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Toyota s Global Sustainability Video

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The company's core competencies are the developing, testing and manufacturing of highly complex components for engines, chassis and cooling systems through to complete chassis units — including all molds — for racing and rally vehicles. All of this is done with maximum flexibility, precision and quality, and in most cases in extremely small batch sizes. At its site in Cologne, the company produces Toyota s Global Sustainability components for three of the very successful cars in the FIA See more Rally Championship WRC and is involved in developing high-performance Toyota road-going cars. TGR-E is also a profit center providing its wide-range of services — from engineering through to manufacturing — to external companies.

One goal is to keep the large machines free for very large components such as complete chassis and to machine medium-sized parts on a somewhat more compact machine with lower hourly rates using dry machining only.

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With travel distances of 2, mm x 2, mm x 1, mm XYZthe DMU Gantry machine is ideal for 5-axis machining of structural parts for racing vehicles and other composite components. These are then machined at maximum cost efficiency levels using both single and multiple clamping.

One Toyota s Global Sustainability is presented by difficult-to-machine composites consisting of several combined layers made, for example, of carbon or Kevlar fibers. The individual layers must be prevented from separating from each other delamination and the fibers prevented from tearing. Machining composite parts with inserts made of titanium and other difficult-to-machine materials is even more complicated. Such operations call for appropriate process know-how, suitable machining strategies and tools and, not least of all, a high-performance computerized numerical control system that supports the operator in every situation.

Management thought

Ultrasonic technology from Sauer GmbH, a member of the DMG MORI group, is a major key to more gentle and efficient machining of composites and other materials such as ceramics or nickel-based alloys. The second generation supports ultrasonic-assisted milling with a defined cutting Toyota s Global Sustainability. This enables higher feedrates and infeeds, leads to longer tool life or significantly improved surfaces. Delamination and fiber tearing are prevented. The company now also repairs larger, more complex chassis parts in order to cut times and costs even further.

This is done by partially removing layers in damaged places and then building them up again. This extends the range of applications for the new Gantry machine while increasing its capacity utilization and profitability.

Way of Thinking Behind Materiality

Sustalnability gear skiving of both straight and helical inner and outer teeth is a further innovative application that TGR-E entrusts exclusively to Sinumerik D sl. Thanks to the openness of the control system, the machine manufacturer was able to incorporate the required special technology and compile cycles into the NC core. They are then simulated and optimized offline during job planning, before being transferred to the machine control system srun in and executed via the network.

All this calls for a high-performance, easy-to-operate control system. After just a short field test, Patrick Garbe from Toyota s Global Sustainability team of experienced senior operators came to the conclusion that it "is very clearly structured, allows intuitive operation, meets practical requirements and brings added benefits.

Fast switching between applications and easy zooming and scrolling within applications during machining are state-of-the-art in multi-touch operation.

This applies, for example, to various machine functions or a PDF viewer, which saves on printouts for clamping for example. Creating new tools on the machine is an intuitive process and the operator can view all the important data. Sinumerik's automatic 3D tool radius compensation keeps the data constantly up to date, thus eliminating the need for manual, and therefore error-prone, calculation. Set-up and process measuring of components simplify and speed up programmable measuring cycles. DMG MORI also uses them for its "L-measuring probe package", which Toyota s Global Sustainability expands the available measuring options, especially with geometries that are bulky or difficult to access. Siemens has also made advances in the development of collision avoidance. The version used by TMG maps the machine components as protection areas in the working area in the form Toyota s Global Sustainability simple geometric bodies.

As an option, the control system also supports collision monitoring for the machine, clamping equipment, tools and workpiece sthus ensuring simple, efficient protection against collisions in every situation.]