DYRTECH, a precision machining project with high flexibility
In other countries, especially the United States, Roberto Corredera and Daniel Izquierdo, the two founding partners of Dyrtech, would be considered as brave entrepreneurs. After the story of his story that we begin with these lines, we hope that they will also be in his own home.
Roberto Corredera is 38 years old and has already accumulated 20 years of experience. “I started working at 18 years old. When I left school I started Vocational Training, then it was five years, from there and with the basic knowledge, I started my career in the sector and I continue in it. I have gone through different processes: I have worked in milling machines, lathes, machining centers …, doing work for various sectors: machine tools, molds, die making … I experienced the great change when I combined daily workshop work with CAD-CAM. I have been working in this field for thirteen years, but without dissociating myself from workshop work ”.
Continuing with his life trajectory, Roberto participated in the start-up of the Sumbitec company where he met who today is his partner at Dyrtech, Daniel Izquierdo, who at the age of 28 shares a good part of his technical and work experience.
“Sumbitec – remembers Roberto Corredera – was a company that had a world patent, with an interesting product, despite which it failed. Sumbitec was closed and Garbitec was created in the same facilities and with the same machinery. We worked together at Sumbitec years ago and then we worked together again when we started Garbitec, a different product but the same machinery. We were dedicated to the same, production processes, quality control, tooling manufacturing and prototypes. When they decided to dissolve the company, this part was left free, the part most dedicated to the trade: making prototypes, tools, design, unique piece… We made an offer for the workshop and bought it ”.
Learning in the most advanced facilities in Europe
In 2008, when Sumbitec installed the facilities that they later used at Garbitec, they did so in a big way, with the most advanced flexible machining cell in Europe. “Finnish, German, English, Italian and Japanese technicians collaborated in its installation, with an investment in the factory estimated at 35 million euros. Then the world crisis broke out, the banks cut off credit, the product needed a lot of commercial development, and although it made a very good product with a world patent, the company closed. But it was an excellent R&D laboratory and we both worked on it, we made a lot of hydraulic tools and a lot of prototypes ”.
When Garbitec opened, it opened up to the world. Unlike its predecessor, it did not have its own product, it manufactured parts for railways, wind power, electrical substations, valves, automotive …
With Hitachi tools, Makino machining centers, the FMS system, integrated management and high technology, Garbitec machined different materials responding to very varied needs, which included short and medium series, highly complex parts, high precision machining and optimization. with casting or forging, among others.
“In our professional career it was an important leap, we went from R&D of a product to improving processes and dealing with many references.
When the factory was operating, there were 600 live tools in production, many part references, with medium-short series, which is where the flexible system works profitably. The series ranged from 10,000 to 200 units. The flexible system occupies a very wide spectrum that not even a transfer in the car with its large productions can cover and is what Garbitec was trying to cover. It was a totally different experience for both of us that lasted just three years but provided us with great insight ”.
As an example, when Daniel Izquierdo joined Garbitec, he did it to work in a workshop, but since customers demanded quality control and measurement of the parts, he took a course on measuring with a three-dimensional machine and was in charge of this task for a year and a half.
But Garbitec did not come to fruition either, and the partners decided to dissolve the project and set up production facilities at their companies. It was then that Roberto and Daniel bid for the part that they did not want.
Collaborators more than suppliers
Due to their previous experiences, Roberto and Daniel declare themselves in love with Makino and Hitachi. “The decision to buy the Makino machine was based on its technology, productivity, precision and versatility. The machine can rough a part and finish it with precision. We can start from a 400kg block, rough it up, finish the part and have entered the nerves of a mold with a 0.5mm tool, there are few machines in the world that can do it.
The same is true for Hitachi tools, we are fully confident in their capabilities. We have known the brand for years and every tool we have bought has worked. When Garbitec started, that relationship was strengthened and they helped us select the products that could best fit into our processes, they gained trust step by step. The doors were open to all firms, the problem was presented to them and they all brought the solution they considered the most appropriate. In the end it was tested and we opted for the best. It is true that for some jobs you cannot always be testing, but when there are doubts and a lot of tool consumption, testing is a must.
In the workshop we look for performance, optimal cutting conditions, efficiency in working time and tool life ”.
Because in a machining company the tools should be important, but they are more so when no one is operating the machine. “Everything is so automated that the tools go to the machine, they are removed from the machine, they go through the tool room where plates are put back on them, they go to measurement, again to the machine and all that data is automatic.”
“From MMC Hitachi, in addition to the quality of its tools, we value the support in the process and the dedication of its technicians. When you are faced with a job that you don’t know how to approach, a new job, being able to sit down with a person who knows their products and spend an hour or whatever it takes working, is a very important help, knowing the high demands that this market poses. You know you can’t fail.
They know that the jobs have to be very well finished, that they are jobs of great precision, of a very high quality of surface finish and if a tool breaks or gets stuck in a 0.8mm wide slot it can no longer be removed. Hitachi offers a product that it knows you are going to win with. We are not looking for a minute, not five minutes, we are looking for a 0.8mm tool that is working 8 hours with full guarantees. At the end of all the problems that may arise from day-to-day work, we seek to rule out some of the possible sources. In our case, we have that confidence in the Makino machine and the Hitachi tools ”.
A great challenge successfully overcome
Of all the experience acquired by these two entrepreneurs, three jobs stand out, each for different reasons, have left a deep mark. “Personally – recalls Roberto Corredera – I was working for two and a half months on a mold 3 meters high by 2 meters wide, both in programming and in the workshop … It was a huge mold full of hairpieces. That was the first job I did with CAD-CAM. Later, at Garbitec I made the prototype of a head for a 5-axis Bost machine. We started with 700 kilos and finished at 110. It was a very complex head that was finished on a precision boring machine in the Basque Country. The third project was a very complex mold made only with Hitachi MMC tools ”.
In total, the project involved 50 hours of tool contact where the maximum diameter burs were 3, 2, 1, 0.8mm. “The machine did not stop at any time, it went through process after process and the work was tacked to perfection. And that when we started, we came to think that we had gotten into a big problem, when we saw the grooves, the small channels, their difficulty and imagined the strawberries that we had to use. I was with the Hitachi technician for a couple of days reviewing tools because we had to face very complex areas to machine. In the end he raised us a complete battery and the machine started on a Saturday afternoon and worked until the mold was finished perfectly. We work with 15 contact hour tools and one of the best things about Hitachi is the low wear on the high performance tools.
THE TOOLS THAT MADE THE MOLD
One of the most complex challenges faced at Dyrtech was the realization of a very complex mold. The test was fully passed using the MMC Hitachi tool Europe tools listed below.
- ASR-30 [Maxi pick]: High feed tool for steels and hardened steels with which a large flow of chips with long tool life is achieved.
- ASM / AHU [Mini Pick]: High feed insert tool in diameters from Ø8 to Ø32. Indicated for machining of remains and semi roughs.
- ABPF / ARPF [Alpha Ball / Radius Precision Finish]: High precision ball or toric tool for finishing with very good qualities and long tool life even in tempered materials.
- ETRP [Epoch Turbo Rib Pencil]: High feed toric tool with 4 lips and diameters from Ø1 to Ø3. With depths up to 50 times the diameter, it is ideal for machining rib grooves. (replaces EDM work).
- EPDBPE [Epoch Miniature Line]: Ball tool with reinforced neck. Perfect for machining spokes, with patented geometry for maximum precision.
Source: & nbsp; http://www.izaro.com