Baltic Metalworking 5/2018

September-October 5/2018

METALWORKING

BALTIC

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The Magazine of Baltic Metalworking Industry

www.balticmetalworking.com

Pr im

Up. Down.

Left.

Right.

ur eT ni ™ ng w ith Co r Tu ro n® Pr im e

Modern turning works in any direction.

PrimeTurning™ and Y-axis parting are new turning methods revolutionizing the industry. By making use of the opportunities given by modern CNC machines and challenging conventional machining directions, the gains in productivity and tool life can reach levels unlike ever seen before.

#turningreinvented www.sandvik.coromant.com

Y-axis parting with CoroCut® QD

Find out where these innovations will lead you.

GS MODELS

from GS-2000 up to GS-8800 from 8’’ up to 24’’

Chuck size Bar capacity Max. turning diameter Max. turning lenght

from Ø 51mm up to Ø 320mm from Ø 570mm up to Ø 970mm from 780mm up to 6,200mm

GS MODELS Maximum Performance §

Rigid Construction §

High Performance Spindle System §

Advanced Turret Technology §

Ultimate Turning Power

Heavy Cutting

U-drill

7

50

Depth of Cut (mm)

0.4

Depth of Cut (mm)

417

0.15

Feed Rate (mm/rev.) Speed (rpm)

Feed Rate (mm/rev.)

764

Speed (rpm)

Work-piece Material: S45C Test Model: GS-3600M

Horizontal Turning

Cylindrical Grinding

Vertical Turning

Official Baltic’s Distributor Machine Tool Center UAB www.mtcenter.lt info@mtcenter.fi

We store up to 11 to 12 thousand tons of rounds with diameters from 30 to 340 mm in our covered storehouse in Vilnius.

Our main competitive advantage is that we have large batches of hot-rolled rounds in stock.

This allows completing urgent bulk orders that cannot be executed by factories functioning under certain production terms. A large range of rounds - 450 standard sizes from 11 constructional carbon and alloyed steels is available at your request.

Our main activity is our engineering round steel warehouse for wholesale trade.

Our main clients are trading and metalworking companies in the Baltic states, Eastern and Northern Europe.

The biggest trader of warehouse engineering steel in the Baltic

www.antejas.lt

HIGH PERFORMANCE LUBRICANTS MADE IN GERMANY

Oest products cover all metalworking technologies: water miscible and non-water miscible cooling lubricants for machining with defined and non-defined cutting edges, spray mist lubricants for minimum quantity applications as well as forming lubricants with a variety of different formulations for sheet metal, tube and massive forming.

PARTNERS WANTED As an internationally expanding company we are constantly looking for new distribution partners. Design your success with brand quality by Oest! You not only benefit from top products, but also you can rely on strong support.

Please contact Pavel Kozelek, Country Manager Eastern Europe, +420 778 030 630, pavel.kozelek@oestgroup.com

www.oestgroup.com

Dear Readers, Who could have thought that this summer would be so hot and long-lasting.

The businessmen of local resorts had no opportunity to complain about another short summer in the Baltic States. Manufacturers also enjoyed the summer vacation, it was felt when trying to get in touch with companies. Want it or not, the heat slowed down everyone’s pace.

Sometimes it seems that autumn is the beginning of a new cycle. Pupils and students start the new academic year. However, for many it is the time of harvesting. Manufacturers also come back to continue their work in order to be able to catch up on plans, to improve performance as there is only three and a half months of intense work before Christmas, i.e. the end of the year.

BECOME

VISIBLE

The Europe’s largest exhibition of metalworking equipment and technology this year – AMB 2018, Stuttgart – will take place in September (18th-22nd). For everyone who still has the chance, it is recommended to visit this event.

In September, we will attend and publish this edition magazine at ALIHANKINTA 2018 Subcontracting in Finland. We hope to raise interest of local producers in the Baltic companies, as the transfer of production capacities and close cooperation with Estonian companies have long existed.

We would like to encourage you to introduce your company and business in our latest issue of this year, which will attend the Swedish exhibition ELMIA Subcontractor, relevant for manufacturers. Remember that this is an additional opportunity to be noticed.

Baltic Metalworking team

BALTIC METALWORKING Subscribe: info@balticmetalworking.com www.balticmetalworking.com issuu.com/balticmetalworking Circulation 6000 printed units How to reach us Published by Baltmedus UAB, Europos pr. 122, LT-46351 Kaunas, Lithuania. +370 37 430401 +370 67767176

www.balticmetalworking.com

September-October 5/2018

|5

CONTENTS 9 New horizons in machining ti-

tanium aero-frames

BALTIC

METALWORKING September/October 5/2018

12

12 Federation of Estonian En-

gineering Industry – great gate to Estonian engineering sector

17

When engineers ruled the world: Robert Bosh starts your car

25

Responsibility - quality - experience - flexibility - that is the values of UAB Telrada.

17

25

9 6|

5/2018 September-October

www.balticmetalworking.com

,

12

6

www.doosanmachinetools.com www.facebook.com/doosanmachinetools www.youtube.com/c/DoosanMachineToolsCorporation

24

Baltic Construction Solutions as a holding company that was founded to join forces and become the leading company in the areas as: • steel structures production acc. EN1090-2 EXC3 • assembling and installation works on site • engineering project management • workforce outsourcing The successful operation of the company is based on the knowledge of the latest construction technologies, materials and corresponding standards and on staff ’s experience in implementation of many significant and technically complicated projects in cooperation with the best local and international experts.

Today Baltic Construction Solutions is focused in following industries: civil and production engineering (production plants, warehouses, logistic centers, sport halls, other civil building), pipe bridges and similar communication constructions, heavy frames and structures in machinery and related equipment manufacturing, mining industry and lifting equipment.

Assembling and site installation works are certified and conform all rules of Scandinavian and Finland legal requirements.

We provide professional engineering management, full structural designing and licensed work-shop drawings execution in Tekla software.

Workforce outsourcing covers short and long-term hires. Baltic Construction Solutions can mobilize staff to your project in a very short turn-around time what will save your company money by providing a flexible and tailor-made solution. The sectors we supply such as Building, Engineering, Manufacturing, Rope access, Automotive, Logistics, Warehousing and Recycling.

Nowadays we successfully effect the services to building and manufacturing industries customers in Finland, Sweden, Norway and other EU/EEA countries.

Contacts: phone +371 266 15 029 aleksandrs.suvorkins@constructions.ee

www.constructions.ee

SWEDEN

NEW HORIZONS IN MACHINING TITANIUM AERO-FRAMES The rise of titanium for aerospace applications has been well documented in recent years. Equally, the challenges associated with the efficient, productive and high-quality machining of this popular material, have also been a topic of debate and scrutiny. Of course, every machine shop wants optimised performance from its cutters when milling titanium, but this can prove less than straightforward without the right technology and know-how in place. Today, however, thanks to a breakthrough in this area, things are beginning to change.

T

he aerospace segment is expected to demonstrate impressive growth in the coming years as consumers continue to drive demand for new routes and greater flight frequency. Further drivers include global demographics and wealth creation in Asia and the Middle East.

In fact, according to Airbus, air traffic is set to double from its current levels over the course of the coming 15 years.

More aircraft required All of these expectations point to one outcome; the need for more aircraft. In turn, the challenge for aircraft OEMs will be to accelerate production.

There is also a clear knock-on effect for the aerospace supply chain. Machine shops around the world serving this sector need to meet increasing requirements for capacity, output, quality, on-time delivery and price.

According to a recent survey by Deloitte, the aerospace

Plura HFS

www.balticmetalworking.com

action

CoroMill Plura HFS

landing gear beam

supply chain is expected to continue its transformation to reduce costs, respond quicker and invest more heavily.

With respect to aircraft structures, the demand for increasing levels of titanium content in aircraft continues to rise, largely as a result of its impressive strengthto-weight performance. However, aero-frames are large components and there is often a considerable amount of material to machine away before the final component emerges ready for subsequent assembly.

With this in mind, it is important for cutting-tool suppliers to offer solutions that allow high productivity, and long and predictable tool life. However, more than tooling innovation alone is needed to meet the requirements of modern machine shops faced with the optimised production of titanium aero-frames.

Sometimes it takes a whole new strategy.

A new approach One such strategy is high-feed side-milling, which differs from traditional machining approaches that utilise large radial engagements and obligate to low cutting speeds of 40-60 m/min. Instead, highfeed side milling is characterised by low radial engagement, constant chip thickness, and high feed rate and speed.

At Sandvik Coromant, the company’s R&D team set about creating a cutting tool that could leverage the benefits of new milling strategies like high-feed side milling with the support of CAM programming; the thinking being that elevated productivity and extended tool life could be notable benefits.

September-October 5/2018

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After two years of intensive development work, the result is the CoroMill® Plura HFS solid-carbide end mill, a unique solution in geometry and grade that has been specifically conceived for titanium alloys and, in particular, to work in combination with high-feed side-milling strategies.

Cutting speeds >100 m/min Productivity has always been somewhat of a stum-

Plura HFS

coolant

booster

CoroMill family

plura

HFS-

bling block for machine shops producing titanium parts.

The reason is that machinability is limited by the high chemical reactivity, low thermal conductivity and work hardening properties of titanium. To combat these issues, the latest end mill has been designed to offer reliable performance when machining titanium alloys at cutting speed in excess of 100 m/min, while simultaneously demonstrating long tool life.

The main wear mechanism during the milling of titanium alloys is diffusion wear, which is provoked by a chemical interaction between titanium from the workpiece material and chemical elements from the tool coating and substrate. A higher temperature in the cutting zone intensifies the chemical reaction, so an effective cooling system is especially important for those looking to achieve prolonged tool-life characteristics.

In order to improve heat transfer from the cutting zone and use coolant in a more efficient way, the latest solid-carbide end mill is equipped with a newly developed internal coolant solution. The coolant channels have exits (one per each flute) that are specifically positioned to let the fluid reach the most thermally loaded part of the cutting zone. To increase cooling efficiency even further, the tool is equipped with the exclusive Coolant Booster (patent pending), which features coolant flow grooves on the clearance side that are designed to improve the heat dispersion.

10 |

5/2018 September-October

Defining the grade and the geometry Sharp cutting edges are another prerequisite when milling titanium alloys as these help to decrease cutting forces and minimise the influence of work hardening.

On the new tool, sharp edges combine with a new (patent-pending) coating that features a TiAlN inner layer and silicon-containing outer layer. The outer layer reacts with titanium alloys and forms a thin sub-micron pro-

Plura application Milling

high feed side

tective layer on top of the original coating. During the cutting process, the newly formed chips glide on top of the protective layer, preventing fast deterioration of the original coating and prolonging tool life.

The potential results of adopting the new cutter in combination with high-feed side-milling strategies have already been demonstrated at a European plant operated by a major aircraft OEM. Here, the company wanted to increase production rates, save time and keep costs under control when machining pockets on aero-frames made from Ti6Al4V using a four-axis horizontal machining centre.

The results By replacing the existing high-feed indexable insert cutter with the CoroMill® Plura HFS ISO S end mill, cutting data could be suitably adjusted to make the required gains. For instance, cutting speed was raised from 50 to 110 m/min, while axial depth of cut was increased from 1 to 30 mm. At the same time, radial depth of cut was reduced. The results proved particularly impressive.

Previously, the machining time for the aero-frame pockets was recorded as 150 minutes, with tool life of 37.5 minutes. Using the CoroMill® Plura HFS ISO S end mill, machining time has reduced by a factor of three, while tool life was four times longer. As a result, the plant is witnessing annual savings of €14,000 for the pocketing operation alone. www.balticmetalworking.com

Innovative solutions of metal furniture 27 years of experience and more than 15 000 products designed to preserve, store, archive, exhibit, trade and work.

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Modern design adapted to the interior High quality Optimal use of space

Products: • • • • • • • •

Cabinets Lockers and benches Shelving systems: mobile and static Safes and cabinets with high security level Workbenches Shop fitting Mail boxes Tolls boxes, garage boxes

Services: • products • • • • • •

Design and manufacture of non-standard Powder coating Metal laser cutting CNC punching CNC turning Welding Folding

JSC VILDETA Justiniskiu str. 16 LT-05100 Vilnius Lithuania +370 52415122 info@vildeta.lt

Your partner of innovative metal furniture, offers in every scope: sport clubs, hotels, museums, archives, libraries, banks, shops, schools, universities, hospitals, ministries, embassies and etc.

www.vildeta.lt

ESTONIA

FEDERATION OF ESTONIAN ENGINEERING INDUSTRY – GREAT GATE TO ESTONIAN ENGINEERING SECTOR Triin Ploompuu, manager

F

ederation of Estonian Engineering Industry (EML – Eesti Masinatööstuse Liit) is a great gate to find cooperation and opportunities with companies and better know-how and understanding what is going on in Estonian market.

About sector, there is about 7000 industrial companies. About 2200 are working in engineering, metal working and machinery industry. There are about 120 000 employees in industrial area, 35 000 working with engineering sector (10 000 white-collars and 25 000 blue-collars). Machinery industry position shows economic health, because this sector produces machinery to all industrial areas.

When we started 3,5 years ago, we had just 28 organizations in. But now, after quick growth, we have 85 manufacturing companies, selling companies, vocational schools and universities. Our organization is growing quickly, because engineering and machine building companies feel that we can win more if we focus to business development, product development and better cooperation between ourselves and the public sector.

Our priorities are: 1)Next generation – how to get more young talents to engineering industry? Manufacturing is not enough at-

Project Instrutec

12 |

tractive to young people. We are organizing practice places, seminars, company visits etc to invite young talents to study engineering and metal work jobs. We know that the same problem is also in Latvia, Lithuania, Germany and other countries. It means that we need to focus to this topic and have a strategic plan how to solve it.

2) Publicity and lobby – society and the decision makers need to know more about manufacturing, because it is very important part of economy how to create value.

Usually people do not notice or know much about industrial companies or products, that is why we need to inform them about it.

3) Business development – exhibitions, requests, business delegations, matchmaking, export and marketing projects etc. The most important is to give and hold our member companies with direct benefits for their business. That is the reason why our organization is growing.

Our project: Exhibition INSTRUTEC 2018 in Tallinn EML is content partner to exhibition INSTRUTEC, which will be on 7-9.11.18 and located Eesti Näituste messikeskus/ Estonian Fairs Centre, Tallinn, Pirita tee 28.

Exhibition organised since 1995, is the leading event of Estonian industrial market. The exposition andinforma-

is great event where to introduce engineering companies to young generation

5/2018 September-October

Photo: Kalev Lilleorg

www.balticmetalworking.com

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plastics for longer life

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EE(EU)-1071+1072-BRG+ECS 210x148,5.indd 1

11.06.18 16:16

JSC KVINT established in 1990 years

Company has a long experience in designing, producing stamps and stamping parts from stainless steel, steel and aluminum.

Our purpose is to make high quality production in time.

Draugystės str. 19 LT-51230 Kaunas Tel./fax. (+370)37 389147 Mob.tel. +370 686 84461 E-mail: kvint@mail.lt

www.balticmetalworking.com

September-October 5/2018

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Our ESTEN GROUP Photo:

visit to

Hannover

messe

2017.

private collection

tion, counselling and training events of Instrutec give an overview of the present condition and development potential of Estonian metal, mechanical engineering, tooling, wood and sawmilling industries and on the other side, bring the specialists the newest scientific, technical and technological advancements of this field in another countries. Instrutec is the leading industriaal fair in Estonia where professionals meet for the exchange of knowledge and experience.

• Approximately 100 industrial companies presenting the latest products and services.

• Seminars and workshops to broaden the scope of news.

• Top management conference for setting goals and hold joint discussions.

• Show area for the presentation of top equipment produced in Estonia.

• In-Action area with practical workshops and competitions.

More information: www.instrutec.ee and mrs Epp Sultsmann, instrutec@fair.ee Instrutec with its international recognition, stable value system, long-term vision and specific goals,ensures all firms and institutions participating in the fair effective positioning on the market andthe opportunity to keep current clients and win new ones.

Our project: ESTEN GROUP If we want to develop or to do product develpments, then we need skilled engineers with competence and experience. That is why we started project based team ESTEN GROUP, which includes best mechanical engineering companies in Estonia from different areas: marine, offshore, mining, energy, food, automotive and many other. Their joint capacity is about 60 engineers and they have the ability to use different programs. Main idea is to go to new export markets and share bigger projects, where different know-how is needed. You can read about their background, references and competence from website: https://www.estengroup.com/ or ask ms Kersti Vatter, kersti.vatter@estengroup.com 14 |

5/2018 September-October

Additional information • Federation of Estonian Engineering Industry – 85 members • Homepage: www.emliit.ee • Social media: special Facebook group “Eesti Masinatööstuse Liit ja tema sõbrad” and LinkedIn “Federation of Estonian Engineering Industry” • Members of the Advisory Board: Tõnu Lelumees (Head of the Board, IMECC OÜ); Priit Lind (BLRT); Emöke Sogenbits (Hanza Mechanics); Kristi Tölp (Electromatix OÜ); Tõnis Raamets (Silwi Autoehitus OÜ); Kristo Kaugija (Raasiku Elekter AS); Marti Jeltsov (Estflow Consulting OÜ); Veljo Konnimos (Radius Machining OÜ); Oliver Mets (Insero OÜ); Heikki Mäki (Finesta Baltic OÜ); Kristo Karjust (Tallinn University of Technology) and Marek Pakkin (Tallinn University of Applied Sciences).

• Projects: CLUSME – how to go to new export markets; 4Change – how to innovate vocational education; new database and system for reguests.

Project CLUSME business Photo: private collection

delegation in

South Africa.

INFO Eesti Masinatööstuse Liit Tel: +372 55 24 240 www.emliit.ee www.balticmetalworking.com www.ok-vise.com/distrubutors

JSC Deliuvis company specializes in sheet steel processing and successfully operates from 2006.

We can manage each of sheet steel processing tasks - laser cutting, bending, welding, robot welding, hot dip galvanizing in our factory.

Laser cutting - up to 12 m length Bending - up to 10 m length

www.deliuvis.lt

t4 �

METAL WORKING

Services:

• • • • • •

STEEL CUTTING STEEL BENDING STEEL ELEMENTS WELDING CNC PLASMA CUTTING BANSAW CUTTING DRILLING

Certifications: • • • •

EN 1090 ISO 9001 ISO 14001 Lithuanian Nuclear Power Safety Inspectorate license

Experience:

• in Norway, Sweden, Latvia • in processing of carbon steel and stainless steel • in production of high quality steel elements for Nuclear Power Plants • in metal processing of semi-finished products

Contacts www.monrema.lt � +370 656 99520 � info@monrema.lt , Lithuania, Visaginas

@

www.balticmetalworking.com

September-October 5/2018

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NOW IN LATVIA!

GREY IRON CASTINGS ACCORDING TO CUSTOMER DRAWINGS AND PATTERNS FROM 0,05 KG TO 25 KG

www.panketus.lt

www.martema.lt

EDGARS FELDMANIS

Sales Manager in Latvia +371 25540648 edgars.feldmanis@mtcenter.fi - Leading modules manufacturer in Baltics

We are proud to announce that we now have our local salesperson in Latvia!

With his educational background in mechatronics engineering, wide expertise in the field of machine building as well as automation and robotics, Mr. Edgars Feldmanis will provide you with our most well-known bestseller products. As well he can help you to find the best possible robot automation solutions for machine tool tending, welding and more.

Is looking for new suppliers that can laser cut and bend up to 3150mm long and 5.0mm thick special mild steel profiles.

WWW.RMODUL.COM SUPPLY@RMODUL.COM Tel.: +370-37-491016

The Finnish company Machine Tool Center, more than 100 years is working in machine tool sales and service.

MTC is a strong Fanuc robot integrator with long experience. More then 2000 robots sold during all this time.

heimatec

www.

QUANTITIES 10 - 10 000 PCS CNC TURNING AND MILLING

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METALWORKING

BALTIC

WE OFFER CNC milling and turning machines and service www.HURCO.de www.TAKUMIcnc.eu www.GOODWAYcnc.com www.FANUC.eu Automation FANUC robots and www.LANG-TECHNIK.de Tool presetters and measuring machines www.ZOLLER.info Air filters www.VELUMprotection.com Workpiece clamping solutions www.LANG-TECHNIK.de www.OK-VISE.com Professional tools and accessories www.HAHN-KOLB.de www.ALBRECHT-germany.co

MACHINE COMPONENTS MANUFACTURING

.com

www.mtcenter.lt 16 |

5/2018 September-October

www.balticmetalworking.com

copyrights of the photograph: www.grupo-bosch.es

WHEN ENGINEERS RULED THE WORLD: ROBERT BOSCH STARTS YOUR CAR Giedrius Drukteinis

E

ach person who drove a car at one point of his life or another has probably seen and recognizes the red logo of the Bosch company which can be found on car batteries, spark plugs, wipers, various wires, and even in car service centres. And even Robert Bosch, the founder of the company himself was always easily recognized in any photo due to his long beard, even in times when beards and moustaches were no longer in fashion. Before his death in 1942, Robert Bosch was asked by someone why does he need such a long beard which has already become a legend, Bosch answered: "I take care of it every morning, and, when I brush it, it reminds me to also take care of the thing that is most important to me in this world – my customer".

I would rather lose money than trust" - this sacral phrase of one of the greatest German industrialists R. Bosch is being continuously repeated in the advertise-

"

“I

would rather lose money than trust” photograph: www.grupo-bosch.es

www.balticmetalworking.com

Robert Bosh

ments of the company's products and was beginning to bore every Lithuanian radio listener several years ago, however it is still the motto of many of our entrepreneurs to this say. "It is not enough to simply want something.

You must work for it" - this and other similar quotes of the founder of the company were placed on every wall of the Bosch factory. We who grew surrounded by Agitpropo slogans might be bored by this, however, unlike the phrases of V. Lenin and his comrades, the sayings of R. Bosch sounded much more meaningful. "Never forget that you are human and everyone you deal with are human too. Respect that" - this is how Bosch educated the sellers of his products a hundred years ago.

And, unlike the states formed by empty slogan creators, the company of Robert Bosch remains to this day.

RESTLESS Robert Bosch was born in 1861 in Albeck, a village near Ulm (Wurttemberg) in southern Germany where his ancestors managed a small hotel since the 16th century. His father was a well-read and bright person, as well as a freemason who never went to church in his life, but was a diligent promoter of liberal ideas. Robert was the eleventh of twelve children and was greatly influenced by the cosmopolitan views of his father and the "idea of a unified Europe" at the time when nationalism seemed to be the only logical doctrine to any educated person living in Europe.

Among the famous German industrialists of the 19th century who created global corporations, Robert copyrights of the

September-October 5/2018

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Bosch was a small exception – unlike most of the latter, ica to be the most ideal economic and political system.

Bosch spent as many as six years in secondary school. However, according to him, it lacked the most imporHis preserved grade-book shows that R. Bosch was an tant thing – "justice". As shown by the later history of the average student, while his own life showed that he was company, America's concept of "justice" caused the most more interested to learn from the school of life rather problems for the industrialist – after both world wars, all than textbooks. In school, the future mechanics tycoon Bosch factories in the USA were confiscated and, for fifwas only interested in zoology and botany (to very end teen years, Robert Bosch was forced to compete with his of his life, R. Bosch was a passionate hunter). In his own own name and inventions registered in America – simwords, he "lacked ambition and patience" for other dis- ilar fate also fell on August Horch, the founder of Audi ciplines. company). But this was still distant future. Before returnHowever, after graduating from school, Robert was ing to his homeland, R. Bosch also worked in England for persuaded by his father to learn more about mechani- some time, in the electronic appliance factory belonging cal engineering - a field that did not interest R. Bosch to the Siemens brothers. whatsoever. In 1876, after a victorious war with France, In 1886, after turning 25 years old, Robert Bosch fiGermany became one of the most powerful countries nally made a decision to no longer be a hired worker. in Europe and technological inventions started to fun- He wanted to be a businessman. The industrialist said: "I damentally change the lives of people. The country had want to create a company that would avoid all problems railways and telegraph lines all over, steamboats disap- typical to companies where I have worked until now." peared over the horizon, and myths about the perception Therefore, in November of the same year, after investing of the world were destroyed by chemists and physicists. 10 thousand marks which he inherited from his father, Within such an environment, fifteen year old R. Bosch Robert Bosch established a "Precision Mechanics and became an apprentice in a mechanics workshop in Ulm Electrical Workshop" in Stuttgart. This was officially conwhere he spent three of his years. According to Robert, sidered to be the beginning of the current Bosch compathis period was "the most wasted years of his life" because ny which now has 270 thousand employees around the the workshop owner did bother to pass on his knowledge world producing 335 thousand different products. and experience to his young assistants. In 1879, the obeAt the time, there were only three people working in dient son listened to his father once again who forced the "Workshop" – R. Bosch himself, a colleague mechanic R. Bosch to work in various factories, travel the world and a teenage assistant. Nevertheless, they had a lot of and see "how people live". And Robert Bosch rediscov- work, even though they only repaired products manufacered himself in this role – even the photographs of that time showed a determined young man with a mane of unruly hair sticking from the top of his head. Within a few years, the future industrialist managed to work for some time in a pipe company in Cologne, steel foundry in Stuttgart, chain factory in Hanau, voltmeter and ammeter factory in Nuremberg, as well as a lamp factory in the latter city. He also managed to serve in Prussian Army engineering units in 1881-1882, as well as worked in an electric lighting installation factory in Magdeburg, and was a free listener in Stuttgart Polytechnic Institute where, according to him, he "did not learn anything very new in half a year, but at least he overcame his fear of technical terms and finally fully realized the true meaning of tension, electric current and horsepower". The same year, with the recommendation letter of one of his Workshop for Precision Mechanics and Electrical Engineerlecturers, Robert Bosch went to America where ing” in Stuttgart, Germany copyrights of the photograph: he began working in one of T. Edison's companies www.bosch-presse.de producing telegraph and telephone machines. His fearful respect of America as the flagship of technologi- tured by other companies. R. Bosch repaired everything cal innovations disappeared within one year, by the end – telephone machines, water meters, typewriters, pens, of which R. Bosch returned to Europe and wrote to his compasses, photo cameras, lighters, humidors for cigars, family that "I did not learn or heard anything new from and even wooden horn instruments. Of course, the road Edison" (even though R. Bosch always considered Amer- to the Olympus of business was not easy. R. Bosch con18 |

5/2018 September-October

www.balticmetalworking.com

tinuously suffered from lack of finances and even borrowed money from his mother in order to be able to pay his employees. However, he also had pride in his work – he acquired a bicycle from England in order to be able to transport the repaired items to his customers as fast as possible – and this was the first bicycle in Stuttgart with equally sized wheels (bicycles with a large front wheel and a small back wheel were popular at the time). This novelty did not go unnoticed – the bicycle of R. Bosch was even published in newspapers, and locals often turned to look at R. Bosch while he was driving through the streets followed by a crowd of clamorous children and dogs. R. Bosch also installed a telephone in his workshop, which cost half a year of his employee's salary, in order to be able to receive customer orders faster. In any case, the future millionaire often lived poorer than his employees who always received their salaries on time (but they had no telephones or bicycles). This went on until the day an unfamiliar customer came to the "Bosch Workshop" and

Robert Bosch with his bike,1890 tograph: www.bosch-presse.de

copyrights of the pho-

innocently asked whether Mr. Robert could copy one item? A magnetic fuel ignition device.

SUCCESSFUL IMPROVEMENT At the end of 1887, R. Bosch rode thirty kilometres on his bicycle to inspect the device in the Deutz factory near Stuttgart. It was an old engine ignition system created by www.balticmetalworking.com

Werner Siemens in 1866 for his dynamo machine – two connected magnets were turned using a straightened "Z" shaped handle which form an electric field that produces a spark in order to ignite the fuel and air mixture – this system can be seen in old films where characters start their cars by turning an inserted handle on the front part of the car.

However, at the time, this system was used to start the engines of large static factories or mills. After making sure that this mechanism was not protected by any patent, R. Bosch copied it and transferred it to the customer by also additionally making his own improvement – reducing the size of the device by installing differently shaped magnets (this anchor form can still be seen today in the Bosch company's logo). As it soon became evident, this was the solution to the greatest problem of the automotive industry at that time.

That year, Bosch received nine orders to manufacture these smaller magnetic ignition mechanisms. And there were twenty orders the next year (all of which were intended for static engines). In 1891, Bosch manufactured as many as 100 of these mechanisms and realized that the sale of magnetic ignition systems brings the company half of its revenue, therefore he focused on producing only the latter.

Even though R. Bosch himself had nothing in common with cars because they were still in their embryo

Magneto

ignition for automobiles, 1897 copyrights of the photograph: www.bosch-presse.de

stage, however, in 1897, Englishman Frederick Simms, member of the board of the Daimler company which produced motorcycles, contacted R. Bosch with a reSeptember-October 5/2018

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quest to install his creation in a three-wheeled car – no one has attempted to do this before. When German Karl Benz patented his first motor vehicle in 1886 (which is now considered to be the beginning of the modern car), the fuel and air mixture in his created internal combustion engine was ignited using an open flame which was both dangerous and impractical (that is why these first vehicles could only travel no more than a few dozen kilometres without stopping), therefore K. Benz considered such an ignition system to be "the greatest challenge of the automobile industry". The compact magnetic ignition system of R. Bosch worked and seemed so practical that his name soon attracted the attention of all the car manufacturers, and, finally, R. Bosch had struck gold. R. Bosch also created his key principles soon after, based on which fuel ignition systems are produced to this day, particularly the famous ceramic spark plug which is the most recognized Bosch product in the world. The company began to expand and now had 25 employees working under it. In 1898, Bosch manufactured 148 ignition systems, however their production grew to a million units over the next fourteen years. And, in 1902, R. Bosch managed to adapt the magnetic ignition system to high speed (1000 rpm) engines – since then, his system became a universal thing and the company itself was a global monopolist up to 1925, until the invention of the accumulator motor ignition principle. At that time, America took over the car industry from Europe and nearly ninety percent of Bosch company's revenue came from abroad. From America alone, Robert Bosch carried out orders which generated a revenue of a million dollars in 1906. In order to avoid high import taxes, an entire Bosch Magneto Company factory was built in the USA with a conveyor system adapted under a principle creat-

Bosch Magneto Company New York, USA, 1906 rights of the photograph: www.bosch-presse.de

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copy-

ed by Ford. This factory enabled to reduce normal production costs by half. Bosch also bought the Rushmore company which began manufacturing electric starters in 1910. Most wealthy people wanted to be able to drive their cars themselves, but turning the engine handle in public was no longer acceptable for them due to status and smart clothing. Bosch perfected the principle of launching the ignition system with the help of a starter – first with a pedal and later by pressing a button (and by turning the car key later on).

RISE OF THE AUTOMOTIVE INDUSTRY Up to 1913, Bosch company, which already had four thousand employees, manufactured two things – magnetic ignition and engine oil distribution systems. Nevertheless, R. Bosch soon realized that this is dangerous due to progress which may produce a new technology at any time and destroy this rapidly aging principle. Production diversification was the optimal solution. The same year, Bosch began manufacturing generators and testing rechargeable high-capacity batteries (due to war, they were massively produced only since 1927). Bosch began manufacturing car lamps (and, even though car buyers had to buy such lamps separately, Bosch was the first to install them in cars as part of the entire set. This was first done

by Daimler-Benz which cooperates with Bosch to this day ever since 1898. The first fog lights, brake lights and rear lights created by Bosch were also installed in cars.

In addition, there was a part of Bosch in each mechanical car improvement and this continues to this day. As people like to say, only toy cars do not have components manufactured by Bosch. Bosch began the mass production of sound signals, wipers and cabin heating systems.

After acquiring the company manufacturing Blaupunkt radio receivers, in 1932, Bosch began to also manufacture the first car radio receivers (however they weighed twelve kilograms and cost 300 marks - half the price of a small car). In the twenties, when diesel engines became a viable alternative to petrol ones (as diesel engines don't even require a magnetic ignition device), R. Bosch was quickly aware of the new prospects and, in 1934, the company was already mass producing diesel injection systems.

NEEDED BY EVERYONE In the 20th century, German industrialists had to face a hard fate – losing two world wars meant a lot – destabilized or destroyed economy, killed talents, disrupted supply and business conditions. And there was nothing worse for an industrialist than to have a typical German surname, such as Bosch. All Bosch factories in the territories of the USA and France were confiscated during both wars, while the remaining factories in the eastern part of Germany were dismantled and taken away by the soviets. The very first historical factory in Stuttgart was completely wiped out from the face of the earth during the aerial attacks of allies in 1944. After World War I, for a while, Robert Bosch had also lost his factories and even www.balticmetalworking.com

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to the speech of M. Suslov in Dnipropetrovsk), in 1912, Robert Bosch himself promised to pay 10 million marks to anyone who could stop the then Balkan crisis and prevent war. Even though with a surname like that you are obviously "the worst of the worst bourgeois" (once again, in the words of M. Suslov), however, among the German bourgeois themselves, Robert Bosch was known as the "red bosch". He was friends with the "German Social-Democracy Marat" Karl Kautsky (whom V. Lenin called a "prostitute" in his letters), and the letters of Karl Marx made it obvious that motivated workers are the most important asset of the company – prior to the implementation of a conveyor system, all works were carried out manually and this greatly influenced quality which R. Bosch strived to perfect his entire life.

As early as in 1906, he implemented an 8-hour work day in his factory, as well as mandatory holidays after a few years.

"I pay high wages not because I earn a lot of money. On the contrary, I earn a lot of money, because I pay good wages", - this is how Robert Bosch spoke about his employees. At the very beginning of the company's activities, people would often see employees of Robert Bosch adverstising magneto ignition Red Devil, 1910 copyrights of the Bosch repairing things in the workshop photograph: www.bosch-presse.de and singing in harmony – this was the perfect illustration of the company's athis brands and patents. His own company in America mosphere. was renamed to American Bosch Magneto Company Nevertheless, Robert Bosch was also a capitalist. and began competing with the products of the found- Unlike Thomas Edison, R. Bosch was impatient and er himself. An agreement to merge the companies was short-tempered. He would not explain things twice and reached only in 1935, however Americans took over the would quickly fire an employee without any remorse. company once again during World War II. Car service However, his employees understood that strict is not centres with the Bosch Car Service sign can be seen even necessarily unjust - punctuality and discipline were mantoday in many places across Lithuania. These service datory for all employees working in the Bosch company. centres were established in 1921 with the aim to promote After all, the German economy was always famous for the name of Robert Bosch around the world and with- these traits. Robert Bosch would inspect his books and stand the competition of yesterday's satellites. records carefully, for long periods of time, questioning Ironically, you would have probably not found a every spent pfennig, but he could also donate millions if keener pacifist among German industrialists than Rob- someone was truly in need. He hated the Nazis, howevert Bosch. And you would have probably not found a er, when he died from an ear inflammation in 1942 (at more active "pan-Europist", as, ever since his childhood the age of 82), Germany gave him a state funeral with all years, R. Bosch believed that Europe can be unified as due respect – after all, Robert Bosch was a famous person an economic community without any political or trade needed by everyone. barriers. Even though soviet propagandists always liked to point out that the "predatory war was caused by Siemens, Krups and Bosch which were led by uncontrollable desire to accumulate even more wealth" (according 22 |

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