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Official Magazine: METALTECH 2010 April 2010 M.I.C.A. (P) No. 233/06/2009

The Leading

Machine Tool Company



Official Media Partner: MTA MALAYSIA 2010

ISCAR’S New Grades and Tool Geometries Lift the Aerospace Industry to New Heights


ISCAR JAPAN 1-5-3 Shinsenri-Higashimachi Toyonaka-shi, Osaka 560-0082 Tel + 81 6 835 5471 Fax + 81 6 835 5472

ISCAR TAIWAN 395, Da Duen South Rd. Taichung 408 Tel +886 (0)4 247 31573 Fax +886 (0)4 247 31530

ISCAR THAILAND 57, 59, 61, 63 Soi Samanchan-Babos Sukhumvit Rd. Phra Khanong, Khlong Toey Bangkok 10110 Tel + 66 (2) 7136633 Fax + 66 (2) 7136632

ISCAR VIETNAM (Representative Office) Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., Ho Chi Minh City, Tel + 84 8 8123 519/20 Fax + 84 8 8123 521

CV MULTI TEKNIK JL. Balikpapan Raya No. 28 Jakarta Pusat 10140 Indonesia Tel + 62 21 6307303 Fax + 62 21 6348062

SINO TOOLING SYSTEM Blk 502, Jurong West Ave 1 #03-813 Singapore 640502 Tel + 65 6566 7668 Fax + 65 6567 7336

MESCO Reliance Corner Brixton St. Pasig City Metro-Manila Philippines Tel + 63 2631 1775 Fax + 63 2635 0276


Perfection is practical. We know bringing your ideas to life requires exactly the right machining. That’s why we provide complete high-tech processes for every turning application. As well as new and constantly improved cutting tool materials and solutions. This means more products in less time and more productivity. The result: shorter set-up times, improved machining capacity, lower costs – bringing you greater efficiency and higher profits. Our innovative Tiger·tec® technology meets tomorrow’s challenges today. No one else competes at this level of precision and productivity. It’s the challenging new standard we've set for metal cutting. Expect more. Engineer what you envision. Experience the new Walter. ENQUIRY NO 057

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Contents April 2010



Tools For Aerospace Industry: Flying High

Tools of better quality and performance are a must to cater to the high flying aerospace industry. Submitted by Yvonne Ng, marketing manager, Walter AG Singapore


Machine Utilisation: Back To The Drawing Board

‘The way we have always done it’, no longer suffices in today’s manufacturing climate. By Curtis Rellick, global product manager, tooling systems, Kennametal



Using the measurement points acquired by a laser scanner and the CAD comparison analysis graphics eliminate prototype rounds and deliver top quality. By Rob Snoeijs, senior editorial writer, Nikon Metrology


Digital Quality Control: Into A New Dimension

3D scanning offers a completely new take on quality control and inspection. By Patrice Parent, regional manager, Creaform (Asia-Pacific)


SolidWorks World 2010 Graced by journalists, users and James Cameron, this year's installment of SolidWorks World defied the recession and provided an entertaining and informative arena for all. By Joson Ng


Give Aerospace Productivity A Five!

The increasing use of five-axis machining is an important trend that is boosting productivity in the aerospace industry. By Peter Dickin, marketing manager, Delcam


Taking The Step Towards 3D

Making the transition from one design software to another is not as simple as installing a new program on the computer, it requires a change in mindset. Submitted by Shirley Lim, assistant marketing manager, Advanced Technology Enterprise



JOINT ADVERTISING DISCOUNT WMEM, 30,000 copies circulated quarterly in China combines with M.E.N, 10,000 copies circulated bi-monthly in ASEAN in joint advertising. Ask for more details now.

INDUSTRY Endorsements


Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA) Federation of Malaysian Foundry & Engineering Industry Associations Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)


Servo Presses Driving Economical Manufacturing

Even small companies can set themselves big targets that will elevate them to lofty heights. By Olaf Pinkenburg, Schuler, Germany 4

SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail:


Increasing Prototyping Speed & Quality


ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd, 1100 Lower Delta Road, EPL Building #04-02 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

metalworking equipment news April 2010

Taiwan Association of Machinery Industry (TAMI)



ST-30THE 2010 TURNING CENTER NEW GENERATION After more 2010 than ST-30 20 years of industry figured 2010 would be a The all-new, turning center firsts, is the we culmination good year “up the ante” again. Soand we it looked anymost and every way of 15 years of to continuous development, offersatthe to the make Haas –VMCs and–then made one last change: performance for money the better, best value of any turning We added more value. center on the market today.

more rigidity. IMPROVED: motion control more tools. coolant containment • chip evacuation more power . . . more value.CNC interface • ergonomics • serviceability r e l e a s e d f o r a cr et il ve ea s de ud t yf o: r 0 a1 c. 0t i1v. e1 0d u t y : 0 1 . 0 1 . 1 0

Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment. Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment.

Haas Factory Outlet Haas Factory Outlet Singapore Singapore DKSH Technology

DKSHFront Technology Harbour Phone: +65 6471 9248 Harbour Front Phone: +65 6471 9248

Malaysia Malaysia A Division of SPC Machinery Sdn Bhd

Thailand Thailand A Division of Machine Tech Co., Ltd.

A Division of Machine Tech Co., Ltd. Bangkok: 02 726-7191-5 Bangkok: 726-7191-5 Chonburi: 6602 3811-2700 Chonburi: 66 3811-2700


Philippines A Division of03-5569-5901 SPC Machinery Sdn Bhd A Division Kuala Lumpur: of Gaylan Technologies A Division of Gaylan Kuala Lumpur: 03-5569-5901 Penang: 604 3801581 Manila: 63 2 915 8725 Technologies Manila: 63 2 915 8725 Penang: 604 3801581



Vietnam Diethelm and Co. Ltd. Diethelm and Co. Ltd. Technology Technology Hanoi: +84 4 9424 725 Hanoi:+84 +84845121 9424334 725 HCMC: HCMC: +84 8 5121 334

Contents 50



Aerospace Parts: Latest Advances In Ti 5553 Machining


The trick to machining difficult aerospace parts is preparing the existing machines to suit the material. By Scott Walker, president, Mitsui Seiki USA

Aerospace Machining: Fresh Opportunities & Choices

Titanium and composites materials are slowly making their presence felt in the aerospace industry. By Reuven Shapir, aerospace industry manager, Iscar

• 10 Business News • 75 Product Finder • 79 Exhibition Programmes • 80A Product Enquiry Card



Steel & Energy: Can You Manage This?

Energy conservation in steelmaking is crucial, to ensure the competitiveness of the industry and to minimise environmental impacts, such as greenhouse gas emissions. By World Steel Association




3D Point-Cloud Processing For MRO

By bridging the gap between the physical and digital worlds, 3D pointcloud processing offers benefits for companies in the MRO business. By Alberto Griffa, US Eastern regional sales manager, Geomagic


Going One Better Than 5

A Northern Ireland aerospace subcontractor identifies interpolative 6-axis machining as the way forward. By Chris Wright


Full Throttle At The Portland Boeing Plant

The Power Of Solutions

A cutting tool supplier offers its expertise to a power generating solutions provider, equipping it adequately to propel the world. By Gisbert Roth, manager, marketing operations Asia-Pacific, Seco


The necessity for lean production process serves as a catalyst for a partnership, which is going from strength to strength. By Dr Ing HansPeter Schossig, engineering consultant, Deckel Maho, Pfronten

Refer to Advertising Index

The Monetary Value Of Safety

Rising awareness of equipment safety boosts prospects for the South-east Asia, Australia and New Zealand machine safety markets. By Vandhana Venkatesan, research associate, Frost & Sullivan



Event Preview: Metaltech 2010 Event Preview: MTA Malaysia 2010

Pg 80

for Advertisers' Enquiry numbers


editor’s note

Published by:

Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C


managing director Kenneth Tan


editor Joson Ng

advertising sales manager Yessica

editorial assistant Sharifah Zainon senior art director / studio manager Lawrence Lee graphic designer Jef Pimentel

The aviation industry has come a long way since the de Havilland Comet. From the 747s to the 777s all the way to the 787 dreamliner and A380, a steady progression can be seen and felt by passengers and enthusiasts alike. The extended range, fuel economy, improved safety and passenger comfort may have dominated the headlines, there are also big changes or improvements made to the materials used. One of which is the usage of titanium and composite materials in the modern aircraft of today. The strength, reliability and the lightweight nature of the materials have put them ahead of traditional materials like aluminium but usage of these materials have pose a new set of engineering challenges for machinists. These challenges, though will test the resolve of engineers and designers alike, should and can be overcome by using advance machine tools and cutting tools available in the market today. In this issue of Asia Pacific Metalworking Equipment News, there are various articles devoted to machining and designing of aircraft

parts, as the aerospace industry is in focus for this issue. Elsewhere in Singapore, the Civil Aviation Authority of Singapore (CAAS) recently unveiled plans to drive the development and growth of the aviation industry in Singapore. With that, an Aviation Development Fund (ADF) has been setup and it aims to promote and develop the aviation sector over the next five years. Though a bustling MRO hub in the region, the setup of ADF will no doubt be a real shot in the arm for many who are involved in the aerospace industry in the island state. From technical improvements to financial benefits, the aerospace industry is moving ahead with some pace. Although the path forward may not be smooth, the spirit and endeavour shown by many in the older generation, when airships were still in vogue in passenger transport, should serve as a great inspiration for many as they try to overcome the difficulties and forge forward.

circulation executive Irene Tow

contributors Yvonne Ng, Curtis Rellick Rob Snoeijs, Patrice Parent Peter Dickin, Shirley Lim Olaf Pinkenburg, Scott Walker Reuven Shapir, Alberto Griffa Dr Ing Hans-Peter Schossig World Steel Association Gisbert Roth, Chris Wright Vandhana Venkatesan board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 233/06/2009 PPS 840/10/2010 (028278) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

chairman Stephen Tay group executive director Kenneth Tan financial controller Robbin Lim

etm Joson Ng Editor



Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806 Thailand Office: Thai Trade and Industry Media Co., Ltd 16/F Italthai Tower, 2034/73 New Petchburi Road, Bangkapi, Huaykwang, Bangkok 10310, Thailand Tel: 66(0) 2716 1722 Fax: 66 (0) 2716 1723

metalworking equipment news April 2010

dmg – technologies for tomorrow

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Medical products and technology are becoming an

indispensable factor in general health. More than 1,000 medical components are manufactured on DMG machine tools today, with a precision and an efficiency that was unthinkable only a few years ago.

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Systematic Partnership Between Walter & DMG

Tübingen, Germany: Tool manufacturer Walter and machine manufacturer Gildemeister have embarked on their long-term systematic partnership at METAV for the first time. In the partnership, Walter AG and the Gildemeister incorporation are giving users around the world access to tool packages when they buy a DMG machine – tool packages that are coordinated with the materials to be processed and the individual industry sector (eg: energy, the aerospace industry, tool and mould making). In future, a Walter tool box will be delivered with each DMG machine of types

DMF, DMC V, DMU 60 – 160 P duoBlock. The precision tool manufacturer offers complete solutions and productivity in the area of machining. From technical support to tool management software, the user receives complete high-tech machining processes from a single source. In addition to its core competence areas in turning and milling technology, as well as ultrasonic and lasertec, Walter also offers solutions in the area of automation and software tools for machine tools. Its portfolio is supplemented by solutions in the area of solar technology.

Delcam Chairman Reports Strong Performance Birmingham, UK: Delcam Chairman Peter Miles reported that the company had performed strongly in the face of challenging trading conditions during 2009. Sales at £31.8 million (US$47.9 million) were slightly down year on year but still represented the second-best turnover in the company’s history and stood seven percent higher than sales in 2007. Reflecting the company’s decision to maintain its high levels of investment in R&D and to continue to employ the largest development team in the CAM industry, the group’s profitability declined compared to 2008. “The reduction was in line with expectations and we anticipate profitability moving higher in the current financial year,” said Mr Miles. The high value that Delcam’s customers place in its product development was seen in the growing revenues from maintenance contracts. These 10

metalworking equipment news April 2010

contributed £10.7m to the 2009 total and showed a year-on-year increase of 10 percent. Looking to the future, Mr Miles commented: “Uncertainty over the timing and strength of the recovery in the global economy continues to make it more difficult than usual to forecast accurately. However, the continued growth of recurring revenues, from annual software maintenance and support income, and the increase in new software sales in the later part of 2009 give us cause for confidence.” “Our policy of offering a wider range of products and services across a broader number of industries, together with our strong balance sheet, puts us in a better position than many of our competitors,” he continued. “We continue to view prospects for the business over the long term very positively.”

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Gildemeister & Mori Seiki Combine Their Activities In The USA & India Bielefeld, Germany: Gildemeister and Mori Seiki are combining their activities in the traditional USA market and the growth market of India. Both companies have agreed to join all their sales and service activities into one company as of 1 April 2010. The DMG/Mori Seiki USA with registered office in Chicago (USA) will be responsible for customer service, the spare parts business, training measures and technical support among other areas. The two enterprises now want to push sales in the traditional USA market jointly. Customers will benefit from a considerably stronger sales and service organisation and will be able to select the most suitable solution from a wide product ranges of both manufacturers. The USA cooperation creates a high additional advantage for customers: They receive high-quality services that are appropriate to their individual production requirements. “Our joint innovative customer focus allows us to approach the challenges posed by the international economic crisis in a targeted manner and to master them,” Dr Rüdiger Kapitza, the chairman of the Gildemeister executive board, explained the reasons for the joint USA approach, which follows on from cooperation activities that have already been successfully implemented in other markets. In the growth market of India, both companies are also combining their sales and service operations as of 1 April 2010. The DMG/Mori Seiki India in Bangalore (India) will be responsible for the complete service and support of the entire product portfolios of both manufacturers. The employee know-how and the technologies of both enterprises complement each other. “Bringing together high-quality technologies and a strong sales and support organisation creates efficiency advantages for everyone,” Dr Masahiko Mori, president of Mori Seiki stated. Both companies are expanding their presence in the fast-growing Indian market and are jointly investing in a new technology centre with a showroom. There, extended solutions for the Indian market as well as products to suit the precise needs and desires of customers will be presented.

Singapore Companies Expanding In Vietnam Singapore: Since the establishment of the SingaporeVietnam Connectivity Framework Agreement in 2005 to promote economic cooperation between Singapore and Vietnam, Singapore companies have broadened their economic interests in Vietnam. Said Chiong Woan Shin, IE Singapore’s regional director of Vietnam and Cambodia: “Regional cities in Vietnam such as Hai Phong City, Danang City and Can Tho City hold good potential for Singapore companies as they offer new business and investment opportunities for Singapore companies. Being relatively less developed than the traditional investment hotspots, there is less competition and hence more room for growth.” “Northern Vietnam, with its close proximity to China and manufacturing bases of multinational companies such as Canon and Samsung, is suitable for Singapore manufacturers who are looking to set up overseas plants. Singapore players can also serve the transportation and logistics needs of North Vietnam’s manufacturing base, as well as the Mekong Delta area in Southern Vietnam, which is the base for the country’s vast agricultural and aquaculture produce.” In 2009, despite the economic downturn, Vietnam registered a positive GDP growth of 5.3 percent, the highest in Southeast Asia. The country also continued to attract foreign investments in 2009, with a total FDI inflow of US$21.5 billion, a 20 percent increase from two years ago. Vietnam also experienced its lowest inflation in six years in 2009 - 6.9 percent, compared to 23 percent in 2008. For 2010, the Vietnamese government has targeted a 6.5 percent growth in GDP, as well as a controlled inflation rate of seven percent.

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metalworking equipment news April 2010


Caltech Researchers Develop Nanoscale Structures With Superior Mechanical Properties Pasadena, USA: Researchers at the California Institute of Technology (Caltech) have developed a way to make some notoriously brittle materials ductile – yet stronger than ever – simply by reducing their size. The work, by Dongchan Jang, senior postdoctoral scholar, and Julia R Greer, assistant professor of materials science and mechanics at Caltech, could eventually lead to the development of innovative, superstrong, yet light and damage-tolerant materials. These new materials could be used as components in structural applications, such as in lightweight aerospace vehicles that last longer under extreme environmental conditions and in naval vessels that are resistant to corrosion and wear. The scientists devised a process to make zirconium-rich metallic glass pillars that are just 100 nanometers in diameter – roughly 400 times narrower than the width of a human hair. At this

size, Ms Greer says, “the metallic glasses become not only even stronger, but also ductile, which means they can be deformed to a certain elongation without breaking. Strength plus ductility,” she says, represents “a very lucrative combination for structural applications.” As yet, there are no immediate applications for the new materials, although it may be possible to combine the nanopillars into arrays, which could then form the building blocks of larger hierarchical structures with the strength and ductility of the smaller objects. The work, however, “convincingly shows that ‘size’ can be successfully used as a design parameter,” Ms Greer says. “We are entering a new era in materials science, where structural materials can be created not only by utilising monolith structures, like ceramics and metals, but also by introducing ‘architectural’ features into them.”

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April 2010 metalworking equipment news



MHI Achieves Mass Production Of HollowHead Engine Valves Tokyo, Japan: Mitsubishi Heavy Industries (MHI) has completed a mass production system for lightweight, high-strength ‘hollow-head’ engine valves employing forging technology that enables hole-forming from the valve stem to head in one process. The forging technology was achieved based on the company’s production know-how in hollow valves for aircraft engines. With hollow valve heads, overall valve weight can be reduced by up to 20 percent compared with solid valves. The technology has also cut hollow-head valve production costs. The company expects demand for this valve type to increase going forward, and is targeting shipments of 1.5 million units in 2014, mainly for the automobile industry as a key measure to improve fuel efficiency as CO2 emission controls become increasingly tighter worldwide. With the company’s hollow-head valve production technology, the hollow is formed during the forging process; no equipment is required other than the forging press. The elimination of conventional boring by drill or electric spark machining enables low-cost mass production. As the company’s production method performs consecutive forming of the hollow-head valve from cylindrical metal material mainly during cold-forging, a reduction in processing time is achieved. To realise maximum benefit from hollow valves, the company analysed various factors - shape of the hollow, valve strength and generated stress and studied how to form shapes that conventional machines have been unable to form. Because hollow valves can add to cooling efficiency through improved thermal conductivity by encapsulating sodium (natrium) in the hollow, the heat resistance of exhaust valves can also be increased, enabling accommodation of the higher exhaust temperatures associated with high-efficiency engine combustion. Coupled with reduced friction loss due to weight reduction, hollow valves can boost fuel efficiency substantially, thereby contributing to reduced CO2 emissions. MHI’s Machine Tool Division has already established a production structure capable of producing 25,000 hollow-head valves per month. It has also started shipments of samples mainly to automobile manufacturers, and launched development of customised products reflecting the diversified needs of users and the results of their evaluation testing. 14

metalworking equipment news April 2010


Walter AG Gets New CEO

Andreas Evertz

Tübingen, Germany: Following the decision of the supervisory board, Andreas Evertz will become the new CEO of Walter AG with effect from 1st April 2010. Mr Evertz joined Walter AG in 2008 and is responsible for R&D, logistics and production on the executive board. He has been acting as Deputy CEO since October 2009.

New President & CEO For Leica Geosystems

Jürgen Dold

Heerbrugg, Switzerland: Jürgen Dold will assume the position as president and CEO of Leica Geosystems as of 1 April 2010. Dr Jürgen Dold has a track record and a keen understanding of the geospatial and geomatics markets. He has been with the company since 1995 and currently holds the position as president of Geospatial Solutions Division of Leica Geosystems.

Posco-VST Examines Investment In South-East Asia Seoul, South Korea: Posco is looking to expand its sales and market share in the South-east Asian market by increasing investment in its cold rolled stainless steel production facilities in Vietnam. Considering the strategic importance of the Vietnamese market in the region, the company plans to upgrade its production facilities at Posco-VST gradually, from the current 80,000 tonnes per year, to 200,000 tonnes in the foreseeable future. As the first step, the Vietnam-based joint venture plans to use 40,000 sq m of vacant land it currently possesses.

Tungaloy Singapore Pte. Ltd. 50 Kallang Avenue, #06-03 Singapore 339505 Tel: (65) 6391 1833 • Fax: (65) 6299 4557


Tungaloy Malaysia Sdn Bhd (876763-H) 50 K-2, Kelana Mall, Jalan SS6/14 Kelana Jaya 47301 Petaling Jaya, Malaysia Tel: +603-7805 3222 • Fax: + 603-7804 8563


Bombardier To Open Regional Support Office In Mumbai

Montréal, Canada: Bombardier Aerospace will open a Regional Support Office (RSO), in Mumbai, India – further strengthening its support for customers in this country. This will be the company’s fifth support office to open in the past three years worldwide and is expected to begin operation in the second quarter of fiscal year 2010/11. The RSO in Mumbai will align the company’s existing business aircraft and commercial aircraft support services in the region situated in New Delhi, Bangalore and Mumbai at the same location. Since embarking on its worldwide customer support

expansion strategy in 2007, Bombardier has opened new RSOs for its commercial aircraft customers in Tokyo, Japan; Sydney, Australia; Shanghai, China and Munich, Germany and has added service and support representatives in these regions. Bombardier’s plan to establish strategically located RSOs is designed to provide a support package encompassing aircraft technical expertise, flight operations support and customer account management functions. As a result of the proximity to its operators’ bases, the company can provide quicker service to customers in their language and time zone.

Iscar Launches The Tool Advisor

Israel: Iscar has developed the Iscar Tool Advisor (ITA), a parametric search engine that takes computer-aided tool and process selection to a new level. The resource is available for free at the company website. The user’s proprietary information is secure at all times. ITA ‘thinks’ like a process engineer, runs as easily as the most popular PC or Mac search engine, and provides real-world solutions to the desired level of detail. The right tool for the job is selected, based on a knowledge base of best practices worldwide. Three key features separate ITA from the other available tooling search engines: • Quick Search/Advanced Search Option With three application facts, the quick search 16

metalworking equipment news April 2010

provides starting ideas and processing strategies, with priority by productivity. The advanced search option takes more comprehensive application input, helps the user narrow down choices and delivers an optimum solution. • Accommodates Shop Preferences & Variables The user can stipulate such preferences as solid vs indexable tooling, tool brand/family as well as productivity/tool cost and power management priorities. • Processing Solutions, Not Just Tooling Solutions With advanced search, the user can get recommended machining parameters for a given shop environment, as well as a short list of tooling solutions.

Easy Navigation

Once the user logs on, ITA can be run either independently or with a field-representative’s assistance. It is designed mainly for independent use. A busy tooling engineer can readily get what he/she wants, to the desired level of detail, at any stage of process development or tooling selection.


JTC & EDB Unveil Masterplan For CleanTech Park Singapore: JTC Corporation (JTC) and the Economic Development Board (EDB) jointly unveiled the master plan for the 50 hectare CleanTech Park at Nanyang Avenue. As Singapore’s first ecobusiness park, CleanTech Park will be the choice location for forward-looking corporations that have embraced environmental sustainability as a means to differentiate their business and also as part of their corporate social responsibility. This development will push the boundaries of green sustainability, serving as a large-scale integrated ‘living laboratory’ for testbedding and demonstration of system-level clean technology solutions. The park will house a core nucleus of cleantech activities to serve as an epi-centre for research, innovation a nd commercialisation in clea n technology. Building on the synergies of being located next to Nanyang Technological University (NTU), CleanTech Park will also house R&D activities from the university. This will foster a conducive environment which promotes collaborations between industry and academia, and unleashes the economic

potential created from these collaborations. The development of the park will be carried out in three phases over 20 years. Phase one will commence in July 2010, starting with the development of the infrastructure within CleanTech Park. When completed, phase one will provide approximately 17 ha of business park land. The park will house a working population of 20,000 when it is fully built by 2030. In line with the overall national effort towards sustainable growth, the park is a key initiative outlined in the S$1 billion (US$712 million) Singapore Sustainable Blueprint for building a greener, more energy efficient and sustainable Singapore. The development also contributes to Singapore’s goal to be a ‘living lab’ where companies can use Singapore effectively to develop, test-bed and commercialise green and urban solutions before scaling up for the Asia-Pacific region and beyond. The Singapore government is committed to growing the cleantech industry as a key cluster which is expected to contribute some S$3.4 billion to Singapore’s GDP and employ 18,000 people by 2015.

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April 2010 metalworking equipment news



Launch Of Asia’s First Shippers’ Academy

Singapore: The local and regional shippers’ community reached a milestone with the launch of Asia’s first shippers’ academy – the Singapore Shippers’ Academy (SA) in Singapore. The Academy aims to bridge the gap in the continuous education and training (CET) landscape for the community and raise standards to the next level by providing comprehensive education and training needs tailored for shippers. IE Singapore and SPRING Singapore are supporting partners of the academy, which is funded under the Local Enterprise and Association Development (LEAD) Programme. The academy is the brainchild of the Singapore National Shippers’ Council (SNSC) – a national body representing cargo owners, including importers, exporters, manufacturers and international traders. The council is known for having played pivotal roles in the shippers’ community locally, regionally and internationally. Currently, training programmes in the marketplace are either too generic or too specialised for logistics and business professionals and catered for service providers, with nothing specific for shippers. SNSC addresses this problem by setting up the SA and bringing together industry leaders, experts and

shippers to provide specialised shippers-centric curriculum and training. The academy’s launch is timely and resonates with recommendations made recently by the Economic Strategies Committee and initiatives proposed in the Singapore 2010 Budget, encouraging productivity and innovation. John Lu, chairman of SNSC, shared: “We are in constant pursuit to advance productivity and innovation for shippers, especially SMEs. From market observations and feedback, we know that shippers can benefit from better understanding of international trade, supply and value chain and security issues. Unfortunately the lack of quality education and training programmes to improve knowledge and expertise among shippers is holding us back from achieving the values we seek. With the Singapore Shippers’ Academy and our international connection, we will overcome this hurdle and help international traders achieve meaningful and enriching life-long learning.” Chong Lit Cheong, CEO of IE Singapore, said: “The Academy will provide customised training programme to the shippers community. With greater competency, Singapore companies, especially the SMEs will be able to compete more efficiently in an increasingly complex trading environment.”

Dassault Systèmes & BMW Sign Sustainable Innovation Agreement Singapore: BMW and Dassault Systèmes (DS) have signed a strategic 5-year global agreement to pave the way to meet the automotive market’s new challenges. Through this agreement, the companies will establish a close link between their research and development centres that will not only improve the DS automotive product offering but also the BMW development and production process. 18

metalworking equipment news April 2010

The necessity to reduce C02 emission levels has forced automotive manufacturers to reshape their business processes to deliver greener cars. Fully embracing the cause of leaving a minimum carbon footprint on the planet, the implementation of the DS solutions will help automakers conceive, analyse and simulate eco-friendly low-emission vehicles like the Project I, a new Megacity vehicle, optimised for better performance and low energy consumption.

Dörries Dörries Dörries Scharmann Scharmann Scharmann ––your –your your partner partner partner for for for South South South East East East Asia Asia Asia Dörries Dörries Scharmann Dörries Scharmann Scharmann offersoffers a wide offers a wide range a wide rangerange of machine of machine oftools machine tools for drilling, tools for drilling, forturning, drilling, turning, turning, boring, boring, milling boring, milling and milling grinding and grinding andof grinding medium of medium of medium and large and large and size large components. size components. size components. The product The product Therange product range includes range includes vertical includes vertical vertical turning turning lathes, turning lathes, high-speed lathes, high-speed high-speed machining machining machining centres, centres, machining centres, machining machining centres centres incentres portal in portal in portal and gantry and gantry and design gantry design anddesign vertical and vertical andgrinding vertical grinding grinding machines. machines. machines. DST isDST facing isDST facing theis future facing the future in thea strong future in a strong in commera strong commercommercial position cial position cial with position awith range awith range of ahigh-tech range of high-tech of high-tech products, products, which products, which are fiwhich nding are finding are markets finding markets with markets with with majormajor international major international international manufacturing manufacturing manufacturing companies companies companies and providing and providing andinnovative providing innovative innovative and and and economic economic solu economic tions solutions insolu thein tions sectors: theinsectors: the sectors: - Aerospace - Aerospace - Aerospace - Oil and - OilGas and - OilGas and Gas - Power - Power Generation - Power Generation Generation - Marine - Marine Equipment - Marine Equipment Equipment Production Production Production - Large - Large Diesel - Large Diesel Engines Diesel Engines Engines

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CAAS Steps Up Efforts To Boost Aviation Industry In Singapore

Singapore: The Civil Aviation Authority of Singapore (CAAS) unveiled plans to drive the development and growth of the aviation industry in Singapore. Following a major restructure of CAAS last year, apart from regulating the industry and providing air navigation services, CAAS is also focusing on building a vibrant and sustainable aviation industry that will continue to make a key contribution to Singapore’s economy. At the inaugural Aviation Community Reception, Raymond Lim, Minister for Transport and Second Minister for Foreign Affairs, announced that CAAS

is introducing an Aviation Development Fund (ADF) with a budget of $100 million over the next five years to promote and develop the aviation sector. Under the fund, various incentive programmes will be introduced to support the development of capabilities in the Singapore aviation industry and ensure its continued competitiveness and dynamism. Built around the three thrusts of enabling enterprise, ideas and people, the ADF programmes will also support broader industry-level initiatives to raise effectiveness and competitiveness through government-industry partnerships. Two ADF programmes, of $25 million each for the next five years, will be launched in April 2010. These are the Aviation Partnership Programme and the Aviation Innovation Programme. Under the Aviation Partnership Programme, CAAS will partner the industry to drive the adoption of new industry-wide standards or processes to enhance its overall productivity, effectiveness and competitiveness. The Aviation Innovation Programme will provide assistance to companies to develop new capabilities, encourage innovation and build aviation knowledge in Singapore. The aviation authority is finalising the details of the programmes as well as others that could be rolled out subsequently, to support manpower development, skills upgrading and overall industry promotion. Like the Aviation Partnership Programme and Aviation Innovation Programmes, these programmes will be developed in close consultation with the industry.

Boeing Production Rate Increases To Meet Demand

Airbus To Increase A320 Production Rate

Seattle, USA: Boeing will accelerate planned rate increases on both the 777 and 747 programs. The accelerated rate increases will support increasing customer demand in the recovering airplane market. “Our customers recognise the capability and value of the 777 and 747-8,” said Boeing commercial airplanes president and CEO Jim Albaugh. “Market improvement and our managed approach to production have put us in a position where we see it necessary to raise aircraft output. Increasing our rate is the right thing to do to support our customers.” The company will accelerate the 777 program’s rate increase to seven airplanes per month (from five per month) by approximately six months, from early 2012 to mid-2011. The 747 program’s planned production rate increase to two airplanes per month (from 1.5 per month) will move from mid-2013 to mid-2012. Suppliers for both the 777 and 747 will be prepared to support the accelerated rate increases.

Toulouse, France: Airbus will increase the monthly production rate for its single-aisle A320 family from the current rate of 34 to 36, starting December 2010. The production rate for the long-range A330/A340 family will be maintained at the current level of eight per month. The company’s decision to raise its single-aisle production rate is driven by the continuing demand for its eco-efficient aircraft and a record backlog in excess of some 2,300 A320 aircraft. “Leading economic indices and business confidence indicators are showing an upward trend again. We see this reflected in the continuing solid demand for our eco-efficient products and our robust backlog,” said Tom Williams, executive VP, programmes. Airbus delivered a total of 498 aircraft in 2009, including 402 A320 aircraft, both new company records for a single year. The company target for deliveries in 2010 is to remain at a similar level to 2009.

Noel Abejo, Philadelphia, USA


metalworking equipment news April 2010

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Nippon Steel Invests In Malaysian Steel Sheet Manufacturing Firm Tokyo, Japan: Nippon Steel Corp has been in discussion with Yung Kong Galvanising Industries (YKGI), a Malaysian steel sheet manufacturing firm, on possible investment in and stable supplies of hot-rolled steel substrates to YKGI. Nippon Steel has now reached an agreement with YKGI to subscribe for redeemable convertible preference shares which will be newly issued by YKGI (if converted, equivalent to 10 percent of the total number of ordinary shares of YKGI) around June 2010. Under a stable political and economic system along with currency and financial policy, Malaysia achieves continuous economic development to the present by attracting foreign investors. Domestic steel demand expansion is regarded as sureness based on high growth rate of population and ratio of younger generations in the future, and demand for flat steel products in Malaysia is expected to grow steadily not in the manufacturing industry alone, but in the construction industry. By investing in YKGI, the company aims to strengthen their relationships and securely capture flat steel demand which is expected to grow steadily in Malaysia, by expanding its business with YKGI through stable supply of hot-rolled steel substrates to the company.

Powder Metal Group Releases Technology Video New Jersey, USA: Powder Metallurgy: The Preferred Metal-Forming Solution, a video showcasing the fabrication capabilities of the various technologies known collectively as Powder Metallurgy (PM), has been released on DVD by the Metal Powder Industries Federation. The 13-minute program, built on the theme, “Every day, in some way, PM touches your life,” uses dozens of examples of actual components manufactured for many different applications to illustrate the benefits PM offers parts designers and engineers. The video is aimed principally at potential end users who may not be familiar with the capabilities of conventional PM, Metal Injection Moulding (MIM), Hot Isostatic Pressing (HIP), and other PM technologies. The narrated piece serves as a brief introduction to the real-world advantages of these forming processes, with particular emphasis on their contributions to the concept of sustainability. PM parts producers should find the DVD a tool with which to equip their sales and marketing personnel. It is a suitable vehicle to use as a seminar introductory piece. Moreover, companies involved in any aspect of PM can use it to orient all employees, as it quickly stimulates an appreciation of the value they bring to customers’ products.


Steelmakers Recycle 99.8 Percent Of Metal Slag

Michael Lorenzo, Pasig, Philippines

Seoul, South Korea: About 99.8 percent of metal slag, a by-product in steel production, was recycled by South Korean steel makers last year, according to a report by the Korea Iron and Steel Association. Of the 16.7 million tonnes of slag produced in 2009, 16.67 million tonnes was recycled, surpassing the 95 percent target set by the government. 22

metalworking equipment news April 2010


Regulations on conservation of resources and enhancement of recycling require makers to adhere to the government-set recycling target for metal slag, with efforts to improve the rate within a technically and economically available scope. By uses, all of the 8.86 million tonnes of blast furnace slag produced was recycled. Some 76.4 percent was used as an ingredient for cement, followed by 4.8 percent for siliceous fertiliser and 0.3 percent for aggregate fill-up. A total of 7.83 million tonnes of steel-making slag was produced last year, with 43.2 percent used for production of aggregate fill-up and 27.2 percent for roadwork. This year, steel makers are expected to contribute to reducing carbon dioxide emissions and help establish a resource-recycling society by speeding up the development of technologies to expand uses of slag, including ways to use steel slag for marine purposes.


Korean Machine Tool Industry In 2010

Outlook In 2010 Domestic machine tool market is expected to recover by the end of second quarter of 2010, boosted by the budget expansion of the government. The international market demand is expected to reach 4,400 billion KRW (US$3.8 billion) in 2010, which is 29 percent increase compared to the previous year. Concerning exports, it is expected that markets of China, India and South America are going to recover. The object-economy of developed nations is improving, and it is expected that exports demand will reach

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US$150 million, which is 25 percent increases compared to the previous year. On the other hand, imports will be affected by increased system investment and dropping currency rate, and it is expected to reach US$130 million (18 percent increase compared to the previous year). Korean Machine Tool Industry Overview (Value: US$ million)





























P (primarily) F (forecast)

Imports Consumption

Source: KOMMA

Thailand Winterthur Technology Co., Ltd. Thailand Thailand 947/37, 8th Floor Thosapol Land, Building 4, Bangna Winterthur Winterthur Technology Technology Co.,Ltd. Ltd. 10260 Bangkok Co., 947/37, 947/37, 8th 8thFloor Floor2Thosapol Thosapol Land, Land,Building Building4,4,Bangna Bangna Phone: +66 744 1577 10260 10260 Bangkok Bangkok Phone: Phone:+66 +6622744 7441577 1577 Malaysia Winterthur Technology (Malaysia) Sdn. Bhd. Malaysia Malaysia No. 22, 1st Floor, Jalan Putra Mahkota 7/6A Winterthur Winterthur Technology (Malaysia) (Malaysia) Sdn. Sdn. Bhd. Putra Technology Heights 47650 Subang JayaBhd. No. No.22, 22, 1st 1stFloor, Floor, Jalan Jalan Putra PutraMahkota Mahkota7/6A 7/6A Selangor Darul Ehsan Putra PutraPhone: Heights Heights 47650 47650 Subang Subang Jaya Jaya +60 35 191 0534 Selangor Selangor Darul DarulEhsan Ehsan Phone: Phone:+60 +6035 35191 1910534 0534 South Korea Winterthur Technology (Korea)Ltd. South South Korea Korea Bucheon Technopark 3 304-704 Winterthur Winterthur Technology Technology(Korea)Ltd. (Korea)Ltd. 365 Samjeong-Dong 304-704 304-704 Bucheon Bucheon Technopark Technopark33 Ohjeong-Gu, Kyungki-Do 365 365Samjeong-Dong Samjeong-Dong Phone: +82 32 310 1000 Ohjeong-Gu, Ohjeong-Gu, Kyungki-Do Kyungki-Do Phone: Phone:+82 +8232 32310 3101000 1000 China Wendt Precision (Taicang) Co. Ltd. China China GreenLand Building No. 2, Room 910, Wendt Wendt Precision Precision (Taicang) (Taicang) Co. Co.Ltd. Ltd. No. 58 Xinjian East Road, Xinzhuang GreenLand GreenLand Building Building No. No.2,2,Room Room910, 910, Shanghai 201100 No. No.58 58 Xinjian Xinjian East East Road, Road, Xinzhuang Xinzhuang Phone: +86 21 5301 4751 Shanghai Shanghai 201100 201100 Phone: Phone:+86 +8621 215301 53014751 4751

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24.2.2010 16:49:42 Uhr


Seoul, South Korea: The machine tools industry of South Korea in 2009 experienced a great fall in the first quarter due to the global recession. But, despite the poor demand rate from international markets, the government’s budget expansion, launching of new vehicle models and tax-cut on old vehicles revived the domestic vehicle market, which revitalised the machine tool industry as well. As a result, domestic machine tool industry is expected to recover its level to the rate in 2007, thanks to increased demands from manufacturing industries such as vehicle industry, semiconductor industry and display industry.

24.2.2010 24.2.2010 16:49:42 16:49:42Uhr Uhr

April 2010 metalworking equipment news




Tools For Aerospace Industry:


Tools of better quality and performance are a must to cater to the high flying aerospace industry. Submitted by Yvonne Ng, marketing manager, Walter AG Singapore


or the tool manufacturer Walter, the aerospace industry is an impor ta nt driver for new developments. For years the standard range for aerospace applications has been experiencing important additions. The ‘Aerospace Engineering’ department also draws up a large number of special solutions. In the aerospace industry, many things are different compared to other areas of machining. The parts are very complex and difficult to machine. In addition, the materials are extremely variable, new materials are developed at breathtaking speed.


metalworking equipment news April 2010

For a long time, aluminium was the standard material; this situation has now changed. The portion of aluminium in the latest generation of aircraft (Boeing Dreamliner and Airbus A350 XWB) is only around 20 percent. Half of a modern jet is made up of composite materials (GFRP, CFC). Titanium materials are also becoming increasingly important. Another material group is the high-temperature materials that are primarily used in the engine area: high-alloy steels, cobalt and nickel-based alloys. The tendency is for these problem materials to become more difficult to machine, as new, stronger alloys are continuously developed.

Over and above these aspects, there are further peculiarities due to safety stipulations. Many manufacturing processes are subjected to strict manufacturing regulations. Often the cutting data or the coatings for the tools are pre-defined. L a b o r a to r i e s c h e c k t h e condition of the parts at great expense; that is whether, eg: unde sirable microstructure changes have occurred under the pressure from the tool’s cutting edge. As a consequence, process reliability is a priority for the machinist. Scrap will be expensive due to the exotic materials and expensive machining. In view of these boundary conditions, it is only possible to fine tune productivity aspects with great care. On the other hand, increases in productivity are urgently needed given the capacity situation in the sector: the demand for new aircraft is very high. The available manufacturing capacity is scarcely adequate. T here is t here fore i nte n se competition for any machine capacity that becomes free. Mix Of Solutions & Standard Bernard Jageneau, EA manager for the Aerospace Engineering department at the Tubingenbased tool manufacturer Walter, is a specialist for the tightrope act between productivity and manufacturing regulations. He emphasises: “In many cases, special solutions are vital. This statement applies particularly in the engine area.” A trend, continues Mr Jageneau, is the preparation of complete machining solutions. The manufacturers of aircraft parts are increasingly using tool solutions from a single source. An example of a special solution: the tool set for machining an impeller made of Ti6Al4V also includes a solid carbide cutter with 16 mm diameter and relatively


high number of teeth, five. Walter produces the milling cutter from a special carbide – and that is without a coating. Due to the regulations, the manufacturing processes have often been frozen for years. For this reason rationalisation projects often involve the replacement of older HSS tools with modern carbide successors. A HSS milling cutter (D = 30 mm, Z = 5) was used, for instance, for pocket milling on a part for the engine on the A320 made of Inconel 718. The company replaced the tool with a custom milling cutter with indexable insert F3038 (D = 32 mm, Z = 3). The increase in productivity due to the change from HSS to carbide is enormous: in the case described, an increase in the feed rate of 80 percent was achieved. New Cutting Tool Materials There have been some changes in recent years particularly in cutting tool materials and coatings. In the meantime, indexable inserts are available both for the complete milling cutter range from Walter and also for turning. The manufacturing feature is the deposition of the aluminium oxide hard coating using the PVD process. Before the company achieved this breakthrough, the process was limited to hard nitridic materials. Indexable inserts coated using the PVD process are very tough. The aluminium oxide also ensures a high level of hardness and high temperature wear resistance. The combination of both properties is particularly desirable on machining high-heat resistant materials. On milling cutters smaller than 50 mm in diameter, in the majority of cases solid carbide cutters such as the Prototyp Protostar Ti40 is suitable for roughing and finishing tasks. The developers improved the fine tuning of the tool for machining the latest alloys: a carbide substrate was developed, a coating (AlCrN)

Indexable inserts are available for the complete milling cutter range as well as in numerous ISO versions for turning. The cutting tool materials are suitable for machining high-heat resistant engine materials

and an optimised microgeometry; the shank was treated for the high torque transfer. Equipped in this manner, the Ti40 permits machining rates at the limit of feasibility. This machining includes, for example, slot milling up to 1.5xD at cutting speeds up to 80 m/min in materials such as TiAl6V4. “Exact fine tuning to the new materials is a trend in standard tools,” states Mr Jageneau, “as in the future we will have to deal with increasingly difficult materials to machine, for example Ti5553, exactly matched tools are in increasing demand.” A further example: for the manufacture of so-called flap tracks made of TiAl6V4, these are parts of the mechanism for the flaps. For a long time a milling cutter with indexable insert with 50 mm diameter and Z = 5 was used. The Walter Aerospace Group modified the process to the Protostar Ti40

with 16 mm diameter and Z = 4. It was possible to increase the metal removal rate from 25 cm3/min to over 90 cm3/min. More Reliability During Threading The last of the machining processes often includes threading. The manufacture of threads is often a delicate undertaking in particular on aircraft parts. If the tool jams in the hard material, the part is generally scrapped. Due to the manufacturing regulations, repairs by spark erosion are hardly possible, as unacceptable microstructure changes would have to be expected. As a consequence, reliable threading tools are required. The company is tackling this requirement with the orbital April 2010 metalworking equipment news



thread milling cutters made of solid carbide, among other ways. These tools are available for threads from M1.6 to M12 and thread depths up to 2xD and 3xD. A special milling strategy for use on machines with 3D CNC control ensures quality and process reliability, particularly in the case of binding materials such as titanium alloys: the tool plunges into the core hole to thread depth and mills, following a helix, quasi in reverse. The result is thread true to gauge over the entire length. C o m p a r e d to H S S t a p s , with the orbital thread milling cutters cutting speeds 10 times higher are possible in some cases. The tool life is also 10 to 20 times higher. A thread is finished in a few seconds. A special cooling lubricant is not necessary, the thread milling cutters achieve this performance with conventional emulsion. To ensure the programmer saves time on the implementation o f t h e s t r a t e g y, t h e t o o l manufacturer supplies the raw prog ra m toget her w it h t he software TEC/CCS. This software also provides a wide range of support during the selection of tools and cutting data for a very wide range of processes. The material data for many materials used in the aerospace sector are included in the database. Fo r t h e m a n u f a c t u r e o f thre aded sleeve s made of Ti99,5, the company supplied the orbita l thread milling cut ter i n a cu stom version for 10-30UNF-3B threads with t he re sp e c t able dept h 5x D (20 mm). The milling process was divided into two cutting actions. The tool life was 1,700 t h re a d s. D e sp ite t he l a r g e t hre ad dept h, t he tool wa s not pushed to the side. The results were absolutely true to gauge. An idle cut was also not necessary. 26

metalworking equipment news April 2010

Innovations For Aerospace Applications In the aerospace sector, the demand for optimised tools is particularly high. Especially for boring composite materials (GFRP, CFC), a PCD twist drill is supplied. The diameter range is 2 mm to 6.4 mm. The PCD cutting edges, also spiral in shape, are manufactured using sintering technology. This a spect gives the tool a high level of process reliability. Failures due to the failure of brazed joints do not occur. The optimised cutting edge geometry prevents delaminations (fibre residue) at the exit to the hole. For more flexibility during m i l l i n g , Wa l te r d e v e l o p e d

t he mo du la r m il l i n g cut ter system ConeFit, comprising solid carbide milling tips and toolholders made of steel. The heart of the system is a selfcentring precision mounting thread, a mixture of buttress and trapezoidal threads. A ground cone ensures exact concentricity, an axial support face guarantees rigidity and as a result process reliability. The system was developed not just for aerospace applications, due to its versatility it is however suited to this sector. The range of milling tips available comprises roughing and finishing versions as well as contour and profile milling cutters in a wide range of forms. Enquiry No. 3001

Walter: Inserts For Aerospace Industry

The increasing importance of titanium materials in aerospace technology and medical technology requires optimised tool solutions. Walter is tackling this challenge with the Skytec family. As a result, turning titanium materials with the inserts (eg: Ti6Al4V and others) will in future be more cost effective and reliable. Three geometries from the maker will make it possible. NFT: for finishing to the highest accuracy; high cutting speeds; circumference-sintered or circumference-ground version. NMT: for medium machining; unstable components and internal machining; low cutting forces thanks to curved cutting edge; circumference-sintered. NRT: for roughing; high machining volume thanks to more rigid geometry; circumference sintered. MEN Enquiry No. 3002



Machine Utilisation:

Back To The

Drawing Board


roductivity improvement is all around us. We are seeing 5-axis and multifunction machine tools or simultaneous machining with both static and rotating tools of identical design. Manufacturers are cutting at higher speeds on more rigid, accurate, and flexible machines, using advanced cutting tool materials and controls that allow innovative part processing and use programming functions for tool management, gauging, and in-process tool sensing. They have adopted modular workholding devices, in-process


metalworking equipment news April 2010

‘The way we have always done it’, no longer suffices in today’s manufacturing climate. By Curtis Rellick, global product manager, tooling systems, Kennametal

and post-process gauging for workpiece and cutting tool with feedback for tool compensation, and tool condition sensors, along with tool identification and management software that interfaces with gauging, storage, tool kitting, and production software. Yet these are not technology breakthroughs that will displace traditional machining methods for lathes, machining centres, and transfer lines. Outstanding results can be derived by using the technology we have on hand effectively. This also requires

going beyond tribal knowledge and establishing standardised, open processes that can be used by all. What is needed is new thinking for implementing an improved machine utilisation strategy. Tr iba l k nowledge is a ny u nw r it te n i n for m at io n not commonly known by others within a company. This term is used most when referencing information that may need to be known by others in order to produce quality products or services. By nature, tribal knowledge contributes to an ‘our way of doing things’ mentality, one that creates


resistance to change or outside knowledge. Such closed thinking is a death knell to a manufacturing company when competitors or entire industries are stressing continuous waste-cutting and productivity improvement in r e s p o n s e to e v e r- g r o w i n g customer demands. Beyond Cutting Alone Process improvement is more than faster spindles or multifunction machines. It begins with understanding the three functional areas of the manufacturing process - inventory planning and control, pre-production planning and setupreduction programs, and in-process manufacturing. Producing smaller lots more often can slash inventory carrying costs and eliminate shelf-life problems like rust, contamination, and deterioration. Instead of producing one 8,000 unit lot of goods to deplete over a fourmonth period, a cost-effective approach is to produce four lots of 2,000 units at one-month intervals. Reducing the average inventory from 4,000 to 1,000 units cuts carrying costs by 75 percent and reduces shelf-life problems. However, achieving these savings means increasing setup time by 300 percent. Conventional tooling systems, setup procedures, and production planning are about 20 percent efficient today. With

Given an improved level of preparation, KM quick-change tooling can push productivity gains even further

60 percent of available machine time traditionally used in setups, and idle and stop time absorbing 10 percent each, only 20 percent remains for cutting. To improve machine and operator efficiencies and minimise machine downtime during tool and part changes, we need to eliminate that 60 percent bite into machine time. Listed below are products and services we recommended that when used as a machine utilisation strategy provide significant cost savings. • Adva nced Cutting Tool M a te r i a l s – i n c r e a s e s production by utilising the most advanced cutting tools which enable you to run faster and longer between tool changes. • Tool Kitting – provides all the tooling necessary (including fixturing) to complete a production run or shift of operation. • P r e - G a u g e d To o l i n g – e l i m i n a te s t i m e sp e n t measuring cuts during the set-up process, reduces the risk of human error at the machine control and provides a quick and efficient method for changing worn tools. • A specific system designed to facil itate t he e f fe c t ive

ma nagement of cutting to ols t hat is e qua lly effective in controlling other types of inventor y and consumable goods. Such a manufacturing strategy tra nsfers tool ma intena nce from the machine tool to the tool room, thereby improving tool maintenance, increasing machine uptime and productivity, and decreasing nonconforming percentages. Tool Kitting The objective of tool kitting is to eliminate time spent searching for tools and performing onmachine tool maintenance. It pulls together all tools required to complete a production run or shift of operation and places them in a tool ta xi near the machine. When tool change is necessary, the process is quick and efficient, permitting more machine run time and increasing productivity. Once all necessary tools are fitted with new cutting edges and assembled in the tool taxi, the ‘F’ and ‘L1’ dimensions should be measured and recorded for each tool. This data will later be used for making offset adjustments following tool changes. A d d i t i o n a l l y, a l l t o o l maintenance is performed in advance of the production run to avoid catastrophic tool failure and in-process tool maintenance. The objective of pre-gauging and preproduction tool maintenance is to eliminate lost production time due to the following: • Insert and insert pocket cleaning • On machine tool maintenance • Measuring cut • Manual test cuts • Gauging • Computations • Offset adjustments

April 2010 metalworking equipment news



Quick-Change Tooling Comparison Given this improved level of preparation, Kennametal’s KM quick-change tooling can push productivity gains even further. The system consists of two basic components: the clamping unit and the cutting head. The clamping unit mounts to the machine tool and is the receptacle for the interchangeable cutting unit. W h e n a to o l c h a n g e i s necessary, an operator simply releases the locking system, replaces the cutting unit, and locks it into position. Machine downtime is a matter of seconds. Consider the following example: Assume that the machine has been set up, the first part has been checked, adjustments have been made and the production run is in progress. The tool condition sensor has detected that the finish turn tool (station #8) shows signs of wear and it has a +/-.003” tolerance to hold on the part. A c o m m o n to o l - c h a n g e sequence includes the following: 1. Loosen clamp to change insert. 2. Clean insert pocket 3. Clean insert and remove build-up. 4. Perform tool maintenance. 5. Index insert and tighten clamp. 6. Close door. 7. Make offset corrections to set cutting tool a minimum of 0.006” away from finish diameter. 8. Run test cut. 9. Open door. 10. Gauge part. 11. Compute math to determine part deviation. 12. Make offset adjustment within the machine tool control for the correct tool number and offset. 13. Close door. 14. Resume production run, or return to step 10 for final offset adjustment. 30

metalworking equipment news April 2010

Total annual potential time-savings due to quick-change tooling can equal 27,000 minutes or 450 hours for one lathe. This is equivalent to 56 eight-hour shifts

15. Complete part and gauge for accuracy. 16. Resume production run if part is acceptable, or return to step 10 if further corrections are required. Using quick-change and pregauged tooling can change this to: 1. Change KM quick-change tool. 2. Make offset correction from pre-gauged data. 3. Close door. 4. Resume production run and place the used tool in the tool caddy. It will then be returned to the tool crib where maintenance, pre-gauging, and tooling for the next production run can be accomplished. Such a process change takes an eight-minute tool- change sequence down to 30 seconds, or saving 7.5 minutes per tool change multiplied by the number of tool changes per year.

Tribal Knowledge Is Out Advanced cutting tool materials and integrative tool-management systems are also importa nt components of a n effective machine utilisation strategy, and certainly information abounds on such products and systems for interested manufacturing companies. It is very important to realise, though, that effectively improving production is not a quick-fix, onetime process. It is both resourceand time-intensive for you and your technology partners. It will involve input a nd commitment from departments out side of pro duc t ion a nd engineering, such as inventory, purchasing, and IT. For those willing to commence such a journey, though, many benefits await. Tribal knowledge, or ‘the way we’ve always done it,’ is no longer enough to succeed in your business. MEN Enquiry No. 3003

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Difficulty: Existing inspection method stretched to the limit

Solution: Using a CMM/Scanner/ Software combination

Conclusion: Reduce process throughput time by 50 percent


’Fallon Casting of St Louis, Missouri, USA, is a nonferrous investment casting company that has built its reputation on making castings to meet end-user applications. In its 50,000 sq ft (4,645 sq m) facility, the company serves a broad range of markets, including electronic packaging markets, valves and pumps, medical and dental equipment, high-speed automated precision machinery, hardware, business machines, robotics, optica l a nd la ser equipment, silicon wafer processing equipment, and semiconductor manufacturing equipment.


metalworking equipment news April 2010

Increasing Prototyping Speed & Quality

Using the measurement points acquired by a laser scanner and the CAD comparison analysis graphics eliminate prototype rounds and deliver top quality. By Rob Snoeijs, senior editorial writer, Nikon Metrology One area of growth for the company has been in its rapid prototyping operation. It uses expendable patterns generated from a 3D model from a CAD file to produce a part and verify its design prior to building production tooling. “In recent years, there have been many improvements in the quality of pattern surface finishes, pattern accuracy, and pattern material alternatives, and today’s patterns are more user friendly to the near net shapes offered by the investment casting process,” said Ben Galmiche, the company’s quality engineer.

Because of these improvements, rapid prototyping of cast parts is good value for customers who want to reduce overall tooling costs and introduce products into the marketplace quickly. Quality inspection is a crucial aspect of the casting business. Complex Freeform Part Surfaces “In the past, we didn’t have an effective and efficient way of inspecting solid models. We had an old cantilever-type coordinate measuring machine and used a touch trigger probe to collect dimensional data. This process was


slow and we were looking for a new alternative,” said Mr Galmiche. For decades, the use of traditional touch probes on CMMs has been the gold standard. However, the time-consuming process becomes an even bigger drain on a quality department’s valuable resources. Metrology engineers are charged with increasingly complex freeform part surfaces that take an exceptionally longer time to thoroughly inspect. To help enhance the turnaround time of its rapid prototy pe inspection process, the company turned to 3D scanning and pointcloud-based inspection. They replaced the older CMM with a Globa l CMM from Hex a gon Metrology and equipped it with a Nikon Metrology cross scanner, a high-speed, multi-stripe 3D laser scanner designed for inspecting part features that provides optimal point distribution in all directions. This 3D measurement system was delivered with the PolyWorks software suite, a metrology software that offers an array of point cloud engineering tools for quality control and inspection. Turbo Charging A CMM This investment proved to be the right move, one that paid off. Particularly when the company received a request in 20 08 to inspect the housing for an integrated wing tip light of the Boeing 787 Dreamliner. Here is how the company integrated the point cloud based analysis in all phases of its rapid-prototyping process:

The company performed efficient scan alignment and overlap reduction using Polyworks’ IM Align module

The CAD model of the housing, from which expendable patterns are generated to quickly prototype a part

3. Once the pattern was verified and approved through 3D scanning and inspection, the company built a ceramic shell around the rapid prototype pattern. 4. The ceramic shell with the pattern went through a burn out process, where the pattern was vaporised to leave only the ceramic mould. The part was cast from A356 aluminium artificially aged to the T6 condition.

1. A pattern of the wing tip light housing was created from the customer’s 3D CAD model of the part using stereolithography and selective laser sintering.

5. The part was then measured using the CMM and the laser scanner. The point cloud data gathered during this routine was transferred to the software electronically via the company’s internal network.

2. The pattern was then visually and manually inspected to determine if it conformed to the reference CAD model of the part and if it was properly proportioned to account for shrinkage.

In the overall process, the company used 3D digitising and PolyWorks to inspect both the foam pattern and its inherent aluminium part. When gathering dimensional data on these prototype parts, the

company uses a very slow scanning speed to assure that a high level of feature detail is captured. In the process, excess data is collected to capture freeform sur face s a nd accurately characterise 3D features, both being essential in increasing the quality of the final product. As the scanner sweeps lasers in three directions, the entire geometry of features is captured consistently, regardless of the scanning direction. This allows the software to extract features through hundreds of points, rather than relying on a handful of tactile inspection points. Simplified scanner motion paths also means more straightforward off-line CMM programming. This also compares favourably with tactile inspection where elaborate programming effort is required to define a rather lengthy sequence of touch sensor movements and measurements. “The non-contact scanning solution offers the advantage of gathering complete data sets, better than what we have ever April 2010 metalworking equipment news



A colour map showing the global comparison between the digitalised points and their CAD reference

Point cloud engineering tools were used to inspect the housing for an integrated wing tip light

been able to accomplish through tactile inspection. Likewise, we now perform a laser-scanning job in less than a day whereas it previously took us nearly one week. We have reached the point where laser scanning is used in virtually all our rapid prototyping projects, paying off big time both for inspection and troubleshooting purposes,” said Mr Galmiche. Point Cloud Processing “We import the dimensional data into PolyWorks software’s IMAlign module where the partial scans are automatically aligned using a best-fit algorithm to create a point cloud model of the part,” Mr Galmiche said. “At this point, we study the model carefully to determine if we have all of the data we need to make an accurate comparison between it and the customer’s CAD model. If necessary, we will reorient the part on the CMM and gather dimensional data from another view. We use the software’s reduce overlap 34

metalworking equipment news April 2010

function to automatically remove the excess in areas of scan overlap and create a single set of data points that precisely defines the dimensions of the part in these areas,” he said. Next, the aligned scans were merged using to create a highly accurate finely detailed polygonal mesh model of the digitised parts. The polygonal mesh model wa s t hen e x p or te d for t he actual dimensional inspection process. This package uses datato-CAD alignment techniques including constrained best-fit, and techniques based on features and reference points. For this specific project, a global comparison was performed by calculating the deviation between each digitised point and its corresponding CAD reference. Graphic Geometry Analysis Using the report generation f u nc t ion o f t he Pol y Work s software, Mr Galmiche prepared an inspection report using the AS9102 format. “In addition to the data, we include snapshots

of the model comparison so that customers can see where the part is out of tolerance. We can also illustrate where the part is just a small amount out of tolerance or greatly so by using different colors to indicate different tolerance ranges.” The company also uses the CMM/laser scanner/software combination to inspect it s own moulds and compressionstraightening tooling to ensure that it conforms to design. This combination has reduced the time it takes to turn around a rapid prototype part at the company. “Globally, we are satisfied with this new point-cloud-based inspection process,” said Mr Galmiche. “For a typical part, we can gather the dimensional data we need in about one day and we can perform the data analysis using the PolyWorks software in less than half a day. That is a reduction of about 50 percent in the amount of time the process took in the past,” he added. In conclusion, he felt that the visualisation of the data also made it faster for customers to review the inspection report and understand the implications of the dimensional data analysis. On the expenses side, they have benefited. By systematically gaining more profound insight, they were able to reduce the number of prototyping rounds, which saved on resources and throughput time. MEN Enquiry No. 3101





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Digital Quality Control:

Into A New


3D scanning offers a completely new take on quality control and inspection. By Patrice Parent, regional manager, Creaform (Asia-Pacific)

The demands for quality and conformity to specifications have increased, making the need for better and more effective quality control that much more critical


s working metal gets more and more specialised, precision and accuracy become factors to be reckoned with. Twenty-first century technology has a way of demanding parts of very accurate dimensions, and the new-age smiths follow suit, shaving off micrograms of matter from complex, custom-built metal components. In such a world, ma k ing absolutely certain a part conforms to original specifications is imperat ive. A non - con for m pa r t ha s a s ma ny negative consequences to a manufacturer today as a dull blade did to a blacksmith in ages past. It incurs costs not only in replacement parts and compensation to the frustrated client, but in reputation as well. For those reasons, quality control in metalworking has become very important.


metalworking equipment news April 2010

Quality control does incur costs in itself; however what it helps save in lost business and scrapped production runs returns such costs many times over. Of course, quality control has followed the same kind of technological path as metalworking itself. From visual inspection to CMMs, the road has been paved with innovation. Probing Issues CMM technology, which is still extant and widely used all over the world, has certainly paved the way by bringing coordinate measurement and computers together. With a CMM, critical points on a part can be closely scrutinised for conformity to specs. Of course, the original CMM machine is hugely expensive and

bulky, and requires a specialist to use it. There a ga in, application prompted innovation, and more portable, multi-jointed measuring arms started replacing the first enormous table-mounted CMMs. More affordable and definitely less bulky, these measuring arms made a great deal of headway in quality control applications, but there were still major issues to be addressed, such as freedom of movement, setup environment requirements, and time consumption. Arming Metrology Me a su r ing a r ms a re mu lt i jointed, and their movements are limited by the mechanical articulations, the axis endstops, and the geometry of the part to


be inspected. Furthermore, the arms are inconveniently heavy; extended use by a specialist can require the addition of a counterweight to avoid the risk of tendinitis. Further, mea suring a rms require a rigid, laboratory-type set-up in order to yield satisfactory results. Instability makes inspection impossible, as do environmental vibrations. Finally, measuring arms need to be re-positioned every time either the part to be measured or the arm itself is moved, even slightly. Reference points have to be re-probed for the work to continue. Although measuring arms have benefitted a wide variety of metal manufacturers, such constraints have definitely discouraged their use in quality control. Scanning For Answers The 21st century has brought in a new player in the field of quality control: 3D. 3D scanning is on the leading edge of the technology wave front. It has pushed the boundaries of inspection and quality control so far that parts can now be scanned, modeled and compared with original design specifications. A 3D scanner does not only output points, like the CMM and the measuring arm: it outputs a polygon mesh. Engineers and technicians can literally see an exact 3D reproduction of the part to be inspected on their computer screen. The mesh file representing the surface of the part, in STL format (the file format most used for rapid prototyping and computer-aided manufacturing), can be exported into any major engineering and inspection software. Quality control becomes the simple matter of superimposing the scanned part onto the original 3D design. Computers are now able to calculate the minute differences between the two

shapes, and deviations are shown in coded colours. A not he r b e ne f it o f t h i s technology lies in its ruggedness: the most advanced 3D handheld scanners are self-positioning; therefore environmental vibrations do not have any impact on the measuring process. Since 3D quality control is still a new application of 3D scanning, te c h n ic ia n s a nd e n g i ne e r s worldwide are only beginning to appreciate its value. New technology inspires a certain dose of caution, as the question of return on investment remains foremost on the minds of the managers. 3D scanning offers a completely new take on quality control and inspection. The benefits of the most advanced 3D scanners are many: they require no external tracking device and allow total freedom of movement; they are handy and user-friendly, boasting a short

learning curve for a metrologist; they are accurate and output high-quality data; because of their comparatively low cost, they offer high return on investment; they are portable and can be set-up just about anywhere; and finally they are versatile, and can be used to scan parts of any shape or size. Quality control and inspection may sometimes seem like an expense many would rather do without. Given the increasing pre cision a nd accu rac y of manufacturing techniques, the demand for quality and conformity to specifications incre a se s accordingly, making the need for better and more effective quality control that much more critical. Quality control and inspection are an important investment that can end up saving a manufacturer not only reruns and lost labour, but a hard-earned reputation. Enquiry No. 3102

Creaform: Reverse Engineering & Quality Control Solution

The fourth version of VxScan, a s of t wa re p ro g r a m, has been developed by Creaform, a technology company that offers solutions for 3D applications. This program can now integrate data acquired by both a Handyscan 3D laser scanner and the HandyProbe portable CMM in the same referential and in realtime. With this platform, it is possible to create geometrical entities such as planes, spheres, or cylinders, directly from scanning or probing data and in a single referential. These entities may be saved in a format that allows direct exporting into most reverse engineering and CAD software (IGES). MEN Enquiry No. 3103

April 2010 metalworking equipment news




Graced by journalists, users and James Cameron, this year's installment of SolidWorks World defied the recession and provided an entertaining and informative arena for all. By Joson Ng


eld at the Anaheim Convention Centre in Anaheim, California, USA, SolidWorks World 2010 provided a tremendous opportunity for users to network and share best practices. The conference was held from Jan 31 – Feb 3, 2010. It provided a platform for users and nearly the entire DS SolidWorks R&D staff to talk, share their experiences, and demonstrate interesting projects. As always, the general sessions captivated and entertained the crowd. The sessions also included a sneak preview of SolidWorks 2011 software and presentations from DS SolidWorks CEO Jeff Ray, Dassault Systèmes president and CEO Bernard Charlès, and DS SolidWorks co-founder and group executive Jon Hirschtick.

Keynote speaker James McLurkin gave a thoroughly entertaining presentation on robotics and how CAD plays an important part in the design stages 38

metalworking equipment news April 2010

Reversing The Trend Jeff Ray kicked off the event in style by brushing off the recession blues that have plagued 2009, much to the crowds’ delight. “Didn’t you get the news? We are still in a recession. Everybody else has been downsizing their event but we blew it. Last year we had 4,300 people in San Diego but this year, over 5,000 people have registered,” he said. He also revealed that the company was able to get through 2009 without any layoffs directly resulted from the poor economy. Instead of restructuring and layoffs, the company increased its investments in R&D. As to why the company took this route, he felt that when the economy gets better, users would want “the best, newest and freshest technology” and the company have been making that investment. Enquiry No. 3201


Innovation Speaks To Rick Innovation according to Rick Chin, director of product innovation of DS SolidWorks, starts with frustration. It may not be the most conventional way to define the word but perhaps the very essence of the word has a tinge of the unconventional. “When you develop a product it starts first with frustration. I look for things that get people upset. I find it and I start probing,” he explains. S p e a k i n g to A s i a P a c i f i c Metalworking Equipment News at SolidWorks World 2010, Mr Chin says: “I always talk about innovation that matters. The product or solutions have to be innovative, described from the users’ perspective. It doesn’t matter if I call it innovative. I want my customers to be so excited and happy from what they received from me.” Putting the onus on users’ satisfaction is also one of the ways Mr Chin approaches innovation. “They (the customers) will call it innovative when the product solves the important problems in a way it is easy to appreciate. It has to address something really important and no one is able to address yet,” he muses. In order to know if he has brought an innovative product to his customers, Mr Chin listens for a key word. He says: “If your customers say ‘wow’, chances are they are going to say the product is innovative without prompting.” Innovation and R&D comes hand in hand. It is therefore no surprise that the company invests in R&D; one way is to get inputs from the users themselves. “There are actually a number of ways how we get inputs from our customers. They can actually go on the SolidWorks website and submit

their request. Something new that we have done is that we made the process a little more community oriented. What it means is you cannot only submit and answer requests, you can also see the enhancement requests other users have put in. In addition, you can forward on it and get comments on it,” he says.

“If your customers say ‘wow’, chances are they are going to say the product is innovative without prompting,” says Rick Chin.

Lending A Listening Ear In addition to getting feedbacks from the website, the company is also proactive in obtaining the information. Says Mr Chin: “SolidWorks is proactive in going out to see customers. It has always been part of our culture. We make a lot of visits over the world and we have customer representations in the US, UK, India and China. Customer input is a big part in the way we design and we have a group called Product Definition, they write the specifications and design user interface and decide how the program should behave.” Conducting surveys may not be the latest information collecting method but Mr Chin conducts surveys with a twist. Though his ultimate aim is to produce a better CAD/CAM product, his questions are often not directly related to the subject. “I ask people what their aspirations are, what is important in their job, what do they wish to achieve in 2010, the challenges they face and where do they see themselves in five years should their career go smoothly. They may be vague questions but at the same time, they give us insights on who they are,” he explains. Enquiry No. 3202

April 2010 metalworking equipment news



Be Part Of The CAD Community & Network Planned out extensively in ‘five year blocks’ as described by Ved Narayan, VP of DS SolidWorks Asia Pacific, the annual user conference is the biggest for a CAD software manufacturer. Boasting the attendance of about 5,000, the event presents a good opportunity for customers and resellers of the company, according to Mr Narayan. “SolidWorks World provides a platform for our users to come and share various technology and talk about future trends in products and applications, as to how people are using the software. People can also learn from each other,” he says. Summing it up, he says the event is all about ‘building community and network’. He sees that as fitting to today’s social climate where people are using various medias to connect professionally and on a personal level. Elaborating further on what the event brings to the table, he explains it in two folds. Says Mr Narayan: “In terms of benefits for our customer, they learn about the investment that they have made in our company, and also the direction we are taking. They can ask themselves question like ‘is the investment in the right hand?’ In addition, they can learn from other customers in similar industry and educate themselves on the best


metalworking equipment news April 2010

practices of the industry.” With over 300 technical sessions, he feels a lot of them are related to best practices. For example, how by using tools and technologies to help them be more productive. For reseller, Mr Narayan views the event as an informative medium for them to learn in terms of strategies and overall focus in the coming year for SolidWorks. Investing For The Future Given the financial crisis of 2009, Mr Narayan explains to Asia Pacific Metalworking Equipment News why the company continues to invest heavily to organise such a big event. From the financial point of view, he feels the event is a long term investment. Quoting an example, he says: “There are many prospects for visitors who come here just to see. With over 5,000 here physically at the show and a million worldwide, they can see for themselves first hand what they stand to get if they choose to join the SolidWorks community. Over here, (Anaheim Convention Centre) there is a different level of energy, which you feel and see. It gives a level of confidence to individuals. MEN Enquiry No. 3203

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Aerospace Productivity A


The increasing use of five-axis machining is an important trend that is boosting productivity in the aerospace industry. By Peter Dickin, marketing manager, Delcam


metalworking equipment news April 2010


ompanies at all stages of the supply chain, and those involved in all types of aerospace component, are successfully using five-axis technology to increase efficiency, improve quality and shorten delivery times, and so raise profitability. Of course, five-axis machining is not a new development for the larger aerospace companies and the tier one suppliers. Many of these companies have used this approach for several years. The big change now happening is that the technology has become available to the smaller sub-contractors supplying the industry. Firstly, the price of five axis machines has been falling steadily and this trend is forecast to continue. Secondly, five-axis capabilities that were once only available on large-scale machines are now becoming available on the smaller machining centres used for sub-contract operations.


Swarf machining is used mainly to machine the sides of pockets in aerostructures, where it gives faster machining and better surface finish

At the sa me time, new developments in five-axis machining software, including Delcam’s PowerMill and FeatureCAM CAM systems, have made programming for five-axis operations easier. More sophisticated simulation software has also been introduced. This makes it easier for the user to check toolpaths on the computer before they are sent to the machine tool and so minimises any possibility of collisions or gouges. Benefits Of Five-Axis Machining The use of five-axis machines offers several advantages over the more conventional three-axis machines. First of all, they enable shorter cutters to be used since the head of the machine tool can be lowered towards the job and the cutter oriented towards the surface. With a three-axis machine, deep pockets can only be reached by increasing the length of the cutter. With these longer cutters, vibration can cause a loss of accuracy and poor surface quality, so the cutting speed may need to be restricted. The shorter cutters that can be used for five-axis machining allow higher cutting speeds to be used with no loss in accuracy nor any deterioration in surface quality.

The ability to vary the angle between the cutting tool and the surface being machined can also give other benefits. With a three-axis machine, the cutter will be almost vertical to the surface when machining a nearly horizontal surface. This means that only a small part of the cutting tool will be used on its tip where the effective cutting speed is at its lowest. Moving the angle of engagement away from the vertical gives faster effective cutting speeds because of the increased distance of the contact point from the tip. It also gives improved cutting tool life by increasing the area of the tool that is being used. Another major benefit of fiveaxis machining is the ability to machine complex shapes in a single set-up. This saves considerable time compared to performing the job in a series of set ups. Furthermore, with multiple setups, there is always a possibility of incorrect alignment each time the part is moved. With more complex parts, special fixtures need to be made to hold the component firmly during machining. Often, a different fixture will be needed for each set-up. By reducing the number of set-ups, five-axis

machining can also save the time and cost of making a multitude of fixtures. The benefits of five - a x is machining give subcontractors the ability to machine complex parts from solid that would otherwise have to be cast. For prototypes and very small runs, this approach is much quicker and cheaper. It can give lead times of one or two weeks, instead of two months or more that would be needed for castings. As a result, an increasing number of companies are now machining prototypes, rather than using rapid prototyping equipment. This approach allows more accurate parts to be produced in the same materials that will be used for the production parts. The other benefit of direct machining is the weight savings that are possible with thin-walled components. Typically, a cast part will require a wall thickness of 2 mm, whereas machined parts can be produced to accurate tolerances with thicknesses of 1 mm. The resultant saving in weight gives opportunities for considerable reductions in fuel costs over the lifetime of the aircraft. Even for longer production runs, where casting might be a cheaper April 2010 metalworking equipment news



manufacturing method, the total life-cycle costs can be less with machined components. Positional Or Continuous? Two t y p e s o f m ac h i ne a re available to companies wishing to invest in five-axis machining – positional or continuous. With positional five-axis machining, which is also known as 3-plus-2 machining, the head is oriented into a series of positions and machining carried out as a set of discreet operations. With continuous five-axis machining,

t here ca n b e simu lta ne ou s movement in all five axes. In both cases, two distinct types of machine are available. Firstly, there are those machines in which all five axes of movement are generated by changing the position and orientation of the head. The more popular option with smaller components is to have a fixed orientation for the head, with the extra two axes being produced by tilting and/or rotating the bed holding the workpiece. Several factors have made positional five-axis machining

the preferred approach for many smaller companies. It is not only because positional machines tend to be less costly. Another important reason is that machining can often be undertaken more quickly. Once the correct orientation has been achieved, the fact that the head is then fixed gives extra rigidity, so it is possible to operate at high spindle speeds. With continuous movement of the head, it is difficult to operate at higher speeds because of the inertia that has to be overcomed. In addition, with positional five-axis

Hitting The Soft Spot In The Aerospace Industry Although the choice of machine is an important factor in five-axis machining, choosing appropriate CAM software is just as crucial.

With the change to continuous five-axis machines, the company felt that it needed a more efficient CAM system to make the most of its new capabilities

Case Study 1 M e s s i e r- B u g a t ti, a provider of aircraf t braking systems, switched to PowerMill to support its move into five-a xis machining. With the change to continuous five-a xis machines, the company felt that it needed a more efficient CAM system to make the most of its new capabilities. A Safran group company with a global


metalworking equipment news April 2010

w o r k f o r c e o f 1, 5 0 0 employees mainly b a s e d i n Fr a n c e , t h e US and Singapore, the company specialises in aeronautical braking systems and carbon brakes. It has equipped more than 3,500 commercial aircraft. The company has been an Airbus partner for more t h a n 2 0 ye a r s a n d i s also an OEM supplier to Boeing, Bombardier and Dassault Aviation. Production manager Mr

Fonferrier and his team at the Molsheim works in eastern France ran trials with PowerMill on landing gear components and hydraulic manifolds. The results were so conclusive that the company bought the software in 2007. In addition, even though most of its parts are made of aluminium, M e s s i e r- B u g a t t i a l s o machines titanium. This is a very demanding material, which requires high-quality toolpaths.

Stéphane Schneider, manufacturing process engineer, described how the Delcam software has become an asset for them. “We find it easy to import CATIA parts into PowerMill fo r p ro g r a m min g,” h e explained. “We check the toolpaths with Vericut. If needed, we can modify any sections of the toolpaths b e fo r e m a c h i n i n g th e parts.” Among the advantages that the program brings to his work, he appreciates especially the control over the different high-speed m a c h i n i n g s t r a te g i e s , the smoothness of the toolpaths and the reduction in the vibration of the parts during machining. As well as helping to maintain accuracy, this protects the tooling and the machines. Enquiry No. 3204


machining, the programming is relatively easy. Once the workplane has been set for each operation, the programming is effectively the same as for three-axis operation. D e spite t he incre a sed complexity, there are many times when continuous five-axis machining gives extra benefits. These include ca ses where undercuts are being machined into the component. In addition, continuous five-axis machining can give better control over the cutting conditions. This can be important when using

particularly thin cutters that could break easily or when an especially fine surface finish is required. There are several cutting strategies for which continuous five-axis operation is essential. Perhaps the most important is swarf machining in which the cutting is carried out with the side of the tool rather than the tip. T h i s i s u s e d m a i n l y to machine the sides of pockets in aerostructures, where it gives faster machining and better surface finish than working down the pocket at a series of Z-levels.

Trimming is another area where continuous five - a x is operation can be required. This is of pa r ticula r impor ta nce in the finishing of composite components, which are, of course, becoming more common in the aerospace industry. Continuous five-axis machining gives the ability to cut the complete part at a fixed angle to the surface and so produce a better appearance on the product without as much hand finishing. Enquiry No. 3205

“If you do not have good CAM software, you cannot be competitive with five-axis machining,” says Ed Padgett

Case Study 2 Pa d g e t t M a c h i n e h a s turned a profit on a new five-axis machine in just four months thanks to the FeatureCAM featurebased CAM system. The AS9100-compliant machining company of 15 employees based in Tulsa, Oklahoma, USA, recently added a five-axis Haas machine and moved up to the five-axis version of FeatureCAM. “Adding this capability has put perhaps 35 percent onto our gross sales,” claimed company president Ed Padgett. “Four months into this new line of work and we are already profitable with it.” “Using the software allowed us to hold the part so that we can machine on the top and four sides in one set-up, saving us quite a bit of time and providing much better results,” said Mr Padgett. “In a three-

axis machine, it would take eight or nine set-ups for some of the parts that we can now do in one operation.” The benefits of FeatureCAM are crucial. “We have to be competitive against many other approved vendors every time a job is offered or I lose my business,” Mr Padgett stressed. “So far, we have been able to keep our niche, working in heav y maintenance programmes for military aircraft.” O n e o f P a d g e t t ’s recent jobs included 75 di f fe re nt re p l a c e m e nt parts for F-16 jet fighters. Among the most complex were 16 supports holding the wings. Each had a different surface where it had to meet the fuselage of the plane. “The surface on this critical par t is accomplished with just one command in FeatureCAM, saving me a

lot of programming time,” commented Mr Padgett. According to his experience, “If you do not have good CAM software, you cannot be competitive with five-axis machining

because the programs cannot be written manually. You would be out of business before you got it done.” MEN Enquiry No. 3206

April 2010 metalworking equipment news



Taking The Step



ith over 15 years of 3D modelling experience, J a ke J o h n s o n , a designer for Kenmode Tool and Engineering, located in Illinois, USA, was the catalyst for change when his compa ny decided to switch to SolidWorks and 3DQuickPress. Prior to 1999, the company used another program to design and build tools at their in-house facility, but as increasing number of customers began to send 3D models, they realised they needed new tools to help them work with parts outside of a 2D environment. “We knew we needed a tool that would help us orientate the parts that customers were sending us and work with them outside of a 2D environment. From there, we decided that with parametric and associatively modelling we could easily control and maintain updates to our designs,� explained Mr Johnson. 46

metalworking equipment news April 2010

Making the transition from one design software to another is not as simple as installing a new program on the computer, it requires a change in mindset. Submitted by Shirley Lim, assistant marketing manager, Advanced Technology Enterprise

As increasing number of customers began to send 3D models, the company realised they needed new tools to help them work with parts outside of a 2D environment


For the company, it was a logical next step to adopt 3DQuickPress

When the company made the transition to SolidWorks in 2000, Mr Johnson was in a position of having over five years of design experience using the mentioned program. “One of my main tasks when I was hired was to convert our department to a fully functioning 3D Design department. The comparison for me was that 3D offered much more vision than we had in 2D allowing the designer to wrap his head around a concept more easily,” he said. Rough Start It was not all smooth sailing though. The biggest challenge the compa ny faced when t ra nsit ioning to t he new program was convincing their designers that a switch to 3D was necessary. “Some of the comments from the other designers were that in the first year of using the software, it was a bumpy road. Due to the fact that we were in the process of customising our PRL’s and their functionality – making it difficult to feel familiar with the process because we kept changing it from design to design in an effort to make things better and more efficient,” said Mr Johnson.

Even with a rough start, the designers at the company could see the benefits of transitioning to 3D by the end of the first year. “Some of our other designers commented on how much more they liked sketching in Solidworks, and that you are still just sketching in 3D with the addition of adding thickness to your sketches.” After switching in 2000, the company adopted 3DQuickPress in 2006. For them, it was a logical next step. “For our business we saw much strength in 3DQuickPress. One of the first things we noticed were the PRL’s and how powerful they could be once they were customised to how we design,” said Mr Johnson. Speed To Market The company’s time to market was reduced after implementing 3DQuickPress. Now Kenmode’s designers are able to focus solely on designing tools rather than spending significant amounts of time dealing with non-design related issues as they were previously. “The mental work you are forced to do previously has disappeared with QuickPress and Solidworks,

giving the designer the ability to focus on actually designing the tool rather than dealing with space, issues or other construction issues or in just dealing with non-design related issues in general. This is mainly accomplished through all of the PRL’s we have designed. They come in finished or very near completion and need very little adjusting,” explained Mr Johnson. The company’s machining centres are getting to market faster now, as well with the use of PRL’s. Because these facilities are able to access models and assemblies directly off the SolidWork s geometry, they spend much less time detailing prints now than they did before. Additionally, there are specific 3DQuickPress features that Mr Johnson is a fan of. “Unfolding Parts in Quickpress is not only fast and easy for us, it is also accurate. We can unfold some parts we get from customers in literally a couple of clicks. The strip layout section allows us to design strip layouts faster than we could have ever done it in 2D. Some other strips come together in an hour or two and we are ready for a design review,” he said. MEN Enquiry No. 3207 April 2010 metalworking equipment news






Driving Economical Manufacturing Even small companies can set themselves big targets that will elevate them to lofty heights. By Olaf Pinkenburg, Schuler, Germany


ngoing crisis or new start for car industry suppliers?’ is the title of a recent study commissioned by the German Association of the Automotive Industry. Its findings show that German suppliers can emerge from the current crisis stronger than their foreign competitors. According to the study, the key to success lies in the company’s respective business model. It must be based on fulfilling customer needs, achieving cost leadership and strengthening innovation. Even small companies must set themselves these aims. Kortenbach, based in Solingen, Germany, produces blanked and deep drawn parts. Annual production figures range from 10,000 to several million parts. The company mostly produces complex parts for car manufacturers – such as fuel pump housings or sleeves for common-rail injectors. Increasing Output & Quality For the expansion of its production facility, it chose a press with ServoDirect technology. The press has a press force of 250 metric tonnes. The solution also includes a roll feed unit supplied by Schuler Automation. After one year of manufacturing with the new line, the investment has already paid off for the company – output of various parts has been raised. The family-owned company put its 250-tonnes press with


metalworking equipment news April 2010


The plant raised its output of various parts with the aid of a servo press

Variable Solution For Varying Conditions Variability in a servo press offers small to mid-size companies in particular the benefit from being able to use the same line

to produce totally different parts in different batch sizes. The stroke height is freely adjustable in oscillating stroke operation. A further key aspect for many businesses is that servo presses can reach their full working range from stroking speeds of 1/min. This also makes them suitable

Enquiry No. 3301

Is Your Design Optimum?

SolidWorks 2010 transforms your concepts into reality and helps your business succeed. ENQUIRY NO 069

ServoDirect technolog y into operation in July 2008. “Any new investment must secure the level already achieved and help maximise the economic efficiency of our production pro ce sse s,” says ma na g ing partner Jens Kortenbach. The press manufacturer was able to meet these requirements with its monoblock servo press. The line is flexible and enhances part quality. A monoblock press can almost be fully assembled at the manufacturer. This means that installation time at the customer’s site is kept to a minimum. Following this fast installation, customers can benefit straight away from the known advantages of presses featuring ServoDirect te c h n o l o g y – t h e i r f r e e l y programmable curves enable variable slide speeds, which in turn reduce the wear and tear on dies and prolong their service life. Depending on the pa r t manufactured, output can also be improved – variable curves enable much higher speeds without having to adjust the die. This leap in output is illustrated by the example of a suspension fastening.

for use as tryout presses. The monoblock construction of the press fits to its flexible image as it allows fast die changes. “The decision to buy a servo press was quite easy. As a contract manufacturer, we need a very flexible line, which will enable us to always find the production parameters for a wide range of blanked and deep drawn parts,” explains Mr Kortenbach. The output levels, which the line offers are also secured by an automation solution. The roll feed unit with two feed rollers operates with a system accuracy of 0.05 mm. A coil width of 200 to 350 mm is moved forward 180 mm in a feed time of 0.42 s. This accurate feed performance is adapted to the performance characteristics of the servo press. MEN

April 2010 metalworking equipment news




Aerospace Parts:

Latest Advances In

Ti 5553 Machining The trick to machining difficult aerospace parts is preparing the existing machines to suit the material. By Scott Walker, president, Mitsui Seiki USA


metalworking equipment news April 2010


itsui Seiki has been an integral partner in an R&D project with Boeing for the last three and a half years. The goal: to determine the optimum machine tool characteristics required to cut the new triple nickel titanium materials productively and economically. Much has been written as to the ‘why’ of the research – the number of parts made of the new triple nickel titanium materials, or ‘heavy metals’, will be increasing to make up 15 percent of the weight of the new generation of aircraft, such as the Boeing 787 Dreamliner.


These include the skeletal structure as well as struts, floor ribs, window frames, door hinges and engine mounts, all parts requiring structural integrity. In all, in each aircraft there will be some 36,000 pounds (16,329 kg) of these heavy metal parts that will be machined out of 240,000 pounds of raw stock. Another ‘why’ is the insufficient titanium machining capacity to meet all the needs of the various high titanium content planes being launched. The aircraft parts suppliers will have to take on more of this capacity, and these new materials, although light in weight compared to aluminium, are extremely tough to machine. Low Frequency Machining The machine tool must have the structural design to machine at low amplitude ranges, in the less than 350 Hz range (especially at the 20, 90 and 320 Hz ranges). A one-inch, four-flute end mill, for example would run at about 90 rpm. Each time a cutting edge strikes the material, it sends a shock wave into the machine. As each cutting edge ‘hits’ the metal in a consistent, repetitive sequence it creates a low frequency wave into the machine. General-purpose machines have a tendency to chatter at low frequency. This negatively affects both the quality of the part and tool life. A machine that is designed specifically for low frequency machining dramatically reduces chatter at the necessary low rpms that the cutting tools must run to cut these materials. Logic follows that eliminating chatter significantly increases tool life. How do we do it? By designing an application specific machine that has structural modifications to reduce the amplitudes of the excitation frequencies in the low frequency ranges. We have also paid attention to requirements for handling the low frequency

With titanium taking a more important role in the construction of new generation aircrafts, more needs to be done to improve the machining of the metal

st re sse s such a s height to width ratios on columns and tables to accommodate high moment loads, optima l ba ll screw locations for axes stability and, of course, hand scraping throughout to provide the high accuracy needed for quality parts in these materials. Hold Tools Tighter At a depth of cut 1-1/4” diameter x 3/8” in triple nickel titanium, the tool starts to separate from the taper at about 8,500 inchpounds of moment load on general purpose machines with a BT/Cat 50 taper. A seven inch long, oneinch diameter four flute cutter will remove about 1.2 cubic inches per minute of material from 5553 titanium before the tool separates from the spindle taper. If you increase the feed to remove more stock, you will exceed 8,500 in-pounds. Through trial and error and ultimately success, we are building tool taper interfaces right now that can handle 35,000 inch-pounds and are able to remove 25 cubic inches per minute of 5553 material with a Mitsui Seiki horizontal machining centre.

Increase Machine Stiffness In ‘heavy metal’ machines, all of the materials in the machine tool must stay within a specific range of stiffness in the modulus of elasticity curve. Adding so much nickel to the titanium results in a material that has an exceptional ratio of tensile stress to tensile strain, which is the tendency of a part to deform along an axis when opposing forces are applied along that axis. (Look up Young’s Modulus of Elasticity for a closer look into this material property.) Conventional machine tools just have not been able to meet the challenge. The machine must bend consistently when cutting under heavy loads. If it does not, the volumetric accuracy is destroyed and so is the consistence in the cutting tool edge contact line – another big key, along with chatter reduction, to increase tool life. Stiffer machine tool materials cost more up front, so the machines cost more, however the definition of ‘cost’ as it relates to ‘profit’ is worth consideration. If you would profit by cutting deeper, faster, and with better quality, then you may be losing money by not doing so. The April 2010 metalworking equipment news



To machine heavy metals efficiently, the machine must bend consistently when cutting under heavy loads

Rethinking WIP

Cutting titanium overhead costs is possible with good WIP management.

extra cost, after scrutiny, could be miniscule by comparison to what you might be losing. Beware of false economy, especially when it comes to getting what you need to produce titanium and other heavy metal parts. Jet Parts Need Jumbo Power To cut heavy metals, the machine needs ample torque. The spindles should produce 2,000 foot-pounds of torque at 100 rpm and large servo motor drives on fine-pitch lead ballscrews. Ballscrew location is also critical for axis stability. These e l e m e nt s w i l l p rov i d e t he advantages to push the tool through these tough materials. But, these power mechanisms need to be designed so as not influence the low frequency excitation conditions. Of course there are several other issues with chip control, coolant (use lots of it), and the types of cutters (cobalt is making progress). Enquiry No. 3401 52

metalworking equipment news April 2010

Many companies use batch manufacturing for part processing. In a hypothetical situation, say there is an engine mount to be processed, they might put three parts on a three-spindle machine, and then move the three parts to the next process, the next, and so on until the parts are finished. So, if you need 12 parts completed in a month and you process three at a time you will have 12 in the shop for the 30 days and then ship. This WIP is costly because unlike aluminium that is inexpensive, these high alloy titanium forgings are very expensive and you are carrying all the material cost through the entire month, plus adding labour and overhead. The trend now is to single piece flow the parts. For example, you would put one part on a single spindle VMC to do one operation, then move it to machine two for the second operation, machine three for the third etc. until finished. This way, you move three parts in a single flow through the shop every week and ship. You still ship 12 sets in thirty days but only have three at any given time in the shop. A titanium forging is US$400,000. Conversely a comparable aluminium part is US$40,000. Reducing WIP is a major cost saving. Enquiry No. 3402

Mitsui Seiki: HMC For Medium Size, Precise Parts Mitsui Seiki has developed the HPX-63, a 4-axis CNC horizontal machining centre. Some of the key design criteria included in this machine include a large work size capacity featuring a swing diameter up to 1,050 mm and a work height (Y-axis) up to 1,050 mm. The machine is made for precision work. Its castings are metallurgically configured for stiffness, its box way axis slides are hardened, ground, and hand scraped. It is suitable for the aerospace, energy, compressor, mould and die, fixtures and tooling, automotive prototyping, and general precision machining industries. MEN Enquiry No. 3403



he push for larger, lighter and more fuel efficient a irpla nes creates real opportunities for alert aviation supply-chain manufacturers to be able to do a better job machining titanium – including the new 5553 grades. In the new Boeing 787 passenger Dreamliner, for instance, the ratio of titanium to steel and aluminium is three times higher than in earlier generation aircraft. Where once you saw high tensile steel in the landing gear, now you find titanium. This is the same for airframes, bogy beam and slider. And that is not all. Wherever you find composites or plastics, you are more likely to find the adjoining members in titanium, because of its closer match in thermal expansion characteristics and better bond strength. These trends are already causing a logjam in airplane parts manufacturing. Why? Because under even the best conditions,


metalworking equipment news April 2010

Aerospace Machining:

Fresh Opportunities Choices


Titanium and composite materials are slowly making their presence felt in the aerospace industry. By Reuven Shapir, aerospace industry manager, Iscar the titanium alloys take 10 times longer to machine than aluminium and perhaps four times longer than high tensile steel. Usua lly it requires more horsepower per unit of metal removed, and a machine with higher torque. And now come the new titanium 5553 (5Al, 5V, 5Mo, 3Cr) grades, 20 – 35 percent stronger than mainstay Ti 6Al, 4V,

but even more difficult to machine by a factor of four to one. As use of Ti 5553 grows – which it inevitably will – so will the machining logjam in aircraft production. That logjam can be your best business opportunity in this tight economy. Titanium is well known as the ‘go-to’ metal for its high strength to weight ratio. That means weight savings, which


translates directly to higher fuel efficiency at a time of rising concern over fuel costs and supplies and lower greenhouse-gas emissions amid worldwide concerns over global climate change. Mastering Titanium Machining Now, how to master titanium machining? First, understand its machining characteristics – the good and the bad – and then select tooling and machining practices specifically tailored to it. The bad news is that, titanium is more difficult to machine than aluminium or stainless steel. There are many reasons for this lower machining rate. Its high strength means more power is required to produce the chip. With a relatively low modulus of elasticity, titanium tends to deflect away from the cutting edge more than aluminium or steel, and as a result, needs a sharper cutting edge to hold tolerance. T he meta l a lso tends to crater upon tool entry and exit unless the cutting edge remains sharp. Its low coefficient of thermal conductivity means more heat buildup in the cutting zone, which leads to smearing, welding and built-up edge, all of which undermine the tool and workpiece. Anatomy Of A Good Titanium Tool The common attributes of these advanced tools include very sharp edges with honed flanks to delay built-up edge; helical cutting edges to ‘ease’ the insert into the workpiece; as well as heat-resistant coatings, internal coolant directed right at the cutting zone. A choice of substrates enables you to optimise either wear resistance on tight machines and optimal cutting conditions, or toughness to withstand impact loads and chatter in less-rigid cutting systems, long overhangs and interrupted cuts.

For jet engine parts, there are specially designed tools to overcome the difficulties in machining them

In both cases, the emphasis is on predictably long life, so the tool runs securely over machining cycles measured in days rather than minutes. One aerospace fabricator reports doubling the edge life on both titanium and other super alloys by switching to the IC380 grade, with no other changes to the process. Two of the typical characteristics of cutting edge wear that occur while milling titanium are chipping and cracks on the cutting edge; which reduces the insert life. In order to prevent the cutting edge from chipping, the Iscar’s R&D division developed a tough reinforced carbide substrate. W hen it comes to rough and tough milling applications in titanium, the tougher carbide substrate exhibits longer tool life. In some applications, when compared to any other available carbide grade, the tool life is even three times longer. This is very important for the production of parts demanded by the aerospace industry. Composite Materials In Aerospace Composite materials have gained popularity (despite their generally high cost) in high-performance products that have a need to be lightweight, yet strong enough to take harsh conditions. Many new

types of aircrafts have composite material structures, which include the wing and fuselage parts. Composite materials provide distinctive advantages in the ma nufacture of adva nced products because of attractive features such as high strength and lightweight. They are easily damaged unless machining is performed properly. By their nature, composite materials are non-homogeneous, anisotropic, and reinforced with abrasive components. Because of their structure and component properties of high abrasiveness, composite materials are much more difficult to machine than metal alloys and fall under the category of difficult-to-machine-materials. T he comp o site mate r ia l workpiece can easily suffer i ntole rable da ma ge du r i n g cutting and the tool wear rate can turn out to be unacceptably high. The company’s ongoing research conveys widespread knowledge to its customers for machining composite materials and on the mechanisms governing the chip formation and tool wear development. Cutting composites may incur more damage to the workpiece (like de-lamination of bottom layers when drilling) if not done carefully or correctly. April 2010 metalworking equipment news



Combining design with the prismatic clamping mechanism allows rigid clamping and use of the groove-turn tools for machining deep cavities

Turning, Grooving & Profiling Applications For jet engine parts, there are specia lly de sig ned tools to overcome the difficulties in machining them. These are tools that are designed for use of highpressure coolant, 70 - 120 bars. These tools ca n improve productiv ity by enabling increased cutting speeds of approx imately two to three times, with no reduction of insert life and they also improve the chipbreaking results. This new line is designated as Jet HP Line (HP = High pressure). Today, the main machine builders are able to fulfill the customer’s demands by equipping their machines with standard built-in high-pressure pumps in a range of 60 - 100 bars. Modern machines equipped with highpressure pumps will give the customers an advantage by using the Jet HP high-pressure line. The benefits include increased cutting speeds, improved chipbreaking, maintenance of low machining temperatures and long extended insert life. Machining Jet Engine Parts The company’s groove-turn tools and especially those under the CutGrip brand are known by customers in the aviation industry. Their design and structure for multi56

metalworking equipment news April 2010

directional machining in grooving, turning and profiling operations of complicated parts and shapes are utilised. Combining design with the prismatic clamping mechanism allows rigid clamping and use of the groove -turn tools for machining deep cavities, where other conventional tools are not able to penetrate due to their limitative dimensions and structure.

For example, on titanium you can reach high speeds of approximately 150 m/min as compared to 60 m/min with regular low pressure cooling. The Cut-Grip line also features a variety of insert selection – width, square and full radius, up-sharp positive polished inserts for finishing operations and other moulded inserts. Enquiry No. 3404

Solution For Drilling Tube Sheets & Baffles

Iscar’s Sumocham system features a clamping system that enables improved productivity output rates. Its double margin inserts for finishing and semi-finishing are suitable for producing heat exchangers. The inserts produce good hole cylindricity, straightness and surface roughness. They are manufactured from a submicron carbide grade, with a TiAlN PVD coating. The insert features include submicron carbide grade, TiAlN PVD coating and it is available in the diameter range of 6 - 32.9 mm. The features result in increased tool life, positive flute rake angle for good chip formation and high penetration rates. MEN Enquiry No. 3405




he term MRO (Maintenance, Repair and Overhaul) has long been part of the aerospace vernacular. But only recently have service providers adopted automated tools to streamline the upfront process of capturing and digitally reconstructing physical parts that require repairs or redesign. The central issues surrounding MRO – speed of repair, accuracy, reliability and quality – are relevant worldwide. In the US, it is a central issue with adherence to FAA Parts Manufacturer Approval ( PM A); simila r cer tification processes are in place throughout Europe and Asia. In all cases, the combination of market demand and certification make MRO a prime application for 3D pointcloud processing. Increa singly, MRO sta r ts with 3D point-cloud processing: digitally capturing physical ob j e c t s a n d au to m a t ic a l l y creating accurate 3D models for downstream design, engineering analysis, inspection and custom manufacturing.


metalworking equipment news April 2010

3D Point-Cloud Processing For MRO By bridging the gap between the physical and digital worlds, 3D point-cloud processing offers benefits for companies in the MRO business. By Alberto Griffa, US Eastern regional sales manager, Geomagic

Applications For MRO Point-cloud processing is suitable for MRO projects for four basic reasons:

different, due to factors such as manufacturing variability and tolerances, wear patterns, and stress.

• It captures and reconstructs parts as they exist, enabling engineers to analyse damage and its underlying causes.

• It improves asset management by speeding part reconstruction and inspection of as-built vs as-designed parts, helping planes return to flight much sooner.

• It enables engineers to accurately recreate parts for which no CAD data or documentation is available. • It enables engineers to analyse situations where every part is

Unlike CAD, 3D point-cloud processing does not require an existing part or assembly to be created again from a blank screen.


Design, engineering and quality inspection processes spring from what already exists in the physical world. Let’s look at a few examples of MRO applications, with an eye on how 3D point-cloud processing could be applied to speed the process and ensure quality. • Commercialising A New Part A compa ny wa nts to commercialise a new part, but the OEM does not release drawings or CAD models. The company needs to be able to capture the part, digitally recreate it, and send data to a CAD program. From there, a model can be created from which the newly fabricated parts can be manufactured with the same form, fit and performance of the OEM parts. • Structural Check A cargo plane from a shipping co m p a n y g o e s i n fo r a maintenance check, often called a C-check. As part of the maintenance, the airframe needs to be checked for cracks and possible repairs. This requires comparing the actual airframe against the nominal CAD geometry to identify areas that are out of tolerance. Engineers need a way to perform a complete 3D analysis of all the surfaces, quickly compare them against the CAD model, and identify out- of-tolerance areas for repairs or part replacement. The shipping company must minimise downtime and get the airplane back in service as soon as possible. • Conversion From Passenger To Cargo Plane A company has been contracted to convert a passenger plane into a cargo plane. It does not have access to the original passenger plane drawings, and

since the plane was first built in the late 1960s, there are no CAD models associated with it. The entire existing env ironment – including electronic cables, hydraulic systems and other internal aspects – need to be captured so that engineers can design the new cargo areas. Engineers have four months to remove all passenger equipment, install the main cargo door, and integrate the new cargo system. • Fixing A Crack In A Fighter Plane A fighter plane undergoes routine maintenance and a crack in the structure is discovered. Repair requires a stainless-steel doubler fitting that is riveted into place, bridging the gap caused by the crack. Obviously, there is no CAD model of the crack. The traditiona l repa ir process requires that an impression of the crack be made with dental putty, measuring the mould manually with calipers, and creating a CAD model that will be sent to a CNC to make the doubler fitting. Typically, it takes five or six prototypes to meet the fit tolerance required, grounding

the plane up to six weeks. By contrast, if an engineer could capture the crack with a laser scanner, it would only take a few days to create a CAD model of the bracket to repair the crack, machine the bracket, scan the manufactured part and compare it to the CAD model to ensure that it meets tolerances, and install the new bracket. • Redesigning A Passenger Plane Lavatory An aerospace company decides to remodel the lavatory of an airliner to increase passenger s at i sfac t io n a nd up date accessories. Since the plane first took flight in 1981, there are no CAD models available. New components need to fit into the current space, while accommodating fixed infrastructure such as water and power systems. The designer must start from existing conditions, tak ing out old parts a nd installing new ones within the same envelope of space. And, of course, this has to be done in a few weeks, as the airplanes need to return to flight as quickly as possible to reduce revenue loss. The digital duplicate of a wing tip created through reverse engineering using software programs

Newly manufactured wing tip based on reverse engineering of the spare part

April 2010 metalworking equipment news



Why Use This Process? There are two central similarities in these diverse cases: • There is a need to capture existing conditions rather than create new models; and • Time-to-market, or getting back into service, is crucial for asset management. Both of these requirements are suited for 3D point-cloud processing. Companies throughout the world are already using 3D point-cloud processing for MRO applications, including aerospace companies such as Pratt & Whitney, NASA and Tinker Airforce. To get a better picture of how 3D point-cloud processing can streamline the MRO process, let’s first review how CAD models are used in downstream applications. Then, we will take a look at the traditional process for creating those models for MRO parts and see how it compares to 3D pointcloud processing. The Importance Of CAD Models Accurate CAD models of parts and assemblies are required for a variety of downstream processes, including: • Generating 2D drawings for documentation and dimensioning; • Providing the model for CAE studies such as stress, thermal or fluid dynamics analysis; • Creating a numerical control path that drives a CNC machine for manufacturing a new part; • Producing physical prototypes to test parts and make sure they meet specifications; and • Inspecting the as-designed part against the asmanufactured part. 60

metalworking equipment news April 2010

The Traditional Process The traditional process used to create a digital representation of an actual object begins with a manual measurement tool such as a caliper or a CMM machine to obtain dimensions. In both cases, users need to have the expertise to know which dimensions will be important for reconstructing the digital shape. With the manual process, the dimensions are in 2D. With CMM, dimensions are captured in 3D, but only a small number of pre-defined points are collected. Collecting a large number of points requires a significant time investment. The output from the data capture phase is a list of measured key characteristics that can be used to model a 3D CAD object. This process requires a great deal of time spent on sketching, extruding and rotating profiles, and blending all the surfaces together. Total time for this process is usually measured in weeks. Streamlining With Point-Cloud Processing Point-cloud processing starts with the existing part. Or, it could be several examples of the same part, since

point-cloud processing provides the luxury of being able to easily obtain the average or optimal shape within a series of parts. Scanners used in point-cloud processing are capable of capturing millions of points in minutes to accurately represent the physical part. From those millions of points representing different examples of the part, point-cloud processing software programs can create a new model that is an average of all the samples. Automated tools recognise primitives and profiles from the scan data, repair holes and noise, and wrap the point cloud to form a polygon model. The polygon model is then converted into a surface model that can be directly transferred into popular parametric CAD software. The points-to-parametric-CAD process typically takes a couple of days. Since it is based on the detailed capture and automated reconstruction of the actual part, it increases accuracy, removes ambiguity, and ensures consistency between the CAD model and the manufactured part. Enquiry No. 3406

Geomagic: Design & Surface Modelling Solutions Geomagic has combined its three Geomagic Studio offerings into a single package that includes both design-intent and exact surface modelling solutions. Design-intent modelling within the software enables objects to be modelled as they were originally designed, with a combination of primitive shapes, swept features and freeform surfaces. This allows users to capture physical parts and model them without showing manufacturing defects or the wear-andtear that results from use over time. MEN Enquiry No. 3407



One Better Than 5

A Northern Ireland aerospace subcontractor identifies interpolative 6-axis machining as the way forward. By Chris Wright


n the past four years, first-tier airframe component supplier Moyola Precision Engineering, based in Castledawson, Northern Ireland, has invested £6.5 million (US$9.6 million) in its aerospace division. More than two thirds has been spent on three highspeed, 6-axis machining centres from Dörries Scharmann Technologie (DST), the latest of which was installed in November 2009. Having an extra CNC axis in addition to the more usual five axes results in productivity and cost benefits when machining aircraft structural parts, according to Moyola’s MD, Mark Semple. Upping Productivity A major advantage is that deep recesses and other awkward areas on components can be accessed and machined at high speed by short cutters. If the same parts were machined on conventional 5-axis machines, longer tools would be needed for clearance. There would be a consequent risk of chatter adversely affecting surface finish. The likelihood, therefore, is that cutting speeds and feeds would have to be reduced, compromising productivity.

The kinematically driven Sprint Z3 head on the two DST Ecospeed F2035 machining centres tilts through ± 40 deg in both the vertical A-axis and horizontal B-axis. This is suitable for a majority of machining tasks. H owe v e r, t he a b i l it y to automatically replace the in-line spindle with a right-angle milling head in under three minutes allows steep angles up to 130 degrees to be achieved. By interpolating the 360-degree C-axis rotation of the head with the X, Y, Z, A and B axes, even difficult-toreach areas on aircraft parts can be machined easily with short, rigid tooling. Irrespective of whether the in-line or right-angle head is in use, full advantage can be taken of the 120 kW / 30,000 rpm spindle on the F2035 and of the 80 kW / 30,000 rpm spindle on an otherwise almost identical machine installed in 2005. It is noteworthy that, unlike on many high-speed machining centres, it is not necessary to be operating at maximum rpm to achieve full power, which is available at speeds as low as 13,800 rpm – less than half of full speed.

This added flexibility enables cutting speeds, feeds and depths of cut to be optimised to achieve maximum performance for each cutting tool assembly. Observations On The Ground Mr Semple said: “We achieve high metal removal rates when roughing as well as good surface finish and high accuracy during finishing cycles.” “In early trials carried out by various machine suppliers, DST produced in 2.05 hours an Airbus A320 wing rib that used to take us 9.5 hours on one of our 5-axis machining centres. The next quickest machine from another potential supplier took over four hours to complete the part,” he explained. “To really appreciate the speed of the machines, you have to see them in action or look at a video. They generate such large volumes of aluminium chips so quickly that we are oblige d to compac t t hem continuously, other w ise we would have a problem with swarf management,” he added. MEN Enquiry No. 3408 April 2010 metalworking equipment news




Throttle At The

Portland Boeing Plant

The necessity for lean production process serves as a catalyst for a partnership, which is going from strength to strength. By Dr Ing Hans-Peter Schossig, engineering consultant, Deckel Maho, Pfronten.

Wall magazine on a universal machining centre saves space 62

metalworking equipment news April 2010


he demand for structural or integral parts consisting of a n ever g re ater number of light but high strength alloys is experiencing disproportionately high growth. Thanks, above all, to the demand of advanced technology in the aerospace industry. Lightweight engineering is also on the rise in car making (just think of chassis, steering parts, cylinders, and engine blocks) and structural alloy parts are finding an increasing number of applications in general machine building as well. Complex five-axes machining experiences the highest growth pattern in chipmaking technology. The manufacture of all these complex workpieces of ever higher quality alloys is associated with high chip volumes. For most small series in the aviation industry,


The manufacture of all complex workpieces of ever higher quality alloys is associated with high chip volumes

this chip volume is generally 90 percent and in some cases even 98 percent of the raw material that has to be milled away. The effects of this complete milling process with its high chip volume have a very deep impact on the technology processes, the cutting tool technology, and the milling machine design. The Right Match It was initially the manufacturers of special machines that had the better positioning in aerospace. The same holds true for the manufacturers of special HSC or HPC milling machines, who have been around in the industry for a long time and are familiar with the industry’s demands. These special machines, though, have their drawbacks. Although customised machines are effective, they are, however, expensive. Consequently, the OEM’s in aerospace conducted suitability tests of standard milling machines within a reasonable price bracket. The results showed suitable machines were found, for example, in the DMC 200 U five-axes universal machining centres with standard equipment. The project deadlines for commissioning these portal type milling centres with machining chambers X/Y/Z = 1,800/2,000/1,100 mm go as far back as the end of 2002. At this time, when suitability tests had been concluded successfully in Allgäu/Bavaria, the first machine was ordered and delivered in April

of the following year. F u r t h e r m o re , t h e c h ip s generated from 90 percent of the blank part could be discharged without problems out of the machining chamber. Moreover its internal coolant supply machine was also fitted with a cooled 3,000 litre tank and minimum lubrication, all parts and components from normal machine accessories. Accommodating New Requirements The Deckel Maho engineering team in Pfronten, Germany, optimised their universal machine

designs further to accommodate the ever growing requirements of the aviation industry. This is based on the belief that ‘the basis from which to further develop are the most modern standard machines that have proven themselves in many industries under the most adverse conditions.’ These standard machines have to be adapted to the demands of aerospace companies and equipped with the necessary options. This had direct effects on the Boeing collaboration with DMG and Deckel Maho Pfronten. In mid-2005 an order was placed for another, correspondingly fitted, DMC 160 U duoBLOCK universal milling centre. I n c i d e n t a l l y, p l a n n i n g preliminary tests, the new DMC 160 aero milling spindle not only generated up to 8,000 cm 3 of alloy-chips per minute, but also discharged them atomatically out of the machine – just as it is necessary for lean – production and complete – machining. Enquiry No. 3409

DMG: Compact 5 Axis Precision Machine The combination of HSC milling and ultrasonic chip removal allow soft plastics materials, demanding metals and high-strength zircon oxide to be machined on one single machine. Ultrasonic 10 by DMG copes not only with this broad spectrum of materials but also with the complex structures. The proven water-cooled high-frequence spindle with HSK-25 holder reaches rotational speeds of 42,000 rpm, and the NC swivel rotary table with torque technology has a swivel range from -20 to +120 deg.


Enquiry No. 3410

April 2010 metalworking equipment news




Steel & Energy:


Chris Chidsey, Marlborough, United Kingdom

Manage This? Energy conservation in steelmaking is crucial, to ensure the competitiveness of the industry and to minimise environmental impacts, such as greenhouse gas emissions. By World Steel Association


teel production is energy i nte n si v e . H owe v e r, sophisticated energ y management systems ensure efficient use and recovery o f e n e r g y t h ro u g h o u t t h e steelmaking process for reuse, wherever possible. I mprovement s in energ y efficiency have led to reductions of about 50 percent in energy required to produce a tonne of crude steel since 1975 in most of the top steel producing countries, as shown in Figure 1. Energy Inputs As Reducing Agents The production of primary steel is more energy intensive than the production of secondary steel

(Figure 2) due to the chemical energy required to reduce iron ore to iron using reducing agents. Table 1 shows the main energy inputs of steel production and their applications as energy and reducing agents. Because reduction does not take place at room temperature, reducing agents such as coal, coke and natural gas also function as the heat supply. Coke, made by carburising the coal (ie: heating in the absence of oxygen at high temperatures), is the primary reducing agent of iron ore, and most other fuels are used to substitute a portion of coke. If a plant does not produce its own coke and/or electricity on-site, these must be purchased externally.

Figure 1: Improvements in energy efficiency have led to reductions of about 50 percent in energy required to produce a tonne of crude steel


metalworking equipment news April 2010

By-Product Gases By-product gases from the coke oven, blast furnace and Basic Oxygen Furnace (BOF) can be fully reused, saving additional fossil f uel re sou rce s. T hey typically contribute 40 percent to total energy and are used either as a direct fuel substitute or for the internal generation of electricity. Innovative technology now exists that allows CO 2 to be recaptured and remarketed, such as a steelmaking plant that is supplying a nearby gas facility with 50,000 tonnes of CO2 per year. In turn, the gas is cleaned up and used to make carbonated drinks.

Figure 2: The production of primary steel is more energy intensive than the production of secondary steel


Table 1: Applications of energy inputs in steel production

Future Improvements In Energy Efficiency Today’s best-available steelmaking processes have optimised energy use. Medium-term energy efficiency improvements in the steel industry are expected through technology transfer, or applying best-available technology to out-dated steel plants worldwide. Breakthrough technologies are expected to lead to major changes in the way steel is made, with a time frame of 2020 and beyond. Steel Production Basics Steel is produced using primary or secondary methods, as shown in Figure 2. Primary steel currently accounts for about 75 percent of world steel production and is produced by reducing iron ores to iron and converting iron to steel. The main inputs are iron ore, coal, limestone, and recycled steel. The main primary production routes are: • Blast Furnace (BF) – Basic Oxygen Furnace (BOF): 66 percent • BF – Open Hearth Furnace (OHF): Three percent • Direct Reduction (DR) – Electric Arc Furnace (EAF): Six percent Secondary steel accounts for about 25 percent of steel and is produced by recycling steel in an Electric Arc Furnace (EAF). The main inputs are recycled steel and electricity. Most steel products remain in use for decades before they can be recycled. Therefore, there

is not enough recycled steel to meet growing demand using the secondary steelmaking method alone. Demand is met through a combined use of the primary and secondary production methods. Open Hearth Furnace (OHF ) technology use continues to decline owing to its environmental and economic disadvantages. Steel’s Role In Energy Production & Transmission Steel is indispensable for energy production and transmission. It is used to manufacture: • Mining equipment and offshore oil platforms • Equipment for oil and gas extraction and production • Natural gas and oil pipelines and storage tanks • Ships, trucks and trains used to transport many forms of energy • Transformers (magnetic steel core) • Generators and electric motors • Power transmission towers and cables Steel also plays an important role in renewable energy technologies. For example: • Solar: stainless steels play a key role in converting solar energy into electricity or hot water. They are used as a base for solar thermal-panels and in pumps, tanks and heat exchangers. • Wave and tidal: a steel pile is the main component of a tidal turbine in tidal energy systems.

Steel is also used to fabricate wave energy devices. The steel used is formulated to withstand the harsh marine environment. • Wind: steel is the main material used in onshore and off-shore wind turbines. Almost every component of a wind turbine is made of steel, from the foundation, to the tower, gears and casings. Steel Saves Energy Over Product Life Cycles While steel products require energy to produce, they can also offer savings over the life cycle of the product, sometimes greater than the energy used during their production. For example, over 20 years, a three-megawatt wind turbine can deliver 80 times more energy than is used in its production and maintenance. Steel also reduces product life cycle energy use and emissions in other ways, including through: • Light-weighting – Advanced High-Strength Steels (AHSS) allow for less steel to be used in cars, reducing their weight by nine percent, fuel consumption during the use phase by 5.1 percent, and greenhouse gas emissions by 5.7 percent, without compromising safety. • Recycling – steel is easily recovered with magnets and is 100 percent recyclable. It can be infinitely recycled without loss of quality. Recycling reduces the use of energy and other raw materials in the making of new steel. In 2006, about 459 million metric tonnes (mmt) of steel were recycled worldwide, saving the equivalent of 242 mmt of anthracite coal. MEN Enquiry No. 3501 April 2010 metalworking equipment news



a complex mix of technical requirements, customised systems, aftersales support, management and co-ordination services, trial operations, supervision and personnel training. At the company’s 214,000 sq m plant in Genoa, Italy, production is divided into three product lines; steam turbines, gas turbines and generators, providing plant engineering for turnkey power plants.

Power Solutions The


A cutting tool supplier offers its expertise to a power generating solutions provider, equipping it adequately to propel the world. By Gisbert Roth, manager, marketing operations Asia-Pacific, Seco


it h 1,70 0 p owe r projects in more than 90 countries, Italy’s Ansaldo Energia, part of the Finmeccanica group is a player in the global energy industry. The company started off as a mechanical engineering company that would make and repair components for railways. Over the years, it diversified into many other businesses where its engineering skills could be used as an advantage. These included shipbuilding, the automotive industry and munitions manufacturing until the company finally settled on what was to become its core business – power generation. A New Challenge Ansaldo’s product range includes electrical power stations of all shapes and sizes including 66

metalworking equipment news April 2010

combined cycle gas turbine, thermal, geothermal and nuclear units, supplied as complete, turnkey plants or as individual solutions. T h e c o m p a n y ’s b i g g e s t challenge, says workshop manager Marcello Parodi, is to boost the number of steam and gas turbines it produces each year while maintaining a high level of flexibility. “We are often asked to have our solutions available within a short timeframe – eight months for a gas turbine and 12 for a steam turbine. We need to work hard to maintain these delivery times and to shorten them further.” Recent events in the world economy will certainly take their toll, but the company expects the global market for efficient and flexible power generation systems to remain high. To meet this demand, the company has to comply with

Turnkey Solution Edoardo Bruno, manager of the turbine blade department, is excited by the company’s ability to provide turnkey power plants. “We start with a green field and finish with the exchange of a key,” he says. “The customer doesn’t have to do anything. The operator just turns the key and produces power for the world,” he adds. Demand is high and keeping up the pace is a priority. Mr Bruno explains: “Our goal is to increase the volume of blades. We have a lot of products to produce and we rely heavily on our suppliers as well as on our own capabilities.” As the main supplier, Seco provides approximately 90 percent of the tools used in the blade shop and the relationship between the two companies, which began in 1988, is strong. Emilio Scandroglio, international application expert at Seco says: “The global demand for energy is huge and the power generation segment is booming. Ansaldo chooses to work with us because we provide solutions, which add value. In other words, we give them more than just inserts. It’s a partnership built on trust.” That is a view that Mr Bruno confirms: “We don’t want our suppliers to supply a single component. We want them to find solutions to machining problems. This usually starts with some tests where we make an evaluation of the performance of a single tool. Then we analyse the cost benefits and


the effect it has on our capacity to produce more blades.” “ T he a im is to i ncre a se the number of products that we produce and to reduce the amount of time spent on a single piece. These were the criteria we used to test products from Seco, machining the blade for a turbine starting from the raw bar. We have achieved good results, making improvements to the previous tool we used.” Benefits – The Number Game In one application, the provided machining solution resulted in a gain of some 50 percent, cutting the time it took to machine one blade from 92 minutes to less than 50 minutes. This was achieved by changing the working method, type of tool and grade. The tool supplier also introduced the MP2500 – the grade featuring

the Duratomic technology. This offers better tool life and increased performance when machining turbine blades. “It represented an improvement compared to the previous method we were using,” says Mr Bruno. “We reduced machining time by about 50 percent so in effect, we increased our production.” There have been many similar successes over the years, not least when it comes to disc milling. Mr Scandroglio recalls: “Once we replaced four special cutters that the plant was using to produce a turbine blade root with just one standard cutter. We completely changed the machining strategy and reduced the milling time by 70 percent – from 75 minutes to less than 30 minutes.” As new machines are installed at the plant, Mr Bruno’s team is taking the opportunity to work

with the tool supplier to develop new methods using Minimaster and helical cutters with Duratomic inserts. “We are also developing, with the supplier, high-tech tools with indexable inserts. This is very interesting for us because we can replace, for example, a lot of old high speed steel conical cutters and improve the machining time,” says Mr Bruno. “With these solutions, we can get a single tool which can be used from beginning to end without having to regrind which saves time and money.” This co-operation looks set to continue. Mr Bruno concludes: “Going forward, I would like to see a continuous development along the road we have made together with more new products, not only in the blade shop, but in all areas of production.” MEN Enquiry No. 3601


April 2010 metalworking equipment news



the demand for machine safety products.


Monetary Value Of

Safe y Rising awareness of equipment safety boosts prospects for the South-east Asia, Australia and New Zealand machine safety markets. By Vandhana Venkatesan, research associate, Frost & Sullivan


20 16


14 12 10 8


6 4 2









Revenues ($ US Million)


hile the dema nd for machine safety equipment is approaching maturity in Western countries, these products are witnessing speedy adoption in South-east Asia and Australia-New Zealand owing to the increase in Foreign Direct Investment (FDI) in industries in the region. These countries are experiencing comparatively higher growth and emerging as equally competitive markets in the global scenario. FDI focus is gravitating away from the primary sector to the manufacturing and tertiary sectors, encouraging more investments in automation and safety. End users have started to consider machine safety as a time and cost saving investment. Stringent safety standards in the South-eastern countries are driving the machine safety market to a great extent. 68

Revenue Growth %

Revenues ($ US Million)

18 200

metalworking equipment news April 2010

2010 Year






Benefits Of Safety In Production Global competition is forcing manufacturers across industries to reduce downtime and increase uninterrupted production. Safety equipment prevents failures by 60 to 70 percent, enabling a decrease in process downtime. Rising global demand for manufactured goods, strain on resources, and growing emphasis on efficiency are factors that impact market dynamics. End users are apprehensive about using new technology in machine safety products, perceiving it as complex and difficult to incorporate at the workplace. In a market that is experiencing fast paced expansion, customer knowledge about new products remains low, and it is challenging to convince them to accept new technologies.

Growth (%)

Increasing Awareness Analysis from Frost & Sullivan finds that South-east Asia, Australia and New Zealand machine safety market earned revenues of over US$93.9 million in 2008 and estimates this to reach US$228.8 million by 2015. Legislations have moved f rom a pre scr ipt ive to a p e r for ma nce - b a se d mo de l, where manufacturers, users, and employers are responsible for the safety of machinery under the Occupational Health and Safety Act. Owing to the increasing awareness of machine safety and compliance requirements, products are being made to cater to specific end-user segments. As the time span for obtaining regulatory approvals in the Southeast Asian countries is short, manufacturers are motivated to set up plants in this region. Besides, multinational companies operating in the market have to adhere to strict safety standards, raising

Meeting Competition Nonetheless, the market is poised for a demand upswing and new opportunities await those operating in this arena. It is imperative for participants to constantly upgrade their products to align with evolving customer needs and focus efforts on improving end-user awareness and acceptance. Global machine safety market participants face competition from small regional manufacturers in their respective countries. Manufacturers competing in this domain must possess the requisite skills to enable higher revenues and the build-up of strong brand image. With a whole new range of co nt rol le d , re l ia ble s a fe t y components entering the market, sa fet y implementation that guarantees optimum machine utilisation is no longer constrained by the limitations that had earlier held back its implementation. MEN Enquiry No. 3602




Event Preview:

Metaltech 2010


etaltech 2010, an annual trade platform for the metalworking and manufacturing industry, will be held from May 5 - 9, 2010 at Putra World Trade Centre, Kuala Lumpur. The event is expected to play host to more than 1,500 exhibiting companies, an overall increase of 30 percent from last year, as well as making this year the largest Metaltech in its history. The show covers a total exhibition area of 30,000 sq m (gross), and expects to attract over 20,000 visitors locally and 5,000 visitors from around the world. Billed as the international machine tool and metalworking exhibition in Malaysia, it is an event for manufacturers and metal industry players from around the world to showcase and source for metal work, machine tools, CAD/ CAM, metrology, mould and die, surface and heat treatment, subcontracting, foundry, industrial automation, robotics, precision engineering and welding technology and products. Happening Concurrently Incorporated into Metaltech 2010 is the Welding Technology Exhibition 2010 (Weldtek 2010), the 10th Malaysian International Exhibition on welding equipments and technology, welding services and welding competition. Co-located at Metaltech 2010, is MTA Malaysia 2010 (MTA 2010), the 7th Malaysia International Precision Engineering, Machine Tools and Metalworking Exhibition, and the Malaysia’s Automation Technology Exhibition and Conference 70

metalworking equipment news April 2010

(AUTOMEX), the Malaysia International Exhibition and Conference on process automation, factory automation, industrial automation, instrumentation and control, bus and wireless technology, hydraulics and pneumatics, and robotics. Manufacturing In Malaysia Initiatives have been taken by the Ministry of International Trade and Industries to promote the activities of manufacturing related services which include operational headquarters, regional offices and distribution centres, international procurement centres, representative offices, research and development (R&D), design and prototyping, technical or vocational training, integrated logistics as well as market support services, integrated centralised utility facilities, total chemical management system, cold chain facilities and services for food products. MD of Trade-Link Exhibition Services, the organiser of the event, Albert Lai said, “Whilst businesses in 2009 have been affected by the weakening of the global economy as

well as the global calamities such as the outbreak of H1N1, the business sectors especially the manufacturing industry is looking forward to an improvement in business activities in 2010. With renewed optimism for a recovery in the economy, the business confidence of various industries in Malaysia has increased and is beginning to flourish again.” He added: “The manufacturing industry in Malaysia has constantly been a major player in the economic growth. Malaysia’s well-established distribution channels, integrated infrastructure, and workforce have made the country an attractive destination for development and investment, particularly in the manufacturing industry.”

Putra World Trade Centre Kuala Lumpur, Malaysia May 5 – 9, 2010 Enquiry No. 3701


Product Highlights Akyapak: Four Roller Hydraulic Bending Machine

Akyapak manufacturers four roller hydraulic plate bending machines with the capacity of bending from 2 mm to 100 mm in thickness and from 1,000 mm to 6,000 mm in width/length. The frames of the machines are of fabricated, welded steel construction. The roll shafts, the materials and bearings used in production are of good quality and the torque limit of the machines is high. NC playback and CNC graphic control systems are available as optional accessory.

Boschert: Cutting, Punching & Forming

Combicut by Boschert allows forming, punching, marking and plasma cutting in one machine. The machine is capable of good cutting quality due to flexible adaptation of the process sequence to the cutting job. The cutting process is optimised by fast control of the cutting current, dynamic response at small contours and reduced run-in path and corner signal. Other advantages include rapid operation because of fast transition from pilot arc to main arc and improved energy blance due to minimised switching losses. Enquiry No. 3704

Enquiry No. 3702

Apex: Oil Coolant Purifying Attachment System

Dahlih: VMC

The AS-320 by Apex, is an oil coolant purifying attachment system which can be installed to a CNC machine, grinding machine, CNC lathe or other machines using oil coolant system. This system can separate oil and other by products from the coolant, rendering it reusable. It also has an ‘industrial ozone making device’, which can produce high dense ozone for disinfections and deodorisation. Finally, the system has a function that reduces junk production, which helps environmental protection and also increases the performance and efficiency of equipment.

With the major casting parts designed and analysed using FEA, the MCV-860 VMC by Dahlih exhibits structural rigidity and accuracy. Suitable for precision parts and general machining, the VMC has applications in the automotive and mould and die industries. The stability of the machine is provided by the wide column base, which in turn allows rigid fastening to the machine base. Other feature includes separate construction of feed systems on the three axes, which results in reducing the length of ball screw and at the same time ensuring good rotational inertia during highspeed rotation.

Enquiry No. 3703

Enquiry No. 3705 April 2010 metalworking equipment news



Product Highlights


Dama: CNC Drilling Machine For Joint-Plate

Mitutoyo: Contour Measuring Instruments

Dama, an automatic steel plate cutting equipment producer headquartered in Taiwan, has developed the DMD-06/20. With interactive command and colour display, the drilling machine allows easy learning and operation. The drill machine has a strong cantilever structure that also adds to the ease of operation. In addition, it is possible to read the DXF file and display the hole pattern on screen. Accurate positioning is provided by the machine’s X and Y axes, which are equipped with ball screw, AC servo motor and linear guide.

The Contracer CV-3100/CV-4100, a contour measuring instrument by Mitutoyo features increased drive speed (X axis: 80 mm/s, Z2-axis: 20 mm/s) that further reduces total measurement time. In order to maintain the traverse linearity specification for an extended period of time, the maker has adopted highly rigid ceramic guides that combine the characteristics of smallest secular change and resistance to abrasion. With the suppor t for a wide range of optional peripherals designed for use with the CNC models, it enables simplified CNC measurement.

Enquiry No. 3706

Enquiry No. 3708

Delcam: Fully Integrated System

Quick-Tech: Nine-Axis Sub Spindle Machine

Delcam for SolidWorks software marks a new direction for the software maker. Previously, the company has supplied all of its machining software as stand-alone systems that can be linked to any CAD program. In contrast, Delcam for SolidWorks is fully integrated into the SolidWorks environment so that the program looks and behaves like SolidWorks. It offers full associativity so that any changes in the CAD model will be reflected automatically in the toolpaths. The program is based on proven machining algorithms that are already used by more than 30,000 customers around the world.

The XP4-42SM is a versatile tooling system that allows complex components to be finished completely in one operation. The tooling design has almost no interference problems allowing the full compliment of tools to be utilised. Synchronised spindles make rapid change from main to sub spindle possible. Simultaneous cutting on both main and sub spindle can be done depending on the work piece. Both spindles are cartridge type, pre-assembled and factory sealed, requiring no maintenance or lubrication.

Enquiry No. 3707

Enquiry No. 3709

metalworking equipment news April 2010


Event Preview:

MTA Malaysia 2010


he diversity of brands and technologies exhibited at this event has been attracting thousands of visitors yearly. Last year’s show attracted some 17,371 trade visitors and buyers from the various manufacturing industries in the aerospace, automotive, electronics and electrical, machiner y and equipment, mould and die manufacturing industries and others to the event which occupied 25,000 sq m of exhibition space and had 900 participating companies from 30 countries/region. Foreign Participation The event will be welcoming once again the international group pavilions from Singapore, Germany and Taiwan in showcasing the latest technology exclusively from the respective countries. The Singapore pavilion is co-ordinated by the Singapore Precision Engineering and Tooling Association (SPETA). The Taiwan Pavilion is co-ordinated by the Taiwan Machine Tool and Accessory Builders’ Association (TMBA). The German pavilion is coordinated by the German Ministry of Economics and Technology (BMWI), the AUMA Association of the German Trade Fair Industry and the German Machine Tool Builders’ Association (VDW). This pavilion will showcase the latest German Technology to this region with participation from reputable companies. Precision Manufactured Equipment Malaysia continues to enhance its position as a centre of excellence for the production of precision

The event is a platform where many exhibitors and visitors can source for new business leads

manufactured equipment and machiner y. Reflecting this market trend, MTA continues to be an important trade show to cater for the growing needs of the industry. Backed by firm endorsements from relevant government and trade associations, MTA Malaysia is a platform where many exhibitors have achieved their objectives in all previous shows – whether looking for an experienced local agent/

distributor, sourcing for new quality business leads and exploring the best ways or to reach Malaysia’s entire metalworking industry.

Putra World Trade Centre Kuala Lumpur, Malaysia May 5 – 9, 2010 Enquiry No. 3710 April 2010 metalworking equipment news



Product Highlights


ABB: Robot For Flexible & Compact Production

Makino: Compact VMC

The IRB 120 robot is the addition to ABB’s fourth-generation of robotic technology and the company’s smallest ever robot. Suitable for material handling and assembly applications, the IRB 120 robot provides an agile, compact and lightweight solution with good motion control and path accuracy. Together with the robot comes the IRC5 compact controller, which extends the IRC5 family of robot controllers. It brings with it the familiar benefits of the robot controller, including flexible RAPID language; whilst adding the advantage of a minimised footprint.

Slim 3 is equipped with coolant and chip management and can mount larger components and heavier fixture. This lean yet productive machining centre by Makino is a compact, rigid machine with the right ergonomics. The machine provides easier tool loading access, shorter and convenient component loading distance of 400 mm and table to floor distance of 810 mm.

Enquiry No. 3711

Enquiry No. 3713

Farman: 5-Axis CNC Tool Grinding Machine

Sodick: High Speed Die-Sinker EDM

The Hawemat grinding machine by Farman features a pickup loading system. It allows one operator to control several machines. With this feature, the process of tool changing is more cost-effective and potential damages are reduced. In addition, the machine also comes with tool support (V block and press finger), which can guarantee minimum run-out of the tool. Available also is the measuring probe for online measuring of grinding wheel and cutting tools data storage.

AG40L by Sodick is the fifth generation linear motor drive high-speed die-sinker electrical discharge machining technology. The ‘LN2 controller’ has adopted the ‘perfect active control’, enabling simultaneous control of high speed electrical discharge and axis movements by using serial communication technology of 1 Gbit/sec. The arc-less system features further improved ‘zero wear’ and also ensures improvements in machining speed and accuracy with copper electrodes. Further standard SVC circuit features quality surface finishing, like satin surface finish with low electrode wear.

Enquiry No. 3712

Enquiry No. 3714

metalworking equipment news April 2010


Adcole: Software Option For Camshaft Measuring Machines

Ceratizit: Milling System

A software option for camshaft machines can measure axial profile across the industry’s n e we r c a m l o b e s , which have become narrower and produced with higher grinding tolerances. T he A dcole 911 ca m sha f t gau ge is suitable for measuring all automobile and diesel lobe lifts, injector lobe profiles and more.Measuring from across the cam lobe at every degree of 360 deg revolution, this software can detect a transversal defect of the cam grinding wheel from the wheel dressing procedure which affects the cam lobe shape.

The MaxiMill 273 with octagon milling inserts from Ceratizit for doublesided utilisation sets standards in terms of economy. The company has for the first time managed to produce a high-precision prismatic insert with a positive clearance angle on both sides. The tooling system combines the advantages of negative inserts (both sides of the cutting edges can be used) with those of positive inserts. The milling system covers machining operations ranging from roughing to finishing at cutting depths up to 3.5 mm.

Enquiry No. 3801

Enquiry No. 3802

TORNOS Sigma 20 II Accessibility, Simplicity

TORNOS DECO 13a/e High Productivity, Very Complex Parts

TORNOS TECHNOLOGIES ASIA LTD Unit 4, G/F, Transport City Building 1-7 Shing Wan Road, Tai Wai Shatin, N.T., HONG KONG Tel. +852 2691 2633 / Fax +852 2691 2133 TORNOS S.A. THAILAND REPRESENTATIVE OFFICE Tel. +66 2 662 3908 / Fax +66 2 662 3910 TORNOS TECHNOLOGIES ASIA LTD MALAYSIA REPRESENTATIVE OFFICE Tel. +60 4 642 6562 / Fax +60 4 642 6561



Almac CU 1007 Machining Centre Progressive and Modular

With the TORNOS range of solutions you benefit from a ONE-STOP SHOP provider for all your high precision machining needs in MEDICAL and DENTAL applications!

April 2010 metalworking equipment news



Faro: 3D Measurement System

Kennametal: High Productivity End Mills

Fa ro, the prov ider of portable measurement and imaging solutions, has released a 3D measurement system, the Faro Laser Tracker Ion. The laser tracker is claimed to be the most accurate available based on the most common types of measurement applications. It also features a longer measurement range, lighter weight, and contains a distance measuring system. Specifically, the Ion has improved the volumetric accuracy by 27 percent over the previous model to 0.049 mm at 10 m. The measurement diameter range has been extended 36 percent to 110 m, and the weight has decreased 12 percent to 17.7kg. Enquiry No. 3803

igus: Fixing Cables In Place


With a short-shank style resulting in stable operation and unequal flute spacing that reduces vibration and chatter, the GOmill line of end mills from Kennametal mean increased metal-removing productivity and good surface finishes for a wide range of metalworking applications. GoMill products are being introduced in three versions: a three-flute ball nose, a four-flute with chamfer, and a three-flute sharp. All feature a short shank for increased stability and rigidity, unequal flute spacing for reduced chatter and vibration, and AlTiN coating for long tool life. Enquiry No. 3805

Master Chemical Corp: Metalworking Fluid For Ferrous Materials

Cologne-based company igus has developed ‘Chainfix’ saddle clamps for fixing cables properly within energy chains. Laboratory tests show that their tensile strength is around three times higher than that of standard clamps (3,500 N instead of 1,000 N). The narrow width and low height make the optimum use of limited space when directly mounted in the energy chain mounting bracket. Ribbed plastic saddles ensure a positive connection with the cables resulting in secure strain relief. The cables remain clamped even under very large pull so that they cannot slip out.

Master Chemical Corp ha s de ve lop e d t he Trim C380, a synthetic meta lwork ing f luid, which has been optimised for high tech ferrous materials including stainless steel and Inconel. T h e s e m a te r i a l s are widely used in the aerospace, medical, and electronics industries. Additionally, C380 provides resistance to corrosion on these high-tech ferrous materials and is easily removed from parts for easy cleanup before assembly, painting, or plating operations. Using the metalworking fluid will produce good surface finish in finish-grinding operations and is high performing in a wide range of operations from general grinding to heavy-duty machining.

Enquiry No. 3804

Enquiry No. 3806

metalworking equipment news April 2010


Matsuura: 5-Axis Multi-Tasking Machining Centre CAD/CAM SYSTEMS Mastercam X4 is here, delivering dozens of new tools based on input from users like you. From dramatically finer machine finishes and efficient dynamic milling to fast multi-core computer processing, Mastercam X4 provides maximum productivity at a great value. Find out how the world’s most widelyused CAM software* can maximise your shop’s machining. *Source: CIMdata, Inc. 2009

See Mastercam X4 in action at

Techtown Pte Ltd • Tel: +65 6741 3318 • Fax: +65 6741 0181


Matsuura Machinery Corp has developed the Cublex-63, a 5-Axis Multi-Tasking Machining Centre. The machining centre is based around the company’s proven 5-Axis machining centre-technology. It integrates 3 functions (milling, turning and optional grinding) into one machine, which have traditionally been executed on different machine types. The machine enables an increase in customer’s process integration. It is configured to allow for easy expansion of the tool magazine and pallet capacity for complete unmanned operation. Enquiry No. 3807

Henko Machine Tools Pte Ltd No.23 Kaki Bukit Industrial Terrace Singapore 416103 Tel: +65 6846 4666 Fax: +65 6846 4555 For enquiries, please email: Website:



Henko Machine Tools Pte Ltd is the authorised Distributor for LEISTRITZ, distributing the Profile and Keyseating Machine. Together with LEISTRITZ unique toolings, the Profile & Keyseating machine is able to manufacture part/components with either taper or parallel keyways. With the use of this machine, it offers you the Flexibility, Productivity & Quick Service.

April 2010 metalworking equipment news



Paragon Machinery: For Small Customised Workpiece


Studer: ecoGrinder

The GA/GU2020 CNC by Paragon Machinery is suitable for grinding sma ll cu stom ise d workpiece s. The wheelhead with hydrostatic-hydrodynamic hybrid bearing offers no friction, no thermal deformation and greater grinding capability, according to the manufacturer. The tailstock equipped with MT4 taper centres can adjust the centre pressure required for the grinding of small, thin parts. The tailstock with micro taper adjustment can make correction in the range below 1 um during grinding between centres.

The Studer CNC universal OD and ID cylindrical grinder is designed for grinding medium-sized workpieces in single and small batch production. The open enclosure ensures an optimal view of the grinding process and easiest accessibility. The practical grinding software with its proven pictogramming means even lesser-experienced users can quickly and practically program grinding and dressing cycle. Special applications such as profiling grinding wheels for complex workpiece shapes can be programmed efficiently.

Enquiry No. 3808

Enquiry No. 3810

Schneeberger: 5 Axis Universal Tool

Widia: Holemaking Advances Catalog

Schneeberger has developed a CNC 5 axis universal tool and cutter grinder. It is an affordable 5 axes in the market with uncompromised technology and power. The new user-friendly software with graphical support and touchscreen enables the operator to program even complex tools in a short time. Equipped with a watercooled high-torque motor, (7.5 kW at 100 percent and 10 kW at 60 percent) this small machine is a solid performer.

‘Holemaking Advances 2010’ is the catalog of Widia brand holemaking solutions, with product offerings, including holemaking products in the Victory line. The catalog is available in print or as a downloadable PDF file. In addition to product specifications and applications, the catalog also describes many additional services, including training, custom tooling solutions, supply-chain services, and carbide recycling and reconditioning.

Enquiry No. 3809

Enquiry No. 3811

metalworking equipment news April 2010

Exhibition Programmes April

19 – 23 Hannover Messe


13 – 16 Intermach 2010

Exhibition Grounds Hannover, Germany Deutsche Messe

BITEC Bangkok, Thailand UBM Asia (Thailand)

21 – 24 Japan Int’l Welding Show 2010

13 – 16 Sheet Metal Asia 2010

Tokyo Big Sight Tokyo, Japan Japan Welding Engineering Society


5–9 MTA Malaysia 2010 Putra World Trade Centre Kuala Lumpur, Malaysia Malaysian Exhibition Services

5–9 Metaltech 2010

Putra World Trade Centre Kuala Lumpur, Malaysia Trade-Link Exhibition Services

8 – 11 MT Duo

Taipei World Trade Center (TWTC) Exhibition Hall Taipei, Taiwan TAITRA & TAMI

13 – 15 Subcon Thailand 2010 BITEC Bangkok, Thailand UBM Asia (Thailand)

BITEC Bangkok, Thailand UBM Asia (Thailand)

20 - 22 Vietnam Manufacturing Expo 2010

ICE Hanoi Hanoi, Vietnam Reed Tradex


2–5 Manufacturing Surabaya 2010

Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo

24 – 27 Automotive Manufacturing 2010 BITEC Bangkok, Thailand Reed Tradex

24 – 27 Intermold Thailand 2010 BITEC Bangkok, Thailand Reed Tradex


6–9 MTA Vietnam 2010

Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam

August 4-7 Taipei International Mold & Die Industry Fair Nangang Exhibition Hall Taipei, Taiwan Chan Chao International

September 13 – 18 IMTS

McCormick Place Chicago, USA AMT

15 - 17 Asiamold

Poly World Trade Centre Expo Guangzhou, China Messe Frankfurt

October 7–9 Metalex Vietnam

Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam Reed Tradex

April 2010 metalworking equipment news


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metalworking equipment news April 2010

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2/18/09 11:19 AM

m na et Vi TA 10 n M 20 d i ly ite Ju hib Ex

SMART Machine SMART Controller SMART User Awarded

Top 10 New Launched Product Prize 2009 And

The Japan Brand Prize,

Hosted by Nikkan Kogyo Shinbun

QUICK TURN SMART NEW! 100S, 150S, 200, 300 & 350

High Productivity

Operator - Friendly

High rigidity integral spindle

Compact servo controlled turret

X-Z axes rigid linear roller guide

NC Tailstock

Conversational CNC with EIA

Energy Saving

Personnel Sensor (Introduced first time in the industry)

Tel : +65 6862 1131 Fax : +65 6861 9284 Email : Website:


Our complete portfolio. Your complete satisfaction.

From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction.


Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call (65) 6265.9222 or visit

• Australia 613.9755.5302 • India 9180.2219.8341 • Japan 813.3820.2855 • Malaysia 603.5569.9080 • Singapore 65.6265.9222 • China 8621.3860.8288 • Indonesia 6281.1148.8217 • Korea 822.2109.6100 • Taiwan 8862.2523.3660 • Thailand 662.642.3455 ©2009 Kennametal Inc. l All rights reserved. l A-09-02229

APMEN April 2010  
APMEN April 2010  

Asia Pacific Metalworking Equipment News