Automation – Page 228
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ArticleStriving for safety
With OEM footprints stretching worldwide, consistency is key to tackling danger points in productionSafety in automotive manufacturing starts with boosting awareness about global safety requirements – which can be a tough ask, given the way some local engineering teams operate. According to George Schuster, TÜV-certified functional safety expert and senior ...
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ArticleNissan Sunderland expands for Q30
UK – The workforce at the OEM’s plant in the north of the country is growing by 300 individuals, more than the 180 originally announced in 2012 following the allocation of the Infiniti model. The factory has already been extended by 25,000 sq.m at a cost of £250m ($388m), incorporating ...
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ArticleAll tooled up for part production
The latest cutting-tool innovations are better able to tackle part complexity while coping with heavy wearTool wear is undoubtedly one of the biggest threats to automotive component production. With this in mind, a familiar practice at automotive part shops is to change tools before maximum tool life is reached, just ...
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Article零部件生产加工
最新切削工具能更好地解决零部件复杂性与严重磨损工具磨耗无意识汽车组件生产中最大的威胁。为了解决这个难题，汽车零部件工作室在工具最大使用期限之前就进行更换，以防万一；在插片完全损耗殆尽之前就更换的成本，远低于在作业中发生事故的成本。当然，还是有很多测量工具使用寿命的方法。有些计算零部件数量，或者使用运行时间，而有些方法依赖材料的使用的数量。无论使用什么方法，节省时间和金钱是最终的策略。在量产过程中，永远都在无限追寻速度。但事实上，速度才是工具磨耗的元凶，因为在切削区域产生过多的热量。因此，很多汽车零部件车间都因为购买了相对廉价的四边插片而后悔不已。然而，这是错误的向法，因为使用8边或16边查遍的成本要高得多；虽然每个插片的成本很高，但是每个边的成本却很低。切削工具供应商为了满足每年的低成本需求，而面临着强大的压力。如果这些目标无法满足，就会丢掉优选供应商的地位。Sandvik Coromant也清楚地意识到这一点。公司最新产品中有一个非常吸引汽车车间的工具，即CoroMill 5B90铣刀，用于加工铝质零部件，比如气缸盖、变速箱、给油阀组、电动滑车曲轴和车厢盖。举例来说，在AISi9Cu-1气缸盖上切削0.7mm时，CoroMill 5B90(160毫米直径，9个切面)以7,000rpm的旋转速度和12,500毫米/每秒的进给速度，成功加工了40,000个零部件。因为每个切削工具都是为组件量身定做，因此工具能够优化切削插片的数量，并且用一个刮片来保证表面的质量。因此，高速进给机器的齿轮数量减少的情况下，也可以实现。M5B90上特殊的轴径向位置，能够减少启动时间，不做任何调整的情况下，也能立即插入切削。西班牙气缸头制造商就深谙此道，并试图解决很多问题。首先，加工工艺还不稳定，产生毛边。另一个不可预知的问题是插片工具受命，这主要依赖装配中不断调整的暗盒。综合破屑机日前还有一个铝合金汽车零部件整机和半整机革新，包括发动机组和变速箱体，即BreakMaster LD型号和GD型号烧结金刚石切削工具，上面有Sumitomo Electric生产的综合性破屑机。用铝合金这个的材料进行加工时会产生大量的切片或切屑，如果切片混进材料当中或工具当中，就会发生故障。最新Sumitomo插片通过在切边旁边的烧结金刚石上加上一个综合性3D破屑机，从而克服了这个问题。Komet称，固定气缸体需要在很多机械操作技术，这些特殊的组件需要特殊的方法。比如，使用KomTronic M042精镗系统就可以完成闭合回路机械制造，在机器上自动重启和修整切削。该工具能为半成品机械提供多个切边，也可以为成品机械提供单边切边。据Komet称，其他需要金鑫考虑的提肛提机械操作有：缸镗初步加工，这里用指导几何和0.4mm提高的插片；利用单独工具进行制造前和后的核心插件；使用三角插片的集成工具对油槽进行精镗操作。当然，许多气缸体仍然使用铸铁，但是这也有困难，包括一个“爆发”现象，就是工件周边产生切片。切削工具插片通过降低切削力量，阻止切边产生，从而提高制造质量。在最新技术革新中还有Kyocera公司的MFK可转位铣刀，拥有两面、十边负极插片。虽然负极插片可以通过在插片双面切边，从而能相抵成本，但是这回增加切屑阻力，会降低锐利度，并增加震颤。为了解决这个问题，Kyocera公司已经开发了一个特殊的插片，使用专用制模技术，通过大角度偏位角设计，减少负面效果。通过增加超前角，还可以减低工件轴向的切削阻力，而且通过一个双面结构产生的插片角度，提高表面质量。这样就缓冲了工件接触时产生的震颤，阻止切边在工作时发生破裂。多任务关节工具除了发动机，还有很多复杂的机械零部件都在尝试切屑技术，比如转向关节。在钻井工艺上，高韧性材料会形成很长的切片，绕在工具上。关键是要尽快破除这些切片。复杂的形状及精确度需要精确地把转向机构相连。去年年底，一个汽车原始设备制造商想要在德国德工厂里，为三种不同级别的汽车生产转向关节。目标是要在单一的机械上用最少的工具生产转向关节。为了实现这个目标，LMT Tools公司与德国机械工具制造商合作，开发一个灵活、精确、经济的工艺理念，每天为每种级别的汽车生产2,000个转向关节。LMT将多多生产步骤和工艺集合到一个工具上。这就精简了整个流程，从PCD圆盘铣刀（用于轮毂单元的前铣刀过程），到PCD盘型铣刀（用于悬挂摆臂的铣面，速度达1,300米/每分）以及PCD球面铣刀（用于球冠的抛光，速度达600米/每分）上只需要22个工具。 转向关节通常是由灰铸铁或钢铁来制造。由于负荷很高，因此在机械加工时在形态上和位置上需要紧密公差 — 当然还要低成本。因此，Mapal也是简章综合性工具的供应商。使用正切可转位刀片是完成加工的最有利工具。因为正前角和紧凑型装置，这种刀片拥有柔和的切口，对高速进给的多刀片工具非常适合。至于转向关节的加工制造，Mapal公司已经发现，减震器座的研磨和钻孔需要综合使用圆盘铣刀和插入式钻孔，以减少工具的变换。同样，对于内部加工钻销，多级正切组合工具可以节省半加工流程，同时对外加工钻孔方面，拥有嵌件腔的多级组合工具可以产生小于±0.1mm的误差。工具节省机械投资在密歇根奥瓦索的Machine Tool&Gear(MT&G)工厂，每年制造超过112,000个卡车机轴。在Mori-Seiki NH 4000卧式电机中心周围建造了一个工作室。然而，最近在公司转型机轴的过程中，涌现出一位出色的制造工程师，Jeff Ochodnicky。他说，“新的几周设计包括平面区，与其他的操作形成90º角度，因此不容易完成。最容易的方法就是使用另一个机械磨平这个平面，但是成本会很高，因此被否决。我就决定寻找新的方法。“相反，我们决定使用两个九十度铣头来加工这个平面区。但是，我们在工具刀片上遇到很多困难，包括过度磨损和表面抛光。通过与刀片供应商合作，我们尝试不同的切削深度，不同的刀片，转速和进给率，但都失败了。最后，我们找到了Horn公司。“最大的困难就是应用22mm直径的铣刀，在机轴上磨平一个38mm长、1.5mm深的平面，而且要高出主轴250mm。任务很艰巨，但是Horn公司认为，只要找到正确的工具就可以。MT&G刀片拥有交错的长笛设计，可以在切削过程中造成推力和拉力。在精细的分析之后，公司决定尝试Horn公司生产的Mini Mill刀片。由于该刀片拥有良好的螺旋，因此可以用于所有切削，上下自如。Ochodnicky说，“由于工具改变，我们节省了大量成本，在机床和人力上保持了成本优势。“ 适应材料改变那么，涡轮增压器和相关组件是用什么制造的呢？由于镍的成本价（从2005年到2013年的浮动区间在5欧元到13欧元每公斤）很不稳定，涡轮增压器的制造商现在使用低镍材料。为了使用这种改变，三家独立Iscar技术中心都致力于开发新的切削材料，几何结构和涂层。研发成果有S845 SNHU 1305 ANR-MM MS32刀片，据说比之前的Iscar工具延长25%的工具寿命。Iscar公司组件制造的核心在于涡轮壳体、转轴、涡轮、压缩机轮等涡轮增压器零部件的制造商。例如，公司已经开发了特殊的工具，用于复杂的V段涡轮壳体的加工制造 — 及使用正切刀片铣刀。工具包括一个嵌入式装置，可以使用任何嵌件腔。至于V段外形，Iscar建议采用最经济的加工战略 — 同时还要避免潜在的碰撞风险。这里采用5边星型Penta刀片，尺寸根据V段凹槽而定。工具上的刀片可以随机灵活地改变，因此可以实现V段外形的紧密公差。此外还有通过一个U型轴或放射面滑动单元制造的轮廓车削，以及插补车削。在加工制造复杂的汽车零部件时需要考虑很多问题，不仅仅是成本。然而，当每个刀片的成本呈现最优效益，每个边的成本才会产生更深远的利益。
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ArticleAutomatic fanatics
Lathe manufacturers are offering single- or multi-spindle machines to meet cost and productivity demandsAutomotive turning shops face numerous market demands, with piece-part price heading the pack. Automatic-lathe manufacturers have been well aware of customer requirements for many years and many now offer both single-spindle and multi-spindle versions. So, which to ...
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ArticleNew Employee Relations head, FCA
US – With Al Iacobelli retiring from the company, Glenn Shagena will assume the role of head of Employee Relations for North America with immediate effect. Shagena was most recently head of FCA Mexico Human Resources.Shagena joined the company in 1985, working in the Labor Relations department at the Sterling ...
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ArticleRenault Dieppe starts making Bolloré Bluecar
France – Assembly began this month of the all-electric city car, which was previously made only in Italy. The vehicles are being assembled from bodies and parts brought into the plant by Bolloré.Renault Dieppe, which was established in 1969, specialises in small production runs and currently makes the Clio RS ...
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ArticleFixed-mount barcode readers
The DataMan 150, 260 and 360 series of fixed-mount, image-based, ID readers run the latest Cognex algorithms to achieve the highest possible read rates, claims the company.The serial USB-based DataMan 150 series and Ethernet-based 260 series models offer straight or right-angled configurations to fit into tight spaces. DataMan 360 series ...
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ArticleNew range of Bi-face radius cutters
Toolex says it offers two types of its new bi-face cutters; mini with two flutes in four radius sizes from 0.2 to 0.5mm and standard with three flutes in ten radius sizes from 0.5 to 3.0mm, all with a claimed tolerance of ±0.02mm on the radius.The company says the cutters ...
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ArticleSkoda halves production energy per car
Czech Republic – Over the 20 years the OEM has been working with its energy provider, Sko-Energo, production has seen a drop of more than 50% in energy use and a “significant” reduction in water consumption (including 15% in 2014).“Using energy efficiently gives companies a real competitive edge,” said Michael ...
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Webinar
ArcelorMittal: Laser Welded Blanks – A key enabler to lighter and stronger automotive steel solutions
How can ArcelorMittal Tailored Blanks help carmakers achieve their weight, safety and cost targets?In this webinar we focused on the benefits of LWB’s applications: Highlighting the advantages of LWBs in combination with hot stamping technology Showcasing the weight saving potential of LWBs by showing examples of innovative solutionsSpecialists outlined ...
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ArticleMercedes chooses Hankook for Actros
Germany – Four product types will be supplied for the heavy-duty truck in accordance with the new deal: the AL10 and DL10 long-haul tyres, plus the AM06 and DM03 off-road tyres. This extends an existing OE agreement from last year.The AL10 will be supplied in two sizes: 295/80R22.5 and 385/55R22.5; ...
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Article
Estrada da China rumo a sustentabilidade
Conforme o governo aumenta os seus esforços para aliviar graves problemas de poluição do país, as montadoras estão tornando as suas operações mais "ambientais" para melhorar as suas pegadas, mas também para ajudar nos lucrosOs problemas de poluição graves na China estão bem documentados, com pesquisa da Universidade de Tsinghua, ...
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Article
Uma nova dimensão
Fabricação aditiva está tendo uma utilização mais ampla em toda a produção automobilística, desde prototipagem até ferramentasApesar de todos os esforços da indústria automobilística para desenvolver motores mais econômicos ou carrocerias aerodinâmicas, um dos determinantes mais básicos da eficiência do desempenho do veículo continua sendo a consistência com a qual ...
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ArticleTVR to return to production
UK – Led by a fresh management team, the brand – established in 1947 – will make its comeback with a new sports car designed and built in Britain, in collaboration with Gordon Murray Design and Cosworth. The project has already spent one year in development.TVR says the vehicle will ...
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ArticleSVW to boost EV production with expansion at Anting
China – The decision between Volkswagen and SAIC to grow the main facility of their joint venture, SVW, will enable the full localisation of VW electric vehicles (EVs) on a gradual basis. In four years’ time, a new EV based on VW’s Chinese bestseller, the Lavida, will roll off the ...
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ArticleFluid thinking in machining
The latest coolant and cutting-oil technologies can support automotive's drive for ever higher productivityTo meet demanding output schedules, automotive manufacturing engineers have little option but to machine fast. However, if there is one thing certain to cause heat in machining operations, it is fast cutting speeds and high feed rates. ...
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ArticleModel predictive control software
Rockwell Automation claims its Pavilion8 Model Predictive Control (MPC) software now offers a more user-friendly configuration environment, step-by-step prompts, warning diagnostics and flexible work flows.The company says this v5.0 software remains control system independent, but integrates with its PlantPAx process automation system and includes four key enhancements: Updated, Windows-based solution ...
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ArticleSurface measurement testers
AMETEK Taylor Hobson says it has added two new products to its range of surface measurement testers. These are the Surtronic Duo portable surface roughness tester for shopfloor and on-site measurement of multiple roughness parameters and the Intra Touch contour and finish measurement system for applications including precision machining.The company ...
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Article
FCA makes senior management changes in UK
UK – Karl Howkins is newly appointed as deputy managing director and will head up a streamlined structure, with two country directors looking after the Fiat/Abarth and Jeep/Alfa Romeo marques – respectively, Elena Bernardelli and Damien Dally.Bernardelli was previously marketing director at Fiat; Dally headed up Alfa Romeo in the ...