Design, manufacture and repair of forming tools with an in-house press shop for sheet metal parts in small series
Karl-Heinz Kup Werkzeugbau GmbH & Co KG
51465 Bergisch GladbachNew on Amplifa
40 years of innovative toolmaking
KUP Werkzeugbau from Bergisch Gladbach is a long-established toolmaking company specializing in forming tools for sheet metal processing. Its range of services includes the design and manufacture of progressive compound dies, stage tools, drawing, cutting and transfer dies as well as their assembly, tryout on its own presses and repair. Mechanical machining comprises CNC milling on bed-type milling machines and machining centers, 4-axis wire EDM (cylindrical and conical) and surface grinding of hardened tool steels with parallelism of 0.01 mm. As contract work, individual components such as cutting blades, form inserts, cam slides and punches are manufactured. Using handheld tools, the in-house press shop produces sheet metal parts in small series, among others for automotive suppliers. Design and programming are carried out with Catia V5, Mechanical Desktop and HyperMil; measurements are documented on a coordinate measuring machine with CAM2 Automotive.
- Site
- Bergisch Gladbach
- Processes
- CNC milling (bed-type milling machines, machining center), Wire EDM (cylindrical and conical), Surface grinding (parallelism 0.01 mm, hardened tool steels up to 64 HRc), Design (Catia V5, Mechanical Desktop, 2D to freeform surfaces), Assembly/repair of tools, component modifications, optimizations, conversions, Quality inspection with individual measurement report, Manufacture of progressive compound dies and stage tools, Manufacture of drawing dies
- Materials
- Tool steel (hardened, up to 64 HRc), Sheet metal, CNC milling, Wire EDM (4-axis), Surface grinding
- Certificates
- Individual measurement reports (CMM, CAM2 Automotive)
- Industries
- Automotive industry / automotive suppliers, Automotive industry / automotive suppliers (sunroof parts, longitudinal
- 01
Design (Catia V5, Mechanical Desktop, HyperMil)
- 02
Machining (CNC milling, wire EDM, surface grinding)
- 03
Assembly and repair
- 04
Tool tryout on own presses
- 05
Quality inspection with measurement reports
- 06
Press shop: sheet metal parts in small series
Materials and manufacturing processes
Tool steel (hardened, up to 64 HRc)
Used in machined tool elements; surface grinding is performed up to 64 HRc with parallelism 0.01 mm.
Sheet metal
Material for small-series parts manufactured in the in-house press shop.
CNC milling
Manufacture of individual components such as cutting blades, form inserts, cam slides and punches on bed-type milling machines and machining centers.
Wire EDM (4-axis)
Cylindrical and conical cuts, e.g. free-eroding of scrap channels in cutting plates; workpieces up to 360 kg.
Surface grinding
Plates up to 700 x 700 mm, corundum and CBN, parallelism 0.01 mm.
Bergisch Gladbach site
Bergisch Gladbach
DEHeadquarters, toolmaking, mechanical machining, press shop
- Part weight / size
- Tools up to 17.5 t; wire EDM up to 360 kg
- Lot size
- Single parts to small series
- Materials
- Tool steel, sheet metal
- CNC bed-type milling machine Novar KBF (table 2500 x 1700 mm)
- CNC bed-type milling machine Anayak VH 1800
- CNC machining center Sailo TV 1000 A
- CNC wire EDM machine Fanuc Mod. Q (4-axis)
- Surface grinding machine Geri (corundum/CBN)
- Hydraulic press Müller Weingarten 630 (6300 kN)
- Hydraulic press Schuler 250 (2500 kN)
- Crank press EBU (1500 kN)
- Coordinate measuring machine Zett (1800 x 1200 x 800 mm)
- Crane DMAG 10 t, in-house crane 5 t
- Forklift Clark (7 t, 2x 5 t)
Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| CNC milling (bed-type milling machines, machining center)Machining | – | – | – | – | Tool steel |
| Wire EDM (cylindrical and conical)Machining | – | – | 360 kg | – | Tool steel |
| Surface grinding (parallelism 0.01 mm, hardened tool steels up to 64 HRc)Machining | 0.01 mm | 700 mm × 700 mm | – | – | Tool steel (hardened, up to 64 HRc) |
| Design (Catia V5, Mechanical Desktop, 2D to freeform surfaces)Engineering | – | – | – | – | – |
| Assembly/repair of tools, component modifications, optimizations, conversionsAssembly | – | – | – | – | – |
| Quality inspection with individual measurement reportInspection | – | – | – | – | – |
| Manufacture of progressive compound dies and stage toolsForming | – | – | – | – | – |
| Manufacture of drawing diesForming | – | 1300 mm × 450 mm | – | – | Sheet metal |
| Manufacture of cutting/trimming diesForming | – | 1100 mm × 550 mm | – | – | Sheet metal |
| Manufacture of transfer dies (drawing, trimming, upsetting, with mechanization)Forming | – | 3400 mm × 1700 mm | 17.5 t | – | Sheet metal |
| Sheet metal parts in small series on own presses using handheld toolsForming | – | – | – | Small series | Sheet metal |
| Digitizing / CAD-CAM programming (HyperMil)Engineering | – | – | – | – | – |
| Contract work: manufacture of individual components (cutting blades, form inserts, cam slides,Machining | – | – | – | – | – |
12 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC bed-type milling machine | Novar KBF | 1 | Table 2500 x 1700 mm, travels x2100 y1000 z1400, installation height 1200 mm | – | Bergisch Gladbach |
| CNC bed-type milling machine | Anayak VH 1800 | 1 | Table 1100 x 800 mm, travels x1600 y800 z600, installation height 700 mm | – | Bergisch Gladbach |
| CNC machining center | Sailo TV 1000 A | 1 | Table 800 x 800 mm, travels x800 y600 z500, installation height 400 mm | – | Bergisch Gladbach |
| Hydraulic press | Müller Weingarten 630 | 1 | Ram force 6300 kN, cushion 2000 kN, blank holder 630 kN | – | Bergisch Gladbach |
| Hydraulic press | Schuler 250 | 1 | Ram force 2500 kN, cushion 1200 kN | – | Bergisch Gladbach |
| Crank press | EBU | 1 | Ram force 1500 kN | – | Bergisch Gladbach |
| CNC wire EDM machine (4-axis) | Fanuc Mod. Q | 1 | Travels x350 y500 z200, max. workpiece weight 360 kg | – | Bergisch Gladbach |
| Surface grinding machine | Geri | 1 | Travels x700 y700 z500, abrasives corundum and CBN | – | Bergisch Gladbach |
| Coordinate measuring machine | Zett | 1 | Travels x1800 y1200 z800, software CAM 2 Automotive (Faro) | – | Bergisch Gladbach |
| Crane | DMAG | 1 | Load capacity 10 t | – | Bergisch Gladbach |
| Crane (in-house build) | – | 1 | Load capacity 5 t | – | Bergisch Gladbach |
| Forklift | Clark | 3 | Load capacities 7 t and 2x 5 t | – | Bergisch Gladbach |
Additional services
Quality
Regular quality inspections with defined inspection cycles are documented, so that defects are corrected already during the production process. An individual measurement report is prepared on request; measurements are performed on a Zett coordinate measuring machine with CAM2 Automotive software (Faro).
| Evidence | Bergisch Gladbach |
|---|---|
| Individual measurement reports (CMM, CAM2 Automotive) |
History
- ca. 1980
The website advertises 40 years of experience in innovative toolmaking (founding year not explicitly stated)