The smart magazine for users Profile Issue 01 · October 2013 35 The carousel for precision grinding wheels Mitsubishi Electric Europe B.V. 38 Slashing machining time by 20 hours Eric Huyghe Formenbau 50 Almond crescents launch bespoke machine building Bott GmbH Contents Contents Contents 50 Almond crescents launch bespoke machine building 60 Moving up into the world league The flavour of success Injection moulds with up to 96 components Bott GmbH ERMO GROUP 56 Uncharted territory Exploring materials right at the machine Empa 06 We are all members of the Möderer family 30 Getting it right first time 75 years, 34 employees and a simple explanation Leaving nothing to chance Hans Möderer Werkzeug- & Formenbau GmbH Walter Pottiez GmbH 12 Intelligent clamping makes all the difference 35 The carousel for precision grinding wheels The key to success lies in good preparation Micrometre precision for the dressing of grinding wheels Aldrovandi AG Mitsubishi Electric Europe B.V. 18 Rust protection with water 38 Slashing machining time by 20 hours 04 Editorial 43 Profile magazine Banishing the risk of rust From 50 to 30 thanks to the MV2400R You’ve missed one of our issues? No problem! Chia-mo Srl Eric Huyghe Formenbau 05 Newsflash 65 Origami 24 Cutting diamonds with precision 44 Tooth for tooth – geared for success The art of mechanics and material Solutions for high-performance machining A Top 100 SME reports Lütticke GmbH Neugart GmbH 11 Competition 66 User horoscope 02 Profile 08.2013 Profile 08.2013 03 Editorial Latest developments HANS-JÜRGEN PELZERS Newsflash Editorial Only walking on air is better … Rapid relief for flood victims LED screens so large they can be measured Any customer who manages to cut machining time for a tool from 50 hours to in wingspans 30 will be walking on air (page 36). And this is pretty much the principle that the With the quick and unconventional donation of 25 dehu- unique Tubular Shaft Motors work on – available only at the top of the range midifiers, Mitsubishi Electric has responded to the To highlight the diversified product spectrum and out- from Mitsubishi Electric. By consistently eliminating friction, wear is excluded flood disaster in southern and eastern Germany. The standing pinnacle technologies of Mitsubishi Electric, from the outset. So it is hardly surprising that customers are increasingly tend- move was initiated by Christina Marx, Mitsubishi the online advertising campaign “You wouldn’t believe ing to ask for just a single quote – a quote from Mitsubishi Electric (page 06). Electric employee, who comes from the affected district the things we do” has been launched. It shows a selec- of Wurzen. Christina has also ensured locally that the tion of products and applications ranging from satellite There are many reasons why Mitsubishi Electric has become the world market dehumidifiers run reliably and safely in tough continu- communication and e&ecoF@ctory to power semicon- leader in the EDM sector. The exclusive Tubular Shaft Motor builds on this lead Legal notice ous operation. ductor modules. and helps many users to achieve better results in shorter job times. And when one considers that the whole system saves energy on a big scale, it becomes Published by: obvious that the current machine pays for itself through higher productivity and Mitsubishi Electric Europe B.V. energy savings alone. You can then enjoy the extra precision and comfort as a German Branch bonus. And, talking of bonuses, ask me about the special energy bonus – you’re Mechatronics Machinery sure to like it! Gothaer Strasse 8 40880 Ratingen · Germany Tel +49 . 2102 . 486 6120 Fax +49 . 2102 . 486 7090 edm.sales @ meg.mee.com www.mitsubishi-edm.de Down-to-earth regards from Ratingen Copyright: 20,000 Blu-ray discs per day on a footprint The new generation of Ecodan heat pump Mitsubishi Electric Europe B.V. of only 17 m² systems Editorial board: Manufacturers of optical discs (DVDs and Blu-ray) have The new generation offers even higher efficiency and Hans-Jürgen Pelzers and Stephan Barg to temporarily produce large quantities of discs in further simplification of planning and installation. rapid cycles. Satisfying such tough requirements in pro- While the solution for indoor units is available with and Hans-Jürgen Pelzers Design and layout: duction, Mitsubishi Electric has been the automation without drinking/hot water storage, outdoor units can Distribution Manager Europe City Update Ltd., Düsseldorf supplier to Singulus Technologies (Singulus), a leading be employed with power inverter or new Zubadan maker of replication systems for CDs, DVDs and compressor technology. The hot water tank volume No responsibility is taken for the accu- Blu-ray discs, since 1999. has been increased to 200 litres net. racy of technical data and information in articles. Profile 08.2013 05 EDM and more EDM and more Hans Möderer WERkzeuG- & Formenbau ised before finally maturing with in some cases demands very high machine avail- massive investment in buildings, the machine park ability. A demand that culmi- » The first and CAD/CAM workstations into a high-tech sup- nated in the purchase of the machine from Mit- plier to specialised machine manufacturers and FA30-S Advance from Mit- subishi completely into a maker of top-class injection moulds. A major subishi Electric in Novem- satisfied our expecta- factor in this was the decision to build larger ber 2007 and hence in a tions, so we didn’t in- moulds and components under subcontract. As a change in supplier. Neu- result, Möderer built another shop in 2007 and pur- bauer: “We were happy vestigate other op- We are all members tions when it came to buying the second of the Möderer family one. « Everyone at Hans Möderer Werkzeug- & A welcoming reception with sparkling wine and soft drinks. Followed by an opulent buffet of hot and Formenbau GmbH, Leinburg, had good reason cold dishes, arrayed around a suckling pig turning to celebrate. In October 2012, there was not on a spit. A mouth-watering sight for the guests, only the company’s 75th anniversary to com- be they friends of hearty Franconian cuisine or more partial to fish and other seafood, cheese, fruit or memorate, but also the change of genera- desserts. But not only the buffet was sub­­­stantial, but tions at top management level. And, on top also the speeches in which company history was “served up” before the informal part of the evening. of this, the company that sees itself as a big family had just invested in a second wire From 1937 to the age of the Internet EDM machine from Mitsubishi Electric. After the welcome address by Managing Partner Norbert Neubauer, politicians turned in their speeches to the company’s development and ac- complishments. The representative of Central chased for all production neither with the competition’s service nor with the Franconia’s Chamber of Trade also stressed that The FA30-S Advance processes machines wire-threading system. Without a reliable thread- the world in 1937, when Hans Möderer estab- was supplied on a equipped with larger ma- ing system and our extra 20-kilo wire station, truck and transported lished his business, was entirely different to to- chining ranges. An ex ample continuous unmanned operation would be out of by a forklift into the day’s. There were neither smartphones nor the production shop. of this is the FA30-V wire the question.” Internet or email. A good deal has happened in the erosion machine from Mit- 75 years since its foundation, reported Norbert subishi Electric with a ma- In choosing the FA30-S Advance, the operator Neubauer in his illustrated talk. At the beginning, chining range of 700 × 500 × went for a wire-cut EDM machine whose machin- Möderer’s lines of business could not have been 350 millimetres (X/Y/Z). The ing range of 750 x 500 x 410 millimetres (X/Y/Z) more diverse. He produced turned parts to customer end of this phase of investment was marked by a matches his maximum workpiece dimensions per- drawings, sold bicycles, mo- FA30-S Advance as the second wire erosion ma- fectly. The new, high-precision erosion system peds, electrical appliances chine, which went into operation just two weeks equipped with an Advance CNC control also has a and sewing machines, drove before the anniversary celebration. greater cutting height than the FA30-V. Möderer workers from the surround- had the machine fitted with the optionally available ing villages to their work with Big extension to production capacity digital FS generator in order to achieve e ven bet- The guests of the anni- his own fleet of VW mini- ter surface quality. versary celebration buses, ran a petrol station Möderer has been working with wire EDM since Now that the company has significantly extended looked forward to an opulent buffet of hot and kept bees. Over the 1989. Sometimes in unmanned operation at night its production capacity by adding the ­second and cold dishes. years, the company special- and at weekends. This is why the company system, it has been able to reduce its production 06 Hans Möderer Werkzeug- & Formenbau GmbH Profile 08.2013 07 EDM and more EDM and more We are all members of the Möderer family and Möderer’s success is our collective success. Since everything is developing promisingly, Neubauer views Georg and Ingrid Weinmann hand over the management ba- the future with optimism. tons to Norbert Neubauer and his wife Andrea. bottlenecks appreciably and to free resources data – from design and mouldmaking through to simply laid on the magnetic clamping plate. Mö- views the future with optimism. “We’ve positioned for new customers. Neubauer celebrated the anni- piloting.