Mitsubishi Materials Craftsmanship Magazine YOUR BM006E GLOBAL CRAFTSMAN STUDIO
DRIVE TO THE FUTURE Spirit and Technology Supporting the Automobile Industry Vol. 6 Stories YOUR GLOBAL CRAFTSMAN STUDIO VOL.6 STORIES VOL.6
3-4 5-8 9-12 EYE on MARKET FOCUS on PERFORMANCE FOCUS on PERFORMANCE Welcoming the Era of AISIN AW Co., Ltd. Fiat Chrysler Automobiles N.V. Next-Generation Vehicles
13-14 15-16 17-20 HISTORY OF MITSUBISHI CRAFTSMAN STORY TECHNOLOGY ARCHIVE Playing a role in the growth of the The search for optimum performance History of large-diameter helical Mitsubishi Group defies conventional wisdom broaches that are key to automatic - Mitsubishi Materials Corporation - - UC51 Series – transmissions
21-22 23-26 ABOUT US CUTTING EDGE A logistic network that supports Tools that absorb chips manufacturing sites throughout the world - Logistic Division –
MESSAGE It’s not too much to say that the history of the We need to show courage in selecting from among automobile industry and the history of cutting the options available to us to move forward into tools are one and the same. The automobile the future. We also need to think now about what industry grew by predicting and satisfying market we should do to prepare and pursue that course. needs, but it is now undergoing significant reform. Meanwhile, we must not forget to address the It is hard to predict what the market trends will be current issues. The issues currently facing the tool in 10 years and it has become increasingly difficult industry include the need to improve productivity to achieve a unified vision of future trends even in by 5% and establish engine processing lines. While individual countries. we prepare for the future, we also need to care for Shinichi Nakamura Significant reform will also be the case for the present by providing goods and services with Managing Executive Officer, tool manufacturers because it is certain that great value. Mitsubishi Materials Corporation the amount of machining per next-generation Mitsubishi Materials’ Craftsman Studio is intended President, Advanced Materials & vehicle will decrease. This is the cold reality that to be the place where innovators striving for Tools Company tool manufacturers will soon face. However, I significant advancements toward the future can believe that we can identify significant business feel free to boldly discuss the current and ideal opportunities even under these circumstances. states of machining with cutting tools.
1 YOUR GLOBAL CRAFTSMAN STUDIO MESSAGE
A spirit of empathy for the customised designing of special tools
Thank you for reading YOUR GLOBAL production & technology and procurement While our Research & Development Division CRAFTSMAN STUDIO vol. 6. divisions to understand. With a spirit of continues to prioritize the performance of empathy, we are responsible for making individual products, we also continue to Volume 6 features the automobile special tools for our customers. provide customer-oriented consultation industry. It is a fact that the growth of our services. Advanced Materials and Tools Business YOUR GLOBAL CRAFTSMAN STUDIO is has been supported in no small part by the the brand message from the Advanced In June 2017, we opened the Central Japan advancement of the automobile industry. Materials and Tools Business. It expresses Technical Center adjacent to the Gifu Our customers in the automobile industry our desire to respond to the wide variety Plant. We are looking forward to seeing have taught us many important lessons, of customer requests to ensure that the automobile industry customers there to and I believe their support has been tools we manufacture meet and exceed showcase our ability to provide the best instrumental in helping us to expand our expectations. We rise to the challenge of engineering solutions. We will continue business. manufacturing the finest specialized tools to innovate and improve our products and for the automobile industry. In addition to services to meet customer needs. There are five major parts to the automobile the wide application of special products, engine, the so-called 5C’s; and most of the the use of standard products has increased. tools used to manufacture the 5C's are The telephone book-size catalogue contains Koichi Ikenaga specialized. The manufacture of these more than 30,000 products and with such a General Manager special tools presents major challenges vast array, it makes it a daunting task for Research & Development Div. because of the need to incorporate a customers to select the most appropriate Mitsubishi Materials Corporation wide range of design perspectives while tools and cutting conditions by themselves. Advanced Materials & Tools Company bringing to bear the most advanced Individual customer needs include the know-how available to satisfy customer necessity to reduce processing costs, requirements. We sometimes, for example, increase productivity, prioritize the finished re-grind inserts used in certain processes surface, utilise a safe chip processing to intentionally reduce their size for further system and also to reduce vibration, noise use on other applications. Designing tools and burrs. To meet these varying conditions, for use across different processes requires we must be increasingly prepared to us to be completely familiar with each of provide comprehensive solutions. Such these processes and the quantity of inserts solutions include a wide variety of services to be used in them. In addition, it is also such as seminars for young engineers, important to design tools in such a way as to process testing in environments similar make it easier for the customer to conduct to those found at the customer’s site, acceptance testing after delivery, to make it technical services such as on-site product easier for the customer to sort for disposal, line inspections and the proposal of new and also make it simpler for the customer’s tools developed through CAE analysis.
YOUR GLOBAL CRAFTSMAN STUDIO 2
EYE on MARKET EYE on MARKET AUTOMOBILE INDUSTRY
Welcoming the Era of Next-Generation Vehicles Next-generation vehicle definitions and 4 major categories
Next-generation vehicles have Economy, Trade and Industry, Land, matter (PM). The four major categories attracted attention as a way to Infrastructure and Transport), next- of next-generation vehicles are (1) save energy and reduce the global generation vehicles are defined as electric, (2) hybrid, (3) plug-in hybrid environmental load. According to the environmentally-friendly vehicles with and (4) fuel cell. Next-Generation Vehicle Guidebook high fuel performance and low or no 2016-2017 (published jointly by the emissions of air pollutants, including Japanese Ministries of Environment, nitrogen oxides (NOx) and particulate
TYPE 1 EV : Electric Vehicles (EVs) Electric vehicles (EVs) are powered by an electric motor charged by Power Battery off-vehicle sources. They do not emit CO , and operational noise is Motor Control 2 Unit reduced significantly. Compared with gasoline vehicles, EVs have a more simplified structure with fewer parts. The parts are also smaller, making it relatively easy to decrease the overall size and weight of the vehicle itself.
TYPE HV : Hybrid Vehicles (HVs) Power 2 Motor Control Battery Hybrid vehicles (HVs) are powered by two or more distinct sources. Unit The most common combination is a gasoline engine and an electric motor. The electric motor is used when starting and driving at low Generator speeds while the gasoline engine is employed when accelerating. Engine Utilizing the advantages of each power source, HVs realize low fuel
consumption and reduced CO2 emissions.
3 YOUR GLOBAL CRAFTSMAN STUDIO EYE on MARKET
TYPE 3 PHV: Plug-in Hybrid Vehicles (PHVs) / Plug-in Hybrid Electric Vehicles (PHEVs) Power Plug-in hybrid vehicles (PHVs)/ plug-in hybrid electric vehicles Motor Control Battery (PHEVs) are powered by a gasoline engine used in combination with Unit a battery and an electric motor charged by off-vehicle sources. PHVs/ Gas PHEVs are powered by the electric motor whose charge is capable of Generator Tank Engine powering the vehicle for a certain distance and discharges zero CO2. When the battery charge drops, the gasoline engine is engaged to power the vehicle and recharge the battery, which enables it to travel longer distances.
TYPE Battery 4 FCV : Fuel Cell Vehicles (FCVs) Motor Fuel H2 Fuel cell vehicles (FCVs) are powered by an electric motor whose energy Tank Power Cell is produced by the chemical reaction of oxygen and hydrogen in the fuel Control cell. Because the electric power is generated by this chemical reaction, Unit only water is discharged in the process. These have attracted global attention as extremely eco-friendly vehicles.
The market share of EVs and FCVs will grow after 2040 While next-generation vehicles are took the initiative in the research and production of a hybrid vehicle and other thought of as the wave of the future, development of EVs; however, poor manufacturers are now accelerating they first appeared back in 1873, way battery performance and improved the development and spread of EVs, before gasoline-powered vehicles. exhaust purification technology HVs, PHVs/PHEVs, and FCVs. Automobile production in the United for gasoline vehicles dampened States around 1900 was approximately enthusiasm. According to the International Energy 4,000 units, 40% of which was EVs. The Agency (IEA), sales of gasoline and rapid improvement of gasoline vehicle This started to change in the 1990s when diesel-powered vehicles will peak in performance and their lower prices, the State of California enacted its Zero- 2020, after which HVs and PHVs/PHEVs meant that EVs disappeared from the Emission Vehicle (ZEV) Programme. are expected to take the lead in the market around 1920. It wasn’t until the This prompted major automobile automobile market. After 2040, it is 1970s that interest in EVs reemerged manufacturers around the world to predicted that the number of vehicles against the background of increasingly initiate full-scale development of EVs. with internal combustion engines will serious air pollution and concerns In 1997, Toyota was the first automobile steadily decrease as the number of EVs about dwindling oil resources. Japan manufacturer in the world to announce and FCVs grows.
Global Projection of Next-Generation Vehicle Fuel Cell Electric Vehicles
Ratios in Passenger Vehicle Sales Electric Vehicles
160 Plug-in Hybrid Vehicles
140 Plug-in Hybrid Vehicles (Diesel) 120 Hybrid Vehicles (Diesel) 100 80 Hybrid Vehicles (Gasoline)
60 Natural Gas / Liquefied 40 Petroleum Gas
20 Diesel Vehicles Passenger Vehicles Sales Sales Vehicles Passenger (million) 0 2000 2010 2020 2030 2040 2050 Gasoline Vehicles
Source: IEA Energy Technology Perspectives 2015
Special Welcoming the Era of Feature Next-Generation Vehicles
YOUR GLOBAL CRAFTSMAN STUDIO 4 FOCUS on PERFORMANCE
CASE 1 AISIN AW CO., LTD. Technical Centre
Joint development of innovative helical broaches Aisin AW Co., Ltd. holds the world’s top share of the automatic transmission (AT) market. The company’s work on advancing processing technology utilizing large-diameter helical broaches has drastically improved AT production efficiency. In this feature, we focus on a new project between Aisin AW and Mitsubishi Materials.
5 YOUR GLOBAL CRAFTSMAN STUDIO Technical Centre built in 2011 for the development of next-generation technology Committed to maintaining its position as the world’s No.1 automatic transmission manufacturer and to lead future automotive development
Founded in 1969 as an automatic its lead in the industry as the world’s the development of electronics. This transmission manufacturer, Aisin AW No.1 AT manufacturer. effort resulted in the successful mass Co., Ltd. is a subsidiary of Aisin Seiki production of a hybrid system in 2004 Co., Ltd. and one of the Aisin Group’s six FY 2016 sales reached 1.2 trillion yen, ahead of other manufacturers. “We would major companies. Since the development AT being responsible for 90% of that like to create a vehicle that we can operate of the 3-speed AT with the front-engine, number. Approximately 38% of the AT almost intuitively and one that inspires the rear-wheel-drive (FR) layout in 1972, units made by Aisin AW go to Toyota driver.” With such commitment, Aisin AW Aisin AW has continued developing Group, and the rest are delivered to more continues to lead the development of AT products that anticipate market trends. than 50 automobile manufacturers across to meet and exceed market expectations. It followed up commercialization of the 15 different countries. In 2012, cumulative world’s first FR type 8-speed automatic production of AT units exceeded 100 transmission in 2006 with the world’s million. As the leading global supplier first front-engine, front-wheel-drive (FF) of AT, Aisin AW keeps an eye on next- layout 8-speed AT in 2012 to help maintain generation mobility and advances
Aisin AW Technical Centre continues developing new-generation technology The Aisin AW Technical Centre features increasing technical development General Manager of the Manufacturing an innovative manufacturing system that capacity through the application of an Engineering Division’s Tool Engineering enables smooth information sharing innovative system that comprehensively Department, “The use of EVs is predicted and cooperation among departments in integrates all phases of new-product to grow and countries are preparing both the Engineering and Manufacturing development, from planning through for the implementation of tightening AISIN AW CO., LTD. Engineering Divisions. This new Technical to manufacture. Serving as a facility regulations around 2020. As a leading Centre was built in 2011 to integrate where Aisin AW can pass its DNA to automotive parts manufacturer, we are all departments engaged in technical the next generation of innovators, the also preparing for this.” Aisin AW has development for the commercialization of Centre sets the goal of maintaining a started development of new systems to AT, continuously variable transmissions lively human network for the continued ensure that it is ready for the emerging Technical Centre (CVT) and hybrid transmission units development of new products. The Aisin era of the EV. manufactured at different locations. AW Technical Centre is well prepared The Centre has approximately 3,000 for the development of electric vehicles employees that are committed to (EVs). According to Shinya Sugiura,
Parts manufacturing sites have as much drama as there are parts While Aisin AW supplies parts to cast iron for the oil pump and differential transmission. Its function is to connect manufacturers across the globe, the cases. Each has unique characteristics the engine and the driver; and the more company’s largest single customer and presents different challenges in luxurious the vehicle, the more important is Toyota Group, which accounts for manufacturing. Thousands of parts go a quiet ride becomes. AT’s from 20 years around 40% of total sales. Aisin AW was into each AT unit, and each one is essential ago were a simple 3-speed unit, but now established as a joint venture between in enabling a vehicle to run smoothly and they include up to 8 and even 10 speeds. To Aisin Seiki and the American automotive quietly. In the process of manufacturing AT fit the gears necessary for this degree of parts manufacturer Borg Warner, which is units with such a large number of parts, performance in a limited space requires a where the “W” in Aisin AW comes from, and the highly skilled engineers involved in much higher level of processing accuracy the American culture is deeply rooted in the design and development of each part for each part than ever before, and such the company. Harumichi Nakagawa, Group find it hard to avoid generating problems accuracy requires cutting tools that Manager of Tool Engineering Group 1 in for each other from time to time, but it’s deliver the highest possible performance the Manufacturing Engineering Division’s the creative energy they have that results and quality.” Tool Engineering Department says, in the best product possible. Step-by- “I can still find sizes written in inches in step, each AT unit takes form through a The most difficult aspect of AT old drawings.” painstaking process of production, and manufacture is ensuring that all there are as many stories that come from gear teeth meet the strict tolerances While the AT is generally unseen by car the process of development as there are determined by the design. To ensure owners, it is every bit as important as the parts developed. success, AT manufacturers and tool engine and just as complicated because suppliers like Mitsubishi Materials work of the planetary gears that make its According to Shogo Itoh of the Subsidiary closely to create new machining methods smooth operation possible.The three Material Purchasing Group, Material and develop new cutting tools. major materials used in the manufacture and Equipment Purchasing Department, transmissions are aluminum for the Purchasing Division, “After the engine, casing, steel for the gears and shafts and the most expensive part of any car is the
YOUR GLOBAL CRAFTSMAN STUDIO 6 Shinya Sugiura Harumichi Nakagawa Naoto Hattori Shogo Itoh General Manager Group Manager Team Leader Subsidiary Material Purchasing Group, Tool Engineering Department, Tool Engineering Dept., Group 1, Tool Engineering Dept., Group 1, Material and Equipment Purchasing Dept. Manufacturing Engineering Div. Manufacturing Engineering Div. Manufacturing Engineering Div. Purchasing Div.
Machining is the final process, and it has a significant influence on fuel efficiency and quietness There are many processes in the infinite. “I feel great pleasure when I find involved in gear cutting, has changed manufacture of AT units. Shinya Sugiura the best combination, and that includes my outlook significantly. I have come to says, “The machining process is the key details such as finding the optimum consider the mechanisms behind the because the accuracy of the gear, the cutting oil. It is often the case that solving phenomena I see in daily life, and this has heart of the AT, is determined by the just one problem in the machining changed the way I live my life. One of my cutting process.” If the part is not cut process increases the overall efficiency of coworkers liked to collect mini-cars. He correctly, then the AT fails to achieve production. There is no doubt that highly carefully observed the size and locations its potential. It’s not too much to say advanced machining technology has of the engines and transmissions, and that cutting process technology is what supported Aisin’s technical development considered how he could apply his makes the manufacture of ATs with new and has maintained the high quality of our observations to automotive technology, added value possible. “AT performance is products. Advanced machining technology weight balance and turning performance. determined by the accuracy of the overall is one of our fundamental assets,” said It surprised me to see his interest in toys, machining, and the outcome of this Shogo Ito. but it made me realize the importance of process has significant influence on fuel considering the reasons for and causes of consumption and quietness,” said Noto Large-diameter helical broaches are even a very tiny phenomenon.” Hattori, Team Leader of Tool Engineering precision tools often used in AT gear Group 1. processing. The number of teeth on one broach can number more than a few Depending on the quality of work thousand, but if a defect is found on only materials and the machining required one tooth, the product is considered scrap. determines the type of tool, heat Hattori says, “When we see a problem, it processing method and type of coating is absolutely essential to find the cause that are to be used. The combinations are of the defect.” Nakagawa says, “Being
Developing a new large-diameter helical broach with Mitsubishi Materials The trend of planetary ring processing Sugiura explains why they chose best partner for joint development.” has been shifting recently from the Mitsubishi Materials as a partner, “Their helical broach method to skiving. Aisin attitude toward product development was The joint project for development of the AW did not want to stand idly by and very forward thinking and they were clearly new large-diameter “Innovative Helical watch their superior processing methods motivated to take part in the development Broach” started in 2013. “Mitsubishi it had developed to become outdated, so of a new tool. We were very proud to have Materials let us see details of broach it initiated a project in conjunction with been a pioneer in the implementation of manufacturing that are usually not Mitsubishi Materials to develop a new the American broach in Japan. We felt shared outside the company. We type of helical broach. This project sought that developing a new future in cutting shared information on design and the to drastically improve productivity and utilizing broaches was our mission and fundamentals of manufacturing to reduce costs in ways that could not be that Mitsubishi Materials’ great attitude advance the joint project. We worked achieved by skiving. and quick response would make it the hand-in-hand with staff at the Mitsubishi
(Left) Tatsuya Nagaoka, Development & Design Section, Gear Cutting Tools Manufacturing, Akashi Plant, Mitsubishi Materials Corporation (Right) Manabu Kimura, Tool Engineering Group 1, Tool Engineering, Aisin AW Co., Ltd.
7 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS on PERFORMANCE FOCUS
Materials Akashi Plant to reach our goal of “For this project, we used the of measurement technology. We had to finding innovative ways to reduce the cost simultaneous engineering method that we surpass the level other manufacturers of AT manufacture. I really appreciated have employed at Aisin AW. We brought in were capable of achieving and because the their cooperation and hospitality. staff who would normally become involved relationship between precision and cost ”Engineers from both companies had only after the design phase has been involves trade-offs, friction between the serious discussions at the Akashi Plant completed to participate. It is extremely parties involved was hard to totally avoid. looking over full-scale drawings that rare, however, that we employ this method However, both Mitsubishi Materials and measured as much as 2 meters long, and with an external partner. We were hoping Aisin AW kept at it until they achieved high there were times when those discussions that Mitsubishi Materials would work levels of both.” became heated debates. In fact, there with us on this project like comrades in were disagreements about the best way arms fighting for victory,” said Sugiura. to proceed from the beginning of the He continued, “The key to achieving joint project. high precision was the establishment
Development of the helical broach, an innovation that achieves approximately five-fold greater performance than the existing broach
Innovative design, polishing and other hours every day. Reducing the frequency concepts were implemented in the of replacement to once every five days development of the new helical broach. improved productivity significantly. It has The original design concept increases been said that technical development for tool life, the polishing concept stabilizes skiving has been delayed because of our the re-manufacturing process, and focus on this innovative helical broach, the innovative machining technique but I disagree. If the limit of broaching enhances processing precision. These were to remain unchanged, we would (Left) Component before broaching three concepts resulted in a truly ground- not need to set a high goal for skiving. (Right) Component after broaching breaking helical broach. However, because broaching productivity has reached an incredibly high level, we a shared a commitment and goal that led “Although the existing broach only needed now need to reconsider skiving from the to success.” to be replaced once a day, this new helical beginning to match the new standard. broach lasts for five days. The time and Helical broach development has had a Both companies learned from each manpower it takes to replace a broach good influence on in-house operations other, reviewed results, supported is significant, and meant stopping the like this, in fact, it was recognized with each other and worked hard together production line for around one and a half the Manufacturing Improvement Award, step by step to overcome challenges which is a highly coveted in-house award along the way. Mitsubishi Materials at Aisin AW,” said Sugiura. will continue to partner with Aisin AW to support its leading position in the Nakagawa looked back on the process automotive industry and the future of and achievements of helical broach automotive development. development and said, “Mitsubishi Materials was quick to respond to our requests and questions and welcomed us with open arms at the plant. They were like comrades in our fight to develop leading-edge technology and this gave us
YOUR GLOBAL CRAFTSMAN STUDIO 8 FOCUS on PERFORMANCE
CASE 2 FIAT CHRYSLER AUTOMOBILES (FCA)
FCA Verrone Plant Partnership between FCA Group and Mitsubishi Materials Mitsubishi Materials Corporation (MMC) has built a firm partnership with Fiat Chrysler Automobiles (FCA) Group, one of the long-established automobile manufacturers in Europe, through the provision of a wide range of thoroughly-customized solutions.
9 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS on PERFORMANCE FOCUS
(Left) Leonardo Rossi, FCA Verrone Plant Chief (Right) Marco Rimoldi, General Manager of MMC Italia
FCA Verrone Plant manufacturing products for all FCA Group brands
FCA Verrone Plant is the production gasoline and diesel vehicles across all base for FCA Group. Located in Verrone, FCA Group brands (Fiat, Alfa Romeo, Piedmont, Northern Italy, the plant is Jeep, Chrysler, and Dodge). surrounded by forests and rice fields. This large plant measures 60,000m², including a 3,000m2 warehouse and produces manual (MT) and dual dry clutch transmissions (DDCT) for both
FCA Verrone Plant awarded World Class Manufacturing’s (WCM) Gold Level in 2015
FCA Verrone Plant’s extremely high and people development. The most production efficiency was recognized important of these is cost deployment, with the Automotive Lean Production which involves the identification of loss Award, a coveted award for automotive and waste in the production process. products, as well as the WCM Gold Level Designed to achieve zero occupational FCA Verrone Plant has also achieved award in 2015. The basis of these awards and environmental accidents, zero both an environmental-friendly manu- was FCA Group improvement plans for quality defects, zero waste and zero facturing system along with its high plants that manufacture Fiat, Chrysler, loss by taking economic impact into productivity. In fact, the plant is located CNH, and Iveco. WCM excels in total account, it resulted in the reduction of in the Baragge national nature reserve productive maintenance methodology costs across all plants. “We are very in Ticino. (TPM), lean manufacturing and total proud of the WCM award. The validation quality management (TQM) based on of the success of our efforts to achieve 10 managerial and 10 technical pillars. maximum efficiency throughout The 10 technical pillars are safety, management increases our motivation cost deployment, focus improvement, to continue striving to improve all autonomous maintenance and plant functions and enhances human workplace organization, professional resource cultivation. Receiving the Gold maintenance, quality control, logistic/ Level means the improvement that we customer services, early equipment have been committed to achieve has met management, early product manage- the standard of WCM,” said Leonardo ment, energy and environment, Rossi, FCA Verrone Plant Chief.
Reasons why FCA Group selected MMC (Mitsubishi Materials)
FCA Group chose Mitsubishi Materials for future manufacturing respectively. The partnership between FCA Group because of its great teamwork and cutting “Solutions provided by Mitsubishi and Mitsubishi is not limited to the technology know-how that has achieved were practical and easy to adjust to development of technical solutions high production efficiency. Mitsubishi’s achieve the desired results. As for the and the provision of advanced tools, technology was essential in helping FCA maximization of machinery capability, but includes training for FCA Group Group to achieve the WCM Gold Level. the tools were highly effective not only staff. The unique training programs MMC Italia General Manager Marco in reducing purchasing costs, but also are customized for individual plants Rimoldi and FCA Verrone Plant Chief in optimizing profitability throughout to achieve FCA Group goals as if they Leonardo Rossi discussed and agreed the entire production system,” were tailor-made suits. Through upon the roles each company would said Rossi. the joint efforts of Daniele Rametta play, as provider and user of the tools (Key Account Manager, MMC Italia),
FCA Verrone
YOUR GLOBAL CRAFTSMAN STUDIO 10 FOCUS on PERFORMANCE
Training program provided by MMC Italia (Marco Giannini, Technical Support and Daniele Rametta, Key Account Manager)
Marco Giannini (Technical Support, ensure a solid understanding of the tailored to individual participants. MMC Italia), Gabriele Raiano technology. The main contents vary “Outstanding collaboration enabled (FCA Verrone Process Improvement from basic to advanced, with basic us to create programs that matched Manager) and Mauro Beltrame knowledge including turning insert individual skill levels, and participants (FCA Verrone Know-how Engineer), machining methods and the meaning were very satisfied with the content. the first FCA Verrone training program of tool names, all in accordance with We are currently planning to provide was implemented in May 2017 and was ISO codes, basic knowledge required programs for more advanced skills. This well received by the 40 employees that for the selection of the correct tool, approach has been working smoothly,” participated. “This program focused on plus an advanced knowledge including said engineer Beltrame. Plant Chief FCA Verrone’s steel, its most common insert grades used for general steel Rossi added, “We pay special attention material to be machined, and cutting and for turning of harder heat- to the performance of the tools. Great technology know-how for turning,” said treated steels. performance leads not only to reduced Giannini, MMC Italia Technical Support. costs, but also to improved process They worked to bring participants of The standard training given to specific efficiencies. Elongating tool life and differing ages, degrees of experience groups achieved impressive results. The stabilizing tool performance can help us and knowledge to a standard level to most effective was personal training to achieve higher goals."
Results that FCA Verrone could obtain through the collaboration with MMC
The major advantages of the were ready to proceed within one week. ability to identify problems and find collaboration between FCA Verrone and Results of the tests showed that we could the best solutions based on logical MMC are the ability to have continual successfully increase tool life by more approaches. discussions among engineers and other than 50%. This is a huge difference,” key personnel from both companies, said Manager Raiano with a smile. “It is essential for us to improve and the shared checking of production “I also participated in the tool testing processing efficiency and speed", lines to identify problems and to confirm performance and reliability,” Rossi confirms. When we encounter establish solutions. said Patrizio Lalà, Tool Specialist at FCA a problem, we require measures that Verrone. “Flexible customized training, produce solutions in a timely manner. “We met the Key Account Manager at products and technical services that We also know that standard measures MMC Italia and asked him to extend achieve high productivity are keywords cannot solve problems promptly. Our the life of tools used in turning by 30%. at MMC,” said the Plant Chief Rossi. joint project with MMC proved this.” We considered solutions involving The greatest strength of collaboration improvement of boring bars, and they between FCA Verrone and MMC is the
11 YOUR GLOBAL CRAFTSMAN STUDIO FOCUS on PERFORMANCE FOCUS
(From the left) Mauro Beltrame (FCA Verrone Know-how Engineer), Gabriele Raiano (FCA Verrone Process Improvement Manager), Patrizio Lalà (FCA Verrone Tool Specialist), Daniele Rametta (MMC Italia Key Account Manager)
Special training for team speakers
The training programs that MMC select the employees with the necessary provides to FCA Verrone prioritize the abilities for each project. We have our cultivation of personnel that play key specialists with higher skills handle roles at production sites. FCA Verrone relatively difficult problems, and we Plant has invested a large amount in the ask on-site workers to handle the cultivation of team speakers. more routine problems directly at site,” said Rossi. “The team speaker position was implemented by FCA Verrone and has “We have asked MMC to create new been expanded to other plants. The title training programs that enable higher differentiates the position from team quantity and quality. In regard to quantity, leaders at plants producing automobile we would like to improve the efficiency bodies and emphasizes their different of basic programs to qualify as many specialties. The most qualified person employees as possible; and in regard to among the workers at the cutting quality, we would like to provide more processing sites is selected to be a specific, highly-specialized programs mediator between the production site that deliver practical and applicable manager and machine operator. Team content. Our final goal is to increase speakers are required to participate the overall specialization of the whole in a wide range of training programs workforce. We would like to establish to gain sufficient know-how of basic a system in which all our employees tools and machining processes and to can accurately perceive situations, improve their communication ability. analyze them to the degree possible at MMC Programs have been very useful the site, and understand the processes because they provided the best training and parameters that influence them, programs to the most suitable personnel. as well as master the technical terms WCM requires the categorization of required to exchange information with human resources according to capability tool manufacturers,” said Raiano. and specialization, which allows us to
What FCA Verrone expects from MMC
The services that MMC provides to and FCA Verrone, as a tool supplier are the quality of its services, the speed FCA Verrone are thoroughly customized. and user, is projected towards a bright of its response and its enthusiasm “MMC reports are extremely useful future. "I expect that MMC will keep regarding tests at the plant. Even when in sharing information at the plant,” sharing with us their know-how related we require solutions to issues that may said Beltrame. MMC Italia Key to technological development, and be outside the range that MMC would Account Manager Rametta added, “We that it will provide us with solutions, usually be expected to handle, MMC determined the format of the report and not only products, with the same staff work hard to provide results. It’s together because communication is the determination and results, as well as this attitude that puts MMC in a category most important product.” The sharing help us in basic and advanced training", of its own.” of information is essential to improving continues Director Rossi. speed and efficiency; the strengths of the plant. FCA is also working on the Process Improvement Manager Raiano development of a software application added at the end of the interview, “We’ve that allows users to check the state of known MMC for a long time and have all manufacturing processes from their worked together in the past outside Italy smart phones. and I really have a good impression of The collaboration between MMC Italia them. The advantages of MMC in Italy
YOUR GLOBAL CRAFTSMAN STUDIO 12 HISTORY OF MITSUBISHI HISTORY HISTORY OF
A water bucket made by Tsukumo Shokai Yataro Iwasaki, Founder of Tsukumo Shokai, (Made in November 1872). The three- predecessor of the Mitsubishi Group MITSUBISHI diamond mark was already in use. Vol. 6 Supporting the growth of the Mitsubishi Group
Mitsubishi Coal and mineral mining business in the 1880s expanded into the major business of Mitsubishi Group Materials (The photo is Takashima Mine).
On April 1, 2017, Mitsubishi Materials introduced a new company logo featuring three red diamonds. This logo represents the Mitsubishi Materials Group’s emphasis on expanding overseas markets with its technological capabilities and facilitating further global business expansion. This feature focuses on the history of Mitsubishi Materials Corporation, a history of support for Mitsubishi Group business expansion. The Imperial estate Sado Mine sold to Mitsubishi Goshi Kaisha by the government.
Mitsubishi’s corporate logo and mining business, purchased Yoshioka (1912-1926) and went on to be major the roots of Mitsubishi Materials Mine and started a metal refining members of Mitsubishi Kinyokai’s Corporation business. Thus, as well as its original group of 28 companies. shipping business, coal and mineral In 1870, Yataro Iwasaki, an official mining became a major pillar of the In line with these developments, of the Tosa Domain, established business. These would become the Mitsubishi Mining Co., Ltd. was Tsukumo Shokai, a shipping company foundation of Mitsubishi Materials established in 1918 to take over the approved by the domain. This was Corporation. Coal and Mineral Mining Division from the beginning of Mitsubishi. In 1873, Mitsubishi and the assets of the Mining the company name was changed to Mitsubishi Mining Co., Ltd. is Research Institute, which handled the Mitsubishi Shokai. Yataro wrote a letter established to handle Mitsubishi mining business. This new company to his brother Yanosuuke telling him, “I mining assets was the predecessor of Mitsubishi changed the name of the company from Materials Corporation. Mitsubishi Tsukumo Shokai to Mitsubishi Shokai. In 1908, Mitsubishi Shokai implemented Mining entered the cutting tool business The company logo is .” This was the a divisional system for its mining, in 1942 and in 1944, it started the mass beginning of the logo that has become banking and shipbuilding businesses production of powdered metallurgy synonymous with reliability. The root of in which each business employed products. Additionally in 1945 it started this logo was three diamonds adorning an independent, self-supporting production of special copper alloys. the flag flown on Tsukumo Shokai ships. accounting system. The implementation These aggressive business expansions It is believed that this logo integrated the of this system for individual businesses became the foundation for the current three layers of diamonds on the Iwasaki managed by a head office was a very Mitsubishi Materials. Family crest, and the three oak leaves of advanced approach in the Meiji Period the crest of the Yamauchi Family, whose (1868-1912). In addition, Mitsubishi Mitsubishi Mining Co., Ltd. Coal and head was lord of the Tosa Domain. established subsidiaries to enter a wide Metal Divisions were separated range of business fields. These became in accordance with the Excessive In the same year, Yataro expanded the independent in the Taisho Period Economic Power Deconcentration Act
13 YOUR GLOBAL CRAFTSMAN STUDIO HISTORY OF MITSUBISHI
A water bucket made by Tsukumo Shokai Mining Research Institute (Around 1920)/ Mass production (Made in November 1872). The three- Hashima Colliery became famous as Gunkanjima. of powdered metallurgy products started in 1944. diamond mark was already in use.
Naoshima Smelter & Refinery In 1950, the Metal Division separated from Mitsubishi Mining Co., Ltd. to established as the central smelter establish Taihei Mining Co., Ltd. This photo is the newspaper and refinery of Mitsubishi. announcement of the separation.
Mitsubishi Mining Co., Ltd. took over the Coal Mining Division from Osaka Smelter in 1906. Mitsubishi (Predecessor of Mitsubishi Cement Corporation). This photo is Kyushu Plant, Kurosaki Manufacturing Section.
Mitsubishi Mining Co., Ltd. encountered Co., Ltd. in 1973. Taihei Mining’s name spirit of mining, Mitsubishi’s major hardship in 1947, two years after the was changed to Mitsubishi Metal business, Mitsubishi Materials has end of the World War II. Under the Mining Co., Ltd. in 1952, and changed expanded its business aggressively. With influence of the American occupation again to Mitsubishi Metal Corporation its corporate philosophy “For People, policy, the Excessive Economic Power in 1973 to start the new phase of Society and the Earth,” Mitsubishi Deconcentration Act was established its business. Materials continues to protect its assets to dissolve large financial combines and traditions, creating new materials and Mitsubishi Mining became a Establishment of Mitsubishi Materials for people, society and the Earth with target. Mitsubishi Mining at that time Corporation its unique technology and aims to be a had capital funds of 407.4 million leader in the establishment of a sound yen and annual sales of 4,400 million On December 1, 1990, Mitsubishi material-cycle society. yen across 46 facilities, including Metal and Mitsubishi Mining & Cement 17 coal mines, 20 metal mines, and merged into Mitsubishi Materials 9 other facilities such as smelters, and Corporation. Forty years after Mitsubishi 69,672 employees. Mining’s Coal and Metal Divisions were separated in 1950, the companies On April 1, 1950, the Mitsubishi Mining merged into one company. This merger Metal Division separated to establish resulted in the solid establishment Taihei Mining Co., Ltd. It was a painful of Mitsubishi Materials’ position as a division for the company; however, comprehensive material manufacturer both Mitsubishi Mining and Taihei holding technology and products in a Mining continued growing under wide range of fields, including smelting, independent management. Mitsubishi cement, cutting tools, alloys, ceramics, Mining merged with Mitsubishi Cement chemicals, silicon, fuels, building Mitsubishi Materials (HQ) Corporation and Hokoku Cement to materials and nuclear power. establish Mitsubishi Mining & Cement Inheriting the assets, technology and
YOUR GLOBAL CRAFTSMAN STUDIO 14 CRAFTSMAN STORY
Craftsman Story Makoto Nishida: Tetsuhiko Honma: Hisashi Hara: Vol.7 Coating Technology Group, Material Designing & Manufacture Engineering Production Engineering Group, & Coating Development Centre, Group, Insert Production Dept., Production Engineering Dept., Research & Development Div. Tsukuba Plant Tsukuba Plant (Joined the company in 2000) (Joined the company in 1997) (Joined the company in 2002) For Turning Processing: CVD Coating Material Super-Diamond Coating UC51 Series Commitment to high performance surpassed the conventional wisdom of the industry
Immediately after the UC51 series was introduced to the market in 2005, monthly sales topped 1 million. Dropping the function of identifying used corners, an innovative idea at the time, the staff sought to prioritize ultimate performance. The all-black body has achieved performance that silenced those who had insisted on using the identifying function. We took a look at the backstories of the all-black super-even coating development.
1515 YOUR GLOBAL CRAFTSMAN STUDIO CRAFTSMAN STORY
UC5105/5115 MC5005/5015
How much could we they were very satisfied with the cutting see that the integration of two different performance. technologies could bring such a significant smoothen the surface? achievement. That experience was extremely Hara: Domestic tests showed a three-fold valuable for me. improvement in performance over existing – Would you please give us a little products. We sought and achieved the best – Following this, the MC50 series was background on the development of the performance in the industry, and this gave launched as the replacement for the UC51 series? us confidence to initiate sales of the all- UC50 series. black super-even coating. Hara: The UC51 series was launched Nishida: Of course our competitors' progress in 2005. Similar products by different – What challenges did you encounter was a significant factor in the development manufacturers whose cutting surface was during development? of the MC50 series, but we also wanted to smoothened (in black) had a known market develop tools for ductile cast iron, which has share. To exceed that share, we needed to Honma: When we were discussing ideas higher hardness than standard cast iron, and offer performance that was significantly at the beginning of development, my we wanted to offer cemented carbide CVD better. We considered smoothening the supervisor asked me to produce mellow, coated inserts for customers that machine entire surface of the insert because it was springy materials. I remember clearly cast iron using ceramic inserts. obvious that focusing on the cutting face wondering what he was talking about. alone would not maximize performance. Honma: The performance of the MC50 series Hara: Yes, we all wondered what was up. for machining FCD700 is exceptional. Nishida: Our competitors also realized We were discussing a cutting tool, but we that at the time. However, improvements in were asked to think of the development Nishida: MC5015’s middle-layer coating the smoothening process would increase in something of a mellow and springy way has been improved significantly to maintain insert production efficiency and allow the rather than a hard task. performance during interrupted cutting and identification of worn corners. Considering tool life is 2 to 3 times higher than the existing production costs and ease of use as well Nishida: But, when we checked the product. We also applied our patented as performance, however, they may have quality and texture of the tool, it is indeed TOUGH-Grip technology (toughening hesitated to focus on the entire surface. metaphorically mellow and springy in technology for coating) to the MC50 series for comparison with other grades, or, technically the first time. Honma: Significant extension of tool life speaking it is durable and versatile. can be achieved through the improvement – Do you have anything you’d like to say to of both wear and chipping resistance. The our readers? key to achieving both was the integration of surface and coating technologies. We Hara: When I joined the UC51 series examined a wide range of approaches for Outstanding performance development team, it was only my second surface processing before deciding upon gained tremendous year at Mitsubishi Materials. While we had the wet-blasting method. We were lucky to work on a wide range of properties, we to have a wet-blasting device on hand. We popularity maintained our focus on performance. I could readily verify a wide range of factors would like to tell young developers not to give and this helped us during the different up. That’s the ticket to success. phases, something that led to a significant – Did you expect this grade to be such breakthrough. a big hit? Nishida: As a developer, it is necessary to discover the rules and principles for each Hara: Removing the gold coating on the Hara: We were certainly confident about the phenomenon. If we understand these, we can surface of the inserts completely to make quality, but we didn’t expect that it would be apply them to the development of subsequent them all black meant sacrificing the ability so popular. products. to identify worn corners. At the beginning of development, the majority of our sales Nishida: Tool sales were supported by the Hara: Analysis at that time was at the staff was against the idea and this made it rapidly growing Chinese cast iron machining micron level while it’s now on a Nano scale. difficult to move forward with development. market. Word-of-mouth is a major factor in Enthusiasm is important in the drive for top the Chinese market; and once a customer performance in the industry and a cool head Nishida: Indeed, identifying worn corners takes to a product, its good reputation is required for logical analysis. is very important. However, I believed that spreads quickly. offering outstanding performance could Nishida: We developed this tool with a help our customers more. When we realized Honma: Since we only had one wet-blasting focus on cutting performance. From the that the establishment of new surface device, it was impossible to keep up with viewpoint of ease of use, we considered the processing and coating technologies would demand. Of course, we wanted to increase corner identification function as an important enhance performance more than expected, production to meet demand, but we were also performance metric. From now, we will the negative opinions about an all-black quite pleased with what we had achieved. develop products not only with a focus on insert gradually subsided. cutting performance, but also ease of use. Nishida: The key to success was having Honma: When we received feedback from surface-processing technology based Honma: We would like to expand the surface pre-sales field testing, we felt that our on the wet-blasting method, and having processing technology we have accumulated decision had been justified. Our customers coating technology capable of enhancing through development of the UC51 series and reported that it was a challenge to identify that surface-processing technology to the apply it to applications over a wide range of worn corners but as compensation, maximum extent. It was a big surprise to products.
YOUR GLOBAL CRAFTSMAN STUDIO 16 TECHNOLOGY ARCHIVE TECHNOLOGY TECHNOLOGY ARCHIVE
History of the large-diameter helical broach that supports automotive automation
Planetary gears are a key component in automatic transmissions (AT). The Large-scale tools shift from manual to automatic transmission required improvements in the production of these essential gears, and the large-diameter helical broach that support was developed to meet this need. The helical broach ensures the consistent machining required throughout the process, from roughing to finishing. We the automotive interviewed staff at the Gear Cutting Tools Manufacturing Department about the history of its broach development, including innovative products developed industry ahead of the global competition.
17 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE
TECHNOLOGY ARCHIVE
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to cut the high-precision gears • The sharpness of the broach and What is broaching? used in automatic transmissions precision of the edge are directly - the roughing, semi-finishing, and reflected on the workpiece. The Broaching is a method of processing finishing - all three steps in one higher the broach performance designed to enable the creation of process, significantly increases is, the higher the quality of the special forms on the interior surface productivity. surface and dimensional accuracy of the cylindrical bore, forms such of the finished product becomes. as splines and key grooves. The Characteristics of Broaching • It is possible to process complex edge of a broach is similar to the axial gears such as those with helix round-hole on the material. The Capable of forming precision angles. teeth are gradually formed as it interior gears on workpieces • Since the amount of cut per edge proceeds toward the centre. And and total amount of cutting can be finally formed into their completed Broaches with many teeth whose set in advance when designing the geometry by the time the broach is forms gradually change from broach, operators do not require pulled all the way through. Thus the roughing to finishing profiles have special skills to pull the broach entire gear forming process, from the following features: through a workpiece. roughing to finishing, is performed • Since the pressure created during in a single process. • Ease of the procedure to pull the cutting works towards clamping broach through a workpiece on a the workpiece, it is not necessary Creating the best cutting conditions broaching machine shortens the to have special jigs to clamp it. for the individual processes required time required for processing.
• High-precision machining Machining with a Gear Shaver Broaching possible within an extremely short time • Easy to process holes with complex shapes • Easy operation that does not require technical skill • Favorable surface and dimensional accuracy possible • Processing time is short, which is advantageous for • Processing requires more time. mass production • Difficult to process bores with specific shapes
Part 1 1962 ~ Akashi Plant started its operation After 1955, the rapid growth of the leading-edge equipment for specific were expected to offer significant merits Japanese manufacturing industry processes such as polishing, quenching. for customers since gears could be spurred demand for cutting tools. To As well as the inspection facilities to aid processed with accuracy and efficiently meet this demand, Mitsubishi Materials manufacture of various cutting tools, with them. Therefore, Mitsubishi opened its Akashi Plant in 1962. The including drills, end mills, reamers, Materials started working on the Akashi Plant had a wide range of and broaches. Broaches in particular development of broaches early on.
Front teeth Front teeth outer diameter Finishing teeth Front pilot outer diameter Rear pilot Pull end Follower end
Nick Finishing Front pilot Semi - teeth Rear pilot outer diameter Roughing teeth finishing outer diameter teeth Shank length Teeth length Rear shank length Total length Fig. 1 Inner Surface Broaching Tool Part Names
YOUR GLOBAL CRAFTSMAN STUDIO 18 TECHNOLOGY ARCHIVE TECHNOLOGY TECHNOLOGY ARCHIVE
1990 ~ thick teeth. Due to the large size, a big Rapid implementation enough precision measurement device at 2 that time was unavailable, meaning it was of automatic transmissions necessary to separate the prototype into the main body and the shell. The form of the broach end is directly transferred to increased the demand for broaching the workpiece. It was difficult to achieve the required precision with the assembly- As the implementation of automatic better precision than gear cutting and it type broach. Several prototypes were transmission accelerated in the 1990s, only requires the simple operation of the provided to automatic transmission production efficiency of planetary gears broach being pulled through a workpiece manufacturers; however, most of them that have relatively large diameters had on the broaching machine. were returned due to their poor precision. to be improved. Before the development To take full advantage of these benefits, For the assembly type, the performance of broaches, gears were cut with gear Mitsubishi Materials started development of the blade in the shell part affects the cutters. Gear cutting required three of a large-diameter helical broach, an precision of the gear teeth. This required processes, roughing, semi-finishing and advanced model of the existing spline making micron-level adjustments to the finishing that required approximately 2 to broach. The first prototype was an form of the blade in the shell. Mitsubishi 3 minutes per gear. Broaching required 30 assembly of the roughing gear (main engaged in a process of trial and error to seconds or less for each gear, which meant body) comprising a cutting blade for improve the blade until a stable level of a 4- to 6-fold improvement in productivity. the outer periphery and a finishing gear precision was achieved in 1995. In addition, broaching achieves much (shell), which was a cutting blade with
3 2000 ~ Development of an innovative measurement device contributed to the world’s first one-piece broach
Mitsubishi Materials started mass device for the tooth form. This was the broach. The one-piece helical broach can production of assembly type broaches in first attempt in the world, and Mitsubishi significantly reduce manufacturing costs the 1990s and also began development Materials’ achievement was recognized through one step manufacturing of both of a new type of broach. The work started with the Japan Society of Mechanical body and shell and realize high-precision on the development of an one-piece Engineer Encouragement Prize. The gear machining. In addition, the cutting broach that combined the main body engineer received his doctorate in load on each blade can be optimized, and the shell part. Due to not having a engineering at Osaka University Graduate which reduces abrasion on the entire device to measure the precision of the School of Engineering. A summary of his broach and increases the tool life thereby teeth on an one-piece broach, it was study was as follows: “Precise grinding extending the time before regrinding is impossible to grind the teeth with high of the form of the teeth used for spur required. Furthermore, the disassembly, precision. The large-diameter helical and helical gears requires measurement reassembly and phase adjustment of broach used to manufacture planetary of grinding errors caused by grindstone the shell required for regrinding on the gears for automatic transmissions would and tooth formation, analysis of the data, assembly-type broach are unnecessary have an outer diameter of ø100 – 180 creation of an automatic error correction with a one-piece broach, which also and a total length of 1,500 – 2,000 mm. program, and immediate feedback to reduces costs. These merits pleased our This necessitated the adoption of an the grinding machine. Combining these customers and the reduction of work for assembled type of broach that separated systems together can secure the required regrinding in particular is highly regarded the shell part, whose teeth had to be precision in gear grinding.” by overseas automatic transmission very precise, but due to the smaller, size manufacturers. precise measurement was possible with The use of this new on-board a gear measurement device. However, measurement device for tooth form on the precise measurement of a large one- CNC grinding machine, made it possible piece broach demanded development of for the one-piece broach to have the tooth a new measurement device. A Mitsubishi form to be ground with high precision. Materials engineer succeeded in creating This led to the successful development an innovative on-board measurement of the world’s first large-diameter helical
19 YOUR GLOBAL CRAFTSMAN STUDIO TECHNOLOGY ARCHIVE
TECHNOLOGY ARCHIVE
2010 ~ Setting 4 further goals
While promoting the development of the that are off-normal types. The number of one-piece broach, Mitsubishi Materials grooves also varies. For example, the teeth has also worked to improve the assembly- on the main body are reduced to from 4 to type broach. Groove types include a ring 6 while those on the shell are increased to groove (right angle to the axis) and a helix from 8 to 10, which improves sharpness. type (off-normal). The ring groove type causes a significant change in cutting load The one-piece broach also has the same compared with the helix type, causing three types of teeth, and a one-piece shorter tool life. The helix type causes less broach whose teeth are changed on the change in cutting load, which improves main body and shell has been under both the precision of the tooth form and development. increases tool life; however, it requires special equipment for regrinding. The manufacture of high-precision broaches requires the strict control of There are three assembly-type broaches. temperature during grinding. Since the accuracy in the final product. Mitsubishi One is a combination of both main body grinding requires a significant amount Materials continues its search for ways and shell at a right angle to the axis. of time, the temperature needs to be to manufacture even higher quality and The second is a combination of the main maintained within a narrow range to higher precision broaches while reducing body at a right angle to the axis while the prevent the grinding machine from even slight changes in temperature. shell is an off-normal type. The third is a expanding and contracting that could cause combination of both main body and shell variations which would influence pitch
Twisted Groove Type Ring Groove Type (Off-normal) (Right angle against the axis)
Looking back on the history of helical broaches
Nishikawa: The Gear Cutting Tools expectations. This is perhaps the Manufacturing Department, which most enjoyable part of manufacturing manufactures broaches is in close broaches. We have developed large- contact with our customers. Since the diameter helical broaches, and some of cutting tools are made to be used by our these exceed 2 meters in length. Only a customers, their feedback after use and small difference in the blades of a broach problems they have are very important has a big influence on tooth precision in to us. Sometimes they have complaints, the final product. For example, the very which we take very seriously; but in slight honing of the cutting edges by (Left) Mitsuo Nishikawa, General Manager, Gear addition to addressing any issues they hand, sometimes improves precision. Cutting Tools Manufacturing Department may have, it is important to develop tools This cannot be explained by theory, and that are even more useful for them. The cannot be done by just anyone. This is why (Right) Kensuke Kohno, Manager, Gear Cutting repetition of this cycle has provided the it is important, that such precision tools Tools Manufacturing Department, Development & foundation for our growth. can be adjusted in such an analogue way. Design Section Kohno: Precision tool manufacturing does not always follow theoretical
YOUR GLOBAL CRAFTSMAN STUDIO 20 ABOUT US ABOUT
A logistics network that supports manufacturing sites ABOUT US throughout the world Mitsubishi Materials promptly and efficiently delivers more than 40,000 products to customers all around Logistics Division the world from five global logistics centres.
Unification of inventory implemented our Zero Stockout Project management through a global network in 2000, and have initiated a unique Mitsubishi Materials sells products inventory system. The Logistics Division around the world, which makes it currently provides unified inventory important for us to have logistic management for individual logistics Ask the Manager! strategies that allow prompt delivery of centres around the world to maintain the our products at the lowest possible cost. optimal balance of supply and demand. Eiji Koga General Manager, Logistics Division The work of the Logistics Division We continue enhancing such approaches is classified into two major roles. to seek an ever more efficient logistics One is “Design and Management,” system to satisfy our customers with We are now setting the which involves creating and executing prompt delivery. We also continue to goal of delivering customer-oriented strategies. The optimize customer services through the products to all other is “System Development,” which use of different packaging for different customers around is supporting the execution of these regions, labeling and special product the world within strategies. marking according to the needs of 24 hours individual customers. In regard to design and management, we have established logistics centres at five Building a supply chain that locations around the world to realize an satisfies customer expectations ideal product supply system. Specifically, We are currently working on improving in addition to the Global Distribution the efficiency and lowering the cost Centre (Narita, Japan), we have of the current logistics system, and established the European Distribution developing our ability to predict changes Centre (The Netherlands), the North in the environment regarding logistics American Distribution Centre (Los services through oversight of the entire Angeles, U.S.A.), the Asian Distribution supply chain. We share, for example, Centre (Singapore) and the China real-time data among our five logistic Distribution Centre (Shanghai, China). centres to ensure the smoothest In regard to system development, we transfer of products and prevent long-
21 YOUR GLOBALGLOBAL CRAFTSMAN CRAFTSMAN STUDIO STUDIO term storage. In addition, we also strive and logistics, results in digitalized and information on a continuing basis. The to realize the most strategic supply accumulated data; however, the system key to the improvement of our services chain possible through the efficient is not yet perfect. We continue to work is sometimes hidden in our daily lives application of the Free Trade Agreement on establishing the ultimate supply outside the industry. We look for hints, A logistics network (FTA). It is important for us to not chain system, a system that enables us implement them without hesitation, and only manage the logistics of products to respond to the full range of changes strive to accumulate experience that manufactured and sold in individual through the visualization of necessary ensures future improvement make the that supports regions, but also to respond effectively information in real-time. system even more efficient. to the FTA, Trans-Pacific Strategic manufacturing sites Economic Partnership Agreement Striving for We work in a great environment that (TPP), and Regional Comprehensive customer-oriented logistics allows us to use highly-advanced internet Economic Partnership (RCEP) to ensure While we prioritize quick delivery, we resources. Taking advantage of this, we throughout the world the efficient transfer of inventories also focus on improving the entire supply focus on identifying information with the between neighboring countries. chain through the implementation of the potential to drive service improvement, Furthermore, meeting customer needs most advanced IT based on our desire to and establishing an optimal global requires that we effectively handle the achieve the highest degree of customer network capable of delivering products number and management of customer satisfaction. Our goal is to realize an to customers within 24 hours. This will lots as we reduce the time required environment that enables the delivery make DIAEDGE the tool-of-choice for for distribution. We need, therefore, to of products to customers anytime, our customers. fully utilize cutting-edge IT. A great deal anywhere. Delivering better services to of information on orders, deliveries, our customers requires that we gather
Global Network
Narita Netherlands (Global Distribution Centre: GDC) (European Distribution Centre: EDC)
Singapore Shanghai Los Angeles (North American (Asian Distribution Centre: ADC) (China Distribution Centre: CDC) Distribution Centre: NADC)
YOURYOUR GLOBAL GLOBAL CRAFTSMAN CRAFTSMAN STUDIOSTUDIO 22 CUTTING EDGE CUTTING
EDGE Vol. 6 Tools that collect chips Qing NEO Chip collection tools were introduced 30 years ago Chip collection is an eternal theme in ago Mitsubishi Materials approached Not only do chips have the potential metal cutting. The improper handling this problem from a completely to damage the interior surface of the of chips can lead to a wide range of different perspective. Suction, like cylinder block, they also need to be problems, including compromised using a vacuum cleaner during cutting, removed, which significantly affects quality of the machined surface and was applied. In 1986, this idea was both the quality and efficiency of damage to the cutting edge. Generally incorporated into Qing cutters. This processing. In order to address these speaking, the focus of improvement special tool was designed to improve issues, it was proposed to collect the has traditionally been on chip breakers chip collection during face milling for chips during cutting. This is the history and coolants. However, around 30 years automotive engine cylinder blocks. of Mitsubishi’s chip-collection tools.
Evolving Qing cutters The first Qing cutter (QSV type) was and was adopted by many customers. Following the introduction of these introduced in 1986. It adopted a dust- The third type of Qing cutter was innovative developments, a wide range collector system which lifts chips with developed in the late 1990s. Returning of chip collection tools were developed a guide plate and then vacuums them to the basic concept of chips not being and sold by many other manufacturers. through a casing with a collector. While collected, but instead being discharged However, the support and maintenance the chip collection capability is highly away from the workpiece. This was for these are costly. In addition, stable, it requires hoses and a collector achieved using by centrifugal force to cellular manufacturing has advanced that are relatively expensive. To improve automatically direct the chips toward as a part of chip prevention and this convenience, a second Qing cutter was a conveyor and thereby alleviate the has caused a gradual decline in the developed (QWA type) at the beginning need for both the dust collector and demand for chip collecting tools. This of the 1990s that applied a double-air air. In addition, it allows a design with prompted many tool manufacturers system. It works by pumping air into a very simple structure, which helps to to withdraw from the manufacture of the case to create a cyclone to blow keep the price of the tool relatively low them; however, Mitsubishi Materials the chips, and then collects them with and enables the use of automatic tool has continued manufacture to meet the an air-amplifier. This was very effective changers on machining centres. existing demand. in processing cast iron and aluminium
1st Qing Cutter 2nd Qing Cutter 3rd Qing Cutter
23 YOUR GLOBAL CRAFTSMAN STUDIO CUTTING EDGE Body structure The establishment of the Arbor most advanced Qing NEO (with a variable flute)
Bearing In 2015, Mitsubishi Materials started on the development of the 4th Qing cutter, the Qing NEO, upon request from Toyota Auto Body Co., Locknut Ltd. Qing NEO comprises an arbor, a bearing, a locknut and a case Case that covers the cutter. This collects chips generated around the (base) edge of the tool and discharges them from the base of the arbor to an external collector, it is an effective design that exerts a high chip-collection rate. While only face milling cutters were mounted on the 1st to 3rd Qing cutters; which limited the variations, Qing NEO is capable of using a wide range of tools, including face milling, profile milling and deep hole cutters. The airflow speed around the Case edge of the tool blade is 10,000 – 40,000 mm/s, which sufficient (tube) to collect chips and they are forced into the channel installed in the arbor, and then into the case via centrifugal force generated by the airflow and the tool rotation. Currently, advancement of Cutter the development of Qing NEO is underway for an automatic tool change type and also under consideration is the application of Qing NEO to turning tools.
Chip collection effect Cutter structure vc=130m/min, fz=1,3mm/tooth ap=1mm, ae=35mm, L200m Machining the L200m block (1pass) Flute Existing AJX Scattered chips 0.0390 kg
Qing NEO Scattered chips 0 kg
Guide plate Looking back on development (Left) Nobukazu Horiike Industrial Tools Group, Indexable Tools Development Centre, R & D Division (Joined the company in 1988) Horiike: I was involved in the development of the 2nd and 3rd Qing (Right) Takahiro Sato Advance & Creation Tools Group, Machining cutters. Although customers had already asked us to develop Technology Centre, R & D Division (Joined the company in 1987) a Qing cutter to machine metal moulds, we did not have three- dimensional CAD or the technology required to analyze fluid phenomena such as sucking chips and our manufacturing technology was not sufficiently advanced for the development of such a product. However, recent progress in a wide variety of technologies has allowed us to design mechanisms that could not have been thought of in the past. We hope this new Qing cutter will be as popular with customers as the previous versions have been.
Sato: Qing NEO was successfully manufactured because we could imagine the final output at the initial stage of design. I gained knowledge about chip collection tools and related technology, including chip collectors, hoses and bearings, that are not related to the usual tool development and this broadened my horizons as an engineer. I would like to focus on the reduction of costs to increase customer satisfaction and expand the lineup of the cutters to broaden the range of use.
YOUR GLOBAL CRAFTSMAN STUDIO 24 CUTTING EDGE CUTTING Special Talk: Toyota Auto Body Co., Ltd. Ideal teamwork EDGE could develop Qing NEO Toyota Auto Body Co., Ltd., with which we jointly developed Qing NEO, was established in 1945 as a truck body manufacturer in Toyota Group. It has expanded business to include commercial vehicles, mini-vans and SUVs. Through a consistent domestic development and production system, its products have effectively responded to market needs. Furthermore, the company has also engaged in the design and development of a wider range of products. These include welfare vehicles and devices that support elderly and disabled transport, as well as micro-electric vehicles that are slated to become the next generation in personal mobility. In this feature, we ask Mitsumasa Okuda, Akihiro Idota, and Satonori Matsumoto of Toyota Auto Body to give us the backstory of the development of Qing NEO with Mitsubishi Materials. Automation of metal mold processes. It was at that point that we Matsumoto: Although we had difficult considered the benefit of developing a requests every time we talked, they processing dedicated tool for chip collection. quickly found solutions that met our needs. Prototype improvement after each – How did the joint development of Qing Sato: Our first meeting was in June 2015. inspection was also very quick, which NEO come about? made me feel very confident about their Idota: We first drew rough pictures to work. Okuda: The Metal Mould Section illustrate our concept and paid a visit manufactures press molds for body to the Mitsubishi Materials Tsukuba Idota: We presented our request in June panels and because the press moulds Plant. At first we weren’t sure if and by the mid-September, Mitsubishi for commercial vehicles, mini-vans and Mitsubishi Materials would accept such Materials had completed a prototype; SUVs are large, means they generate a a complicated request, however, the staff including the main body and the case, and large amount of chips during machining. there were eager to become involved. not just a design model. Currently, dealing with the chips requires that machining be brought to a halt, taking Okuda: Although Mitsubishi Materials Sato: When we carried out the in-house valuable time away from production. had manufactured the Qing cutter, we inspection in September, we confirmed Since the automation of processing wanted a cutter designed specifically that there was no abnormality in is essential for reducing costs and for mould machining, which meant machining; including chatter marks, and increasing productivity, chip removal is an Mitsubishi Materials would have to start the chip collection rate exceeded 90%, important issue. We knew that there was from scratch. However, their enthusiasm a tool designed for chip collection during to work with us on this was clear from the machining and we thought that using this start, which pleased us greatly. (From left) Takahiro Sato (Mitsubishi Materials), might be the right approach to realizing Akihiro Idota and Satonori Matsumoto more effective automation. Sato: Thank you so much for your kind (Toyota Auto Body), Yoshiyuki Sugiura (Mikawa words. When I heard their request for Office, Sales Division, Mitsubishi Materials), – When did you start working on the first time, I was a little worried about Mitusmasa Okuda (Toyota Auto Body) the automation of press mould whether or not we could meet their needs. manufacturing? What they needed would require us to defy gravity to collect the chips and we Okuda: We decided to change the had to give it a great deal of thought. My fundamental method of metal mould experience in developing drills helped me manufacturing in 2012. As an important to conceptualize a new shape and when part of this we discussed the reduction this concept began to evolve in my mind I of waste during individual manufacturing felt we would probably be able to succeed.
Mitsumasa Okuda: General Akihiro Idota: Project Manager, Satonori Matsumoto: Metal Mold Manager, Machinery Engineering Machinery Engineering Division, Group, Machinery Engineering Div., Division, Machinery and Tool Dept. Machinery and Tool Dept. Machinery and Tool Dept.
25 YOUR GLOBAL CRAFTSMAN STUDIO CUTTING EDGE
which met our target. We felt that we had collection rate. However, we worked satisfaction when everyone else involved succeeded. diligently to identify the cause and create is satisfied. a solution for each problem that we Partnership seeks magical encountered. Okuda: While value has been shifting from products to services, the desire to machining Sato: During machining on a 75-degree create equipment capable of increasing angle, we still have a lot of uncollected quality and reducing costs will continue. Okuda: When I saw the machining chips. This is an issue we need to focus I am proud that the machining of metal test, I was amazed. Since having chips on from now. moulds are a part of what creates value during machining was natural for me, in products. it was incredible to see that they were Okuda: When we changed the entire automatically disposed of. design to eliminate the interference Idota: There are still many undeveloped between the case and arbor, the chip fields, and Qing NEO was one of these. Sato: We were very happy that everyone collection rate was already at about 96% Additionally, materials that are hard to cut was amazed to see no chips during to 97%, and more than 90% on slopes. We with existing technology are constantly machining. That motivated us to strive were satisfied with the results, but Mr. being developed, meaning there is always for even greater customer satisfaction. Sato worked to make those results even a great potential for the creation of It was exhilarating to impress customers better. A major goal, using Qing NEO with innovative metal cutting technologies. by delivering performance that surpassed an ATC, should be attainable and we are their expectations. still looking to identify ways to reduce Okuda: Toyota Auto Body has often manufacturing costs. customized existing tools; however, we Idota: Mr. Sato was very helpful rarely develop tools from scratch jointly and responded quickly to meet our Idota: The relationship we developed like this with another company. I would expectations. He always found solutions during this joint development allowed like to find more business partners that to issues we brought up at meetings and us to feel comfortable about exchanging are willing and able to work like this with included them in the next prototype. opinions freely and honestly; and this led end users. I am confident that despite the to success. We continue working together challenge it presents, halving the current Sato: Everyone was very happy to be able with the hope of bringing manufacturers machining time will be possible. I would to solve the problems we encountered. of peripheral equipment and processors like to realize the ideal machining method It was my first experience discussing into future projects. for press moulds. problems and solutions with customers in joint development, and we took our – Before we finish, I would like to ask you time and discussed all issues until we what it is about metal cutting work that were satisfied that we had come up with interests you. the best solution. I enjoyed working with Toyota Auto Body staff. Sato: At first glance, metal cutting looks very simple; but in fact, it is Idota: In November of each year, we very complicated. Each customer has present technical improvements that we unique goals, such as chip removal, the have been working on. One presentation elongation of tool life and achieving a I gave was on Qing NEO using a prototype good finished surface, and there are many that I had asked Mitsubishi Materials to different ways to approach these. As we have ready for me on a short deadline. I achieve each goal, I feel the satisfaction showed the chip removal operation and of seeing that we are moving closer to the everyone in attendance was impressed ideal. with its effectiveness. Matsumoto: For me, it is that the value of – Did the development go smoothly? what we have planned and carried out can be quantified. For example, chip cleanup Idota: The shape of the workpiece and has been reduced from one hour to just a style of machining sometimes created few minutes, meaning overall machining problems such as interference between time has been halved. Our achievements the case and arbor or a reduced chip are clearly visible and it brings me great
YOUR GLOBAL CRAFTSMAN STUDIO 26 Mitsubishi Materials | Advanced Materials & Tools Company YOUR GLOBAL CRAFTSMAN STUDIO 006 http://www.mitsubishicarbide.com Your Global Craftsman Studio Vol. 6 Studio Vol. Craftsman Global Your Department Strategy Business Company & Tools Materials Advanced Corporation Materials Mitsubishi of of the contents or reproduction The copying without and photos, this journal, including text is prohibited. permission BM006E The meaning of our logo holding on a circle, standing people, shows Our logo the earth. Holding represents hands. The circle and succeed to grow commitment our hands reflect work and closely “hand in hand” with our customers the globe. across performance improve with them to of ideas. It embodies a variety The shape of the logo with combined tools” “cutting of image the captures Materials “M” of the Mitsubishi the dominant letter symbolises a flame that name. It also depicts brand craftsmanship. for our passion 2018.08 (8.0 DP) - Printed in Germany 2018.08 (8.0 DP) - Printed perceive the shift to next-generation automobiles pessimistically. In pessimistically. automobiles next-generation the shift to perceive and terms in absolute machining has decreased the need for fact, However, fierce. increasingly will become in the industry competition It is in demand does not signal the end of the industry. the reduction opportunity. business the birth of a new as a valuable serve to continues industry I hope the cutting tool in that students an industry industry, the automobile partner for career. as a future to looking and engineering are science Nada Yutaka Chief Editor Editorial Note Editorial The publication of the MMC Magazine Vol. 6 was made possible made possible 6 was of the MMC Magazine Vol. The publication and people, and dedicated of many talented the cooperation through those who accepted to my deep appreciation express to like I would cooperation. for our requests of a continuation as industry automobile the on focuses issue This automobiles. of next-generation trend the future featured 2. We Vol. within a period of change significantly can predictions trend Market experienced the most months, and this means that even a few just opinions. differing wildly have can minds in the industry is also closely of automobiles that the history say much to It is not too to tend manufacturers Tool tools. of cutting with the history linked YOUR GLOBAL CRAFTSMAN STUDIO GLOBAL YOUR MITSUBISHI MATERIALS It is the studio where we think, share, create and develop together together and develop create think, share, we where It is the studio meet their specific needs. solutions to exciting with our customers, It is the place where you can: you where It is the place and products. technologies Find state-of-the-art in the world. anywhere Find solutions, anytime, from and product trends technology about the latest our excitement Share innovation. We will strive to become the only tool manufacturer globally globally manufacturer tool the only become to will strive We our for a unique service studio”, craftsman personal “your offering customers. We are committed to responding promptly to customers’ challenges challenges customers’ to promptly responding to committed are We of a with the dedication success their to contribute actively and to craftsman. professional Mitsubishi Materials is not just a tool manufacturer a tool is not just Materials Mitsubishi