February-March 2/2018
METALWORKING
BALTIC
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The Magazine of Baltic Metalworking Industry
www.balticmetalworking.com
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Dear Readers, we were more than happy to see your smiles after you received the new Baltic Metalworking magazine during a Tech Industry exhibition in Riga. Some of you were surprised, others - became very interested, but the overall reaction was positive and inspiring to even intensify our efforts towards improving our periodical. We hope that if you, for some reason, did not receive our first magazine during the exhibition, you received a copy by mail.
BECOME
VISIBLE
Christmas and New Year holidays have passed by so quickly but we believe that you found time to gather together with your family and friends, have a rest and recover strengths. 2017 was a successful year for many companies operating in the metalworking industry. 2018 is also expected to be a good year. E.g., the growth of the economy of Germany is expected to be approximately 2.3 %, of Sweden and Finland - approximately 2.7 %, of Estonia - approximately 3.3 %, of Latvia - approximately 3.5 %, of Lithuania - approximately 2.9 %. Metalworking companies feel positive vibes and plan further investments. During the last year, many companies were increasing capacity by purchasing additional equipment. This is an easy and fast way; however, there are specific concerns related to the lack of qualified employees. Therefore, news related to Industry 4.0 are becoming increasingly topical; attention is being increasingly focused on increasing the productivity through the use of more efficient technologies, digitisation, automatization and etc. We wish you to keep in step with the latest technologies, remain competitive and meet your bullish targets in 2018. 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
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CONTENTS
BALTIC
METALWORKING FEBRUARY- MARCH 2/2018
6 6
10
Our passion - metal cutting
10
Experience that reflects in products quality
12
12 How BMW descended from heaven to Earth
18 Make your work more
effective with low-profile clamps
22 www.balticmetalworking.com
22 Tiger-tec Gold – a quantum
18
leap achieved
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LITHUANIA
OUR PASSION - METAL CUTTING
M
etaco company has been producing sheet metal products for more than 10 years already. The company’s strong side is laser cutting of metal sheets, perforation of metal sheets, metal sheets bending, assembly of products. The company has accumulated extensive design experience, which allows us to offer a design service for designing various equipment as well as preparation of production drawings. In the company we can offer other services, such as metal sheets powder coating, welding, welding of frame structures. The company’s production always has high quality requirements, which is why our customers always remain satisfied and our services are recommended to other customers.
•
Metal sheet thickness of laser cutting: 20mm mild steel, 10mm stainless steel, 10 mm aluminum.
Bending of metal sheets with Trumpf bending machines “Trubend 3120” and “Trubend 5085”. 4 CNC-controlled backgauge axes system has proved to be a true benefit when producing different parts, with existing equipment we can get banded sheet metal parts exactly as we wish. Trubend 3120 • Bending force 1200kN • Bending length 3110mm (depending on the thickness of the bending sheet and the type of material) Trubend 5085 • Bending force 850kN • Bending length 2210mm (depending on the thickness of the bending sheet and the type of material)
What we do offer? Using universal laser cutting and punching machine we can offer you shape cutting, hole punching, laser cutting combine processing, also forming different elements like jalousie, hooks and other elements you will ever need for your technical solutions. Metal sheets perforation and laser cutting the „Trumpf TruMatic 6000L“ combined machine. • Laser cutting power 3kW • Sheet dimensions 1250mm x 2500mm • Punching force 220N • Metal sheet thickness of laser cutting: 8mm mild steel, 5mm stainless steel, 4mm aluminum.
Powder coating The greasy surface of the parts is cleaned up or phosphated before color coating. Electrified dry color powder
Cutting of metal sheets with CO2 laser “Trumpf L4030 CO2 laser”. • Laser cutting power 4kW • Sheet dimensions 2000mm x 4000mm 6|
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www.balticmetalworking.com
Tiger·tec Gold Go for better, go for Gold. ®
For those who won’t settle for anything but the best: Tiger·tec® Gold If you had to make a choice right now – between maximum tool life, uncompromising process reliability and optimum productivity – which one would you pick? Why not choose the freedom to never have to choose again. Stay true to your own high standards in every way. Choose Tiger·tec® Gold.
walter-tools.com
5 nius
7 6591 argasas.lt lt
DESIGN AND PRODUCTION STAMPING, OF STAMPING DEEP DRAWING TOOLS DESIGN AND
is spread on the surface of the part, goes to cure oven, powder melts down and polymerizes. Customer can choose color and tone from RAL color pallete, colored surface can be smooth or rough, mat or lustrous.
Industrial equipment design
STAMPING, PRODUCTION OF STAMPING TOOLS DEEP DRAWING RESISTANT WELDING
RESISTANT WELDING
We also have a great design experience in the company, so we carry out various non-standard product design, 3D modeling, calculations, and production drawings. We use advanced 3D modeling systems.
Other services •
Mig/Mag, Tig and spot welding of metal sheets and frame structures Product assembly Subcontracting service
• •
INFO Metaco UAB Draugystes g. 17, LT51229 Kaunas +370 37 351129 info@metaco.lt www.metaco.lt
Turbine grinders
CNC MILLING AND TURNING, GRINDING, POWDER COATING AND ASSEMBLY SERVICES
www.vaivora.com
Powerful tools for
BECOME
VISIBLE
PNEUMACON OY Palo-ojantie 5 05810 HYVINKÄÄ Puh. 010 778 1400
BALTIC METALWORKING
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•
PNEUMACON OY ESTONIA Peterburi tee 2 F 11415 Tallin, Estonia Tel. 010 778 1400 • www.pneumacon.ee
www.balticmetalworking.com
F I NN H I NG E
Find our new hinge webshop: www.finnhinge.com +358 400 772118 • info@finnhinge.com • Tampere, Finland •
www.balticmetalworking.com
Spring hinges • Adjustable hinges • Special hinges • •
Safety gates Safety gates hinges Piano hinges Bearings
February-March 2/2018
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LITHUANIA
EXPERIENCE THAT REFLECTS IN PRODUCTS QUALITY
W
ith 20+ years of experience in metalworking, UAB koncernas “ALGA” (ALGA) is a leading manufacturer of metal constructions in Southwestern part of Lithuania. As a family business still run by founders and other members of Linkus family, the company has earned the name of a stable and reliable partner not only in Lithuania, but also in other EU countries such as Latvia, Estonia, Germany, Finland, Norway and Sweden. The main areas of production are steel products, various containers, tower, masts and modular buildings. ALGA group unites 10 companies with 430 employees ensuring the highest quality of metal processing and production. It is an honour to talk to Mr. Antanas Linkus, the CEO and co-owner of the group.
constantly modernises production technologies and this helps to respond to changes in the market and grow. One more major success factor I believe is that the company has always followed its values: honesty and transparency. A wise businessman once told me that the honesty pays off financially in the long run. We have been following this principle which yielded positive results: the corporation has been noticed by world-known companies.
Mr. Linkus, what do you think are the main reasons why the company has been successful for such a long time? 20 years of experience in the production of metal structures speak for themselves. We have learned to ensure the highest quality of our products. This helped us to earn trust from foreign customers. 97 percent of our customers are satisfied with the final result and come back to place new orders. This is also an accomplishment of our professional team that is always ready to advise the client. The company complies with quality control indicators,
What are some of the companies that you successfully cooperate with? UAB koncernas “ALGA has achieved most of its recognition through telecommunication masts and towers commissioned by telecommunication companies “Telia” and “Bitė”. Actually, the idea of masts and towers itself belongs to my father and the founder of the corporation - Andrius Linkus. He was once passing by a metal tower thinking that he could manufacture something like that in Marijampolė and make it even better. He did exactly as he thought. In addition to that, ALGA designs and produces towers for radiolocation, fire and lightning protection as well as self-supporting mobile masts. ALGA offers a large variety of containers for transportation and storage of explosives that are gaining popularity among Scandinavian construction companies. We constantly participate in international exhibitions, establish direct contacts and use unconventional marketing such as exhibition in Vilnius International Airport (EXPO Center) to inform potential customers about our production capabilities and increase customer base. Recently we have modernised our production premises and expanded production
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and will keep an advantage over competitors because we can manufacture telecommunication towers or masts on site, install them and perform annual services, maintenance. It is especially convenient for the customer to receive full package of services. We have identified huge potential in the neighboring Latvian market, that is why in 2018 and 2019 we are planning to expand there. A branch which will rent telecommunication towers and masts is already established. Although this requires large investments, we rely on our internal resources and not on banks, foreign investors or other external sources of finance. This is also one of the company’s strengths – we have learned to discover, develop and apply our internal resources. capacities. We are open for new partnership opportunities and interesting projects. Do you provide subcontracting services? Yes, we offer high quality services, that cover major Sargasas UAB needs of metalworking. Some of the services include: Popieriaus g. 15 cutting, plasma cutting, steel surface preparation by abrasive LT- 08404 Vilnius cleaning method, automatic punching, steel plate up to 3 Lithuania mm unwinding from a reel, steel bending, welding, turnTel. +370 5 277 6591 Email: info@sargasas.lt ing, drilling, protective wet priming and painting. A large variety of services brings us where wewww.sargasas.lt are today. What are your future plans for the upcoming years? We experience strong competition in the market of metal constructions’ producers, however ALGA keeps
In 2018 the Baltic States are celebrating 100 years of Independence. What is your wish for your partners and colleagues in metalworking industry? In 2018 and the next 100 years, I wish everyone to be free to create, expand, share and most importantly to do what they believe in and believe in what they do.
INFO UAB koncernas „ALGA” Gamyklu g. 4, LT 68108 Marijampole, Lithuania Tel.: +370 343 98737 alga@alga.lt www.alga.lt
W ELCOME BUSINESS EXHIBITION!
www.balticmetalworking.com
February-March 2/2018
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HOW DESCENDED FROM HEAVEN TO EARTH Giedrius Drukteinis Verslo klasė
N
owadays Company BMW is a well-known manufacturer of great automobiles and motorcycles, which had many fathers, including Gustav Otto, Karl Rapp, Franz Josef Popp, Camillo Castiglioni: all of them contributed their efforts in development of vehicles you drive today. The history of BMW started at Oberwiesenfeld Army Airfield located in the Northern part of Munich, the capital of Bavaria, which has been used for military purposes since the 18th century. This place has become the centre of gravity for many aviation enthusiasts after 1903 when the Wright brothers demonstrated that it was possible to raise a “heavier-than-air-aircraft” above the ground. The wave of enthusiasm for flying spread across the world, including Germany. A number of workshops eager to make aircrafts and engines for them began to set up in Oberwiesenfeld. A small factory “Gustav Otto Flugmaschinenfabrik” was also established there in 1911. It was owned by G. Otto (1883–1926), who was the son of the famous German engineer and inventor Nikolaus August Otto, one of the “fathers” of an internal combustion engine. He has been surrounded by various machinery and drawings since his childhood so his destiny as an engineer was predetermined very early in his life. Gustav gained excellent education in engineering, which secured his career at the most famous industrial companies in the Empire. Nevertheless, this had some negative consequences as well, because the shadow of his famous father followed him during his entire life constantly pushing G. Otto into depression, which had a negative impact both on his work and personal life. In 1910 he learnt to operate an aircraft and in the same year he built his own monoplane by using plywood and tarpaulin, which became a sensation in entire Germany. “Gustav Otto Flugmaschinenfabrik” launched production of this aircraft in 1911. He also established G. Otto’s flying school nearby, and, by the way, Ernst Udet, who would become the German ace pilot, who shot down so many enemy aircrafts during World War I, that he came in second to the Red Baron 12 |
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Manfred von Rittenhofen in this ranking, also gained and improved some skills there. In 1913 “Rapp Motorenwerke” motor factory opened its doors just a few streets away from Gustav Otto’s factory. Its founder K. Rapp (1882–1962) was born in Ähingen, Donau Region. There is very little information about his childhood and his life as a young man, thus his biography starts with employment at “Züst” vehicle company within the period of 1908–1911, where he probably became familiar with engines, and he then expanded his knowledge by working at “Daimler” factory in Stuttgart. The reasons why he left “Daimler” and how he became fascinated with aviation are unknown, but there are no doubts about one thing: he indeed was fascinated by it. K. Rapp made the first aviation engine with his own two hands, which was then presented at the Berlin Aviation Exhibition in 1912 where he was awarded a silver medal. In 1913 he used investors’ money for purchasing all required equipment and started the operations of “Rapp Motorwerken” in Munich after hiring seven employees. The start of World War I has provided great opportunities for the entire German aviation industry. In 1915 “Rapp Motorenwerke” had already 370 workers, Otto’s factory expanded as well, which was renamed as “Otto Werke” that year. Both of them have become the biggest suppliers for military aviation in Bavaria, however, none of the engine models manufactured by them had much commercial success. Moreover, both companies did not manage to get out of the minefield of technological problems. Shortly the six-cylinder engines manufactured by K. Rapp were rejected by both Bavarian and Prussian military administrations as unfit for use because of excessive vibration. The wave of orders placed to “Otto Werke” by the military completely dried out at the end of 1915 because of poor quality of the engines. G. Otto himself paid no attention to customers’ comments and requests, because at that time he was undergoing treatment at a www.balticmetalworking.com
„The best German military aviation engine BMW “IIIa” has been manufactured with the current BMW logotype since 1917. Copyrights of the photograph: “Wikipedia.“
psychiatric hospital because of another case of clinical depression. During his stay there he notified about his resignation from the position of the head of the company and announced his intention to sell it. In March 1916 the investor consortium took over control of “Otto Werke”, renamed the company as BFW (“Bayerische Flugzeugwerke”), and started manufacture of aircraft engines from a clean slate. At the end of that year BFW manufactured approximately 100 engines per month, and when the number of employees reached three thousand, BFW became the largest engine manufacturer in Bavaria. First success After World War I ended, G. Otto himself had been cooperating with vehicle company “Starnberger” in designing a luxury car “Otto-Mercedes” for some time. However, his personal problems did not go anywhere: in 1924 he divorced from his wife Ada and sunk into depression again. His ex-wife remarried in 1925 and shortly died under mysterious circumstances, meanwhile the tabloid press vaguely accused G. Otto of this. This did not help him raise his spirits and in 1926 G. Otto committed suicide at the age of 43. The Bavarian Military Administration had plans to get production at BFW up and running and to turn K. Rapp’s engine factory into engine repair shop and supplier of spare parts, however, unexpectedly the company’s prestige was saved by F. J. Popp (1886–1954), a foreigner, who, by the way, represented another unhappy customer of the factory. He was the one destined to become the most important “godfather” of BMW. F. J. Popp was born in Vienna from where his family moved to Brno, another city of the Austrian-Hungarian Empire, in 1901. There he finished school, studied, www.balticmetalworking.com
and received a diploma in electrical engineering in 1909. Upon returning to Vienna, F. J. Popp found employment at electric train and locomotive production division of company “AEG-Union” where he quickly climbed up the career ladder and became a manager there. When World War I started, he volunteered to join the Austrian Army, but after three-week service at Pula Military Naval Aviation Base (presently in Croatia) he was called back to Vienna to oversee production of aviation engines at AEG, later on – at company “Austro-Daimler”. He was continuously sent to business trips to Germany for qualification improvement courses and negotiation of licences for production of engines, however, neither “Daimler”, nor “Benz”, nor NAG companies agreed to transfer them to the Austrian Empire. After these failures the management of “Austro-Daimler” decided to develop and manufacture their own engines for the Austrian imperial military aviation. And yet they still lacked the required equipment. F. J. Popp recommended his management to conclude a contract with “Rapp Motorenwerke” factory in Munich, which was then struggling because of financial problems, but had all required equipment and labour force not burdened by orders. In 1916 F. J. Popp was sent to K. Rapp’s factory to organize and oversee engine production, however, upon getting acquainted with the actual situation, he diligently became involved in the production process. He realized right away that K. Rapp, who had many good engineers, lacked only one thing, i.e. a good designer. F. J. Popp invited Max Friz, a young and talented engineer from “Daimler”, who could solve such problems, to join him in Munich. Even though Bavarian military inspectors decided to turn K. Rapp’s factory into BFW’s engine repair shop, February-March 2/2018
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F.J. Popp managed to convince them to let him try once again over a dinner. M. Friz brought a vision of a “high altitude” engine from Vienna, which at K. Rapp’s factory turned into “IIIa” engine with a part, which was never seen before, i.e. carburettor, which gave the engine enough power to take an aircraft to an impressive five-kilometre height within 29 minutes. The Prussian Army Administration order production of 600 high altitude engines and this changed the entire structure of the Company. At the same time this also predetermined the destiny of K. Rapp himself. The Bavarian Military Administration found it obvious that only F. J. Popp was the best manager because of his talent for organization. Meanwhile K. Rapp was removed from the company he established, which was renamed as BMW (“Bayerische Motoren Werke” – Bavarian Engine Factory) on 21 July 1917 in order to avoid the shadow of infamy. Since 1917 the best German military aviation engine BMW “IIIa” has been manufactured with a new BMW logotype, which everyone is familiar with: it is a combination of the colours incorporated into the Bavarian flag symbolizing a white propeller in a blue sky. F. J. Popp became the General Manager of BMW. His efforts resulted in increasing numbers of public orders, the State even gave a loan for reconstruction of the factory in order to adapt it for mass production of engines. However, ultimately the Governments of Bavaria and Prussia required that this would be funded by investors rather than state
grants. Another godfather This is how the fourth godfather of BMW showed up in the picture: this time it was financier C. Castiglioni (1879–1957). At one point C. Castiglioni was referred to as the richest man in the Central Europe. He was born in Trieste, a city in the Austrian-Hungarian Empire (presently Italy), in the family of the Jewish rabbi. He studied law, worked at a bank in Padua for some time, where it did not take long for him to master the secrets of capital management and international finance law. Later on he worked as an agent for tyre company “Kaufmann” in Constantinople, where he established himself as a clever salesman, which led to his promotion to the position of the director for export at the company and eventually he climbed his career ladder right to the top and became the CEO of the company. During World War I C. Castiglioni became one of the most important players in the military aviation industry of the Austrian-Hungarian Empire, he also supplied parts to the German navy. He convinced familiar bankers in Vienna to invest in reorganization of BMW and heavily contributed to flourishing of the company. Unsuccessful end of the war hit BMW very hard, because engine “IIIa” was the only product manufactured by the company. The German economy was in chaos, the future of aviation was cloudy after the Treaty of Versailles banned production of aircrafts and aviation engines,
„BMW’s first motorcycle, the R32.
copyrights of the photograph: “Wikipedia.”
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„BMW automobiles have been equipped with the perfectly recognizable grilles since 1933. copyrights of the photograph: www.bmwusa.com therefore BMW was forced to land on the ground. In order to get by, the factory had to engage in production of small engines for motorized boats, cars and motorcycles as well as casting aluminium pots for some time. In 1919 production of engines was terminated completely, however, “Knorr-Bremse”, the company established in Berlin, which dealt with railway facilities, signed a contract with BMW for supplying brakes for wagons. But this was not enough for C. Castiglioni, who was the main shareholder of BMW, therefore in 1920 he sold his BMW shares to the same “Knorr-Bremse”. In 1922 C. Castiglioni acquired BFW, which barely vegetated by engaging in production of furniture and kitchen utensils as well as engines for motorcycles, he also bought out the entire patent package and the brand of BFW. Both companies were merged into a new company BMW. By the way, the title BFW was created in 1926 as the title of the subsidiary of BMW AG, but shortly it was changed into the infamous “Messerschmitt”, which was the most important supplier of warplanes to the Third Reich. In 1923 BMW produced its first motorcycle R32. As the burden of bans placed under the Treaty of Versailles became lighter, BMW officially returned to the aviation sector: in 1927 aircrafts equipped with BMW engines held one third of height and distance records on a global scale. In 1928 the first four-wheel vehicle manufactured by BMW factory was placed on the market: it was automobile “Dixi” manufactured based on the licence held by the English company “Austin”. Organization of automobile production at BMW factory was C. Castiglioni’s swansong at the company itself. In 1924 he lost millions due to speculation in the French Frank, which led to bankruptcy of “Depositenbank” in Austria under his management: C. Castiglioni hid in Italy from the arrest warrant issued in Austria. The financial
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empire developed by him collapsed in 1926, and in 1929 C. Castiglioni was forced to sell his BMW shares to a new consortium of bankers. However, by then he still managed to convince the Board of Directors of BMW to purchase automobile factory “Eisenach Automobilwerke” in Berlin and to start production of these vehicles. The first original BMW automobile BMW AM1 (“Automobilkonstruktion Miunchen 1”) was produced in 1932. The luxurious BMW 303 was produced in 1933 which marked the start of the tradition to equip all future BMW models with 6-cylinder engines and liver-shaped grilles. The company was expanding rapidly and bought several automobile factories by the start of World War II. In 1935 a new huge BMW aviation engine factory was built in near Munich, in Allache, and the company became the main engine supplier for Luftwaffe. Naturally, the Nazi regime sought to involve the most prominent German companies in operations for the needs of the upcoming war, because this was very financially beneficial. F. J. Popp, then already a long-time General Manager of BMW, resisted such temptation because he sensed not only commercial benefits but a potential risk associated with relying on orders placed by the regime alone – the company already had hectic experience from the World War I period. Although F. J. Popp himself had been a member of the Nazi Party since 1933, in 1936 he was under consideration at the Party’s Committee because he allowed to be treated by a Jewish doctor. His resistance to work only for the needs of the war led to accusations of sabotage and his removal from the position of the General Manager of BMW in 1942, and even though he nominally remained a member of the Board, he no longer had any decisive vote. In 1940 BMW completely stopped production of automobiles and became only a supplier of engines and
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motorcycles for the German Army. BMW manufactured “the very best war motorcycle R75”, which is well-known from the war chronicles. Not only BMW supplied 30 thousand engines to Luftwaffe, but it also became the first company in the world to engage in mass production of jet engines for “Mmesserschmitt” “Me 262”. BMW also developed strategic bomber projects, but their production was never launched. At the end of the war 50 thousand people worked at BMW factories and half of them were prisoners of war from Dachau concentration camp. World War II hit BMW badly again. The factory in Munich sustained damages from bombs beyond repair in 1944, meanwhile three BMW factories in the Eastern Germany fell into the Soviet hands, so they were dismantled and taken away. Things were not any better in the West either: all assets of BMW were seized after the capitulation of Germany. The BMW factory in Allache was allowed to repair automobiles of the occupation government after the War, but essentially it engaged in production of pans and pots, bicycles and kitchen cookers again in order to get by. In 1947 the factory in Allache was allowed to manufacture motorcycles and in 1948 the first post-war R24 drove away through the gates. Later on BMW brand disappeared from the economic map of Germany until 1953, but returned to the arena in style: that year BMW pro-
duced motorcycle R68, which not only fascinated with its sophisticated design, but it also became a standard for the entire industry because of its technical characteristics. You are very well aware of what happened next. In 1973 BMW again became the first company in the world to start mass production of turbo-engines for automobiles, it was a leading company in production of software for engines for some time, manufactured the world’s best armoured automobiles. Production of BMW 3 Series was launched in 1976 and in 1980’s the MTV Channel established a strong association between BMW and yuppies (MTV made the term “bumer” popular). At the moment BMW is a part of the Big Three in the German automobile industry along with “Mercedes Benz” and “Audi”: it manufactures luxury and high-quality automobiles well established on a global scale. Moreover, they are positive that peace is better than war without a shadow of a doubt.
RESTORATION OF INDUSTRIAL COMPONENTS • Laser Cladding • Thermal spray • Hard chrome replacement • Precision cylindrical grinding • Heavy duty turning and milling • Research and development • Technical solutions and consulting BEFORE
Laser cladding is a process to apply metal and metal-ceramics coatings using a laser as tool for precise impact of base and an additive materials. The laser beam in a very thin top layer melts base material and an additive metal or metal-ceramics material compositions to create a protective coating. AFTER
www.dicoating.com
FINLAND — LITHUANIA
MAKE YOUR WORK MORE EFFECTIVE WITH LOW-PROFILE CLAMPS
O
perating principle is very simple – OK-VISE low-profile clamps expand when they are tightened down, simultaneously pressing the workpieces against the guide and preventing their movement. Fastening with only one bolt ensures quick set-up times. To explain how it works in real everyday production we will present few examples from our existing customers how to make work more effective.
First example is from company which is using vertical 5 axis CNC machines. Machine table is Ø630x500mm. In the most case customer is using standard or dedicated 5-axis machine vises for 5 side machining. When part size is big enough, there is no problem with spindle/tool reachability of part from all 5 sides. What to do if task is to cut complex part of size for example 25x25x25mm by using existing machine and table size. Specific vise is needed to lift part from table base to make possible to reach part with spindle/tool. Customer started to use low-profile clamp. From the photos you can see simple solution: customer using standard machine vise to clamp block of aluminum, which we
could name riser. On top of riser one low-profile clamp is used to fix the blank material for 5 side machining. Solutions is simple and doesn’t requires big investments into specific clamping equipment. One more example from company Ignetas UAB, which is mid-size company, working in subcontracting field and can offer such service like robot welding parts, over molding parts, semi-automatic and manual riveting parts or complex assembly parts. Also, company have few CNC milling machines. There was a task to save production time for one specific part which they are producing from aluminum profile. They are using small 3 axis vertical machine (table
Aluminum riser and OK-VISE low-profile clamp in combination for better accessibility at 5-axis table.
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fixtures ourselves took lot’s of time, and luckily we can now use our time much more effectively in productive work” says Mikko. “In some prototypes we still use old‐school machine vises. However, in true batch‐production machine vise is not a rational choice, additionally cleaning large in a vise is time consuming. size 300x250mm) for this task. Part is small and has some milling and drilling operations also 3 setups are needed. Very short cycle time doesn’t give any space for operator to do some additional work between cycle start and stop. Using traditional machine vises one-part production time including all setups was 2min and 25s. We recommended to use low-profile clamps and make dedicated pallet, where all setups are clamped in same time, total 6 pcs on one pallet. It gives production time of one part 1 min and 15s. Also cycle time of one setup is 2.5 minutes. It gives more space for machine operator between cycles. MJM‐Koneistuspalvelu Oy is a small workshop in Central Finland. Just like thousands of OK‐VISE users, they are serving local industry with flexible deliveries and affordable pricing of their services. The young entrepreneur Mikko Mäkelä took over the company from his father in 2015, and since then he Sargasas has beenUAB upgrading the operations and equipment of workshop to be15 able to Popieriaus g. serve his customers more efficiently. LT- 08404 Vilnius Mikko and his machinist SeppoLithuania are working with +370 5machining 277 6591 very typical machines, including twoTel. vertical Email: info@sargasas.lt centers. Now one of the focus areas in the machinery is www.sargasas.lt fixturing. Earlier they have been using self‐made dedicated fixtures and traditional machine vises. Now they invested on OK‐VISE Multi‐Rail RM System, which is a system for generic‐purpose workholding. “OK‐VISE Multi‐Rail System adapts easily to various workpiece types. Earlier manufacturing the dedicated
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May be the most important factor in their new workholding concept is that instead of one workpiece only that a machine vise could hold, Multi‐Rail system clamps typically 6 to 12 workpieces at a time “All in all, investing for a Multi‐Rail RM system has been a clever move” says Mikko.
INFO Official distributor Machine Tool Center UAB info@mtcenter.fi www.mtcenter.lt www.ok-vise.com/distributors
Ignetas UAB info@ignetas.lt www.ignetas.lt
MJM-Koneistuspalvelu Oy mikko.makela@mjm-koneistuspalvelu.com www.mjm-koneistuspalvelu.fi/
www.balticmetalworking.com
DESIGN AND MANUFACTURE PROGRESSIVE DIES WELDING FIXTURES BENDING FORMING STAMPING TOOLING FOR CONTOUR CUTTING WWW.SDLE.LT www.balticmetalworking.com
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SWEDEN
TIGER TEC GOLD – A QUANTUM LEAP ACHIEVED
Users worldwide are delighted: The new generation of cutting tool materials increases productivity by up to 300%
T
he audience of industry professionals was expectant. After all, Tübingen-based Walter AG had done their best to raise expectations in the run-up to the premiere at AMB 2016. Walter’s Tiger·tec Gold, the new generation of cutting tool materials, was said to represent a technological leap for the entire sector. The first indexable inserts with the new coating have been on the market since the beginning of 2017 – and one thing is already clear: The developers at the Tübingen machining specialist were not exaggerating. On the contrary, as Wolfgang Vötsch, Senior Product Manager for Milling at Walter, emphasises: “I cannot remember ever receiving so much positive customer feedback for any other product innovation”. Countless users around the globe are now working with Tiger·tec Gold. And they are all simply thrilled by the properties of the new grade. As Vötsch says: “The term has seldom been more accurate than in this case.” It is no wonder: The customers are from a wide range
Image 1: Wolfgang Vötsch
of different sectors, such as the automotive and energy industry or die making and mechanical engineering. One after the other, they report results with Tiger·tec Gold that are rarely seen in practice. “We have cases in which performance increases of several hundred per cent have been documented. In almost all applications, the tools last two to three times longer than conventional tools.” Fundamental innovation The global machining industry had worked with cutting tool materials based on titanium carbon nitride and 22 |
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Image 2: Walter BLAXX M3024
aluminium oxide for over two decades. Of course, the properties of these coatings were continuously optimised throughout the years, but it was becoming clear that they had their limits. Today, new application areas and materials with increasingly difficult cutting properties in the high-tech, aerospace and the automotive sectors require coating properties that are almost impossible to achieve with conventional coatings. Tools that are significantly more robust and more efficient than existing solutions are in demand. Performance improvements of a few percent are no longer sufficient. “It has been clear to us for several years that there is a need for fundamental change, and we were determined to be at the forefront of development in this area too,” explains Wolfgang Vötsch. “That we have achieved.” Tübingen-based Walter AG has created a completely new technological platform with Tiger·tec Gold – on the basis of titanium aluminium nitride (TiAlN), manufactured with a newly developed CVD coating process. This material is ideal for milling steel and cast iron workpieces at medium to high cutting speeds thanks to its unique properties. Tool life increased by around 80% The developers at Walter had field-tested the new Tiger·tec Gold WKP35G grade extensively before its launch. As expected, tests showed significant improvements in three areas in particular, which are now also confirmed under real conditions: The tools coated with WKP35G stand out thanks to significantly higher wear resistance on flank faces, lower rate of hairline crack formation and improved resistance to plastic deformation. Intialfield test results showed a tool life that was on average 80% longer, however users in today’s market re-
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port performance increases averaging between 100% and 200%. “At peak levels, we even achieved a 300% longer tool life, not just for some particularly exotic application but with different components and materials – from structural, alloy and stainless steel to grey cast iron, compacted and spheroidal graphite,” explains Wolfgang Vötsch. An application engineer from one of Walter customer stated: “The new grade ran far better than the previous one in compacted graphite iron.” Another engineer was also quite astonished: “The wear is so low, you cannot see anything. I was starting to wonder whether the inserts had been replaced, but no, they had not.” Since the launch of Tiger·tec Gold, the following components, among others, have been treated with the new coating – all with excellent results: - Engine block made from GG25 (grey cast iron) - Machine bed made from GG25 (grey cast iron) - Digger support plate made from St42 (structural steel) - Drive shaft made from 35CrMo (alloy steel) - Cast mould for glass bottles made from GG25 (grey cast iron) - Connecting rod made from C70 (alloy steel) - Steering knuckle made from GG25 (grey cast iron) The significantly increased performance of the new generation of cutting tool materials is mainly due to the unique coating properties: TiAlN, with its very high aluminium content of around 85%, stands out due to its high level of hardness and especially because of its compressive residual stress.
Image 3: Tiger·tec Gold WKP35G coating
Still one of a kind on the global market The engineers at Walter developed an entirely new manufacturing process to support the deposit TiAlN in series production: ULP-CVD technology – a combination of ultra-low pressure (ULP) methods chemical Sargasasand UAB Popieriaus g. the 15 only vapour deposition (CVD). So far, this process is LT08404 Vilnius one of its kind on the entire global market. Lithuania In addition to TiAlN as the mainTel. coating, the new in+370 5 277 6591 dexable inserts also use titanium nitride (TiN): It is apEmail: info@sargasas.lt www.sargasas.lt plied both as a link between the carbide base substrate and the TiAlN main coating and as the top layer above www.balticmetalworking.com
Image 4: Walter BLAXX F5041 shoulder milling cutter
the main coating. It is the golden glow of TiN from which the new generation of cutting tool materials takes its name. A welcome side effect: It is much easier to identify tool wear compared to black or grey top layers. While the hardness of the new coating leads to the previously mentioned higher wear resistance on flank faces and the improved resistance to plastic deformation, the new manufacturing method also significantly lowers the rate of hairline crack formation. Unlike the CVD coatings subjected to tensile residual stress, which have previously been commonplace across the sector, the Tiger·tec Gold TiAlN layer is “the first coating subject to compressive residual stress manufactured with the CVD method,” according to Wolfgang Vötsch. In addition, the new coating technology is suitable for both dry and wet machining. “Dry machining has further advantages: It is environmentally friendly, significantly lowers costs for coolants and additionally increases the tool life, because the smaller changes in temperature put much less strain on the tool.” As one enthusiastic customer states, all in all, Tiger·tec Gold “significantly improved both the process reliability and the tool life. In my opinion, Walter has achieved a quantum leap.” In addition to the Tiger·tec Gold WKP35G grade, Walter will launch further grades of the new cutting tool material generation. According to Wolfgang Vötsch, the entire range of indexable inserts for milling will also be available with the Tiger·tec Gold WKP35G grade by early 2018.
INFO
Baltijos pramoninis tiekimas UAB +37060826989 Mindaugas Pipynė, mindaugas@baltpt.lt www.tigertec-gold.walter February-March 2/2018
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Multi-Rail RM Combo-Rail Multi-Rail RH Grid Fixturing Blank Fixturing Clamp modules Stop modules Riser blocks Side guides
Hydraulic Clamping
Sales: www.ok-vise.com/distributors
www.ok-vise.com
GS MODELS Maximum Performance §
Rigid Construction §
High Performance Spindle System §
Advanced Turret Technology §
Ultimate Turning Power
Horizontal Turning 24 |
Cylindrical Grinding
2/2018 February-March
Vertical Turning
Official Baltic’s Distributor Machine Tool Center UAB www.mtcenter.lt info@mtcenter.fi www.balticmetalworking.com
Optimise your business deals. With precision. At the complete production technology fair you can explore the latest machines in operation and discover the equipment of the future. Quite simply, this is where everything is gathered that has to do with machine tools, tools and measuring technology. Here you can strengthen your competitiveness. Together with five parallel production fairs, Elmia Machine Tools is a platform for tomorrow’s industry. And the focus is on doing business.
One ticket admits you to all the fairs!
May 15-18th 2018 Produktionsmässorna.se Jönköping, Sweden
Baltic Bearing Company is the new European manufacturer of wide bearing range. The company has its own plant equipped with modern and high-performance grinding machines, assembly lines and control equipment in Riga (Latvia), its own warehouses and dealership network in the CIS and Europe. At the end of 2017, we can confidently say about the positive results of achieving the company’s goals for the performance of the production plan, customer satisfaction and sales volume.
“Indicators for the performance of the production plan
for relevant year are 100% in volume and in nomenclature. Over the past year, new bearing types have been developed, production has been modernized, and additional 4 assembly lines for ball and tapered bearings have been installed and launched, the technological process of washing and preservation on automatic washing machines has been mastered and introduced. The actual production release in comparison with 2016 has grown by more than 50%“. General Director Shevelev. S. “Today the main advantage of the company is the optimal balance of competitive prices and constantly high level of product quality, and the main goal is the customers’ satisfaction. In particular, a shining example of this can be the level of 0 PPM, controlled by our OEM customers“. Chief Customer Officer Nosenko S.
“An integral part of the successful product promotion on the market is the constant work of improving the marketing management system at the plant, market analysis, development of the sales network. This year, for example, we opened an office in Poland (Lodz). The company constantly works with consumers, and regularly participates in industry exhibitions". Director of Sales Lorentz A Baltic Bearing Сompany invites present and future partners to visit our booth stand № D 44 in Hall №22 at the exhibition in Hannover (Germany) from 23 to 27.04 2018. Regarding regional distribution, please contact by e-mail bearingnet@bbcr.eu More information you can find at our website www.bbcr.eu Uriekstes str. 18 LV-1005, Riga, Latvia
INDUSTRY EVENTS
2018
20-24 of February Metav Dusseldorf, Germany https://www.metav.com/ 20-22 of March Konepaja’18 Tampere, Finland www.konepajamessut.fi/en/ 20-22 of March Nordic Welding Expo Tampere, Finland https://www.nordicweldingexpo.fi/en/ 10-13 of April Metalworking Minsk, Belarus http://metalworking.minskexpo.com/ 16-20 of April Tube Dusseldorf, Germany https://www.tube-tradefair.com/ 23-27 of April Industrial Supply / Hannover Messe Hanover, Germany http://www.hannovermesse.de/en/exhibition/trade-fair-line-up/industrial-supply/ 24-27 of April Control Stuttgart, Germany http://www.control-messe.de/en/ 16-18 of May Balttechnika Vilnius, Lithuania https://www.litexpo.lt/en/exhibitions/balttechnika-2018-4 15-18 of May Elmia Sheet Metal Joenkoeping, Sweden https://www.elmia.se/en/plat/ 15-18 of May Elmia Welding & Joining Technology Joenkoeping, Sweden https://www.elmia.se/en/Welding/ 15-18 of May Elmia Machine Tools Joenkoeping, Sweden https://www.elmia.se/en/verktygsmaskiner/ 18-22 of September AMB Stuttgart, Germany http://www.messe-stuttgart.de/en/amb/ 25-27 of September Alihankinta Tampere, Finland https://www.alihankinta.fi/en/ 09-11 of October Aluminium Dusseldorf, Germany https://www.aluminium-messe.com/en/ 23-26 of October EuroBLECH Hanover, Germany https://www.euroblech.com/2018/english/ 07-09 of November Instrutec Tallinn, Estonia https://instrutec.ee/en/ 13-16 of November Elmia Subcontractor Joenkoeping, Sweden https://www.elmia.se/en/subcontractor 29 of November - 1 of December Tech Industry Riga, Latvia http://www.techindustry.lv/ www.balticmetalworking.com
February-March 2/2018
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LITHUANIA
Tiger·tec Gold Go for better, go for Gold. ®
BUSINESS INSIDE Pramonės įrenginių detalių restauravimas
- CNC frezavimas ir tekinimas - Šlifavimas - Miltelinis dažymas - Surinkimo paslaugos
Robotizuoti
suvirinimo sprendimai For those who won’t settle for anything but the best: Tiger·tec® Gold If you had to make a choice right now – between maximum tool life, uncompromising process
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reliability and optimum productivity – which one would you pick? Why not choose the freedom www.dicoating.com to never have to choose again. Stay true to your own high standards in every way. Tiger·tec Gold ®
Choose Tiger·tec® Gold.
SDL Engineering
VELOPMENT
Go for better, go for Gold.
Štampų projektavimas ir gamyba
modern laboratory technology
walter-tools.com
ANTS
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onomic and ecologic
01.08.16 11:34
+37060826989
c solutions for all industrial application ranges
TION
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+370 609 978 75 sales@sdle.lt www.sdle.lt
For those who won’t settle for anything but the best: Tiger·tec® Gold If you had to make a choice right now – between maximum tool life, uncompromising process reliability and optimum productivity – which one would you pick? Why not choose the freedom to never have to choose again. Stay true to your own high standards in every way. Choose Tiger·tec® Gold.
mindaugas@baltpt.lt
www.tigertec-gold.walter
Patirtis atsispindinti darbuose www.alga.lt
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STRIBUTION
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ct portfolio with optimised logistics
Oro kompresoriai Vakuuminiai siurbliai Pramoninės dujos
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LATVIA
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Didelis nerūdijančio plieno gaminių pasirinkimas
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Metalo apdirbimas: - štampavimas - štampų projektavimas ir gamyba, - kontaktinis suvirinimas
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Miltelinio dažymo sprendimai +37065500157 baltics@helios-group.eu
RŪPNIECISKO ŠĶIDRUMU RAŽOTĀJS
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Save time with Twin-tool holders
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The new all-directional PrimeTurning™ method and CoroTurn® Prime tools allow you to do your existing turning operation in a much more efficient way. Broaden your capabilities even further with new CoroTurn® Prime tool holders for multi-task and vertical lathe machines.
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Seeing is believing, visit our website to see PrimeTurning in action: www.sandvik.coromant.com/primeturning
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February-March 2/2018
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INNOVATION IS SHAPING TOMORROW’S SHEET METAL INDUSTRY. At this dedicated industry fair you can explore news and innovations and discover the technology of the future. The fair offers a wide range of machines in operation, tools and accessories for the sheet metal working industry. Here you can strengthen your competitiveness. Together with five parallel production fairs, Elmia Sheet Metal is a platform for tomorrow’s industry. And the focus is on doing business.
One ticket admits you to all the fairs!
May 15-18th 2018 Produktionsmässorna.se Jönköping, Sweden
Gamechanging compressors With Variable Speed Drive technology you can reduce energy consumption by 50 % on average. Atlas Copco in Latvia “Mārtiņmuiža”, Mārupes novads LV-2167, Latvija +371 67 609190 info@lv.atlascopco.com
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