Mitsubishi Materials Craftsmanship Magazine YOUR BM007E GLOBAL CRAFTSMAN STUDIO
SUPPORTING MEDICAL PROGRESS Supporting the Medical Care Industry with Processing Technology Vol. 7 Stories YOUR GLOBAL CRAFTSMAN STUDIO VOL.7 STORIES VOL.7
3-6 7-18 EYE ON MARKET FOCUS ON PERFORMANCE Regenerative medical devices exhibit Star Micronics Co., Ltd. outstanding technical innovation Suzuki Precion Co., Ltd. Takayama Instrument, Inc.
19-20 21-22 23-26 HISTORY OF MITSUBISHI CRAFTSMAN STORY TECHNOLOGY ARCHIVE Gunkanjima Island (Battleship Island) Producing a CVD coating with the Metal mould development driving the A coal mining operation that supported perfect properties for sharp edged evolution of inserts Mitsubishi Mining Co., Ltd. materials -DF2XLBF-
27-28 29-30 ABOUT US CUTTING EDGE TianJin LingYun Tool Design Co., Ltd. – Analytical technology designed to MTEC TianJin (China) visualize problems and improve Education base in China for cutting processing tool markets
1 YOUR GLOBAL CRAFTSMAN STUDIO MESSAGE
Tsukuba
We continue to improve manufacturing with an eye on the future
Thank you for reading MMC’s YOUR GLOBAL changes highlight the importance of the that we deliver the best products and CRAFTSMAN STUDIO Vol. 7. Your Global Craftsman Studio brand services. concept in ensuring the most effective Volume 7 features the approach we are solutions for customers as we maintain and making in the medical field. In addition improve business infrastructures to ensure Yasunori Murakami to our ongoing work in the automobile, safety and quality. Vice President & General Manager aircraft and metal mould sectors, the past of Production Division few years have also seen a focus on the To maintain and improve business Metalworking Solutions Company medical industry. With an eye on further infrastructures, we keep a constant eye on Mitsubishi Materials Corporation improvement, we hope to gain continuing the future to develop ever more innovative support and take increased knowledge production technology and manufacturing from the marketplace. capability based on accumulated wisdom and DNA that features ingenuity. Along with the expansion of information technology and the globalization of business More than 7,000 employees are engaged activities, the environment surrounding in our carbide business both at home and the manufacturing industry has witnessed abroad. Although not all employees come significant change. We also feel the need into direct contact with customers, our to reconsider business procedures and Customer First attitude expressed in the goals in line with progressing technology spirit of Mitsubishi Materials’ Your Global and changing demographics. Such Craftsman Studio brand concept ensures
Gifu
Akashi YOUR GLOBAL CRAFTSMAN STUDIO 2 EYE ON MARKET EYE on MARKET MEDICAL INDUSTRY Technical innovation in regenerative medical devices Environment surrounding the regenerative medical devices industry The goal of regenerative medicine is the Regenerative medicine is classified into obstacles to meaningful progress. recovery of biological functions that have biological substitution and biological Meanwhile, aging populations in Japan, usually deteriorated due to disease, regeneration. Biological substitution the United States and Europe have had environmental factors and aging. is the use of artificial devices such as a serious impact on medical expenses, The United States and Europe have joints and bones to recover function. which in turn affects national budgets. dominated the regenerative medicine Biological regeneration strives to This has prompted accelerated markets; however, Asian markets have regenerate organs and tissue. Materials research and development in medical been attracting increasing attention. used in biological substitution are technologies to reduce total costs. Aging populations and improving called substitutive devices. Although 3D Therapeutic technology using iPS cells, standards of living, driven by significant printer technology for the production which exhibits great biocompatibility, economic growth in Asian countries of surgical instruments and implants is safe and reduces patient burden, is have drastically expanded the need has found some practical application, nearly ready for practical use. However, for regenerative medicine. Africa is the quality of this new method of before practical application can be also expected to become an important manufacture remains lower than the fully realised, medical care systems market in the future. These conditions existing methods, especially with regard (insurance/ certification) must improve suggest stable growth potential for to initial investment, material costs and and hospitals are also looking to regenerative medicine markets. manufacturing time, which serve as advance their technologies.
Predicted changes in population age in major countries
(%) 45.0
40.0
35.0 Japan United States 30.0 Germany 25.0 China England 20.0 France 15.0 India Indonesia 10.0
5.0
0.0 2010 2015 2020 2025 2030 2035 2040 2045 2050 2055 2060 (Year)
Source: United Nations, Word Population Prospects The 2015 Revision
3 YOUR GLOBAL CRAFTSMAN STUDIO EYE ON MARKET
Predicted world population
60
50 Africa 40 Europe North America 30 Asia Latin America & Carib 20 (100 million persons) Oceania
10
0 2015 2017 2018 2020 2025 2030 2035 2040 2045 2050 2055 2060 (Year)
Source: United Nations, World Population Prospects 2017
Increasing demand for improved productivity and cost reduction Substitutive devices are processed with As new material development has tool manufacturers to improve cutting cutting tools to a greater degree than advanced, machining has become a technology and reduce costs through general parts are. Hard-to-cut materials greater challenge. It is because of this, improvements in production technology such as ceramics and carbon-fiber major medical device manufacturers to satisfy market needs. reinforced plastics (CFPR) have been face significant costs associated with increasingly used along with titanium, research and development required to stainless and cobalt-chromium alloys. enter new markets. This forces cutting
Major substitutive devices
Substitutive device market prediction
(M USD) 160
140
120
100
80
60
40
20
0 2015 2016 2017 2018 2019 2020 2022 2024 2026 2028 2030 (Year)
Estimates by Mitsubishi Materials Corporation based on a major medical device manufacturer's annual report
Technical innovation in Special Feature regenerative medical devices
YOUR GLOBAL CRAFTSMAN STUDIO 4 EYE ON MARKET EYE on MARKET MEDICAL INDUSTRY Providing total solutions to the medical care industry Effective use of cutting tools improves the processing of substitutive devices
Hard-to-cut materials such as cobalt- diameters and deep holes in cobalt- solutions for such an extensive range chrome, titanium and stainless alloys chrome alloys used for substitutive of complex applications, Mitsubishi are often used for substitutive devices. devices present a challenge. Mitsubishi Materials is highly regarded for This means extremely short tool life Materials has commercialised products processing hard-to-cut materials used for the tools that machine them, which that improve tool life and processing by medical care device manufacturers requires manufacturers to strive for efficiency through the development of in the North American market, one improvement. Along with improved wear the base ingredients. As one of only a few of the major markets for substitutive resistance, applications such as small cutting tool manufacturers that provide devices.
Total Tooling
Torx screw Processing Outer diameter lathe turning: VQXL For titanium alloys MT9005 FS-P: LS-P: Low depth of cut High depth of cut
Pilot Hole Drilling MVS Chamfering DLE
Small Diameter Processing Solid Bar
Deep hole drilling Outer diameter lathe turning: Solid drill with through coolant holes For titanium alloys MT9005, MGS Mini MVS Cutting-off CCM alloys MP9015, SUS alloys Gun drills Mini GY FS: Low depth of cut LS:High depth of cut
Medical screw tooling
5 YOUR GLOBAL CRAFTSMAN STUDIO EYE ON MARKET
Improvement Case Increasing tool life and improving the efficiency of processes that cause bottlenecks
Before Torx screw machining Deep hole drilling (gun drills) Screws Turning improvement (double -blade)
After MVS VQXL Screws Turning improvement Deep hole drilling Four-blade 40% reduction of processing time
Processing time
Work material Ti-4AI-6V Machine to be used Small-size CNC automatic lathe Deep hole MVS Process Torque processing processing Tools to be used MVS0180X30S030 VQXLD0050N025 n = 35,000min-1 Machining n = 1,750min-1 F = 300mm/min parameters fr = 0.02mm/rev VQXL Ap = 0.03mm Coolant Oil (Internal 7MPa) Oil (External)
Improving customer satisfaction through enhanced proposals
Multi-task machining centres and five- through the enhancement of cutting machines, and a wide range of CAM to axis machine tools have been used to tool performance. We are now required prioritise the enhancement of highly- manufacture complex medical device to provide total solutions utilising advanced proposals. MMC continues parts. These machines have made it cutting tools, machine tools, CAM and to be a comprehensive cutting tool possible to improve productivity while analysis. manufacturer capable of proposing reducing manpower requirements, Mitsubishi Materials (MMC) has customer-oriented and globalised total which has accelerated cost reduction. worked in cooperation with machine solutions for the substitutive device The increasing complexity of processing tool manufacturers and CAM software market. technology that such change brings suppliers to implement multi- makes proposals for improved task machining centres (including machining and technical development small automatic lathes), five-axis
Dental CAM Simulation CAM Simulation for Small Automatic Lathe with Small Automatic Lathes Low-frequency Vibration Cutting Function
Technical innovation in Special Feature regenerative medical devices
YOUR GLOBAL CRAFTSMAN STUDIO 6 FOCUS on PERFORMANCE CASE 1 Star Micronics Co., Ltd (Kikukawa City, Shizuoka Prefecture) Engaged in the development and manufacturing of Swiss-type automatic lathes suitable for medical device manufacturing. The company has approximately 30% of the global market share.
7 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS ON PERFORMANCE FOCUS
Fumio Masuda Noriaki Ozeki Daisuke Suzuki Executive Manager, Sales & Marketing Dept. Manager, Technical Sales Support Sec. Executive Manager, Development Dept. Machine Tools Division Sales & Marketing Dept., Machine Tools Division Machine Tools Division
Automatic lathes for users developed by users Star Micronics Co., Ltd. opened its Marketing Department, Machine Tools The combination of long thin geometries doors in 1950 as a small parts factory Division. and difficult-to-cut materials that with only six employees. The company comprise a lot of medical components, began with the manufacture of precision Star Micronics started global expansion means that they are difficult to parts for watches using automatic of its automatic lathe sales with exports manufacture without Swiss-type lathes from Switzerland and Japan. To to England in 1962. Currently, they automatic lathes. This is why Star’s produce higher quality precision parts, have established production, sales products have been chosen by the the company shifted to manufacturing and service structures in Europe, the medical industry as the machine its own machine tools for in-house use. United States and Asia. They do not tools of choice. “Additionally, because The shift was driven by the founder’s rely on distributors and sales agencies, bone screws and other parts used in desire to develop an automatic lathe. instead they send employees directly medical treatment are placed inside our The company touted its product as to customers to provide thorough body, they must conform to extremely “Made by machinists for machinists” before and after sales service of their high standards, conform to blood and soon began receiving orders for products. Such close attention has compatibility and be corrosion resistant. automatic lathes from other companies. been highly regarded by the market, To meet these demanding requirements, “We have been manufacturing a wide and their Swiss-type automatic lathes they are manufactured from difficult-to- range of precision parts using machine have now captured around a 30% share cut materials such as titanium alloys and tools that we have developed internally. of the global market, establishing also require extremely high geometrical Our Development Division takes their position as the leading automatic accuracy,” said Noriaki Ozeki, Manager, feedback on the usability and reflects lathe manufacturer. Their Swiss-type Technical Sales Support Section, Sales it to the development and improvement automatic lathes have also been used & Marketing Department, Machine of new and existing products. This is a in the manufacture of bone screws, Tools Division. major strength that we have,” said Fumio artificial tooth implants, auxiliary Masuda, Executive Manager, Sales & material for joints and much more.
Superior machine rigidity enables machining for medical devices
Swiss-type automatic lathes have structures, including a spindle sleeve implants sometimes require the drilling designs and specifications that respond sliding surface that supports the cutting of a hole 80 mm deep, but only 1.8 mm to such exacting requirements and load on the spindle during processing in diameter. Drilling such holes on the are highly regarded by medical device increases machine rigidity. They also main side of a machine is a problem manufacturers. elaborated on a wide range of ingenious due to limitations in length; therefore, designs to realize an even higher degree we fit an attachment on the spindle on “When developing Swiss-type automatic machining precision. the back side that can drill up to 100 lathes, we focused on machine rigidity. “For example, artificial teeth for dental mm hole depth,” said Ozeki, Technical We utilised a slant-bed structure with trapezoidal sliding dovetail type surfaces. In this structure, fixed and movable parts are constructed in a way Ball Screw that brings the ball screw centre closer to the cutting point and therefore reduces Tool Post the moment load during cutting. This reduces the vibration caused by cutting resistance and improves accuracy. This Tool Holder makes it possible to maintain smooth, Cutting Point stable machining accuracy even when significant changes of the cutting depths are required,” said Daisuke Suzuki, Executive Manager, Development Department, Machine Tools Division. In addition to the dovetail slant bed, the application of a wide range of YOUR GLOBAL CRAFTSMAN STUDIO 8 FOCUS ON PERFORMANCE
(From left) Junya Maki, Manager, Kikukawa Branch Office, Sanritsu Machinery Co., Ltd.) Keiichi Kuroda, Sales Div. Fuji Sales Office, District Manager, Mitsubishi Materials, Hiroaki Ohara, Sales Div. Fuji Sales Office, Mitsubishi Materials, Shoichi Fujisawa, Drill, CBN & PCD Products Development Center, Tools R&D Group, Mitsubishi Materials
Sales Support Section Manager. Also, in motion control system was developed cations, such as forming cylindrical bars order to restrain thermal displacement, for superior overall control. This system into squares or other shapes. Lathes a unique design has been applied that changes spindle speed at the most with low rigidity frequently fail to meet makes it possible to measure and appropriate timing and ensures smooth the desired geometrical standards for predict heat changes and to adjust movement throughout the cycle to these types of product, therefore, the the machine accordingly. “Medical achieve a significant reduction in non- improved surface finishes and accuracy professionals sometimes visit us to cutting time. During preparation for of Swiss-type automatic lathes are of observe the manufacturing process. subsequent steps, the system reduces great benefit for companies that have Therefore, we also focused the design cutting feed to allow adjustments at encountered such problems. on building a simple structure that predetermined locations and timing. prevents oil leakage, this in turn helps This helps to reduce vibration and cleanliness,” added by Fumio Masuda, increases accuracy. Executive Manager, Sales & Marketing Many metal cutting companies employ Department. Meanwhile, the Star highly-complex manufacturing appli-
Tools that allow maximum machine performance
The partnership between Star coated with high heat resistant coatings parts. When I was assigned to China, Micronics and Mitsubishi Materials were required. As a solution, Mitsubishi we started to use Mitsubishi Material started in the early 2000s. At that Materials developed the MWS drill using tools for medical parts due to previous time, the materials being processed a VP coating with an extremely high heat experiences when manufacturing by automatic lathes were shifting from resistance. Since its launch Mitsubishi aircraft components. Overall, I was free-machining steels to stainless Materials and Star Micronics have used impressed with the quality of the tools.” steels. This material change was used the MWS high-performance drill for test At Star Micronics exhibitions in Europe increasingly for injector systems for applications and also included them and the United States in 2016, we tested automobile engine, and use of SUS316 as part of turnkey package tooling. a solid carbide spot/chamfer drill that and titanium materials in medical Keiichi Kuroda, who was in charge of was under development on a Swiss-type device parts also increased. While chip sales in 2000, looked back that time automatic SR series lathe. It provided control is important in stainless steel and said, “We used a wide range of excellent performance, and this led to machining, tool life is a major factor for small-diameter long drills for various use of the DLE spot/chamfer drill at automatic lathes. However, they tend to in-house applications, and this led us to exhibitions both at home and abroad in use oil coolants that are not as effective recommend these drills for deep hole FY 2018. In June that year, the DLE series for stainless steels. Furthermore, processing.” We asked Mr. Ozeki what of drills was introduced to the market. difficult-to-cut titanium materials are his impression of Mitsubishi Materials Drills Development manager Shoichi used often to manufacture medical was at that time. He said, “The tools we Fujisawa, (Drill, CBN & PCD Products device parts, and this means greater used to process aircraft parts had high Development Center, Tools R&D Group, challenges when drilling. To address durability, and even when the feeds Mitsubishi Materials Corporation) these challenges, smaller diameter and speeds were increased, the tools explained the characteristics of this drills with through coolant holes, continued to produce high-precision new drill: “Existing spot drills had
9 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS ON PERFORMANCE FOCUS
(Left) Takuji Uchiyama, Assistant Manager, Technical Sales Support, Sales & Marketing Dept., Machine Tools Div., Star Micronics Co., Ltd. (Right) Masahito Mukouyama, Assistant Manager, Sales & Marketing Dept. Machine Tools Div., Star Micronics Co., Ltd.
sharp edges, which were often chipped that realised low resistance to reduce to develop tools that allow maximum during the machining of hard-to-cut the load on the machine tool.” performance for individual machines.” stainless materials. Making many Mr. Masuda said, “Machine tool “Hiroaki Ohara, Sales Division, Fuji prototypes to ensure the strength of compatibility is important for improved Sales Office, Mitsubishi Materials said, the edge solved this problem; and after processing accuracy. We would like tool “The development of this new spot drill repeated inspections, we decided to manufacturers to carry out development is a prime example of our commitment apply a double-angle point geometry. We from a wide range of perspectives, to deliver ever better tools for our also combined this with point thinning including feed, speed and chip control, customers.”
Responding to developments in the medical industry
Mr. Ozeki, Technical Sales Support machines to reduce costs. The most satisfy an ever wider range of material Section Manager told us about their important priority for machine tools is applications. future vision, “We are planning to development, and this is something that The challenges manufacturers face expand the sales of products related to will always remain true. We felt great change significantly over time. Mr. the medical industry in India and other responsibility to design products that Masuda, Star Micronics Sales & regions with large populations. It is satisfy customer needs, and we maintain Marketing Department Executive essential for us to consider measures a particular focus on improving machine Manager said, “It is predicted that the to reduce costs and for us to develop rigidity. spread of electrical vehicles in the future not only Swiss-type automatic lathes, will reduce the number of automotive but also fixed-type automatic lathes They also want to develop machine tools parts. However, demand for the small- that respond to the increasing demand capable of processing hardened steels size precision parts that we manufacture in the United States for spinal plates. for high-precision parts, and hope that will increase along with the trend of Our main job, though, is addressing tool manufacturers can develop inserts minimisation and the need for precision customer feedback regarding technical that support this goal. Mr. Fujisawa, in final products. Using our position in issues. Along with providing solutions Tools R&D Group, Mitsubishi Materials such a growing industry, we will continue we also want to make proposals that Corporation strongly said, “The strength innovating to ensure that our products lead to better results for customers.” of our group is in the manufacture of satisfy customer needs.” Mitsubishi Mr. Suzuki, Development Department materials and tools, and we excel at Materials will continue working with Executive Manager, continued, “We development and manufacture of tools Star Micronics as we move into the have been working for more than three for hardened steels. We will continue future to fulfill our mission to contribute years on developing structures for each responding to customer needs using to further growth in the medical industry module that are compatible with other high-performance tools developed to around the world.
YOUR GLOBAL CRAFTSMAN STUDIO 10 FOCUS on PERFORMANCE
CASE 2 Suzuki Precion Co., Ltd. (Kanuma City, Tochigi Prefecture)
Japanese super-precision machining capable of drilling holes smaller than the diameter of a hair. Developing their own high-speed rotating tools for automatic lathes.
11 FOCUS ON PERFORMANCE FOCUS
Isao Suzuki, Executive Vice-President, Suzuki Precion Co., Ltd.
Two crises increased management’s ability
Two buildings stand on a wide expanse customer’s office, he was wearing work machine titanium materials for the first of land along the Oashi River in Kanuma shoes that had oil on them from the floor time. Company sales at that time were City, Tochigi Prefecture. The plant built of his factory. The customer scolded him driven by shafts, arms and computer in 1991 began as a small work place harshly: “Don’t ever come into my office parts, of which a few million units were more than half a century ago and was in dirty shoes.” It was this experience being produced every month. However, founded by Etsuro Suzuki, grandfather that caused President Suzuki to realize when President Suzuki visited Southeast of current President Takuya Suzuki. the importance of sorting, setting in Asian countries such as Thailand, he Etsuro loved making things and gathered order, and shining (3S), and he started was shocked to see that their plants friends to found the company and prioritizing factory cleanliness. were manufacturing the same parts 24 started work making shoe decorations. hours per day. He quickly realised that Following this, the company shifted to In 1991, the company moved the factory the production base for the parts Suzuki general parts machining. In 1971, Suzuki to its current location. In 1992 they Precion was manufacturing would Precion Ltd. was founded to start full- reorganised the company into Suzuki eventually move out of Japan to where scale machining of metals. Precion Co., Ltd. However, it was about labour costs were cheaper. As he was The company increased its workforce to the time that the Japanese “bubble considering changes in the company’s 10 and added NC lathes to its hydraulic economy” collapsed and the company management strategy, he received news equipment. Vice-President Isao Suzuki encountered its first business crisis that would threaten the very foundation looked back that time and said, “The 2nd due to a significant decrease in work. of his business. In 2001, the company’s generation president, my older brother, President Suzuki felt that they should largest partner, a partner that accounted Yosuke Suzuki, really loves special not continue as a subcontractor simply for approximately 30% of sales at that machines and implemented a wide range waiting for work. He hired managers time, declared bankruptcy. This was of such equipment. He first operated the to reinforce the company’s sales force Suzuki Precion’s second business crisis. NC lathes himself and at that time they and the number of customers began to The Vice-President looked back on this were programmed by using a punched grow. At the same time, the company and said, “Suppliers changed their paper tape.” also focused on developing a better work attitude quickly and told us that they environment for employees. would supply materials and tools on a While serving as a subcontractor for cash basis only. Our major bank rushed manufacturers, the then President While improving its business, the to us to check our ability to repay loans. I Yosuke Suzuki had an experience he company also started machining dental thought we were finished.” would never forget. On a visit to a implants, which gave them a chance to
A positive attitude improves technical strength
After the bankruptcy of the company’s Jun Hanawa, who joined the company’s fine machining techniques improved. major customer, Suzuki Precion decided sales staff at that time said, “President One example of such improvement to make a bold change in its management Suzuki told us to get the orders first and was the ability to machine a 0.03 mm strategy. They shifted target production then the company would find a way to diameter hole, which is smaller than one to medical equipment, switched their fulfill them. He told us to be confident strand of hair, in a stainless steel plate. manufacturing method from small-item and think positively.” This positive “The key to successful machining is large-scale production to larger-item, attitude also led to improvement of the the proper setting of conditions. When small-scale production and focused on company’s technical strength. They cutting titanium dental implants in securing orders with a higher degree of focused on winning technically difficult particular, achieving better machining engineering difficulty. orders and finding ways to meet the conditions significantly changes requirements. They also created a production efficiency. This does not database so information could be shared mean, however, that quick cutting is with others at the company. the best because it is often necessary to take 20 to 30 minutes per part. We In addition, the experience of machining manufacture on a 24-hour schedule a dental implants significantly increased large production run and optimise it their technical strengths. While considering the lifetime of the cutting manufacturing parts that are extremely tools. This could be achieved with unique small, but require strict dimensional know-how accumulated through the tolerance, the company’s precision and machining of difficult-to-cut materials.
Jun Hanawa, Executive Operation Officer, Suzuki Precion Co., Ltd. YOUR GLOBAL CRAFTSMAN STUDIO 12 FOCUS ON PERFORMANCE
Yuzo Morita, Sales Department Kazuhiro Ugajin, IB-SPINDLE Chief Suzuki Precion Co., Ltd. CNC 4 × Mechanical RPM Multiplier Spindle
Discovering a way to surmount challenges in medical equipment manufacturing
While the company proceeded “All of the companies at the exhibition significant boost to their business. with its shift to medical equipment except ours had many more employees manufacturing, they learned about the than we did; but having the medical “One of the people on our development revision of the Pharmaceutical Affairs device manufacturing license and staff,” explained Hanawa, “had a friend Act (current Pharmaceutical and Medical ISO13485 certification raised interest in living in the United States, and that Device Act) from customers in 2006. our company. When customers began friend visited our booth. When he saw They acquired a Medical Equipment contacting us, we began to see our parts we had produced that were the Manufacture License under the new efforts paying off,” said Hanawa. size of a grain of rice, he was extremely act that imposed stricter regulations impressed with the technique and on medical equipment manufacturing. Kazuhiro Ugajin added, “Dental implants introduced our products to others at In 2007, they also acquired ISO9001 are very small, but require a high the exhibition. He brought an engineer and ISO 13485 certifications. ISO 13485 degree of technical capability to prevent working at one of the world’s top is the standard for medical equipment imperfections, and ensure dimensional medical equipment manufacturers. This manufacturing and quality management accuracy. Biological implants, on the led to business negotiations and orders, systems. “The acquisition of these other hand, simply require different and a relationship with the customer certifications made a big difference,” sizes, which was difficult for us.” that continues to this day.” said Yuzo Morita from the Sales Department. He continued, “ISO13485 In 2010, they participated in a medical In 2012, the company reached a turning is essential for medical equipment equipment exhibition in Germany for the point. They received the Nippon Brand manufacturers. However, few of our first time; and in 2012, they participated Award for the IB-SPINDLE, a 4 × RPM competitors had acquired certification, in MD & M West, the world’s largest high precision, mechanical speeder tool, so it became a strong advantage for us.” exhibition for medical equipment, parts using precision machining technology In 2009, Suzuki Precion exhibited and materials in the United States. They developed by the company for CNC at Medtec Japan, one of the largest also exhibited at the Japan Pavilion automatic lathes. exhibitions for manufacturers and sponsored by JETRO, and were fortunate developers of medical equipment. to meet someone that would bring a
Developing unique company brand products to become an OEM supplier
The development of the IB-SPINDLE changed their approach. Considering planetary gears that increase CNC started from the previous president’s that most automatic lathes only rotated automatic lathe speed four-fold. “It is a dream of the company developing at 5,000 to 6,000 rpm, if they developed spindle unit capable of increasing speed, its own products. The company first spindles whose circumferential developed to achieve high-precision and produced 50,000 to 60,000 rpm spindles speed could be increased, production cost-performance in the processing for machining centres and lathes. efficiency per hour would increase. This of parts for medical equipment. We They made the mistake, however, of would be an advantage for the company decided that this would fit the market,” not considering specific customers, so and manufacturers alike. This is how said Ugajin. sales suffered. the IB-SPINDLE came into being. The In an attempt to correct this, they IB-SPINDLE features ultra-precision IB-SPINDLE does not require a control
13 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS ON PERFORMANCE FOCUS
unit or connections. Replacement with lathe manufacturers as an optional existing tools requires only one wrench. part through the OEM supply system, While increasing the speed of rotation by and we are also selling to metal cutting four times using the same power as the manufacturers both at home and existing rotating tools, the IB-SPINDLE abroad. From 2013, they started full- can reduce the deflection accuracy of scale sales that totaled 92 units in 2013 the main body to within 3μm for micro- and had expanded approximately seven- hole drilling and small-diameter end fold by 2017. “Currently, IB-SPINDLE mill processing. accounts for about 25% of all company sales,” said Morita. Currently, we are supplying the IB- SPINDLE to Peterman type automatic
Shifting business to expand into target markets outside machining
Suzuki Precion’s sales comprise medical ideas, so we prioritise the creation of a Suzuki Precion also assigned equipment (approx. 50%), IB-SPINDLE corporate climate that allows employees a Vietnamese trainee who had (approx. 25%), and semiconductor to express themselves freely.” accumulated experience in Japan to producing equipment and automobile take charge of IB-SPINDLE sales in parts (approx. 25%); but the company is To expand its range of business, overseas markets and dispatched planning to focus on medical equipment Suzuki Precion joined REG Partners, him to METALEX, an exhibition held in and the IB-SPINDLE rather than ultra- an organization of small and medium Thailand. They consider Vietnam as the precision machining technology. sized corporations engaged in a wide second most important overseas base, range of manufacturing. Established after the United States. Mr. Hanawa said, “We consider Suzuki by Tanaka Medical Instruments Co., Precion as a total advisory company. The Ltd., each company in the partnership They introduced the MIT Force 3 mm, technology required in manufacturing gathered their individual technology a needle for laparoscopic surgery, is not limited to machining alone. We to work on the development of spinal at Medtec Japan 2017. Although it integrate other elements of technology implants for orthopedic treatment. has a very thin shaft, it has rigidity from the development and design We attracted attention in the market capable of minimizing deflection to stage to ensure the best approach with the commercialization of Class II meet the increasing need for minimal for customer’s needs. We want to be medical equipment. After confirming invasiveness in surgical treatment. a one-stop supplier providing a full that it did not infringe upon an earlier Suzuki Precion changed business range of support, from inspection, patent, the RENG Spinal System sold by strategy with a shift from the production cleaning and sterilization through to KiSCO Co., Ltd. was marketed under an of medical equipment to the expansion packaging for medical equipment. In agreement among partner companies of sales of products that it developed order to do so, we established a Class to disclose technical information, to increase its competitive strength by 10,000/ ISO14644-1 Class 7 rated clean prioritize profit as an organization and leveraging the ultraprecision machining room. With a focus on reducing labour allocate profit based on the contribution technology that they had accumulated. load, we also implemented a multiple- of each company. The unique approach Their shift is an example that the piece system and 24-hour operation to to development was recognized when machining industry would do well to improve production efficiency. We also REG Partners received the 6th Medtec follow. want to ensure a wide range of new Innovation Award.
YOUR GLOBAL CRAFTSMAN STUDIO 14 FOCUS on PERFORMANCE
CASE 3 Takayama Instrument, Inc. (Arakawa Ward, Tokyo)
Blade thickness at the edge is only 0.08 mm. Scissors used deep into the brain. Leveraging technical skill to help doctors save lives.
15 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS ON PERFORMANCE FOCUS
A small-size machining centre S191 made by BUMOTEC operated Ryushi Takayama, CEO, Takayama Instrument, Inc. at the Arakawa Factory
Called an artist for his machining technique
When we entered the 1st floor of a said Takayama with a laugh". They have become the global standard building that looked like an ordinary for scissors used in neurosurgery. The house in Arakawa Ward, Tokyo, a small Another factory has three of these thickness of the edge is only 0.08 mm, machining centre S191 from BUMOTEC machining centres. “These are the extremely thin, but very sharp. With (Switzerland) caught my eye. CEO Takashi TRAUB, Swiss-type CNC automatic lathe a sales force active in 30 countries, Takayama had traveled to Switzerland TNL series, manufactured by INDEX in overseas sales have grown to account to purchase this high-performance Germany. There are only three in Asia, for approximately 30% of the company’s machine. He related what the BUMOTEC all at our factory.” turnover in the two years since they were President said to him after the sale had introduced to the market. been completed. He was surprised that a Takayama Instrument employs these company with fewer than 10 employees machines from overseas to manufacture “I’m spending about 100 days a year wanted to purchase this machine. When scissors and tweezers used in neuro outside Japan for business. As the he saw how effectively Takayama had bypass procedures. Domestic market number of exporting partners increases, employed the S191 to manufacture share for the scissors has reached the need to adjust to conform to products, however, he called him an approximately 90%, which means that regulations in different countries has artist. most of the neurosurgeons in Japan are increased. Satisfying the requirements using them. One Takayama Instrument for all production processes has been a “BUMOTEC now tells Japanese product is called the Kamiyama challenge, but it’s well worth the effort to companies considering purchasing Microscissors Muramasa Special. These achieve customer satisfaction,” said CEO their machining centres to consult with micro scissors were custom developed Takayama. me first. It looks like I’m working as a for Hiroyasu Kamiyama, a neurosurgeon volunteer consultant for BUMOTEC,” at Sapporo Teishinkai Hospital.
Muramasa Special custom-made for a physician
Since its foundation in 1905, Takayama To cut out small lesions located deep in for permission to watch surgeries so Instrument has manufactured scissors, the brain, the blade edge needs to be as he could observe the movements of scalpels and other tools for medical thin as possible. However, the extremely the surgeon’s hand during procedures. use. Until they mechanised, however, thin edges prevented the two blades from Reading many books on neurosurgery everything was made by hand. “We aligning smoothly, and this resulted in a and observing the actual movement of didn’t have drawings, just old samples loss of performance. Dr. Kamiyama then the surgeon allowed him to deepen his that our craftsmen used for comparison. considered adopting blades that were understanding and pick up many ideas It was like we were starting from bent like a curved lance to add rigidity. for new product development. scratch each time. I knew we had to Takayama took this idea and succeeded mechanise to ensure stable quality for in producing micro scissors that now mass production.” However, with little provide a sharp cut. know-how in machining and no machine tools, Takayama hit the books to learn. Since then, CEO Takayama has been He read up on material engineering engaged in product development and machining. He implemented and based on requests from Dr. Kamiyama. adjusted machines and designed tools Takayama also asked Dr. Kamiyama by himself to develop effective methods and techniques. Muramasa Special highly regarded as the Meanwhile, CEO Takayama met Yasuhiro global standard for neurosurgical scissors Kamiyama, a surgeon well known for his outstanding skill. Dr. Kamiyama also developed surgical instruments in the hope of advancing the state of neurosurgery. One of these is the Kamiyama Microscissors Muramasa Special.
YOUR GLOBAL CRAFTSMAN STUDIO 16 FOCUS ON PERFORMANCE
Masaki Nakamura, Chief at the Arakawa TRAUB made by INDEX in Germany Factory, Takayama Instrument, Inc. Swiss-type CNC automatic lathe, TNL series
Designing tools to reduce the load on the surgeons
While observing surgeries, CEO This led to the development of tweezers in Japan during the first year alone.” Takayama noticed something important. with tungsten tips. Suturing requires Neurosurgical procedures last at least tweezers and microneedles. However, Takayama told us that the idea of adding two hours. The core is only about 20 the material was stainless, which was something to the edge to prevent minutes, during which the lesion is slippery. It takes eight stitches to suture slipping was not new; and when they removed, but the neurosurgeon has to a blood vessel measuring 1mm in asked a contractor to have tungsten maintain a high degree of concentration diameter, and few surgeons are skilled added to the tips, they could not handle throughout the procedure. enough to do this easily. it easily. Then they figured out how to maintain tungsten in the condition of “Even when tired, the surgeon cannot Takayama worked with Dr. Rokuya plasma, ionized, then let the tungsten relax for an instant. I wondered what Tanigawa, who trained under Dr. infiltrate the edge of the suturing tool.” I could do to reduce the load on the Kamiyama, to develop better tools. One It is actually a simple idea, but it was surgeon. After watching many surgeries, of these was tweezers with tungsten tips built upon the foundation of an extensive I understood how the surgical field looks that would not slip. “Having tweezers knowledge of metals. How does he and how much space they have in the with non-slip tips has reduced suturing continue to have such innovative ideas? operating room. I decided to develop time from 20 to 15 minutes, and it has Takayama says, “I’m always looking for easy-to-use tools focusing, on cutting completely changed the technique that ways to make surgery safer.” and suturing.” surgeons use. About 600 units were sold
Accuracy and safety that saves lives
Takayama Instrument tools are samples we had. Next, I used the through a wide range of improvements. highly regarded by surgeons because drawings to design programs for the It was hard to achieve accuracy in they shorten the time required for machines. I observed the machine continuous operation because materials procedures. The instruments cut well movements and designed programs like titanium alloys are hard to cut, and and grasp securely. Improvements in for all the patterns that I could think of. this caused workpieces to slip in the the quality of endoscopes and other In the end, I had about 100 programs. chucks. To correct this, they designed optical equipment enable more delicate When I ran the programs, though, different programs for different parts, procedures, but such surgeries require the tools collided so I asked the used special tools and developed special the highest quality instruments. manufacturer to make adjustments. The lubricants. To ensure such quality, CEO Takayama excellent working relationship we have employs expensive, highly functional with BUMOTEC allowed us to achieve Takayama Instrument has developed and rigid European machining centres. the modifications we required to the a wide range of manufacturing The BUMOTEC machines allow all point that our machines are almost methods in-house, acquired ISO13485 processes, from cutting to milling, to be completely customised.” certification and passed inspection completely automated. However, it took by the United States Food and Drug time to come this far. They worked tirelessly to modify the Administration (FDA). “First, we created drawings from the machines and increase performance
17 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS ON PERFORMANCE FOCUS
Newly developed suction device with an irrigation function. A uniquely developed surgical tool, requested by Dr. Kamiyama. It took five years to develop this all titanium tool for both suction and irrigation. Already patented internationally.
“ISO13485 requirements are very However, when customising processes, a procedure? What if a surgeon drops complex, and compliance was a major production quality is not the only a screw because it is slippery? You can challenge with the in-house processes concern. A current project being carried never overdo risk management, and we we had in place. To identify better out in collaboration with companies in fully leverage the know-how we have approaches to the requirements, we the medical and engineering industries, accumulated over our 100-year history consulted with an expert. This allowed CEO Takayama placed the highest to ensure the highest degree of safety. us to satisfy the requirements in a priority on safety. This is a very detailed Importantly, because our products have way that was more compatible with and painstaking process. For example, a great impact on lives, we never stop our established systems. As a result, Takayama considers the potential for thinking about safety.” we customised processes to satisfy risk if part of an instrument can’t be all the requirements and passed final sterilized completely, or corrosion inspection. caused by combining different materials. “What if an instrument breaks during
Improvements that ensure the highest degree of efficiency and precision
CEO Takayama says that there is always maximize their capability.” the area of product development, and room for improvement in cutting tool we are looking for help in enhancing the manufacturing. “Takayama Instrument’s Factory Chief Masaki Nakamura said, quality of our products with Mitsubishi strength in manufacturing is built upon “Mitsubishi Materials promotes product Materials’ know-how and technology as a firm foundation of craftsmanship, development for medical use and tool cutting tool professionals.” and we have continued to improve upon development for automatic lathes. I am this strength to supply the highest especially interested in products and Our vision has not changed. We quality in value-added products through know-how for hard-to-cut materials. continue to develop instruments that automated machining. We handle hard- The Smart Miracle End mill Series enable surgeons to operate safely and to-cut titanium alloys, and accept the for hard-to-cut materials and mirror comfortably. If we can safely reduce the challenge of processing special parts finished turning inserts for titanium time required for procedures, patients that require us to implement unique alloys are very close to our needs. We’d will benefit. We maintain this spirit in procedures. In some cases, using an like to test them.” product development and improvement end mill for plastics produces better of manufacturing processes. Products results than when processing titanium CEO Takayama told us what he expects based on this spirit save lives around alloys, a material that is difficult to grip from Mitsubishi Materials: “Although the world. with chucks. Implantation is required I have plenty of ideas, and because we to be a minimally invasive procedure; design instruments for specific needs, therefore, all edges need to have a tool manufacturers may not see a round honing. In such machining, tools major benefit in developing tools for our have to cut accurately even at high smaller-scale production. I feel strongly speed. Considering such a wide range that collaborative relationships between of conditions, we want suggestions and machine and cutting tool manufacturers advice from cutting tool manufacturers will become increasingly important. on the best conditions and how to Mitsubishi Materials is impressive in
YOUR GLOBAL CRAFTSMAN STUDIO 18 HISTORY OF MITSUBISHI HISTORY HISTORY OF
MITSUBISHI A panoramic view of Hashima Island (Gunkanjima). Vol. 7 A coal mining operation from Mitsubishi Mining Co., Ltd. Gunkanjima Currently, entry to the island is prohibited except for some areas. Island The island has also been used for filming movies. (Battleship Island) Located in Takashima-cho, Nagasaki City, Hashima Island is also known as Gunkanjima Island (Battleship Island). It served for 84 years as a coal mine operated by Mitsubishi Mining Co., Ltd. (currently Mitsubishi Materials Corporation). The name Gunkanjima comes from the island’s appearance of it floating on the sea with smoke billowing from its chimneys, making it look like a giant battleship. Gunkanjima became world famous in 2015 when it was listed as a UNESCO World Heritage Site as a part of “Sites of Japan’s Meiji Industrial Revolution: Iron and Steel, Shipbuilding and Coal Mining.” In this feature, we look back at the history of this facility that supported Mitsubishi’s mining business.
Beginning of Hashima Island and Mining, which had operations at the production of 410,000 tons. This level Mitsubishi Mining Takashima Coal Mine near Hashima of production continued until Japan’s Following a 50-minute boat ride from Island. The purchase price was 100,000 defeat in World War Two. Earlier in Nagasaki, we arrive at Gunkanjima yen, the equivalent of 2 billion yen in this period in 1916, when most of Island, part of which was listed as a today’s economy. the housing in Tokyo was one-story World Heritage Site in 2015. The island structures, Japan’s first reinforced measures 480m from north to south History of Hashima Coal Mine concrete apartment building, Building and 160m from east to west. This is Coal production at the Hashima No. 30, was built on Hashima. approximately three times its original Coal Mine continued for 84 years size after six reclamation projects were after Mitsubishi Mining’s purchase. During the postwar period between carried out to expand the island. Now Production can be classified into four 1945 and 1964, coal production abandoned, it was owned by Mitsubishi distinct periods. The first, between decreased. However, an annual rate of Mining Co., Ltd. (currently Mitsubishi 1890 and 1914, was mainly focused 300,000 tons per year was maintained Materials Corporation) and supported on expansion and Mitsubishi Mining and the population was gradually its coal mining business for over 100 accelerated coal production to between increased to 5,259 by 1959, the highest years. 100,000 and 200,000 tons annually. They in Gunkanjima’s history. Population built housing and other facilities for density at that time was nine times that Coal was found on Hashima Island workers and an elementary school was of Tokyo. around 1810. It was heavy coking coal of built to accommodate the increasing higher quality than coal generally mined population of children in the workers’ Life at Hashima Coal Mine in Japan. Mining started in earnest in families. Along with the expansion of production around 1870. In 1883, it was owned by at Hashima Coal Mine, and even with Sonrokuro Nabeshima, the feudal lord The second period between 1914 limited space, living conditions were of the Nabeshima Domain, who had and 1945 was the prewar production always being improved. Hashima worked to modernise the operations. period when deep mining and technical Island became home to a wide range In 1890, it was purchased by Mitsubishi innovation contributed to a record high of facilities beyond those related to
19 YOUR GLOBAL CRAFTSMAN STUDIO HISTORY OF MITSUBISHI
A seawall included in the World Heritage. It is under repair, therefore A photo of the area where a coal storage is located. A passenger ship stone masonry with red clay and lime as adhesives (called the seen in the background has started on a voyage. Amakawa method) is exposed.
Showing the east side of the Japan’s first reinforced concrete Children playing baseball inside the empty apartment block, built in 1916 (Building No.30). municipal swimming pool, around 1952.
A movie theater. Mitsubishi gave priority to this A giant multiple-dwelling complex with more than 300 units, to enrich employees' lives. from around 1970.
coal mining operations. Residents had Closure of Hashima Coal Mine following year, they proposed that housing and many other facilities that Inclusion in the World Heritage Sites Hashima Island be recognized as a Site enhanced their quality of life. With During the restoration and final period of Japan’s Meiji Industrial Revolution. elementary and junior high schools, between 1964 and 1974, due to the shift In 2015, it was listed as a UNESCO hospitals, temples, a movie theater, of the government’s energy policy from World Heritage Site as a part of “Sites hair salons, pachinko halls, mahjong coal to petroleum, Mitsubishi Mining laid of Japan’s Meiji Industrial Revolution.” parlors and bars, the island had just off and reassigned employees and the This has increased its popularity about everything available the same as population of the island also decreased. as a travel destination for visitors. cities on the mainland did. While other coal mines closed one So even after closing, Gunkanjima after another, however, Hashima Coal Island has remained an important In addition, there were many events on Mine significantly increased production part of Japan’s industrial history. the island. Residents enjoyed summer despite the decrease in population The island now serves as a and May Day festivals, plus recreational through the full-scale mechanisation of reminder of the hardworking activities both on and off the island mining in new coal seams. Production people who supported the were organized by the residents continued at 300,000 tons annually, growth of Mitsubishi and the themselves. The Yamagami Festival however, due to a decrease in the modernisation of Japan. on April 3 of each year was also a big demand for coal, it was announced in event. Hashimia Shrine was home to 1974 that Hashima Coal Mine would the mountain god and this place was close. In 2001, Mitsubishi Materials where the employees and their families Corporation donated Hashima Island prayed for safety. On festival days, the to Takashima Town. In 2005 a merger entire island was excited about the wide between Nagasaki City and Takashima range of events that took place and in Town placed Hashima Island under addition portable shrines blessed by the the administrative control of Nagasaki priest at Hashima Shrine were paraded City; and in 2008, Gunkanjima was through the streets by residents. opened to the general public. In the
Cunkanjima Island YOUR GLOBAL CRAFTSMAN STUDIO 20 CRAFTSMAN STORY
Craftsman Story ww Vol.8 Masayasu Hosokawa: Hina Ikuta: Shinichi Ikeda: Akimitsu Tominaga: Yoshitaka Tsuji: R&D, Solid Tools Devel. Centre Aerospace Dept. Aerospace Dept. Aerospace Dept. Aerospace Dept. Solid Tools Devel. Sect. Akashi Aero Sect. Akashi Aero Sect. Akashi Aero Sect. Akashi Aero Sect. Joined in 2014 Joined in 2015 Joined in 2007 Joined in 1999 Joined in 2004 For processing graphite Diamond coated end mill (For Finishing) DF End mill series DF2XLBF A CVD coating with the perfect balance for sharp edged materials
Launched in 2016, DF2XLBF was developed as a special product for a specific customer. The development goal was to prolong the life of tools used in the processing of hard composite resin materials to approximately twice that of existing products. Although the in-house small-lot test on the prototype revealed favorable results, the medium lot test at the customers’ site was disappointing. Their tireless efforts, however, led to unexpectedly long tool life. It was the determination of young staff that brought success.
2121 YOUR GLOBAL CRAFTSMAN STUDIO CRAFTSMAN STORY
DF2XLBF
The evaluations the machining load differed depending site. We started test machining, knowing on the part. We considered the difference this would be the last chance for in the form of each part and quickly Mitsubishi Materials. During this process, – Would you please give us the improved the cutting edge geometry. We Ms. Ikuta was key. background of DF2XLBF development? were confident that the improvement would solve the problem and asked the Ikuta: It was my first year after joining Tominaga: Mitsubishi Materials already customer for just one more chance to test Mitsubishi Materials, and I was very had a CFD diamond coated end mill for the new edge geometry. nervous about being assigned to such an important project. We took pictures machining graphite. This new DF2XLBF of the tool edge and components and is used for finishing and the letter – What made you so confident in the checked them after machining one batch result? “F” actually stands for “finish”. It was of five parts. One part took 30 minutes. originally developed as a special product Therefore, one batch took around three Tominaga: ordered by a customer in the medical It was simply the optimization hours. We repeated the process every day industry, and we later expanded sales to of the coating and edge geometry. Hard until we finished 40 batches (200 parts). all customers. composite resin materials cause serious We sent 10 batches to the customer, who abrasion, but they are not iron metals then checked the results. Hosokawa: We were initially asked by that tend to react with carbon. Therefore, the customer in November of 2014 to we used CVD diamond coating, which – When did you start feeling that you manufacture the tool. They wanted to has extremely high abrasion resistance. would be able to achieve good results? improve tool life on hard composite In general, CVD coating film tends to be resin materials. The goal was to double thick, which makes it hard to create sharp Hosokawa: It was around the time that we the existing tool life. Although this was edges. However, the tool we developed had finished processing about 150 parts. extremely difficult, we began making was for finishing and so required sharp My concern changed to confidence and and testing prototypes and by the next edges. So, we optimized the coating to after completing 200 parts, we reported summer, our customer reported that our be thin enough to enable sharpness, but our results to the customer. The customer product had passed in-house inspection thick enough to resist abrasion. conducted tests at each manufacturing and we began receiving orders. To be site and achieved an average of four honest though, the real development Hosokawa: We also improved the neck times the tool life of the existing tool. The results had significantly exceeded started from that point. diameter and cut length. Increasing the original goal, and the customer was rigidity and tool life generally requires visibly pleased. Our in-house testing a larger neck diameter and shorter cut – Did you have any trouble after delivery could be conducted successfully within of the product? length, but we needed an end mill with such a short period of time because of Ms. a smaller diameter for insertion into the Ikuta’s efforts. Tominaga: When the customer started deeper sections of components because using our tool at its manufacturing sites, of the characteristics of their forms. This Ikuta: I just continued machining as there was a significant deterioration meant that we needed a smaller neck much as possible. I was fully aware of of tool life. Of course, we made diameter and a longer cut length. We the project’s importance for Mitsubishi improvements each time a problem was considered what neck diameter would be Materials, so I concentrated on moving found and we tested quality through in- rigid enough but not cause interference forward. house inspections to confirm the basic during machining. We decided that a performance before delivery; but actual diameter change from 1.90 mm to 1.86 Tominaga: The key to success in this case performance at the manufacturing sites mm might suffice. Although it was such a was two young employees of the project varied and was altogether unsatisfactory. slight difference, we were excited to see if team. Employees with experience like us this would solve the problem. are often quick to decide that a request is Hosokawa: The customer was irritated impossible. Both Mr. Hosokawa and Ms. one day and said we should think about Ikuta, however, were new enough not to stopping development. We suspected that Last test determines our let a request that seemed impossible get there must be a fundamental problem in their way and were eager to make this destiny work. They were positive and not worried somewhere, so we asked the customer to about failure. allow us to visit their site. The customer’s – What was the customer’s reaction? attitude toward our request was very – Do you have a message for our readers? severe: “It has been taking too much Hosokawa: time for inspection and development, The customer agreed to allow us one more chance to test the Hosokawa: We are very proud of the and the results have been completely tool, but with certain conditions. Under DF2XLBF. Its price, tool life and cost unacceptable. We feel we can do without the same processing environment, that performance ratio are excellent. We Mitsubishi’s tools.” When we examined is work materials, cutting conditions and recommend this tool for the processing of the manufacturing processes, however, machines, we were required to machine a materials to which CVD diamond coating we noticed something important. The designated number of parts within a set can be applied. individual parts they manufactured had time limit with favorable results before slightly different forms. In other words, conducting a final test at the customer’s
YOUR GLOBAL CRAFTSMAN STUDIO 22 TECHNOLOGY ARCHIVE TECHNOLOGY TECHNOLOGY ARCHIVE
Metal mould development driving the evolution of inserts
High-performance materials frequently used in cutting-edge fields such as Manufacturing the automobile, aircraft and medical industries are hard to process; and this has driven the advancement of cutting tools. While uniquely formed inserts technology of metal with newly added capabilities have been developed in the tool industry, the history of geometry technology is not well known. One of the departments that supports insert manufacture is the Mould Group. This department moulds is essential manufacture moulds that are essential for the production of inserts. Let’s take a look at the history of Mitsubishi Materials’ mould manufacturing from for insert production the time before the NC machine was popular, to the present day.
23 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE
TECHNOLOGY ARCHIVE
CLOSE UP
The role of metal moulds for insert manufacturing
The following processes result in carbide inserts: Most of the inserts manufactured by Mitsubishi Materials are created through these steps. Step 2 1. Tungsten (WC) is mixed with cobalt (Co) and dried to on the left (presswork) uses metal moulds for the produce powder. manufacture of inserts. A mould is installed on the 2. The powder is placed into a mould and pressed. press machine, filled with the powder and then 3. The pressed powder is heated at 1,300 degrees C or pressed. With an automated press line, several higher to make a sintered body. thousand pressed powder forms can be manufactured 4. The sintered body is machined (ground, honed, etc.). in 24 hours. The moulds are designed to withstand a 5. The final product is CVD or PVD coated, few hundred thousand pressings. then a final inspection is conducted.
Mould parts and combinations Procedures for the manufacture of moulds for upper and lower punches General mould Special mould 1. Punch material 2. The neck is formed (Type that separates the by machining female part)
Upper punch
Female part 3. Carbide material 4. A breaker is formed on is fixed to the neck by the carbide material by EDM Lower punch brazing (electric discharge machining).
Discharge electrode Core rod
1 1970 ~ The dawn of inserts Mitsubishi Materials launched brazed be discarded when any part of it was breakers had a longer manufacturing tool holders in 1956. These were made damaged. lead time as well as a higher price. This by attaching cemented carbide blades prompted us to develop a method of onto the edge of a copper shank by using To address this problem, we developed directly embossing the breaker onto the a silver brazing method. While they tools with replaceable carbide inserts. surface of the insert during pressing. featured excellent abrasion-resistance, The first inserts were simple triangular, This enabled chip breaker formation into fracture-resistance and high machining square or circular shapes with flat faces. the carbide material by the forming the performance, the cost was prohibitive Soon afterwards the first chip breakers faces of the upper and lower punches of because the entire tool holder had to were formed on the rake face to improve the press mould using electric discharge chip control and reduce machining machining (EDM). However, because we resistance. It is worth noting that it was only had general-use milling machines difficult at that time to form breakers by for producing electrodes, we could only grinding, even simple cross-sectional manufacture breakers with a simple shapes proved challenging. Added to cross section along the edge. These this was the fact that inserts with ground were called perimeter breakers.
YOUR GLOBAL CRAFTSMAN STUDIO 24 TECHNOLOGY ARCHIVE TECHNOLOGY TECHNOLOGY ARCHIVE
1980 ~ Beginning of the NC era 2 Appearance of moulded chip breakers
NC machining centres became popular of the Mould Group remembered the old the upper and lower punches, therefore, around 1980. The introduction of three- procedures well and said, “Paper data they used a uniquely developed technique dimensional CAD made it easier to tape was used to input the data. This black called Suriawase (manual adjustment) for create NC programs for the processing paper tape had holes punched in it and the fine manufacturing adjustments. of electrodes, which allowed complex information given by the sequence of the curved surface machining using ball nose holes was read by a special machine. This end mills. This flexibility in designing was a long and drawn-out process and the breakers instantly expanded to allow information for just a simple perimeter the manufacture of a wide range of chip breaker would mean a tape about 10 m breakers for different purposes. This long. It also took time to input the data; made the development of the MA type and if we made a mistake, we needed to and standard breakers with a 7-degree start from the beginning. It took a lot of positive rake angle possible. time and energy.”
Before the development of machining Then, specialists would use manual centres, the programming data for measurement devices such as toolmaker’s electrode machining was input using microscopes and micrometers to confirm punched paper tape and floppy discs. that the finished mould conformed to This entailed difficult procedures that the drawings. It was difficult to measure we cannot imagine now. Yoji Takimoto the space between the female part and
2000 ~ Curved cutting edges, two-hole inserts 3 and other complex insert geometries
After the year 2000, all the insert and Tomotsugu Goda who was involved at Our mission, however, is to develop a mould designing was done using three- that time looked back and said, “Due to method to realise all the forms that the dimensional CAD. From the three- the expanded flexibility of insert design, development staff request. dimensional model, CAM capability orders from the development group had improved to enable the creation of became more complex. Our role is to programs to machine electrodes used produce moulds to form pressed powder for EDM. This drastically enhanced units based on requests. CAD allows design flexibility, not just for breakers, easy modeling, but producing the actual but for the entire insert. In addition, pressed powder units is a challenge. measuring devices and the equipment used to manufacture moulds improved significantly. It was because of these improvements, inserts with new geometries that were impossible to make with the standard technology, became possible.
The three-dimensional measurement devices implemented around that time also made it possible to accurately measure the new geometries. These improvements in processing and measurement technology drove advances in manufacturing. Along with the progress of such manufacturing technologies, mould production also increased rapidly.
25 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE
2010 ~ Aiming for further 4 improvement with new machining technology and innovative ideas
After 2010, inserts with more complex machines also becomes more complex. forms were launched one after another. Throughout its long history, the Mould Major examples are inserts for the VFX Group has contributed hugely to the cutter with vertical cutting edges and commercialisation of a wide range horizontal holes, and inserts for the of inserts by improving the moulds, VOX series with multiple corners and developing machining methods and moulded chipbreakers. Some inserts had upgrading preparation. Mr. Goda, who forms whose pressed powder unit could was involved in solving the problems of for 10 years and he wants customers to not be removed from the female part of producing a wide range of moulds said, “I appreciate the intricacies of inserts. Each the mould by using the regular pressing encourage the new product development insert is the result of the enthusiasm and method. Therefore, special moulds that team members to speak out and make technique brought to bear by dedicated could separate the female part were requests. While we may not be able to professionals. He told us his vision at the developed. realise their ideas, we will work tirelessly end of the interview, “When people in this As insert performance increases, forms with them to try. We never know what we industry, including our customers, see our tend to become more complex, which can accomplish until we try. Striving for inserts, I hope they wonder how we did it. in turn makes the manufacturing of the innovation is the real charm of mould With this in mind I would like to continue moulds more difficult. For example, manufacturing.” creating such innovative products.” spilt moulds mean more parts; and this requires that each part to be more Kentaro Ono is in charge of press work accurate to fit properly. The procedures in the same Production Engineering for setting the moulds in the press Department. He was in the Mould Group
Looking back at the history of the development of moulds for inserts
Moulds are our life, so when we see a problems and making proposals for new product, we naturally start imagining machining methods. We continue to what the mould used to make it looked cooperate with one another without regard like. A mould is like the shadow of the to age or experience to manufacture article they produce. innovative moulds.
The moulds we manufacture don’t appear in front of the customer, but inserts are impossible to make without them. We (From left) each feel individual responsibility and Kentaro Ono, Production Engineering Dept. pride in the important work we do as Production Engineering Group (When we professionals supporting the development interviewed them). and manufacture of outstanding inserts. Yoji Takimoto, Production Engineering Dept. Young employees who have only been Mould Group with the company for a short time also Tomotsugu Goda, Production Engineering contribute significantly by identifying Dept. Mould Group
YOUR GLOBAL CRAFTSMAN STUDIO 26 ABOUT US ABOUT
Education base in China for cutting tool ABOUT US markets China launched its China Manufacturing 2025 initiative to promote further industrial growth. In this TianJin LingYun Tool Design Co., Ltd. – feature, we focus on MTEC TianJin, a technical centre MTEC TianJin (China) strengthened to support Chinese market movement.
Renewed MTEC TianJin comprehensive machining solutions that MTEC TianJin (China) was founded include the most up-to-date CAM, CAE, at TianJin LingYun Tool Design Co., simulation technologies and tooling Ask the Director of Ltd. in 2004 as a base for machining support. MTEC TianJin technology education and application Mitsubishi Materials has six technical services tailored to customers in China. centres around the world. Each centre Hiroyasu Shimizu Thirteen years after its foundation, it has equipment suitable for the needs Director, Cutting Technology Center, was reorganized in October 2017 to of each region. In addition, they have TianJin LingYun Tool Design Co., Ltd. respond to growth and changes in the access to different types of equipment Chinese market. Japanese-affiliated that can be shared when needed. When companies have already entered TianJin, one of centers lacks the specialised Providing timely, a city located just 30 minutes southeast equipment required to effectively handle high-quality of Beijing by high-speed rail. TianJin a request from a customer, it can be solutions in Airport and Chubu Centrair International transferred to a technical centre that has cooperation Airport, which is located in the heart of the required equipment. For example, with technical the Japanese automobile industry, are when an MTEC TianJin customer centres around connected by direct flights. requires an application to be machined the world. When MTEC TianJin was founded in 2004, on the horizontal machining centre with China was already serving as a global an HSK100 spindle, owned by the Central factory. However, with the announcement Japan Technical Center (MTEC Gifu) in of Chinese Manufacturing 2025, the Japan, MTEC TianJin can ask MTEC Gifu. Chinese version of Industry 4.0, in In addition, the MTEC TianJin translation May 2015, the manufacturing industry department translates technical is predicted to grow even further. In documents from Japanese to Chinese order to attract Chinese automobile to make them quickly available in China. and other manufacturers with high Furthermore, the majority of staff at technical capability, it is necessary to MTEC TianJin is able to communicate provide not only education in the basics in Japanese, which ensures the timely and applications of machining, but also sharing of information about new
27 YOUR GLOBALGLOBAL CRAFTSMAN CRAFTSMAN STUDIO STUDIO products and technology developed in market remained low. However, better Japan. public relations leading up to and Ask the Cutting Technology We respond to each customers’ request following the re-opening of the centre Team Manager with care, implement the solution succeeded in bringing in many visitors technology developed in Japan and from both in and outside the company. introduce the most advanced machining I’m looking forward to even more people Fang Fan technology developed in China to the coming to see us. Manager, Cutting Team, Cutting world. Recent growth in the Chinese market Technology Ctr., TianJin LingYun Tool Design Co., Ltd. is significant. Along with this, requests Being an effective partner for solution services as well as product I joined TianJin LingYun Tool Design quality and performance enhancements Co., Ltd. in 2008. I am assigned to have also been increasing. In response to Delivering the the Cutting Technology Center, which this, the Cutting Technology Center has quickest, most handles a wide range of work carried shifted its focus to machining trials and effective solutions out at customer’s sites. For example, we technical support. In striving continuously to every provide technical seminars and services to be an effective partner by quickly customer as well as machining trials. The Cutting responding to changes in customer we serve. Technical Center had been conducting needs, we go beyond the provision of trials on prototypes on request from the trials to provide attractive total solutions. Development Division in Japan rather Everyone at the technical centre is than from customers; and although committed to providing the quickest and we responded to customer requests most effective solutions as we work to for lectures at technical seminars, increase our standing among customers recognition of the Cutting Technical in China. Center among companies in the Chinese
MTEC TianJin Solutions
A wide variety of Demonstrations using Machining trials to cover 1 education programs 2 actual equipment 3 a wide range of requests
YOURYOUR GLOBAL GLOBAL CRAFTSMAN CRAFTSMAN STUDIOSTUDIO 28 CUTTING EDGE CUTTING
EDGE Vol. 7
Hiromitsu Tanaka, R&D Div., Machining Technology Ctr., Solution Group Analytical technology designed to visualise problems and improve processing Providing analytical solutions accumulated through tool development
The wide variety of solutions provided designs proposals for improving increase the quality of our proposals by the Mitsubishi Materials Machining machining processes through a to optimise machining conditions. For Technology Center includes machining combination of analytical technology example, although recent CAM software trials, proposals for machining methods and experience utilising three methods is capable of automatically creating utilizing CAM, telephone consultations, of analyses - rigidity, chip form and tool paths after stabilizing machining seminars and technical services. One machining load. load, they cannot accommodate the focus is analytical solutions utilising Among these, machining load analysis characteristics of a wide range of tools technology accumulated through is frequently employed to visualize the and materials and they are sometimes product development. Such analytical load on the material and cutting tool not effective for actual machining. information contributes to the (main component force, thrust force, We try to calculate more accurate improvement of quality and efficiency spindle force, etc.). To realize highly machining loads, analyze deformation at manufacturing sites. However, it is efficient machining, it is important to of the work materials and jigs and difficult for the customers themselves understand tool characteristics. It is not consider how to shorten machining to clearly understand certain aspects too much to say that an understanding time to make the most appropriate of machining such as load and of machining load is key to efficient proposals for improvement. deformation. To help customers better machining. However, our goal is not understand, Mitsubishi Materials only to conduct analyses, but also to
Improvement of machining utilising machining load analysis and CAM High-efficiency rough machining (TROCHOID + Climb Milling) Machining load analysis results
Machining load analysis
Time (sec) Main Component Force (N) Main Component Force After smoothing of the data...
Machining load analysis
Tool VQMHVRBD 1600R 100 (φ16×R1) Tool protrusion 40 mm Work material SCM440 (27HRC)
Main Component Force (N) Main Component Force Time (sec) Spindle speed 2,000 → 3,000 min-1 (150 m/min) 480 → 1,800 mm/min Feed → Variable between 1,680 and 1,800 mm/min (Max. fz 0.15 mm/tooth) Depth of cut ap 12 mm, ae 6 mm → ap 30 mm, ae 2.5 mm Coolant Air blow With the optimal use of tools Machine tool Vertical type machining centre (HSK A63) Stable Machining + High-efficiency Machining Volume of 36 → 135 cc/ min + Long Tool Life discharged chips Machining time 39 → 10 min 29 YOUR GLOBAL CRAFTSMAN STUDIO CUTTING EDGE
Wang Wei, Research & Development, Harumi Kosaka, Research & Development, Machining Technology Centre, Solution Group Machining Technology Centre, Solution Group Increasing quality of proposals for improvement using analytical data
It is necessary to obtain 3D modeling In 2017, Mitsubishi Materials staffing in the future. In addition, the and NC programs data from customers implemented reverse engineering, number of requests from customers to conduct analyses. However, we heat transfer analysis and other in Chubu Region has increased. often require more information, technologies. At the same time, We will expand the functions of our so we cooperate closely with other we accumulated analytical results, second technical support base, the departments. Ms. Kosaka, who is in compared these with actual Central Japan Technical Center (MTEC charge of analyses, says: “We first focus measurement values to increase the Gifu), to facilitate speedy services, on what customers explain. However, accuracy of analytical values. We try to and we are planning to develop the we consider the reasons for the improve accuracy not only through the same system at our overseas bases. results of our analyses to identify the combination of innovative machining Making comprehensive approaches fundamental problems. When solutions and our tools, but through proposals with technical services, analyses and derive from the results of our analyses for innovative machining methods that machining inspections will improve the and the questions we pose, we feel a increase the economic benefits. quality of our proposals and provide great sense of satisfaction. Success There are currently five specialists useful total solutions; in addition we is not simply a matter of the analyses assigned to the East Japan Technical will reinforce our capability to provide we conduct or the software we use, but Center (Saitama City) providing about comprehensive solutions for machining. our logical consideration of causes and 10 analytical solutions every month, results.” and we are planning to increase
Flow of Analysis Analysis conditions 1. Analysis results (Clamp only)
When the inside diameter When the inside diameter Clamping force clamping force is strong clamping force is weak Machining load Clamping force
Clamping force
Changing the inside diameter clamping Visualization of work and deformation of jigs by clamping force force to compare Inside diameter deformation volume clamping force 3. Analysis results (Overall)
1. Inner 3. Provision of 2. Bridge clamp Flow of analysis diameter clamp machining load 2. Analysis results (Clamp+Machining load)
When the inside diameter When the inside diameter clamping force is strong clamping force is weak
Deformation around machined part becomes smaller
Visualization of work and deformation volume under machining load
Jig models provided YOUR GLOBAL CRAFTSMAN STUDIO 30 by OKS Co., Ltd. YOUR GLOBAL CRAFTSMAN STUDIO CRAFTSMAN GLOBAL YOUR
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