HIGHER PRODUCTIVITY THROUGH COMPLETE MACHINING
The length of the respective processing time per machine has become an established yardstick for the performance of manufacturing processes with regard to costs. It is generally accepted that the shorter the primary processing time, the more efficient the process.
Success Stories - Plastics
MILLING PLASTICS: PRODUCING HELMET VISORS IN RECORD TIME
Every year, according to Germany’s Federal Statistical Office, some 250 million tonnes of plastic are produced worldwide. There are reasons for the fact that polycarbonate accounts for only roughly 1.3% of that total. Nevertheless, although it costs more than other plastics, it retains its shape better and offers higher optical clarity, which is why it is used when a plastic material has to meet certain requirements. A good example of this is the visor of a pilot’s helmet.
ALUMINUM: THE RIGHT TOOL SOLUTIONS FOR VERY VARIED APPLICATIONS
When it comes to the number of application fields, aluminum is the true factotum of the metals. The question is not so much where it is used, but rather where it is not! It has long been indispensable as a structural material for making cars and planes. Aluminum offers low weight and high strength here. Due to its high electrical conductivity, it is valued by electrical engineers as a material for antennas and for conductive cast components. The fact that aluminum is also used, for instance, as a material for making cooking pots or electric irons points to its good thermal conductivity. Against this background, one thing is clear: machining it with cutting tools presents a varying challenge.
THREAD ROLLING: STABLE PROCESSES AT SMALL BUSINESSES IN FOCUS
Chipless thread fabrication using a thread rolling head has a full range of advantages: the finished surfaces are smooth and have increased strength, and the material fibers remain unbroken. An English example illustrates how the highly reliable process offered by this method is important, in particular, for small businesses. The component supplier LMS Precision Engineering is using thread rolling head from LMT Fette in the fabrication of jointing elements from EN1A steel, and gains a competitive advantage through this process.
AIRCRAFT CONSTRUCTION: TITANIUM THE TOOL-CHALLENGE UNDER CONTROL
Nowhere is the search for new materials more intense than in the field of aircraft construction. The reasons for this are easy to see: on the one hand the materials must withstand particularly high stresses. At the same time, however, it is important to lower the total weight of the aircraft and so minimize fuel consumption.
Success Stories - Composites
PERFECT ALUMINIUM SURFACES CATCH THE EYE
What makes a car fascinating? Why is it fun to drive? Of course, the acceleration, the smooth purring of wheels and even the noise of the engine all play a role. However, an appealing interior design is just as important as the driving experience. Faurecia Angell-Demmel produces components that have a major impact on the appearance of car interiors: the international automotive supplier is a market leader for high-quality components with genuine metal surfaces – ranging from individual switches to entire consoles.
Success Stories - Composites
ROBOTS OPTIMIZE CFRP FINISHING
Carbon fibre reinforced plastic (CFRP) is increasingly being used in the automotive industry. Overall it makes for lighter and therefore more fuel-efficient vehicles. Even complex components like side panel frames, for example, are now made of CFRP. But how can you guarantee the efficient and high-quality mass production of these elements?
SETTING NEW STANDARDS IN GEARWHEEL PRODUCTION
Gearwheels production often means mass production. In the automotive industry, for example, the main components for gearboxes are required in huge quantities. Accordingly, if there is an increase in car production, the demand for gearwheels rises exponentially. So how can automotive suppliers open up new production capacities in such situations – while simultaneously minimizing the production costs of their components? Gearwheel experts from LMT TOOL SYSTEMS have demonstrated one way of doing just that with its customer Stelter Zahnradfabrik. Stelter was able to free up machine capacities simply by deploying the new Speedcore hob. The tool’s incredible performance eventually tipped the balance for the company.
PROTEC JUST KEEPS ON GOING
Thread production on an industrial scale always involves high standards both in terms of quantity and quality. After all, it is not just a matter of machining large numbers of components. At the same time, each individual thread has to be produced to a high level of precision. What is more, this has to be achieved with increasingly demanding, high-tensile materials. The situation is no different at the IBMO company: among other things, the Polish automotive supplier manufactures brackets for car trailer axle mounts. LMT FETTE’s new Protec thread roller enables significantly lower tool costs and higher productivity.
TERASPEED IMPRESSES SHIPBUILDER
Higher speeds, greater perfection, finer precision – enormous performance increases have been achieved in the production process since a North German manufacturer of marine engines began relying on an LMT tool to machine one of its components. LMT experts have now been asked to help the company optimize other machining processes.
FIVE AT ONCE
The Czech Republic is an important part of the international motor vehicle value creation chain. That means, that the supplier industry has to orientate on the quality and efficiency criteria of their worldwide consumer in the automotive industry. As a manufacturer of pulleys, E.C.J. is well aware about the specific requirements – and has already reacted successfully: application of the Pentatec indexable insert from LMT's alliance partner BOEHLERIT has reduced production costs for each component by about 55 cent. When a typical production series for E.C.J. is around 80,000 parts, this has an enormous effect. This is made possible by the special geometry of the tool.
HOB CUTTERS: LMT SERVICE PROVIDES PERMANENT PERFORMANCE ADVANTAGE
From initial consultation to reconditioning, in practically no other industrial sector are support services more important than in the field of precision tools. Take hob cutters, for example. They are essential in the production of gearwheels and toothed components. However, the performance of tools over their entire life cycle depends crucially on the quality of reconditioning. What that means in practice for tool services is made clear by a closer look at Kownatzki, the Wehr-based engineering company where an LMT Service team has been supporting the use of Nanosphere hob cutters and ensuring reconditioning and recoating to original quality. The full Nanosphere performance advantage is always available.
MEDICAL TECHNOLOGY: CLAMPING DEVICE BRINGS A LEAP FORWARD IN PERFORMANCE
Implants and supports in the vertebrae are helping more and more patients to overcome one of the most widespread disorders: back pain. But the construction of the prostheses for this delicate part of the body is not easy. They must withstand very high stresses and must continue to function faultlessly for a long time. A large number of these high-tech implants are created at Ulrich Medical in Ulm. The medical technology experts rely on TER collet chucks from LMT's alliance partner Bilz for machining vertebral supports from the extremely strong titanium alloy Ti6Al4V. With success: the clamp significantly lowers tool costs, and production is more effective.