Mitsubishi Materials Craftsmanship Magazine YOUR BM002A GLOBAL CRAFTSMAN STUDIO
Road to Evolution Generations of Technology MESSAGE
Listening to the voice of the customer We are pleased to publish the second issue of our envisioned. We will continue to respond by exceeding Craftsman Magazine that was first launched in their expectations through harnessing all our April 2015. strengths with a feeling of excitement when realising As we and everything else around us is moving their goal, and when witnessing performance and forward, we strive to continuously develop our quality that goes beyond their imagination. We invite technologies and evolve our company so that we you to look forward to the evolution of our studio as contribute to the success of our customers’ business we aim to become an ever more professional tool activities. Our primary target is to be the reliable manufacturer, capable of delivering results never partner to whom customers can turn to for advice before envisioned. and whom they can trust for advanced solutions that go hand in hand with profitability and the highest quality. Dairiku Matsumo This evolution naturally applies to tools and other Vice President / General Manager of Production Div. technological advancements, but also to such aspects Advanced Materials & Tools Company as the content and quality of services. Each and every Mitsubishi Materials Corporation employee must keep in mind that customers do not just benefit from a good product; they benefit from the right solution at the right time. To this end, it is vital to listen attentively to the customers’ needs and respond with new initiatives and innovations. Our will to “fulfill all customer needs” and “respond to every demand” forms our core identity as a Craftsman Studio that caters for each individual customer. Our customers’ satisfaction and their positive feedback about Mitsubishi Materials’ consultancy and technologies fuels our will. Nothing would give us more pleasure than receiving a customer reaction that goes beyond simple satisfaction about a product or a solution. Such a reaction is seen when customers encounter something that surpasses what they originally
1 YOUR GLOBAL CRAFTSMAN STUDIO Vol. 2 Stories Your Global Craftsman Studio VOL.1 STORIES
7-12 FOCUS on PERFORMANCE
MITSUBISHI MOTORS collaboration 3-6 Photo: Mitsubishi Motors Corporation with MITSUBISHI MATERIALS AUTOMOTIVE: Evolution of fuel efficiency A manufacturing bond that has produced EYE on the MARKET and machining technologies continuing technical innovation
13-14 15-16 17-20 HISTORY OF MITSUBISHI THE CRAFTSMAN STORY TECHNOLOGY ARCHIVE
SADO GOLD MINE - World Heritage and BC81 SERIES - Coated CBN grades for SOLID CARBIDE DRILLS 400 years of history high-hardened steel turning ZET1 - Drilling performance at its peak
21-22 23-24 25-26 ABOUT US CUTTING EDGE WA
THAILAND ENGINEERING CENTER Advanced technical services in the The development of an ingenious rotating WA (Japan) – SUMO industrial heart of Thailand tool that reduces abnormal damage Instilling the spirit of Japan
YOUR GLOBAL CRAFTSMAN STUDIO 2 EYE ON THE MARKET THE ON EYE EYE on the MARKET AUTOMOTIVE INDUSTRY
Evolution of Fuel Efficiency and Machining Technologies An era where almost one in every six people in the world owns a car
Automobile production by country In 2013, the number of automobiles owned throughout the world surpassed (No. of automobiles) 1.1 billion, which means that one in every 6.2 people in the world’s total population 10M. of about 7.2 billion owns a car. In fiscal 2014, 89.75 million automobiles were 1M. manufactured globally and the numbers continue to grow in the huge Chinese and 100k. U.S. markets. 10k.
1k. Motor vehicle produced by country in 2013 Source: Khassen Y., Wikipedia. Organisation Internationale des Constructeurs d’Automobiles (OICA). Material from the Japan Automobile Manufacturers Association, Inc.
3 YOUR GLOBAL CRAFTSMAN STUDIO EYE ON THE MARKET
Environmental issues caused by the explosive demand
The global spread of automobiles has totally surpassed the imagination of the early days and has given rise to new issues in the form of environmental Fuel economy standard in each country concerns. In the 1960s, exhaust gas regulations were first established in EU California and Japan, and from this emerged the development of various environmental technologies by automobile manufacturers striving to Japan Stricter fuel economy satisfy these regulations. Today, automobile manufacturers are expected regulations year by year India not only to make continuous efforts to eliminate harmful substances from China exhaust gas in order to prevent air pollution, but to also minimize the Canada emission of carbon dioxide, which is a principal greenhouse effect gas. U.S. These modern countermeasures have also had the effect of reducing fuel consumption and generating advantages for the consumer. Brazil South Korea Fuel economy standard (km/L) standard economy Fuel Source: The graph represents a simple conversion of the fuel standard in each country from Mexico the International Council on Clean Transportation. When a correction is applied by a simple calculation to account for a fuel consumption measurement mode, taking into account deregulation measures and differences in vehicle types, the fuel standard for the EU becomes 21.1 km/L (2021 reference value is calculated by METI), and for the U.S. it becomes 16.5 km/L (2020 reference value calculated by METI). The 2010-2015 values for Japan have been added by METI (they are reference values, as the measurement mode differs from 2015).
Evolution of Fuel Efficiency Special Feature Photo provided by: Mitsubishi Motors Corporation and Machining Technologies
YOUR GLOBAL CRAFTSMAN STUDIO 4 EYE ON THE MARKET THE ON EYE EYE on the MARKET AUTOMOTIVE INDUSTRY Evolving fuel efficiency technologies
Some of today’s representative fuel ratio maximized to the utmost limit and to the development of fuel efficiency efficiency technologies for gasoline and hybrid systems that utilize both engine enhancement, with the result that kei diesel vehicles include the incorporation and electric motors are other examples. cars now deliver greater fuel saving of a direct-fuel injection and a turbo Low prices and running costs have also performance than regular passenger charger to a downsized engine that been strongly demanded by consumers of cars. In fact, models have emerged that discharges less exhaust gas than Japan’s category of small vehicles called deliver fuel efficiency that far exceeds previous engines. Naturally aspirated “kei cars”. For this reason, all the latest 30 km/L*. gasoline engines with a compression available technologies have been applied
The introduction of electric vehicles
Electric vehicles, which do not consume reciprocating engines, rotary engines gasoline have also begun to penetrate and turbines are already commercially the market. These include electric available or have been proposed. They vehicles that require charging, those that are one of the most practical systems are equipped with fuel cells that generate for the diffusion of electric vehicles as electricity within the car (use hydrogen they utilize existing fuel infrastructures and oxygen to generate electricity and even though they are specifically discharge water as a result), and those designed to generate electricity. that are equipped with an engine that Some vehicles equipped with acts as a generator in addition to fuel a range extender even deliver cells. Engines for electricity generation a fuel efficiency of more than are also called range extenders. Various 60 km/L*. types of range extenders, such as
Various types of electric vehicles are emerging (the photo shows Mitsubishi Motors i-MiEV) Diverse technologies that Key components of the i-MiEV continue to evolve for (system configuration diagram)
Negative pressure Combination meter Battery management unit environmental conservation motor pump Battery charger Invertor (100/200V) Energy diversification (independence from oil, resource CAN conservation) • Recycling technologies DC/DC • CNG technologies
• Utilization of bio-fuels (ethanol ratio) ECU CAN Motor Battery • FCV EPS Transmission • HEV EV-ECU Prevention of global warming • Variable displacement engines • Clean diesel engines Heater Cell monitor unit • High-efficiency transmissions Accelerator Air condition battery module compressor • Variable valve system engines Brake Selector lever Elimination of the use of organic substances (in advance of The drive battery and other key components for electrification are installed under the floor. regulations and voluntary targets) • Offers the same in-car space and luggage space as the base car. • Catalyst technologies • The passenger space is separated from high-voltage wires to ensure safety. • Greater dissemination of low-emission vehicles • The lower gravity center of the body contributes to excellent handling. • Elimination of the use of organic substances A compact, high-efficiency motor is adopted and installed in the rear (in advance of regulations and voluntary targets) (same rear-wheel drive as the base car). A large-volume drive battery is installed to realize sufficient cruising distance for the daily use for a kei car.
* Measurement based on the JC08 mode fuel economy test cycle
5 YOUR GLOBAL CRAFTSMAN STUDIO EYE ON THE MARKET
COLUMN PHEV Technology Mechanism of the plug-in Hybrid EV System
Component layout Self-generating electric vehicles that maintain optimal driving Engine mode in various driving situations Front transaxle Rear motor control unit The Plug-in Hybrid EV System (PHEV) was developed independently by Mitsubishi Motors as a new derivative electric vehicle. When driving at low to medium speeds through residential areas, PHEV switches to EV Driving Mode that mainly uses electricity from Drive battery the drive battery. When the drive battery runs low or powerful acceleration is needed, it switches to Series Driving Mode so that the engine automatically begins to generate electricity and supplies power to the motors and battery. When driving at higher speeds it switches to Parallel Driving Mode to convey the high-rpm, high- Generator Fuel tank efficiency driving power of the engine directly to the transmission Front motor Rear motor and to also assist the motors. Furthermore, when decelerating the Front motor and motors act as a generator to regenerate the deceleration energy generator control unit Rear transaxle and recharge the drive batteries. EV-based plug-in hybrid EV system • A large-volume battery is installed under the floor in the center to ensure a sufficient cruising distance. • Twin motor 4WD is adopted with a drive motor in both the rear and front. • An engine for power generation and drive is installed in the front. • The driving force of the motor and engine can be switched using the front transaxle.
Drive system Twin motor 4WD Permanent magnet Type Motor (front/rear) synchronous motors Max. output 60 kW Drive battery Lithium ion battery Engine 2.0l four-cylinder MIVEC Outlander PHEV (Mitsubishi Motors) Fuel efficiency and machining technologies FMAX face milling cutter for high-efficiency finish machining
The advancement of production tool business has worked closely with drive systems and bodies to which these technologies is essential to the realization automobile manufacturers both in Japan components are assembled and mounted of fuel efficiency. This is also true in and overseas and has engaged in the to are mostly made of metal. Automobiles the metal cutting industry. The turbo advancement of machining technologies may someday be made solely of plastic charger is not new technology, but throughout its 80-year history. and electric parts, but that day is probably the production of efficient turbos was Thus far technologies that support still far in the future. Mitsubishi Materials made possible by the advancement of improved fuel efficiency of automobiles, cutting tools will therefore continue cutting tools capable of high-efficiency, with the main focus on the motor to provide machining processes that prolonged machining of materials that have been introduced. However, contribute to the further growth of the can withstand high-temperature exhaust in reality the foundation of such automotive industry. gases, the source of power for turbines. technologies is extremely wide and Additionally, lower production costs have includes transmissions that are used become possible, for example by the in combination with the motor, drive high efficiency machining of cylinder systems and lightweight bodies and even blocks and heads previously made of cast extends to motor oil, low-resistance iron but that are now made mainly from tyres and improvement of the fuel itself. aluminium. Mitsubishi Materials’ cutting Nevertheless, motors, transmissions, FMAX
Evolution of Fuel Efficiency Special Feature Photo provided by: Mitsubishi Motors Corporation and Machining Technologies
YOUR GLOBAL CRAFTSMAN STUDIO 6 FOCUS ON PERFORMANCE ON FOCUS FOCUS on PERFORMANCE
MITSUBISHI MOTORS A manufacturing bond that has produced continuing technical innovation
to attend technical exchange meetings. Part1 They also come together once a year to share the progress they have made in Mitsubishi Motors and Mitsubishi Materials their processing technology improvement activities. The purpose of these meetings Mitsubishi Motors evolving while expanding is to exchange technical information beyond company boundaries. In addition global sales to the regular members, young engineers are invited to participate in these activities Japan’s ancient capital of Kyoto remains (EV) and plug-in hybrid vehicles to cultivate next-generation engineers. a rich treasure trove of history and (PHEV). Such leading-edge innovation Approximately 420 engineers have culture, and is known as a popular tourist has provided the foundation for participated in Council activities over destination. Within this quaint capital, manufacturing technology throughout the half century since it was established just 15 minutes by car from Kyoto Station Japan’s automobile industry. The and hundreds of presentations covering sprawls a vast manufacturing plant. It is development of technology at Mitsubishi a wide range of technologies have the Mitsubishi Motors Powertrain Plant. Motors has been promoted by the “Tool been given. These activities provide Mitsubishi Motors started production Technology Council,” a group of process opportunities for interaction among of the Mitsubishi A type in 1917 and technology specialists. engineers, users and manufacturers continued manufacturing automobiles Established nearly 50 years ago in 1966, and have resulted in new tools that have that are popular throughout the world the Council comprises of engineers supported Mitsubishi Motors through such as the PAJERO and LANCER selected from departments and the development of highly advanced EVOLUTION. Mitsubishi’s “Drive@earth” divisions at Mitsubishi Motors group production lines. We asked Mitsubishi project aims to deliver an enjoyable companies and Mitsubishi Materials to Motors and Mitsubishi Materials Tool driving experience for the global market develop innovative technologies for the Technology Council members to tell us with an emphasis on coexisting with automotive industry. Under the concept about the history and achievements of nature through the development, of “Creating Dreams in Manufacturing,” the Council. production and sales of electric vehicles Council members are selected each year Tool Technology Council‘s support for production lines Shimizu (Mitsubishi Motors): It has been work on low-fuel consumption vehicles. course, this meant that we needed to about 40 years since I became involved That was a time when automobile adapt tools capable of machining these with the Tool Technology Council, which manufacturers were under pressure to new materials. I look back and feel like I guess, makes me one of the oldest reduce both weight and cost. it was a time of competitive evolution members. I was working in engine Ogino (Mitsubishi Motors): That’s true. between materials and tools. A new tool production for Mitsubishi Jeep when I Engine improvements required the that had low cost-performance that but was asked to join the Council. Looking development and application of stronger hard to pre-set, or difficult to adjust was back on its history, I remember most our materials which were difficult to cut. Of no good to us.
(Left) Hiroshi Shimizu: Production Engineering Group, Powertrain Production Engineering Department, Mitsubishi Motors (a pioneer at the Tool Technology Council) (Middle) Takashi Ogino: Powertrain Production Engineering Expert, Production Engineering Division, Mitsubishi Motors (in charge of machine technology) (Right) Makoto Nishida: Chief of the Powertrain Production Engineering Department Group, Mitsubishi Motors (chief)
7 Japanese industry has taken its lead FOCUS ON PERFORMANCE from the automobile industry, which continues to show growth driven by demand in emerging markets. Technical innovation such as the production of electric vehicles has also accelerated and Mitsubishi Motors has continued to innovate and produce even better products. Mitsubishi Motors 50-year collaboration with Mitsubishi Materials has supported this history of innovation. In this feature, we visit Mitsubishi Motors Powertrain Plant in Kyoto to ask about the collaboration between both companies in the development of process technology, global expansion and the contributions made by Mitsubishi Materials.
The Tool Technology Council benefits Ogino (Mitsubishi Motors): The and passed down by the Council has from a history where engineers from Mitsubishi Powertrain Plant (Kyoto) is a contributed to growth over the past 50 different areas had discussions and major production facility for the engines years. ideas to ensure that quality wasn’t used by Mitsubishi Motors. At its peak, Nishida (Mitsubishi Motors): I am compromised. Despite the difficulties, some 5,000 employees operated world- currently the Mass Production Team ultimately, solutions were always found class production lines twenty-four leader at the Council and I feel that The Tool Technology Council has also hours a day. To support this operation, employees from both companies bring focused on the cultivation of young Tool Technology Council members needs and seeds to the same table, engineers, serving as an opportunity were required to have the highest level set common goals and discuss issues for them to objectively examine their of knowledge and skill and it was quite together. The Council has become an technical capability. Mid-level engineers an honour for young engineers to be excellent place for technical exchanges. are also involved in Council activities, selected as members. Mitsubishi Materials used to dispatch constantly challenging one another to Takiguchi (Mitsubishi Materials): Only personnel to Mitsubishi Motors but then improve. about 5 employees from Mitsubishi stopped 25 years ago. Just this year Shimizu (Mitsubishi Motors): The Materials are selected to join the Council though, Mitsubishi Materials rejoined opportunity to share the most advanced each year. New members are selected the Council and sent Mr. Uno to join. information that individual members had as the Council evolves and adapts along The Tool Technology Council really is an was quite meaningful, and it served to with the trends in industry. To date, it has outstanding venue for human resource vitalize technology. That is how new ideas accumulated know-how and experience exchanges. and opinions were generated. The Tool over 50 years. Technology Council is an organisation Uno (Mitsubishi Motors): Yes. For the where core elements of automobile young engineers, it is a big honour to be manufacturing are brought together in involved with the Tool Technology Council. the search for future directions. The technology that has been developed
through the Tool Technology Council was Producing excellent tools to support the busiest very useful. production lines in the world Kitamura (Mitsubishi Materials): We needed to continually produce faster, so Takiguchi (Mitsubishi Materials): I was Takiguhi (Mitsubishi Materials): Yes, it we also had to reduce the time it took for on the production line in 1987 when was 50,000 vehicles per month, right? tool replacement. Mitsubishi started producing the V6 Under such tough conditions, Mitsubishi Shimizu (Mitsubishi Motors): It was in engine. Materials tools had their job cut out 1897 that we developed a system that Kitamura (Mitsubishi Materials): The for them. We were always aware that allowed replacement of tools with the V6 was being supplied to Chrysler at even the tiniest of problems could stop click of a button. We developed this that time. We produced 50,000 vehicles a production line so we were always system in collaboration with machine per month. I think then it was the busiest thinking of ways to process high efficiency design engineers, but the sharing of production line in the world. tools. The know-how accumulated a wide range of knowledge through
(Left) Taizo Uno: Powertrain Production Engineering Group, Powertrain Production Engineering Department, Mitsubishi Motors (Middle) Atsushi Kitamura: Manager at the Sales Department, Osaka Office, Global Key Accounts Department, Sales Division, Mitsubishi Materials (Right) Masaharu Takiguchi: Machining Technology Center, Research & Development Division, Advanced Materials and Tools Company, Mitsubishi Materials
8 FOCUS ON PERFORMANCE ON FOCUS the Tool Technology Council had a is one of the PAJERO colors, which we can achieve up to 70 percent of the significant impact. One of the concepts decided to use to show our spirit. improvement but the other 30 percent for technical improvement at that time Kitamura (Mitsubishi Materials):There must be found in manufacturing was the “Constant Search for Quick was no other production line in the techniques. Employees devote them- Change.” The development of spring world that was as complex as ours. selves to improvement and that has not clamps for face milling cutters and the Our achievement was outstanding and changed. hydraulic clamping mechanism reduced it made us proud that our tools were Takiguchi (Mitsubishi Materials): tool replacement time to less than one used on one of the busiest and toughest Experience in manufacturing can be minute, and eliminated the need for production lines in the world. applied to design. wrenches and other tools. Shimizu (Mitsubishi Motors): We did Kitamura (Mitsubishi Materials): The All: Yes, those are great memories! have some troubles though. Line origin of all tools sold by Mitsubishi Takiguchi (Mitsubishi Materials):There maintenance required a serious effort. Materials to automotive industries were no machining centers at that time The lines only stopped for a short time around the world can be found in the and it was impossible to exchange during summer and at year end. During history of the Tool Technology Council. tools automatically; but we had already these times we analysed and accumulated Everyone knows that a defect in a tool can developed a system very close to data about the products we developed. cause the stoppage of a production line the automatic replacement type you We also inspected deterioration of that produces 50,000 vehicles per month, see today. I can tell you that the Tool cutter reference planes and worked in and that would be a serious problem. Technology Council played no small role cooperation with the tooling center to Uno (Mitsubishi Motors): We will continue in making it possible to produce a large examine changes in runout. We worked recording the problems that come up number of engines, very quickly. constantly to monitor machined surface in production lines and reflect them in Ogino (Mitsubishi Motors): It is really accuracy over the years. improvement proposals. The importance great to get together with the major Kitamura (Mitsubishi Materials): We of sharing problems and solutions has players that were on the Council at that worked hard on maintenance. All through been passed down from past members time to share memories. our 20s, we spent our summer and New and we want to continue this great Shimizu (Mitsubishi Motors): Our Year holidays ensuring that the lines tradition through Tool Technology Council proposals for technical improvements would keep running. activities to ensure a level of quality that are summarised in this edition of “THE Shimizu (Mitsubishi Motors): For leads the automobile industry. TOOLING.” The color on the front page solutions to problems, the initial design
(Left/ Right in the photo) Tadashi Terasaka: Powertrain Production Engineering Group, Powertrain Production Engineering Department, Mitsubishi Motors (Left/ Left in the photo) Hajime Goto: Powertrain Production Engineering Department (in charge of machine technology), Production Engineering Division, Mitsubishi Motors (Middle/ Right in the photo) Hiroyasu Furubayashi: Keiji Office, Osaka Branch, Advanced Materials & Tools Company, Mitsubishi Materials (Right) Motoki Yamada, Global Key Accounts Department, Sales Division, Advanced Materials & Tools Company, Mitsubishi Materials The Tool Technology Council is a generator of wide ranging achievements The Tool Technology Council expanded as well as multi-layer chemical vapor machining. The technology accumulated its activities in 1993 by adding mass deposition (CVD) coatings and cubic boron here supports the production lines at production and metal mold processing nitride (CBN) materials. Simultaneously, Mitsubishi Motors and technical research teams. Cutting tools have improved we set new themes for further technical conducted at user sites has become significantly over the past 50 years and developments. These included lowering know-how that Mitsubishi Materials the Council has been a key factor in tool costs, increasing productivity, uses for proposals over a wide range of development each step of the way. It better chip control as well as improving industries. produced tools utilizing the UTi20T grade, tools for mass production and mold
9 FOCUS ON PERFORMANCE
challenge. What type of processing Part 2 - Development of next-generation tools method is required to create high-quality, high-performance and low-cost tools? through partnerships Mitsubishi Motors and Mitsubishi Materials are on top of the challenge. Updating processing methods for Their solution is the development of next- generation tools that enable cylinder core vehicle parts machining without a semi-finishing process. We asked Mr. Goto (Mitsubishi Machine processing relates directly to movement and the parts that convert Motors), Mr. Terasaka (Mitsubishi vehicle performance and it has improved this explosive power to inter-connected Motors Engineering), and Furubayashi, on a daily basis along with automobile energy requires materials that exhibit Sakuyama and Yamada (Mitsubishi development. The cylinder, the heart excellent strength. High-strength Materials) about the background of of the engine, plays an important role cylinders are made of difficult to cut development and methods in translating explosive power into materials and machining these is the
Making cylinder processing possible without a semi-finishing Terasaka (Mitsubishi Motors): In we let them know at a Tool Technology be effective when used on a rough boring automobile parts processing, we Council meeting that we could help them tool. constantly encounter many high make improvements and cut costs. Terasaka (Mitsubishi Motors): The wiper demands. Of particular concern in Goto (Mitsubishi Motors): Cylinders geometry requires significant power; but our recent challenge was the cost of currently undergo three boring process because the machine tool that performs machining a high-precision cylinder. The steps, rough, semi-finishing and finishing. the rough boring application had twice cutting tool for this one step accounts for Our plan was to reduce this to two steps the power of a general machining center, the lion’s share of the cost of tools used by alleviating the semi-finishing process. I was confident that it would be powerful in cylinder block processing. Thus, with In order to do so, however, we had to enough to allow us to get the most out of an eye to reducing this cost, it was first figure out how to improve rough boring the wiper geometry. sought to clarify the potential within the quality. Furubayashi (Mitsubishi Materials): production lines. Sakuyama (Mitsubishi Materials): We After six months of preparation, I was Furubayashi (Mitsubishi Materials): That proposed a wiper geometry to improve confident that we would be able to do this. was about four years ago, right? After the surface quality of rough boring and I was very excited to know that we would looking at Mitsubishi Motors’ approach, we were quite confident that this would achieve our goal.
Ideas are connected and shaped Sakuyama (Mitsubishi Materials): We insert becomes. However, the sharper difficult. Taking account of the facility’s put maximum effort into satisfying all the tool the more breakable the cutting capability, we accumulated data on needs, such as achieving high-quality, edge becomes. To prevent breakage and location accuracy to set the amount of high-efficiency and low cost, shortening achieve a rigid high feed cutting action, stock removal. Previously, we had set work processes. We examined a wide we modified the geometry to achieve processing conditions along the lines range of wiper geometries to find one that more rigidity. Additionally, the original of two-dimensional thinking, of feed would achieve surface quality equivalent insert was square and only provided the and depth of cut, this time however, we to semi-finishing boring. The result was a use of four corners; but the new insert increased efficiency by simultaneously new insert that applied a double-positive is hexagonal, allowing six corners to be optimizing 3 parameters, feed, depth of breaker to reduce cutting resistance. We used, thereby lowering the cost. cut and speed. During testing we found also developed a rough boring tool whose Goto (Mitsubishi Motors): For rough the optimum parameters that gave us inserts and layout angles were arranged boring, where cutting is more difficult higher-quality, higher efficiencies and to achieve a stable process. than the existing process, the set-up lower costs. Yamada (Mitsubishi Materials): The of stock removal and the optimum Furubayashi (Mitsubishi Materials): We larger the rake angle, the sharper the machining conditions was the most processed approximately 20,000 holes
(Left) Toru Sakuyama: Insert Tool Development Center, Development Department, Advanced Materials & Tools Company, Mitsubishi Materials
10 FOCUS ON PERFORMANCE ON FOCUS it was a great chance for me to really see how the tools we develop are used by Mitsubishi Motors. As a developer it was my pleasure to know how satisfied both users and manufactures were with products that employed our tools. Although we are working in different places, we are connected; and such bonds can achieve outstanding results. Goto (Mitsubishi Motors): I want to further advance the technology and methods we have developed. There are unlimited possibilities for added value in cutting tools, unlimited potential for cost reduction and the development of tools that can control chips and alleviate burrs. Terasaka (Mitsubishi Motors): We always look to develop the best in high- performance cutting tools. However, it is also important to optimize the principal three factors of high-quality, high-efficiency and low-cost. Mitsubishi to assess performance. The new tool improvement has the effect of eliminating Materials spared no effort to help us life increased by six fold and processing the need for an entire machine that costs develop new ideas and realize production efficiency jumped by 10%. This is why we tens of millions of yen. and was largely instrumental in have great confidence in our new product. Yamada (Mitsubishi Materials): We spent producing the excellent achievements Terasaka (Mitsubishi Motors): The four years improving this tool; but this is we attained. The high-performance tools processing efficiency of the machines now an outstanding development that developed here will also contribute to increased more than 10%. You may represents a new era in tool technology. other industries. think 10% isn’t much, but that 10% Sakuyama (Mitsubishi Materials): Yes,
processing methods carries the risk of Part 3 - Cooperation with Mitsubishi Materials impacting on quality. Mr. Oka, Mitsubishi Motors Production Engineering for global Expansion Department, who was also involved in the establishment of the production Establishing a new plant in Thailand line, wanted to install the exact same production line we had at the Mitsubishi Mitsubishi Motors is currently focusing engine processing line project in 2012. The Motors Powertrain Engineering Plant on expanding production capacity in engine was used for the MIRAGE, which in Kyoto. He felt that having the same Asia. Mitsubishi Motors Thailand Co., was produced entirely in Thailand. These production line would make it possible to Ltd. built an engine plant in 2008. days, it is easy to procure everything we reduce risks in applying new processing Building a new production line overseas need in Thailand; but it was not that easy methods and that implementing the most was more difficult than building one in back in 2012. Of course, it was not Japan, advanced production line, one whose Japan. Mr. Masago, Mitsubishi Motors so everything was different, including quality had already been proven in Japan, Kyoto Engineering Department, who the way orders were placed.” We need to would ensure the best performance. was involved in the establishment of the develop production lines that are suitable production line said, “I was involved in the for each country and culture but changing
11 FOCUS ON PERFORMANCE
Specialist support for overseas expansion
At the same time, Mitsubishi Materials markets. In 2013, Mitsubishi Materials engine plant in Thailand, our Global Key predicted expanding demand for established the Global Key Accounts Accounts Department was involved in the cemented carbide tools in Thailand, which Department, a specialist group to project. “When we launched the plant had become a base for automobile parts support overseas business expansion, project, we were constantly aware that production in Southeast Asia. Kitamura to help achieve this goal. Kitamura said, we had to come up with quick solutions from Mitsubishi Materials said, “Since “The Global Key Accounts Department to problems that were encountered. there was a need to set up a fine-tuned provides support to help our customers Mitsubishi Materials staff always helped customer service system in Thailand, we enter overseas markets. We provide us check production lines and conditions. planned to establish this and focus on them with the best solutions and services We placed priorities to on-site work, on- major countries from the perspective of and promote the enhancement and site production and I really appreciate the demand”. Mitsubishi Materials promotes optimization of their production system cooperation we received from Mitsubishi the expansion of accumulated technology, with a focus on a new framework that Materials staff. It was instrumental in experience and human resources on a allows each customer to create new helping us maintain our priorities,” said global level, not only to provide products, values and bolster competitiveness.” Mr. Oka. but also to respond to expanding global When Mitsubishi Motors was planning its
(Left) Mr. Furubayashi, Mr. Kitamura, and Mr. Yamada (Mitsubishi Materials) from the left (Middle) Yoshiki Oka: Powertrain Production Engineering Expert, Production Engineering Division, Mitsubishi Motors (in charge of machine technology) (Right) Toshio Masago: Engine Department 1, Kyoto Engineering Department, Powertrain Production Plant, Mitsubishi Motors
Need to work together to solve difficult problems
Installing a production line where no line information with Mitsubishi Materials is the willingness to work together with previously existed requires manpower. staff and obtained knowledge and customers to overcome difficulties.” Both Therefore, there was an urgent need information regarding processing. It companies have the same desire to work to cultivate human resources capable was very helpful.” Mr. Yamada from with customers to improve our products of operating cutting tools. In particular, Mitsubishi Materials said, “We placed and services and this strengthens the meticulous cost calculation is an integral great emphasis on matters that are relationship between us. During the part of processing in Japan, but it was highly regarded in Japan, such as interviews, they expressed an attitude of a challenge for the original project communication with overseas workers seeking the best process as professionals members to establish the importance of about products and sharing information in manufacturing. Mitsubishi Materials this system and way of thinking among on processes with our customers. continues to provide the best to each of its the local staff. Mr. Masago said, “Quality We worked hard to build cooperative customers around the globe by delivering comes first. People who had worked relationships at home and abroad to the most advanced process technology, in completely different areas needed ensure a prompt response to customer technology that can only be provided by to be trained in production line skills. needs.” Mr. Furubayashi from Mitsubishi a company that is intimately familiar with This required thorough instruction and Materials added, “We worked hard to the characteristics of each product. monitoring to ensure that everyone perceive and accommodate customer understood the work. We exchanged needs. The most important thing for us
12 HISTORY OF MITSUBISHI OF HISTORY HISTORY OF MITSUBISHI Power lines installed inside the tunnel to increase production (1939) Vol. 2 Japan’s treasure trove, boasting the largest-ever production of gold Switching yard in the former Ohdate shaft hoisting house (made of wood) Sado Gold Mine
The Kitazawa flotation mill (rear center) during the Meiji Period One of Mitsubishi Materials’ roots goes back to Sado City, Niigata Prefecture. Sado appears in Konjaku Monogatari Shu (The Tale of Times Now Past), written toward the end of the Heian Period and in Zeami’s Kintosho (The Book of Golden Island) and has been known since ancient times as the “island of gold.” The Sado mine, which belonged to the Imperial family was sold to Mitsubishi Goshi Kaisha in 1896 and thereafter supported the growth of Japan’s industries with the largest-ever production of gold in Japan. This article introduces the history of Sado Gold Mine and the development of mining technology. “Sado Mine Open House,” held since the Taisho Period
Gold Rush in Modern Japan vein of gold amongst the silver. In 1603, thereafter until the end of the Edo Period, Shogun Tokugawa Ieyasu placed Sado a total of 41000kg of gold were mined The Historical Site of Sado Gold Mine under his direct control immediately and supported the Tokugawa Shogunate is roughly four hours from Tokyo by after winning the Battle of Sekigahara. financially. Shinkansen and jet foil (high-speed The Shogun immediately appointed passenger boat). Found on Sado Island, Okubo Nagayasu as its administrator Rapid Growth Owing to the Development located in the western part of Niigata because Okubo was originally from of the Mining Technology and Transfer Prefecture, the mine has some 400km of Kai and had knowledge of gold mining. of the Mine to Mitsubishi tunnels (same distance as that between Under Okubo, the Sado mine was Sado and Tokyo) and is known as the exploited, beginning with the largest The Sado mine became famous as a gold largest gold and silver mine in Japan. The Aoban vein, followed by the open-pit mine, but its production declined from vast site includes various mining facilities Dohyu vein, the Ohkiri vein and then around the middle of the Edo Period that are designated a National Important the Torigoe vein. At its peak in the first prompting the Meiji government to send Cultural Property, Historical Site or half of the 1600s, the mine produced a Western engineer to the mine in 1869 Heritage of Industrial Modernization. more than 400kg of gold and 40 tons of to deal with the situation. As a result, in It is said that the history of Sado Gold Mine silver per year. The Sado mine suddenly 1877 an ore mill was built using Western began in 1601 when three speculators became Japan’s largest gold and silver technologies and the Ohdate shaft, the who were mining for silver in the Tsurushi mine and precipitated a gold rush. first Western-style shaft to be used in a Silver Mine in Aikawa discovered a new Over a period of approximately 270 years metal mine in Japan was opened. With the
13 YOUR GLOBAL CRAFTSMAN STUDIO HISTORY OF MITSUBISHI
The Sado Koban coin foundry in the Edo Period (reproduction)
Shotoku Sado Koban coin
Mining inside the Sohdayu “Dohyu-no-wareto” (split mine of Dohyu) the symbol of Sado Gold Mine. It is said shaft during the Edo Period that the mountain split in two as a result of many people vying to dig for ore. (reproduction Mitsubishi Material gold bar
The Kitazawa flotation mill, the largest flotation mill built in the Showa Period in Asia
Dohyu-no-wareto (site of gold The former Ohdate shaft hoisting house, built using Western technologies in the Ohdate shaft ore mining by hand) early Meiji Period and the Ohdate mill, built in the latter Meiji Period (front)
addition of these facilities, the government Thereafter in 1896 the Sado mine Long-lasting History of Sado Gold Mine aimed to acquire foreign currency with was sold to Mitsubishi Goshi Kaisha an eye toward modernization and also to (predecessor of Mitsubishi) and along with Sado Gold Mine’s history as Japan’s acquire monetary benefits. Furthermore the Ikuno mine achieved rapid growth. largest gold mine ended when operations in 1885, the new Meiji government By promoting mechanization such as were closed down in 1989, after attempted to increase production at the through the automation of power systems, producing a total of 78000kg of gold Sado mine in preparation for shifting to Mitsubishi succeeded in returning the and 2,300 tons of silver. Today, the site a modern monetary system based on mine’s momentum back to the level of is open to the public as the Historical a gold standard. Oshima Takato, upon production it achieved at its peak during Site of Sado Gold Mine (operated by being appointed director of the Sado the Edo Period. New production levels Golden Sado Inc.) and is striving to mine, subsequently opened several helped it to achieve far more than the be inscribed on the World Heritage new facilities including the Takato shaft, 400kg of gold it produced annually during List. Though now dormant, to this the Kitazawa flotation mill using new the latter half of the Meiji Period. During day, the Sado mine still continues German technology and also developed its 93 years of operation, Mitsubishi to convey its long 400-year history the Oma Harbor. In 1890, a mining school produced approximately 33000kg of of mining technologies was also opened to promote the domestic gold, and it was Mitsubishi’s modern and production systems. SADO production of mining technology and mining and ore processing technologies important policies were implemented that made a significant contribution in regard to mining education in Japan. to the increase in gold production.
YOUR GLOBAL CRAFTSMAN STUDIO 14 CRAFTSMAN STORY CRAFTSMAN
Craftsman Story Vol. 3 Kiyoshi Okada Toshiaki Kubota Kenji Yumoto Makoto Yasuda Toshiyuki Kodera Takuya Maekawa Manufacturing staff / Manufacturing staff / Development staff / Development staff / Manufacturing staff / Development staff / Joined in 1985 Joined in 1989 Joined in 2006 Joined in1983 Joined in1989 Joined in 2007 Coated CBN material for high-hardened BC81 steel turning SERIES The challenge of the CBN/PCD team in developing high-performance, long-life CBN materials
The team embarked on the development of the BC81 Series (BC8110, BC8120) in 2011. To develop a new CBN series for high-hardened steel that would outstrip other companies, a completely new technology needed to be developed. Below is an interview with six development and manufacturing members who tackled this goal.
15 YOUR GLOBAL CRAFTSMAN STUDIO CRAFTSMAN STORY
Q: Tell us how the BC81 Series came to be developed. Yumoto: In recent years, the automotive and machine industries have entered a growth trend and there has been an increase in demand for CBN (cubic boron nitride) tools that could be used for machining high-hardened steel parts. Mitsubishi Materials launched BC8020, a coated CBN material for general cutting of high-hardened steel in 2010, but in some cases it lagged behind the products of There were bound to be disadvantages to new technology that would control residual our competitors. Taking this disappointment to increasing the number of work processes, stress in order to enhance adherence strength. heart, we drew fully upon the strengths of new but a comprehensive review needed to be As a result, we achieved greater adherence technologies and developed the BC81 Series performed, beginning with the manufacturing strength than ever before. coated CBN material for machining high- stage in order to achieve the performance we hardened steel. desired. Q: Were any special efforts made in Okada: Frankly, as a member in charge of manufacturing the BC81 series? Q: Tell us about the development of BC8110. manufacturing, I doubted whether increasing Kodera: Because the BC81 series is a new Yumoto: BC8110 was developed as a coated the number of work processes would make type of material, we began searching for CBN material for continuous cutting of high- any difference. However, seeing one of our processing methods only after gaining a hardened steel. In our development process, members passionately explain the need to thorough understanding of the material. It was we committed ourselves particularly to increase the number of processes to achieve a tremendous challenge to produce samples in pursuing “what customers seek.” By having the goal, I had to believe in him. In the end it a short time without any disruption to regular our entire team focus on user-oriented product led to good results, although there is still more production. development rather than on technology-driven room for improvement. Yumoto: Mr. Kodera is a specialist, so he development, we were able to proceed towards Yasuda: In the product testing stage, we would make a sample three times faster than the same goal without going off track. performed repeated field tests with the other people. That is why we always ended up Maekawa: When starting our development cooperation of our customers. By proposing a asking him to make a sample (laughs). Having we exhaustively investigated “what needs to new perspective to the customer at this stage, someone like Mr. Kodera on the manufacturing be improved” in comparison with competitors’ they came to value our product more than staff is an enormous support to production products. The result pointed to an improvement our competitors, especially as we ultimately development. of wear and chipping resistance, so we set our succeeded in extending tool life. Kodera: The result was achieved not only by me, eyes on developing as our main concept “a Maekawa: Customers who cooperated in the but by the cooperation of the manufacturing CBN base material with excellent chipping testing requested to buy the product before staff. The members of the CBN/PCD team are resistance and a coating with superior wear its release, even if it was a special-purpose extremely cohesive and tend to want to help resistance.” product. Receiving such high commendation whenever someone needs it (laughs). before a product’s release has left a very strong Kubota: On the production floor, we hear our Q: How was the development actually impression on us. customers’ appreciation and words that they carried out? are awaiting our product and this motivates Yumoto: First of all, to develop “a CBN base Q: Tell us about the development of BC8120. us to make greater efforts. In hindsight, I think material with excellent chipping resistance,” Yumoto: BC8120 is a successor of the BC8020 that our wish to “make outstanding CBN/ we single-mindedly worked to improve the coated CBN grade for general cutting of PCD products” created a solidarity beyond toughness of the CBN base material. However, high-hardened steel, which was released in the bounds of departments and roles. This is all sintered CBN materials, including those 2010. Some application problems arose with because we had a relationship of mutual trust of our competitors, had the same type of BC8020, such as degradation in dimensional that we were able to realize our product goals. composition, so it was evident that CBN base precision due to delamination of the coating material produced in the ordinary way would and also when chipping occurred during Q: Please say a few words to your only provide the same level of performance continuous cutting. When developing BC8120, customers. in the final analysis. Therefore, to achieve a we therefore aimed to resolve these problems Yumoto: We have absolute confidence in the toughness that outstrips our competitors, we and to develop a material that delivers greater BC81 series, particularly considering all the invented the new “ultrafine binder” technology. intermittent performance compared to struggles we have gone through. We will Owing to this technology, we were able to competitors’ products. actively engage in cutting tests and PR activities make the BC8110 binder much finer than Yasuda: BC8020 lagged behind our and hope customers will try our products. our previous and competitors’ products and competitors’ products in some areas, so we Maekawa: This fiscal year, BC8105 coated succeeded in developing a ceramic binder with knew that we would fall further behind if we CBN material for finishing high-hardened improved toughness. We were thus able to were to spend four to five years developing steel and the BC8130 coated CBN material for achieve extremely good resistance to chipping. something new. For this reason, it was continuous cutting of high-hardened steel are Maekawa: Following the development of essential to develop our next product in a short scheduled to be released. However, we will the base material, we embarked on the period of time. As a matter of fact, it took us also focus our efforts on further developments, development of “a coating with superior wear only a year or so to further improve our CBN so please look forward to our future lineup of resistance.” Generally speaking, coatings base materials and coatings. products. do not adhere as easily to CBN tool material Yumoto: It was necessary to increase the compared to other carbide tool materials. chipping resistance of the CBN base material. So what needed to be done to achieve both We initially thought we could enhance adhesive strength and wear resistance? As a toughness to a certain degree by applying the result of examining the issue in various ways, ultrafine binder technology to BC8120 that had we decided to modify our company’s unique been developed for the CBN base material, Miracle coating technology so that it could be but this was no easy task. Due to limited time, applied to CBN. This involved what seemed to we even worked over the weekends making be an endless series of trials and errors to find sample after sample and ultimately succeeded the appropriate conditions, this was because in applying the ultrafine binder to develop a carbide tools and CBN tools differ completely dedicated CBN base material for BC8120. in the way a coating adheres to them. We also Maekawa: For the coating our main objective Cutting Speed m/min introduced new facilities to the manufacturing was to control delamination. We began by stage and added a new process after coating. considering film compositions and applied a Fracture resistance
YOUR GLOBAL CRAFTSMAN STUDIO 16 TECHNOLOGY ARCHIVE TECHNOLOGY TECHNOLOGY ARCHIVE History of the Evolution of the Solid Carbide Drill
The ZET1 drill appeared in the latter half of the Hidden within the design lies the history of 1980s as the first solid carbide drill in the industry. Its genes have been inherited by the WSTAR a challenge that became a breakthrough drill, the current core drill product of Mitsubishi Materials. In this issue, we trace the evolution of in drilling technology the solid carbide drill.
17 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE
TECHNOLOGY ARCHIVE Part 1 1987 ~ The ZET1 drill that rewrote the book on drilling performance In the latter half of the 1980s, when At the time, high-speed steel drills what is known as peck or step drilling brazed and high-speed steel drills were had approximately a 70% share of the cycles, and at that time many customers the mainstream product used across market, so we were very confident of the only used conventional machines and various industries, Mitsubishi Materials ZET1’s performance as a solid carbide methods that were not suited to the peck embarked on the development of the drill. It delivered five times greater or step drilling processes. Therefore, solid carbide drill. Brazed carbide drills drilling efficiency, ten times longer tool we offered trainings in cooperation already existed in the market, but due to life, steady discharge of chips and an with machine tool manufacturers, and technical reasons they were only available overall higher drilling performance. provided information to customers so in large diameters. Nevertheless, In other words, it represented a that they knew of the correct methods Mitsubishi Materials anticipated that dramatic evolution. However, contrary to gain the most efficiency from the there would surely be a time when small to expectations, it did not sell well. The new drills. Furthermore, since many diameter solid carbide drills would be first reason was its price. Compared to customers were not familiar with the in demand and began development in high-speed steel drills, the carbide type need for accurate resharpening of a small corner of a factory. However, was around 30 times more expensive. solid carbide drills in order to maintain during the 1980s, computing technology This meant that what customers used the drills’ performance levels, we also was in its infancy and all calculations to buy for 500 yen would become 15,000 disseminated knowledge of how to and design was done manually. Days yen. In the final analysis, one hole would care for them. These efforts, made in upon days were spent designing the ideal cost less and production efficiency conjunction with marketing activities flute and cutting edge geometry through would increase, but it was difficult to required a large amount of time, but simple trial and error. It was a time set a precedent in the market so that it owing to their steady influence the ZET1 when products were developed based on would open up to the overall advantages drill eventually came to be accepted, engineers’ experience and sense, rather of the solid carbide drill in terms of cost. primarily by the automobile industry. In than on the basis of data and simulation Another reason was that initially there hindsight, the sense of accomplishment that have become the standard today. was little knowledge about how to handle we experienced after overcoming the After several years of development, the and operate solid carbide drills and we hardships and receiving customers’ ZET1 solid carbide drill finally came into needed to begin by teaching customers understanding of the advantages of existence in 1987 as the first solid carbide how to use the drill correctly. Solid the product, plus their words of praise, drill in the industry. carbide drills perform best when using remain strong in our minds.
HISTORY Evolution of the solid carbide drill
1973 Gifu Plant is established. 2007 The MNS drill for aluminium alloy machining The manufacture of cutting tools begins. is released. The MGS solid gun drill is released. The ZET1 drill is released. 1987 The MHS drill for die machining is released. The Super Burnishing - brazed drill is released 2008 1995 (receives an award from the Japan Cemented The MMS drill for stainless steel machining is Carbide Tool Manufacturers’ Association). 2010 released. The MQS drill for steel and cast iron machining The WSTAR drill is released. 2011 is released. 2002 The MCS drill for CFRP machining is released. The MiniSTAR drill is released. 2004 The small-diameter MHS drill for die machining The WSTAR Super-long drill for deep-hole 2013 is released. 2006 machining is released. The MVE/MVS new-generation general-purpose drills are released.
YOUR GLOBAL CRAFTSMAN STUDIO 18 TECHNOLOGY ARCHIVE TECHNOLOGY TECHNOLOGY ARCHIVE Part 2 2002 ~ Beyond the ZET1 drill, the origin of the WSTAR series Roughly ten years after the ZET1 drill was in our hands, such as where the point born, the solid carbide drill had become of resistance begins and how chips are widespread across the industry, and discharged. This led to a shift in concept various products including those of other from the ZET1 drill’s linear cutting edge companies had appeared in the market. to a curved type. We thus explored how to New developments were also demanded realize a wavy type cutting edge that no of the ZET1 and the development team one had ever seen before. The inspiration had run up against a wall as to what for this curved shape came suddenly efficient discharge. In addition a newly types of improvement should be made. from a moment while cooking when using developed point shape ensured excellent It was then that the general manager a food processor to chop ingredients. concentricity and positional accuracy of development gave the following Inspired by the bold curves on the blades of holes. Furthermore, we were able advice: “Go and hand cut holes in bars of the food processor and after much trial to extend tool life by adopting VP15TF of soap until you find an answer.” We and error, we ultimately came up with the Miracle coating. These features ensured spent several days thereafter, using WSTAR solid carbide drill with its unique that the WSTAR drill series, launched in both Mitsubishi and competitors’ drills, wavy cutting edge. 2002, became recognised for its accuracy single-mindedly drilling a huge amount and long tool life and has become a holes in soap by manually rotating Through the wavy edge and new flute product that is still favoured by many them. As a result, we discovered many geometry we succeeded in minimizing customers today. things through the sensations we felt the size of chips and this enabled a more
Part 3 2006 ~ The ongoing evolution of the WSTAR drill series drills for machining deep holes with an innovative approach to increasing the aspect ratio of up to L/D = 30. Each of flow rate, we succeeded in enhancing these products embodies technologies, cooling performance, lubricity, discharge originality and ingenuity that only of chips and the overall performance of Mitsubishi Materials could achieve. An the drill itself just because of the design example of this originality is the MNS of the coolant hole. Long tool life against drill that was developed for machining a wide range of work materials was aluminium alloys. To lubricate the precise also realised by applying a PVD coating spot near the center of the drill where (DP1020) that was designed specifically The WSTAR drill has further evolved since chips tend to adhere, further improvement for drills. WSTAR is indeed the perfect 2006 in response to the needs of the of the coolant flow was required. Straying solid carbide drill series for the new market. The series of drills has expanded beyond the conventional two-hole drill, generation of engineering needs. and now includes the general-purpose we collaborated with the manufacturing Further innovation MWE/MWS drills designed primarily for technology group and created a drill with TRI-Cooling technology New material carbon and alloy steels. In addition, the four coolant holes, the first drill of its kind MVS New wavy cutting MQS MNS, MHS, MMS and MCS drills that in the world. Then, taking this technology edge design New MNS are designed specifically for machining further, we developed and released the MPS shape MWS DP1020 DP1021 aluminium alloy, high-hardened steel, MVE/MVS general-purpose solid carbide MZS stainless steel and CFRP materials drill series in 2013 by employing TRI- MIRACLE SIGMA respectively, have also been launched. Cooling technology to create an originally VP
Productivity & tool life & tool Productivity MIRACLE SIGMA Amongst the highlights that are available shaped coolant hole that requires GP / AP / VP today are also the super-long type extremely high precision. By taking an 2002 2014 History of the solid carbide drill (standard size)
19 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE
CLOSE UP Manufacturing technology for tools with coolant holes: The results of Mitsubishi Materials’ technology and persistence Mitsubishi Materials began manufacturing tools with coolant holes in 1988. For 27 years thereafter, coolant holes continued to evolve, supported by production technology. Below, we introduce the work processes involved in manufacturing tools with coolant holes.
Tungsten is mainly used Raw material in powder form is fed into a Step 1: Raw material to make carbide products. Step 2: Extrusion press press and extruded. The finished product It is an extremely heavy simply appears like a twisted rod, but spiral substance, but it has fine coolant holes are already inside at this stage. particles that flow like The key here is the accuracy of the position of liquid. the holes. The holes are spiral in shape, but are positioned so that the same thickness is maintained from the outside at any point along the drill. Production technology born from long years of trial and error is at work here in stabilizing the lead length while the raw material is pliable.
After pre-sintering the The drill is sintered at high Step 3: Molding drill so that it is as strong Step 4: Sintering temperature so that its as chalk, spiral flutes volume is roughly halved but are cut in the drill. This is the density greatly increases. done without reaching the This means the coolant coolant holes inside, using holes are made in a size an advanced technology and position that takes into that ensures the holes are account the shrinkage in line with these spiral factor from the beginning. flutes.
All drills are not only Step 5: Final inspection inspected for flaws, but also checked whether the coolant holes are made as specified even after shrinkage during sintering has occurred. Only materials that pass strict inspection procedures are approved and made into a product.
Round hole (2002 — ) Four holes (2007 — ) Triangular holes (2009 — )
The demand for drills with smaller diameters and longer lengths in recent years has meant increasing difficulties when manufacturing tools with coolant holes. For Unraveling the history of the solid drill example, in ultra-small diameter drills, the product itself is thin and the flutes are The ZET1 drill appeared 30 years ago. As I extremely narrow, so even greater hole positioning precision and pitch precision is look back at the history of the solid carbide required. Similarly, with longer drills, it has become even more important to ensure drill thus far, I realise it is precisely because the lead of the helix remains constant, and production technologies continue to we are a manufacturer capable of developing evolve daily toward that end. Additionally, tools with coolant holes generally have and producing a whole gamut of items, round coolant holes, but Mitsubishi Materials develops and manufactures tools with that we are able to continually produce coolant holes that differ from the conventional two round holes—such as four holes new drills that the market requires. This and triangle holes—to increase drill performance. Only Mitsubishi Materials uses process is a direct result of our interlinked coolant holes of differing shapes according to the work material. The various coolant work processes and through the concerted hole shapes are able to be produced precisely because the drill and materials plants efforts of the entire development team. are located on the same site, and are the product of strong cooperation and hard Going forward, we will continue with a flexible work among members of both plants. The three types of coolant holes embody outlook to produce new materials and shapes Mitsubishi Materials’ technologies and pride as a company that manufactures in order to pursue further innovations. Kazuya Yanagida products from its own raw materials. Leader, Drill, CBN & PCD Products Development Center
YOUR GLOBAL CRAFTSMAN STUDIO 20 ABOUT US ABOUT
Thailand Engineering Center About Us Center of Technical Support in Southeast Asia For the automotive and other industries that are looking to expand their facilities and build plants overseas, Thailand is a popular choice. This article introduces Thailand the Thailand Engineering Center that was established to provide speedy, high- Engineering quality technical services. Advanced services in the industrial surveys and reports. The Center is located Center heart of Thailand in the Amata Nakorn Industrial Estate, Mitsubishi Materials Advanced Materials & considered as the geographical hub of the Tools Company promotes the localization Thai automotive industry. It is the largest of technical services to provide prompt industrial estate in Thailand and is open support to customers throughout the to all customers, both large and small. world. Therefore in early 2014, the Thailand This location is advantageous because Engineering Center was planned. When customers can call in at any time to consult opened, it was to be available as a source of about technical matters and in turn allows technical solutions to customers in countries us to provide speedy support. Today, a year throughout the neighboring Oceania region. after commencing operations, we already “We aim to provide the same quality After roughly a year of intense preparation provide technical support to approximately of technical services as in Japan.” to ensure the strongest and most reliable 84 companies. An interview with Takayoshi Saito services possible, the official opening came MMC Hardmetal (Thailand) Co., Ltd. Technical Director / GM Engineering Center in January 2015. The Center now provides Comprehensive support to customers as diverse services ranging from standard their partner by offering learning programs machining tests through to workshops on and other diverse solutions machining technologies, product workshops We offer learning programs on machining and studies related to machining, plus other technologies in both English and Thai languages. Through regular courses and new product demonstrations we actively provide information that lets customers gain an understanding of our products and enables them to utilize the product’s features to the fullest. There is extremely strong demand for such learning and there have been cases where our customers have incorporated our machining technology programs into their own in-house training. With continued focus on providing high quality technical services at the same standard as found in Japan, we aim for further growth and cooperation as an engineering center that our customers can always rely on.
21 ABOUT US
An employee’s view: facilities along with other colleagues by I wish to provide close support to our using the knowledge I gained during my customers’ production sites time in Japan. After MTEC was officially opened I was given a number of roles to My name is Napatpol Artharamas, my carry out. I was given responsibility as nick name is Phyte. I studied Electronics the main operator for the CNC lathe and “Our engineering team works as one to and Communications Engineering in also as a sub-operator for the machining provide a high standard of services and Thammasart University after which I center. I conduct seminars, training and solutions.” joined MMC Hardmetal (Thailand) in machining demonstrations when MTEC May 2014. I spent 6 weeks training based has visitors from Thailand or abroad. Napatpol Artharamas around the Tooling Technology packages Another important role I am involved with MMC Hardmetal (Thailand) Co., Ltd. Technical Engineer 1 and 2, then I had the chance to spend 7 is to assist our local Thai sales staff in weeks of study and hands on training at areas such as troubleshooting as well as the Omiya Technical Center, Japan. Whilst carrying out machining tests and writing there, I learnt several new skills and had of technical reports. many new experiences. On reflection, Even though I have only been a member it was the most influential period of my of the technical team for a short time, career so far. the experiences I have everyday help me When I arrived back in Thailand I was to continuously improve my knowledge transferred to Amata Nakorn, where and understanding of metal cutting the construction of MTEC had already processes. I do believe that we as a team, been started. Amata Nakorn is one of will develop and look forward to furthering Thailand’s largest Industrial Estates and deepening our relationship with other and is an excellent location in which to global technical centers, ensuring that we establish the MTEC Technical Center. offer current and potential customers a I helped set up the equipment and higher standard of services and solutions.
Thailand Engineering Center’s solutions services
Demonstrations using actual System for live streaming of R&D collaboration between machines and a rich seminar demonstrations industry and academia 1 curriculum 2 3
We provide lectures on the basics We have established a ubiquitous We cooperate in research and of metal machining technologies, training system equipped with development projects based such as milling, turning an internet-based live streaming on new business models. and drilling using materials system showing demonstrations The ASEAN market promises published in Thai, Japanese and for remote customers. This future expansion, therefore to English languages. We also give enables them to “attend” our strengthen responses we are active demonstrations using the programs and seminars at their also exploring the possibility latest CNC lathes and machining convenience. of a joint development with centers in the engineering major universities and research machine room. institutions in Thailand.
YOUR GLOBAL CRAFTSMAN STUDIO 22 CUTTING EDGE CUTTING CUTTING EDGE
Vol. 2 Tomoyoshi Sakamoto (left), Yuji Takaki (center), Wataru Takahashi (right) Advanced Technology Team, Development Division Processing Technology Center Seamless and self-turning A rotating tool developed for the market 20 years ago
It all started with a customer’s request. sliding and other types of bearings (oil lubrication and also to prevent shavings They wanted to reduce the number retaining, solid lubricant, carbide + DLC from penetrating the bearing housing. of insert corner changes on a mass coating). However, these types could not Downsizing was also challenge. We production machining line. They also successfully overcome the problem of cleared each problem step by step, by wanted to make complete use of the the insert rotation stopping under certain using different seals and so on until the insert’s peripheral edge. There was a cutting conditions. After finding that tool could finally withstand practical use. definite need for imagination in order to mechanism using sliding type bearings When put into actual use, it was found that meet this seemingly impossible request. made it difficult to reliably rotate the it was possible to use the entire periphery That’s when we came up with the idea insert, we replaced the slide bearing of the insert, but it was also evident that to rotate the insert itself: and invented with a needle roller type. This solved the the effects of lowered relative velocity the rotary holder. The insert had to be rotation issue, but new problems arose. with the workpiece also contributed to rotated, therefore in the early stages of There were side effects from the cutting improved wear resistance. development we experimented with a temperature, it was difficult to improve
Newspaper article about the development (Nikkan Kogyo Shimbun November 12, 1996)
23 YOUR GLOBAL CRAFTSMAN STUDIO CUTTING EDGE
Reducing abnormal damage with an ingenious rotating tool
Mitsubishi Materials developed the rotary As shown in the graph below, these three holder, a turning tool designed so that the advantages made it possible to create cutting forces caused the round carbide a stable, long-life when compared to insert to rotate automatically; it achieved a fixed insert tool. If the workpiece is the following benefits: manufactured from a tough material, 1. Unified wear eliminated the need for abnormal damage can occur due to insert positional changes until the insert high temperatures when cutting, or the was spent. workpiece can be easily work-hardened. 2. The constantly moving cutting point For a standard tool, lowering cutting meant no boundary wear (see column conditions helps to prevent abnormal below) to the cutting edge. damage, however, this also reduces 3. Non-concentrated cutting heat reduced efficiency. The rotary tool negates the insert wear. need to reduce cutting conditions by rotating the edge of the tool during cutting, thereby improving machining efficiency and extending tool life.
grease nipple insert Conventional holder (Fixed insert) sheet VB=0.60mm
rotary shaft thrust bearing
mechanical seal Rotary holder VB=0.14mm
radial bearing VB (mm) flank wear
thrust bearing
cutting time (min.)
YOUR GLOBAL CRAFTSMAN STUDIO 24 Instilling the spirit of Japan WA
Sumo “Hakkeyoi, nokotta!” The Gyoji clad in his sumahi people (sumo wrestlers) to entertain middle of the Edo Period (18th century) beautiful costume signals the start of a nobility and the emperor. After the bouts, different sumo groups that had independently powerful bout between two sumo wrestlers. grand banquets were held. Sumahi continued been holding performances, gathered together. The setting is perfectly set, with the suspended as a court event for 400 years, while slowly This gathering created the basic structure roof over the dohyo and ready to show the developing into the form we know today as of what would later become professional distinguished rituals of the ring entering sumo. sumo wrestling, with six scheduled Honbasho ceremony and the bow dance. When you go to a In the days of the samurai from the Kamakura tournaments per year. Sumo’s popularity grew Honbasho to watch sumo, there is far more to Period (1185~) through the Azuchi-Momoyama quickly with the rise of great wrestlers such as enjoy than simply the “match”. Period (1573~), shoguns and feudal lords Onogawa Kisaburo and Tanikaze Kajinosuk, began to take an interest in sumo wrestling and one of the first Yokozuna’s. Along with Known as Japan’s national sport, sumo dates they too, gathered wrestlers to watch. Warring kabuki, it became established as the people’s back to the age of mythology. The word sumo Lord Oda Nobunaga had a special preference entertainment of the Edo Period. originally comes from the ancient noun sumahi for sumo, inviting wrestlers from all over Japan Throughout its long history, sumo gradually meaning “battle”. The word sumahi can be to the Azuchi Castle in Omi to perform. It is well took shape as a sport and became a traditional found in Kojiki (Records of Ancient Matters) known that he welcomed the strongest into the culture unique to Japan. Today, while balancing and Nihon Shoki (Chronicles of Japan) written castle as retainers. tradition with innovation, sumo still continues in around 720 A.D., to describe contests of Sumo started to become a form of box office to fascinate fans from across Japan and all strength between the gods. entertainment when collecting entrance over the world. During the Heian Period (794~), messengers charges from the public started during the were sent around the country to gather Muromachi Period (1336~). By around the
Ryogoku Kokugikan (Our editorial team is located in Ryogoku, the Sumo town) The heartland of Sumo
Six sumo tournaments called Honbasho are gate. There’s a good chance of meeting stable of sumo artifacts such as woodblock prints, held each year. Three of them (the January, masters, who were once famous wrestlers banzuke (rank charts), and keshomawashi May, and September Basho) are held in because they stand there as ticket collectors. (ornamental aprons worn by Yokozuna). Tokyo, at the Ryogoku Kokugikan just north Once inside the hall, you are enveloped of JR Ryogoku Station. Colorful banners with in the sumo world with 20 information names of sumo wrestlers written on them booths side-by-side and the area is usually line the streets during the tournament, adding bustling with ushers dressed in hakama and a true ambience to the sumo town. The first ladies dressed in kimono. There is a sumo thing that makes visiting Ryogoku Kokugikan museum on the first floor of the Kokugikan especially exciting is approaching the stadium where you will find an abundant collection
25 YOUR GLOBAL CRAFTSMAN STUDIO Sumo basics There are 82 winning WA moves in Sumo Sumo rules are simple. The Gyoji is the referee and A winning move in sumo wrestling is called a kimarite, two men wearing sumo belts wrestle until one wins by of which there are currently 82. Of these, the most knocking the other down or pushing him out of the ring. commonly used is yorikiri, followed by oshidashi. Nearly If one commits a foul such as intentionally pulling the half of the kimarite used in post-intermission bouts opponent’s hair or by grabbing him, he automatically during the 2015 Hatsu Basho (January tournament) loses. Tournaments called Honbasho are held six times a were yorikiri and oshidashi, which are classified as year and each lasts for 15 days. The wrestlers engage in basic kimarite skills. Other skills include sokubi otoshi one bout a day and the wrestler with the most wins is the where an opponent is struck downs from above the champion. The official list showing the wrestlers’ rankings neck and tsumadori where the opponent’s foot is pulled is called the banzuke. There are ten ranks, from Jyonokuchi back in order to make him fall. at the bottom through to Yokozuna at the top. In Japanese sumo wrestling, the banzuke means everything. The ranking represents the size of each wrestler’s salary and Yokozuna the level of privileges they are entitled to. Only wrestlers Wrestlers are who have reached Sandanme (third stage) are allowed to divided into wear leather-soled sandals and only Juryo and above can ten ranks. Ozeki Makuuchi wear the formal attire, haori hakama.The promotion and Each level has Sekiwake Sanyaku (max. 42) Sumo wrestler demotion in ranks is determined at the banzuke ranking a maximum Komusubi number of Maegashira conference held after each tournament. Essentially, the positions. Sumo wrestler names are larger and rank of a wrestler goes up when he wins eight or more Juryo Juryo (max. 28) thicker as the rank rises bouts during a tournament and goes down with eight or Makushita more losses. Traditionally there are no bouts held between Sandanme Under Makushita members of the same stable or between brothers. This is Jonidan Source of Emotions based on the deep-rooted hidden samurai compassion Jonokuchi “I hope to pass on this cultivated that would pity both parties confronted in such a situation. Fig. Rank and number of wrestlers technology.” “Drill a hole by hand through soap and feel with all of your senses.” “Daily repetition makes people strong.” Even in interviews that start off on a nervous note, after several carefully chosen questions there usually comes a time when even experienced interviewee’s let their guard down and open Oshidashi (frontal push-out) Yorikiri (frontal force-out) Uwatenage (overarm throw) Kinjite (forbidden) up their inner thoughts. It is at this moment that the really Strike the opponent’s side or chest to Push the opponent out of the ring by To grab the mawashi (belt) from over Dangerous and dirty moves such as push him out of the ring. attacking the torso and moving him the opponent’s extended hand and grabbing hair, striking with a closed pertinent points can be expressed backwards or sideways. throw him. fist or slapping both ears at once with freely and openly and a genuine open hands are forbidden. article can be written from those reactions. Pure emotions make people Sumo Trivia try harder and they follow their heart, wherever it leads. Their 1. Only men can become sumo wrestlers. 4. Throwing salt before a bout is to cleanse strong desires push them along Women are not allowed. impurities. and these repeated efforts can To become a sumo wrestler, you need to clear Before a bout sumo wrestlers sometimes throw create a breakthrough. People three conditions to pass as a new apprentice, salt. This custom began as a ritual to cleanse known as a Shin-deshi 1) You are a male, under the dohyo, which is considered a sacred place. are attracted to their crystal clear 23 years of age and have completed compulsory During the Honbasho, about 45 kilograms of salt source of emotions, as these are education. 2) You are at least 173cm tall. 3) You is used a day. This adds up to more than 650kg the efforts that make them real. weigh at least 75kg. It is documented in the for the duration of the tournament. Wrestlers are sumo rules that “wrestlers are limited to the only permitted to throw the salt after they reach male gender”. Makushita status, and only when time allows. ”Your Global Craftsman Studio” 2. The “Splits” are an important part of the 5. Like businessmen, sumo wrestlers are paid Chief Editor; Hideyuki Ozawa training to become a strong wrestler. salaries. (Business Development and The most important thing for a sumo wrestler Sumo wrestlers are paid on a salary system, Planning Department) is to train his body to be flexible so that he but salaries are paid only to wrestlers who are doesn’t get injured. As part of this routine they at Juryo ranking or higher. The Makushita and Your Global Craftsman Studio practice the “splits”, stretching their legs to the lower ranks are paid an allowance for each left and right. Wrestlers who have completed Basho. A Yokozuna’s basic salary is 2.82 million Vol.2 training must be able to spread their legs 180 yen per month and a Makushita’s allowance Published by Business degrees while touching their torso and chin flat is 150,000 yen per Basho. There is also prize on the floor. New wrestlers practice in the sumo money and the more a wrestler wins, the more Development and Planning training room in the Kokugikan for six months to money he can earn. Department, Mitsubishi Materials learn the basics, including the splits. Corporation 3. Ryogoku is filled with restaurants that 6. The Man-in Onrei (full house) banner is specialize in chanko nabe, a sumo wrestlers displayed in accordance with ticket sales Unauthorized copying and cuisine. Chanko nabe is known as standard sumo The banner over the suspended roof reads replication of the contents of wrestler food. It is a huge hot pot with stewed “Man-in Onrei” and means that it is a full house this site, text and images are seasonal vegetables, fish and chicken, eaten (see upper photo on previous page). This banner with a dipping sauce or ponzu vinegar. Many is lowered after the Juryo bouts are finished at strictly prohibited. MIRACLE in specialty restaurants line the streets Ryogoku, the moment the “ki” (wooden clappers) start to this document is a registered home of the Ryogoku Kokugikan where chanko signal the beginning of the Makuuchi bouts. It is nabe originated. said that the banner is only shown if at least 80% trademark of Mitsubishi Materials of the admission tickets for that day are sold by Corporation. 3:00 p.m. YOUR GLOBAL CRAFTSMAN STUDIO 26
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