6-Sided turn-mill complete machining in mold making
SET Mühendislik Sanayi ve Ticaret Ltd. Şti from Istanbul, with its owners Mr. Celalettin Aydemir (Senior Mechanical Engineer) and Ms. Hale Gürçay (Chemical Engineer), has been a competent partner to the glass industry for more than 30 years, particularly for the manufacture of molds and accessories for so-called individual section machines.
Well-known customers trust the quality awareness of SET Engineering. The integrated 5-axis and 6-sided precision machining on three NTX 1000 Turn & Mill centers is regarded as the manufacturing key to the company's success.
High manufacturing depth and full service mentality
“We manufacture each mold and each component in-house with a high manufacturing depth, maximum precision and documented care in order to achieve certified fulfillment of the extreme requirements of international customers,” reports managing director Ergun Tanaçan. In this context, he is proud of the team of employees, which can exploit the potential of the innovative process chain perfectly at all times thanks to the comprehensive training measures. Tanaçan then mentions the full service mentality of his company as another pillar of the business success.
Integrated process chain for glass molds
The customer therefore only has to provide the 3D model of the end product and the technical specification of the manufacturing IS systems. All other aspects of the manufacturing process of hollow glass mold production are then the responsibility of SET. This includes the production of the technical drawings and the NC programming with simulation, and also the subsequent precision machining and the comprehensive quality assurance measures.
Three NTX 1000 machines for complex glass molds
The manufacturing process chain of SET Engineering currently includes around 40 CNC machines for cutting, coating, engraving and polishing. The manufacturing backbone consists of several machines from DMG MORI, including three NTX 1000 Turn & Mill precision centers for 6-sided complete machining. PROCESS INTEGRATION: MILL TURN High-precision component of a bottle mold, manufactured on one of the 3 NTX 1000. 6-SIDED TURN-MILL COMPLETE MACHINING IN MOLD MAKING All information about the NTX at: ntx.dmgmori.com 42 TECHNOLOGY EXCELLENCE SET Engineering has also recently significantly extended its repertoire in the laser texturing area with the LASERTECH 45 Shape, whereas the area of classic universal turning has been reinforced with an NLX 2500 | 700.
Turnkey project for quick commissioning
The example of the three new NTX 1000 machines which were ordered by SET as a turnkey project shows just how comprehensive the trust in DMG MORI as an excellence partner for machining has now become. In addition to the machine, DMG MORI has also developed and implemented the entire technology design from the machine to the tools and the programming in Japan. “The NTX 1000 machines then smoothly went into 2 to 3 shift operation within our company within a few days, since when they have been operating problem-free”, reports Ergun Tanaçan.
Continuous accuracy and reliability
As far as the managing director is concerned, this high degree of reliability is evidence of the outstanding mechanical engineering skill of the Japanese supplier. He explicitly refers to the high-rigidity machine bed and the roller guideways, and also praises the thermo-symmetrical headstock-cooling structure with coolant circulation. “This all but eliminates temperature-related fluctuations, which is vital for our precision requirements”, says Ergun Tanaçan. Tanaçan also pays tribute to the performance of the 20,000 series compactMASTER milling spindle, whereby he is less enthusiastic about the cutting performance than the impressive surface quality. “The surface quality is the most important criterion with glass molds, because it directly influences the quality of the final products.” The highprecision CNC machines from DMG MORI can reliably manufacture these surfaces up to Ra 0.5 μm with 5 axes.
NTX 1000: Productive Turn & Mill Complete Machining
As well as the surface quality, the complexity of the glass molds is a challenge during machining. Ergun Tanaçan refers to the free-form surfaces: “We are reliant on 5-axis simultaneous machining to do this.” The compactMASTER milling spindle turns the NTX 1000 into a versatile 6-sided complete machining center. “Machining in a single clamping removes the need for manual re-clamping. This avoids mistakes, and the throughput times are considerably shorter.” The NTX 1000 therefore makes a significant contribution to increasing productivity.
Digital monitoring for maximum machine availability
SET Engineering monitors the entire machining of the glass molds in order to minimize stop times. “Since we know the status of every machine, we are always in a position to react quickly if there is a problem anywhere”, says Ergun Tanaçan about the benefits of digital monitoring. A high degree of machine availability is essential in competitive production. “The outstanding availability of the local service from DMG MORI is an important aspect in this respect.”
LASERTEC 45 Shape for laser texturing of surfaces
SET Engineering also wants to continue its success story in the future with innovative manufacturing technologies. By way of an example, Ergun Tanaçan refers to the LASERTEC 45 Shape, which is representative of the pursuit of innovation and continuous improvement of added value for customers. “Laser texturing of three-dimensional freeform surfaces has opened up completely new perspectives in surface structuring”, summarizes an impressed Tanaçan. “This allows us to produce any required surface structure within a very short time. Reproducible at any time and without the use of etching, which is harmful to the environment and the health” says Ergun Tanaçan, and gives a small glimpse into the future: “We want to automate our manufacturing with robots together with DMG MORI in the future.”
SET Mühendislik Sanayi ve Ticaret Ltd. Şti
İstanbul Deri OSB Yan Sanayi
Cad. No: 27
34956, İstanbul / Turkey
www.seteng.com