPa Overwhelming deburring power Tough burrs can be removed by mach2 ultrahigh-speed water jet Specialty: deburring deep holes, cross holes and stepped part Areas where brush and tool cannot access can be deburred. Minimize Air Cutting Time High speed travel can be achieved by newly developed machine driving components (XYZAC-axis). And with highly accurate positioning will surely aim the target. BEFORE AFTER 54
Deburring Sample deburring gear teeth made of stainless steel and the result every pressures. microphotographs of deburring conditions in case of steel material. 55
From Machining through Washing Video Washing, Deburring & Drying by JCC 603 Robo Machining by Self-Center Drilling & Tapping by Self-Center Transferring by Swing Arm Transferring Column Robot 56
JCC KEY CUSTOMERS (JAPANESE CUSTOMERS NOT INCLUDED) Sugino Machine s High Pressure Washing Machines have been delivered automobile manufactures all over the world. And also our technologies are highly evaluated. 57
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