Walter is introducing a new double-sided indexable insert for turning machining operations under the designation “MU5”. The insert can be used universally both for steel forged parts in automotive series production, such as drivetrain or gearbox components, and for components made from stainless materials.
In forged parts, the MU5 geometry minimises crater wear and thereby enables reliable, fully automated series production. For users with changing materials and small quantities, the MU5 is appealing due to its universal use for steel and stainless materials. The combination of improved chip breaking with longer tool life will be equally beneficial for both target groups. These characteristics are due to the positive macro-geometry, featuring an open chip breaker groove for long tool life and soft cutting characteristics, a V-shaped chip breaker for improved chip breaking and a curved cutting edge promoting high surface finish quality.
For copy turning, the MU5 geometry does not just improve chip breaking for longitudinal turning and facing, but also for inclines or radii that would otherwise be critical. During the numerous field tests, the MU5 has also already proven that it significantly lowers tool costs, particularly when combined with the wear-resistant Tiger·tec® Silver grades. The machining parameters of the insert are f: 0.15–0.6 mm; ap: 0.5–4 mm, which applies to 60 per cent of all applications. In order to offer customers the best possible solution for their applications, the new MU5 insert is available in all common basic shapes.
For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144
MAPAL is expanding its portfolio in the area of high-performance milling cutters in the OptiMill family for aluminium and steel machining.
Reliably machining structural parts made of aluminium
The full potential of new, powerful machines can be used with the new OptiMill-SPM milling cutters “Rough” and “Finish”. They exploit their strengths especially during the machining of structural parts made of aluminium.
High infeed depths as well as the highest feeds during roughing are possible with the new OptiMill-SPM-Rough. The reason for this performance is its innovative knurled roughing geometry that ensures the power consumption during machining is significantly lower compared to tools with a straight cutting edge. Furthermore, the heat introduction into the part is minimal due to the excellent plunging characteristics of the tool.
For finishing contours and pocket walls even at large depths in one pass, MAPAL is announcing the OptiMill-SPM-Finish with newly developed geometry. It operates without problems even with large wrapping, while in the corners with enormous tool contact and a high load, the tool remains stable. The optimally designed cutting edge geometry ensures there is no vibration during the machining. The chip flutes are polished, while as a consequence chip removal functions optimally.
At a glance
OptiMill-SPM-Finish and OptiMill-SPM-Rough for finishing and roughing
For machining structural parts made of aluminium using new, powerful machines
Advantages
High cutting performance
Vibration as well as heat introduction into the part are prevented
Finishing large depths in one pass using the OptiMill-SPM-Finish
Roughing with high material removal rate and high machining values using the OptiMill-SPM-Rough
Optimal for slot milling in steel
The OptiMill-Uni-Wave is the tool of choice if the issue is full slot milling with a groove depth up to 2xD in different materials. Due to its geometry, the highest machining rates are possible. Irrespective of all the advantages of the OptiMill-Uni-Wave, machinists often faced the difficulty that chip removal was not reliable, particularly in steel materials during the machining of slots with a depth ≥ 1.5xD. For this reason, MAPAL now offers the OptiMill-Uni-Wave also with central internal cooling. This feature ensures optimal removal of the chips and longer tool lives. In addition, MAPAL is announcing the OptiMill-Uni-Wave as an extra-long version. An efficient solution for roughing even in deep cavities is therefore now available. Despite its length, the new milling cutter is extremely stable due to its conically shaped neck.
At a glance
OptiMill-Uni-Wave now with central internal cooling and as extra-long design
Reliable slot milling also in deep cavities as well as in steel materials
Advantages
Extremely stable also in extra deep cavities
Optimal chip removal
For more information, please contact Spectra Carbide Tooling Technology – Tel: 021 555 4144
Established 45 years ago, manufacturer of cut to length lines, machine tools and special purpose machinery A.P. Design has always taken advantage of new technology, including intelligent servo drives. While even today small machines are fitted with PLC’s, we now upload links via the internet to PLCs & HMIs.
Together with latest technology available, comes the need for smart interfaced advanced field devices. These range from a sub miniature infra-red sensor to vision recognitions systems. With the vast amount of options available we can build machines that are much more cost effective and user friendly.
At our company all design work is done on Autodesk Inventor 2019 work stations. These software packages allow A.P. Design engineers to system check the functionality of machines prior to being built, which includes FEA (Finite Element Analysis).
All components used in the building of machines including electronic and system interfaces are manufactured in-house.
While A.P. Design provides press shop turnkey solutions and automation of presses and guillotines, the company also manufactures vibratory bowl feeders for small parts, servo drive roll feeders and eccentric presses. Our servo roll feeders come in any length required. While the units are controlled by a closed loop servo drive, models are available from 200mm to 1 250mm wide. We have strip feeders available up to 400mm wide and 400mm feed length x 4mm thick. Smallest available 38mm wide and 50mm feed length x 1mm thick with feed accuracy ± 0,15 per 0,5m.
Our range of products also includes two-in-one decoiler straighteners used to straighten material from coil for subsequent use in a strip feeder or electronic roll feeder; this material will then be fed to a press or guillotine. Coils over 2 000kg and more than 1 100mm in diameter and 200 to 1250mm width can be fed.
A wide range of custom made hydraulic presses are available from 30 to 1 000 tons. These are either simple machines with a cylinder and platens or maybe more complex with die cushion.
We manufacture decoilers in a number of varieties, widths and tonnage with small units from 500kg and a width of 100mm to 30 tons and 2 500mm wide. These units can be non-motorized (Haul-off ) or fully motorized with electronic controls.
Our cut to length lines (CTLL) will comprise of a decoiler, feeding the coil into a leveler. The leveler will straighten the steel and an encoder will measure the steel to the correct length for cutting. Most CTLL have guillotines fitted which will do the cutting. Some CTLL have slitters fitted (blanking line) which will cut the material into strips and then recoil the steel onto spools or into coils. Most CTLL are run by a PLC and HMI screen which are programmed to do batch cutting and setting parameters. The operator will programme the length and number of pieces required, and the unit stops when the programme is finished. For increased production a flying shear is incorporated. These units can handle 30 ton coils and widths of material up to 2 020mm.
Our vibratory bowl feeders are used to orientate parts and feed them to down line assembly machinery by means of a vibrator pack and an aluminium spiral track bowl ranging in diameter from 150mm to 710mm and various track sizes. Typical feed rates are 40 to 200 parts/minute.
We have manufactured special purpose machinery for the production of roll-on deodorants, making bricks and even roof tiles. Most car manufacturers have A.P. Design equipment in their plants. We help to keep the railways running and help to make industrial diamonds.
For more information, please contact A.P. Design – Tel: 011 010-0495.
Following years of successful experience with MULTI-MASTER milling heads, ISCAR is expanding their application range by increasing the depth of cut vs. tool diameter ratio from the current 0.7xD to 1.5xD.
The new milling heads have been designed for shoulder roughing, semi-finishing and finishing applications with ramping down capability and are available in an 8 to 25 mm diameter range. The range includes the MM EC-CF-Z7/9-1.5xD interchangeable 7-9 flute solid carbide endmill heads with 1.5xD flute lengths, different helix, variable pitch and various corner radii, the MM EC-CF-Z4-1.5xD interchangeable solid carbide heads with variable pitch and 1.5xD flute lengths for chatter free roughing and finishing operations with high material removal rates and the MM ERS-1.5xD interchangeable solid carbide rough milling heads with 1.5xD flute lengths, for high metal removal applications.
For more information, please contact ISCAR South Africa (PTY) LTD – Tel: 011 997-2700
Endmills featuring a cutting edge that is actually the segment of a large-diameter arc were introduced approximately 25 years ago. As the cutting-edge shape of these endmills is reminiscent of a barrel profile, terms such as “barrel milling cutters”, “barrel endmills” or, in shop talk, often simply “barrels” soon became common when referring to these types of endmill.
At first, the use of these barrel-shape mills was limited more or less to a few specific applications, such as machining 3D surfaces of complex dies and turbomachinery components. However, advances in 5-axis machining and in CAM systems have significantly expanded the boundaries of barrel endmill applications.
At the same time, the design principle of a cutting edge as the segment of a large-diameter arc, has been realized successfully in other types of milling cutters – the tools for high feed milling (HFM), also referred to as “fast feed” (FF) milling. The concept provides a toroidal cutting geometry that ensures productive rough machining at extremely high feed rates due to a chip thinning effect. Unlike high feed milling tools, barrel endmills are intended not for roughing but for finish – and semi-finish machining of 3D surfaces with low stock removal.
Traditionally, ball-nose and toroidal cutters perform these machining operations. However, the large-diameter arc of the endmill cutting edge results in a substantial reduction of the cusp height generated between passes machined by a ball-nose or toroidal cutter. Another advantage of this type of cutting edge versus ball-nose and toroidal cutters is a significant increase in the distance between passes (a step-over or a step-down, depending on the direction of a cutter displacement after every pass) – at least five times more without degradation of the surface finish parameters! This means that the number of passes and, subsequently, machining time can be noticeably reduced. Increasing the distance between passes also improves tool life and, therefore, diminishes tool cost per part.
The classical barrel shape in endmills has undergone some changes to make these cutters more versatile. Combining a ball-nose tip with peripheral large-arc cutting edges creates a multi-purpose “cutting oval,” which facilitates the use of a barrel endmill as a ball-nose milling tool.
In taper endmills, transforming the profile of a major cutting edge into a large-arc segment generates another cutting oval – a taper barrel. When compared with a common taper endmill, the taper barrel provides pinpoint contact between the major cutting edge and a machined surface that decreases accuracy errors, while preventing re-cutting of a produced shape. The taper shape also contributes to reducing tool overhang, an important factor for improving tool performance.
Barrel and oval endmills are mainly utilized for cutting side surfaces. If machining a complex bottom surface is needed, a lens-shape endmill offers a good solution. This tool features barrel cutting edges on its end surface to ensure milling with a large stepover.
The barrel endmills – classical barrel-, oval- and lens-shaped cutters – provide efficient tools for machining 3D surfaces. Nevertheless, for a long time the complexity of CNC programming for applying barrel endmills was a constraining factor in actively integrating these promising tools into the appropriate branches of the metalworking industry. The growing use of 5-axis machine tools and the latest progress in CAM software has changed the situation dramatically and today, we see intensive utilization of barrel endmills in manufacturing various parts with geometrically complex surfaces. The main consumers of these “cutting barrels” are producers of aerospace, die and mold, medicine, turbine and compressor components.
Cutting tool companies in turn have strengthened their efforts to develop and manufacture more advanced barrel endmill designs to meet increased customer demands. Some of ISCAR’s latest products, barrel endmills in the SOLIDMILL and MULTI-MASTER families, offer good examples of this trend.
The MULTI-MASTER Advantage
ISCAR offers oval- and lens- shape endmills in diameter ranges of 8 – 16 mm and .312″ – .500″.In addition to their availability in sold carbide design configurations, the new barrel endmills have been manufactured as exchangeable carbide heads with MULTI-MASTER threaded adaptation. MULTI-MASTER’s distinctive “no set-up time” feature, which enables the replacement of a worn head without withdrawing a tool from the machine spindle, can be particularly effective in the case of barrel tool applications in semi-finish and finish milling operations.
Additional factors in favour of applying the MULTI-MASTER concept to barrel endmills are economic feasibility and sustainability. Due to the complicated shape of its cutting edges, a barrel endmill is designed as a throwaway tool. When the wear limit is reached, the entire carbide endmill simply becomes waste. In contrast to solid tools, the MULTI-MASTER design provides a valuable option for careful and cost-effective use of cemented carbide materials. And, of course, a rich variety of available MULTI-MASTER shanks, reducers and extensions enables optimal assembly of a required tool from these elements.
At present, barrel milling cutters are not in incredibly high demand by the metalworking industry as they are intended for very specific parts and effective application of such cutters requires highly engineered multi-axis machines and, especially important, leading-edge CAM systems. However, advanced workpiece manufacturing technologies, such as metal injection molding, 3D printing, investment casting, close-tolerance forging and innovative machine tools plus a quantum leap in digitizing of manufacturing will increase the need for finishing complex surfaces with minimum machining stock. In this light, ISCAR’s specialists estimate that barrel endmill consumption in the metalworking industry will increase exponentially, and cutting tool manufacturers should be shaping up to what is evidently a promising new industrial trend.
For more information, please contact ISCAR South Africa (PTY) LTD – Tel: 011 997-2700.
The management and staff of First Cut, together with local and international colleagues mourn the loss of First Cut’s Sales Director Gary Willis, who passed away on Thursday evening 1st April at the age of 51. Gary bravely fought an 18 months battle with cancer, remaining resolutely positive until the end.
Since starting work at his late father’s tungsten carbide tool tip business in 1990, he gained a wealth of experience in the industrial tool sector and the supply of cutting consumables.
Gary had a 25 year history with First Cut, some 15 years in a senior management position, followed by his appointment as Sales Director, heading up the consumables division. He took his role extremely serious, was highly diligent and always thought deeply about his responsibilities.
Gary was a ‘hands-on’ person, practical, logical and with a talent for dealing with detail. These skills came to the fore when implementing a sales strategy. Gary’s careful and consistent approach contributed substantially to the successful management of the First Cut consumables division – very much the ‘heart’ of the business.
He was always well prepared, whether for an Exco meeting, a meeting with a customer or his weekly Friday afternoon sales meeting and never missed to consider the well-being of his staff, his customers and suppliers before making a decision. Gary will indeed be sorely missed by the staff and management of First Cut.
While he was open – ear, heart and mind – to the people around him, he listened carefully, considering everyone’s viewpoints with calm and sensitivity. He was a very loyal manager, who always fought for the benefit of his team and therefore, Gary was trusted and respected by all.
Gary leaves his wife Katy, daughter Lauren, his mother and his brother David. He was a dedicated family man, loving and highly protective over his family, while always focussing on their safety and well-being. He put the loves of his life – Katy and Lauren – first. Our thoughts and prayers go to his family during this very difficult time.
It has been an honour and privilege working with and getting to know Gary over the past 25 years. We complemented one another’s strengths and weaknesses, forming a close and cohesive partnership with much mutual synergy and benefit. He was both a colleague of the highest order and a genuine friend. We worked hard together, we laughed, we celebrated, we dug deep when necessary – but most of all, we enjoyed and valued his company.
When purchasing a laser cutting system, there are a number of things to consider, this goes far beyond the purchase price or service intervals. But what exactly has to be taken into consideration? This guideline might help.
What are the differences between a CO2 laser and a fiber laser?
As the name suggests, the CO2 laser uses a gas mixture that is based on carbon dioxide. This mixture, which usually consists of CO2, nitrogen, and helium, is electrically excited to generate the laser beam. Solid-state lasers are available in the form of fiber or disk lasers in similar power levels to their CO2 counterparts. As with the CO2 laser, the laser-active medium gives the fiber laser its name, which in this case is a glass-like or crystalline solid in the form of a fiber or a disk.
While with the CO2 laser, the laser beam is guided through a beam path using optics, the beam of the fiber laser is generated in an active fiber and guided to the machine’s cutting head via a transport fiber. One of the key differences, apart from the laser medium as such, is its wavelength. With a fiber laser, the laser wavelength is around 1µm and with a CO2 laser 10µm. The fiber laser’s shorter wavelength results in a higher absorption rate when cutting steel, stainless steel and aluminum. A higher absorption rate means lower heat generation in the material that is being processed, which is, of course, a positive attribute.
CO2 technology is ideal for all-rounders who process a wide variety of materials and thick metal sheets. A fiber laser cutting system, on the other hand, is capable of processing the thin to thick range of sheet thicknesses with materials ranging from steel, stainless steel, and aluminum, right through to non-ferrous metals (copper and brass).
What are the benefits of a fiber laser compared to a CO2 laser?
The advantage of the CO2 laser is its superior cutting quality in thick steel (mild steel). The fiber laser, on the other hand, offers high cutting speeds and lower operating costs per hour. Fiber lasers require nowhere near as much energy as CO2 lasers and their electrical efficiency is up to 5 times higher. What is more, the beam path of fiber lasers is simpler. Another big bonus is the more compact footprint: A fiber laser system with 8 to 10 kW laser power requires only about one fifth of the floor space of a CO2 laser system of comparable power.
Fiber laser technology has advanced rapidly in recent years. However, it is important to consider more factors than just the laser power and cutting speeds. Success in the sheet metal processing sector is dependent on an entire array of diverse and individual factors, all of which revolve around the core question: What is the optimal workflow? Even the most high-performance machine can only be cost-effective if its potential is fully exploited.
What should be considered when purchasing a laser cutting machine?
The factors vary enormously. In order to be able to evaluate which machine is best suited, one must first understand the intended application and define not only its requirements, but also its limits. One should also consider potential new objectives on the horizon and other options. After all, the purchase of a laser cutting system represents a major investment, and the decision concerns not just the machine itself. The purchase has an impact on the entire manufacturing process, covering everything from manpower, service and maintenance, consumables, right through to know-how.
Other factors are also involved: The fiber laser allows companies to increase the speed of a single process step. However, this may make it necessary to automate loading and unloading, since otherwise the machine will frequently be idle because its operators cannot keep up.
The prime objective is clear: Reduce costs while increasing product quality and productivity. Achieving this objective with the purchase of a new system requires know-how that may not yet be available within the company. The capacity and performance of the system must correspond to the needs. If you invest a significant sum in a fiber laser cutting system in combination with complex material management solutions, you naturally expect to achieve a favourable ROI.
How has the laser cutting system market developed in recent years?
15 years ago, there were perhaps no more than 20 laser cutting machine OEMs, and the industry was dominated by a handful of leading suppliers. In the meantime, however, the market has opened up, and today, there is a multitude of laser cutting machine manufacturers on the market. The number of suppliers of other components, such as software and CNC controls, has also increased dramatically, with the result that virtually anyone with a modicum of know-how can now produce a fiber laser cutting machine.
This development has resulted in the market being flooded with cheap equipment, and this is precisely where the problem lies: Sheet metal processing companies are faced with a large number of new suppliers who have little process knowledge, do not guarantee spare parts availability and do not offer any customer services, because their only goal is to sell at low costs in order to increase their own market share. This often results in the fact being overlooked that rather than being a plug-and-play solution, a laser cutting system only works when countless components interact flawlessly.
The industry has experienced significant technological advancements over the past 25 years – and major technological rollouts are always challenging.
How important is customer service?
Architekturfotograf
Very important! Current fiber technology does not require the same level of maintenance as CO2 technology, but if a machine breaks down, it is imperative to get it back up and running as soon as possible.
CO2 lasers require extensive and time-consuming maintenance. It is not unusual for a service technician to be on site for up to three straight days. CO2 lasers require servicing every 12 months or every 2,000 operating hours. With increasing service life, the overhauls required (for example of the resonator, optical components and beam path) increase.
In comparison, the maintenance of fiber laser machines is considerably less time and cost intensive. A fiber laser has fewer parts that require maintenance, which translates into real cost and time savings. Thus, the time required for maintenance and inspection of fiber lasers is significantly reduced and usually takes just a few hours.
However, both laser technologies require the service intervals to be adapted in the event of shift operation. Naturally, a laser cutting machine that is in operation 24/7 requires more frequent overhauls. This has an impact on both the maintenance costs and the downtime for servicing.
At the end of the day, the choice of a laser cutting machine should be based not only on the purchase price, but also on the total cost of ownership, calculated over the machine’s entire service life. Maintenance and energy costs as well as machine downtime should definitely be factored in. The energy costs, which can make up a considerable portion of the total annual expenses, are significantly lower with fiber lasers.
For all these reasons, potential buyers should obtain information about the availability and supply of spare parts, so their machine can be promptly repaired in the event of a breakdown. They should also clarify whether the supplier has a service technician stationed nearby who speaks their language.
When you use sophisticated, highly complex technologies, you have to reckon with hiccups. A laser cutting machine that is unable to cut because of a single damaged part is simply not an asset for the customer.
What is the service life of a laser cutting machine?
A laser cutting machine can last a long time, provided that a few points are observed:
A suitable environment for the machine (air temperature and humidity), regular cleaning, and above all regular and professional maintenance are essential. These are the basic factors that ensure a long service life.
How much must one be prepared to invest?
There is no simple answer to this question, because it depends on so many factors. As previously mentioned, the demands you place on the laser cutting machine play a key role. This has an impact on the size and capacity of the system. The peripheral equipment is also an aspect that must be considered: For example, do the workflows require an automatic loading and unloading system?
If you decide to buy a laser cutting machine, you should not only focus on the costs of the purchase itself, but also evaluate the total cost of ownership, calculated over the machine’s entire service life, including maintenance costs and machine downtime.
In addition, your staff’s current technical skills and their training needs must also be addressed.
Companies that do not consider these factors often make decisions that can have dire and long-lasting consequences: They choose a cheap system. Poor quality, the lack of know-how and experience, no spare parts and poor service can, in the worst case, rapidly shut down the entire production process.
An integrated concept that takes into account all the points mentioned above is absolutely essential. In the final analysis, it is a matter of working in partnership to find the optimal solution for you, because only a satisfied customer is a good customer.
For more information on the Bystronic range of laser machine and press brakes, please see www.bystronic.co.za or contact us on 010 410 0200.
Exceptional rigidity, accuracy and dynamic performance are the key features of Takumi’s high-speed portal machines.
The H series machines operate with outstanding accuracy and achieve an exceptional surface quality thanks to their sophisticated measuring and sensor control systems. Absolute direct measuring systems, internal coolant feed through the high-speed spindle, direct drives on all axes and electronic temperature compensation come as standard. Despite their relatively low procurement costs, the technical performance characteristics and values of Takumi’s H series machines are all top of the range.
Fast and accurate: the Takumi H7 and H10 models
These two machining portals have the shortest travel paths in the H series. The H7 and H10 models focus on the high-speed applications involved in tool-making, mould-making, medical technology, and the aviation and aerospace industries. They are designed to work with exceptional precision to create the optimum surface finish even in the very tightest spaces. The robust and stable portal design and resistance to high temperatures are the cornerstones of the machines’ operating excellence.
The designers have made a lasting improvement to load distribution on the spindle head by designing the portal frame as a ladder-type structure. The H7 and H10 machining portals can handle maximum table loads of up to 500 or 800 kilograms. All of Takumi’s H series models come equipped with a Heidenhain control system as standard. Together with the Heidenhain components integrated in the machining centers, they make a huge contribution to the accuracy of the result. The control systems allow programming in dialog and in parallel mode. They also have functions for freely programming contours and options for ISO-NC programming.
The Volkswagen Group Components plant in Braunschweig is significantly expanding its production of battery systems for the latest electric vehicle generation.
Following the first expansion stage with a maximum capacity of 250,000 battery systems, the second expansion stage has started up with the same capacity. This means that once the site is fully ramped up it will now be able to fit up to 500,000 batteries a year for models based on the modular electric drive matrix (MEB) ‒ in this case for the fully electric Volkswagen ID.31 and ID.42, as well as the ŠKODA ENYAQ iV3, which should soon be quietly and powerfully cruising the streets of Europe with a battery heart from Braunschweig. In addition to that, up to 100,000 battery systems for the beloved models e-up!4, SEAT Mii electric5, ŠKODA Citigoe iV6 and as well as for hybrid vehicles such as the Volkswagen Golf GTE7.
In total, the site can bring more than 600,000 battery systems into the vehicles each year. “The strong demand for attractive and affordable electric models based on the modular electric drive matrix has the lines of the first expansion stage working at full capacity, so we have fired up the second stage. As such, the component is underpinning the Group’s unprecedented electric campaign”, explains CEO of Volkswagen Group Components and member of the Group Board of Management for Technology, Thomas Schmall. “Volkswagen Group Components has taken on the management of the ‘Battery Cell & Battery System’ and ‘Charging & Energy’ business units within the Volkswagen Group, and plans to use its economies of scale and innovative power to develop optimum batteries and charging offers for Volkswagen customers. Within this, thanks to its development and manufacturing competence for battery systems, the Braunschweig site has been assigned a key role”, continues Schmall.
And the next ramp-up is coming soon: the plant has received approval for expanding PHEV production capacities. While more than 50,000 hybrid battery systems a year are leaving the plant today, as of 2023, this will be up to 300,000 battery systems.
“Through the consistent orientation toward electric mobility and a clear focussing of the product range, the Braunschweig site is lining itself up to be economically future-safe. The transformation of the site goes hand-in-hand with the transformation of its employees, who have been comprehensively qualified for working with batteries. This way, we can contribute to job security at the site”, maintains Plant Manager, Martin Schmuck.
In addition to the battery systems, Braunschweig also produces steering systems, brake discs, suspension struts, wheel bearing housings, wheel drives and subframes, and also front and rear axles, for example.
Series production of MEB batteries takes place using the state-of-the-art, largely fully automated production technology in a new manufacturing hall spread across more than 40,000 m2, and more than 300 million euros have been invested in the new building.
Production of the battery housing employs the latest welding, adhesive and sealing techniques. The housing units are then assembled together with the cell modules and a control unit to form the actual battery systems. Several in-line, air-tightness and end-of-line test beds guarantee uniformly high quality. The development of the battery system, including its hardware and software, also took place at the Braunschweig site. The knowledge gained here sets new standards for the whole Group, and is being used within the international network.
The battery system product provides employment for more than 800 employees. The employees required for the expansion of the production capacities were largely retrained for the new tasks within the site and prepared for working with high voltages through tailored training courses and qualifications.
1 ID.3, combined power consumption in kWh/100 km (NEDC): 15.4-13.1, CO2 emissions in g/km: 0; efficiency class: A+
2 ID.4, power consumption in kWh/100 km (NEDC): 16.9–15.5; CO₂ emission in g/km: 0; efficiency class: A+
3 ŠKODA ENYAQ iV 50, combined power consumption in kWh/100 km: 14.6; CO₂ emissions in g/km: 0; efficiency class: A+
ŠKODA ENYAQ iV 60, combined power consumption in kWh/100 km: 14.4; CO₂ emissions in g/km: 0; efficiency class: A+
ŠKODA ENYAQ iV 80, combined power consumption in kWh/100 km: 16.0; CO₂ emissions in g/km: 0; efficiency class: A+
4e-up!, combined power consumption in kWh/100 km: 12.7; CO₂ emissions in g/km: 0; efficiency class: A+
5SEAT Mii electric, combined power consumption (NEDC) in kWh/100 km: 12.9–12.7; CO₂ emissions in g/km: 0; efficiency class: A+
6 ŠKODA Citigoe iV, combined power consumption (NEDC) in kWh/100 km: 12.8–12.9; CO₂ emissions in g/km: 0; efficiency class: A+
7 Golf GTE, combined fuel consumption in l/100 km (NEDC): 1.5; combined power consumption in kW/h/100 km: 11.4; CO₂ emissions (combined) in g/km: 38; efficiency class: A+
The German automotive industry sees potential in Africa and strengthens its ties to the continent. The German Association of the Automotive Industry (VDA) joined hands with the African Association of Automotive Manufacturers (AAAM) as part of the “PartnerAfrica” project of the German Federal Ministry for Economic Cooperation and Development (BMZ). AAAM is the first automotive association with a pan-African approach, established in 2015 by global Original Equipment Manufacturers (OEMs).
The partnership-based cooperation between VDA and AAAM is mutually beneficial: in cooperation with local and regional structures it helps the automotive industry to improve access to sometimes difficult markets and at the same time it is in the interest of German development policy to improve local prospects by involving the private sector and to create sustainable jobs and sustainable mobility in partner countries.
The VDA-AAAM partnership sees itself as an engine for dynamic growth, high innovation speed and state-of-the-art jobs.
For the VDA, cooperation with Africa focuses on priorities, such as expanding the sustainability strategy beyond products and production to include energy sources, including e-fuels and digital mobility solutions; in addition, strengthening the development partnership, increasing trade volume and investment and further opening market access for manufacturers and suppliers. Equally important is supporting the development of local supply and value chains. In addition to stakeholder management and partnerships, topics such as promoting training and employment are also part of the comprehensive program.
Hildegard Müller, President of the VDA, said: “We highly appreciate our partnership with AAAM as the VDA intends to increase its involvement in Africa. With the joint project, VDA and AAAM are pursuing the goal of creating improved conditions for a flourishing automotive industry on the African continent, in order to increase economic growth and welfare in Africa and enable German as well as African member companies to participate in market growth and foster win-win trade and investments between Europe and Africa. This commitment of the VDA and AAAM is a significant contribution to growth and prosperity in Africa, supported by the investments of car manufacturers and suppliers on this emerging continent.” An in-house cluster for the association partnership at VDA’s headquarters in Berlin and two project offices in South Africa and Ghana are now responsible for project implementation and supporting direct local contacts for members and partners.
Africa has in some countries fast growing economies with a young, growing population and rapid rates of urbanization along with very low rates of motorization. By 2035, the continent is expected to have the largest labour force potential in the world. The automotive and logistics sector holds a key position due to its sustainable value creation in supplier networks, assembly plants, distribution structures and pan-African trade relations. And it offers great potential for innovation, growth and jobs. The motorization rate in Africa is just 45 vehicles per 1,000 inhabitants, which is significantly below the global average of 203 per 1,000.
In 2019, the total volume of new vehicles sold in the African market (passenger cars) was 869,000 vehicles. Africa has great potential as a market and production location for the German automotive industry. In 2019, 62,000 passenger cars were exported from Germany to Africa. 49 percent of these went to South Africa, the most important market in Africa.
In 2019, 355,000 passenger cars were sold in South Africa, with German OEMs accounting for 34 percent or 119,000 cars.
Total passenger car production in Africa in 2019 was around 787,000 units. 44 percent of the total car production in Africa took place with 349,000 units in South Africa. German OEMs have steadily expanded their production in South Africa in recent years. Compared to 2010, their production has increased by 44 percent to 317,000 passenger cars in 2019. This means that 91 percent of passenger car production in South Africa is carried out by German manufacturers.
For the German automotive industry, Africa is becoming more and more important not only as an export destination, but also as a local production site: In recent years, German automotive manufacturers and suppliers have made increasing investments not only in the established markets of the Maghreb region and South Africa, but also in future markets such as Ghana and Rwanda.
The German automotive industry is globally connected. With over 2,500 production facilities abroad, German manufacturers and suppliers contribute to growth and prosperity in over 70 countries around the world. At the same time, the companies use their know-how to contribute to sustainable mobility with environmentally friendly technologies on site.
The untapped demand from Africa is coupled with a steady rise in consumer spending, which has risen over the past few years at an annual rate of 10 percent. The estimated sales forecast of new light vehicles in Africa will be 1.8 million in 2027. This is a doubling compared to the market volume of 2019. Dave Coffey, CEO of AAAM: “Our experts estimate that the African new-vehicle market can initially grow to 3 million by 2035, with the potential of 5m, by implementing effective automotive policies and ecosystems. We are excited about our partnership with the VDA as it will provide expertise, resources and a strong network that will facilitate the development of the automotive industry in Africa.”
VDA and AAAM strongly support the industrialization on the African continent by sharing their industry knowledge, by creating platforms for exchange and by building bridges between countries and between public and private institutions. Furthermore, Africa is expected to play an increasing role in producing and exporting renewable energy. Therefore, a reliable trade framework between Africa and Europe is needed. Also, within Africa trade relations should be eased and intensified.
While A.P. Design provides press shop turnkey solutions and automation of presses and guillotines, the company also manufactures vibratory bowl feeders for small parts, servo drive roll feeders and eccentric presses. Our servo roll feeders come in any length required. While the units are controlled by a closed loop servo drive, models are available from 200mm to 1 250mm wide. We have strip feeders available up to 400mm wide and 400mm feed length x 4mm thick. Smallest available 38mm wide and 50mm feed length x 1mm thick with feed accuracy ± 0,15 per 0,5m.
Our cut to length lines (CTLL) will comprise of a decoiler, feeding the coil into a leveler. The leveler will straighten the steel and an encoder will measure the steel to the correct length for cutting. Most CTLL have guillotines fitted which will do the cutting. Some CTLL have slitters fitted (blanking line) which will cut the material into strips and then recoil the steel onto spools or into coils. Most CTLL are run by a PLC and HMI screen which are programmed to do batch cutting and setting parameters. The operator will programme the length and number of pieces required, and the unit stops when the programme is finished. For increased production a flying shear is incorporated. These units can handle 30 ton coils and widths of material up to 2 020mm.
