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Industry 4.0 Strategies to Inspire Metalworking Solutions

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Industry 4.0 Strategies to Inspire Metalworking Solutions VER 1 - 2018 The LOGIQ of Industry 4.0 for Cutting Indexable Tools A Road Map For Effective Machining Intelligently Tool Manufacturers Challenge Solid Carbide Cutting Tools In The Taking the concept of machining What does Industry 4.0 signify For Small Diameters Automotive Industry intelligently even further by in practical terms and how do Precision and performance Pinpointing automotive OEM applying logical improvements we apply related technologies advantages position indexable needs to create smart combined to tool development [p. 4] to our processes? [p. 8] solutions competitively against tools that improve productivity solid carbide tools [p. 30] and reduce cost per unit [p. 44] Industry 4.0 Strategies To Inspire Metalworking Solutions www.iscar.com Become an INDUSTRY 4.0 Master! System Integration IoT Robots Big Data Cloud 3D Simulation ISCAR’s Easy to Use Digital World of Applications Web Apps E-CAT CLOUD Mobile Apps Table of Contents The LOGIQ of Machining Intelligently 4 Industry 4.0 for Cutting Tool Manufacturers 8 A New Look for Gear Milling? 18 Harmonizing Vending Systems with Industry 4.0 25 Indexable Tools Challenge Solid Carbide for Small Diameters 30 Machining Miniature Medical Parts 36 A Road Map for Effective Cutting Tools in the Automotive Industry 44 The Right Grade for Industry 4.0 Productivity 50 ISCAR 3 The LOGIQ of Machining Intelligently This year has seen ISCAR launching its new LOGIQ line with a series of major events at ISCAR locations around the globe, where thousands of customers and ISCAR salespeople have been captivated by ISCAR CEO and IMC president Jacob Harpaz’s comprehensive and compelling presentation featuring ISCAR's latest cutting tool developments. An industry leader and innovator in the world of procedures to meet these objectives. Machining metalworking, ISCAR has taken the IQ concept of logically responds to this need. ISCAR provides machining intelligently even further by applying logical the tools to make it happen. improvements to tool development. The result is the LOGIQ range of tooling solutions that both predicts LOGIQ applications have created new tool and fulfils customer needs. LOGIQ represents a families, upgraded existing lines, and inspired smart logical progression in a series of strategic innovative product ranges to maximize equipment moves to implement Industry 4.0 standards while utilization and optimize performance. Listening to ensuring continuity and stability. customer concerns and staying ahead of market developments, ISCAR’s product managers, R&D Industry 4.0 directives - to integrate interoperability, engineers and designers have combined their technical task assistance and decentralized decision- expertise and experience to develop highly effective making into factory practices - challenge machining and logical tool solutions that meet today’s machining centers to review their operations and adopt center demands. DUSTRY 4.0 MACHINING INTELLIGENTLY 4 ISCAR IMC President and CEO of ISCAR, Jacob Harpaz ISCAR 5 LOGIQ Campaign Launch at ISCAR Headquarters In an industry where every second makes a difference strength – a key factor for boosting productivity in and every movement counts, logical strategic design unfavorable cutting conditions. The latest cemented and tactical enhancement of even the most basic carbide grades reflect ISCAR’s forward looking cutting tool can contribute to increased productivity, knowledge and know-how in powder metallurgy and less wastage and lower costs. coating technologies. The toolholding line includes LOGIQ's unrivalled, out of the box tool innovations new heat-shrink-fit and vibration-dampening devices, include new cutting geometries and locking which significantly improve performance when tool mechanisms for stable, vibration free machining rigidity is critical. with higher repeatability. The indexable inserts are equipped with sophisticated chip formers and The new LOGIQ milling solutions include strong, contain geometries that facilitate soft cuts at high durable inserts and milling heads with enhanced feed rates. capabilities. The LOGIQ turning applications offer new solutions to decrease machining loads, produce Solid carbide tools are enriched with new designs thinner and wider chips, and resolve vibration issues that feature substantially increased anti-vibration and coolant flow capabilities. DUSTRY 4.0 6 MACHINING INTELLIGENTLY The LOGIQ drilling tool concepts provide advanced From concept to realization, LOGIQ-inspired tools productivity solutions for high accuracy and reflect ISCAR’s commitment to create and deliver repeatability, to reduce machine cycle time and high quality products that contribute to increasing produce high-end machined components. productivity and profitability. The LOGIQ lines feature LOGIQ3CHAM to The fourth generation of the Industrial Revolution significantly improve drilling productivity; has unveiled new standards and requirements for LOGIQ4TURN for enhanced performance in general- machining metals. duty turning operations; LOGIQ4FEED, which ISCAR is at the forefront of this important industry enables rough milling at high metal removal rates; trend, developing relevant technologies and LOGIQ8TANG, a new 90° square milling shoulder; implementing methods of effective machining to LOGIQ5GRIP, a versatile and high-efficiency solution reflect and respond to the dynamic needs of the for parting and grooving, and other tool families metalworking industry. comprising hundreds of new products; each designed and developed to perform essential tasks in the most efficient possible method. LOGIQ Campaign Launch in Las Vegas, U.S.A. ISCAR 7 Industry 4.0 for Cutting Tool Manufacturers The term “Industry 4.0” has already entered our everyday lexicon in many spheres: from journalism and applied science to vocational training and industry. Concepts such as “smart factory”, “Internet of Things”, industries. A source of irresistible inspiration to “cyber physical systems” and “machine to machine” even the most cynical industry players, the Industry are no longer considered science fiction and we may 4.0 concept has brought the ideas of complex soon be meeting the reality behind these phrases computerization and production automation, inter- in metalworking plant processes. Yet there remains object data exchange, and decision-making processes a world of misinterpretation and miscomprehension to formerly unattainable levels. “Industry 4.0” between terminology and implementation. What does epitomizes the fourth industrial revolution. Industry 4.0 signify in practical terms and how do we The first industrial revolution saw the transition from apply and optimize Industry 4.0-related technologies in manual labor to machine production and the second our manufacturing processes? industrial revolution – the technological revolution – transformed mass production. The third industrial Industrial Revolutions revolution replaced analog with digital electronics, Originally, “Industry 4.0” (“Industrie 4.0”) was a German also causing radical changes not only in governmental initiative to digitize manufacturing manufacturing but in everyday life. DUSTRY 4.0 8 MACHINING INTELLIGENTLY Industry 4.0 for Cutting Tool Manufacturers “Industry 4.0” is how we refer to the fourth industrial revolution, which encompasses cyber physical systems - integrating digital components into physical processes, the Internet of Things (a concept of networking physical objects with embedded informatic technologies), 3D modeling and printing, virtual reality applications and other concepts; some already implemented and some waiting in the wings. ISCAR 9 ISCAR Industry 4.0 DUSTRY 4.0 MACHINING INTELLIGENTLY Smart Factory The smart factory represents the central model for smart manufacturing. Cyber physical production systems perform under the conditions of real-time information exchange in an environmental context that combines real and virtual worlds, with systems interacting via the Internet of Things. For example, the physical system shows the position of a cutting tool and acting cutting forces, and the virtual system specifies the tool’s 3D path during operation and set machine stock allowance. 10 ISCAR Integrating IoT processes increases flexibility and adjustability, The main principle of a cyber physical system (CPS) with the potential to improve efficiency considerably. involves the integration of digital resources into physical Today’s cutting tools and toolholders contain processes and their reciprocal interaction – the Internet microchip sensors to automatically control tool of Things (IoT). IoT ensures data exchange between identification and changing, and a range of devices the systems and so interconnects the objects or and machine-tool blocks offer automatic tool wear “things”, which are then able to understand each other, monitoring, temperature changes, and more: the tool intercommunicate, and make decisions depending on evolves to become a component of the emerging a current situation. Introducing IoT in manufacturing cyber physical system. The main principle of a cyber physical system (CPS) involves the integration of digital resources into physical processes ISCAR 11 ISCAR Adopts 3D Printing Technologies DUSTRY 4.0 12 MACHINING INTELLIGENTLY DUSTRY 4.0 MACHINING INTELLIGENTLY Virtual Manufacturing (VM) integrates digital modelling and technical process simulation. VM started as a production design tool and a means for collision checks during machining; it is considered a textbook “Industry 4.0” solution, combining virtual
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