AMT FEB 2014

feb14 Australian Manufacturing Technology

Your Industry. Your Magazine.

Automotive – Is additive the future?

PAGE 40

.Motorsport & Automotive .Cutting Tools .Forming & Fabrication .Q&I .Materials Handling

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contents

Volume 14 Number 01 FEBRUARY 2014 ISSN 1832-6080

MOTORSPORT & AUTOMOTIVE Ford Performance Racing – Leading the field Olympus helps keep Frosty on track TaeguTec – For the love of the sport Monash dominates 2013 Formula SAE

42 48 50 52

CUTTING TOOLS Milling tooling progress Milling intelligently: Indexable chatter free Tapping into Sutton Tools’ expertise High-feed milling – tips and tricks

58 60 62 63

FORMING & FABRICATION Steelpro brings in giant CMT- Yawei press brake Recent advances in plasma cutting of stainless steel To test cut, or not to test cut?

64 66 70

QUALITY & INSPECTION The evolution of CMM probing systems ‘The next inspector is the customer’

74 76

MATERIALS HANDLING Energy savings conveyor investment How to listen to a forklift truck

78 80

From the Minister From the Industry From the AMWU From the CEO

10 12 14 16

INDUSTRY NEWS Lovitt and Marand to supply F-15 fighter jet ACS Australia co-op deal with Smart Fibres Global output growth at 32-month high Australian among winners in 3D competition Australia’s first Flow Control dump truck body Jamaica buys 12 Bushmasters Delcam: Autodesk takeover

18 18 20 22 24 26 26

PRODUCT NEWS Our selection of new and interesting products

29

COMPANY FOCUS Barden Fabrications

72

AMTIL INSIDE The latest news from AMTIL

90

AMTIL FORUM Forum Finance: Offshore investment opportunities knock Forum HR: The cos of not having a drug-free workplace?

Forum Law: Product importation Forum OHS: Work health & safety laws: Update

84 85 86 87

Manufacturing History – A look back in time

88

feb14 AustrAliAn MAnufActuring technology

your industry. your Magazine.

Automotive – Is additive the future?

PAGE 40

.Motorsport & AutoMotive

6 |

.Q&I .Cutting Tools .Forming & Fabrication

.Materials Handling

40

Additive revolution, automotive evolution The list of things that additive manufacturing can do seems to get longer by the minute, but for a long time the idea of 3D printers being used to build cars has seemed far-fetched. However, if the work of KOR EcoLogic is anything to go by, that future may not be so far off after all.

54 ONE ON ONE – Stuart Charity Stuart Charity is the Executive Director of the Australian Automotive Aftermarket Association. He explains what Australia is really good at: specialty equipment (ie 4WD products and high-performance or motorsport products).

He also discusses automotive aftermarket manufacturing; Holden, Ford, Toyota; what the government should be doing to help and the outlook for the future.

68

Cover KOR EcoLogic, Canada, had a vision for a more fuel-efficient car that would change how the world approaches manufacturing. They have now completed the prototype of Urbee, the first car to have its body 3D-printed, and reportedly the greenest practical car ever made.

Page 40

AMT February 2014

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FROM THE

Editor William Poole

The road ahead It’s not easy producing an Automotive feature at a time Australian car-manufacturing is arguably facing its greatest period of upheaval in decades. You get everything planned out: a broad round-up of the industry, its future outlook, the steps that could be taken to support it… then someone holds a press conference, and it’s back to the drawing board.

Of course, some mild disruption to AMT’s editorial planning is utterly trivial compared with the impact Holden’s decision to cease manufacturing in Australia in 2017 will have on the thousands of workers, suppliers and communities affected. The announcement, a few months after similar news from Ford, ended 2013 on a bleak note.

Thousands of column inches have been generated since the 11 December announcement.

And argument continues to rage over what might have been to done to avert Holden’s departure; how Toyota, now the last remaining local car manufacturer, will respond; and what it means for Australian manufacturing.

Editor WIlliam Poole wpoole@amtil.com.au Contributors Carole Goldsmith Sales Manager Anne Samuelsson asamuelsson@amtil.com.au Publications Co-ordinator Gabriele Richter grichter@amtil.com.au Publisher Shane Infanti sinfanti@amtil.com.au Designer Franco Schena fschena@amtil.com.au Prepress & Print Printgraphics Australia AMT Magazine is printed using FSC mix of paper from responsible sources FSC© C007821

AMTIL has maintained a clear stance that a local car manufacturing industry is something we should fight to retain and support. And this month’s AMT does not shy away from the issues arising from Holden’s decision. But overall, we felt there would be little value for our Automotive feature to further rehash a debate covered the last few weeks. Instead, we’ve sought to highlight areas where Australian manufacturers might find new opportunities to prosper, as well as areas where Australia already excels.

So we learn how radical changes to automotive design, engineering and production are beginning to emerge as a result of additive manufacturing; one of many areas where Australia, with its demonstrated talent for innovation, has a chance to become an influential player internationally. We look at motorsports, an Australian obsession, and the manufacturing processes it involves – a field in which we can already claim to be a genuine global leader.

And in our report on the Formula SAE-Australasia finals, we see how a new generation of design and engineering students are showing the potential to become world-beaters.

Back in late October, just after AMT began its annual summer shutdown, the GermanAustralian Chamber of Industry and Commerce (GAC) held a conference in Melbourne. One of the highlights was a presentation by Professor Hermann Simon, chairman of the global consultancy Simon-Kucher & Partners.

A renowned authority on German business, Simon discussed a category of manufacturing companies he identifies as ‘Hidden Champions’. He defines Hidden Champions as companies that are globally competitive in niche sectors – in the top three worldwide and number one in their home continent – but that are usually relatively small (with revenues below €5bn), and that are not well known to the general public. Germany has by far the most Hidden Champions, with 1,307 companies meeting the criteria – in second place by some distance was the US, with 366.

Australia currently has 10. But what struck me was that many of the conditions required for Hidden Champions to thrive are abundantly present here. There’s just one important caveat: according to Simon, it’s vital to have a strong manufacturing base, and crucially, to defend that base.

The blame game over Holden’s departure will be played out in the media for some time yet.

But Australian manufacturing can still have a bright future, provided there is the political vision and will to support it.

AMTIL DIgITAL MeDIA KIT 2013 8 |

AMT February 2014

Contact Details AMT Magazine AMTIL Suite 1, 673 Boronia Rd Wantirna VIC 3152 AUSTRALIA T 03 9800 3666 F 03 9800 3436 E info@amtil.com.au W www.amtil.com.au Copyright © Australian Manufacturing Technology (AMT).

All rights reserved. AMT Magazine may not be copied or reproduced in whole or part thereof without written permission from the publisher.

Contained specifications and claims are those supplied by the manufacturer (contributor)

Disclaimer The opinions expressed within AMT Magazine from editorial staff, contributors or advertisers are not necessarily those of AMTIL. The publisher reserves the right to amend the listed editorial features published in the AMT Magazine Media Kit for content or production purposes.

AMT Magazine is dedicated to Australia’s machining, tooling and sheet-metal working industries and is published monthly.

Subscription to AMT Magazine (and other benefits) is available through AMTIL Associate Membership at $165 (inc GST) per annum.

Contact AMTIL on 03 9800 3666 for further information.

The bIgger pIcTure In A sMALLer pAcKAge For further information call Anne Samuelsson on 03 9800 3666, mobile on 0400 115 525 or email asamuelsson@amtil.com.au

FROM THE

Minister Ian Macfarlane – Minister for Industry

An integrated, strategic approach to supporting manufacturing There’s no getting around it, late 2013 was by any measure a tough time for Australian manufacturing.

GM Holden’s decision to follow Ford in pulling out of Australian auto production presents a challenge not only to auto workers but to component manufacturers and to Toyota.

As GM’s then-Chairman and CEO Dan Akerson said in announcing the closure, “The decision to end manufacturing in Australia reflects the perfect storm of… the sustained strength of the Australian dollar, the high cost of production, a small domestic market, and arguably the most competitive and fragmented auto market in the world.”

The fall in manufacturing production over the last few years makes it obvious that at least some of these factors are having an effect on manufacturers outside of the auto industry. But despite these tough circumstances, this government is committed to supporting Australian manufacturing through an integrated and strategic approach.

Assisting auto workers and communities Of course, our immediate priority is to support the workers, communities and economies affected by the Holden and Ford closures in a real and meaningful way. To do this we’re putting in place a $100m growth fund aimed at driving practical initiatives to assist manufacturers in responding and adapting to the changing environment. The central aim is to help them transform from heavy industrial manufacturing to higher value-added production.

We also aim to work with state governments and local business to boost the competitiveness of South Australia (SA) and Victoria. To make sure that we fully understand the issues involved, and to make sure that we get the maximum return on the funds invested, we’re putting in place reviews of the economies of both these states.

Reviewing state economies The reviews are underway with submissions received, a public consultation being held in January and February, and the final report due by the end of February.

As the chair of these reviews, I am seeking submissions that address the best ways to: • Encourage investment and innovation in new or emerging high-growth sectors.

• Support the diversification of the automotive supply chain businesses.

• Support the training and redeployment of workers displaced by the closures.

Listening to business Another of the government’s priorities has been listening to the business community. That is why we established the Prime Minister’s Business Advisory Council, as one of our first initiatives. The Council recognises that a strong economy needs profitable and dynamic businesses to generate jobs and revenue.

The Council’s advice helps to guide the development and implementation of programmes and policies that are sympathetic to the needs of both small and large Australian businesses. To ensure that manufacturing has voices at the table, Barry Irvin AM, Chairman of Bega Cheese, and Graham Kraehe of BlueScope Steel, have been appointed as two of the 12 members.

10 |

AMT February 2014

Promoting competiveness and productivity One of the first roles of the Business Advisory Council is to contribute to the development of the Prime Minister’s National Industry Investment and Competiveness Agenda. This is a high-level plan to sustain and grow our manufacturing industry, developed by a taskforce including the PM, the Treasurer, the Minister for Trade and Development, and myself as Minister for Industry.

The taskforce will focus on measures to promote national competiveness and productivity by lowering the costs of doing business, encouraging innovation, developing productive infrastructure, and boosting investment. We anticipate having a plan to government by the end of June.

Where to from here?

As Minister for Industry, I’ve spent the first few months meeting with many of the main players in the automotive and food-processing sectors, as well as other industries.

One thing that business has already told me is that the carbon tax is a major impediment to business and our natural competitiveness.

Repealing the carbon tax is critical to creating a fair playing field for our manufacturing in particular. Legislation for the tax’s repeal has already been passed by the House of Representatives and is up for debate in the Senate. I expect the Senate to heed the result of the last election and to pass the legislation in line with the will of the electorate.

Another significant cost factor hurting business is excessive red and green tape, which is why I’ll establish Action Agendas this year. These agendas will enable me to set out reductions in red and green tape and develop a framework to promote investment and jobs growth.

I’ll also invite prominent Australian business people to join a Ministerial Advisory Council to ensure that I hear from business about the most appropriate ways to tackle over-regulation and consult on policy.

And, as Minster responsible for skills and training as well as industry, I will use the scope of this portfolio to deliver the skills that industry wants and needs, to build on productivity and innovation in 2014.

“The decision to end manufacturing in Australia reflects the perfect storm of… the sustained strength of the Australian dollar, the high cost of production, a small domestic market, and arguably the most competitive and fragmented auto market in the world.”

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FROM THE

Industry Innes Willox – Chief Executive Australian Industry Group

Opportunities await, along with tough decisions For many manufacturers it almost goes without saying that 2013 was a very tough year. There are some signs of improved conditions in 2014, but businesses and governments alike must act to seize the opportunities that arise.

In 2013, the Australian manufacturing industry battled against the considerable headwinds of the strong dollar, intense competition from emerging economies, a legacy of low productivity growth, a growing unit labour cost disadvantage and considerably higher energy prices. However, with the dollar closing the year about 16% off the high points of 2013, and hopefully some further falls to come, manufacturers will be in more of a position to take advantage of the opportunities that lie ahead of us, particularly in the growing markets of Asia.

To make the most of this will require new business directions and the right policies from federal and state governments to encourage a new phase of investment and innovation. In addition, the new Federal Government in Canberra faces intensifying industrial restructuring, and the Australian Industry Group will continue to argue for strategies and policies that promote a balanced and diversified growth path – one that reduces the risks to national wellbeing associated with our heavy reliance on the export of a handful of commodities to a handful of countries.

As General Motors’ recent decision to cease manufacturing in Australia has emphasised, decisive action – both from Government and industry – will be necessary in 2014 and beyond if we are to continue to ensure a strong and dynamic industrial sector in Australia. Among the most urgent priorities for the year ahead are:

In this regard, the Australian Industry Group does not support “corporate welfare” if that refers to handing out taxpayers’ funds without proper justification and transparency. At the same time it is too easy – and indeed it is counter-productive – to lump all expenditure and tax expenditures related to business in the “corporate welfare” bucket. The Research & Development Tax Incentive is a case in point as it has a very strong policy rationale behind it. Similarly, government funding of, and incentives for, workforce training initiatives are well supported by very good policy arguments.

The same can be said for programs like the federally funded Enterprise Connect program, which is proving to be very successful at lifting the productivity of small and medium-sized businesses.

Measures that address the failure of financial markets to provide early-stage capital are similarly well supported. In the end, in place of ideological positioning, it must come down to a careful evaluation of the community-wide costs and benefits and the alternative uses of the funds. This assessment must take into account the inefficiencies associated with taxation as well as any benefits that flow to the broader economy as a result of the spending programs.

• Improving our tax system to help industry invest and contribute to new employment growth.

One very topical area is the programs that assist in redirecting Australia’s manufacturing efforts as the industry itself undergoes rapid restructuring. As mentioned, the benefits of well-targeted and carefully designed programs in this area include reducing the exposure of the economy to what has become an excessive reliance on commodity exports. Broad economy-wide benefits can be achieved if programs can assist in the more rapid development of the new sources of industrial strength than would occur if we relied purely on market forces to deliver us a diversified and balanced growth and to provide opportunities for employees ‘liberated’ in the course of restructuring.

The current budgetary difficulties make it even more important to look very closely at all areas of public sector expenditure and to eliminate wasteful or inefficient programs. Expenditure directed to businesses and business programs should not be shielded from rigorous assessment.

It is critical, both at the political level and in our own businesses, that we get these tasks done. The Australian Industry Group intends to continue to take a leading role and will consult widely to meet our objectives of working in the best interests of our members, the manufacturing sector and the strength of the broader economy.

• The repeal of the carbon tax and the implementation of its replacement policy.

• Further workplace relations reform to allow greater flexibility and to boost productivity.

• Defining a credible path for getting the federal budget in order.

Manufacturers will be in more of a position to take advantage of the opportunities that lie ahead of us, particularly in the growing markets of Asia… To make the most of this will require new business directions and the right policies from federal and state governments.

12 |

AMT February 2014

FROM THE

AMWU Paul Bastian – National Secretary Australian Manufacturing Workers Union

Urgent vision needed for manufacturing’s long game Australia goes into a new working year after a traumatic period for manufacturing. The challenges of the high dollar and intense international competition are well familiar. But late last year a disturbing X factor was added – a new Federal Government seemingly intent on standing idly by and letting the sector be hollowed out.

In the cases of Electrolux, Caterpillar and Simplot, we saw the Government point blame at overseas management. We saw SPC Ardmona’s business case misrepresented in the media through leaks by government ministers. And we saw the future of a whole region and industry be put on tenterhooks while the government debated whether it believed manufacturing was ever worth saving.

And then there was the issue of the auto industry and Holden’s future. No-one would have guessed how this absurd drama would play out in the twilight of 2013.

We are all familiar with its acts and they are not worth reliving here, but Tuesday, 10 December 2013 will forever be remembered as the day the Federal Government turned its back on decades of bipartisan partnership and support, and publically goaded an Australian manufacturing icon into closing. As a result, there is a very real threat of closure of the entire automotive manufacturing sector, its 50,000 direct jobs, many other related jobs, and a hit to the national economy of over $21bn.

It is the Government’s actions that will determine whether Toyota stays, whether the auto supply chain diversifies into new products and new export markets, and whether workers find good new jobs. A new dawn, or darkness for future decades. It underlines the urgency for a thoughtful, strategic industry plan, not a token political plan.

The AMWU has formulated some key ingredients of such a plan in our study A Prosperous Australia, which we will be further developing in early 2014.

The blueprint includes: • Establishing a new expert Manufacturing Finance Corporation, similar to the Export Finance Insurance Corporation, to allow viable firms access to funds for diversification, restructuring and investment; something any manufacturer can tell you is extremely difficult. It would require a $2.5bn commitment in federal funds to get going, but since it would be an equity injection, it would not hurt the budget deficit.

• The expansion of the Automotive New Markets Program from $47m to $150m to 2016, and new Manufacturing Transition Grants worth $100m to 2017.

• Moving the Productivity Commission’s role in trade disputes to the new Anti-Dumping Authority, which has shown itself during the recent SPC case to be a more realistic adjudicator in fair trade than the ideologically-driven PC. The risk to skills, technical expertise and managerial knowledge through the loss of Holden’s global links makes the strengthening of our defence industries in these areas all the more vital. Holden was effectively a funnel through which such expertise is transferred across the defence and higher technology sectors, or as South Australia Premier Jay Weatherill described it ‘a giant training college’.

A start on retaining this can be made in coming months if the Government meets the urgent need to safeguard shipbuilding

14 |

AMT February 2014

jobs and skills by commissioning a fourth Air Warfare Destroyer or announcing replacements of two transport ships to be built in Australia. This would also prepare Australia, particularly Adelaide’s defence sector, for the coming decade’s massive project to replace the existing Collins Class submarine fleet. Such a move would be a first step in securing the $250bn, 30-year shipbuilding pipeline for our domestic industry.

The costs of letting a manufacturing icon go run deep, and go beyond the purely economic. They hit thousands of workers, families and their communities. Some, like Elizabeth in SA, are already under enormous social pressure, with unemployment there around 14%. We don’t want US-style urban ghettos or “no-go” zones in Australia. Our people deserve better.

An adequate Community Support Program to protect the fabric of those Melbourne and Adelaide suburbs is likely to run to $877m, but this could reach $1.8bn if Toyota closes, taking the rest of the supply chain with it.

So far the response from the Federal Government has been manifestly inadequate and fails to recognise the impact Holden’s closure will have on the entire auto sector – a mere $60m with the expectation SA, Victoria and Holden will boost it to $100m. That’s a paltry sum, a little over 2.5% of the $3.6bn total spend outlined in A Prosperous Australia (which does not include the cost of additional shipbuilding projects) to ensure a transition for workers, support for communities and an ongoing manufacturing sector.

Senior AMWU officials met Prime Minister Tony Abbott just after he announced the $100m package. They came away feeling that the PM has little conception of the depth of the shockwave that will sweep through the auto sector and into the wider manufacturing industry as a result of Holden’s loss.

For all Abbott’s faith that the “invisible hand” of the market will create sufficient jobs to replace those lost, experience is never so neat and simple. Mitsubishi closed its gates five years ago, yet only about one-third of its workers have found full-time jobs. About a third struggle along as lower-paid part-timers or casuals, while the others who did not retire are still long-term unemployed.

The role of co-investment remains vital, but Abbott has dumbed the concept down, misrepresenting it in the media as the negative notion of ‘corporate welfare’.

This Government rated manufacturing as the first among its five pillars for a stronger economy. The PM pledged he would create 2m new jobs in the next decade. In its first months, we have seen Holden announce closure, SPC hang on the edge, and $96m cut from manufacturing programs in the MYEFO mini-budget.

It’s not too late for the PM to grab the wheel back from the “drys” in Cabinet before they run his Government – and Australia – off the road.

For the AMWU report A Prosperous Australia go to: www.amwu.org.au/content/upload/files/publications/A_ Prosperous_Australia_final.pdf

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FROM THE

CEO Shane Infanti – Chief Executive Officer AMTIL

Do we have a manufacturing vision?

Can we survive as “a farm, a hotel and a quarry”? As important as farming, tourism and mining are to the Australian economy, manufacturing is still the biggest provider of full-time jobs in the country. It simply must command more attention and urgency from our Government.

We run the significant risk that within five years we will be the only G20 nation without its own car manufacturing industry. There has been, and will continue to be, enough written about the influence that the Federal Government can have on the future of our automobile industry so I will refrain from adding to that in this column.

What I am just as interested to know from the leaders of this country is where they see the future of manufacturing. If the car industry is non-existent in five years, what do we replace it with?

What will we be recognised as (in a manufacturing sense) by the rest of the world?

Is it possible, for example, for us to become world leaders in the agricultural and food production industry? I’m not just talking about the cultivation of plants and animals. What about biotechnological innovation in pesticides and food fibres? Or what about the manufacturing of farm equipment and the fabrication of food and processing equipment? Smart conveying with robotic vision systems, recycling and waste management, efficient engines and pumps, helicopters for aerial spraying or livestock herd management are just some examples that this industry could spawn.

We are the most drought-affected country in the world. We could become world leaders in the development and implementation of infrastructure for water movement. We are the most remote country in the world. We could become world leaders in material handling and the development of equipment to transport food over long distances. We are already a nation where agriculture is an established industry. We could become world leaders in the new wave of agriculture – industrialised farms, innovative irrigation systems, computer monitoring systems, GPS locators and driverless tractors, for example.

We are already in many of the areas I have mentioned above. In a lot of cases we have very successful companies, ‘Hidden Champions’ if you will, in this industry. There is something for us to build upon.

The challenge is for it to be recognised by the rest of the world that this is our space. Building the champions, developing strong local supply chains, becoming world leaders, and marketing and branding ourselves as that – all of this requires leadership and vision.

The future of modern agriculture and food manufacturing is at our feet. What can we make of it?

On the topic of leadership, AMTIL will be running the inaugural Australia’s Manufacturing Conference, with the theme ‘Leadership In Business’, at the Sheraton Mirage on the Gold Coast from 5 to 7 June 2014. There are 28 local and international speakers delivering keynote addresses and streams including technology, management and opportunities. The Conference also includes dinners, networking and social activities. This is a great opportunity for education, learning, networking and business generation.

For more information visit www.amtil.com.au

16 |

AMT February 2014

industry news

Lovitt and Marand to supply F-15 fighter jet Boeing has expanded its relationship with Australian industry by selecting Lovitt Technologies Australia and Marand Precision Engineering to make components for the F-15 multi-role strike fighter jet.

Lovitt and Marand are part of the Defence Materiel Organisation’s Global Supply Chain (GSC) Program, which works with the Boeing Office of Australian Industry Capability (OAIC) to match Boeing to the capabilities of Australian industry.

“Boeing continues to develop tremendous value in Australia by working with local defence industry partners to build capability and deliver products into our global supply chain,” said Ian Thomas, president of Boeing Australia & South Pacific. “Through the OAIC, Boeing has issued contracts totalling more than US$285m to highly skilled Australian companies over the past five years.”

“The fact that Lovitt has been able to break into a program for which Australia is not a current customer is evidence that the GSC program is working really well,” said Lovitt Managing Director Marcus Ramsey.

“It is a definite source of pride knowing that Lovitt’s high-quality work is a part of multiple Boeing aircraft platforms that serve the needs of customers all over the world.”

Lovitt will manufacture trailing edge fairings for the F-15, the fifth Boeing aircraft program it will supply. The company now makes components for the Boeing P-8A Poseidon maritime reconnaissance aircraft, F/A-18E/F Super Hornet fighter, the CH-47 Chinook helicopter and the Bell Boeing V-22 Osprey tiltrotor.

Marand, in its first defence contract with Boeing, will supply fuel tank installation equipment, specialised hand tools and structural support pieces.

“This contract is a great step for us in extending our relationship with Boeing in both work scope and outside of Australia,” said Rob Kusters, Aerospace and Defence Manager at Marand.

In addition to the F-15 work, both companies also support activities producing flight control surfaces for large commercial aircraft at Boeing Aerostructures Australia, the company’s largest manufacturing footprint outside North America.

STC launches ‘The Tap’ technology coworking space STC (the Small Technologies Cluster) has announced the launch of ‘The Tap’, an advanced technology coworking space designed to meet the needs of small teams, start-ups and consultants who want to get things done in advanced and emerging technologies like micro-, nano- and bio-technology, medical devices and ICT as it converges with these areas.

Located at 1 Dalmore Drive in Scoresby, Victoria, The Tap offers flexible open workspace in a hotbed of collaboration, connectivity, networking and support. Participants get actionable advice through regular TechTalks and can receive one-on-one pro bono consultations with leading experts through the Help Desk. The space also boasts a workshop that includes a suite of 3D printers for basic modelling needs and an advanced CAD workstation and a business intelligence portal. The Tap is also an international soft landing where overseas advanced technology professionals can work, network and collaborate with Australia’s advanced technology cluster.

“Whether it is an entrepreneur connecting with an industrial designer over a cappuccino, or getting feedback from coworkers on your newest 3D printed model, the quality and quantity of interactions is effectively ‘facilitated serendipity’ that helps connect those with similar challenges and complementary experiences and wisdom together in a space where participants can share in individual successes,” said Laura Faulconer, STC’s Head of Business Development and Marketing. “In addition to a ‘cool vibes’ facility with fast internet and flows of really smart

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AMT February 2014

people, ‘The Tap’ offers a flexible, low-cost and vibrant place to get things done,” said Buzz Palmer, STC’s General Manager.

The Tap has been launched with assistance from long-term supporters of the advanced technology cluster, including Caribbean Business Park, Wilkore Construction, SKM, RDA Melbourne East, and LEAP Australia. More information can be found at www.STCaustralia.org/coworking.

STC promotes commercialisation and entrepreneurship around next-generation innovations with programs that grow new businesses. Many sectors, like biotechnology, medical devices, life science and information technology, are converging around this rapidly growing core of cutting edge innovation. STC seeds and catalyses new industry opportunities through the development and uptake of small and emerging technologies. STC provides the infrastructure to accelerate commercialization, links with key stakeholders across industry, government and academia necessary to nurture cross-fertilisation of innovation, and is the clear and consistent voice of those developing, integrating, or supporting emerging enabling technologies.

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industry news

Australian PMI: Slow end to sluggish year for manufacturing The Australian Industry Group Australian Performance of Manufacturing Index (Australian PMI) ended 2013 where it was for most of the year – in negative territory.

The latest seasonally adjusted Australian PMI recorded 47.6 in December, which was broadly unchanged (down 0.1 point) on the November result and below the 50 point level separating expansion from contraction. The negative results for November and December brought an abrupt end to a promising two months of mild expansion in activity.

“2013 ended without much cheer for many Australian manufacturers with the gains recorded in September and October reversed in the closing months of the year,” said Ai Group Chief Executive Innes Willox. “New orders and employment fell further behind in December casting doubt over whether the start of 2014 will usher in a more positive outlook for manufacturing activity.

The manufacturing sector had been showing signs of recovery, in September recording the first expansion in over two years.

October’s index saw a further rise, climbing 1.5 points to 53.2, a result largely driven by improvements in new orders, production and deliveries. However, in November the index fell by 5.4 points to 47.7.

Levels of contraction varied between the major indexes in December, with employment dipping below 50 points following an expansion in November. Production levels improved to 48.6, but manufacturing exports remain very low with a December reading of 30.1. Wages grew at a slower pace (54.8).

“The sector, and indeed the broader economy, remains stuck behind the eight ball and manufacturing in particular is, as yet, in no position to assume a role in generating alternative sources of growth as the mining boom fades,” added Willox.

“Notwithstanding that interest rates are at low levels and that the Australian dollar appears to be on its way back down to more realistic levels, conditions in the sector remain very tough.

While all the activity indexes remained below 50 in December, across the sub-sectors food and beverages continued to expand (55.8 points, 3 month moving average), as did two of the smaller sub-sectors of wood & paper products (73.1) and printed & recorded media (59.0).

“This latest snapshot is yet another reminder of the urgency for Australia to put itself on a more balanced and diversified growth path,” added Willox. “Manufacturing and related industries have a critical part to play in this strategy.”

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AMT February 2014

Global output growth at 32-month high The end of 2013 saw growth of the global manufacturing sector accelerate to a 32-month high.

The JPMorgan Global Manufacturing PMI – a composite index produced by JPMorgan and Markit in association with ISM and IFPSM – rose to 53.3 in December, up from 53.1 in November, to signal expansion for the twelfth month in a row. The average reading of the headline PMI through 2013 as a whole (51.5) was better than the stagnation signalled over 2012 (PMI: 50.0). The rate of expansion registered for the final quarter of 2013 was the best since Q2 2011.

Global production expanded for the 14th straight month in December. Moreover, the pace of increase was the fastest since February 2011, as the growth rate of new orders held broadly steady at November’s 33-month record. New export orders rose for the sixth month running. Output growth was again led by the G7 developed nations in December, as robust expansions in the US, Japan, Germany, the UK (which registered the highest Output PMI reading of all countries) and Italy offset the ongoing contraction in France and a sharp growth slowdown in Canada.

Among the larger emerging nations covered by the survey, already muted rates of increase for production eased in China, India and Russia, and remained similarly modest in Brazil and South Korea despite slight accelerations. Taiwan was a brighter spot, with output growth hitting a 32-month high.

December PMI data signalled an increase in global manufacturing employment for the sixth consecutive month. Although the rate of jobs growth was again only moderate, it was nonetheless the fastest for almost two-and-a-half years. Payroll numbers were raised in the majority of the nations covered, including the US, Japan, Germany, the UK, India, Taiwan and South Korea. Job losses were recorded in China, France, Spain, Brazil, Russia, Austria and Greece. Input price inflation accelerated to a 20-month peak in December, and was slightly above the survey average. Part of the increase in costs was passed on to clients, reflected in the pace of output price inflation reaching a near two-and-a-half year peak.

“The global manufacturing sector ended 2013 on a positive note,” remarked David Hensley, Director of Global Economics Coordination at JP Morgan. “According to the global PMI, output was rising at the fastest pace in almost three years. Both final demand and inventory dynamics are supporting production. In addition, near-term dynamics appear to remain favourable, based on the elevated level of the global new orders PMI.”

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industry news

Australian among eight winners in GE 3D printing competition Sydney local Nic Adams has won fourth place in GE’s global 3D Printing Design Quest, with eight winners selected from nearly 700 entries across 56 countries GE’s 3D Printing Design Quest challenged innovators to redesign loading brackets found on jet engines using 3D printing.

Loading brackets on jet engines play a critical role: they must support the weight of the engine during handling without breaking or warping. Through open collaboration, the redesigned brackets reduce engine weight and improve fuel and cost savings.

An engineer based in Drummoyne, Adams won fourth place in the Quest with a design that reduces the weight of jet loading brackets by 80.4%. He achieved this by minimising sharp corners and using a hollow structure to best distribute material and stress.

Adams was encouraged to enter because of the opportunity to work with GE to advance his designs through modern manufacturing techniques. Adams had had experience with manufacturing techniques previously, having worked on a pathology lab automation system in a Sydney hospital featuring robotic handling and analysis of hundreds of test tubes per day.

First place in the Quest was won by M Arie Kurniawan of Indonesia, who collected a US$7000 prize. The balance of the US$20,000 prize pool will be awarded to the finalists capturing second through eighth place.

The top-ten bracket designs were additively manufactured at GE Aviation’s additive manufacturing facility in Cincinnati and subjected to rigorous load testing, at GE’s Global Research Centre in Niskayuna in the US. Testing parts to failure was performed to ensure the winning designs met the highest quality and performance criteria.

“At GE, we know innovation can come from anywhere,” said Steve Liguori, GE Executive Director of Global Innovation.”

This challenge tapped into the ingenuity of the GrabCAD community to unleash new solutions to tomorrow’s challenges using additive manufacturing. By applying GE’s scale and expertise to open innovation, we can continue to grow the ecosystem of designers, engineers, materials scientists, and other partners to redefine the industry and drive real results for our customers.”

GE and GrabCAD, working closely with digital strategy firm Undercurrent, launched the Design Quest in June 2013, drawing a record number of entries via GrabCAD’s community of engineers and designers, with nearly 700 entries from 56 countries.

“Our community really responded to this real-world engineering challenge from GE,” said Hardi Meybaum, CEO of GrabCAD. “There were an extraordinary number of submissions from around the world

Nic Adams

because engineers want the chance to design something that may make it into production and solve a real problem. GE’s Jet Engine Bracket Design Challenge exceeded expectations and shows its commitment to seeking innovation through open engineering and collaboration. It’s the way of the future, and we love that it’s happening on our platform.”

ACS Australia in co-op deal with Smart Fibres Advanced Composite Structures Australia (ACS Australia) has signed of a Heads of Agreement with Smart Fibres, a company that provides innovative optical fibre sensing technology, to establish a cooperative relationship regarding the use of sensing technology in composites applications worldwide.

ACS Australia was established by the Cooperative Research Centre for Advanced Composite Structures (CRC-ACS) in 2008 for the commercialisation of the expertise and the technologies developed by CRCACS since 1991, into the broader market.

Leveraging the broad experience and global presence of both companies, this agreement will allow the composites community to take advantage of a unique service in a wide variety of markets and applications.

technology development and implementation, partnering with customers to enable innovative design, low-cost manufacture and support of applicationcritical composite structures. ACS Australia provides engineering products, services and technical expertise to companies looking for a competitive advantage in a variety of markets including aerospace, defence, automotive, renewable energy and oil & gas.

“With the increased use of composites in remote and critical applications such as off-shore wind turbine blades and oil & gas pipelines, the ability to monitor the health of the structure is proving to be of significant value for the end-user,” said Andrew Gunnion, Operations and Sustainment Program Manager at ACS Australia.

Smart Fibres pioneered the development of Fibre Bragg Grating (FBG)-based monitoring systems and has been an industry leader in the field of innovative optical fibre sensing technology for over 15 years. With a broad range of FBG fibre optic sensor and interrogator products and a wealth of applications knowledge, it serves some of the world’s leading companies and

ACS Australia is a leader in composites

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AMT February 2014

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industry news

Intercad completes Solidtec acquisition Intercad, a leading supplier of 3D solid modelling products and services across Australia and New Zealand, has acquired fellow 3D CAD specialist Solidtec Solutions.

As part of the deal, Solidtec personnel will join Intercad to increase the level of expertise at the company, which over the past three years has transitioned into a full-service mechanical computer-aided engineering solutions provider.

“We will merge the two businesses to support a larger range of services,” said Max Piper, Chief Executive Officer at Intercad.

“Established nearly 25 years ago, Intercad is the longeststanding 3D solid modelling specialist in the region, giving us a depth of industry knowledge that is evidenced in the range of services we offer and the breadth of products we represent. This merger of operations will serve to enhance these offerings which can deliver competitive advantages to those customers.”

Solidtec sales personnel will join Intercad as a result of the acquisition. Former Solidtec Chief Executive Officer Shane Preston said the sale will ultimately benefit both organisations – their personnel and the customers.

“Now is the time for the manufacturing industry in Australia to embrace innovation and efficiency as a means to global competitiveness, especially given a stubbornly high Australian dollar as well as increased competition from many low-cost countries,” said Preston. “In this climate, the best way for both

companies to help their customers is through the combination of their expertise. The integration of Solidtec with Intercad will provide a focus on customer success and ensure Australian and New Zealand manufacturers, engineers and designers have the best available tools, training and support to increase productivity and better compete on a global scale.”

Solidtec customers will now be able to access the full portfolio of products that have been introduced to Intercad customers in the past 12 months.

“Manufacturing is facing significant headwinds, but it’s a resilient industry and companies are constantly looking to invest in services that increase productivity in a competitive global market,” said Piper. “Intercad is working on developing partnerships with organisations such as IC3D to further strengthen our ability to offer customers a more complete solution that meets their requirements and maximises their investment in SolidWorks, including products for steel fabrication and simple language translation. Our commitment to helping our customers navigate through a challenging time has not wavered, and this deal opens the door for increased customer feedback and collaboration.”

Australia’s first Flow Control dump truck body launched Austin Engineering has announced the official launch of Australia’s first Westech Flow Control body for off-highway dump trucks.

The first Flow Control Body to be manufactured in Australia was on display at the Hunter Valley event in December, which was well attended by representatives of local mine sites, OEMs, government and media. Austin Engineering built two of the innovative dust supressing bodies for use at Vale’s Integra mine site in the Hunter Valley, with the bodies going into operation on site immediately after the launch.

“We are very pleased at the level of interest shown at the launch of the Flow Control Body,” said Tim Ekert, Executive General Manager – Eastern Australia for Austin Engineering. “Its dust control properties along with improved truck stability offers a clear benefit to mine sites, particularly in the Hunter region where dust mitigation is a hot topic. Our ability to engineer products to solve specific problems is something we’re known for, and the Flow Control product is a great example of that”.

Austin Engineering is a non-OEM designer and manufacturer of customised dump truck bodies, buckets and ancillary products used in the mining industry. It is also a complete service provider, offering on and off-site repair and maintenance and heavy equipment lifting services to customers including miners, mining

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AMT February 2014

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industry news

Jamaica buys 12 Bushmasters Thales Australia has signed a contract to supply 12 Bushmaster vehicles to the Jamaica Defence Force.

The vehicles are all troop carrier variants equipped with Thales’s SOTAS M2 communication system, and deliveries will begin in 2015. The contract also includes a five-year support package to ensure the highest levels of availability and performance.

Chris Jenkins, Thales Australia CEO, said: “The Jamaica Defence Force has a longstanding interest in Bushmaster, and we are now very pleased to add them as an export customer.

“The Bushmasters are ideally suited for both internal security and humanitarian operations. The inclusion of the support package demonstrates the customer’s trust in us to deliver and maintain an effective capability over several years.

“Once again, the confidence shown in Bushmaster’s ability to protect troops and save lives reflects very well on the skills of Australian industry, and the important role that Thales and the 120 companies in the Bushmaster supply chain play in providing a unique Australian capability in protected vehicles.”

Delcam shareholders accept Autodesk takeover Shareholders in Delcam, one of the world’s leading suppliers of advanced software for manufacturing industry, voted on 15 January to accept the offer made by Autodesk to acquire the company. The acquisition is expected to be completed during February.

Headquartered in Birmingham, UK, Delcam has more than 30 offices worldwide and over 700 employees.

The company’s range of design, manufacturing and inspection software provides automated CADCAM solutions for a variety of industries, ranging from automotive and aerospace to footwear and healthcare.

On completion of the acquisition, Delcam will become a subsidiary of Autodesk. It will maintain its focus on accelerating the growth of its market share in the manufacturing sector, with the added strength that will come from being part of a larger organisation. Delcam customers will continue to be supported by its engineers through its global network of subsidiaries, joint ventures and sales partners.

Autodesk announced its intention to acquire Delcam in November. The companies offer complementary ranges of software, with Autodesk’s programs for design, engineering and entertainment able to be combined with Delcam strengths in manufacturing.

Delcam’s status in the CAM industry was confirmed in the latest NC Software Market Analysis Report from leading US analysts CIMdata. The report showed that, in 2012, Delcam again had the highest vendor revenues and received the highest end-user payments of all the

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AMT February 2014

CAM-centric companies. This meant that the company had completed 13 years as the world’s leading specialist supplier of CAM software and services.

Commenting on the planned acquisition, Carl Bass, President and Chief Executive Officer of Autodesk, said: “We are taking an important step on our path towards delivering a better manufacturing experience. Together, Autodesk and Delcam will help further the development

and implementation of technology for digital manufacturing.”

Clive Martell, Chief Executive Officer of Delcam, added: “I am very excited by the opportunities from combining Delcam with Autodesk to create a compelling platform from which to service both companies’ manufacturing clients. The added strength and status that we will gain from being part of the Autodesk Group will benefit our customers, our staff and our sales channel.”

government news

Enterprise Connect – Enhancing Ellex’s vision Headquartered in Adelaide, Ellex has evolved over the years from a small scientific laser company to a global leader in vision-care technology.

Since the introduction of Ellex’s first ophthalmic laser in 1985, the company has been building a knowledge base and reputation for excellence in ophthalmology, the branch of medicine that deals with the anatomy, physiology and diseases of the eye. With a vision to provide leading-edge laser and ultrasound systems that help fight blindness, more than 20,000 Ellex ophthalmic laser and ultrasound products are used around the world today.

Ellex has moved from an original equipment manufacturer for renowned brands to a globally competitive producer of selfbranded instruments for the diagnosis and treatment of various eye related conditions, including premium laser and ultrasound systems. Ellex regularly applies for and receives international patents for device and method innovations aimed at treating ophthalmic disease. The business’ current research efforts include Retinal Rejuvenation Therapy (2RT), a project focused on new treatments for Diabetic Retinopathy and Early Age-Related Macular Degeneration (AMD).

Despite its success over the past three decades, Ellex required advice and support on how to improve workflow efficiencies in the current factory and how to optimise its business in a new factory. The company sought advice from Enterprise Connect Business Adviser Donna Edwards, who conducted an independent and objective Business Review. An Australian Government initiative backed by industry, Enterprise Connect offers comprehensive advice and support to eligible Australian

small and medium businesses to help them transform and reach their full potential.

Donna laid out an action plan for Ellex to introduce a Lean culture to its production techniques, administrative staff and supply chain operations. In addition, Donna recommended that Ellex develop Lean layout options for its factory site.

“Donna was very professional and easy to work with,” said Richard Stone, VicePresident of Business Development. “She knew how to question and challenge different parts of the business to identify key issues. “We proceeded with implementing the Business Review recommendations and were able to improve workflow and efficiencies in the current factory. We also identified a ‘future state’ factory layout and specification for a new factory.

“We have also implemented some training at the shop floor level. Due to changes in the economic environment from the global financial crisis, we have not proceeded with a new factory yet, but have maintained continual improvement in our current location.”

Ellex continues to review its training needs across the manufacturing teams and sets goals for continuous improvement and lean manufacturing projects. In the coming years, Ellex plans to introduce more products to meet today’s needs, and to engage in research aimed at finding future treatments for the common causes of blindness.

For more information on how Enterprise Connect can assist your business call 131 791 or visit www.enterpriseconnect. gov.au. www.ellex.com

AMT February 2014

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Tech news

Germany: Laser welding Can a laser weld with precision amid pounding machinery? The prototype of a new laser welding machine has demonstrated that it can operate reliably under tough working conditions. It is designed to replace the time-consuming welding guns traditionally used in manufacturing to weld perforated tube sheets with thousands of tubes. In future, lasers will do this job: baseplate and tube are welded together quickly and with pinpoint accuracy; a few seconds later, the robot arm, which transports the processing head, moves on to the next hole. The prototype can even fuse materials that are considered difficult to weld.

Fraunhofer

USA: First 3D-printed electronic component Researchers have 3D-printed a working loudspeaker, seamlessly integrating the plastic, conductive and magnetic parts, and ready for use almost as soon as it comes out of the printer. But it will be a while before consumers are printing electronics at home because most printers cannot efficiently handle multiple materials. It’s also difficult to find mutually compatible materials (conductive copper and plastic coming out of the same printer require different temperatures and curing times). It was hoped that this demonstration will show 3D printing technology moving from printing passive parts toward printing active, integrated systems.

Cornell University

Germany: fast tracking mass car production The protracted ramp-up time in auto body assembly are causing challenges for manufacturers, who need to adapt production systems to each of the new parts. In order to assemble individual elements, manufacturers clamp the individual parts into modelspecific clamping devices and weld them together. The devices must be calibrated exactly, which can take several months. A new procedure - called “try-out” - allows already determined parameters to be directly transferred to serial production, potentially reducing start-up times by up to 50%.” Try-out” is already applied to the reshaping process.at the press plant, but now the process has been transferred to car body assembly (clamping devices) which is breaking new ground.

Fraunhofer

USA: 3D printed hand Three years ago, Paul McCarthy began searching for an inexpensive yet functional prosthetic hand for his 12 year-old son Leon, who was born without fingers on his left hand. McCarthy came across an online video with detailed 3D printing instructions and designs by inventor Ivan Owen. McCarthy borrowed a 3D printer and the materials for the hand cost about $10. Leon can now grab water bottles, pens, and utensils using his once-functionless hand.

A prosthetic hand would have cost US$30,000; additionally the printed hand can be added to and re-printed as Leon grows up. McCarthy plans on working with Leon’s school to teach students how to print hands and give them to other children who need them.

Mixed

USA/Singapore: Adding fourth dimension to 3D printing A team has developed and tested a method for 4D printing. The researchers incorporated “shape memory” polymer fibres into composite materials used in traditional 3D printing, which results in the production of an object fixed in one shape that can later be changed to take on a new shape, opening up exciting possibilities for the creation and use of adaptive, composite materials in manufacturing, packaging and biomedical applications .For example a solar panel or similar product could be produced in a flat configuration onto which functional devices can be easily installed. It could then be changed to a compact shape for packing and shipping).

University of Colorado Boulder

Germany: Ultra-thin tool heating for injection moulding In future, “thin-film” heating will allow plastic parts to be produced with greatly improved surface quality. Researchers have also found a way to make the whole process more energy efficient. A new kind of tempering technique has been developed that, depending on the product, is up to 90% more energy efficient than other techniques used to date. The trick is to avoid having to heat up the entire tool; which can weigh half a ton or even more depending on the plastic part being produced. All that is heated now is the surface of the tool that actually comes into contact with the plastic melt. By “thinfilm” heating, researchers coat the wall of the forming tool using a vacuum-based coating technique known as sputtering. Electrical insulation is provided by a ceramic layer that shields the conductive heating layer from the steel tool underneath.

Fraunhofer

USA: Innovative “gripper” robotics The robot gripper invented by researchers at the University of Chicago and Cornell University is now available commercially. The grippers are able to handle a wide range of different objects on the same manufacturing line (objects with holes in the center like hexnuts, glass or plastic bottles, and objects that have odd shapes or shapes that vary between the individual parts). The science behind the gripper is a physical phenomenon called the jamming transition.

VERSABALL grippers take advantage of this jamming behaviour so that when the gripper is soft, it can be pressed against an object -- passively conforming to take the object’s shape. The gripper then vacuum-hardens to grasp the object firmly. It’s a sharp deviation from the way other robot grippers work, but this simple idea is now poised to solve a broad range of automation challenges.

University of Chicago

USA: Human arm sensors for robotics Arm sensors can “read” a person’s muscle movements, allowing a robot to anticipate a human’s movements and correct its own.

For example, as human operators shift a lever; the robot recognises the command and moves appropriately. But upon stopping the movement and holding the lever in place, people tend to stiffen and contract muscles. The confused robot responds to that bounced force, creating vibration .The system eliminates vibrations by using sensors worn on a controller’s forearm. The devices send muscle movements to a computer, which provides the robot with the operator’s level of muscle contraction. The system judges the operator’s physical status and intelligently adjusts how it should interact with the human, resulting in the robot moving more easily, safely and more efficiently in manufacturing plants.

Georgia Institute of Technology

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Walter expands “Expert team” in taps With the introduction of the Xpert tap family, Walter simultaneously established a new designation system enabling the user to immediately recognise what his tool can be used for. The Paradur Xpert P from the Walter Prototyp brand continues this basic approach.

The Paradur Xpert P has expanded the existing trio of Prototex Xpert P, Prototex Xpert M for through hole threads, and Paradur Xpert M for blind hole threads into a quartet. Steel materials from the range of tasks of the new addition to the family are in accordance with ISO lettering, and with strength values up to 1000 N/mm2.

The tool optimised for this can optionally be supplied with a TiN or THL coating. Features such as 45-degree helix angle, chamfer according to form C, and a tapered guide ensure reliable thread cutting in blind holes up to a depth of 3.5 times diameter. As a secondary application, the tool is also suitable for Al-Si alloys with an Si content of 0.5% to 12%.

The steel expert is available in numerous variants. Except for metric thread M2 to M64 and M2.5x0.35 to M52x3, it is also available in many inch versions (UNC, UNF, UNEF, UN-8, G, BSW). In addition, the catalogue range also contains left-hand thread variants (LH) and variants with interrupted teeth (AZ). The user can also choose from three tool lengths – M, L and XL – alongside tolerance classes 4H, 6H, 6G, 7G, 2B and 3B.

Dimensions and thread profiles not available in the standard range are supplied by the Walter Xpress Service within a few days. The Paradur Xpert P produces threads with high surface finish quality.

Due to excellent cutting and guide characteristics, cutting mistakes in materials are virtually eliminated. www.walter-tools.com

Syspro announces new scalable ERP Syspro has announced its latest enterprise resource planning (ERP) software offering for on-premise and cloud-based utilisation across manufacturing and distribution. Syspro 7 adapts to the growth requirements of organisations by providing scalability, mobility, and enhanced performance.

“As Australia’s manufacturing industry continues to face increasing international competition and a high dollar, streamlining operations and driving efficiencies is one way companies can lower production costs without lowering product integrity,” says Shaun Butler, General Manager of Syspro APAC. “The launch of Syspro 7 will allow our local clients to enhance performance of their operations and improve output.”

Syspro has expanded its user interface (UI) capabilities, with active tiles and touch capabilities styled along the lines of Windows 8, enabling manufacturers and distributors to easily create a personalised solution for their business. To support large-scale customisation, the new UI also enables enterprisewide modifications and themes. The new industry layouts can be particularly helpful for corporate alignment within specific vertical industries such as food, medical devices, machinery/equipment, electronics and pharmaceuticals/chemicals markets.

Recognising the necessity among mid-sized manufacturing and distribution companies for faster performance, capacity and volume requirements, Syspro 7 provides powerful processing for higher transactional throughput whilst building on the software’s scalability for enterprises of all sizes.

Syspro Espresso is a new mobile platform, which allows users of Syspro ERP to access their vital business data in any location, at any time, for device-agnostic data collection and transaction processing. It is one of the first platforms of its kind to use a single source codebase to create native applications for any mobile device, with built-in powerful customisation capabilities for both the end-user and developers to engage. Syspro Espresso enables easy, anywhere access, to Syspro business information; and the enhanced reporting capabilities ensures customisable reports are efficiently supplied anywhere, even without the need to have Syspro installed on the desktop.

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AMT February 2014

Syspro’s Software + Services deployment methodology enables Syspro 7 to be installed easily and remotely with just one click, and allows organisations to run Syspro whilst also providing greater control over security and firewall settings across the network and/ or internet. www.syspro.com

product news

Enerpac adaptor kit boosts hydraulic safety and efficiency A new adaptor kit released by Enerpac enhances workplace safety and efficiency by angling widely used high-pressure hydraulic gauges (700bar, 10,000 psi) to the ideal position for visibility when undertaking jobs such as lifting, pressing, cutting, crimping, forming and maintenance.

TheGA45GC Gauge Adaptor Assembly – which is on introductory offer till the end of February – positions its G Series glycerine-filled pressure gauge at 45 degrees to ensure operators get the best readings possible and can easily monitor the system, enhancing safety.

“Accuracy and safety are crucial when working with high-pressure hydraulics,” said Enerpac National Sales Manager Darryl Lange.

“This assembly acts as a clear window on a broad range of commonly used systems, where it helps minimise hazards such as overloading.”

Elements of the system, which fits hand, air and electric pumps, include: • A G2535L gauge with dual-scale readout and pressuresensing parts sealed and dampened by glycerine for long life. The gauge includes safety blowout disc and equalising membrane.

• A GA45 gauge adaptor and CR400 high-flow female coupler for easy integration into a broad range of hydraulic systems used by industry, including those heavily used during the maintenance season.

G Series gauges are widely used with Enerpac hydraulic tools and lift cylinders, which include one of the most comprehensive and widely used ranges available throughout Australia and New Zealand and globally. The gauge assembly adaptor can also be used with a wide range of compatible high-pressure

hydraulic tools that are widely used throughout industries such as: construction and infrastructure; civil, mechanical, production and process engineering; electrical distribution and maintenance; energy production and reticulation; government utility; mining and resources; manufacturing and materials handling; safety, water and waste water. www.enerpac.com

Fixturing tables gain favour through rent-try-buy facility Leussink Engineering has reported a significant increase in uptake of its inventive demmeler fixturing tables for industry since it introduced a rent-try-buy facility.

Leussink had enjoyed steady sales of its technology for the fabrication, engineering, assembly and welding sectors, but the rent-try-buy facility has had a notable impact by allowing potential users to gain an in-situ insight of the benefits. By renting these modular fixturing tables at a fraction of the cost, companies have reportedly been able to pick up and test a table and see the advantages of using a demmeler table.

A demmeler modular fixturing and holding table provides workshops and assembly plants greater welding accuracy while saving operators time, money and material. Because it is modular, it allows the use of CAD to create – as well as to document – the fixture.

A typical demmeler system features a five-sided table with a regular pattern of bores located across the top and around the sides. Table sizes range from 1000mm x 1000mm, to 2000mm x 4000mm.

They are coated with a weld spray so that any wayward welding spatter will not stick to them. This modular fixture also serves as the first in-process quality check for all of the loose pieces.

The tables are suitable for use in any industry where accurate and rapid assembly methods are required and wherever economic positioning, clamping, tacking and welding is necessary. They can be used in car-making, farm machinery and defence products construction, container production, gate and handrail manufacture,

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mining equipment making, food machine manufacture, building and construction material making. They can even be employed in the production and reworking of non-metallic parts such as those made of wood, plastic or glass.

Apart from practical gains the rent-try-buy facility, Leussink reports distinct tax advantages through deductions in company tax. If at the end of the rent-try-buy period the user chose to buy the demmeler table, Leussink engineering reimburses 50% of the rental already paid. www.leussink.com.au

product news

Automatic quick-change system for small robots Schunk has enlarged its standardised robot accessories program to allow users the full use of a small robot’s efficiency potential.

The extremely flat quick-change system, the SWS-001 with less interfering contours is currently the smallest automatic robotchanging system on the market.

With a handling weight of up to 1.4kg, it is ideal for small robot types, where the grippers and tools are automatically exchanged within seconds.

Four integrated air feed-through valves, and up to eight integrated electric feed-throughs ensure a reliable energy supply of the coupled modules. A patented self-retaining locking system ensures that robots and effectors stay connected, in case of a sudden energy failure.

Due to the ISO connecting flange, the SWS-001 can be fast and easily connected to various robots. With 22 different series and 2000 variants, the competence leader for clamping technology and gripping systems offers the world’s largest variety of quickchange systems. The standardised module program ranges from miniature changeover systems up to heavy-duty change systems for payloads of up to 1,350kg to cater for the diverse demands of industry.

NEW Introducing the HDV300

Video-based Measurement System The power of an optical comparator, meets the precision of digital video.

• Electronic overlays – no more Mylars!

• Easy to use M3 software – for both shop floor and lab • Fast measurement processing • Interchangeable lenses for large part images • DXF CAD Import • Touch-screen Windows 7/8 technology • A new generation of Optical Comparators for the 21st Century.

www.schunk.com

Fluke – protecting inspectors of high-energy equipment With an installation time of five minutes or less, there’s no need to sacrifice safety or compliance to take infrared camera readings More than 99% of all arc flash incidents occur when a panel door is open, exposing workers to potentially lethal amounts of energy.

The new Fluke ClirVu CV Series IR Windows eliminate the need to open the panel door to take infrared camera readings, and with an installation time of five minutes or less, there’s no excuse not to protect workers’ safety.

The ClirVu CV Series offers protection for the electricians, engineers and inspectors who work around high-energy equipment. The product has been “Torture Tested” to the highest arc blast test ratings and, when properly installed, maintains a panel arc test rating of up to 63kA. Once installed, there’s no need to power down or remove panels. Inspections can be conducted quickly, easily, and safely often with little, if any, personal protective equipment.

Installation takes one technician five minutes or less. Simply lockout-tag out, punch one hole with a standard conduit punch without removing the panel door, attach and secure the cover. The AutoGround feature instantly grounds the IR window to the metal enclosure, eliminating the need to separately ground each metal component of the window.

The hinged cover is easily opened with a quarter-turn latch or key to perform infrared inspections. It also protects the window from accidental exterior impact. www.fluke.com.au

What company has such vision?

Innovation Rules www.starrett.com.au

Contact Us on (02) 9620 6944 AMT February 2014

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product news

Lange Engineering reaps returns from Mazak STX Lange Engineering is a general engineering and manufacturing business based in Geelong, Victoria, primarily focussed on servicing the region’s aluminium, automotive, and agriculture industries.

With 30 staff and over 40 CNC machine tools, Lange Engineering is a significant business and employer in the Geelong region and further afield. The company recently installed a Mazak STX Mk III RTC (rotary/tapping/chamfering) 4.0kW laser-processing machine. This investment delves into a new market area for the business, but has seen great returns early on.

The machine was purchased for its extra-high working envelope and a versatile rotary table system capable of processing tube and pipe, structural sections, and rectangular hollow sections (RHS) in addition to the machine’s standard 1500mm by 3000mm flatbed capability. Flexibility is enhanced further with tapping and chamfering capability for both flat sheet and sections. This unique combination allows the team at Lange Engineering to entrust the machine with any job with confidence.

According to Robert Lange, owner of Lange Engineering, “There have been very few jobs the Mazak STX hasn’t been able to take on.”

Whilst Lange Engineering has completed some interesting sectional work using the rotary table, it is the Mazak STX’s capability to regularly cut 25mm, grade-250 mild steel with reliability and excellent edge quality that sets the machine apart. This grade of mild steel is notoriously difficult to cut and pushes the limits of what most laser processing machines can achieve. However, this has become a simple operation for Lange Engineering using the Mazak STX Mk III RTC.

The introduction of laser processing was indeed a challenging step into a new technology for Lange Engineering. However, after just the first two days of training from John Hart, they were operating the machine with confidence and producing parts – a testament to the machines simplicity and ease of programing.

Continued support from John Hart’s application engineers, combined with the machine’s intuitiveness and the operators’ enthusiasm to learn, has helped to bolster Lange Engineering’s new venture and provide a significant return on investment.

Lange Engineering purchased its first machine from John Hart in 1993 and has never looked back, citing “quality and service” for the continued business relationship. John Hart has supported the company throughout its many Mazak purchases, to ensure each investment remains a positive addition to the company’s growth strategies. www.langeengineering.com.au www.johnhart.com.au

Delta Tau introduces Advantage 900 CNC control Delta Tau Data Systems has launched the Advantage 900 CNC package, the newest member of its CNC control family.

The Advantage 900 CNC combines a sleek operator console with an integrated controller/amplifier, resulting in a cost-effective solution for machine tool OEMs and retrofit applications.

With four, six, or eight axes, the Advantage 900 CNC is specifically designed to meet the next generation of CNC control requirements.

“We designed the 900 to leverage the capabilities of the PC at the operator interface while utilising a real-time DSP to handle the motion related tasks of the CNC machine,” says Vince Burokas, Product Manager for CNC at Delta Tau Data Systems. “This gives the customer the best of both worlds, a cost-effective PC front end with true real-time servo performance at the servo.

“The digital amplifier and control were integrated into one unit to streamline the manufacturing process and ultimately save the end user significant dollars

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AMT February 2014

at the time of purchase and through a greatly reduced installation process, which requires less wiring, space, and set-up time. This design embraces a modular philosophy allowing an infinite number of machine configurations. The 900 provides OEMs and end users with a long list of features, performance and value.”

The feature-rich 900 CNC includes a 38cm LCD screen and customisable operator controls for an easy-to-integrate, openarchitecture solution. The Advantage 900 CNC supports high-speed machining, dynamic multi-block segmented lookahead for path fidelity at any speed, kinematic capabilities for non-traditional mechanical configurations, fifth-axis programming capability, and lead screw and backlash compensation. www. motiontech.com.au

product news

Workbench from Rockwell Automation streamlines process-safety applications Rockwell Automation has released the AADvance Workbench 2.0 to help manufacturers get processsafety applications up and running faster.

Ideally suited for applications that require a flexible architecture, distributed safety and mixed SIL levels, the AADvance Workbench is a complete design, configuration and maintenance software environment.

range of modules and assemblies. It is particularly well suited to emergency shutdowns and protection applications for fire-andgas detection by providing a system solution with integrated and distributed fault tolerance.

“This new offering stems from the acquisition of ICS Triplex and represents the continued investment Rockwell Automation is making as a world leader in the industrial process-control and process-safety markets,” said Julien Chouinard, Director of Process Safety and Critical Control, Rockwell Automation. “The Workbench is now an integral part of the PlantPAx process automation system, which is capable of managing the entire range of plant automation applications, including process control, discrete control, power, information and process safety.”

The new Workbench is one of the industry’s first T3-compliant software tools, as per the IEC61508 standard that generates SIL3 code certified by TÜV Rheinland. This significantly reduces the burden of validating the application.

The AADvance system is designed to enable companies to protect people, equipment and the environment by ensuring safe and continuous operation. The system consists of the scalable AADvance controller platform configured to any mix of SIL1 to SIL3 simplex, redundant or triplicated safety loops. Several units can be used to form a network of distributed safety controllers seamlessly integrated to monitor and control thousands of safety I/O points.

A system is configured using the workbench software to suit any functional-safety or critical-control application using a standard

AADvance Workbench 2.0 features a multi-user, multi-controller environment with built-in version control and traceability. A modern graphical user interface (GUI), drag-and-drop configuration, builtin simulation, and compliant IEC61131 programming languages for optimum flexibility are also featured. With the workbench, application designers can import, export or migrate projects, as well as use convenient plug-ins to monitor and manage controller status and communication protocols, along with other time-saving development tools.

“With the modern GUI of the workbench, users aren’t confined to a single pane anymore,” added Chouinard. “The floating windows improve productivity by giving the viewer more navigational flexibility and a more holistic view of their application.” www.rockwellautomation.com.au

AMT February 2014

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product news

Precision welding from Castolin Eutectic New from Castolin Eutectic comes the EuTronic GAP 2501DC PTA welding system for precision and high deposit quality in joining, coating and brazing welding – now with touch-screen control.

Brimming with new features, the Eutronic GAP 2501DC welding unit has been designed for integrating with both automated process and manual welding applications, including PTA, TIG and MMA welding. A user-friendly 14.5cm touch-screen control panel with newly developed user interface allows the operator a simpler and faster pre-selection of welding parameters and is designed to work even with welder gloves on. All the settings are displayed on the touch-screen, with 1000 memory locations available.

The extremely powerful inverter delivers 2-250A, which is sufficient for almost all powder applications. Optional features are available such as fully electronic gas control and second motor control card to operate a second powder feeder and an extended automation interface for full integration in an automated process.

The GAP (gas arc process) technology developed by Castolin Eutectic – distributed nationally by SMENCO – is designed for work that requires extra precision, low heat generation and minimal distortion. The GAP technology also provides an exceptionally high purity and quality of the welding bead from the very first layer.

In conjunction with the high efficiency of the process, the precise control of the layer thickness and the smooth weld beads, these advantages generate considerable economies by cutting both operating costs and welding consumable requirements.

Application examples include:

• Feeding screws repairs.

• Repairs on tool steels, rebuilding of cutting edges, forging, stamping dies, aluminium die casting moulds.

• Hard-facing on down hole equipment, drilling tools, valve seats and valves, mining machinery, milling tools.

• Repairs and refurbishment of cast iron, glass moulds.

www.smenco.com.au

Safe standstill monitoring from Treotham Automation Wieland Electric’s new SVM 4001K monitors have been specifically designed for the safe standstill monitoring of all AC drives without the need for any additional sensors.

Available from Treotham Automation, the SVM 4001K monitors enable back EMF safe standstill detection through the evaluation of the induced residual voltage during the run down of one-phase or three-phase AC motors. The SVM 4001K monitor is connected directly to the supply voltage connections of the AC motor.

If this voltage exceeds the adjusted threshold voltage at the terminals L1, L2 and L3 of the device, the relay contacts open instantaneously. However, if the monitored voltage falls below the adjusted threshold voltage during the run down of the AC motor in question, the output relay is turned on after an adjustable delay.

Benefits and features of the Wieland Electric SVM 4001K monitors include:

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AMT February 2014

• No sensor is needed.

• Back EMF. • Supply voltage up to 690V AC 3.

• Adjustable threshold voltage.

• Adjustable on-delay time.

• Control of safeguards and interlocks with guard locking and relay outputs (230V AC / 8A).

• Supply voltage of 24V DC. The monitors come with TUV approval and are suitable for use up to PL e / Category 4 or SIL 3. The UL approval for the device is pending. www.treotham.com.au

product news

ABB robots get smart with real-time tactile feedback ABB has introduced Integrated Force Control, which it claims will allow robots to handle process variations with the sensitivity of the human hand, while shortening programming time up to 70%.

This new technology makes robots more intelligent and able to handle variations in the process with real-time external inputs – much like a human would when handling a delicate item or precise dimensions. From machining to small parts assembly, dexterous handling of workpiece and tools is of the utmost concern. Small variations in the manufacturing phase can mean the difference between utmost success and failure.

Conventional robotic solutions are controlled by predefined paths and speeds. However, with ABB Integrated Force Control, the robot reacts to its surroundings and can deviate from its programmed path or speed based on feedback from the force sensor. It is possible to automate complex tasks that previously required skilled personnel and advanced fixed automation.

“Integrated Force Control opens up the possibility to automate tasks that have not been possible using traditional robot automation,” says ABB’s Robotic Product Specialist Paolo Maggi. “Compared with expensive, hard automation, robotic solutions are less expensive and require a greater degree of flexibility.”

Robotic assembly can be very demanding with small tolerances and small parts that must fit together. With ABB’s Integrated Force Control Feature it is possible to assemble parts with tolerances that are within the range of the robot’s incredibly precise repeatability without requiring highly accurate and expensive fixtures. In addition, a force-controlled robot can be programmed to mimic the movements of a human arm, applying search patterns to find the correct position to assemble a given part. In this way, Integrated Force Control Feature also significantly reduces the risk of assembly failures, which can result in production problems or damaged parts.

ABB’s Integrated Force Control enables system integrators a new dimension of robot intelligence in machining applications such as grinding, polishing, deburring and deflashing. One of the package’s features allows a robot to grind, polish or buff parts while maintaining a constant force between the tool and the workpiece. Another feature enables a robot to deburr or deflash partlines and surfaces of parts at a controlled speed, thereby slowing down when encountering excessive burrs or casting flash.

The force sensor is fully integrated into ABB’s hardware and software, protected against overload and EMC, certified to IP65 and suitable for high precision robotic applications with a compact and lightweight design. When combined with vision sensors, ABB Integrated Force Control Function also allows for new ways of thinking about a myriad of other robotic automated functions that previously required skilled personnel. www.abb.com

AMT February 2014

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Motorsport & Automotive

Additive revolution. automotive evolution.

Ground-breaking developments in additive manufacturing are already having an impact across an array of manufacturing sectors. Now automotive is the latest area set to be transformed.

The list of things that additive manufacturing can do seems to get longer by the minute, but for a long time the idea of 3D printers being used to build cars has seemed a little far-fetched, like something that might only come to fruition in the distant future. However, if the work of KOR EcoLogic is anything to go by, that future may not be so far off after all.

Based in Winnipeg, Canada, the team at KOR EcoLogic had a vision for a more fuel-efficient car that would change how the world approaches manufacturing. Last year they completed the prototype of Urbee, the first car to have its body 3D-printed, and reportedly the greenest practical car ever made.

Now KOR EcoLogic’s team of designers are at work on a followup, Urbee 2, which will take the basic concepts of Urbee 1 to a higher level, including features like a fully functioning heater, windshield wipers and mirrors. The goal is for Urbee 2 to drive from San Francisco to New York City on only 10 gallons (38 litres) of fuel, setting a new world record.

The KOR EcoLogic team will fully design Urbee 2 in CAD files, sending them to rapid prototyping service RedEye On Demand, where the parts will be built through Stratasys’ fused deposition modeling (FDM) process. This process applies thermoplastics in layers from the bottom up, yielding parts that are durable, precise and repeatable.

The finished two-passenger vehicle will comprise 40 large, intricate 3D-printed parts, compared to hundreds of parts in the average car. The strong, lightweight vehicle will be designed to travel at a top speed of 110km/hour, using a biofuel such as 100% ethanol.

President and Senior Designer Jim Kor has always believed in the potential of technology to help solve some of society’s greatest challenges, such as minimising dependence on oil and reducing emissions. Urbee 1 proved that 3D printing could produce

Jim Kor, president and senior designer at KOR EcoLogic.

large, strong parts that meet accurate specifications of a car body. Kor learned that product design is nearly unencumbered by considerations on how parts can be made with digital manufacturing, and he believes that that liberation is incredibly powerful with a lot of potential for the future of manufacturing.

Now, the plan with Urbee 2 is to put a next-generation vehicle on the road that will eventually be sold to the public.

“As a design engineer, I feel a responsibility to act, to initiate positive change,” says Kor. “The goal is to create a sophisticated automobile that drives on the power of sunlight, harnessed regionally through a mixture of solar, wind, hydro, and bio-fuel technologies.”

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AMT February 2014

Motorsport & Automotive

Prodrive’s MINI John Cooper Works WRC race with 15 FDM parts.

Racing ahead Cutting edge innovations in automotive engineering often tend to come through the field of motorsports. Additive manufacturing has been a lynchpin for design and testing for year, but race teams are now discovering that 3D-printed parts are even ready for the rigours of the track on race-day itself.

Previously, teams have been highly reticent about their use of additive processes, anxious not to reveal their secrets to their rivals. However, a recent white paper by Allen Kreemer of Stratasys reveals the extent to which the technology has been adopted across a range of motorsports competitions.

In Nascar, for example, Joe Gibbs Racing (JGR) has expanded its additive applications to produce carbon monoxide (CO) filter housings. The housings are manufactured with polycarbonate (PC) material, which JGR selected for its ability to withstand temperatures of 93 degrees Celsius over a four-hour race. The optimised design leverages FDM’s ability to minimise weight.

gravel courses with blind crests and big jumps. Rally cars can hit jumps at 160km/hour, and the impact on landing can bend the chassis, rip out suspension, or injure the driver. Yet despite some of the toughest conditions on the planet, UK-based Prodrive outfits its car, the MINI John Cooper Works WRC, with up to 15 FDM parts.

According to Chief Designer Paul Doe, FDM was vital in the design assessment and testing of the car. Now it is racing, Prodrive uses its FDM machine nearly full-time for production parts that include gauge pods, wheel arches, and hood vents.

Across all Prodrive team cars and customer cars, these parts have endured upwards of 9650km of abusive rally racing. Doe cites many advantages to additive manufacturing, primarily cost.

Continued next page

“It is a design that would be very difficult and time-consuming to CNC machine,” says JGR Design Engineer Brian Levy. “We produce ten a day in one run with our FDM machine. And we make them on demand, which we could never do with our CNCs.” The FIA World Rally Championship (WRC) pits cars and drivers in two-, threeor four-day events, on tree-lined,

++++++++++++++++++++++++++++++++ AMT February 2014

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Motorsport & Automotive Contiued from previous page

“We make only 25 cars per year, so it is hard to justify tooling costs,” says Doe. “FDM eliminates tooling, which keeps cost down and shortens response time.”

The MINI’s two-piece gauge pod shows what unconstrained design can do for an assembly. Manufactured from ABS, the pod integrates all mounting features and has channels for electrical components. If made from carbon-fibre, these features would have been manually bonded to the pod in secondary operations.

The gauge pod also includes a hollow, yet completely enclosed, mounting brace that maintains strength while minimising weight.

“We couldn’t have done that with any other process,” says Doe. “The FDM technology is so easy to use, sometimes I have to rein people in. They are designing wild ideas just because they can. A lot of the time, we can’t justify not using FDM.”

Titanium breakthrough To date, automotive has proved relatively resistant to the 3D printing revolution because the technology has generally focused on the use of plastics. The automotive industry has embraced plastics and composites to a degree in recent decades, but when it comes to the core material that goes into a car, the emphasis remains heavily on metal. And printing with metal has been prohibitively expensive.

However, UK-based company Metalysis has now developed a way of producing low-lost titanium powder, heralding a new era in additive manufacturing with greater use of titanium in components across the automotive, aerospace and defence industries. The process was demonstrated by on a Renishaw 3D printer at the University of Sheffield’s Mercury Centre using to produce titanium components.

The Metalysis process is radically cheaper and environmentally benign compared with existing titanium production methods, with titanium powders selling for $200-$400 per kilogram. Metalysis takes rutile sand, a naturally occurring titanium ore present in beach sands, and transforms it directly into powdered titanium via electrolysis. The low-cost titanium powder can be used in various applications in mass production of lower-value items, where previously it would have been too expensive. 3D printing brings further cost benefits by reducing waste compared with current subtractive production methods.

“There are significant challenges to overcome in taking emerging technologies like metallic 3D printing from the lab to production, not least of which is material cost,” said Professor Iain Todd, Director of the Mercury Centre. “The step-change in terms of process economics that this material breakthrough provides takes us ever closer to the time when 3D printing of metals such as titanium is considered the norm rather than exceptional.”

In addition to titanium, Metalysis is developing tantalum powder and will use its technology to produce a wide range of specialist metals (including rare earths). Innovative alloys can be produced using Metalysis’ technology because the process is conducted in the solid state, hence metals with significantly different densities or melting points can be alloyed. Metal powders created by the Metalysis process can be engineered to get particle size and distribution correct for a range of applications.

“The Metalysis process could reduce the price of titanium by as much as 75%, making titanium almost as cheap as specialty steels,” says Dion Vaughan, CEO of Metalysis. “We believe that titanium made by the Metalysis process could replace the current use of aluminium and steel in many products.” www.korecologic.com www.redeyeondemand.com www.stratasys.com www.sheffield.ac.uk www.metalysis.com

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AMT February 2014

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Motorsport & Automotive

Ford Performance Racing – Leading the field Ford Performance Racing (FPR) delivered a highlight of last year’s V8 Supercars season, when its driver Mark Winterbottom and co-driver Steven Richards won the Bathurst 1000 event in October.

However, it is behind the scenes that one gets the full picture of what makes FPR a winning team.

By Carole Goldsmith.

Seeing FPR’s cars speeding around the track at an average of 250km/hour at V8 Supercar events is undeniably an exhilarating spectacle, but the speed, power and performance of the vehicles and engines all originate from the team’s headquarters, located near Ford’s Broadmeadows assembly site in north Melbourne. Among the many factors driving FPR’s track performance are the team’s wealth of engineering and design expertise, the individually built and tested vehicles, the precision manufacture of components, the meticulous testing and readjustment of the engines after each race, and the advanced vehicle safety features.

To see how the cars are built and kept at peak performance, AMT magazine was given a tour of FPR’s operations by Peter Trevaskis, General Manager – Communications and Marketing. Trevaskis explained that FPR is backed by a range of supporting partners headed by Ford Australia and Pepsi Max. Last January, leading Australian motorsport personalities Rod Nash and Rusty French purchased Prodrive Racing Australia (trading as Ford Performance Racing) from British engineering firm Prodrive, which had run the team since it was created in 2003.

With ten years’ experience in motorsport, including three years at FPR, Trevaskis certainly knows the industry, and his enthusiasm for the sport is contagious.

In the engine room Starting the site tour in the engine preparation clean rooms and engine testing area, Justin Way, Engine Performance Manager, was busy testing one of the team’s V8 engines, secured in the soundproof, fireproof and temperature-controlled adjoining room. While revving the engine, Way observed its performance on the walllength Prodrive computerised system to assess energy efficiency, speed, output, fuel consumption and other performance factors.

“We have 17 engines in total,” said Trevaskis. “FPR handles the service development and testing of these engines for our vehicles and for other teams who lease our engines.”

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AMT February 2014

“Engines are removed from the vehicles after each race and they go through this rigorous testing,” added Way. “Depending on the engine’s performance, it will either be returned to the guys in the engine room for improvement and modification or it will be used in a future race, if it passes the tests.”

Moving on to the general car preparation area, the skeletons of the four FPR vehicles used in the most recent V8 Supercars races had been jacked up and were being rebuilt for the following weekend’s event. Trevaskis advised that the bonnet, roof, boot, lights and door on each of the vehicles comes from the Ford assembly line.

Everything else is built on site, including the chassis, wheels, engine and other mechanical componentry. On-site fabrication of parts encompasses everything from the roll-cage safety system right down to the steering wheel.

“Safety is the top priority for FPR and the cars are designed to protect the driver,” said Trevaskis. “The metal roll-cage as well, as the carbon plate seat and door, provides protection if an accident occurs. The driver wears a mandatory helmet and neck protection system as well as fireproof clothing. The fuel tank is now built within the roll-cage containment instead of being stored in the boot. This protects the fuel tank and makes it a lot safer.”

The company’s engineers create many of the FPR vehicles’ components literally from scratch. The initial designs are transferred for manufacturing and tooling to the machine shop, where the team relies on a range of machines tooling supplied by the likes of Mori Seki and SEI Carbide.

“Our engineers can design components like these wheel nuts and brake parts, then work out what the components can do or can’t do before they are made,” said Trevaskis. “Producing individual parts in-house is cost-effective and allows us to reduce expenses.

“We also use external companies for specialist work, including Albins Off Road Gear, which specialises in the design and manufacture of drivetrain components, and B&S Precision Engineering, as contractors for surface grinding and electrical discharge machining.”

Motorsport & Automotive

the USA, and then we are arguably next in ranking, alongside categories such as the IndyCar series in USA and Canada as well as DTM (German Touring Car Masters)”.

V8 Supercars is the premier Australasian motorsport category and is one of fastest growing sports in the country. Last year television coverage of the V8 championships was broadcast into 137 countries. Just under two million people attended the 15 events held across Australia and internationally in New Zealand and the USA. Staff operating CNC Machinery at Albins Off Road Gear.

It is immediately noticeable how much pride and enthusiasm that FPR’s near-70 employees take in their work – both on site and during race days. Trevaskis said the engineers, mechanics and other trades people all have background experience and training in motorsport.

When asked what makes specialist motorsport vehicles go faster than the average road car, Trevaskis replied: “The engine has a lot more power and the overall car is much lighter than a road car.

Tyres can last around 60-100km and vehicles are serviced every 200-300km. A lighter composite is used for windows instead of the heavier glass used in road cars.”

FPR produces four new vehicles a year costing around $500,000 each with an average lifespan of 18 months. There have been many technical changes over the last 12 months, with the cars getting lighter, faster and safer. The team currently races a car based on the road-going Falcons, but according to Trevaskis, FPR may have the ability to switch to any number of vehicles in Ford’s line-up, such as Mondeos, in the future.

“In reality, we are a halo on the Ford brand. Motor sport is an exciting industry to be in, generating a lot of jobs for suppliers and for teams on the track. The main aim for us in 2014, is continuous improvement in our vehicles and in our team’s performance. We aim to win the V8 Supercar championships in 2014”.

V8 Supercars – a global frontrunner Cole Hitchcock is the General Manager Communications at V8 Supercars, and he is proud of its position in the global motorsport arena and the interest it generates worldwide.

“V8 Supercars is widely known as the best touring car championship in the world,” said Hitchcock. “In terms of international motorsport excellence, there is Formula One, which is global, NASCAR in

Inside the transmission, showing isotropically finished gears and the selector barrel.

“The V8 Supercars sport employs around 2000 people full-time, including teams and their support, plus the management arm has around 60 fulltime employees,” added Hitchcock. “At a major event like Sydney, our final event for the year, there were 450 V8 Supercar fulltime and contracted staff involved, including TV and film crew, plus thousands of officials and volunteers.”

An interesting aspect of the V8 Supercars championship is the way all the teams have a stake in the success of the event, as Hitchcock explained: “Our teams own a percentage of the sport and they all receive a dividend from the profits. Teams have major sponsors, partners and in some cases, manufacturer support, plus their own business income which allows them to go racing”.

V8 Supercars has undergone something of a revolution in the last year with the advent of the new Car of the Future (COtF) regulations, which made their debut in 2013. The COtF project introduced a new generation of cars that would be cheaper to build and repair, making them safer, lighter and stronger. In addition, the new rules saw an increase in the number of V8 Supercars events, across multiple countries.

Another key driver of the COtF project was to allow other manufacturers to enter. As a result, the Ford-versus-Holden battleground in V8 Supercars of the past 17 years has been radically expanded, with new teams entering the competition with cars from Nissan, Mercedes Benz and Volvo.

Hitchcock welcomes these newcomers: “For any newcomers to the sport, it does take some time to win. The current leading team - Red Bull Australia (a Holden team) - took three years to reach the top level in the V8 Supercars events. We have no doubt that the new players will rise to the top over time. As it stands, Nissan won a race in its first year and had several top ten finishes. Erebus Motorsport V8 with their Mercedes Benz E63 AMG also achieved some top ten results. That’s an outstanding first year from both teams.”

Continued next page

The V8 Supercar Transmission: an Albins ST6 transaxle.

AMT February 2014

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Motorsport & Automotive

Continued from previous page

Suppliers roaring ahead When AMT magazine spoke to Steve McDonald, Director and owner of Albins Off Road Gear, he had just hired seven new employees to cope with the company’s increasing motor sport business. Based in Ballarat, regional Victoria, Albins designs and manufactures drivetrain components, and is in the first year of a five-year contract with V8 Supercars supplying transmissions to all the teams’ vehicles. Albins also provides other drive-line components to the teams, such as tail shafts, centrebearing assemblies and spline couplings for connecting motors to gearboxes.

When asked about the demands of working as a supplier to FPR and other motorsports teams, McDonald said: “They are all very professional and have high demands for on-time delivery, high-quality R&D, and continuous improvement. The benefits of dealing with companies like FPR are many, including the technical development and the fantastic publicity. Technically, the guys there monitor the application of our transmission closely and give us accurate and detailed feedback. Without that feedback it would be much more difficult to develop the equipment for their vehicles.”

Around 80% of Albins’ business is in motorsport, with V8 Supercars representing around 15%. Around 60% of its products are exported, mainly to customers in the off-road racing business.

The company has distributors across the USA, in Canada, the UK, South Africa, the UAE and Japan. In the Dakar off-road rally in South America last month, 12 vehicles were running with Albins transmissions.

The company also supplies transmissions and other drive-train components to circuit racing teams.

“Australia has a very good reputation in the motorsport industry and it is a great industry to be involved in,” said McDonald.

“Our employee numbers have almost doubled from 30 to 54 in the last 12 months. I think it is easier to get employees to work in motorsport, as it is an industry built on pride and passion. The biggest issue we have is to keep up with the Australian and global motor sport demand for our products.”

Based in Mentone in south-east Melbourne, B&S Precision Engineering supplies FPR with high-end components including spindles, torsion bars and suspension components for V8 engines.

Some of the components produced by B&S Precision Engineering

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AMT February 2014

The company also does R&D of custom component designs. Customers develop designs and if B&S sees a potential fault or an opportunity for improvement, it will offer suggestions to make it better.

“As a supplier to the motorsport industry, you need to provide a quick response and be correct, first time and on time,” says B&S General Manager and owner Richard Bauer. “The FPR designers, engineers and other employees are great communicators and that keeps the business moving.”

B&S, which employs 17 people, also services other high-performing racing industries like marine sports and manufacturers of drift cars. It also provides machining services to Albins Off Road Gear and to other motorsport industry suppliers.

“The overall benefits to our company of being part of motorsport and these other fast moving industries, is that it keeps the work in Australia,” added Bauer. “Our company motto is: ‘Like it here - then make it here’.” www.fpr.com.au www.v8supercars.com.au www.albinsgear.com.au www.bseng.com.au

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Motorsport & Automotive

Olympus helps keep Frosty on track When Mark “Frosty” Winterbottom joyously lifted the winner’s trophy for the 2013 Bathurst 1000 race, it was a triumph for the whole Ford Performance Racing (FPR) team. Among those celebrating behind the scenes were the engine technicians who had used an Olympus videoscope before the race to inspect the engine of his V8 Supercar.

FPR competes all over Australia in the V8 Supercar Challenge race series, and the win on the Mount Panorama circuit at Bathurst was the team’s first victory in the nation’s premier motor racing event.

Olympus has partnered with FPR since 2007 to provide the team with the latest technology to ensure their cars are tuned for success.

An FPR engine technician inspecting the engine of a Ford V8 Supercar.

“The level of support – in terms of servicing the scopes we have and upgrading equipment to the latest model – has been sensational,” according to FPR’s Chief Engine Builder, Ashley Campbell.

Olympus has been at the forefront of videoscope development for many decades. FPR used an Olympus videoscope before the Bathurst race to visually inspect the inside of the engine of Winterbottom’s car to detect cracks, scoring, material transfer or other flaws that could have potentially lead to a catastrophic engine failure during the race.

The inside story The governing body for V8 Supercar racing stipulates the performance characteristics that all vehicles must comply with in order to participate in a race or series. This means that the size and weight of each front-engined, rear-wheel drive vehicle is essentially the same. The only differentiation is in the tuning and performance of the engine. A videoscope is an inspection instrument that consists of a small camera mounted on a length of cable. The camera can be controlled remotely by an operator while it is inserted in the cavity to be inspected. The latest model supplied to FPR is lighter, easier to use, and more conducive to how the team operates in the ‘pressure cooker environment’ on the Saturday night of a race meeting.

“To us, the videoscope is absolutely essential and we are able to eliminate major failures because we are able to know the condition and viability of an engine throughout its life,” stated Campbell.

The highly skilled FPR engine technicians spend the time between races stripping down and rebuilding racecar engines in preparation for the next race. It takes between six and ten weeks to build an engine from scratch and about two weeks to strip down and rebuild an existing engine. The FPR team has a full CNC machine shop that is used to custom-make components for its engines. The technicians know the entire history of every part and component. According to Campbell, each conrod spends its life in a specific location in the engine and each piston is dedicated to a particular cylinder. Cranks and rods are matched to a specific piston weight in order to balance the engine. Once a part is allocated to a position in an engine, that is where it stays. Most items go into an engine ‘new’ and remain in that one power plant until they need to be replaced. FPR also makes its own timing gears, manifolds and exhaust systems.

The aluminium sump doubles as the engine mounting block.

“We mount the engine rigidly to the chassis cross member to give some stiffening to the front of the car,” said Campbell. “There is no commonality with a car you might buy from a dealership: it may look like a Falcon, but take off the skin and it is a very different machine.”

Once an engine is ready, it is run on a fully automated dynamometer, which allows the technicians to check ring seals, pistons and bore seals. The engine is run under optimum conditions for oil temperature and pressure. It is also connected to a computer ‘mapping’ program that maps the generic tuning to match all the idiosyncracies of a particular powerplant. It is run up from a base RPM to the mandated peak RPM of 7500rpm. This gives a read-out of the horsepower and torque values to ensure that the engine is giving the expected performance. At the end of the procedure, the technicians set the idle rate and shut the engine down.

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AMT February 2014

After the engine is removed from the dynamometer, it is inspected using the Olympus videoscope to see if there are any signs of wear or damage or if unplanned events have occurred in the engine. The Olympus videoscope has enabled the team to catch many potential failures before they cause problems while racing.

According to Campbell, technicians can detect indications of markings in the cylinder wall or evidence of transfer of material from the piston to the cylinder wall. By removing the engine and stripping it down to its components, the engine technicians are able to limit damage to a single part or component before it impacts the rest of the engine.

Preparing the car at the track FPR technicians plan for an engine to be in a car for the full race meeting. However, the team always has a spare engine in the support truck. Except for the exhaust manifold and pipes, the spare unit is ready to go with all ancillary components and plumbing already attached.

On race days, there is a dedicated team for each car. The team comprises the number one and number two car mechanics assigned to a particular vehicle and, usually, two engine technicians who work on all the team’s four cars as well. There may also be one or two ‘floaters’ who provide extra muscle for moving equipment and tools around the garage.

“Any more than this and it gets a bit claustrophobic within the confines of the chassis,” said Campbell.

During an engine change, everything from the harmonic balancer at the front of the unit to the flywheel with the clutch attached is removed and replaced. To assist with the changeover, the engine has lifting tags attached to the exhaust system. When a new engine is placed in the car the first two things connected are the oil and water.

“The oil is kept heated and the water is at 65 degrees prior to starting the engine,” said Campbell. “This is to eliminate cold start wear because when engine components are cold, they are not at their operating size.” Once the water and oil supply and return pipes, the radiator bleed pipe and the fuel line are connected, all the wiring associated with the injectors and all the monitoring sensors need to be plugged back in.

Between V8 Supercar race meetings, the cars and engines are returned to the main FPR facility. The workshops are remarkably clean and uncluttered.

Motorsport & Automotive

An Olympus iPlex LX in the engine bay of an FPR V8.

“We are spoilt to some extent that we are able to work in this environment,” Campbell mused. “I am continually amazed when I show someone around here that they can be so passionate about the outfit, which, for us, we are lucky to have as our day-to-day job.”

According to Campbell, all team members are dedicated professionals who are willing to put the effort in to make sure the cars always perform at their peak.

“Race day is everyone’s Number One priority,” he said. “The team is prepared for the sacrifices they sometimes have to make to their personal lives.”

During a standard rebuild, the piston rings and pistons are replaced.

Technicians also check the bearings but usually these can be reused until they do show signs of wear, though gaskets and seals are always replaced. Every ferrous and steel item is crack-tested, while aluminium components are tested using dye penetrant procedures.

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The cylinder head is under high stress during a race so it is checked after a race and technicians inspect the valve and valve seats where they meet the cylinder head.

“We have worked with FPR for several years now and have upgraded their equipment to the latest, lightweight model,” said Mark Wheatley, Sales Specialist at Olympus. “With the new untethered videoscope, the race technicians can quickly inspect an engine in the pit straight if necessary, rather than bring it into a workshop.”

Campbell and his team are now looking forward to trialling Olympus’s new high-speed camera systems.

“We will be able to view and record the actions of most parts of our engines and see what might be the actual event that causes an engine failure, rather than just the aftermath,” he said. www.olympus-ims.com

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AMT February 2014

| 49

Motorsport & Automotive

TaeguTec – For the love of the sport The technology behind the latest generation V8 Supercars has grown in leaps and bounds since the concept took shape in the early 1960s.

Consider the practical challenges of taking a road-going four-door sedan and transforming it into a V8 Supercar. A quick review of the engine and drive-train demonstrates the stringent requirements – all cars must have a front engine with a rear-wheel drive system. Only 5.0litre V8 engines with electronic fuel injection producing 620-650 horsepower are considered. All engines are electronically limited to 7500rpm with a compression ratio of 10:1.

Power to the rear wheels is delivered via a six-speed sequential transaxle with an integrated spool differential, while the individual gear ratios and final drive ratio are fixed with drop gears at the front of the transaxle. And that doesn’t even include the specifications for brakes, suspension, wheels and tires.

Building from the ground up Building a V8 Supercar is what Jeff Stewart, a TaeguTec sales engineer with much V8 motorsport experience,describes as “a full-time job and a half”. Thousands of components go into its construction, from a simple part like a ferrule to something complex as a front upright. A modern-day Supercar includes metres of chrome-moly tubes attached to a steel chassis, with panels made from composites and bonnets made from steel.

Specific metal and metal alloys must be used in production, and only the best will do because the slightest flaw could end in a disaster for the driver, the car or both. Generally, the parts used in the production of these monsters of the race circuit are made from a range of materials such as: 7000/aircraft grade aluminium; 1020 (AS14421992 1022), 4140 (AS1444-1996 4140) and 4340 (AS1444-1996 4340) steel grades; 316 stainless steel; and various composites.

Because of the varying grades of alloys and kinds of materials, a motorsport shop has to be on par with shops that have the ability to meet ISO 9001 standards practiced in the aerospace industry.

If a component does not have the correct surface finish or the right tolerance it has to be scrapped. To complicate matters even more, time and money are always of the essence, while quality standards are stringent. According to a machinist in a shop using TaeguTec product lines, “when you’re building a race car, you are in search of stiffness and minimum weight. The stiffness will result in the car reacting to a change in set-up.”

The importance of lightness allows the team to place weight where needed, bringing the car to minimum weight. Cutting tool suppliers such as TaeguTec offer comprehensive cutting tool solutions that make the metal shaping of these components simple and fast, which helps the motorsport machine shops meet the tight cycle time demanded by the sport.

Stewart recounts the impressions of a V8 Supercar machine shop that was introduced to the MillRush range of cutters using the 3PKT insert. “What impressed the shop most was the tool’s versatility and how fast the operation was when machining aluminium components.”

The 3PKT has three cutting edges and is characterised by a unique thick geometry and high super rake angle that generates a low cutting force. The shop was particularly impressed by the low cutting force because most of their machining was not conventional production work.

“In certain applications it was necessary to hold back the cutting by 5mm but it still required a very fine finish,” says Stewart. “This is a tricky thing to do.”

For difficult-to-cut materials such as aluminium, race-car shops machine their parts using a low cutting force at high speeds.

“The insert wiper gave the proper quality surface finish that was required for the component,” says Stewart. “In this case, the 3PKT

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AMT February 2014

inserts fit the bill nicely.”

A further benefit was the opportunity to test the 3PKT on 316 stainless steel, where tool life and productivity increased by 60%.

“Put simply, the MillRush line demonstrated outstanding performance and that was how they became a repeat customer,” says Stewart.

Stewart’s own experience machining V8 Supercars illustrates where other TaeguTec product lines are the optimal solution.

“Consider front and rear spindles made from 4130 (708 A 25) billets,” he says. “If I had known about the TurnRush range for semiheavy machining with double-sided inserts beforehand, much time could’ve been saved on certain operations requiring a lot of material removal.”

The HB chip breaker’s optimised configuration enabled stable performance but its best feature was the increased clamping force due to its hook lever design.

“The billet, when set up in the fixture, is a 300mm blank with an uneven black scale skin surface,” explains Stewart. “Ideally, a machinist would want to get under the skin on the very first cut.”

The TurnRush line performs best on operations that use finished spindles, with its advantage being its capability to rough turn blanks quickly, which sped up the heat treatment time required prior to the finishing stage.

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Another application that Stewart found a chore was radius milling using solid carbide cutting tools.

The associated chatter not only produced waste but was causing complaints on the shop floor. He switched to TaeguTec’s AluMill Wave, which handled radius cuts smoothly and at very high speeds, minus the chatter. The endmill’s unique cutting edge wave, variable helix and unequal spacing of cutting edges “really reduced the chattering while generating a lower cutting load,” according to Stewart.

Furthermore, the end mill’s wide gash design and improved chip evacuation due to its polished flutes increased productivity. Not only did the AluMill Wave reduce chatter, but the cycle time of machining components proved to be a time-saver and a morale booster on the shop floor.

A challenge for machine shops This past November, V8 Supercars governing body initiated new regulations aimed at keeping the circuit competitive. For starters, owners are now required to reduce the cost of building a V8 prototype from the approximate AU$450,000 to AU$250,000 for the entire car.

More importantly, the cost of building a completely new V8 engine must be cut from AU$175,000 to AU$100,000. This new initiative caused some concerns for race-car shops. For starters, the dayto-day costs of machining Grade-A materials are capital intensive.

Motorsport & Automotive

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Ironically, these changes have not had a negative impact on the machine shops that use TaeguTec’s high-productivity and economical cutting tool solutions like the MillRush line with its 3PKT inserts. It is a win-win scenario for both the V8 Supercars championship and shop owners: the organisation now has levelled the playing field and the race team owners’ bottom line has not been impacted by the changes.

Serving the V8 community “Most teams build 90% of their cars in-house, employing a minimum of 30 people,” says Stewart. “For them, it means long unnoticed hours. Were it not for these machine shops and fabrication shops, the engineering miracle that is the V8 Supercar would not be possible.”

Demonstrating the capabilities of the TaeguTec product line of cutting tool solutions makes the job of the machinists easier. Stewart believes the best way to serve this community is to show what TaeguTec tools can do.

And when asked why people work in a pressure-filled environment such as V8 Supercar racing, Stewart reflects on his own experience: “We love it, that’s why we do it.” www.taegutec.com

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AMT February 2014

| 51

Motorsport & Automotive

Monash dominates 2013 Formula SAE-Australia competition Advanced aerodynamics, new suspensions and a turbo-charged engine powered the Monash University team to a fifth consecutive victory in the Formula SAE-Australasia competition in December.

Monash used a sophisticated points simulator program to benchmark its car’s performance against the competition during the design and engineering phase. This reinforced an already confident team as it continued its winning streak.

With 937.5 points out of a possible 1000, Monash was a clear winner, beating its own 2012 tally of 899.4 points. The remaining podium places were closely fought, with Curtin University second on 754.2 points and University of Melbourne in third place with 685.8 points. The remaining top ten positions were hotly contested with the best placed overseas team, University of Waikato, taking sixth place from University of Queensland in seventh and University of Sydney in eighth. Hosted annually by the Society of Automotive Engineers – Australasia (SAE-A), 350 competitors in 23 teams were welcomed to the 2013 Formula SAE-A competition, which ran from 12 to 16 December at the Victoria University Werribee campus near Melbourne. The event features cars using 98RON and E85 fuels, with a separate division for electric cars.

Formula SAE-Australasia is a competition for university students to design, build, test and then compete in a single seat autocross race car during the academic year. The competition extends classroom learning by creating a real-world engineering and business environment where students develop teamwork, learn hands on fabrication skills, and face the time and cost pressures of managing a complex major project.

Aerodynamic innovations Society President Adrian Feeney said the creative juices flowed freely in the 2013 Formula SAE-Australasia contest.

“Many innovative design concepts brought to the competition by teams from across Australia, and from Japan, New Zealand and the United Kingdom, were proven in this year’s competition,” said Feeney. “More cars appeared with advanced aerodynamics, including the second place Curtin University car. Among their goals was to qualify for entry to international Formula competitions and that was readily achieved.”

Fourth-placed University of Adelaide, 13th-placed University of Auckland and 19th-placed University of Wollongong also entered cars with large wings front and rear. A different aerodynamic approach was taken by fifth place University of Western Australia with the team producing a second iteration of the ‘aerobeam’ chassis concept introduced in 2012. This design features a carbon composite under tray fitted below the suspension.“The rapidly developing electric car category was won by the pioneering RMIT University team, with Swinburne University of Technology second and University of Western Australia third,” added Feeney.

RMIT University was the first team home in the electric car division of the 2013 Formula SAE-Australasia student design and engineering event

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AMT February 2014

The Monash University team powered to first place in the 2013 Formula SAE-Australasia engineering education competition, held in December at Victoria University near Melbourne.

Formula alumni in demand Launched by the SAE-A in 2000, the Formula SAE-Australasia competition has become an established fixture on the international Formula SAE and Formula Student calendars in Asia, Europe and the USA. Executive Director Natalie Roberts said Formula SAEAustralasia is renowned for producing top engineering graduates that are in great demand in the aerospace, automotive, transport, motorsport, mining and manufacturing industries.

“With Formula SAE-Australasia on their CV, graduates have scored engineering positions locally and internationally with major manufacturers,” said Roberts. “While some pursue careers in mainstream transport working with cars, trucks, trains and planes, other are attracted to the highly competitive world of racing at V8 Supercar and Formula 1 levels.

“These industries benefit greatly from the job-ready skills that Formula alumni bring to employment. To keep this regional event delivering such important outcomes in the future, we need continuing investment in the program from sponsors.”

On behalf of the SAE-A and all competitors, Roberts thanked the sponsors of the 2013 event, including Robert Bosch Australia, Ford Motor Company Australia, GM Holden, Mitsubishi Motors Australia, Toyota Technical Centre Australia, Toyota Australia, and the Confederation of Australian Motorsport.

“We offer a special thank you to Victoria University for providing an excellent competition venue for many years. We look forward to new on-track challenges at Calder Park Raceway in 2014,” added Roberts. “And most importantly, we thank the 100-plus people who volunteer their time and skills to make Formula SAE-Australasia happen year after year. Working with this team is awe inspiring – people just jump in and make it happen.” www.saea.com.au

Scoring seventh place was the harddriving University of Queensland, pictured here taking a two-wheeled turn.

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One on one

Stuart Charity is the Executive Director of the Australian Automotive Aftermarket Association (AAAA). He spoke to William Poole.

AMT: Let’s start with your professional background and how you ended up at the AAAA. Stuart Charity: I’d done a graduate recruitment program with the Victorian Government and ended up at Business Victoria, where I was working in investment attraction and international business, but also with the automotive unit. I then moved across to AusTrade, where I was the automotive industry specialist for a number of years, helping the OE (original equipment) and aftermarket component supply base internationalise by taking trade missions overseas, bringing inward buyers and so on. I was then offered the role of Executive Director at the Society of Automotive Engineers, and seven years ago I came across to run the AAAA. AMT: Talk us through the AAAA’s role and objectives.

SC: We’re the peak industry body for the automotive aftermarket in Australia. The aftermarket in layman’s terms is anything that goes on the vehicle post-manufacture: replacement parts, accessories, specialty equipment. We represent the end-to-end supply chain, from manufacturers through to retailers. We have about 1700 member companies, from Bosch, Repco and Supercheap Auto, through to small, independently owned “mum-and-dad” retail stores.

Our role is to represent our industry and be its voice to government.

We’re also focused on activities that make our member companies more profitable by providing commercial opportunities. We run a trade show, the Australian Automotive Aftermarket Expo, along with conferences, networking events. We run a magazine that goes to 15,000 workshops nationally every six weeks. We run national pavilions at trade shows around the world and provide a turnkey service for our exporters. We have a suite of business services for smaller members, like free HR and industrial relations advice, EFTPOS banking facilities and so on. It’s a diverse offering for a diverse membership.

AMT: How does the aftermarket sector compare in size to the OE suppliers?

SC: It’s difficult to get accurate estimates of the different segments’ size, but we surveyed our members and researched all the available data and concluded that automotive OE component manufacturing is worth about $3.9bn annually, while automotive aftermarket manufacturing is about $5.2bn. So it’s actually larger. There’s about 16,000 direct employees, and 21,000 including indirect employees.

The total aftermarket is about an $11bn industry, of which $5.2bn is locally manufactured. And 15% of that, around $800m, is going to export, so it’s a significant amount of exports.

A lot of low-value-add product has gone offshore, which is the way of the world, but it’s whittled the industry down to what we’re really good at, mainly specialty equipment like four-wheel drive products, high-performance or motorsport products. Products that are almost tailor-made – low-volume, high-quality. And these products are bought on features, benefits and performance, rather than price.

A company like ARB is a high-profile example – an Australian company started in a garage that’s now a publicly listed, multinational corporation exporting four-wheel-drive parts to over 100 countries.

Pedder’s Suspension is another; their network today has over 100 stores Australia-wide and they export all over the world. There’s numerous examples, and most of them don’t supply to the car industry. Pedder’s makes springs in Australia, but they don’t supply the car companies here. They supply through their own distribution networks with their own branded product.

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AMT: What are the AAAA’s plans for 2014?

SC: From an advocacy point of view, the biggest issue facing our industry is what we call Choice of Repairer, which is about access to car manufacturer-controlled technical and diagnostic information.

Vehicles today are computers on wheels, and independent repairers need access to repair and service data to diagnose faults and service vehicles, or they’ll be at a competitive disadvantage to the dealerships. There’s a global Right to Repair campaign that we’re running in Australia, and we’re hopeful the government will introduce a mandatory code of conduct for information-sharing by vehicle manufacturers. It also covers things like warranties – there’s a lot of confusion among car-owners about getting their vehicle serviced at a non-dealer repairer during the warranty period. You don’t have to have your vehicle serviced at a dealership to maintain your warranty, and we need to get that message out.

From a manufacturing point of view, we’re involved in the current Productivity Commission (PC) review into automotive manufacturing.

Aftermarket manufacturers have been excluded from any Federal Government automotive industry assistance over the last ten years. So when the media talks about the industry getting all this taxpayer-funded assistance, it isn’t flowing through to independent aftermarket manufacturers.

Many of those manufacturers are Australian-owned, and they choose not to deal with the car industry because of low margins, declining volumes, and dealing with the car industry is notoriously difficult. You control your own destiny by supplying to the aftermarket, you can brand your product, access multiple distribution channels, export and so on. It’s a more entrepreneurial market. The problem is our manufacturers are highly trade-exposed. The Australian dollar’s been high, and there’s been a flood of products coming in from lower-cost manufacturing countries at zero or near-zero tariffs. That’s impacted upon our manufacturers, and we believe if something’s not done in five to ten years, we’ll see much of that manufacturing gone.

AMT: That’s interesting. We often hear how Australian-manufactured cars face an uneven playing field regarding tariffs, but not how it affects aftermarket manufacturers.

SC: In our PC submission, we had a table outlining the tariff and non-tariff barriers in place with our major trading partners, and some of them make exporting to those countries completely prohibitive.

Now our government is negotiating free-trade agreements and we’re sitting at the table with tariffs at 5%, while countries like China, Malaysia and Indonesia are at 25% or even 40%. Then they negotiate a transitional arrangement, so we go to zero from day one and they go to 35%. It’s far from a level playing field.

I’m not advocating putting tariffs back up again. We can’t go back.

But I think the government’s got to look at the new global reality.

Automotive aftermarket manufacturing is sustainable, but it needs the right policy settings.

AMT: What impact do you see Holden’s decision to follow Ford in ceasing manufacturing in Australia having?

SC: I think it’ll have a devastating impact on our industry as a whole, but specifically on car manufacturing. Car manufacturing is all about scale – a plant really isn’t sustainable unless it’s producing a minimum of 200,000 units a year. Our whole industry is only just producing 200,000 with three plants, so we’re well below scale.

And exports of Australian-built vehicles are on a real decline. The highest-selling vehicle in Australia is something like 40,000 units a year. That won’t sustain a car plant. You can’t manufacture cars

here without an export plan. That’s what led to Ford’s demise, and I believe it was a major contributor to Holden’s decision, because they used to export large volumes to the Middle East but that’s died off.

That’s what sets Toyota apart – they export more Camrys than they sell in Australia.

Ford still makes the Falcon and Territory here, but we’ll see the full impact when they wind down production in 2016. Add Holden around the same time, and you’re taking about half the volume of production out of the industry. And you’re down to one manufacturer, Toyota, and their future’s uncertain. They’ll find it increasingly difficult sustaining a viable supplier base after those pure OE component suppliers have lost half their business.

The OE suppliers have to diversify into other markets: industrial, mining, aerospace, marine, but also the aftermarket. Aftermarket is still making auto components, but for a different client. It’s a different distribution structure, but the same product. But we felt the urgency for those companies to diversify was already there before the Holden announcement.

For the broader automotive industry, it will have an impact. Many of our members do supply to car companies; Bosch, Hella, Continental and so on have an aftermarket business, but they’re also OE suppliers, so they’ll be heavily affected. Other members supply parts to all the car companies through their parts and accessories networks, so there will be some impact. But we believe about 85% of the product made by aftermarket manufacturers is supplied to the independent aftermarket, meaning you’ll probably see about a 15% reduction in overall volume in aftermarket manufacturing.

AMT: What should the government be doing to help?

SC: I think the government has to take a holistic approach to the entire automotive industry – that’s certainly the theme of our PC submission. Let’s start looking at the inherent strengths and weaknesses in every part of the industry, whether it’s making trucks and buses, or automotive components.

But the government also needs to take its head out of the sand and stop pretending no-one else is supporting their industry. I just got back from China, where the automotive industry is one of the main pillars of their economy, with massive government support.

But the industry here has failed to get the message out that this is commonplace all around the world. What’s happened in Australia is we have moved from tariff support to financial support, and that plays out in the media as cash hand-outs. The net support for the industry is actually much less than 20 years ago; it’s just it’s in cash now.

Our mantra is “Internationalise”, and the government should do more to support our exporters. Austrade’s almost wiped its hands of export support; it used to facilitate trade missions and run national pavilions, and now we’re doing that. The Export Market Development Grants (EMDG) program is useful for companies starting out, but once they start to hit their straps after five years the government pulls out and says “you’re on your own”. There’s a real lack of vision and support by government to help manufacturers internationalise.

Australia should have a vision for manufacturing across the board.

If you’re competitive and sustainable with strong international prospects, you should get government support to achieve that potential. By doing that Australia will transition into areas we’re good at and we’ll grow our markets.

AMT: So what’s the outlook for the future?

SC: I’m pessimistic about car manufacturing in Australia. It came through very clearly in the PC’s preliminary report that the outlook’s bleak. I don’t think Toyota can survive as the sole manufacturer. The chances of government attracting another car manufacturer to come into Australia now are pretty remote. Global OEMs are rationalising platforms, rationalising plants, getting scale – some Chinese plants are building 500,000 vehicles.

Having said that, I think there’s a bright future overall, provided the government puts the right policy settings in place. If the government sits on its hands, the manufacturing will go, and we’ll be a servicesand resource-based economy. Some economists will say that’s fine, but I don’t subscribe to that. You can blame the high Australian dollar, but it won’t be high forever. The problem is if the government doesn’t do anything now, by the time the dollar comes down, all the manufacturing will be gone and it won’t come back.

But if the government refocuses and supports companies in the right areas, I think we can be a world-class manufacturer in niche volumes in niche industries, and do very well. If Germany can do it… they’ve got high wages, high quality of living, and a vibrant manufacturing industry with powerful multinational companies across many sectors.

The US is doing everything to hold onto its manufacturing base, and I don’t think we should just let ours go. www.aaaa.com.au

The FAPM (Federation of Automotive Products Manufacturers) put out a summary of the different levels of support for different industries in Australia, and automotive was fourth or fifth. Mining gets a whole range of fuel rebates, the banking industry has the deposit guarantee and so on. But the car industry, because it’s cash and it’s high-profile and they’re multinational corporations, seems to be the whipping boy of the media.

Governments have got to view our industry in a new paradigm and think about where our place is in the future. Australia can still undertake advanced manufacturing, but we need to work out what our strengths are, and have government support mechanisms in place to help grow those companies.

And I don’t mean subsidies. We’ve never said we want to be subsidised. I think if you need subsidisation you shouldn’t be in business. But government can add value in helping companies to be world’s best practice, to be streamlined, to get access to R&D, to the latest equipment.

The future of Australian manufacturing is to make our companies global. Australia is a small market, but there are massive markets out there for the products we produce. We’re a niche manufacturer, that’s where our strengths are. We only need small bits of these large markets and we’ve got great business.

AMT February 2014

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Cutting Tools

Milling tooling progress Recently developed milling tools provide the operational flexibility required to machine increasingly complex components. By Tapio Alatalo, Global Product Manager for Square Shoulder/Helical Milling at Seco Tools.

As manufacturers introduce products with greater functionality and efficiency, the components that comprise those products become more complicated and increasingly difficult to manufacture. In addition to featuring complex contours and tighter tolerances, the parts are often made of high-performance materials that provide strength and reliability but negatively affect machinability.

Toolmakers continuously develop new tools engineered to maximise machining efficiency. Progress in milling cutter technology is one example of this effort. Solid carbide cutters have traditionally provided high metal removal rates and excellent accuracy.

However, the one-piece nature of the cutters necessitates that they be reground when worn. Changing tools for regrinding interrupts production and consumes time and money. Applying a reground cutter requires changing NC program parameters, and producing a different part contour may mean choosing a different cutter with a more appropriate tooth geometry.

As a cost-efficient alternative to solid cutters, toolmakers have developed milling cutters with indexable, replaceable inserts. When cutting edges wear, inserts are simply indexed or rotated. Worn out inserts can be quickly replaced with the tool body still in the machine, and different insert geometries can be fitted to the same cutter body to create a variety of contours.

Negative vs. positive The geometries of indexable inserts have evolved as well. Many indexable inserts have cutting edges on both top and bottom sides.

Turning such a double-sided insert over after indexing doubles the number of available cutting edges. However, the design of doublesided inserts does not include space behind the cutting edge for a clearance angle, and thereby does not permit the tools to be applied in a positive-rake approach.

In a positive rake tool, the bulk of the insert body is tilted back from the cutting edge, enabling the edge to shear the workpiece material. On the other hand, in a negative-rake tool the bulk of the insert body tilts toward the workpiece and the tool essentially pushes the material being cut. Because of its design, the cutting edge of a double-sided insert must approach the workpiece from a negative angle.

abrasive workpiece materials such as cast iron. The availability of multiple cutting edges results in tool cost savings that can make double-sided negative inserts an economical choice in simple 2-D milling of easy-to-machine workpiece materials. However, because negative rake tools push the work material instead of shearing it, they generate high cutting forces and heat. If the machine tool’s power is lacking or if the entire machining system is not sufficiently rigid, final accuracy will suffer. The cutting forces generated by a negative-rake tool, for example, can distort a thin-walled part.

Conversely, a positive-rake tool is free cutting, which minimises cutting pressure, and often can cut tight contours that a negative tool cannot reach. Positive insert geometries provide a large degree of flexibility to perform a variety of operations including slotting, contouring, helical interpolation and ramping. The tools can help stabilise machining on older and/or less rigid machines. Moreover, minimising cutting forces is crucial when machining tough materials such as titanium, Inconel, and many stainless steels.

One-sided inserts – geometries, grades and coatings To provide indexable inserts that can cut in the positive mode, tool manufacturers offer one-sided inserts with clearance angles behind the cutting edges. Although the inserts cannot be turned over they can be rotated in the holder, providing multiple useful cutting edges.

The free cutting nature of positive-rake tools reduces cutting forces and heat generated in the cut, which enhances tool life. That is important because a one-sided insert must have three times more tool life per edge to be cost effective, compared with double- sided inserts.

Among the available high-performance, one-sided, positive-rake inserts developed for milling are the XO.X10 tools developed for the Turbo 10 series of milling cutters from Seco Tools. The inserts are engineered to minimise cutting forces and control chips while providing the flexibility to cut a wide variety of part contours and materials.

Negative-rake cutting tools do offer certain benefits. They are strong; they can withstand heavy chip loads and cutting forces and thereby can handle rough milling, interrupted cuts and tough,

Beyond the basic distinction between positive and negative cutting edges, tool manufacturers have developed a variety of edge treatments aimed at maximising productivity in different workpiece materials. For example, up-sharp, uncoated polished edges work

Positive Rake Angle

Negative Rake Angle

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Cutting Tools

well in softer materials such as free-machining aluminium alloys.

For more difficult-to-machine materials such as steels, cast iron, or stainless steels, honing or chamfering the tool edge is necessary to protect it from chipping. Inserts engineered to machine cast irons, for example, often feature edge treatments including both a negative chamfer and an edge hone in the order of 30-35 microns.

Inconel and titanium, on the other hand, require a freer-cutting geometry with no chamfer and an edge hone in the range of 20-25 microns.

Much of a cutting tool’s performance is determined by combining substrate characteristics with wear-resistant coatings. Insert substrates generally strike a balance between toughness and hardness. A tough grade has impact resistance to handle interrupted cuts, certain difficult workpiece materials, and lessthan-rigid machining setups. Wear-resistant grades, on the other hand, have the hardness required to machine abrasive workpiece materials.

Coatings are intended to further fine-tune tool performance by providing additional resistance to wear and heat. Basic coatings include general-purpose materials such as TiN (titanium nitride), which is cost-efficient and good for ferrous metal applications not involving high levels of heat. A more advanced coating material is AlTiN (aluminium titanium nitride). It is more expensive than basic coatings but possesses good resistance to high temperatures, making it excellent for use in challenging applications such as milling of titanium, nickel-base alloys, and cast irons. In some situations, the coating’s high heat resistance makes dry machining possible.

Each tooling manufacturer develops its own variations on basic coating concepts; in Seco’s Duratomic coating, for example, the atomic structure of the aluminium oxide outer layer is controlled to maximise surface smoothness, tool life, and high-speed capability.

Square shoulder and helical cutters Milling cutters generally are configured to handle specific machining situations. Square shoulder cutters, with a single row of inserts located radially around the cutter periphery, are appropriate where axial cutting depths are less than the length of a single insert´s cutting edge. For greater depths of cut, helical cutters, with staggered rows of inserts arranged axially, can be used for slotting, pocketing and ramping as well as circular milling and helical interpolation.

A milling cutter’s pitch, or the spacing between the inserts it holds, will influence its performance. Coarse pitch (large spacing) cutters are appropriate when machine power and rigidity are limited, or when the cutter is mounted on a long extension or applied in a deep axial cut. Fine pitch cutters, on the other hand, provide maximum metal removal rates when used in rigid setups on powerful machines. If machine power and rigidity are lacking, aggressive application of a fine-pitched cutter can result in vibration.

available in a variety of mounting systems. The Turbo 10 system’s flexibility is underlined by a choice of 13 carbide grades, three PCD tipped grades and five geometries suited for a variety of materials including steel, stainless steel, cast iron, hardened materials, hightemperature alloys, and nonferrous materials.

In regard to accuracy, solid carbide tools generally have less runout than indexable tools and normally can achieve a better surface finish. As such, in many situations, it is appropriate to rough and semi-finish with an indexable inserted cutter and create the final surface finish with a solid endmill. On the other hand, some cutter bodies, including Turbo 10 cutters, feature precision-ground pockets to minimise mismatch between insert levels and thereby boost machining accuracy as well as tool life.

The correct application Advanced tools must be applied correctly to take full advantage of their increased capabilities. A typical case of application error is the use of an incorrect grade, such as employing a hard, wearresistant substrate in a cut where a tough, impact-resistant tool would be more appropriate. However, the most common error in the application of advanced milling tools is the use of cutting parameters that don’t fully exploit the tools’ performance potential.

Many users run the advanced tool at the same parameters as they employed with the lesser tools they replaced, often using too slow of a cutting feed, speed, or both. The key to productivity is to machine more aggressively. For some tools, it is necessary to increase the speed, while other geometries require increased feed rates. Users should be sure to consult the cutting data toolmakers provide when they introduce new products.

Many industries, especially aerospace, power generation and defence, are developing new products that feature complex, highprecision components and utilise new workpiece materials that are more difficult to machine. More and more parts will feature contours that demand five-axis machining technology, and some components that formerly were assembled from separate parts will be machined as a unit.

Those trends will further spur development of new milling tool technologies. Free cutting, high-performance tools that can machine exotic alloys with low cutting forces and high accuracy will be increasingly in demand. The evolution of milling tooling will continue unabated. www.secotools.com/au

The Seco Turbo 10 selection of milling cutters includes both square-shoulder and helical examples. With the appropriate insert geometry, the square-shoulder cutters can mill corner angles to 90 degrees. The cutters are offered in two pitches, with four- and fivetooth versions. The recently-introduced Turbo 10 helical cutters are available in diameters from 32 to 80 mm, for cutting depths from 0.8xD to 2.0xD. Both square-shoulder and helical cutters are AMT February 2014

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Cutting Tools

Milling intelligently: Indexable chatter free Chatter poses an eternal headache for manufacturers. The far from harmless vibrations produced during metal cutting bring about poor surface finish, loss of accuracy, reduced tool life and intensive wear of critical machine tool parts.

To avoid these negative effects, manufacturers must use expensive vibration-resistant tooling devices and reduce cutting data, leading to increased costs and lower productivity. Iscar’s latest High QLine family of cutting tools offers an interesting solution: an indexable milling insert with an asymmetric shape. This opens up new opportunities for reduction of vibrations in metal cutting and marks a rather different approach to the design of vibration-proof inserts.

In metal cutting, every possible means for reducing vibration is an important factor for improving performance. There are various technological methods, including changes in workholding principles, using more rigid clamping fixtures and adoption of toolholders with vibration damping properties. If you experience vibrations during machining, you should react rapidly.

In most cases the response is simply to reduce the cutting data, but this causes decreased productivity. Ensuring stable cutting in a wide range of applications without considerable productivity losses is clearly a reasonable expectation. In milling, periodically changed impact load and thickness are sources of forced and self-generated vibrations. Therefore, prevention of chatter in milling is very important.

Tool manufacturers face limited options in terms of possible design solutions. Of course, the manufacturer relies on the basic design methods: the highest possible rigidity and strength of a milling cutter, progressive cutting geometry and so on. The field of special interest is in the specific principles that allow creation of a robust, vibrationproof cutting tool.

An unequal tooth pitch (angle pitch) gives good results. In the case of solid carbide endmills, a variable helix angle significantly improves chatter stability (for example, in the Iscar ChatterFree family). Also, a cutting edge with chip splitting action has definite advantages and effectively helps in reducing vibrations (Iscar’s SolidShred family). In addition, a combination of the above can be very successful (ECH5M-CFR of the Finishred family).

Attempts to apply these principles to indexable milling cutters (with inserts) often meet with difficulties. Making a chip-splitting cutting edge led to considerable success for Iscar, with the popular MillShred family. However, making indexable milling tools with a variable positive axial rake entails a lot of design constraints. Varying axial rake angle by changing the inclination of an insert pocket is actually very limited: a correct design has to ensure proper tool-back clearance. Evidently, another solution is required.

The design of the new one-sided insert HM90 ADCT 1505-CF, which is intended for clamping into Heli2000 milling cutters, uses a fundamentally different approach. A typical laydown indexable milling insert features rotational symmetry of its cutting edges about an axis perpendicular to the insert base. As a rule, it is the axis of a mounting hole. The new product bends this classical configuration.

The insert HM90 ADCT 1505-CF has two helical cutting edges, but their inclination to the base is different. Consequently, when the insert is clamped into a tool, its cutting edges produce various axial rakes. Thus, the achieved result is basically similar to the variable helix angle of the solid endmills, which is so effective in the reduction of vibrations during machining.

It’s important to note that the new asymmetric insert is suitable for already-existing milling cutters. This feature ensures significant improvement of the cutters’ performance in shoulder milling when rigidity of a technological system is low, due for example to high cutter overhang, a thin-walled workpiece or problematic workholding. As a

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result, the tool life of the insert increases by 15-20% and the power consumption is reduced by 10% or more.

According to Iscar, the new design approach for indexable inserts is very promising. Development of powder metallurgy and pressing technology will bring further increases in the height difference between corners of an insert and therefore will expand possibilities of changing the axial rake. Moreover, the portions of the rake face adjacent to the cutting edges may have a different topology that also allows varying the normal rake.

These properties provide a good base for producing vibrationproof indexable milling tools. There is especially high potential for extended flute cutters, the teeth of which are formed by a set of inserts. The new solution opens several options for varying the cutter geometry only by changing of the order of mounting the inserts on the pockets, such as: a consistent tool axial rake (two versions); an alternating tool axial rake from one flute to another; or a variable tool axial rake along each flute. In addition, changing the rake angle can be combined with the chip-splitting shape of insert cutting edges.

The peripheral surfaces of Iscar’s insert HM90 ADCT 1505-CF have different colours: golden on one side and black on the other. This seemingly ordinary detail is very convenient. It serves as a good indication of edge inclination and makes mounting the inserts in a desired order more simple.

Chatter has a complex nature. Simulating vibrations is difficult – it depends on many factors. In the design stage, simulation does not always help to find the geometry of a vibration-proof indexable milling cutter for broad-spectrum applications. Therefore, the ability of simple “cutter tuning” for a vibration-free mode only by changing the order of insert clamping looks very promising.

For Iscar, the new asymmetric milling insert is another product of the commitment to ongoing research and development, at a company whose motto for years has been: “Where innovation never stops!” www.iscar.com.au

Deep Hole Drilling Specialists Gun Drills: Ejector Heads BTA Heads

with brazed heads with indexable inserts & guide pads double tube system single tube system

Deep hole drilling machines The machines are built in Germany, to German Standards, and will be equipped to your requirements.

Tibo can offer a delivery time for a new machine of 4-6 months ex works, depending on the layout.

There are several TIBO machines in production in AUS and NZ, with more on order. Several customers have purchased their second machine now.

Feel free to contact TIBO direct: www.tibo.com

TECO Tooling has a full range of Botek Drills in stock, in addition to airfreight shipments arriving weekly. Contact us for catalogues and advice.

Tel: (03) 9775 0522

www.teco.net.au

Cutting Tools

Black Magic: tapping into Sutton Tools’ expertise Tapping requires very specific tool characteristics to ensure the accurate and consistent production of threads. Sutton Tools’ Export Manager Jeff Boyd explains how the unique design of the company’s latest release of Black Magic Taps can help manufacturers minimise their tap inventory.

Compared with drilling and milling, tapping is a process that places very different stresses on a tool – a factor that Sutton Tools has addressed with the design of its new Black Magic Tap range. Where drilling and milling tend to be high-speed low-feed operations, tapping is a slow-speed, fixed-feed process. These differences mean that the design of base material, coating, geometry and edge preparation that have been developed for drills and endmills are not necessarily the same for taps.

When it comes to tapping 300- and 400-series stainless steels, component manufacturers typically encounter a number of problems, including work-hardening, cold welding and chip evacuation. If too much heat is generated in the process, work hardening will occur. This can damage the workpiece itself, is likely to cause lower tool life, and may actually result in tool breakage.

Commonly, this work-hardening occurs during preparation of the pre-tapped hole, making the correct drill selection extremely important in order to maximise the tap tool life.

Another common problem is that of ‘cold welding’. Workpiece material becomes tenaciously attached to the cutting tool cutting edge and clearance faces. This causes local geometry changes and creates frictional drag on the tool. The increased frictional load can therefore cause heat build-up, and as the tap moves from one hole to the next, this extraneous material on the tap impairs the quality of subsequent threads and lowers the tool life.

A third issue arises when the long chips typically produced during the tapping of stainless steel wrap around the tool. If premature tap failure is to be avoided in this scenario, the operator must stop the machine to remove the swarf, thereby disrupting production.

Taking the ‘Hardlube’ line Mindful of the many issues that can impair production while tapping various materials, Sutton Tools has incorporated a number of innovative features into its recently released range of Black Magic taps. Designed for use on various materials such as stainless steels, alloy steels, general steels, low-alloy steels, as well as copper and aluminium alloys. This multipurpose range has been carefully developed to eliminate or minimise the common problems encountered during tapping, in order to maximise productivity for the end user while reducing tooling and inventory costs.

The base material that Sutton Tools has chosen for its Black Magic taps is a premium grade of powdered metallurgy high-speed steel (PM-HSSE).

This 3% vanadium grade incorporates a much finer grain and homogenous structure compared with conventional high-speed steel (HSS), allowing for greater toughness of the tool while maintaining high hardness. The end result is a material that offers better edge hardness for the tap, without suffering from brittleness.

A new coating introduced to the Black Magic taps complements the properties of this base material.

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Known as ‘Hardlube’, this comprises of a titanium aluminium nitride (TiAlN) coating with a top layer of tungsten carbide/carbon.

This multi-layer PVD coating combines the hardness and thermal stability of TiAlN with the sliding and lubrication properties of tungsten carbide/carbon.

The lamellar structure of the coating enables the layers to slide as they wear, offering low friction in the contact zone. Hardlube delivers excellent friction and lubrication properties for optimal chip flow, making it ideal for minimum quantity lubrication (MQL) and dry machining applications, in which it provides excellent resistance to cold welding.

Speed without stress The tap design features high relief to allow the tap to cut freely and generate less heat. The 500 helix of the spiral tap design offers faster chip transportation, while the three-pitch lead-in lightens the chip load compared with a standard spiral tap. This eases the stress on the tap when breaking the chip during reversal at full depth.

Furthermore, the flute design incorporates a positive rake on the heel that produces a superior cutting action on reversal. Together, these features allow higher tapping speeds to be attained.

The properties of the base material, coating and geometry are further enhanced by the edge preparation, also known as micro-geometry. This comprises a post-grinding treatment to polish the tool. The edge preparation helps to stabilise the loads on the tap and improve the subsequent adhesion of the coating, and – in conjunction with the coating – substantially reduces the likelihood of the development of a built-up edge from cold welding during operation. This improves the stability of the threading process and delivers a better thread surface quality.

To further enhance the quality of the tapped threads, Sutton Tools recommends the use of a square drive ER collet, thereby eliminating the possibility of tool slippage, ensuring the production of more accurate threads and improving tool life from each tap.

Sutton Tools’ Black Magic taps are multipurpose, suitable for CNC-synchronised tapping of a wide range of materials across a broad spectrum of industrial applications, from small-scale jobbing shops through to high-volume component production. Testing indicates that these taps perform well in real-life applications, able to be used at higher tapping speeds in synchronised CNC machines compared with conventional taps, and consistently outperforming higher-priced brands.

Recognising that a quality tap relies on the accuracy of the pre-tapped hole – parallel and without workhardening having taken place – Sutton Tools is offering its customers Black Magic drill-and-tap packages to ensure operations are simplified through the optimum combination of drill and taps for the material that needs to be machined. With the Black Magic taps, end-users can enjoy a high level of performance assurance, benefitting from the latest coating technology developed specifically for these taps to deliver improved surface finish, increased production and longer tool life. www.sutton.com.au

Cutting Tools

High-feed milling – tips and tricks High-feed milling has revolutionised milling applications today. John Mitchell, General Manager of Tungaloy Canada, offers some advice on how to make the most of it.

High-feed milling works from a chip thinning principle using the lead angle of the cutter. A 90-degree cutter will produce an average chip thickness of the programmed feed rate. When you program a feed rate of 0.25mm per tooth the average chip thickness will be 0.25mm. In a 45-degree lead cutter, the average chip thickness is about 70% of the programmed chip per tooth. In high-feed milling, the average chip thickness is about 15% of the programmed feed per tooth. Therefore a programmed feed rate of 1.5mm per tooth will generate an average chip thickness of only 0.23mm.

The lead angle also has a major effect on the cutting forces. With a 90-degree cutter, the cutting forces act perpendicular to the spindle. The net result is the forces are trying to push the spindle and or part away. This is very hard on the spindle. The tool should extend from the spindle the minimum amount to avoid deflection.

A 45-degree lead cutter will have the cutting forces act at 45 degrees to the spindle and the part. This is an improvement, but care should be taken when machining a thin part as the forces may try to push down on the part and cause “oil canning”. Oil canning is where the cutter pushes the workpiece down and the material springs back after the cutter passes. With high-feed milling, the cutting forces act almost parallel with the spindle. Since the cutting forces are directed back up into the machine’s spindle it is easier on the spindle and the cutter can be run at extended lengths.

High-feed milling is a very versatile way to remove material. The tool can ramp and interpolate. Unlike many other types of milling, this means the tool never has to leave the part. The tool can be ramped down to the next level while continuing to mill. Since the tool is never lifted from the part, it reduces the probability of re-cutting a chip and breaking an insert. High-feed milling is now commonly used for hole-making. It is about six times faster than drilling and one tool is capable of producing numerous size holes, reducing cycle time to index to different drill diameters, reducing the cost of the additional tools and reducing tool inventories.

offer some shock resistance, it limits the amount of effective teeth, slowing the process. Other manufacturers have opted to make their high-feed inserts much more positive and reduce the cutting forces, which maintains super high-feed rates, reduces cutting forces and is easier on the machine’s spindle. www.tungaloy.co.jp/au

Care should be taken when selecting the size of the high-feed cutter. Often programs use short, jerky motions when creating a tool path, often making it difficult for the machine to ramp up to the desired feed rate. For example, an 80mm-diameter cutter may be programmed to run at 7600mm per minute but since the short jerky movements don’t allow enough travel for the machine to reach this speed the cutter may only average 1000mm per minute, whereas a 25mm-diameter cutter may reach the 7600mm per minute of feed rate since its tool path is longer. Although the 25mm cutter has three times the distance to travel it is doing so 7.6 times as fast.

Many CNC controls today have a safety feature that limits the maximum feed rate. Many shops put in a new high-feed cutter, program the feed rate for 6400mm per minute or more and have the false sense that they are running faster, even though they are not because the maximum feed rate is set to 3800mm per minute.

A new trend in high-feed milling is the use of rectangular inserts.

The benefit of this style of insert is that it does not take up as much space in the cutter body as a trigon or square type of insert.

This means the cutter body can have a higher density of inserts per diameter. Some cutting tool manufacturers have cutter bodies with five inserts in 25mm-diameter cutters or ten inserts in 50mmdiameter cutters. With a chip per tooth of 1.5mm, five effective cutting edges and elevated rpm due to the small diameter the tool is easily capable of running at feeds exceeding 15,000 or 18,000mm per minute.

With metal removal rates as high as that the cutting forces produced are tremendous, and some cutting tool manufacturers have opted to build a big bulky insert to prevent insert failure. While this may AMT February 2014

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Forming & Fabrication

Steelpro brings in giant CMTYawei press brake Complete Machine Tools (CMT) recently installed a massive CMT-Yawei CNC press brake at Steelpro in Darra, Queensland.

According to Enzo Salerno, Sales Manager at Complete Machine Tools, it was a challenge from the very beginning to sell a Chinese press brake to a customer that has always purchased machinery out of Europe and Japan. When a customer always buys machines from these countries, their mentality is difficult to change, especially when a Chinese machine is being presented.

“The customer has a certain perception of poor quality of a typical Chinese press brake,” said Enzo. “Unfortunately in most cases this is correct, but in the case of CMT-Yawei press brakes it’s very far from the truth.”

When the proposal was handed over to Steelpro, it was met with a lot of negativity and questions regarding quality and reliability. At this point, CMT felt that radical action was necessary or the deal would be lost. So at its own expense, and with no expectation on Steelpro, CMT flew the customer over to the Yawei factory in China to see it in operation.

The CMT-Yawei CNC press brake installed at Steelpro

“We were so confident that the customer would be blown away by Yawei’s factory, the quality of the machine and how they manufacture it, we were happy to spend a few thousand dollars out of our own pocket,” recalls Enzo. “We knew the customer’s perception of our machine would change completely, and obviously it did!

CMT and Steelpro spent a few days at the Yawei factory. The move evidently did the trick, because when they got back, an order was placed. According to Enzo, CMT-Yawei press brakes offer exceptional value for money. “You get a fantastic machine with world-class components at a price which is incomparable,” he says.

“In the end the specification that was settled on was a capacity of 1200 tons, over a length of 10.2m, with a Cyberlec Modeva 10S controller and a six-axis (X1, X2, Z1, Z2, R1, R2) heavy-duty back gauge.

A few months later, the press brake arrived, with eight pieces from break bulk comprising the frame of the machine, along with various smaller parts in containers. In total it weighed just over 200 tons.

Two engineers along with one of CMT’s technicians installed the machine, which took 25 days from start to finish.

“When the machine is shipped from the factory it is completely stripped into pieces and needs to be reassembled here because it’s just too big to ship fully assembled,” explains Salerno. “It was a big job and was a bit hairy at times when the side, front and top beams had to be put together, because you have two mobile cranes being used to strategically position parts that weigh around 20-40 tons each. The machine required a considerable foundation, with the bottom beam needing a 2820mm hole and the rest of the machine sitting on a 1020mm deep foundation.

The tooling on the machine was made specifically to accommodate Steelpro’s current tooling and can be interchanged with the company’s other large press brake. Now, the CMT-Yawei press brake is working well and is reportedly pumping out the work.

CMT-Yawei press brakes come equipped with world-class components, including a Hoerbiger/Rexroth hydraulic system, Heidenhain linear scales, Panasonic servo-motor and drives, Siemens/Telemecanique electrics, and a choice of Delem or Cyberlec controllers. A large number of accessories can also be chosen to adapt the press brake.

The Delem DA-69T and the Cyberlec Modeva RA are both 3D controllers that can be used with offline software. This is ideal for companies that use lasers or turret punches because all machines can use the same software, improving efficiency. A six-axis back

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AMT February 2014

Installation of the machine took 25 days from start to finish.

gauge can be optioned up so all six axes can be programmed from the controller, minimising operator interference.

In addition, the Data-M laser measurement system will automatically move along the machine to the programmed bending area and adjust the machine to give the perfect angle each and every time.

This is helpful for shops that need precision bending or mass repetitive bending that has to be spot on.

The only publicly listed manufacturer of sheet metal machinery in China, Yawei is a stable, well-funded company with over 1200 employees. Yawei has become the premium sheet metal machinery supplier out of China. Along with press brakes it makes laser-cutting machines, turret punches and guillotines.

“What they did many years ago was extremely smart,” says Enzo. “They started co-operations with European and Japanese companies, with the foresight to improve quality, reliability and manufacturing processes. This has paid off because now Yawei competes successfully on a world scale. Their manufacturing processes have been adopted from Europe and it’s incredible to walk through their massive factories and see lines and lines of lasers, turret punches, press brakes and guillotines.

CMT has been representing Yawei in Australia for over 12 years and was the first worldwide to import the Yawei brand of machines.

“We carry a huge amount of CMT-Yawei machines and spare parts in stock,” says Enzo. “So if you after a world-class press brake, turret punch, laser or guillotine, without the price tag, give us a call!” www.steelpro.com.au www.completemachinetools.com.au

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Forming & Fabrication

Recent advances in plasma cutting of stainless steel When it comes to cutting stainless steel, plasma offers a number of advantages over the other methods available, and recent technological developments are delivering improved speed, quality and flexibility.

By Steve Liebold, Jon Peters and Jesse Tyler of Hypertherm.

Early plasma systems designed for cutting thick stainless steel used very high amperage and delivered slow cut speeds compared with recent technological developments. Modern plasma systems, however, allow end-users to select from an expanded range of gases and amperages, to produce optimal cut speeds and deliver the desired cut quality for a variety of needs.

For customers with experience in cutting mild steel, expanding into cutting stainless steel brings new challenges, and several factors must be taken into consideration in order to ensure success.

Gas types and selection When cutting mild steel, oxygen plasma gas and air shields can effectively deliver excellent cut quality across the full range of thicknesses. Success with stainless steel, however, requires a different type of gas and consumable technology for varying thickness ranges and grades. Proper gas selection is the first step toward success in plasma cutting stainless steel.

The table top right gives an overview of the results of using various plasma and shield gases when cutting 304L stainless steel:

Technology requirements by stainless steel type Plasma processes engineered for a specific grade of stainless steel may not necessarily perform well on other types of the same metal. For example, a plasma system

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Air

Shield

Air

Result ----------------------------------------------------------------------------------------

Among these systems, a plasma set-up presents a number of benefits. Plasma uses thermal energy and high-velocity gas to melt and remove material from a cut surface, resulting in fast cut speeds when compared with bandsaws and waterjet systems. And unlike laser, plasma features a thicker cutting capability, and the flexibility to quickly switch from severing 160mm stainless steel plates to cutting fine features on thin stainless (0.8-6.0mm) and mild steel, as well as on aluminium.

Plasma gas ----------------------------------------------------------------------------------------

Stainless steel accounts for a relatively small percentage of the worldwide steel consumption, but it is vitally important to economies, particularly in the energy and food-processing markets. Where cutting stainless steel is concerned, manufacturers employ several cutting technologies.

The most common of these are plasma, bandsaws and waterjets for broader thickness ranges, and laser and sheers for thinner plates.

----------------------- --------------

N2

N2

-------------H2O

----------------------- -------------F5 (5% Hydrogen, 95% Nitrogen)

N2

----------------------- -------------H35 35% Hydrogen, 65% Argon)

N2

Pros: Fast, minimal dross, square edge, low costs -----------------------------------------------------Cons: Surface is black, rough and heavily oxidised; secondary operations often required -----------------------------------------------------Pros: Smoother than air cutting, fewer oxides formed -----------------------------------------------------Cons: Edge is black, top edge is rounded; significant angularity can result -----------------------------------------------------Pros: Silver to straw-coloured surface, sharp top edge, fume suppression, low cost -----------------------------------------------------Cons: Water management, potential impact when used on a dry/downdraft table -----------------------------------------------------Pros: Silver colour, good cut angles and sharp top edge -----------------------------------------------------Cons: Thickness limitations, useful to about 10mm only -----------------------------------------------------Pros: Gold to blue to grey colour, square cut edge -----------------------------------------------------Cons: Gas mixture not readily available in all regions, limited to mid-range thickness and above (dross results on thin stainless steel)

meant for use on 304L, an austenitic stainless steel that is the most commonly used grade worldwide, brings about dross and a rough cut edge when used on 316L. When used on 304L, cuts are clean with no visible dross. The 316L cut can be improved to the same cut quality of the 304L cut by increasing the cut speed and shield pressure slightly.

As the above instance illustrates, each material type responds differently to plasma cutting. In order to cut various grades of stainless steel, a wide range of cutting processes is necessary in order to attain the best results.

Molten material viscosity and piercing Two other challenges presented by cutting stainless steel with plasma are molten material viscosity and piercing. Unlike cutting mild steel with oxygen or air, the viscosity of the molten material when working with stainless steel is much higher.

As a result, secondary operations such as grinding often need to be carried out in order to remove the slag. Factors that can reduce, or even eliminate, the formation of

dross on stainless steel include equipment design, gas type/selection, gas settings, cut speed, and cut height.

Achieving quality cuts Recent years have witnessed the development of a vented nozzle process that allows manufacturers to attain excellent cut quality on thin stainless steel. This technology was initially meant to advance cut quality on mild steel. Higher gas volume within the vented nozzle increases pressure to form a tighter constriction on the plasma arc, which enables use of a smaller nozzle bore, and results in higher energy density.

Venting improves nozzle life by constricting the arc, while higher flows cool the nozzle.

Additional innovations are also available that can deliver cuts with extremely sharp top-edge quality, a shiny surface finish, and superior angularity with reduced angle variation. Such solutions combine great cut quality with extended consumable life for consistent, productive and cost-effective results.

Forming & Fabrication

Using 304L process settings results in dross and rough cut edge when used on 316L.

Mixing gases well Despite modern advancements, the cutting of mid-range stainless steel (6-50mm) still brings to mind the topic of gas selection.

Using H35 (35% Hydrogen, 65% Argon) delivers the benefit of good cut quality and cut-edge colour with a non-oxidised edge, but cut speeds are relatively slow. On the other hand, nitrogen produces much faster cut speeds for increased productivity, but the cut edge is oxidised.

In order to realise the benefits of using each individual gas, and to minimise the disadvantages, auto-gas consoles for mechanised set-ups with the ability to mix H35 and N2 have been developed. The plasma gas mixture significantly improves cut speeds while maintaining the desirable silver or grey cut edge.

Fuss-free piercing Recent innovations are available that extend the thick stainless steel (50160mm) piercing and cutting range of plasma far beyond what was previously attainable. One such technology enables

Air/Air

the liquid-cooled shield to repel molten material, and prevents it from adhering to the torch shield during piercing. The liquidcooled shield technology also reduces: • O-ring melting.

• Interference with initial height sensing.

• Clogging of the shield’s vent hole.

• Orifice melting.

Another method is to use a new innovative controlled-motion to deliver maximum pierce. While so-called moving or “flying” pierce processes have been practiced for many years, the new process provides the advantage of minimal pierce length – usually only about as long as the material is thick. This essentially involves controlling table motion with torch height, to create a trough that enables the slag to exit the pierce hole and direct it away from the torch front-end. The pierce is initiated as high above the plate as the power supply will allow without losing the arc, and then traversing at a relatively high (gouging) speed to create the trough. The torch then begins to drop while at the same time table

motion slows until the pierce is achieved and normal cutting speed ensues.

‘Dogleg’ for thick stainless steel cutting and piercing The extended thickness capability for piercing and cutting stainless steel brings with it a new challenge due to the physics of plasma: the arc lags behind the torch at around 15 degrees. As a result, a small tab may develop when cutting a thick part in a nest, causing parts to stick to the nest, and internal features may have pronounced dings, bumps or nubs. This can be overcome with the new ‘dogleg’ technique, which also minimises any additional plate consumption.

The dogleg method for cutting and piercing thick stainless steel takes advantage of this lagging arc by focusing it onto the tab section of the cut. At the point where the leading kerf edge breaks into the leadin edge (and before the voltage reaches the critical value of the transformer), the cut path changes direction into an acute angle (60 degrees works well) toward the skeleton. This allows the arc to transfer to the skeleton material, which reduces the voltage while driving the molten material down towards the tab and subsequently melting it off.

Plasma: The choice solution

N2/N2

H35 & N2/N2

H35/N2

F5/N2

Using plasma to cut and pierce stainless steel plates has traditionally been known to be a tedious process. When using conventional plasma systems, operators needed to apply the appropriate mix of gases to bring about optimal cut speeds, while knowing which technology works best for the different grades of stainless steel.

However, with recent technological advancements, cutting the metal has become much easier. A variety of new technologies and methods are now available, which allow manufacturers to efficiently produce clean, high-quality cuts for thin, mid-range and thick stainless steel. www.hypertherm.com AMT February 2014

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Forming & Fabrication

Australian Steel Fabricators takes on global stage Based in North Queensland, Australian Steel Fabricators (ASF) is a new joint venture company incorporating some of Australia’s most experienced steel fabricators that is targeting the sort of largescale projects that have all too often gone overseas in the past.

The company has been established with the specific aim of answering demand for a steel fabricator that can meet demands of significant volume, whilst also being based within Australia and thereby offsetting the risks associated with the supply of steel from overseas. The purpose of ASF is to cater to the market for locally-based steel products for Australian-based mining and construction projects, while also maintaining Australian jobs.

ASF is a joint venture founded by a group of fabricators from Cairns and Townsville, consisting of Australian Professional Galvanizing, Cairns Steel Fabricators, Industrial Laser Cutting, Thomas Steel Fabricators and Totalfab Engineering Services. The concept behind the joint venture was to enable local companies to compete with overseas rivals, while keeping local jobs and encouraging innovation based on their extensive combined knowledge of unique local conditions.

ASF becomes one of the largest regionallybased steel fabricators in the country, meeting a critical demand within Australia for locally sourced, high-quality steel fabrications. The company has already begun talking with major engineering, procurement and project management firms about future work. Previously, managers of large-scale projects such as mining developments and large property developments would have usually found it necessary to source their steel from overseas suppliers.

ASF was assisted through its inception phase by officers of the Federal Government’s Enterprise Connect program attached to the Australian Industry group (Ai Group). Ai Group and Enterprise Connect are working together to help small and medium-sized manufacturers become more innovative, productive and competitive. Enterprise Connect offers comprehensive, confidential advice and support to eligible Australian small and medium-sized businesses to help them transform and reach their full potential.

ASF brings together well over 100 years of combined experienced of steel fabrication within Australia, with a unique understanding of the particular conditions that projects face in tropical Australia.

This understanding helps to reduce the risks associated with steel fabrication outside of Australia, such as shipping and delivery delays, communication challenges

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and quality control, by having a product delivered from within Australia. The company is equipped with the experience and resources to provide professional products and services to demanding clients such as those in the mining industry, delivering them at an international standard on a local level, using local assets, skills and knowledge.

One of the key advantages ASF can offer is that any client will deal with one single project manager across any job. Normally, a client involved in the management of a large-scale steel fabrication job (involving, for example, 15,000 tonnes of steel) would need to either go offshore, probably to China, or source production from a number of Australian firms. By working with one project manager based within Australia, the customer works with a common language, has easy access to service and technical support, and ultimately can expect improved lead times for the finished product.

ASF has the ability to offer all aspects of structural steel supply including: • Steel fabrication.

• Workshop detail drawings.

• Material procurement.

• Quality assurance documentation and inspections.

• Surface treatment (painted or galvanised).

• Transport logistics.

• Site installation and erection.

• Blasting and painting.

• Galvanising.

• Crane hire.

• Project management.

• Stud welding.

• Laser and plasma cutting.

The ASF board has appointed experienced Mining Manager Peter Van Iersel to be its inaugural Chairman.

“Before the existence of ASF, a number of managers of large-scale projects such as mining developments and large property developments were being forced to seek steel from overseas suppliers to meet demand,” said Van Iersel. “This reliance on overseas suppliers placed these projects at risk of a number of factors that were difficult to manage including: language and communication challenges, freight and port delays and the impact of a fluctuating exchange rate. We strongly believe that having a locally based, large-scale steel fabrication firm on the doorstep of these significant projects will create major cost savings and efficiencies.” www.australiansteelfabricators.com.au

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Forming & Fabrication

To test cut, or not to test cut?

Buying machinery such as an abrasive waterjet is a big investment, and it can be difficult to ensure that you get the product that best suits your needs. Patrick Turpin, Asia Sales Manager for OMAX Corporation, offers some helpful tips on how to make an informed choice.

The 19th-century English art critic and philosopher, John Ruskin was credited with once writing: It is unwise to pay too much, but it is worse to pay too little. When you pay too much, you lose a little money – that is all. When you pay too little, you sometimes lose everything, because the thing you bought was incapable of doing the things it was bought to do.

Scholars today debate whether Ruskin actually wrote those words – he had been dead for ten years when they first appeared in print in 1910. Nonetheless, the sentiment is as true today as it was 100 years ago.

When buying a machine tool, companies have differing expectations: some need faster turnarounds; others need better precision; some care about lowering operating costs; and others are interested in financial incentives. The one thing in common is that they all need the right machine for their application and expectations.

When I am working with a prospect who is considering the purchase of an abrasive waterjet, I recommend that he get test cuts before he makes the final purchasing decision. This is because after he has read all the marketing information, reviewed the proposals, and heard the testimonials, he still needs to ensure the machine will meet his specific application.

Trade shows such as Austech provide excellent venues for comparing various machines. Machine tool companies spend tens of thousands of dollars on booths, staffing and machines specifically so that the buyer can put them to the test. Given a little advanced notice, it may be possible to arrange to get a test cut done during the show. Being able to compare different machines practically side by side allows buyers the opportunity to compare the strengths of different machine tools, and make a truly informed decision. However, if your machine does not coincide with a show, you’ll have to expend a little more effort to get your test cuts completed.

have to limit your data gathering to just the marketing specifications the salesman has provided; the internet offers a wealth of information on which machines might best fit your requirements. There are discussion groups, blogs and articles, so take the time to look these over.

Next, contact the companies and set up your visits. Machine tool companies want to sell you their products and they have the ability to use various webinars to help you learn more about their strengths. Of course, many will open their facility for your visit, and will go out of their way to recommend a convenient hotel and even meet you at the airport. In some cases, companies may work with other machine owners in your area, so you can get a live demonstration.

The good news is that today you can get a real-time software demonstration and even a test cut from the comfort of your own office. With webcams and Skype, the process of working through a demonstration should be very simple.

When setting up the visits, it is important to remember to ask the salesman if they have your particular material available to process. They may not stock a warehouse full of material, but if you indicate what you want to cut, they will try to get that material for your visit. If they do not have your material in stock, ask if you can bring some with you. For example, if you are going to be cutting some gnarly, warped, cold-rolled steel, then you should see what is required to cut that material.

Your first step should be to narrow down your choice to the machines that fit your application, through simple questions such as “Is the bed the right size?” and “Can it machine my specific material?”. You don’t

In advance of your visit, send a geometry that is representative of what you want to cut with the machine. The effort required to program a part should be just as important to you as how the machine cuts. If you have

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to hire an applications engineer or buy new software in order to program your parts, you certainly want to know that before you buy a machine. Make it clear that you want to see the machine being programmed for your geometry.

Lastly, on the day of the cut, bring a watch. Time how long it takes to set up your material to cut. Machines use different methods to line up a cut. Also time how long it takes to actually cut your part. Compare your measured cut time to the time on the controller. Some machines’ user manuals clearly state that the cut time is an estimate based on straight-line cutting, and can be off by as much as 15%.

While this should not necessarily be a deal-breaker, you need to be aware of it. Remember: the time to cut a part represents energy costs, manufacturing capacity, labour costs and consumable costs. If one machine is even 10% faster than another, that 10% will have an impact on your bottom line.

Once you have completed your personalised demonstrations with various machine tool companies you will be in a great position to choose a machine that fits your application but your work should not end there. You should take a minute to tell all the salesmen you have been working with your decision; we are all professionals and we can take rejection. Your insight on your buying decision is important to us and we appreciate your feedback. www.omax.com

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company focus

Barden Fabrications – From design to delivery Barden Fabrications opened its doors for business in 1983, since when it has adapted and evolved into a one-stop shop for sheet metal fabrication solutions. Now, with its new joint venture, the company is doing its bit to avert the loss of skills from the industry.

Based in Bayswater, Victoria, Barden took its name from the first three letters of the forenames of its founders, Barry and Denise Stokes. Starting life as a manufacturer of roofing componentry, the business has grown and diversified over time. Barry and Denise have since handed over the reins to their son Brett Stokes, who now serves as Managing Director.

Today, Barden employs 30 staff, all at its Bayswater sites, but it ships to customers all over Australia, as well as exporting to customers overseas. Its client base encompasses a broad spectrum of industries, with the company placing a significant emphasis on delivering added value for its customers by providing a high level of service and expertise, while helping them through cost reduction projects.

“We see ourselves as a one-stop-shop, with the capability of full design through our engineering team, which can help develop customers’ ideas and concepts from drawing right through to manufacture,” says Stephen Bridger, Barden’s Operations Manager. “It was a strategy we put in place a couple of years back to value-add to our clients. We do a lot of work with clients to help reduce their manufacturing costs, where we can actually review their designs work with them and help modify them to take costs out.”

Bridger acknowledges that the strategy represented a conscious decision by the company’s management to pursue competitive advantage through criteria other than price. “We can’t compete against high-volume imports from overseas. What we’re trying to compete on is quick-turnaround, value-added services, where a client comes to us and we can help them develop low-end, hightech products.”

Barden offers a full suite of sheet metal fabrication services, including laser cutting, CNC machining, CNC turning, turret punching,

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AMT February 2014

metal folding via CNC brakepress, and MIG and robot welding.

The automotive industry has been a key market for the company for many years, where it has produced various components for direct feed and aftermarket requirements. It has also provided a variety of services for defence applications, and is affiliated with the Defence Materiel Organisation (DMO) and the Australian Industry and Defence Network (AIDN).

In addition the company has performed general fabrication services for clients in the construction and hospitality sectors, including high-end design furniture for a number of government buildings, as well as display, signage and safety products.

Continually upgrading its technology has been a fundamental part of the company’s development and growth. Barden uses M1, a fully integrated enterprise resource planning (ERP) system, which enables the team to track each job through from the concept-andquote phase to final delivery.

“We’ve had major timeframes where we’ve expanded by purchasing and reinvesting in new equipment through looking at the direction of the business growth prospects,” says Bridger. “It’s the type of industry where if you don’t keep up with the latest technologies, you’d be left behind. You can’t compete. So you’re always looking at where your investments are going to go and where the business is going to grow.”

This policy of continual improvement is not just confined to the equipment that the company uses, but is also reflected in its production processes. The company is fully accredited to ISO 9001, 14001 and is currently in the midst of a transition to Lean manufacturing practices under Enterprise Connect’s Defence Supplier Continuous Improvement Program (SCIP).

“We’ve started our Lean journey by improving and developing our processes and change implementation programs,” says Bridger.

company focus

Members of the engineering team at Barden Fabrications.

“It’s a matter of getting our staff on board. We actually shut our facility for three days to do Lean training, so everyone had the same level of skill and knowledge. We’re serious about it. It’s a culture change and it takes time to make those changes within an organisation.”

Barden works closely with its clients on their concepts and drawings, helping to refine the designs and identifying potential flaws before they go into production. This again is an area where Barden is able to differentiate itself from overseas rivals who, while appearing on paper to be cheaper, can result in unexpected costs for the customer.

According to Bridger, the key to success for a business like Barden has moved away from the need to be the cheapest, towards having the capability to turn around high-quality products at short notice, delivering on time to the requirements of the customer.

Joining forces to preserve skills Barden’s latest initiative is a joint venture with Exacturn Engineering, based in the Victorian town of Healesville. Barden recognised Exacturn’s capabilities and expertise, and decided that the two businesses were a good fit. The result is Barden Exacturn Engineering, adding value in machining and turning within Victoria and the broader Australian market.

“The joint venture enables us to keep quality tradesmen within the industry. We saw that if we didn’t do something, we would have lost that expertise for good,” adds Bridger. “From our point of view, you can’t afford to lose that type of skill the joint venture offered. So the concept is to combine our capabilities and Exacturn’s expertise to form a really good operation, to compete on basically any product, from your high-volume, quick-turnover products, through to the high-end, high-tech, down-to-a-micron type of requirements. By doing this joint venture we’re able to retain that skill base and hopefully grow a business which stands on its own two feet, and can then also actually develop young people through traineeships.”

Still very much a family-based organisation, Barden clearly invests a great deal in training and developing its staff. The company runs a graduate engineering program – starting its third engineering graduate in 2013 – and has just employed its second apprentice in two years; in addition it recently brought in a graduate accountant.

It works closely with organisations like Swinburne University,

VCAL (Victorian Certificate of Applied Learning) and the Knox Innovation, Opportunity and Sustainability Centre (KIOSC), looking for youngsters with the right qualities to bring in as apprentices.

For Bridger, the loss of skills is one of the biggest challenges facing manufacturing in Australia. “Once it’s gone, it’s going to be very hard to get it back… it costs a lot of money and time to recover.

It’s cheaper for governments and authorities to actually support industry now – not wait till it goes and then find out we needed it.

“As a country we shot ourselves in the foot years ago when we shut the TAFEs, because not everyone is cut out to go to university,” he adds. “You’ve got talented kids who may not be academically inclined or capable of such study, but are good with their hands.

There has to be areas that they can go into and in which they can excel.”

Bridger believes that both governments at both the state and federal levels need to be more supportive of Australian manufacturing in general. He cites issues such as the uneven playing field regarding tariffs on cars and other imports between Australia and other manufacturing nations, and the differing levels of support that other countries’ government provide for their industries.

“If other countries see a need to support their local manufacturing, then why can’t we?,” he says. “It’s not rocket science. Because once you lose it, it’s generational change before you get it back.”

Overall, Bridger sees more hard times ahead for Australian manufacturing, with more companies going out of business in the next few years. Nonetheless, Barden is planning for the future, with the aim to remain competitive and to keep moving the business forward.

“What we’re trying to achieve – in Barden and Barden Exacturn Engineering – is to keep the resources, keep the high-end quality staff training up, develop capabilities we can offer to industry, and look at other markets as well,” says Bridger. “We’ve got machines capable of doing that. We’ve got the people and the programs to do that. We just now need to develop that business, get the confidence within the market, and get people on board to support it and maintain that expertise within Australia.

“That’s our vision – to grow the business through talented people and strategic infrastructure.” www.bardenfab.com.au

“We see ourselves as a one-stop-shop, with the capability of full design through our engineering team, which can help develop customers’ ideas and concepts from drawing right through to manufacture. We do a lot of work with clients to help reduce their manufacturing costs, where we can actually review their designs, work with them and help modify them to take costs out.”

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Quality & Inspection

The evolution of CMM probing systems Stationary and portable metrology probing systems have undergone a radical evolution over the years, from traditional single-point tactile probes to today’s advanced laser scanners, such as the CMS106 and CMS108 probes, available in Australia and New Zealand from Hi-Tech Metrology.

The aim of metrology is quite simple: to ensure that the items manufactured match the original intent of the designer.

Metrology is accomplished by gathering as much mathematical information about the physical dimensional characteristics of the “as built” parts and comparing them against the designer’s specifications. Over time, the technology to do this has become increasingly sophisticated, capable of reliable, high-speed metrology of a wide range of materials in the most demanding of environmental conditions.

Initially, metrology was limited to measuring in just one dimension at a time – height, length or depth. It was not until the late 1960s when the first true three-dimensional co-ordinate measuring machines (CMMs) debuted in the market. At this juncture, metrology began to realise its true potential, where it began to become possible to compare the physical characteristics of a part three-dimensionally to the design intent. CMMs are used in manufacturing and assembly processes to test a part or assembly against the design intent.

By precisely recording the X, Y and Z coordinates of the target, points are generated that can then be analysed via regression algorithms for the construction of features.

The typical “bridge” CMM is composed of three axes: an X, Y and Z. These axes are orthogonal to each other in a typical threedimensional co-ordinate system. Each axis has a scale system that indicates the location of that axis. The machine will read the input from the touch probe, as directed by the operator or programmer. As the probe touches the surface of the component the stylus deflects and simultaneously sends the X,-Y-Z co-ordinate information to the computer.

These points are collected using a probe positioned manually by an operator or automatically via Direct Computer Control

Contact scanning probe

Reverse engineering – clay design

(DCC). DCC CMMs can be programmed to repeatedly measure identical parts.

More recent innovations are touch probes that drag along the surface of the part taking points at specified intervals, known as scanning probes. This method of CMM inspection is often more accurate than the conventional touch-probe method and can be many times faster as well. Portable CMMs are different from “traditional” CMMs in that they most commonly take the form of an articulated arm. These arms have six or seven rotary axes with rotary encoders, instead of linear axes. Portable arms are lightweight – typically less than 10 kg – and can be carried and used nearly anywhere.

The inherent trade-offs of a portable CMM are manual operation and an accuracy level that is generally less than a bridge-type CMM. Non-repetitive applications such as reverse engineering and large-scale inspection of low-volume parts are ideally suited for portable CMMs. In addition, if parts are too large or heavy or if they have to be inspected while still in the fixture, a portable CMM that can be brought to the part is often the only solution.

The next generation

Optical scanning probe

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Optical scanning probe

The next generation of scanning probes is advancing very quickly. Known as noncontact scanning, this category includes both point and line scanning probes. Optical probes – particularly line scanners – work

many times faster than the most advanced touch-scanning probes to create very large data sets, called ‘point clouds’ due to their large size. Point clouds can be used to not only check size and position, but also, given the high density of point information, to create a full 3D image of the part. Optical scanners are most suited to complex freeform parts where the shape is not easily represented by simple prismatic entities, such as: aerospace components; car and motorcycle bodies, trim and seats; many consumer products; medical components; and blade shapes such as used for power generation. These scanners have created a whole new range of solutions to common customer problems. Typical applications include: target inspection and validation; reverse engineering; and replication.

Target inspection and validation In this application, measurement of specific features contained within the point cloud can be made for the purpose of dimensional inspection or geometric dimensioning and tolerancing (GD&T), and the results compared against nominal values. This latter step could of course be performed using conventional tactile measurement but for larger parts where tolerances can be up to 0.5mm or more, an optical scanner is often faster since non-contact measurement is more tolerant to large deviations of the part from nominal.

Quality & Inspection

Replication – restoration

In addition, due to the high density of information contained in the point cloud, the whole cloud can be compared against the full CAD surface model to give a ‘colour map’ of the deviations across the whole part. Such a tool is extremely powerful for first article inspection and production line tuning processes. Typically a customer will just measure parts but in many cases the tool that produced the part will also be inspected.

Reverse engineering Reverse engineering is the process of taking a physical part, measuring it to determine its size and creating a CAD design from these measurements. This is most often used in cases where the product design process has significant manual operation, such automotive design. Despite the advances in CAD, many designs still start life as a physical model, which then needs to be converted into electronic form. In other applications, legacy parts, for which engineering drawings no longer exist, are unavailable or out of date, need to be scanned to generate a CAD model to make tooling for replacements. In both these cases, point clouds can either be processed by special software packages to create 3D CAD models or transferred directly to CAD software where a full working 3D model is created.

Replication (copying/scaling) For applications where a one-off replica of a part is needed it may not be necessary to create a full CAD model. In this case the point cloud may be turned directly into a polygonal mesh that is a basic form of a 3D model. This mesh can be edited; for example, it can be scaled, or a half model can be mirrored to create the desired electronic part.

From this final mesh a physical replica can be created using standard manufacturing techniques like milling or rapid prototyping. Typical copying applications include cultural heritage, such as with buildings where a façade has eroded over time and needs restoration or replication of sculptures in different scales.

Summary The applications described above cover a wide range of objects with different materials (metal, plastic, clay). The key customer requirements for an optical probe are: • Repeatability – For series measurement, the results must be highly repeatable.

• Reproducibility – The results should be the same, independent of the operator programming or running the system.

• Flexibility – The probe should be able to measure a wide variety of materials and be used easily on a range of different part sizes.

• Reliable – It must work under a wide range of environmental conditions.

• Easy to use – Minimal operator training is desirable.

• Accurate – Last but not least, the accuracy must meet the needs of the application.

Stationary and portable CMM probing systems have evolved over the years. The unique technology in the CMS106 and CMS108 scanners now produces an accurate, fast non-contact probe capable of measuring a wide range of materials in demanding environmental conditions while being repeatable, reproducible, flexible and easy to use. www.hitechmetrology.com.au AMT February 2014

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Quality & Inspection

‘The next inspector is the customer’ Quality and inspection is essential in automotive manufacturing. At BMW they’ve been using thermal imaging cameras from FLIR for fault detection for years, but recently they also began using them for quality control.

BMW produces its 5-Series, 6-Series and 7-Series models at its massive Dingolfing plant in Lower Bavaria. The BMW 3-Series Gran Turismo has recently been added to this product line as well. Around 18,500 people work at the site.

inspector who sits in the vehicle monitoring displayed inspection data. The tests vary in both type and duration according to the specification of each model, and are programmed to be conducted in an automated sequence.

thermal imaging cameras – a different brand to FLIR – were initially specified for each dynamometer rig. Their purpose was to visualise the thermal profile of the respective tailpipes in the dual-pipe exhaust system.

“FLIR has been providing thermal imaging cameras for thermal inspection to the BMW plant in Dingolfing since 1997,” explains Robert Halbritter of FLIR Systems’ sales partner and integrator, TOPA.

Checking exhaust flow

Each system comprised two thermal imaging cameras, mounted to inspect the left and right tail pipes from above and the side. The solution was not only expensive to buy, but costs also increased with time as the cameras required frequent repair.

Therefore, after eight years, the viability of a new system was evaluated.

For most of the time, BMW has primarily used the cameras for electro-thermography of switch cabinets and rooms. Hot components indicated a problem and were then replaced. This is the still the case today. But now BMW is using FLIR thermal imaging cameras for quality control too.

New vehicles are subjected to a number of individual and automated quality control measures including analysis in one of ten separate roller dynamometers. Basic functions from signal horn to enginespecific performance are thoroughly tested, as is the BMW Night Vision System, based on a FLIR detector.

The entire process just takes a few minutes, during which each correct function has to be confirmed either automatically or by an

Whilst cost- and time-efficient testing is the common goal, identifying the optimum procedure for each inspection task needs individual consideration. This is the case, for example, when testing the exhaust flaps on the dual exhaust system. Twin tail pipes are a feature of the high-performance BMW vehicles with large, eight-cylinder engines.

On the BMW M5 model the requirement is different again, as the exhaust flap on the second tailpipe is only activated at a specified rpm.

The reason for this may be at first surprising as it’s all about acoustic design but the sound of a powerful engine should be impressive. Therefore a BMW M5 only opens the second tailpipe exhaust flap when it is really needed. Of course this feature has to be inspected, which is more complicated than it appears at first glance.

To check the efficiency of this operation

BMW’s Dingolfing facility in Southern Bavaria, Germany.

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Halbritter offered a solution that would halve the cost of new camera hardware. He recommended the use of a single, fixedmount FLIR A310 with a 45-degree lens for each dynamometer. The advantage: components that were previously inspected using two cameras mounted on the sides could now be visualised using a single centrally positioned FLIR camera.

This is possible because the field of view of the FLIR A310 with 45-degree wideangle lens means that it is capable of showing the entire end of the vehicle from a distance of approximately 2m. As a result, comprehensive inspection could

Quality & Inspection

be conducted by just ten cameras, one for each dynamometer, instead of the 20 units required by the previous system.

The FLIR A310 generates an analogue thermal imaging video signal with a frame rate of 30Hz. This model is particularly suited to recording exhaust flow as it is simple to integrate and provides easy access to PAL video.

“The camera also provides multiple connection options,” explains Christoph Hörnlen, who is responsible for fixed thermal imaging cameras for automation applications at FLIR Systems. “The FLIR A310 has a digital output for alarms and for controlling external devices. Additionally the data can be transmitted via TCP IP or Ethernet and the FLIR A315 even supports the GigE Vision standard as well as the GeniCamprotocol.”

Careful monitoring The performance of the exhaust system is checked on a monitor in front of the vehicle, which displays a thermal image.

From this the inspector can see if the flap is functioning properly from changes in the thermal profile. Even though the FLIR A310 can visualise heat distribution using various colour palettes, the simplest and clearest option is used here: black and white.

The reason for this is the irregularity in air flow of the exhaust streams. A relatively

high amount of air is displaced and the exhaust stream does not remain constant.

The flow rate also has to be taken into consideration. These are all factors that could be visualised using a wider colour spectrum but could serve to confuse the inspector. In the final analysis all that is required of this test is confirmation that the flap is opening and closing correctly.

A key factor in BMW’s decision to switch to the FLIR camera solution suggested by TOPA was the company’s reputation for quality service and post-sales support. The technical implementation of the solution also played an important role.

“We were often on site and able to support BMW with the installation and calibration of the cameras,” explains Halbritter. “This investment represented excellent value for money by comparison with the previous system.”

The FLIR A310 has shown an impressive degree of reliability. The first camera systems were installed in the autumn of 2011 and have been in operation, around the clock, since then. Although they are not always needed between 11.00pm and 5.00am the next day, they are always on, achieving true 24/7 operation. A spare FLIR 310 camera has been supplied in case an urgent replacement is required, but it has never been used. www.flir.com

Thermal images of the rear end view. Visible on the left: the exhaust flaps open at a higher rpm.

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Materials Handling

Energy savings conveyor investment The potential to realise energy savings in the thousands of dollars every year made a compelling case for the decision to use SEW-Eurodrive equipment as part of a major factory refurbishment project in Sydney.

Bruce Granger is the General Manager at Industrial Conveying Australia (ICA), one of Australia’s leading project-orientated conveyor companies, operating since the mid-1970s across a wide range of industries. The company specialises in materials handling, transporting raw materials, processed materials and finished products for a diverse range of manufacturing industries, with a lot of its work in the food and transport industries According to Granger, the increasing cost of electricity means that energy efficiency is becoming increasingly important for his clients and end users. “Companies are now looking closely at what their energy consumption is, so anything they can do to reduce it is a huge advantage for them.”

The refurbishment project involved a multinational manufacturer consolidating one of its Sydney plants. While the project was in an existing building, it had been completely stripped and refurbished inside with new equipment from ICA and equipment from other plants. ICA was not just able to offer the client significant energy savings. There were also substantial savings in installation and wiring costs as well.

“This project is a prime example of one of our customised projects designed and built to the client’s specific requirements,” said Granger.

There were two phases to ICA’s part of the project. The first phase involved taking cartons from the plant’s manufacturing cells through an overhead conveyor system, then carrying the cartons down to a sophisticated palletising system, with around 250m of conveyors in total. The system has several automated mergers where cartons from four different manufacturing cells travel on the overhead conveyor systems.

“Then they all merge onto one main trunk line which takes the cartons to the palletising system,” added Granger.

The manufacturer has more than 30 stock-keeping units (SKUs) with two main variations of cartons. The smaller one measures 400mm by 250mm by 200mm, while the larger carton measures 650mm by 300mm by 280mm and weighs up to 20kg.

“While the flow rate through the system is modest at the moment, the system has the ability to be increased when needed as production rates increase,” said Granger.

“We have designed the overhead conveyor system to accumulate via particular types of belts that we use, with the ability to turn the drives off and on as needed.

“From the overhead conveyor systems, the cartons feed down to the palletising

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ICA did a lot of pre-installation work in their Bendigo factory, which gave them an advantage of reduced on-site work.

unit itself where the sorting system sorts the cartons into various lanes. Like most of our projects, we are using SEW-Eurodrive electrical equipment with various types of the Movigear Mechatronic drive system, which is ideal for materials handling systems.”

Granger explained that the Mechatronic drive system comprises an efficient electric synchronous motor and gear unit with matching electronics in a single compact housing.

“Overall, we are using 56 SEW-Eurodrive motors on this project; the Movigear SNI, linked to Movifit field controllers, and Movigear DRCs. The Movifit system has allowed us to control up to ten of the Movigear drives from just one controller, which has significantly reduced our fieldwiring component and simplified the controls.

“It has also considerably cut our installation times by allowing us to do the pre-wiring of many of the components, such as the photoelectric cells where they are connected straight back to the Movigear units, in our factory set-up. By doing a lot of the preinstallation work and dry commissioning the system in our Bendigo factory this gives us the considerable advantage of reduced onsite work.”

Reliability and efficiency Granger said the main reason ICA uses SEW-Eurodrive equipment is the high quality of all the equipment.

“It is very reliable and efficient, plus we get excellent service and back-up. It’s the

whole package. In fact, SEW-Eurodrive is our preferred supplier. The only time we use other motors and drives is when, for some reason or other, the client dictates we use another brand, often to match other motors in the plant. However, we find the vast majority of manufacturing plants in Australia are using SEW-Eurodrive equipment anyway.

“In the over 30 years or so I have been dealing with SEW-Eurodrive, I could count on one hand the issues I may have had with their drives over that period of time. SEW’s equipment is highly reliable, the company’s service and back-up is the best bar none.

That plus innovation are just some of the reasons we keep going back to them.”

Granger believes that the factory refurbishment, with its 56 motor system, offers a great demonstration of what can be achieved using SEW-Eurodrive equipment, above all in terms of improved energy efficiency.

“Across the drives, we estimate the current draw will be as low as 20 Amps, whereas if we had designed the project the conventional way, the current draw would be much higher, could be up to 60 Amps, and cost the manufacturer considerably more to operate,” said Granger. “Over the life of this equipment, there will be substantial savings in energy consumption; savings in the region of thousands of dollars every year.”

While with energy consumption was a key element in the project, reliability was also important to the manufacturer, given that many of the conveyors are suspended

Materials Handling

overhead. With the plant currently operating two shifts, six days a week, reliability is paramount in helping to ensure the manufacturer does not encounter any production downtime.

The motors are also compact and lightweight meaning the overall weight is reduced.

“This was another advantage for us, with the drives offering reduced suspended weight,” said Granger.

Intelligent technology John Gattellari, SEW-Eurodrive’s National Industry Specialist – Food and Beverage, claims that the Movigear drive system is a remarkable intelligent device and one every manufacturer should be taking advantage of.

“A systematic development approach was taken right from the start of the design process of the drive system with a very

high level of system efficiency, which in turn helps lower energy costs,” he explains.

“While the technology has been around for a couple of years now, today with electricity costs continually rising, companies really appreciate the benefits of investing in this technology.”

The motors comply with IE4 (Super Premium Efficiency) energy efficiency classification, and higher, offering substantial energy savings. According to Gattellari, depending on the application, the drive system offers customers potential energy savings of up to 50%. The Movigear SNI (Single Line Network Installation) is designed to allow simplified installation, which leads to significantly reduced installation and system costs.

In contrast to current decentralised automation technology, which relies on two separate cables for energy and communication, the single-line technology

deployed with Movigear communicates over one of the phases of power, reducing the complications and cost of on-site installations. This simplified system structure can reduce the time taken for start-ups from weeks to a matter of days.

For ICA’s factory refurbishment project, the manufacturer linked the Movigear drives to Movifit SNI controllers, which have been designed for decentralised installation in the field. The Movifit SNI can control up to ten Movigear drive units, passing the control information via Ethernet signals. Movigear unit can be optimised for different speeds, meaning a reduction in the number of variants required, with the corresponding number of spares required also heavily reduced.

Gattellari believes that when it comes to old and new technologies, the difference is huge.

“With this new technology, the payback is often within two years, as opposed to old technology, which is considerably longer. In fact the ROI on this project is expected to be even less than 18 months.”

As well as providing the conveyor systems for the new section of the plant, ICA is also upgrading other parts of the plant and installing SEW’s Movigear DRC motors.

These motors can simply be plugged into our standard gearbox. In this section of the plant, the manufacturer didn’t want to change anything mechanically, they just wanted to lower their energy costs and improve efficiencies. So they took off the old gearboxes and put new ones in with the same mountings.

There are two variants of Movigear DRC motors available – one with brakes, one without – with both types used on this project. The Movigear is a hygienic drive, with a totally smooth design and no sharp edges.

ICA was able to offer their client energy savings, installation savings and wiring costs on the conveying system.

“It is also fully enclosed with no air, dirt or germ swirls, and with low noise emissions, due to the drive operating without a fan, it is ideal for use in manual work stations,” adds Gattellari. “The optional HP200 coating is designed so nothing can stick to it, making it ideal for hygienic or ‘wash down’ applications in the food and beverage industry.”

Gattellari reports that more and more customers are taking advantage of the Movigear drive system, including major global companies such as Coca Cola.

“They have all been very impressed with the system’s ease of installation and the ongoing reduction in energy costs.” www.sew-eurodrive.com.au www.icaust.com.au

The Mechatronic drive system from SEW-Eurodrive comprises an efficient electric synchronous motor and gear unit with matching electronics in a single compact housing.

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Materials Handling

How to listen to a forklift truck The forklift truck is evolving into a platform for data collection, enabling managers to optimise the equipment, the operator and the facility. By Josh Bond, Associate Editor of Modern Materials Handling.

Few fleet managers will be surprised to learn that a modern forklift truck can collect data about every facet of its operation, well beyond the simple hour meter.

Many are familiar with the concept that microprocessors onboard even the most standard forklifts are ready to interface with computers, tablets, voice systems or a warehouse management system (WMS).

What some may not realise is that this capability is not reserved solely for massive fleets with deep pockets.

The brains inside newer forklift trucks are great for turning them into advanced mobile data collection platforms, but they are also designed to enable small, specific changes to a truck’s operation, even for a fleet of one. These changes increasingly allow a forklift truck owner to shape the truck to the application while improving the productivity and uptime of both.

With plug-and-play technology, a forklift truck can even be made to respond to voice commands. Other solutions enable the forks of a reach truck to rise to the precise level of the pallet opening at the push of a button. By collecting information about a forklift’s travel through a facility, it’s also possible to identify areas of traffic congestion, restructure the placement of racks or pinpoint problems with the floor surface that could lead to excessive damage.

However, for all the innovative options, the most important factor to consider before a fleet owner unlocks the potential of a truck is whether it will create measurable results.

“A lot of technology has come onto the scene in the last ten years, and it can be distracting to a fleet owner who is just trying to procure a piece of equipment,” says Scott McLeod, president of Fleetman Consulting, an independent forklift fleet management and procurement consulting company. “As forklift truck suppliers try to differentiate themselves, customers should be careful about gimmicks and look for tangible results.”

Feedback from forklifts Borrowing from the automotive industry, diagnostic ports and microprocessors began to creep into forklift trucks in the last decade. Forklifts are now primarily governed not by mechanical systems, but by electronic ones, with wires replacing levers.

Sensors embedded throughout the truck can now collect data about every aspect of a truck’s operation, from lifting and lowering to idle time and average speed.

In an effort to make the most of this available data, the popularity of fleet management technology has grown as

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well, even if the implementation results have been mixed. The most common culprit of a failed implementation is the inability of the customer to effectively manage all the data the truck can produce.

“Data in a variety of platforms, many times not integrated, can be overwhelming to customers if left unattended,” says Mark Faiman, Product Manager for IC, AWP and GSE products at Toyota Material Handling.

“The customer might review reports periodically, but without a conclusion or direction little progress can be made toward improving a process or productivity.”

Thankfully, the technology on forklift trucks allows data to be relayed directly to the dealer, who is increasingly called upon to manage that data on behalf of the customer.

“When customers buy this technology, probably 80% of the time their expectation is that they will somehow get control over it themselves,” says Jonathan Dawley, President of Hyster Distribution. “Then they find they really don’t have the time to dig through all the data. The other 20% of the time, we are effective in explaining that our fleet management expertise can help them focus on their core competencies.”

For instance, a forklift truck can report a fault code to a service technician who can repair the problem before the customer or operator knows something is wrong. An overheated forklift truck might need $20 brushes and one hour of labour. However, in the interest of productivity, an operator might turn the forklift truck off, reset the fault code and get back to work.

“They’ll keep doing that until the equipment fails,” says Scott Craver, Product Manager of Business and Information Solutions for The Raymond Corp. “That customer is now looking at a blown motor and a much lengthier downtime.”

Reading between the aisles The assortment of sensors on a forklift truck is good for tracking what forklift trucks do best, which is picking things up and putting them down. However the data they collect can also paint a picture of processes and pinch points throughout a facility.

“By far, the biggest trend we see is creating business intelligence using the forklift truck almost as a sensor in the warehouse,” says Lew Manci, Director of Product Development for Crown Equipment. “It has

Materials Handling

to do with the fact that the WMS can see what happens at each barcode scan, but it can’t see what happens between them. The forklift truck now has the capability to collect that information and provide it to management.”

Managers can now identify high traffic points and look at how the facility layout might change to make traffic run more smoothly.

Moreover, while impact monitors will tell a manager when a collision has occurred, says Craver, a deeper look into the data might reveal that the operator is not entirely to blame for each impact. Damage could also be caused by variances in the dock level or cracks in the floor that can ruin wheels and tires, resulting in big costs.

According to Craver, one customer used this technology to detect that a particular operator tended to have a lot of impacts around 10.00am every morning. Someone else had been unloading trucks and putting some heavy materials in the operator’s way. While navigating the containers, he would often collide with them.

“We adjusted the facility layout, creating a path that improved that operator’s speed and productivity while eliminating that damage,” says Craver. “Some managers might just write him up. Others will look into the data for a huge return on investment.”

Beyond picking up and putting down Even the most rudimentary modern forklift trucks come with standard diagnostic ports and microprocessors.

“The difference between forklift trucks of today versus ten years ago is that they have a brain,” says Bill Pfleger, President of Yale Distribution.

While the electronics embedded throughout the forklift truck are great for sending data out, they also allow commands to be sent in.

The operator’s controls no longer rely solely on levers and hydraulics, but pass through the central brain of the forklift truck. This allows a variety of technologies to directly control various functions of the equipment.

For instance, when integrated with the facility’s WMS, an onboard computer can direct an operator to a pick location. Once the operator reaches the location, whether two or ten metres high, he or she can simply press a button on the computer screen to send the forks up at the fastest possible speed before they stop precisely in front of the pallet opening.

Similarly, the forklift truck’s onboard intelligence can control the process of lowering the mast. By monitoring the forces applied during descent, it’s possible to more than double the speed of lowering.

“In tall or narrow aisle racking, lowering can account for 25% of the overall forklift truck cycle,” says Manci. “By doubling the speed, customers can see a 12% or 13% improvement in productivity.”

The microprocessors in a forklift truck can also enable anti-slip technology that monitors wheel spin and improves traction in applications with slick floors, such as cold storage. The same onboard electronics make it possible to configure a pallet jack to accept voice commands, says Dawley.

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Materials Handling Continued from previous page

By integrating with an existing voice picking solution or operating as a stand-alone module, this voice technology can allow a picker to advance the forklift truck while a few steps away in a pick location. Married with some guidance technology borrowed from automatic guided vehicles (AGVs), the forklift truck can even sense and avoid obstacles as it moves alongside a more productive picker.

three weeks from order to application, as compared to three months for the scale customer.

Tailoring the truck

Tips from the scales

Instead of shaping an application around the limitations of an off-the-shelf forklift truck, technology enables a truck to be highly customised to the application. One example is narrow-aisle applications, where traditional wire guidance or rail guidance are enough to keep the forklift truck safely away from racking. However, radio frequency identification (RFID) technology is capable of communicating a variety of information to the forklift that can alter its performance, says Chad Munger, Product Line Manager of Warehouse Products for Mitsubishi Caterpillar Forklift America.

Lutton’s customer is not alone in benefiting from forklift truck-mounted scales. The growing trend sees many forklift trucks that can now bypass a stationary scale to weigh product on the move. When integrated with the WMS, this can add further visibility and accountability into product movement.

For instance, an RFID transponder embedded in the floor of a facility can ensure a forklift truck will only forklift to a certain height near low-hanging air-handling units or conveyors. It can control deceleration at the end of an aisle, or bring the forklift truck to a complete stop.

By tracking the speed and direction of travel of the forklift truck, RFID can also position the equipment in three dimensions. If moving from one elevated pick location to the next, the operator need only apply the throttle and the system will determine the precise optimal speed to travel forward, lower, then elevate again, ending directly in front of the desired location.

“When an order or command is received, the operator simply navigates to the correct aisle and the forklift truck takes over from there,” says Munger. “Through this technology, the WMS can actually manage the equipment, instead of relying on the operator to make each of these decisions about what he’d like to pick next. Even with the most experienced operators, efficiency can improve by as much as 25% on a given pick.”

Brandon Lutton, manager of product engineering for UniCarriers Americas, offers another example of the ways a customer can shape the forklift truck to their needs.

He recently worked with a customer to integrate onboard scales, which required extensive collaboration between the scale supplier, the onboard computer supplier, the bar code scanner supplier, the customer and UniCarriers.

In the past, Lutton’s department primarily installed attachments, applied special paint colours, and installed aftermarket parts. These projects typically take two to

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“The amount of changes made for this individual project were greater than what would typically be required for an entire model upgrade,” says Lutton. “I expect these sorts of projects to be more common in the future as customers demand fully integrated forklift truck technologies.”

“This helps eliminate lost revenue created by shipping weight discrepancies, which can have a major impact on operation costs,” says Toyota’s Faiman. It can save on labour, fuel and travel time by eliminating trips to scale stations or having to repack pallets to weigh items, while recovering floor space previously used for scale stations.

“Quite frankly, I wish the onboard scale would be standard on every forklift truck and not an option,” says McLeod, who adds that improved safety is an essential by-product of integrated scales. “It allows a

forklift truck operator to know he’s operating within safe limits. This is a huge issue as I see it. A lot of the experienced people just do it by feel, but you need to know the capacity of your forklift, and you should know what the load weighs along with its corresponding load centre.”

As with each of the forklift truck technologies, a scale can be attached to the truck for the simple benefit it provides, or fully integrated with the customer’s other technologies for even bigger results. Although the latter option calls for a much more involved project, Craver predicts the combination of data from the WMS, onboard scale, fleet management and labour management will become more common, in a trend he calls “data fusion.”

Hyster’s Dawley agrees: “There’s a gap there at this point, but I foresee these systems starting to come together, and a complete picture of what is going on in the facility will emerge.” www.crown.com www.hyster.com www.fleetmanconsulting.com www.mcfa.com www.raymondcorp.com www.toyotaforklift.com www.unicarriersamericas.com www.yale.com Reprinted with the permission of Modern Materials Handling, a Peerless Media LLC publication

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forum – Law

Product importation and Australian patent system Australian patent law differs significantly from the laws of other countries, which may have important ramifications for your business. Ben Mott explains.

If you import product into Australia, the Australian patent system may have important consequences for your business: • Importing even original equipment manufacturer (OEM) product can constitute patent infringement.

• You may be able to stop others making, using, selling and/or importing product.

Importing can constitute infringement An Australian patent gives its owner the right to stop others making, using, selling and/or importing product covered by the patent (aside from a few rare exceptions).

The mere act of importing product can constitute patent infringement regardless of what happens to the product after importation. Additionally, the use and/or sale of the imported product may also constitute infringement. There are no special exemptions for product that you have simply purchased or for product that you intend to use yourself.

Generally speaking, patent rights are granted on a country by country basis. Additionally, Australian patent law differs significantly from the laws of other countries. It is routine for patent protection in Australia to be different from the patent protection in other countries.

Due to these routine differences in patent protection, importing (into Australia) product legitimately sold in another country may infringe an Australian patent.

By way of example: • OEM 1 has US and Australian patents on a cutting tool.

The Australian patents cover more than the US patents – a common situation given the differences between Australian law and US law.

• OEM 2 makes and sells in the US cutting tools that are not covered by OEM 1’s US patents.

• Your importation of OEM 2’s cutting tools into Australia may constitute infringement of OEM 1’s Australian patents.

and then propose a search strategy using the classifications and/or keywords. Searching for patents owned by a particular competitor is usually straightforward, but of course depends on how many patents the competitor has and the complexity of those patents.

It’s important to bear in mind that no search is exhaustive.

Searching minimises but does not eliminate risk - even after a thorough search there remains the risk of a relevant patent that has been misclassified and uses different keywords.

As per other business risks, it may be possible to insure against patent infringement. Eg. OEM 2 might be prepared to warrant that their cutting tool is not covered by any relevant patents, although of course that warranty is only worth as much as the OEM 2’s capacity to pay.

Stopping others making, using, selling and/or importing product Often OEMs do not patent their products in Australia, even if they patent their products in other countries. If importing OEM equipment is an important part of your business and Australian patent protection would be useful to you, it may be time to ask the OEM to extend their patent filing strategy to include Australia.

As noted above, Australian patent law differs significantly from patent laws elsewhere. It is routinely possible to obtain more effective patent protection in Australia than in other countries such as the US. Indeed effective patent protection is often possible in Australia for products that would be considered un-patentable elsewhere (e.g. for products that would be considered unpatentable in the OEM’s home country). This may be another point to raise with your OEM partners.

If such patent protection is of interest, it is important to ensure that you can, or the OEM will, enforce the patent when required. Only a patentee (patent owner) and the patentee’s exclusive licensee can take action for patent infringement. If you are not the exclusive licensee you might reach an agreement with the OEM: 1. to have the patent assigned to you; or

In this example, the default position is that you (rather than OEM 2) could be held responsible for the infringement and forced to pay damages to OEM 1.

2. to the effect that the OEM will take action in certain circumstances (e.g. when a particular competitor enters the market and/or certain sales volumes are exceeded).

Reducing the risk of infringement

For either option, an IP lawyer should be engaged to advise on the agreement. There are a variety of challenges specific to IP agreements. By way of example, if a competitor challenges the validity of the patent is the OEM obliged to resist the challenge?

Patent infringement disputes are notoriously expensive. Before importing a new product ,it may be prudent to search for relevant Australian patent rights to reduce the risk of dispute. This searching is often referred to as an “infringement search”, a “clearance search” or a “freedom to operate search”, and should be performed by a professional patent attorney firm. Searching the databases is nontrivial and interpreting the located patents and patent applications requires a patent attorney’s skill.

The cost of the search depends on the search strategy. The patent databases are classified by subject matter (much like the Dewey Decimal Classification of library books) and can also be searched by keywords. To arrive at a cost estimate, a patent searcher will discuss with you the features that might be subject to patent protection

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Key points • Considering the Australian patent system before importing a new product reduces the risk of a costly dispute.

• Discussing the Australian patent system with your foreign OEM partners may lead to valuable Australian market exclusivity.

Ben Mott is a mechanical engineer and patent attorney and Principal WADESON. WADESON offers a wide range of patent attorney & trade mark attorney services. Ph: 03 9819 3808 or 0402 319 189 ben.mott@wadesonip.com.au www.wadesonip.com.au

forum – finance

Offshore investment opportunities knock for Aussie manufacturers Andrew Watson explains how to overcome the challenges faced by Australian companies seeking to expand overseas. To this end, EFIC commissioned independent research involving over 2000 Australian SMEs. Despite difficult conditions in Australia’s manufacturing sector, there continues to be a strong appetite for expansion abroad, with SMEs in particular primed and keen to invest overseas. Whether looking to grow your existing export business, enhance supply chain activities, facilitate regional expansion or increase your international competitiveness, overseas direct investment provides a wealth of opportunities.

It also comes with its own unique set of challenges. The difference between success and failure often comes down to local market knowledge, access to finance, careful planning and the ability to overcome local management and execution issues. Navigating these challenges is all part of the growth journey and understanding how to prepare for them will ensure a smoother path to expansion.

To better understand the drivers, triggers and obstacles for SMEs making overseas investments, Export Finance and Insurance Corporation (EFIC), Australia’s export credit agency, commissioned independent research to measure the experience of over 2000 Australian SMEs who have already established offshore investment operations or plan to in the near future.

SMEs are increasingly looking offshore

markets and overcoming tariffs were also identified as reasons for developing offshore facilities.

For SMEs with established facilities outside Australia, their focus is on supporting sales in overseas markets, with 65% operating a sales or marketing office in at least one country. More than half have warehousing facilities, and more than a third have a service or business processing centre, suggesting a strong on-ground presence is required for many SMEs to grow their international business, although few – less than one in twenty – have established manufacturing facilities.

Financial barriers and informal guidance are major hurdles Obtaining finance is a major obstacle for SMEs establishing a footprint overseas.

The research indicated that 58% of Australian SMEs that have already established overseas facilities reported difficulties in accessing finance. Many are turning to overseas banks to fund their investments, reflecting a lack of support from Australian banks when the assets being funded are overseas.

Australia’s innovative capacity in manufacturing is in demand throughout global supply chains, as the nation’s deep pool of technical talent across all industries becomes known internationally.

Equally concerning was the failure of SMEs to consult professional advisers or export agencies to gain advice. Investing overseas without proper consideration of legal, tax, regulatory and compliance issues puts a business at serious risk of failure.

In response to this demand, Australian businesses are keen to invest and grow overseas. EFIC’s research indicated that one in four SME exporters has already expanded overseas or intends to in the near future. The research also suggests around 450 SMEs are planning overseas direct investment in the next 18 months, with a debt funding need of around $400m.

Rather than seek appropriate professional advice, many business owners have relied on their personal networks for advice, and this is not always reliable. The research indicated more than one third of SMEs have experience failure in offshore ventures, although the good news is that those who did seek professional advice were twice as likely to succeed as those who relied on their informal networks.

Of those already operating offshore, traditional low risk markets such as New Zealand, the United Kingdom and the United States remain the locations of choice. Surprisingly, perhaps, there has been relatively low penetration into Asia. Despite our reliance on China as an important source of demand for Australia’s rural, manufactured and service exports, only 12% of SMEs surveyed have offshore investments within the region.

Expert advice is readily available

Winning new business is a major driver

Similarly, Austrade, with its network of overseas offices and local staff, and links to professional legal and accounting firms, can provide information and insights on markets you are looking to operate in.

The chief motivation for SMEs planning overseas investment is seeking greater market share or making strategic investments.

Almost one in three suggested a move offshore was driven by a desire for increased sales, while one in five said they were motivated by lower costs. Improving proximity to suppliers and buyers in export

This is where government channels, like EFIC and Austrade, can play a key role. EFIC assists SMEs with access to finance to grow their overseas sales and operations. It looks to accept risks where the commercial market will not, enabling SMEs to enter or expand in offshore markets when bank funding is constrained. .

Increasingly, successful Australian manufacturers are competing overseas, and to do this, a strong on-ground presence is vital.

Understanding the challenges, opportunities and financial assistance available should be the first step for any manufacturing business undertaking investment internationally.

Andrew Watson is EFIC’s Executive Director, SME EFIC (Export Finance and Insurance Corporation) supports the growth of Australian companies in their international activities by providing tailored financial solutions when the private market faces constraints.

As Australia’s export credit agency, EFIC assists Australianbased businesses so that they can take advantage of commercial export and overseas investment opportunities. Support to buyers of Australian goods and services in emerging markets and subcontractors to Australian exporters is also provided.

Ph: 1800 093 724 info@efic.gov.au www.efic.gov.au

AMT February 2014

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forum – HR

What is it costing you by not having a drug-free workplace?

Have you considered workplace place drug testing? asks Michael Wheeldon, Managing Director of Integrity Sampling (Australia) P/L Workplace drug testing can be a controversial issue in the modern day work place.

Drugs • Nearly one in two adults (49.0%) aged 16–64 years had used drugs for recreational purposes in their lifetime.

When companies hire a new employee, it is common for employers to check references, employment history, qualifications and even conduct pre-employment drug testing. However, ongoing drug testing for substances of abuse has only recently become an accepted part of an employee’s work agreement.

• Cannabis - rose from 9.1% in 2007 to 10.3% in 2011

Do people really go to work under the influence of drugs?

The answer is YES. Did you know that 17% of workers admit to using illegal drugs?

• Cocaine - rose from 1.6% to 2.1% in 2011

Integrity Sampling’s statistics indicate that the number of positive test results for “recreational drug use” is continually on the increase in Australian workplaces. This coincides with Victorian police roadside drug testing statistics - “As of 2013 about 4,000 drug tests are conducted each month with a strike rate of 1 in 30”.

Integrity Sampling conducts approximately 35,000 tests nationally per annum. The rate of confirmed positive test results is approximately 3%. This equates to 1 in 33 employees returning a positive test result to drugs or alcohol in the workplace. The most common drugs detected in the workplace are Cannabis (THC), Methamphetamine (Speed- Ice- Ecstasy) and pharmaceutical type medications (Codeine-Morphine-Dexamphetamine).

Facts and statistics for employers Many government studies reveal that one in every six workers has a drug or alcohol problem.

The Cost for Employers • Drug related workplace accidents cost approximately $1.3bn - half of which is borne by employers.

• Approximately 15% of workplace injuries are attributable to drug and alcohol misuse.

• Alcohol and drugs is a contributing factor in approximately 5% work-related fatalities in Victoria alone.

• Alcohol and other drugs result in costs from lost productivity and absenteeism of over $2.9bn.

• Drugs are present in about one quarter (25%) of Victorian driver fatalities, a level comparable to alcohol.

• Absenteeism can occur up to sixteen times more often.

• Workers are one third less productive.

• Workers admitted selling drugs to co-workers.

• Workers admitted stealing from employers.

Alcohol • 6.6% of Australians attend work under the influence of alcohol and 10.2% admit to consuming alcohol at work.

• An average of 3.9% of workers missed at least one work day over a three month period due to alcohol abuse.

• Those that drink more than ten standard alcoholic drinks per week were approximately 1.3 times more likely to have had a workers’ compensation claim during a five year period.*

• Illicit drug use increased in 2011, mainly due to an increase in the proportion of people who had used : • Pharmaceuticals (used for non-medical purposes) - rose from 3.7% to 4.2% in 2011 • Hallucinogens - rose from 0.6% to 1.4% in 2011 • Methamphetamine/Amphetamines - rose from 2.1% to 2.5% from 2011

Legislation There are various laws, acts and regulations that are relevant to alcohol and other drug issues in the workplace.

Criminal Legislation Concerning Illicit Drugs Under Federal and State criminal legislation, employers may be held accountable for any activities involving illegal drugs that occur at work. Under the occupational health safety and welfare legislation in all Australian jurisdictions, employers have an obligation to provide a safe working environment for all employees.

What type of testing?

Urine tests are predominately used to conduct pre-employment testing. These tests are intrusive and are not gender friendly and can easily be adulterated. The drug metabolites analysed by a urine test may be present in the urine for weeks, making it impossible to specify how long ago the patient may have taken the drug. Most common drugs can be detected for up to two to three days after use. Marijuana (THC) can be detected for up to 30 to 40 days.

Blood tests involve the taking of blood which can only be conducted by qualified medical staff. Blood tests are considered to be the most invasive form of testing. These tests can check for all types of drugs, including alcohol and tobacco. Unlike the urine test, a blood test usually determines whether the patient is under the influence of drugs at the time of the test and is predominantly conducted after a serious incident.

Saliva tests are now more commonly used in workplaces for ongoing drug testing. The test is fast, non invasive and gender friendly. The sample cannot be adulterated and the drugs detected in oral fluid (saliva) correlates with any drugs present in the blood, providing a reliable indication of recent use. Integrity Sampling use a fully auditable electronic drug detection analyser (Drager Drug test 5000) which provides a printed result within

Conclusion An effective drug and alcohol management policy coupled with a reliable device, is essential in minimising the risks associated with drug and alcohol abuse in the workplace.

Integrity Sampling specialises in providing workplace drug and alcohol management solutions. For enquiries please contact 1300 SALIVA (725 482) www.integrity sampling.com.au (NCETA – Alcohol and the Workplace 2009) - (Flinders University – National Household Survey) (Australian Drug & Alcohol Foundation)

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forum – OHS

Work health & safety laws: Update Is Australia moving towards a consistent national standard? Greg McCann explains the lack of a state-wide consensus.

Not all states have adopted the model harmonised WHS laws Consistency in work health and safety (WHS) laws between the different Australian states is still a work in progress, with VIC and WA not having adopted the model harmonised WHS laws.

Business regards uniformity of WHS laws across Australia as an ideal Most national corporations would like to see consistent safety laws implemented in the different Australian states. NSW, QLD, the NT and the ACT commenced their model harmonised WHS laws on 1 January 2012.

Earlier this year, TAS commenced its WHS laws and SA implemented the bulk of the model WHS laws. VIC and WA are still utilising their existing safety laws.

Post the recent federal election, will the two remaining states move towards implementing the model WHS laws?

WA may consider implementing model harmonised safety laws The view of the WA government has not changed: the government has consistently advised that there are four areas of the model WHS laws that would not be implemented. These are: • Penalty levels • Union right of entry • Health and safety representatives’ capacity to direct the cessation of work • Reverse onus of proof in discrimination matters One key step in the harmonisation process for WA will be implementing consistent mining and non-mining safety laws to replace the current Occupational Safety and Health Act 1984 and the Mines Safety and Inspection Act 1994, which have very similar general duties.

The draft model WHS Mines Regulations and Codes of Practice for Mining that have been developed by Safe Work Australia in conjunction with the National Mine Safety Framework are still to be finalised. When this step has occurred, WA may consider implementing the model WHS laws, which will include the Mines Regulations and Mines Codes of Practice.

No change from current safety laws envisaged in Victoria VIC has advised that there will be no change from its current existing safety laws. It should be noted that the model WHS laws were modelled on the Victorian Occupational Health and Safety (OHS) laws.

One item of difference is the current “right to silence” that exists in the VIC OHS laws, where in a Worksafe investigation, individuals have a right to silence if answering a question may incriminate them. SA has varied the model WHS laws to incorporate the right to silence in its adoption of the bulk of the model WHS laws earlier this year.

Have the model WHS laws extended further than anticipated?

As a person conducting a business or undertaking (PCBU), how far does your safety duty now extend?

If you are a designer, manufacturer or supplier, builder, project manager or operate a number of mining sites, the current WHS laws have expanded to as far as your business or undertaking extends. The traditional workplace within the fenced area is now a notion of the past.

The safety obligations extend to taking reasonably practicable steps to manage your undertaking, as expressed in the High Court decision of Baiada Poultry Pty Ltd v The Queen [2012] HCA 14, where, although Baiada was found not guilty of an alleged breach of the Victorian OHS laws for a workplace incident on its contractor’s worksite, the application of the OHS laws was within the objects of the OHS Act.

Officers of PCBUs must understand the hazards and risks of the business Officers of a PCBU must take reasonably practicable steps in the implementation of a due diligence system that is suitable for the business or undertaking and relevant for their role within the PCBU.

How can you achieve best practice in an effective safety management system?

How is this achieved when the guidance material for the minimum standard of safety (ie Codes of Practice) is still in the consultation phase?

Safe Work Australia has recently released its new Code of Practice for Managing Risks in Construction Work. Other key codes still yet to be finalised include Bullying and Harassment and Fatigue Management.

The failure of an engineering company in NSW to implement simple risk management measures to obviate the risk of its employees being struck by a chain or similar object whilst working under a coal shuttle car, led to one employee suffering fatal injuries. In September 2008, the employer, Seovic Engineering Pty Ltd conducted a business of repairing and maintaining mining equipment for various mining companies as well as general engineering activities at its workshop. On the day of the incident, an experienced fitter/ machinist was working with two other employees to re-fit a conveyor flight chain on a coal shuttle car with the use of a forklift to tow the chain. During this process, the chain or other object has struck the fitter/machinist who was under the shuttle car viewing the movement of the chain. On the 3 June 2013, the employer company was convicted and fined $100,000, and its Sole Director and General Manager were each fined $8000 by the Industrial Court of NSW, for breaches of the then Occupational Health and Safety Act of NSW. Inspector Nicholson v Seovic Engineering Pty Ltd [2013] NSWIRComm 41 Colin Biggers & Paisley is a commercial law firm with offices in Melbourne, Sydney and Brisbane. The firm provides representation and advice on construction and engineering, insurance, commercial litigation, dispute resolution, property, planning and environment, corporate and commercial law, restructuring and insolvency, transport and logistics, workplace relations and WHS where it is assisting to identify current best practice and assist both the PCBU and its officers to implement safety standards to achieve a safe and cost- effective operation.

Greg McCann - gam@cbp.com.au www.cbp.com.au

AMT February 2014

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manufacturing history

60 YEARS WITH MEN AND MACHINES – PART 40

Yoroshiku onegaishimasu Part 2

We continue our instalments from the book “60 years with men and machines” - the autobiography of US machinist and author Fred Herbert Colvin (1867-1965). It was 1929 when Fred was asked to visit Japan. By Fred Colvin It is 1929 and I had been asked to visit Japan as a delegate at the World Engineering Congress being held in Tokyo. This congress demonstrated Japanese advances in building a machine tool industry .

I visited a fair number of Japanese machine tool shops during my time there. One such visit was to a large railway shop at Omiya where I found the workmen stretching boiler tubes to required length after cutting them out of a locomotive boiler, instead of welding on safe ends as is the practice in the United States. The stretching of the tube, it was claimed, helped to remove the scale accumulated from impure water, but it also made the tube thinner and weakened it considerably.

They followed a practice, moreover, of building up worn carwheel treads with welding rods while the wheels and axles turned under the torch—a method that had long before been abandoned in the US. I next got around to the shops at Osaka. There were many American machine tools in evidence—Bradford, Pratt and Whitney, Lodge and Shipley, Gisholt, and others. But in the railroad shops, the English machines prevailed—Herbert Asquith, Milton, Bath, etc.—for the railroads had been built by an English company and planned by English engineers with the meter gauge as standard.

I am certain that most of the delegates to the World Engineering Congress went to Japan laboring under the delusion that the ricksha (rickshaw) was a native institution that dated way back to the dark ages. We were apprised of the true situation by a number of well-informed natives and by an excellent guidebook. The ricksha, or more properly jinrikisha (from the Japanese - jin= man; riki=strength and sha= carriage) was at first a makeshift vehicle that an American missionary threw together in order to take his invalid wife out for an airing.

Originally made from the wheels of a baby carriage brought over by the missionary, its usefulness and portability became readily apparent, resulting in its widespread adoption in Japan and China.

“Can’t you see I’m in a hurry, Toshio? I have an engagement.”

“Has not Colvin-sama neglected the hai hato, gomen-kudasai?

It is most necessary to be worn, gozaimasu. I have brought it, Colvin-hakase.” And sure enough, he produced it from behind his back, and I was trapped.

My wife and I were entertained at the home of a Mr. Wada, who was then high in the management of one of the many Mitsui organizations. Mr. Wada, who had invited a number of Japanese engineers and industrialists to the gathering, was very flattering, and told me in broken English that the “American Machinists’ Handbook” was very widely used as a reference work by Japanese engineers, and that it was being sold in many Japanese bookstores.

My wife and I spent another evening at a typical Japanese teahouse, in the company of a Mr. and Mrs. Burlingame and the Brown and Sharpe representative of the Ataka Company in Osaka. The geisha girls filed in carrying the food, which was known as “sukiyaki”. The girls also acted as hostesses, singers, dancers, conversationalists, and all-round entertainers.

Naturally I do not know how far they might go in the field of entertainment, since I was not very responsive to their beguilement, but I have heard that they will supply every conceivable requirement of the tired Japanese businessman.

We eventually took leave of Tokyo, having said our sayonoras all around.

Next stop: China!

To be continued…

Contrasts in methods of transportation, in clothing, and in building construction seemed to me an outstanding feature of Japanese life. Reinforced concrete was seen side-by-side with wooden construction and tile or even thatched roofs.

When it came to entertaining, the Japanese were second to none. The government-owned railroad gave all the delegates free passes permitting us to ride anywhere on their lines, and the Japanese officials invited all of us quite liberally into their homes for dinners and formal gatherings. I will not soon forget the reception held at the home of the then Prime Minister, or our presentation at the palace of Prince Chicibu, who was the brother of the renowned Emperor Hirohito, the gentleman who recently declared he was no longer divine (ie after WW2). The Japanese, we had been warned, were very, very formal on such occasions, and laid great emphasis on proper attire. Cutaway coats, striped trousers, and a high hat were always in order for morning affairs, and in the evening, tails were rigorously prescribed. I hated above everything to wear a high hat, and although my wife had arranged to take one along for me, I was anxious to avoid wearing it. Leaving the hotel on the way to the reception, I tried to substitute a grey fedora, but my Japanese cicerone nailed me at the door.

“Ara hai hato o wasurimasen, deshita ka?’ he hissed, grinning pleasantly. I caught the familiar words “high-hato,” but feigned ignorance.

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AMT February 2014

Sixty Years With Men and Machines The Autobiography of Fred H Colvin, Master Machinist Original © 1947, McGraw-Hill Publishing, reprinted by Lindsay Publications Inc, 1988, Bradley IL 60915, USA.

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91 Enterprise Connect 92 AMTIL Conference 93 AMC Speaker Program 94 AMTIL Golf Day 2013

Shane Infanti – Chief Executive Officer AMTIL

The importance of work-life balance For most of us, Christmas is a time of relaxation, maybe a holiday, catching up with friends and family and putting on those “holiday” kilograms. For me, I did all of those things (especially the latter)!

Having recharged the batteries and coming back refreshed for a new year it got me thinking – How do I maintain this level of energy for the next 12 months? This is the importance of work-life balance. We shouldn’t have to wait for the Christmas period each year in order to get back to some sense of normality in our lives.

So my New Year’s resolution (besides the normal weight loss commitment) is to use smarter techniques, work less hours and have personal things to look forward to each month.

There are any number of methods one can use to work smarter and I am not an expert in this area so I’ll let people investigate their own ways. For me, implementing a process that makes me analyse where I spend my time is the first step towards then committing more time to the activities that give the best pay-off. Looking at the four or five really important aspects of my role and forcing myself to spend 80% of my time in those areas is something I am committing to address.

By doing this and eliminating waste in my day I am going to work one hour less than I would otherwise do. My work hours will reduce. I am one of the fortunate ones that have less than a five minute drive to the office so by doing this I am spending significant quality time at home at a reasonable hour.

Family and friendship are important to me, as I am certain they are for most people.

Having something to look forward to each month, however big or small, is a strong motivator for the work life balance idiom. I have a family weekend planned for midFebruary and we have had some fun in discussing what we are going to do, which includes a winery tour, strawberry picking, camping and a visit to some hot springs on the Mornington peninsula. In March I am heading for a six day golfing adventure to the east coast of New Zealand with a dozen golfing mates. The courses are spectacular and we are sure to be engaging in a few nice glasses of red. I’m lucky enough to have a very good friend turning 50 in April and we are heading for a long weekend to Darwin on a fishing charter. We’ve been best friends since we were 8 years old and I am looking forward to this trip immensely. You are probably asking yourself “why is he telling me this, it is of no interest to me”, but I’m writing it because I am excited.

If you have nothing to write about or get excited about over the next few months, do something about it!

I don’t need to be motivated to go to work. I love doing what I’m doing. But doing it smarter, making a bit more ‘me’ time and stopping to smell the roses – well – I’m looking forward to that as well.

Here’s hoping for a successful 2014 to our members.

Cheers to all.

AMTILinside

Gregg Eaton – Bringing experience to Enterprise Connect Part of AMTIL’s team of Enterprise Connect business advisers - Gregg Eaton - services Adelaide and the Riverland region of South Australia.

Gregg’s input to the program comes from a career dedicated to improving the commercial prospects of small-to-medium enterprises both here and overseas. His broad experience base includes food and technology manufacturing, printing and publishing, medicinal drug discovery, medical devices, waste management, resources and technology service industries, and especially electronics and IT.

With his focus shifting towards the consultancy side of the business, Gregg’s horizons expanded to assist businesses in North America, Germany and other EU countries. Gregg was named ‘Inventor of the Year’ for his circuit breaker design, one of various awards he has won as he has assisted his client businesses to broaden their commercial profiles and secure their financial sustainability.

Gregg’s technical background began immediately after school, when he developed an award-winning earth leakage circuit-breaker design while studying at university. As a student, he also worked as a research assistant on both tissue culture and transplant research teams.

In recent years, Gregg has taken lead roles in re-engineering organisations in fields as diverse as pharmaceuticals, university departments, farming, internet and IT companies, book publishing and the manufacture of medical devices, solar engines, and pumps. Gregg has invariably taken on executive roles during his consultancy assignments, including acting as CEO of a pharmaceutical company, technical director of a medical devices company, general manager of a software company and many others.

After university, Gregg went on redesign European-style televisions for the Australian regulatory environment as colour TV was introduced to the country, setting up a factory for this purpose. He lectured on colour TV and managed the state service team for these new televisions, before founding his own engineering business and consultancy to capitalise on the burgeoning electronics and computer industry, while additionally establishing a family-run chain of restaurants.

The engineering business designed, developed and built bespoke electronics, including: ATMs for a national bank; water supply and pump control systems for municipal authorities and power stations; fire safety control systems; computer power supplies; and industrial computers. It also developed approved lightning and surge

protection products for communications equipment and power supplies, and UPS systems for military and industrial use. In addition, the company produced a newsagency management software package on CP/M operating systems, long before MS-DOS. At this time, Gregg consulted on business commercialisation and technical matters, for clients including IBM and several other private and public companies, government departments and the armed forces. He also served on the science curriculum advisory committee for Griffith University, and became the Australian Chamber of Commerce and Industry (ACCI)’s representative on several key Standards Australia electrical safety committees, which he continued for the next 20 years.

ManufactureLink proudly owned and operated

by AMTIL

Of particular relevance to his current position is his tenure as a member of the Industry Research and Development (IR&D) Board’s Tax Concession Committee, which vetted and approved R&D concessions for industry.

Close investigation of companies’ strategic plans and finances has given Gregg a solid understanding of the many permutations of activities that lead to success or failure.

To discuss how Enterprise Connect can help your business, contact the AMTIL Projects team on 03 9800 3666, or email: gchalker@amtil.com.au. www.enterpriseconnect.gov.au

Follow our members on

Go Get linked!

Manufacturelink is your directory for all things Manufacturing. processes. services. technology.

1186AMT

We’ve got the link to make it happen.

Visit www.manufacturelink.com.au to learn more.

AMT February 2014

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AMTILinside

Australian Manufacturing Conference proudly owned and operated

by AMTIL

REGISTER

Australian Manufacturing !

W O N Conference Early Bird

rate

Manufacturers across Australia are invited to attend the Australian Manufacturing Conference, themed ‘Leadership in Business’.

Registration is now open for the Conference, which will be held at the Sheraton Mirage Resort, Gold Coast, on 5 & 6 June 2014. The Conference will present a unique opportunity to learn, network and celebrate Australian manufacturing.

Benjamin Roberts-Smith Frontline Leadership – the Battle for Success Born in Perth in 1978, Ben joined the Australian Regular Army in 1996 and passed the SAS selection course in 2003. In 2006, during the second of six tours of Afghanistan, he was awarded the Medal for Gallantry for his actions as a patrol sniper in the Chora Valley. On 11 June 2010, he was involved in an action that earned him the Victoria Cross.

Why? Because manufacturing matters.

Manufacturing matters to Australia and the entire world, because manufacturers make the things that make modern life possible.

From our computers to our telephones to our automobiles, from our houses to our schools to our workplaces, manufacturing matters because we rely on it every day.

Avril Henry Generational Recruitment and Retention Avril is a widely acclaimed keynote speaker, consultant, business and career coach, mentor and author. Her management consulting business, Avril Henry Pty Ltd, was one of the five finalists in the City of Sydney Business of the Year awards in 2008.

Manufacturing matters in Australia because our manufacturers lead the world in many products and industries. Australia’s manufacturing industry contributes around 8% of our gross domestic product (GDP), is a major contributor to our economy each year, and employs around a million people. Our manufacturers employ people in challenging and rewarding work and provide the basis for stable, diverse communities.

Ross Greenwood Economic Update – Post-Federal Budget Ross is the Nine Network’s Finance Editor, having previously been editor of Business Review Weekly (BRW), Personal Investor and The Age’s money section. For the past four years, Ross has been the editor-in-chief of Shares. In the finance industry, Ross has been a director of a sharemarket-listed investment company and for six years was chairman of the investment committee of the JUST superannuation fund.

Megan Quinn Intuition and Creativity – Which global businesses are reaping the rewards of valuing both?

Megan has built a 25-year career specialising in retail, advertising, publishing and design for the fashion, jewelry, hotel and airline industries. She has held a variety of leadership and senior executive as well as non-executive board roles, and notably was co-founder of the internationally acclaimed Net-A-Porter in 1999.

At this Conference, we will cover the importance of innovative thinking and collaboration, we will explore how technology can be transformational for SMEs in Australia, we will provide you with a framework for working towards higher profitability in a high-cost environment, and so much more. Just as importantly we will provide opportunities for networking, socialising and business development with over 200 delegates expected to attend.

So, regardless of who you are or where you live, whether you make products or use them, manufacturing matters! I hope to see you at this inaugural event.

Shane Infanti CEO, AMTIL

Steven Bradbury Overcoming Adversity Steven Bradbury created history when he won Australia and the Southern Hemisphere’s first Winter Olympic Gold Medal, winning fans the world over for the honesty and humility he showed after the win.

He saw the victory as reward not for one race, but for 12 years of hard training that included more than his share of misfortune.

Venue Sheraton Mirage Resort, 71 Sea World Drive, Main Beach, QLD, 4217 Tel: 07 5591 1488 Registration Fees

Sheraton Mirage Resort, Gold Coast

Early Bird Rate (March 2014)

AMTIL Members (per delegate) $1,390.00 Non-Members (per delegate) $1,690.00

Standard Rate $1,590.00 $1,990.00

For more information visit: www.amtil.com.au/Events/AMTIL-Conference Sponsors Gold www.sme.org

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Bronze www.wadesonip.com.au

Speaker Lanyard www.txm.com.au www.tick-off.com.au

AMTILinside

Please note that the Program is subject to change and will be updated as speakers are confirmed. AMTIL accepts no responsibility for speaker changes that are outside its control.

Wednesday 04 June 2014 WELCOME Function Drinks and canapes

07:00Pm – 09:00pm

Thursday 05 June 2014 - DAY 1 Registration, tea and coffee

08:15am – 09:00am 09:00am – 09:15am

WELCOME Shane Infanti, AMTIL CEO

09:15am – 09:30am

OFFICIAL OPENING Federal Government Representative

09:30am – 10:10am

Keynote 1: TopIc Speaker TBC

10:10am – 10:30am

Energy Break Technology

Leadership

Opportunity

10:30am – 11:10am

Additive Manufacturing – No Longer Just For Prototyping Simon Marriot 3D Systems Asia Pacific

Collaboration, Co-operative Research & Commercialisation Andrew McLellan Advanced Manufacturing CRC

Clean Technology Opportunities For The Future Marc Newson Clean Technology Supplier Advocate

11:20am – 12:00pm

Advances in Robotic Machining Clive Martell Delcam

Strategic Planning for Business Success Paul Valentine, Stratas Group

Accessing major domestic and international projects Derek Lark, Industry Capability Network

12:00pm – 01:00pm

Networking Lunch

01:00pm – 01:40pm

Keynote 2: Finance Update Ross Greenwood

01.50pm – 02:30pm

02:45pm – 03:30pm

Emerging Technologies – translating research into production Erol Harvey, MiniFab Another great presentation will be confirmed for this timeslot soon.

Intuition and Creativity: Which global businesses are reaping the rewards of valuing both?

Megan Quinn, Co-founder Net-a-Porter Journey of Growth and Success for SME’s Linsey Siede Automotive Supplier Excellence Australia

Workforce Development: An Investment Opportunity Robert Cugno Swinburne University The Internet: opportunity, or threat to your business Jeremy Nathan, IndustrySearch

03:30pm – 04:00pm

Energy Break

04:00pm – 04:45pm

Keynote 3: Frontline Leadership – The Battle for Success Benjamin Roberts-Smith

06:00pm – 07:00pm

Networking Drinks

07:00pm – 11:00pm

Keynote 4: Conference Dinner Speaker TBC

Friday 06 June 2014 - DAY 2 09:00am – 09:20am

WELCOME Shane Infanti, AMTIL CEO (includes tea and coffee)

09:20am – 10:00am

Keynote 5: Generational Recruitment and Retention Avril Henry

10:10am – 10:50am

Investment – Reaping the Rewards Case Study Session

11:00am – 11:40am

Another great presentation will be confirmed for this timeslot soon.

Aligning Organisational High Payoff Activities to increase productivity and performance Gary Hickingbotham, LMA Intellectual property tricks and traps – simple steps to minimise risk and maximise profit.

Ben Mott, Wadeson

11:40am – 12:00pm

Energy Break

12:00pm – 12:40pm

Keynote 6: TopIc Speaker TBC

12:40pm – 01:40pm

Networking Lunch

Predatory Marketing Ashton Bishop Step Change Marketing

What is an Opportunity? And how to systematically search for one Roger La Salle, Matrix Thinking

01:40pm – 02:20pm

Research Provider Panel - Access to Resource Organisations Damien Thomas, CSIRO Stuart Wallace, R&D Connect Milan Brandt- RMIT University

An insight into what it takes to play on the world stage Goran Roos

“Enterprise Connect and Australian SME’s – Partnerships into the future” Enterprise Connect

02:30pm – 03:10pm

Utilising Technology to Profit from your Client Database Debbie Mayo-Smith

ANCA – A Global Organisation Grant Anderson

Taking on the Chinese - How to compete and thrive in Manufacturing in the 21st Century TXM Lean Solutions

03:10pm – 03:40pm

Recharge and Networking Break

03:40pm – 04:20pm

Keynote 7: Overcoming Adversity Steven Bradbury Farewell Function Networking drinks and canapes

04:20pm onwards

Saturday 07 June 2014 Optional Social Activities Refer to conference website for pricing - Gold Coast Waterways Cruise or 18 Holes of Golf at Royal Pines Resort

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AMTILinside

AMTIL Golf Day 2013 AMTIL members once again took the fairways on 29 November for our Annual Corporate Golf Day. Held at Riversdale Golf Club, AMTIL’s 13th Annual Corporate Golf Day proved as popular as ever, with even the weather obliging the players with clear, mild conditions, after a decidedly wet November.

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AMT February 2014

Congratulations to Capral Aluminium, who fielded the winning team in Ed Kim, Peter Gower, Peter Bulka and Richard Axe.

AMTILinside

New AMTIL Members

Abcor Pty Ltd 140-146 Barry Road Campbellfield, VIC 3061 Tel: 03 9357 0011 www.abcor.com.au

Elmass (Australia) 1/6 Moonbi Street Brendale QLD 4500 Tel: 07 3881 1919 www.elmass.com.au

Philtech Enterprises Factory 4/61 Whiteside Road Clayton, VIC 3169 Tel: 03 9543 1829 www.philtech.com.au

Alfred Lewis Engineering 152 Woodlands Drive Braeside, VIC 3195 Tel: 03 9580 8652 www.alfredlewis.com.au

Engineered Components 57 Chetwynd Street Loganholme QLD 4129 Tel: 07 3801 1488 www.engineeredcomponents.com.au

PTronik Pty Ltd 17 Windsor Street Richmond, NSW 2753 Tel: 02 4578 9611 www.ptronik.com

Amon Engineering Pty Ltd 44-46 Gilbert Road Preston, VIC 3072 Tel: 03 9484 1057 www.amonengineering.com.au

Gravotech Unit 3, 9-11 South Street Rydalmere NSW 2116 Tel: 02 9684 2400 www.gravotech.com.au

Stahl Engineering 3 Acheson Place North Coburg, VIC 3058 Tel: 03 9355 8664 www.gasgep.com.au

CammPro 18 Rivulet Crescent Albion Park Rail 2527, NSW Tel: 02 4257 3201 www.cammpro.com.au

Harrop Engineering Aust. Pty Ltd 96 Bell Street Preston, VIC 3072 Tel: 03 9474 0900 www.harrop.com.au

TRJ Engineering 17-19 Apollo Drive Hallam, VIC 3803 Tel: 03 9703 1701 www.trjengineering.com.au 1193AMTIL

Keeping it simple.

One Membership.

Many Benefits.

For more information, visit www.amtil.com.au or contact Member Services Manager Peter Lambe on 03 9800 3666 or email plambe@amtil.com.au

www.amtil.com.au

industry calendar

Please Note: It is recommended to contact the exhibition organiser to confirm before attending event

INTERNATIONAL China CNC Machine Tool Fair China, Shanghai 24-28 February 2014 www.ccmtshow.com/enshow.shtml AeroDef USA. California 25-27 February 2014 Exposition and technical conference for the aerospace and defense manufacturing industry. www.aerodefevent.com Intertool Kiev Ukraine 4-6 March 2014 Exhibition for hardware, tools and DIY. Includes: Tools and machines for metal, wire, pipe, stone, glass, ceramic and plastic work; workshop tools; construction and installation equipment; hardware; laser technology; diamond and carbide tools etc. http://en.intertool.kiev.ua/index.html EXPO MANUFACTURA Mexico, Monterrey 4-6 March 2014 Includes: automation; CAD/CAM, microprocessing; cutting/milling/waterjet tools; laser, preforming; quality control. www.expomanufactura.com.mx METAV Germany, Dusseldorf 11-15 March 2014 International fair for manufacturing technology and automation. Includes: machining centres; milling/turning/drilling/boring/grinding machines; metal removing machine tools; sheet metal working; material handling; rapid prototyping. www.metav.com/ St Petersburg Technical Fair Russia, St Petersburg 12-14 March 2014 DeLocal and global issues of metallurgy, welding, metalworking, tools and instruments, materials and machinery, high technologies and innovative developments. Covers the full process from metal production to engineering in automotive industry and metalworking. http://ptfair.ru/en/index Modex USA, Atlanta 17-20 March 2014 Newest expo for the manufacturing, distribution and supply chain industries. www.modexshow.com AmCon USA Orlando: 18-19 March 2014 Seattle: 9-10 April 2014 Kansas City: 29-30 April Denver: 13-14 May 2014 Austin: 21-22 May 2014 Design and contract manufacturing expo.

Includes: forming; fabricating; machining; engineering; prototyping; finishing; assembly; electronic manufacturing; design. www.amconshows.com/spring-shows/ orlando-fl/

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Manufacturing & Automation Expo Sweden, Stockholm 18-21 March 2014 Competitive production and automation in the manufacturing industry. Focus areas are machine tools, tools, test- & measuring systems and solutions for automation and manufacturing. www.maexpo.se/en Fabtech Canada Canada, Toronto 18-20 March 2014 Exclusively fabricating, welding and metal forming event. www.fabtechcanada.com International Machine Components and Metal Working Fair Turkey, Istanbul 19-22 March 2014 www.win-fair.com/en STOM-BLECH Poland, Kielce 26-28 March 2014 Includes metal processing machines, machine tools and technological equipment. www.targikielce.pl MECSPE Italy, Parma 27-29 March 2014 Meeting point between production technologies and industrial supply chains for the manufacturing industry. Includes seven trade shows (Logistics, Eurostamp, Plastics, Control, Automation, Subfornitura, Machines & Tools), www.senaf.it/MECSPE/117 Industrie Paris 2014 France, Paris 31 March - 4 April 2014 Includes: assembly – mounting; forming/cutting (sheet metal); industrial computing; machine tools; measurement/control; robotics; welding; treatment of materials. www.industrie-expo.com Arabia Mold United Arab Emirates 7-10 April 2014 Trade fair for mould-making, tooling, design and application development. Will be held jointly

by Expo Centre Sharjah and DEMAT GmbH (Germany). Co-located with Plastivision Arabia. www.arabiamold.com Metal & Steel Saudi Arabia 2014 Saudi Arabia, Riyadh 7-10 April 2014 Event for the steel, steel fabrication and metallurgy industry: Includes iron and steel production; technology and equipment; metal cutting/milling/forming/drilling/grinding machines. www.metalsteelsaudi.com Hannover Messe Germany, Hannover 7-11 April 2014 Trade fair for industrial technology. Includes industrial automation and IT, energy and environmental technologies, industrial supply, production engineering and R&D. www.hannovermesse.de

MACH UK, Birmingham 7-11 April 2014 A diverse, engineering-based manufacturing exhibition covering all aspects of manufacturing at all levels of the supply chain and support services. www.machexhibition.com/ PaintExpo Germany, Karlsruhe 8-11 April 2014 Leading international trade fair for industrial coating technology with comprehensive focus – ranging from pre-treatment to final inspection. www.paintexpo.com SIMTOS 2014 South Korea, Seoul 9-13 April 2014 International Manufacturing Technology show.

Includes: machine tools (metal cutting/forming); measurement; CAD/CAM; laser/water jet cutting; welding; automation etc. www.simtos.org Northeast International Machine Tool and Metal Working Exhibition China, Shengyang 10-12 April 2014 www.bfexpo.com.cn/jbh/gbh_jc.asp AeroCon 2014 - Charlotte USA, Charlotte 15-16 April 2014 Leading event for manufacturers of aerospace and defense products. www.canontradeshows.com/expo/ aerocon13 Intermold 2014 Die & Mold Asia 2014 Japan Metal Stamping Technology Exhibition 2014 Japan, Osaka 16-19 April 2014 http://intermold.jp EMTE-EASTPO joint event China, Shanghai 14-17 July 2014 EMTE (European Machine Tool Exhibition) and EASTPO (Shanghai International Machine Tool Fair) joint event www.emte-eastpo.com IMTS USA, Chicago 8-13 September 2014 One of the largest industrial trade shows in the world. Co-located with Industrial Automation North America. www.imts.com AMB Germany, Stuttgart 16-20 September 2014 Among the world’s top five exhibitions for the metal working industry. www.messe-stuttgart.de/en/amb JIMTOF Japan, Tokyo 30 October – 4 November 2014 Leading international machine tool exhibition for machine tools and related equipment www.jimtof.org/eng

industry calendar local Australasian Oil & Gas Exhibition & Conference Perth Convention Exhibition Centre 19-21 February 2014 Australia’s largest oil and gas exhibition, with over 500 exhibitors from 20 countries.

Ph: 03 9261 4500 www.aogexpo.com.au Global Iron Ore & Steel Forecast Conference Perth 11-12 March 2014 The world’s largest gathering of iron ore executives. Delivers vital information on the status of the global iron ore and steel sectors.

Ph: 02 9080 4307 Email: info@informa.com.au www.globalironore.com.au Safety in Action Darwin: 19- 20 March 2014 Perth: 11-12 June 2014 Sydney: 2-4 September 2014 www.safetyinaction.net.au National Manufacturing Week Sydney Showground, Sydney Olympic Park 13-16 May 2014 Manufacturing exhibition showcasing latest products and technologies in the expanding manufacturing market. Includes dedicated product zones and an extensive program of education and networking events. Opportunity for suppliers of manufacturing technology equipment, technology and services to showcase their leading products to senior decision-makers from Australia’s manufacturing industry.

Ph: 02 9422 2568 www.nationalmanufacturingweek.com.au Advertiser Index 65 Acra Machinery AlfexCNC 29 Amada 98,99 AMTIL AMT 8, 42 AMTIL Conference 15 AMTIL Membership 95 91 AMTIL ManufactureLink Applied Machinery Aust. P/L 21 51 BAC Systems BOC 43 71 CMTS Sheetmetal Machines Complete Machine Tools 37 31 Compresssed Air Australia Delcam 63 DMG Mori Seiki 25 Hare & Forbes 23 9 Headland Hi-Tech Metrology 77 Iscar 2, 3

Your Industry. Your Magazine.

Australian Manufacturing Conference Leadership in Business 5-6 June 2014 Qld. Gold Coast Discover new strategies to help your business to thrive, connect with key industry contacts and be informed by 25 knowledgeable and inspiring presenters. The Australian Manufacturing Conference, operated by AMTIL, will incorporate a comprehensive speaking program plus a conference dinner. Two cocktail functions will also be hosted. Speakers include: Benjamin Roberts-Smith, Ross Greenwood, Avril Henry, Megan Quinn and Steven Bradbury.

Ph: 0417 146 102 Email: kwarren@amtil.com.au www.amtil.com.au/Events/AMTILConference Foodpro Melbourne Convention and Exhibition Centre 22-25 June 2014 Australasia’s largest and longest running food manufacturing trade show, Showcasing every aspect of the Australasian Food Processing industry. One section of the show will cover processing equipment for meat, poultry, seafood and vegetables, while a technical area will cover food science and technology, including Food Safety. Also includes a dedicated plant equipment section featuring water treatment, doors and flooring, pumps.

Includes a packaging and handling area specialised for the food industry.

Ph: 03 9642 4107. www.foodproexh.com

LMC Laser LS Starrett Machinery Forum Metal Cutting Technology MTI Qualos OKUMA OMAX OSG Asia Pty Ltd Seco Tools SEW-Eurodrive Sheetmetal Tooling Tech SICK Siemens Industry Software Standaco Machinery Sales Steelmaster Teco Tooling Thyssenkrupp Tungaloy Australia P/L Walter

69 33 89 56,57 Cover, 35, 75 7 49 4&5 19 47 38,39 83 13 27 81 61 53 17 11, OBC

Would you like to advertise in Australia’s No. 1 precision and manufacturing magazine?

Call Anne Samuelsson of AMTIL on 03 9800 3666 or email asameulsson@amtil.com.au

Furnitex Melbourne Exhibition Centre 10-13 July 2014 For members of furniture & soft furnishings industry. Showcases hundreds of exhibitors with Australasia’s most comprehensive range of contemporary furniture and furnishing. www.furnitex.com.au Queensland Mining & Engineering Exhibition Mackay Showground 22-24 July 2014 Since the first edition in 1993, QME has grown to become the leading industrial exhibition in central Queensland. Ideally timed during a period of unprecedented growth in Queensland’s mining industry.

Ph: 02 9422 2563 www.queenslandminingexpo.com.au Cleanscene Sydney Olympic Park 2-4 September 2014 National cleaning and hygiene expo. Co-located with Safety in Action. www.cleansceneshow.com.au Queensland Gas Conference & Exhibition Brisbane Convention & Exhibition Centre 10-11 September 2014 This event will bring together international opinion leaders, executives from the global energy market and senior decision-makers from the Australian LNG industry and supporting infrastructure.

Ph: 02 9422 2955 Email: rme@reedexhibitions.com.au. www.queenslandgasconference.com.au

mar14 Australian Manufacturing Technology

Your Industry. Your Magazine.

NEXT MONTH…

AEROSPACE We look at how the goal of weight reduction is driving increasing use of advanced exotic materials in the aerospace industry ROBOTICS & AUTOMATION SOFTWARE SAFETY MATERIAL REMOVAL

AMT February 2014

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Expanding the support Seminar for Operator and Programmer Targeted towards machine operators and programmers, the content is how to use.

Sydney

Melbourne

Mar

Bending

Bending

Apr

Software

Laser

May

Laser

Software

Jun

NCT Tooling

NCT Tooling

Jul

Bending

Bending

Open House for Owner / Manager Targeted at owners and managers, the content is on how to realize the value of a new machine purchase.

Also used to introduce new machines by explaining the benefits in capability, capacity and cost reduction.

Sydney

Melbourne

Mar

Yes

Yes

Apr

Yes

–

May

Yes

Yes

Jun

Yes

–

Jul

Yes

Yes

Study tour Mar

Australia

Apr

International

May

Australia

Jun

International

Jul

Australia

You can opt in to receive email notification of each event at www.amada.com.au/optin

Amada Oceania Pty Ltd www.amada.com.au

of the sheet metal working industry.

Tooling Amada provides industry leading technology for Australia’s manufacturing sector, including a comprehensive selection of innovative press brake and punch press tooling.

Contact us to get a quote on price and delivery at www.amada.com.au/contact-us

Amada’s Commitment Amada Oceania is committed to expanding support to Amada users. In addition to our 10 Service Engineers we have added another layer of support; our CE’s or Customer Engineers.

Our 4 CE’s are ready to help you get more from your Amada equipment; more efficiency, more speed, more accuracy, more value. And we opened a new technical centre in Melbourne with machinery, tooling, software and spare parts.

Amada Oceania is introducing new machinery and tooling concepts in bending, turret punching and laser cutting.

Stay informed on how we can support you and your business at www.amada.com.au/optin

Sydney 02 8887 1100 | Unit 7, 16 Lexington Dr., Bella Vista NSW 2153 Melbourne 03 9020 1400 | Unit 1, 3-4 Anzed Court Mulgrave VIC 3170 Perth | Brisbane

Fully

integrated performance

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Remarkable increase in performance: Competition Tiger·tec® Silver WPP10S

Walter AG Singapore 20 Science Park Road, #01-04A / 05, Teletech Park Singapore Science Park II, Singapore 117674 www.walter-tools.com www.youtube.com/waltertools www.facebook.com/waltertools

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See the product video: Scan the QR code or go to http://goo.gl/frwc2