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How Small

?

Can It Get

A Look At Micromachining

A

Cool Weld To

Way

Can Welding Really Be Cold?

The Of The Official Magazine For Metaltech 2011


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April 2011

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How Small

Cover credit: Hexagon Metrology

VOL. 24 NO. 3 APRIL 2011

April 2011

ASIA PACIFIC METALWORKING EQUIPMENT NEWS

Contents

Official Media Partner Of MTA Malaysia 2011

?

Can It Get

A Look At Micromachining

A

Cool Weld To

Way

Can Welding Really Be Cold?

28 Machine Tool Design & Operation

M.I.C.A. (P) No. 133/06/2010 • PPS 840/09/2011 (020177) • ISSN 0129 5519

First Cut

The Of The Official Magazine For Metaltech 2011

FC Apr11.indd 2

4/4/11 3:14 AM

Strategies For Green Manufacturing Strategies to reduce energy demand in manufacturing processes are becoming necessary due to the growing concern of carbon emissions and the expected rise of electricity prices over time. By Nancy Diaz, University of California, Berkeley

Technology Insights

32 Working In The Scale Of Microns Milosz1, Poznan, Poland

Micromachining is evident in manufacturing microcomponents for watches and surgical implants where titanium is often the material of choice due to its innate properties. By Natalia Tee

Software & Metrology

36 Cross Scanners – Automating Inspection

Taking data points faster without the need to make contact, cross scanners are proving to be a welcomed addition to the world of measurement. By Rob Snoeijs, Nikon Metrology

38 The Accuracy Of Laser Measurement Specifications and actual performance of the angular measurement system on a laser tracker plays an important role. By Ken Steffey, Faro

44 When Things Get

Complicated, Scan It

The complex shapes and tight tolerances are part of the natural evolution in engineering. Luckily, measurement instruments have also undergone their own transformation over the years to keep up with the changes. By Neven Jeremic, Hexagon Metrology

Fab & Form

46 Welding: All The Fireworks

Viewing welding in its individual segments, it is clear the joining process has come a long way since its inception. By Augustine Quek

48 A Cool Way To Weld

Cold welding can be misleading at times because of its name but the benefits that come with the technology have no ambiguity attached. By Gerd Trommer, for Fronius

4

metalworking equipment news April 2011


Best choice. User-friendly performance. Laser | Bending | Waterjet bystronic.com

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Contents

April 2011

50

Country Visit Business In Vietnam

The measures in place to help streamline the process of starting a business in Vietnam will no doubt provide much impetus to those who want to be part of the rapid growth. By Michael E Neumann

Industry Focus 52 Holding Uneven Aircraft Parts In Place

Combining vacuum clamping with integrated controls is the way forward for holding large aerospace parts. By Maren Roeding, Witte Far East

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 #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806. 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: irenetow@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

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.

56 Making A Clean Break With Waterjet

Commercial and military aircraft manufacturers are increasingly using composites in their structures, making waterjet cutting a desirable technique in the industry. By Marjorie Millay, Flow

INDUSTRY Endorsements

SPETA

Features

Federation of Asian Die & Mould Associations (FADMA)

58 Solid Edge Product Launch

APMEN was at the launch of Solid Edge ST3 to find out more on the CAD software product that uses synchronous technology to improve design, validation and collaboration. By Joson Ng

Federation of Malaysian Foundry & Engineering Industry Associations

60 Events & Exhibition

Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

• SolidWorks World 2011

The Henry B Gonzalez convention centre was a scene of technological advancements, creative interaction and for some, a place to catch up with old friends. Be it users, resellers, partners and employees of the company, they all bore witness to the power of 3D designing. By Joson Ng

• Event Preview: Metaltech 2011 • Event Preview: Intermach 2011 • Event Preview: MTA Malaysia 2011

Regulars 10 76

6

Business News Product Finder

metalworking equipment news April 2011

Singapore Precision Engineering and Tooling Association (SPETA)

Parting Shot

Machine Tool Club (MTC)

74 Journey To A

Cleaner Future Electric and hybrid vehicles will take over the cities. By Fraunhofer.

80A Product Enquiry Card

Taiwan Association of Machinery Industry (TAMI)

80

Refer to Advertising Index

pg

For Advertiser's Enquiry Numbers


ENQUIRY NO 028


editor’s note

Power The

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

Of

Cooperation

2010 is attributed to the agreement. With 47.2 percent (US$1.12 billion) of Taiwan’s machine tool export value finding its way into China, the positive effect of the agreement is spectacularly evident prompting a senior official in TAMI, Alan Lu (the chairman of the machine tool committee) to predict a “golden 10 years” for Taiwanese machine tool makers. Though there are pertinent positives in ECFA, detractors no doubt exist. For now at least, the numbers do not lie. With US$2.37 billion worth of export (Taiwanese machine tools) from January to October in 2010, it does seem to suggest the power of cooperation is a very shrewd piece of lucrative business. In the spirit of cooperation, Asia Pacific Metalworking Equipment News has teamed up with industry leaders in metalworking at MTA in Singapore to bring insights to market sentiments in this region in order to better serve our readers. To incre a se our re ach, the interviews are presented as videos and hosted in our website. In addition, we also conducted a comprehensive survey on buying trends at the show. The results will be featured in our May/June issue.

Joson Ng Editor

8

metalworking equipment news April 2011

nataliatee@epl.com.sg

business development manager Randy Teo

In the face of globalisation, the belief of ‘one man’s island’ is no longer sufficient in world trade, not even for big nations with substantial financial clout. Flying solo in today’s world is almost inconceivable. Countries run the risk of losing its competitiveness and clout in the global arena should they choose the path of ignoring the value of cooperation. With economic integration almost an inevitable course of action, up step Free Trade Agreements (FTAs), where a group of countries come together in agreement to eliminate tariffs and preferences on goods and services traded between them. In June last year, the People’s Republic of China (mainland China) and the Republic of China (Taiwan) inked the Economic Cooperation Framework Agreement (ECFA), a preferential trade agreement between the two governments. ECFA aims to reduce tariffs and commercial barriers between the two sides. It is touted to boost the bilateral trade which is estimated to be US$110 billion. The agreement has been a real shot in the arm for the Taiwanese machine tool builders. In the recently concluded Taipei International Machine Tool Show (TIMTOS), much of the territory’s sterling performance in

josonng@epl.com.sg

writer Natalia Tee

randyteo@epl.com.sg

advertising sales manager Yessica

yessica@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow

irenetow@epl.com.sg

contributors Nancy Diaz Natalia Tee Rob Snoeijs Ken Steffey Neven Jeremic Augustine Quek Gerd Trommer Maren Roeding Marjorie Millay Michael E Neumann Fraunhofer 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. 133/06/2010 PPS 840/09/2011 (020177) ISSN 0129/5519

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etm

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Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806


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Businessnews CEOs' Confidence Restored To PreCrisis Levels

Davo s , Sw it zerla nd: CEOs' confidence in future growth has returned to nearly pre-crisis levels, according to PwC's 14th Annual Global CEO Survey. In the worldwide poll of 1,201 CEOs, 48 percent said they were “very confident" of growth in the next 12 months. That is a major shift from the 31 percent last year who were "very confident" last year and approaches the 50 percent reached in 2008 before the onslaught of the economic crisis. In total, 88 percent of CEOs said they now have some level of confidence for prospects in the next 12 months, up from 81 percent last year. Longer term, 94 percent now are confident of growth three years from now, an increase of two percentage points.

Renewed confidence was spread across all continents, with CEOs in India, Austria, Colombia, Peru, China, Thailand and Paraguay particularly upbeat about near term growth. Regionally, CEOs in Western Europe were the least confident. German CEOs were an exception, with nearly 80 percent of CEOs "very confident," up from about 20 percent last year. CEOs said they considered China the most important country for future growth. China was named by 39 percent of CEOs, followed by the US, 21 percent; Brazil, 19 percent; and India, 18 percent. And China, the US and India were seen as the most important future sources for products and raw materials. Regionally, 90 percent of CEOs said they expect their

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operations to grow in Asia in the next 12 months, followed by Latin America, 84 percent; Africa, 75 percent; the Middle East, 72 percent; and Eastern Europe, 70 percent. But just a third of respondents said the country in which they are based offers high growth potential. S t r a t e g i c a l l y, t h e b e s t opportunities for growth in the next 12 months will come from the development of new products and services and from increasing share in existing markets, both cited by 29 percent of CEOs, and by penetration of new markets, 17 percent. Mergers and acquisitions and joint ventures and alliances trailed as growth strategies. "CEOs have emerged from the bunker mentality of surviving the recession. They now see renewed opportunity for growth, even in the near term, and are determined to take advantage of better global economic conditions and increased customer demands," said Dennis M Nally, chairman of PricewaterhouseCoopers International. "The post-recession global economy is recovering on two-tiers. Emerging economies like China, India and Brazil are growing at rates that far surpass the developed nations. The shift in the economic balance of power creates challenges for CEOs in deciding how and where to invest in facilities, people and innovation. Companies that understand and capitalise on the diverging growth patterns of the developed and emerging economies will be the winners in the years ahead," he added.

Sandvik Coromant & Dormer Merge Sandviken, Sweden: Cuttingtool suppliers Sandvik Coromant and Dormer are merging into one organisation in order to strengthen their round tools offer, creating a competitive high speed steel and solid carbide 10

metalworking equipment news April 2011

product program. T he t wo compa n ie s w il l continue to exist as distinct brands. By joining forces within re se a rc h a nd developme nt and coordinating marketing and sales the two brands will

meet the demand for tools that yield higher productivity and cost savings. Together with a widened distribution network and a leveraged presence in the market, this will enhance growth for both brands.


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Sutton Tools Singapore Pte Ltd, No. 1 Ubi View #03-18, Focus One, SINGAPORE 408555 Phone: +65 67457366 Fax: +65 67455080 Mail: ekoh@sutton.com.au Sutton SuttonTools ToolsSingapore SingaporePte PteLtd, Ltd, www.hoffmann-group.com No. No.11Ubi UbiView View#03-18, #03-18,Focus FocusOne, One,SINGAPORE SINGAPORE408555 408555 Phone: Phone: +65 +65 67457366 67457366 Fax: Fax: +65 +65 67455080 67455080 Sutton Tools Singapore Pte Ltd,


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Blum-Novotest Establishes Subsidiary In India

APPOINTMENTS

Ravensburg, Germany: Blum-Novotest has established a subsidiary office in Bangalore, India. Appointed directors of the JV company are BV Shyam and A Venkatesh. “The new subsidiary in Bangalore will serve as a sales and service hub, supporting the other local sales and service offices in New Delhi, Pune and Chennai, while coordinating the setup of other future sales and service offices. Through this local presence, Blum-Novotest is able to provide the combination of service and customer specific problem solving capabilities for its customers,” says Alexander Blum, president Blum-Novotest.

KOMMA Gets New Chairman Jong-Hyeon Sohn has been elected as the 15th chairman of the Korea Machine Tool Manufacturers’ Association (KOMMA), for a three-year term (2011 to 2014) at the general assembly meeting. He is currently the chairman of Namsun Machinery Corp, a company manufacturing machine tools.

Jong-Hyeon Sohn

APAC To Account For 1/3 Of Airplane Deliveries Over Next 20 Years

Abel Heinsbroek, Bergen, Netherlands

Hong Kong: The Asia Pacific region’s air traffic growth will exceed the world average by a large margin over the next two decades, according to the Boeing Company. In a media briefing at Asian Aerospace 2011, Randy Tinseth, VP of marketing for Boeing Commercial Airplanes, said the region’s air traffic growth is expected to grow at an average annual rate of 6.8 percent over the next 20 years, compared to the world average of 5.3 percent. “Asia Pacific will account for one-third (10,320) of new airplane deliveries worldwide over the period,” Mr Tinseth said. “This demand is driven by the fact that Asia Pacific will account for 44 percent of travel in 20 years’ time, up from around 34 percent today.” 12

metalworking equipment news April 2011

“China’s air travel growth is even more dramatic, with an 8.6 percent increase over the next two decades,” he added. “This is sweet music to an airplane manufacturer’s ears.” The rosy outlook is not limited to growth in passenger service. World air cargo traffic will triple over the next 20 years, according to Jim Edgar, regional director of Cargo Marketing for Boeing. “From now through 2029, we expect world air cargo traffic to grow at an annual rate of 5.9 percent,” Mr Edgar said. “Asia will continue to be at the forefront of the air cargo industry. Routes associated with Asia will continue to experience the world’s highest growth rates over the next 20 years, at 6.8 percent.” Of local interest and in line

with the cargo recovery, Hong Ko n g A i r C a r g o Te r m i n a l s announced that total annual tonna ge for 2010 hit a new handling record of 2.9 million metric tonnes, an increase of 24.8 percent over 2009. “China represents 40 percent of the trans-Pacific cargo market, and Hong Kong is a key gateway for air cargo connecting China with the world,” Mr Edgar said. “This area stands to benefit greatly from future increases in air cargo traffic.” Mr Tinseth said that rising passenger and cargo traffic is creating pressure for fleet growth. Globally, airlines will need 30,900 new passenger and freighter airplanes through 2030, valued at US$3.6 trillion. Fourtyfour percent of these aircraft will replace older, less-efficient airplanes, while 56 percent will account for new aircraft needed to meet air traffic growth. The world fleet is projected to double from 18,890 to 36,300 airplanes during this span. “The near doubling of the world fleet size is an indicator that airlines not only will plan for growth, but will take the economically rational step of modernising their fleets as a hedge against high and unpredictable oil prices,” Mr Tinseth said.


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Siemens PLM Software Reaches Milestone Singapore: Siemens PLM Software, a business unit of the Siemens Industry Automation Division has surpassed 3.5 million active enduser seats of software based on its Parasolid software. As a widely used 3D geometric modeling component, it prov ide s solid modeling functionality and interoperability to over 150 Independent Software Vendors (ISVs) and over 350 of the

industry’s software applications across a cross section of disciplines. “The functionality and quality of Parasolid, along with its appeal to innovative software developers of all sizes and across multiple disciplines, has helped us achieve this milestone,” said Joan Hirsch, VP of product design solutions, Siemens PLM Software. “Our long-term relationships

with Parasolid licensees have promoted mutual growth and success over many years, and our dedication to open technology and an open business model helps these ISVs foster innovation and collaboration. These qualities, combined with the resulting growth and stability of Parasolid, provide our customers with a competitive advantage.”

Haas Production Result & Open House

Oxnard, USA: Haas Automation’s fourth-quarter 2010 revenues were up 118 percent over 1st-quarter 2010, and the company more than doubled production in 2010 to meet growing demand for its products. “We closed out 2010 with our best quarter since 2008,” said Haas GM Bob Murray, “both for orders and for revenue. We saw a steady increase in demand last year, with each month better than the previous month. December was our best month since June 2008, with orders up 150 percent and revenue up 96 percent, year over year. We see that trend continuing in 2011. Sixty percent of the machines sold in 2010 went to international markets, noted Mr Murray. Sales in Russia increased more than 120 percent, and sales in India grew by 107 percent. In China, sales expanded 14

metalworking equipment news April 2011

by 68 percent, and sales in Latin America increased by 65 percent. HaasTec Open House The event drew more than 2,100 attendees to the company’s headquarters and manufacturing facility in Oxnard, California. Of the 20 machines on display at HaasTec, four were brand-new for 2011, and two – the large-capacity ST-40 and ST-40L turning centres – debuted at the show. Also on hand were the rest of the company’s generation ST and DS turning centres – including dual-spindle and Y-axis models – as well as the DT-1 Drill/Tap Centre. In addition to the CNC machines, the event also featured a selection of rotary products on display, including the HRT160SS high-speed rotary table.


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grinding Wheels from Winterthur: passionately precise Winterthur Technology (Thailand) Co. Ltd. No. 1 M.D. Tower, 13th Floor, Block C1, Soi BangnaTrad 25, Bangna,10260 Bangkok / Thailand Phone: +66 2 744 1577 nattana@winterthurtechnology.co.th Winterthur Technology (Malaysia) Sdn. Bhd. C-3A-13A, Center Wing, Metropolitan Square, No. 2 Jalan PJU 8/1 Bandar Damansara Perdana, 47820 Petaling Jaya Phone: +603 7724 2611 Fax: +603 7724 2612 michael.lee@winterthurtechnology.com.my P.T. Winterthur Technology Indonesia Ruko Mega Grosir Cempaka Mas Blok I/32 Jl. Let. Jend. Suprapto No. 1, Cempaka Putih 10640 Jakarta Pusat / Indonesia Phone: +62 21 4288 8550 irwan.pramono@winterthurtechnology.co.id

Winterthur Technology (Taicang) Co. Ltd. No. 8 Loujiang Road North Taicang Economy Development Zone 215400 Taicang / P.R. China Phone: +86 512 8161 6800 sales@winterthurtechnology.com.cn

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Winterthur Technology (Korea)Ltd. 06, Venture Valley, 958 Gosaek-Dong, Gwonseon-Gu, Suwon-Si 441-813 Gyeonggi-Do / South Korea Phone: +82 31 298 1777 lee@winterthurtechnology.com

April 2011 metalworking equipment news

15


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Structural Reform In APEC Vital For Economic Growth

Ilker, Izmir, Turkey

Singapore: Introducing more competition in the energ y, telecommunications a nd tra nsport sectors of the A PEC reg ion w ill generate US$175 billion a year in additional income, new analysis shows. The calculations are contained in a new report released by APEC’s research arm, the Policy Support Unit, and underline the need for ongoing structural reforms, including of competition policy, to increase the potential for strong, long-term economic growth in the wake of the global financial crisis. The report includes 14 case studies of structural reform undertaken in the APEC region in these three sectors and the subsequent impact on their economies in terms of lower costs, increased competition and improved efficiency and productivity. It includes reform of electricity sectors in Russia and South Korea, natural gas in China, maritime transport in Australia, rail transport in New Zealand and Chile, road transport in Thailand, aviation in South Korea and telecommunications in Chinese Taipei and Vietnam. The report says a package of further such reforms in the three sectors would generate US$175 billion a year in additional real income (in 2004 dollars) across the whole APEC region. APEC-wide, the projected gains from these structural reforms are almost twice as big as the gains from further liberalisation of merchandise trade, the report concludes. However, the sectors where the

structural reforms are targeted are less than one quarter of the size of those engaged in merchandise trade. These additional reforms could lead to weighted average productivity improvements in the range of 2 to 14 percent across the three sectors in the APEC region, it says. The report shows the benefits for consumers and small and medium sized enterprises arising from introducing competition in terms of improved quality of service, greater choice and lower costs. Removing barriers to open markets involves introduces competition, encourages companies to become more productive and innovative, and potentially leads to better economic growth. Another benefit of structural reform is economic resilience and stability, meaning economies in the region can become less vulnerable to shocks and turbulence in global markets, the report further says. More efficient, flexible and productive economies could be better protected against a future global financial crisis. “Structural reform is crucial to achieving growth and to providing greater flexibility and resilience with which to deal with and withstand shocks, both internal and external,” said APEC secretariat executive director, ambassador Muhamad Noor. “This report underlines the importance of APEC’s agenda on addressing ‘behind the border’ barriers to trade and investment,” he said.

Embraer Grows Its Customer Support Capabilities In Australia São José Dos Campos, Brazil: ExecuJet Australia will provide enhanced Maintenance, Repair and Overhaul (MRO) services for Embraer’s Phenom 100 at its Melbourne and Sydney facilities. ExecuJet’s certification by the Australian Civil Aviation Safety Authority (CASA) to offer MRO, warranty and heavy maintenance services for Embraer’s Phenom 100 complements its existing services 16

metalworking equipment news April 2011

provided to Embraer Legacy 600 and Legacy 650 operators in the country. “We are very pleased to provide Embraer Executive Jet operators in Australia with added service capabilities to meet their maintenance needs. This is an example of our commitment to providing the region with best-in-class support for all operator maintenance and service needs for the growing fleet of executive jets,” said Andre Luis Vieira

de Sousa, director, customer support and services – Embraer Executive Jets in Asia Pacific. “ExecuJet is excited to have added Embraer products to our existing maintenance capability at our Melbourne and Sydney facilities, and we look forward to supporting the operators of the Legacy and Phenom aircraft in the region,” said Darren McGoldrick, MD ExecuJet Australasia.


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UTC Chairman & CEO Honoured Ha r t for d, U SA: United Technologies Corp chairman and CEO Louis Chênevert has been honoured by Singapore with its Public Service Star for contributions to the nation’s economy. The awa rd recog nise s busine ss le aders who have made outstanding contributions t o S i n g a p o r e ' s e c o n o m y, st re n g t he n i n g it s bu si ne ss and technological capabilities a nd i nter nat iona l sta ndi n g i n i n du s t r y a n d e co n o m i c

competitiveness. Recipients are known as distinguished friends of Singapore. “It is a great honour for me a nd United Technologies to be recognised with a Public Service Star as a distinguished friend of Singapore. We look fo r w a r d to d e e p e n i n g o u r friendship with Singapore and finding new opportunities to continue our shared pursuit of business growth and economic prosperity in the years ahead,” said Mr Chênevert.

Bombardier Expands Aftermarket Services In China

New Bombardier Regional Support Office in Hong Kong. From left to right: Gaëtan Dureau, director, business development, Bombardier Customer Services; James Hoblyn, president, customer services & specialised and amphibious aircraft, Bombardier Aerospace; Lanny Schindelmeiser, director, customer response team, Bombardier Business Aircraft; and Anthony Cox, manager, regional support office - Hong Kong, customer services and support, Bombardier Business Aircraft.

Hong Kong, China: Bombardier Aerospace has ramped-up its aftermarket ser vices for its business aircraft operators in China. The ra mp - up, which includes a new Regional Support Office (RSO), parts depot and Line Maintenance Facility (LMF), as well as a newly appointed director, business development, is part of the company’s planned investment of up to US$30 million aimed at boosting support for its growing customer base in the region. This investment is the first phase of a much broader strategy to establish a service and support 18

metalworking equipment news April 2011

network centered in China and supported by satellite facilities throughout the Asia-Pacific region. “With these investments, we are laying the groundwork for a stronger, fully integrated Bombardier support system in Asia-Pacific,” said James Hoblyn, president, customer services & specialised and amphibious aircraft, Bombardier Aerospace. “China will play a critical role in the development of our business in the next five years, and we want to make sure our operators can count on having the highest level of support and service when and where they need it.”

Louis Chênevert

ArcelorMittal To Invest In Thai Steel Producer Lu xembou r g: A rcelorMitta l h a s s i g n e d a g r e e m e n t s to invest new capital resulting in a shareholding of 40 percent in G Steel Public Company (G Steel). G Steel and its subsidiary GJ Steel Public Company (GJ Steel) are producers of hotrolled coils. G Steel ha s a n EAF-based medium slab rolling facility in Rayong and GJ Steel ha s a n E A F-ba sed thin slab rolling facility in Chonburi, with a combined annual capacity o f ove r 2 . 5 m i l l io n to n ne s per annum. The investment by A rce lorM it t a l i n G Ste e l i s part of a broader plan by G Steel to st reng t hen its a nd GJ Steel's financial position. The amount of capital to be invested by ArcelorMittal will be determined closer to the completion of the transaction. Completion of the transaction is conditional on a reduction in the outstanding liabilities of G Steel and GJ Steel and a range of other conditions, including re g u lator y approva ls a nd approval of the shareholders of G Steel and GJ Steel.


ENQUIRY NO 058


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AEROSPACE

UPECA Manufactures Aerostructure Parts For Airbus A350 XWB Series

The handover ceremony between UPECA Aerotech CEO Simon Yew and Spirit AeroSystems Malaysia MD, Francis Hiew, witnessed by president/CEO of MIGHT, Mohd Yusoff Sulaiman

Kuala Lumpur, Malaysia: The first machined detail part manufactured in the region for the fixed leading edge of the wing of the new Airbus A350 XWB Series took place at UPECA Aerotech’s Shah Alam plant on February 9, 2011. I n D e ce mb er 2 0 0 9, t he company was awarded contracts worth RM270 million ( US$89 million) by Spirit AeroSystems Eu rop e (Spir it), which wa s publicly a n nou nce d du r ing t he L a ngk aw i I nter nat iona l Aerospace and Maritime Show in Langkawi, Malaysia. With the Spirit contract award as the catalyst, the company launched its expansion plan by setting-up a 110,000 sq ft (10,219 sq m) facility in Shah Alam, Selangor. With a total investment of approximately RM 25 million, the expansion and new contracts will create over 100 new skilled aerospace jobs, which include a dedicated manufacturing cell for the A350 XWB program. “We are using the latest Mazak

CNC machines and an Airbus compliant surface treatment line at our Shah Alam plant,” said Simon Yew, CEO for UPECA Aerotech on the occasion of the first metal cut on February 9, 2011. Witnessing the event was Mohd Yusoff Sulaiman, president/CEO of Malaysian Industry – Government Group for High Technolog y ( M IG H T ), t he Ma laysia n government think tank for high technology industries who is also the Secretary of the Malaysian Aerospace Council. Mr Yusoff said: “The Malaysian aerospace manufacturing industry is estimated to hit RM1 billion this year and has created approximately 4,500 highly skilled jobs. UPECA’s achievement today is a testimony to the success of the nation's foreign direct investment policy which has not only enabled our local companies to be in the global supply chain of Airbus and Boeing, but also move up the value chain to Tier two.”

Kennametal Receives Carnegie Science Centre Award Latrobe, USA: Kennametal’s B eyond Bla st me ta lcut t i n g technology has been honoured with a 2011 Carnegie Science Centre Award in the category of advanced manufacturing. The awards program recognises and promotes outstanding science and technology achievements in Western Pennsylvania. The technology represents a significant advance for Kennametal customers, delivering, in some cases, as much as a 300 percent improvement in productivity. By channeling coolant through the insert, it delivers the coolant not merely in the general area of the cutting zone, but directly to the juncture where the tool edge meets the material. This ensures longer tool life, better cutting performance and chip control, and more efficient coolant delivery, heat transfer and lubricity. In addition to improv ing part-production processes, the technology decreases power consumption a nd improve s coolant management, thereby mitigating a ma nufacturer’s impact on the environment. “Without question, Beyond Blast represents a moment in the history of manufacturing, and we are thrilled to receive the Advanced Manufacturing Award in honour of our commitment to innovation,” said Kennametal chairman, president and CEO Carlos Cardoso.

Autodesk To Acquire Blue Ridge Numerics San Rafael, USA: Autodesk has signed a definitive agreement to acquire Blue Ridge Numerics, a provider of simulation software, for approximately US$39 million in cash. Blue Ridge Numerics’ CFdesign 20

metalworking equipment news April 2011

technology will be an important a d d i t i o n to t h e A u to d e s k simulation software portfolio for manufacturers. It will broaden the Autodesk solution for Digital Prototyping to provide customers

with a spectrum of Computational Fluid Dynamics (CFD) capabilities that help automate fluid flow and thermal simulation decision-making for designs, while eliminating costly physical prototyping cycles.


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The The Leica Leica Absolute Absolute Tracker Tracker can can now now be be used used in in fully fully automated automated measuring measuring systems. systems. Measurement processes are from now on more time and cost efficient than ever before. Measurement processes are from now on more time and cost efficient than ever before. The process accuracy is no longer limited by the positioning device. The unparalleled accuracies The process accuracy is no longer limited by the positioning device. The unparalleled accuracies of the 6DoF Leica Absolute Tracker can now be applied to any robotic positioning system turning of the 6DoF Leica Absolute Tracker can now be applied to any robotic positioning system turning it from an ordinary robot into an incredibly accurate metrology device. it from an ordinary robot into an incredibly accurate metrology device. With a Leica T-Scan mounted on a robot or a Leica T-Mac equipped with a tactile or optical probe, With a Leica T-Scan mounted on a robot or a Leica T-Mac equipped with a tactile or optical probe, the Leica Absolute Tracker is the core of a completely automatic coordinate measuring installation. the Leica Absolute Tracker is the core of a completely automatic coordinate measuring installation. Leica Automated Solutions also pave the way for Metrology Assisted Assembly. Work pieces can Leica Automated Solutions also pave the way for Metrology Assisted Assembly. Work pieces can be processed automatically while the exact position is monitored by the 6DoF tracker system. be processed automatically while the exact position is monitored by the 6DoF tracker system. This guarantees extreme production accuracy for a maximum product quality. Leica Automated This guarantees extreme production accuracy for a maximum product quality. Leica Automated Solutions are also capable to control and inspect large-volume work pieces. Solutions are also capable to control and inspect large-volume work pieces. www.hexagonmetrology.com www.hexagonmetrology.com

29 April 2011 ASX 2011 27 –Stand No: 111 Singapore

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Hexagon Metrology Asia Pacific Pte. Ltd. 2 Woodlands Sector 1 #01-10 Woodlands Spectrum 1 Singapore 738068 Tel : +65 6463 6242 Fax : +65 6463 8030 contact@hexagon-metrology.com.sg

Hexagon Measurement Technologies Sdn.Bhd 11 Jalan PJS 7/21 (758921-A) Bandar Sunway 46150 Petaling Jaya, Selangor, Malaysia Tel : +603 5632 8900 Fax : +603 5632 8955 contact.my@hexagonmetrology.com

Hexagon Metrology (Thailand) Ltd. 3 Soi, Bangna-Trad 34, Bangna-Trad Rd. Bangna, Bangna, Bangkok 10260 Tel : +66 2361 3695 to 9 Fax : +66 2746 9607 hexagon.thailand@hexagonmetrology.com

Hanoi Representative Office 5th Floor, Regus Hanoi Press Club, 59A Ly Thai To Street, Hoan Kiem District, Hanoi, S.R. of Vietnam Tel: +84 4 3936 7935 Fax: +84 4 3936 8069 hexagon.thailand@hexagonmetrology.com

ENQUIRY NO 063


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Jaguar Land Rover & Dassault Systèmes In Partnership France: Jaguar Land Rover and Dassault Systèmes have entered a strategic partnership that formalises future cooperation and collaboration between the two companies. The agreement, signed by Dassault Systèmes president and CEO Bernard Charlès and Jaguar Land Rover CEO Dr Ralf Speth, will see digital 3D simulation and development tools transform

Jaguar Land Rover’s product development processes. Jaguar Land Rover will deploy V6 solutions for product lifecycle management. The process, which drives and controls all vehicle creation processes, increase operational efficiency and reduce complexity through enhanced innovation a nd accelerated development capabilities. In addition to supplying existing

EADS/Airbus Expands Qualified Suppliers Of Aluminium

Hankook Delcam Signs Strategic Alliance With Star Korea

Toulouse, France: Airbus and its parent company EADS have signed a procurement frame contract with Southwest A l u m i n i u m G r o u p ( S WA) , one of the largest aluminium product producers in China, for the manufacture and supply of aluminium plate. EADS’ sourcing strategy aims to develop a global supply chain that will enable the group to create a more competitive cost base and provide natural hedging while gaining access to strategic markets in Asia. To drive this business tra nsformation, EADS’ Global Sourcing Network supports Airbus to identify new potential partners around the world that can meet its quality sta nda rds a nd optimise its existing industrial assets. Today, aluminium is of utmost importance in the production of airplanes as it is used in many different parts of an aircraft such as fuselage panels and frames, floor beams, and wing spars/ribs. SWA’s aluminium products will initially supply both Airbus’ singleaisle and long-range families, and the contract could be extended to other programs in the future. 22

metalworking equipment news April 2011

South Korea: Hankook Delcam, Delcam’s joint venture company in South Korea, has signed a memorandum of understanding with Star-Korea covering technical support and sales cooperation between the two companies. This strateg ic a llia nce w ill benefit customers using Delcam’s PartMaker CA M software to program Star’s Swiss-type CNC machines in the country. Under the agreement, technical staff from the two companies will cooperate on the development and testing of a comprehensive set of postprocessors within PartMaker for

system programs, development engineers from both companies will work together on processes and solutions that will provide the combination of simplification and specialisation required to create new generations of premium vehicles. The focus on commonality, innovation and integration will have the dual benefit of significantly increasing efficiencies while reducing cost by a similar margin.

Star’s full range of Swiss-type lathes. Going forward, Star-Korea will share product development details with Hankook Delcam so that proven post-processors can be supplied for new Star machines as soon as they are introduced to the South Korean market. Hankook Delcam will provide PartMaker training to the staff at Star-Korea. This will allow them to program demonstrations on the machines and to provide better support to their customers. The two companies will also cooperate on marketing and sales activities, including exhibitions and open houses.


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statistics

World Crude Steel Output Increased By 15 Percent In 2010

Figure 2: Crude steel production annual growth trend

Figure 1: Annual crude steel production

Brussels, Belgium: World crude steel production reached 1,414 million metric tonnes (mmt) for the year of 2010. This is an increase of 15 percent compared to 2009 and is a new record for global crude steel production. All the major steel-producing countries and regions showed double-digit growth in 2010. The EU and North America had higher growth rates due to the lower base effect from 2009 while Asia and the CIS recorded relatively lower growth. In December 2010, world crude steel production for the 66 countries reporting to the World Steel Association (worldsteel) was 116.2 mmt, an increase of 7.8 percent compared to December 2009. The crude steel capacity utilisation ratio of the 66 countries in December 2010 declined slightly to 73.8 percent compared to 75.2 percent in November 2010. Compared to December 2009, the utilisation ratio in December 2010 is 1.1 percentage point higher. Annual production for Asia was 897.9 mmt of crude steel in 2010, an increase of 11.6 percent compared to 2009. Its share of world steel production decreased to 63.5 percent in 2010 from 65.5 percent in 2009. China's crude steel production in 2010 reached 626.7 mmt, an increase of 9.3 percent on 2009. China's share of world crude steel production declined from 46.7 percent in 2009 to 44.3 percent in 2010. Japan produced 109.6 mmt in 2010, 25.2 percent higher than 2009. In 2010, South Korea's crude steel production was 58.5 mmt, a 20.3 percent growth compared to 2009. The EU recorded an increase of 24.5 percent compared to 2009, producing 172.9 mmt of crude steel in 2010. However, crude steel production in the UK and Greece continued to decline in 2010.

In 2010, crude steel production in North America was 111.8 mmt, an increase of 35.7 percent on 2009. The US produced 80.6 mmt of crude steel, 38.5 percent higher than 2009. The CIS showed an increase of 11.2 percent in 2010, producing 108.5 mmt of crude steel. Russia produced 67 mmt of crude steel, an 11.7 percent increase on 2009 and Ukraine recorded an increase of 12.4 percent with a year-end figure of 33.6 mmt. Annual production for Asia was 897.9 mmt of crude steel in 2010, an increase of 11.6 percent compared to 2009. Its share of world steel production decreased to 63.5 percent in 2010 from 65.5 percent in 2009. China's crude steel production in 2010 reached 626.7 mmt, an increase of 9.3 percent on 2009. China's share of world crude steel production declined from 46.7 percent in 2009 to 44.3 percent in 2010. Japan produced 109.6 mmt in 2010, 25.2 percent higher than 2009. In 2010, South Korea's crude steel production was 58.5 mmt, a 20.3 percent growth compared to 2009. The EU recorded an increase of 24.5 percent compared to 2009, producing 172.9 mmt of crude steel in 2010. However, crude steel production in the UK and Greece continued to decline in 2010. In 2010, crude steel production in North America was 111.8 mmt, an increase of 35.7 percent on 2009. The US produced 80.6 mmt of crude steel, 38.5 percent higher than 2009. The CIS showed an increase of 11.2 percent in 2010, producing 108.5 mmt of crude steel. Russia produced 67 mmt of crude steel, an 11.7 percent increase on 2009 and Ukraine recorded an increase of 12.4 percent with a year-end figure of 33.6 mmt.

German Machine Tool Manufacturers Anticipating 30 Percent Growth For 2011 Frankfurt am Main, Germany: T h e G e r m a n m a c h i n e to o l industr y is forecasting a 30 percent increase in production output for 2011. “With the return to an anticipated volume of a lmost €13 billion ( US$18.1 24

metalworking equipment news April 2011

billion), we would have caught up on almost all the deleterious effects of the crisis. That’s something we could be more t h a n s a t i s f i e d w i t h ,” s ay s Martin Kapp, chairman of the VDW (German Machine Tool

Builders’ Association), speaking at its annual press conference in Frankfurt am Main. Since the end of 2009, the sector has quarter by quarter achieved double-figure growth in order bookings, primarily driven


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Martin Kapp

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initially by China, South Korea and India. These nations had quickly shaken off the crisis, returned to a growth trajectory, and as a result helped to progress a rapid recovery of the sector in Germany. Meanwhile, demand from abroad has picked up on a broad front. “O u r i ndu st r y ’s worldw ide presence, its high proportion of exports, at two-thirds, and its superlative technological position on the international stage are paying off here,” says Mr Kapp. Subsequently the upturn spread to domestic demand as well. Back in August 2010, for the first time in two years, turnover showed a plus. Over the year as a whole, production output still exhibited a small minus of three percent compared to 2009. Exports, the machine tool industry’s showcase discipline, at minus one percent in 2010, were only insignificantly below the preceding year’s figure. For some years now, China has been the biggest market. With a share of around 28 percent, and further growth of 29 percent compared to 2009, China buys almost four times as many machine tools as the US in second place. The machine tool sector was able to respond quickly to the incipient upturn, because during the crisis it had as far as possible held onto its highly qualified specialist staff in the core workforce. In December of

“Internationally, the crisis has meant a major reshuffling of the machine tool industry,” is how he describes the ongoing situation. Countries like Taiwan, South Korea, Japan and China achieved high double-figure growth rates in 2010. The figure in Europe was a meagre one, with a production output minus of one percent. The USA, too, fell significantly short of actual growth, with a minus of nine percent. This put China in front of Japan, Germany, Italy and South Korea at the top of the machine tool production rankings last year for the first time. The USA is in 8th place, with other European countries (Switzerland, Austria and Spain) ranking 7th, 9th and 10th. For the present juncture, however, M r K app see s no immediate threat to the German machine tool industry from the Asians. Ninety percent of China’s production output comprises relatively simple machines in large numbers for the domestic market. According to a recent V DW study, moreover, there is hardly any autonomous technological innovation work being done at present. With a government plan for restructuring the innovation system, however, the aim is to explicitly encourage innovative initiatives in the corporate environment. The second major competitor, Japan, predominantly produces standard machines with short lead times. Changes in order bookings are swiftly reflected here in the production output, in both the upturn and downturn phases of the business cycle. G e r m a n y, w i t h i t s h i g h p r o p o r t i o n o f c u s to m i s e d machines and lengthy projects, will be catching up this year, predicts Mr Kapp.

April 2011 metalworking equipment news

25


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Machine Tool Design & Operation Strategies

Green

For

Manufacturing Strategies to reduce energy demand in manufacturing processes are becoming necessary due to the growing concern of carbon emissions and the expected rise of electricity prices over time. By Nancy Diaz, et. al., Laboratory for Manufacturing and Sustainability (LMAS), University of California, Berkeley

I

mproving the performance of machine tools as measured by metrics including availability, reliability, dimensional accuracy, and precision has been a major concern for machine tool builders. To a c h i e v e t h e d e s i re d performance, machine tools have become increasingly complex and automated in their design. These changes have resulted in increasing energy requirements, which are antagonistic to rising power costs, limited access to resources (particularly fossil fuels), increasing environmental consciousness among customers, and increasing government regulation. These concerns are further exacerbated by manufacturing’s already large environmental impact – 19 percent of the world’s greenhouse gas emissions and 31 percent of the US’ total energy usage is due to industrial activities, of which manufacturing and specifically machining plays a crucial role according to World Resource Institute and US Energy Information Administration. As such, there are strategies to implement green manufacturing in machining including machine tool design, process planning, and machine operation.

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metalworking equipment news April 2011

Reducing Energy Consumption Machine tool energy consumption may be reduced in one of four areas of its life-cycle: manufacturing, transportation, use, or end-of-life. The manufacturing portion of the machine tool is indeed relevant depending on the manufacturing facility that is used and that HVAC and lighting effects are significant. Early life-cycle assessments of machine tools and manufacturing processes have focused on quantifying the energy and resource consumption of the use phase. The use of recycled material in manufacturing a machine tool was negligible. This occurs when the magnitude of the use phase energy consumption was considered while minimising cutting fluid consumption provides a more effective means of saving energy. Design-level changes provide the greatest flexibility and therefore potentially offer the greatest opportunity for energy savings.

Such strategies include design for disassembly and remanufacturing to reuse material for the machine tool frame. Strategies that require a design change of the machine tool to save energy during use have also been extensively studied, such as Minimum Quantity Lubrication (MQL). MQL enables the use of three to four times less cutting fluid than conventional flood cooling, but these strategies require modification of the machine tool’s cooling system if using an internal cooling system. Kinetic Energy Recovery System There are significant energy requirements of peripheral equipment and systems such as HVAC and lighting. Given these large energy ‘sinks’, methods that can recover energy from the cutting process using Kinetic Energy Recovery System (KERS) may provide substantial impact on

Power Reduction

Ivan Prole, Zemun, Serbia

Number of Tools

Time Per Part (min)

Figure 1: Estimated power reduction (%) using KERS on a NV1500DCG

Figure 2: Processing time and energy consumption of various tool paths


firstcut

overall energy requirements. To evaluate the feasibility of KERS systems, a dynamic model of the spindle and table of a Mori Seiki NV1500DCG was defined. Once matched to the actual machine tool performance, the deceleration of the spindle motor to stationary was the only scenario studied that provided sizable energy recovery. So, a system was modeled in a way that it recovered energy from a spindle. The deceleration rate of the spindle was from 20,000 to 0 rpm and stored in a bank of 400 supercapacitors. These supercapacitors were rated at 350 F using a voltage of 1kV and a charge/ discharge efficiency of 90 percent. A Monte Carlo simulation was performed on this design that varied tool selection (two to five tools with mean cutter diameter 5 mm and standard deviation 2 mm in increments of 0.5 mm) and

cycle time (2 to 5 min) for a general, nonstandard part; these results are shown in figure 1. An analysis of the simulation results shows that the use of KERS on a Mori Seiki NV1500DCG provides a power reduction of 5 to 25 percent relative to the same machine tool without KERS. If one specific simulation result is considered – three tools (cutter diameters of 5 mm, 2.5mm, and 4mm) and a cycle time of 2 min – that provides a power savings of 20.4 percent. Assuming a lifetime of 500,000 manufactured parts with the KERS machine tool, then the supercapacitor bank must cost $162 to be economically feasible. Given the $7,200 required for the current design, either energy costs must increase or the cost of supercapacitors must decrease for a KERS system to become a viable option.

Alternative approaches, though, should be considered including the direct use of recovered energy or the use of a common storage bank shared across several machine tools. Web-Based Energy Estimation Tool The relationship between machining time and energy consumption was used to create a web-based tool to estimate the energy consumption of machine tools. As highlighted in a paper entitled ‘Efficient Tool Paths and Part Orientation for Face Milling’, the direction of axis movement can strongly influence the processing time. Moreover, non-idealities in machine tool components may result in deviation between the ideal and actual processing times. To estimate energy demand and processing time, an NC code is uploaded to the software tool

ENQUIRY NO 075

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April 2011 metalworking equipment news

29


firstcut

as well as basic machine related parameters such as motor drive characteristics and motor ratings. The candidate NC code is parsed block-by-block sequentially considering only those blocks that cause either an actual motion of the axes or imply tool movement as a result of some other function. During the parsing process the software tracks the tool tip position, the active command, and the feed rate to enable efficient calculations of energy and time. While the time and energy for accelerating or decelerating drive axes are influenced by the specification of the drive motors, the energy required to move a specific axis is affected by the specification and number of drive motors for the axis and the axes configuration. This analysis assumed the geometry of a Mori Seiki NV1500DCG where the y-axis has two drive motors and the x-axis has one drive motor (since it sits on top of the y-axis). Gravity was neglected in calculating the energy consumption of the z-axis drive. It was assumed to be the same as that of the x-axis drive. Since part features can be manufactured in a number of ways because of tool path flexibility, a pilot analysis was performed on five NC codes to produce a 100 × 100 × 40 mm pocket with a 20 mm diameter flat end mill (for rough cutting) and a 10 mm diameter flat end mill (for finishing). These results are presented in figure 2 and show that moving principally in the y-direction requires more energy due to the design of the machine – more mass is in motion since the x-axis is carried by the y-axis and two drive motors are utilised versus only one for the x-axis. These results also highlight that longer tool paths generally result in larger energy consumption due to the direct correlation between processing time and energy. Saving Power The magnitude of the manufacturing 30

metalworking equipment news April 2011

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sector’s environmental impact calls for an emphasis on energy consumption reduction strategies to supplement machine tool performance improvements. Given the prevalent nature of

machining, strategies to reduce the energy consumption of machine tools in the design and operation phases are significant. Enquiry No. 3001

Process Parameter Selection In addition to implementing machine tool design changes, energy consumption during the use of a machine tool may be reduced through process parameter selection.

Although machine tools have various purposes and capabilities, power demand may be classified by three categories: constant, variable, and cutting power. The ‘constant’ power demand can be attributed to auxiliary equipment that consumes power at a specified rate independent of material processing inputs (eg: the computer panel, light fixture, and coolant). ‘Variable’ power demand is consumed by machine tool components that the operator controls (eg: the spindle motor and the x- and y-axis drives). The constant and variable power demand together form the ‘tare’ power demand of the machine tool since this is the minimum power that will be demanded for a given set of process parameters regardless of whether or not material is cut. The magnitude of the cutting power is determined by material type, material removal rate and cutting tool, so a strong correlation exists between the load from the material removal process and the power demanded. Since the end goal is to reduce energy consumption while machining a part, the energy consumed per volume of material processed (the specific energy of the cut) should be reduced. Strategies to reduce overall energy consumption by decreasing processing time include modifying the workpiece orientation or changing the cutter type, which is a more straightforward strategy. For example, a change from a two-flute to a four-flute end mill allows the operator to double the feed rate while maintaining the same feed per tooth, as such, halving the process time. Additionally, by changing the cutting tool material from high speed steel to carbide, the user can increase their cutting speeds by two to three times. Even the application of a tool coating allows increases in feeds between 25 and 50 percent. While energy savings result from such a change in cutting tool since machining time decreases, the variable and cutting power demanded by the machine tool increase since the spindle speeds, feed rates, and material removal rates increase with such a change in the cutting tool. The scope of the analysis must therefore be expanded to incorporate the manufacture of the cutting tool since the material extraction and processing energies of the cutting tools would differ. MEN Enquiry No. 3002


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Milosz1, Poznan, Poland

technology

In The Scale Of

Microns Micromachining is evident in manufacturing microcomponents for watches and surgical implants where titanium is often the material of choice due to its innate properties. By Natalia Tee

T

o d a y, m i n i a t u r e c o m p o n e n t s a r e manufactured and put together to form complex micro assemblies, magnifying the need for micromachining. Micromachining is a technology for fabricating micro-components of sizes ranging millimetres to micrometres, the latter commonly referred to as microns. Yet, this technology is not as new as it thought to be. Many manufacturers have been dealing with these miniature components for several decades; in this case, the watch-making industry and the production of surgical implants. The wealth of experience and expertise gathered in this area is advantageous to the selection of materials and production processes. Micromachining Materials Titanium, silicon nitride ceramics and nivarox alloy are commonly used in making micromachining parts. The suitability for both titanium and silicon nitride ceramic as surgical implants is dictated by the fact that they are biocompatible. From the medical perspective, it means that they are chemically inert and do not have any reaction with various bodily fluids. As such, these materials are often used to either replace organ or tissue or function together with living tissue. Nivarox alloy, on the other hand, can be found in both watch-making and medical applications, even though it is more commonly found in watches. This steel

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metalworking equipment news April 2011

alloy is compounded with cobalt, nickel, chromium and small amounts of titanium or beryllium. When used in making watch components, the alloy reduces errors due to temperature variation. They are therefore commonly made as nivarox springs. Titanium – Choice For Medical Industry Specifically to titanium, there are two beneficial properties. They are high strength-to-weight ratio and corrosion resistance. In its unalloyed state, titanium is as strong as steel but 45 percent lighter. Coupled these with its non-toxic state and non-ferromagnetic properties, which allow patients to be safely examined with MRIs and NMRIs, makes the metal a suitable choice for the medical industry. Titanium is used in surgical implements and implants such as hip balls and sockets that can stay in place for up to 20 years. With metal-on-metal implants, both the ball and the socket of the hip joint are replaced with a metal prosthesis, with a metal spacer placed in between. Therefore, metalon-metal implants do not wear out as quickly as the usual metal-on-plastic implants. The metal and plastic implants wear at a rate of about 0.1 mm each year whereas the metal-on-metal implants wear at a rate of about 0.01 mm each year, about 10 times less than metal and plastic.


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In addition, since titanium is able to osseointegrate, they are used in orthopaedic implant applications. Skeletal loads are more evenly shared between bone and implant, leading to a lower incidence of bone degradation due to periprosthetic bone fractures. However, titanium’s stiffness is still more than that of the bone so adjacent bone bears a greatly reduced load and may deteriorate. Cutting In The Scale Of Microns Micro cutting, particularly micro milling, and laser micromachining are some of the micromachining processes. In order for micro cutting to take place, the cutting speeds and feeds to remove material at an acceptable rate must be increased, requiring specialised high-speed spindles. In addition, cold air guns and misters are preferred to flood coolant in cooling during cutting. Another aspect to consider is the end mill selection as it is important to maintain tool life and fixturing. The tool bit for milling should follow a diameter as small as 0.1 mm with a high-speed spindle rotating at 20,000 to 150,000 rpm. It is capable of milling steel, brass and aluminium with depth of cut at about 30 microns and feed rates of 120 to 240 mm per min to provide

surface quality finishes as good as 0.2 microns. In spite of micro milling being applied in manufacturing biomedical components, one common problem that many users have identified is the breakage of the tool bit, which is usually caused by the amount of force associated with removing material at the particulate level. During the process of removing metal, specific energy required increases as the chip thickness decreases. As such, the micro tool bit is subjected to greater resistance as the depth of cut decreases, as if the workpiece material becomes harder during micro machining. The resistance force is strong enough to exceed the bending strength limit of the tool bit before the tool experiences any wear and tear. As such, the edge radius of the tool bit has to be larger than the chip thickness. Moreover, the micro cutting machine should have high tolerance as small vibrations are amplified relative to the tool diameter as it is reduced. Such vibrations not only cause reduced precision, but can also fracture end mills. Makino tackles this problem by producing the direct tool-change type spindle. It reduces the total run-out caused by tool holder variation by eliminating the use of a tool holder.

APMen_ASIEN_3406147_EMO Hannover 2011 18.03.11 13:36 Seite 1

INFO: VDW – Generalkommissariat EMO Hannover 2011 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstrasse 4, 60325 Frankfurt am Main, GERMANY Tel. +49 69 756081- 0, Fax +49 69 756081-74 emo@vdw.de ¡ www.emo-hannover.de

ENQUIRY NO 062

The world of metalworking

April 2011 metalworking equipment news

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Colin Adamson, Northmead, Australia

Many watch manufacturers have been dealing with miniature components

Mike Baird

Titanium is used in surgical implements and implants

The method of cooling and lubricating the spindle also has an impact on the spindle growth and movement during the machining process. Makino’s spindle core cooling and under race lubrication system, Spindle Core Cooling, is used to suppress spindle thermal distortion. It circulates the temperature-controlled cooling oil through the centre of the rotating spindle, cooling the liquid from the inside. Also, with under race lubrication, the cooling oil circulates through the spindle flows through holes in the inner bearing races to lubricate the bearings.

Laser Micromachining The sharp focusing of a laser beam coupled with high power density at the focus makes it an attractive tool for cutting materials at the micron level. Laser cutting process is carried out by a computer numerical control moving a tiny focused laser beam along the surface of a workpiece. This process is not only non-contact, it is also flexible and free from vibration. Laser micromachining encompasses varied functions including micro cutting and micro drilling. Unlike established fabrication technologies, laser micromachining provides optimum preconditions for the required quality and precision. For laser cutting of implants, foils and wires can be cut on the 10-micron scale. Foils and tubes can also be machined with cutting widths of below 20 microns. Continuous Wave (CW) lasers or pulsed solid-state lasers can be used for micro welding, leading to a production of cochlear implants. Lumera Laser’s picosecond lasers offer quality in laser micromachining by cold ablation, a cold removal of thin material layers, without mechanical force, wearand-tear and thermal damages. The power of the lasers ranges from 6 W to 50 W and is based on a 50 MHz mode locked oscillator, which generates approximately 10 picosecond-pulse-train and a subsequent power amplifier. The combination of high pulse power and high repetition rate produces high average power. Furthermore, its pumping technology allows the lasers to exhibit beam pointing and focus location stability, a prerequisite for high-precision micromachining. Micromachining has been in the industry for several decades as companies began dealing with making parts for watches. It is important for manufacturers to know that the materials used for making microcomponents should be strong enough to withstand constant cutting and drilling. In the process of manufacturing surgical implants, materials used should be biocompatible and have high resistance to wear.

Last Words On Micromachining...

Enquiry No. 3101

Cold clamping and waterjet technology are two processes applicable in micromachining, tackling the issues faced in rigid clamping and conventional micro cutting. Cold Clamping Microcomponents are difficult to hold securely with rigid clamping, which brings about the concern of the workpiece fragility as high clamping force can either distort or damage materials. The GF Series Icing Plates from AMCC use the power of ice as an adhesive to hold parts for milling, turning or grinding. The clamping system is rigid as well as stress-free on the part and hold parts

34

metalworking equipment news April 2011

on a single face. On metals, ice has a tensile strength of 97.07 kg per sq inch as compared to magnets at 77.11 kg per sq inch or vacuum at 6.35 kg per sq inch. Besides, the Z-axis repeatability of the icing plates is dependant on the surface of congelation as there is no water thickness under the part. Standard lubrication is redundant as well since the plate evacuates the calories generated by machining.

Waterjet Technology One breakthrough in the micromachining industry is the waterjet technology, providing an alternative in manufacturing miniature, highprecision components without the heataffected zones. Its positioning accuracy reaches 3 microns and cutting accuracy of 0.01 mm. MEN

Enquiry No. 3102


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Metrology

Cross Scanners:

Automating Inspection

Taking data points faster without the need to make contact, cross scanners are proving to be a welcomed addition to the world of measurement. By Rob Snoeijs, senior editorial writer, Nikon Metrology

3

D digitising and point cloud processing drive a digital inspection process that drastically improves CMM productivity while accelerating design-through-manufacturing by providing full geometry feedback. Customers in automotive, aerospace or general manufacturing industries use this technology to speed up their inspection process. Using a whole product approach reduces the total measurement and analysis time, increasing efficiency of the inspection process and reducing costs Limitations Of Tactile Inspection Sheet metal spring back and plastic part shrinkage illustrate that product quality concerns the entire shape of parts and not just a few geometric features. Even for a limited number of measurement points, CMMs require considerable programming overhead. In addition, tactile measurement falls short on soft and fragile parts. Economic pressure and higher quality standards force the metrology department to provide more detailed geometric information in less time. To a certain extent, 3- and 5-axis tactile scanning overcomes

36

metalworking equipment news April 2011

the limitations of discrete touch trigger measurements. Highspeed bridge CMMs equipped with this advanced touch sensor speed up dimensional inspection on prismatic driveline parts. Characterising a drilled hole by scanning a spiral line on its bore surface reveals much more valuable information than four discrete points. Also on the aerofoil surface of a turbine blade and other freeform surfaces, 5-axis analog scanning is an improvement compared to traditional tactile inspection. Although analog scanning provides much more data, elaborated CMM programming is required to ensure that the probe tip continuously follows the part surface without colliding with the part or the CMM structure. 3D Digitising & Measurement Productivity The sensor that undoubtedly gets most out of a CMM is a non-contact 3D laser scanner. New innovations in 3D scanning technology and point cloud processing software are key enablers of an entirely digital inspection process. The concept of digitising parts up-front and running inspection

on the digital copies of the samples streamlines metrology operations and embeds them into the CAD-centric design-throughmanufacturing process. From measurement preparation to final report, this approach is faster, provides more profound insight, and takes advantage of the typical flexibility and automation benefits of a digital process. A 3D laser scanner essentially projects a precision laser stripe on a specimen while its built-in digital camera captures the projected laser line under a fixed angle. Today’s digital 3D scanners with CMOS camera technology offer point resolution and image acquisition rates, capture over 75,000 noninterpolated points per second. As they reconcile high point cloud density, they digitise freeform surfaces and geometric features at high speed. Line scanners such as LC15 with a smaller field of view suit detailed inspection of smaller parts by offering measurement accuracy down to 5 micron. To effectively scan surfaces with varying colour or high reflectivity, digital laser scanners adapt laser source intensity point-perpoint. This capability is essential in dealing with different sample materials and surface finishes without operator interaction or powder spraying, also for shiny surfaces and abrupt transitions under any lighting condition. Intelligent intensity adaptation helps automatically scan similar parts in different manufacturing stages; initially dealing with bare sheet metal parts and finally scanning finished products painted in any colour. Full Capture Line scanners may be stretched to their limits when digitising parts with more complex surface shapes or numerous geometric features. For such applications, it is better to opt for a multi-line scanner – a cross scanner that incorporates three


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lasers in a cross pattern. These scanners realise full coverage on concave surfaces, in between ribs, and inside the cavities of deep pockets. By observing geometric features from three sides, a cross scanner is able to digitise the bore of a hole or the flanges of a notch in a single scan. A cross scanner enables full 3D digitising of features like slots, notches and edges as well as specialised geometric features, including connection pins, welded bolts and T-studs. Where tactile measurement relies on a handful of accurate points to define the orientation of an elongated feature, optical inspection does a better job by fitting lines through hundreds of points acquired along the feature flange. In this way, geometric features can be extracted from the acquired point cloud with higher confidence and accuracy.

SOLID DRILLING - Maximum performance and tool life - Indexable insert drills - Ø 14 – 155 mm - 2xD to 9xD

Spending Less Time On The CMM With high 3D scanning speed and short scanner motion paths with limited or no head indexing, laser scanners digitise freeform surfaces and geometric features in a fraction of the time. At car manufacturers, cross scanners automate the inspection of so-called ‘Christmas tree’ features. Robots weld these complex metal features on sheet metal body parts to allow trim to be easily and securely connected by means of screws. In roughly five seconds, a cross scanner digitises the complete geometry of a single Christmas tree feature in order to determine its actual welding position. Scanning avoids spending hours manually mounting cylindrical extensions on the Christmas trees required for tactile measurement and removing them afterwards.

With la ser sca nning, the entire CMM inspection process is executed more than 10 times faster. High standoff distance and field-of-view depth enable cross scanners to realise major time savings when inspecting automotive casted parts. To take a full 3D scan of one side of an engine block, cylinder head or gearbox cover, the CMM only needs to move the scanner along parallel motion paths without indexing the head. W it h suc h l i m ite d CM M overhead, the scanner captures the complete surface, including full 3D characteristics of ribs, holes, flanges and pockets, at record speed. One hour is sufficient to set up and execute inspection, whereas detailed tactile inspection easily lasts more than a day. MEN Enquiry No. 3201

JEL THREADING SYSTEMS -

Drill thread milling tools Thread milling tools Taps Roll form taps 1.5xD to 2.5xD M2 to M14

Distributors invited for South East Asian countries. Please contact k.ravikumar@kometgroup.com

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KOMTRONIC u-axis-systems Economic turning contours on machining centre when working with a stationary workpiece

PCD TOOLS - Tool life without end - Reaming without premachining - Inner coolant supply for through and blind holes - Multi step combination tools to reduce your tool numbers

KOMET GROUP GmbH Germany Zeppelinstraße 3 74354 Besigheim Tel. +49(0)7143.373-0 Fax +49(0)7143.373-233 info@kometgroup.com www.kometgroup.com

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DIHART REAMERS

April 2011 metalworking equipment news

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The

Accuracy Of

Laser

Measurement

Specifications and actual performance of the angular measurement system on a laser tracker plays an important role. By Ken Steffey, director of product management, Faro

M

e a s u r e m e n t i n st r u me nt s a nd systems evolve constantly, enabling the user to take advantage of a whole host of features. The technical specifications of most me a su rement system s may include reference to such entities as resolution and repeatability but will always include reference to the term accuracy. The meaning of accuracy in the context of metrology in general and in particular for the use of a laser tracker instrument are particularly important in today’s context, much as the importance in distinguishing between in-line (or radial accuracy) and angular accuracy. The consequence of poor angular can be disastrous, as such; it is worthwhile to study angular errors, which has the tendency to dominate during the measurement of a typical object. Laser Tracking Instruments Laser tracking measurement instruments are very versatile by nature, although their use is frequently for applications where there is a demand for the highest possible performance from the measurement system to characterise the object being measured. One of the reasons why laser trackers have evolved into this high accuracy sector is because of their ability to accurately measure distances. This was initially due 38

metalworking equipment news April 2011

to the use of laser Interferometers (IFM) followed later by Absolute Distance Metres (ADM). Dista nce measurement capability on its own is not enough if a set of coordinates is required. In order to achieve this, the laser tracker instrument in its basic form is equipped with an angular measurement system to enable the distance measurement to be processed alongside two measured angles to arrive at the required coordinates. It is clear then that in order for the ever-increasing customer specifications to be met, there has to be an emphasis upon the accuracy of both the distance and angular measurements of the instrument. Distance & Angular Measurement Accuracy Dependent upon the manufacturer of the laser tracker, specifications over the last few years have varied in the sense of their presentation, usefulness and practicality to the user. The introduction of the ASME B89.4.19-2006 standard has helped manufacturers to standardise the approach toward specifying, although there is some way to go in order complete agreement is reached across continents. The ASME standard offers the concept of Maximum Permissible Error (MPE) to the manufacturer and subsequently the user. MPE

is useful in the sense that it encompasses the extreme values of error that are permitted by a specification. The following is a typical distance measurement specification offered by a manufacturer. Please note that actual numbers are for reference only: For the IFM system: 4 micrometres + 0.8 micrometres/ metre For the ADM system: 20 micrometres + 0.8 micrometres/ metre For the Angular or more often called the Transverse system: 36 micrometres + 0.6 micrometres/ metre Note that in all cases there are two terms – the first term is the offset, while the second term is the slope or scale factor. The slope or scale factor is predominantly a function of distance; therefore it should encapsulate the range of specified environmental conditions together with the specified range of the instrument. The MPE specifications can sometimes be offered as ‘typical’, in which case they constitute a halving of the full MPE value for the purposes of portraying a value, which will be typically achieved the majority of the time.


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

ENQUIRY NO 059

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 www.tungaloy.co.jp


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Theoretical deviations (in mm) based upon a pure included angle measurement capability of 1 arc second (0.00027째)

Figure 1: In-line concept to achieve highest possible distance or ranging accuracy Figure 2

Distance Measurement (Ranging) Accuracy As mentioned previously, the distance measurement systems typically found in a laser tracker are an IFM and ADM or even ADM only. Independent upon whether IFM or ADM systems are being used, the ability of these systems to detect and measure displacement is well known and documented. Interferometers were typically used to measure the displacement between two points and therefore the product would be a distance between the two points. It follows that in order for a laser tracker instrument to measure distance optimally, it needs to be positioned in line with the points to be measured. In this case there is no influence from the angle measurement system. 40

metalworking equipment news April 2011

Angular (Transverse) Measurement Accuracy The angular accuracy of a laser tracker de scribe s how well the instrument discerns angle measurements from its angular measurement encoders prior to processing them together with the distance or ranging element in the form of a coordinate. Figure 2 shows the theoretically possible deviations at the distances shown from a laser tracker that is operating within an effective angular specification of +/-0.5 seconds of arc. Angular Measurement Accuracy Vs Distance Figure 3 shows the comparable accuracies between a typical ADM distance specification (eg: 10 micrometres + 0.4 micrometres/ metre) for a laser tracker against a typical angular performance of +/- 0.5 arc seconds as depicted in Figure 2. With some laser trackers specified out at ranges of 50 m or more, you can see that the pure

ability for the unit to accurately measure angles is very important for respectable performance in the field. This becomes more or less important depending upon the volume of the object and where it is practical and economical to position the instrument in order to measure the points of interest. Volumetric Accuracy Volumetric accuracy is often used as a term to describe how accurate the instrument is for a particular measured volume. Where they exist, illustrated concepts of volumetric accuracy from manufacturers have to be aligned with the ability of the user to practically position the instrument in the real-life situation for their particular measured object. Where measurement volumes are large it is sometimes more efficient for the user to reposition the instrument in strategic and practical positions to enable the viewing of all the required points of interest. The use of more instrument

Typical Angular Versus Distance Measurement Capabilities Of A Laser Tracker Deviation (micrometres)

As for the relevance of the MPE specs to the user, it is clear that the declared MPE values ca n be compa red to a ssess the relevance of the purchase across manufacturers. If pointto-point accuracy is of interest to the user, some manufacturers publish the formulae used to calculate the MPE, making it possible for the user to calculate his or her own situation. Some manufacturers also offer to certify the instrument with respect to the B89.4.19-2006 standard. If this is available, together with processes to protect or guard-band the MPE specifications, it can only be of benefit to the user.

Distance from instrument to measured point (metres)

Figure 3

Angular capability

Distance capability


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Figure 4

Figure 5a: Points on measured object in line with the laser tracker

Figure 5b: Line between two points on the object perpendicular to the laser tracker

stations will have the effect of reducing the distance from the instrument to the points of interest, which will also tend to weight the contribution of the angle measurement. This is especially true if there are practical limitations for the positioning of the instrument, pl a c i n g m o re e mp h a si s o n the a ng ula r mea surement c a p a b i l i t y i n t h e qu e s t to ac h ie ve a n accu rate se t of coordinates. Figure 4 shows a situation where the angular measurement capability of a laser tracker is exposed more so that the distance (ie: angular errors) dominates. In this scenario the following is relevant: • The laser trackers have limited room to maneuver in the Z direction • All points of interest cannot be seen from a single position • Multiple laser tracker positions are required to achieve the required accuracy • The highest possible accuracy is required • The measurement volume dictates that the laser tracker angle measurement capability is exercised, especially in the Y (vertical) direction 42

metalworking equipment news April 2011

• Measurement distances have been cut, but laser tracker angles are exercised more severely. In order to illustrate how much angular errors dominate for a measured object, consider figures 5a and 5b. If the laser tracker in figures 5a and 5b is deemed to be 2 m from the measured object, the following typical MPE performance is attained from a measurement of the 2.3 m length. Assume use of IFM and a Typical MPE Figure 5a = 3 micrometres Figure 5b = 33 micrometres Note the relatively la rge difference – this is because in figure 5b the laser tracker’s relative position to the points which require to be measured dictate that the angular or transverse measurement system errors dominate. Objects with features, which require measurement, are rarely offered up as depicted in Figure 5a. Objects tend to be more irregular in shape and size, and very often not all points can be viewed from an in-line position. Typical examples might be large assembly tools for the aerospace industry. Figure 5b orientation is more common with the scenario shown in Figure 4 coming into play if not all points can be seen from

one position. The moment that multiple laser tracker positions come into play coupled with objects positioned to the laser tracker as depicted in Figure 5b, means that the angular measurement system errors dominate. It can therefore be concluded that the specifications a nd actual performance of the a ng ula r or tra nsverse measurement systems onboard the typical laser tracker play a ver y important role in its day-to-day performance for the average user. It is very easy to forget this fact when confronted with the specifications and by the outstanding performance of modern IFM and ADM distance measurement systems. Selected Consequences Of Sub-Optimal Angular Accuracy Examples of sub-optimal angular accuracy are apparent for large assembly tooling within the aerospace industry. If angular accuracy is sub - optimal, the following could ensue: • Poor initial reference system leading to a lack of accuracy and repeatability when setting and certifying the tool • Poorly fitting parts leading to cost issues downstream of the assembly process • Costly rework based on a poor signal from the measurement system (costs include labour and time tying up a tool which is on critical path) If the angular accuracy is optimised, it is more likely that the tool will not have to be reworked during its first recertification due to measurement variation at least. Reworking tools such as these described can cost several thousand dollars. MEN Enquiry No. 3202


Release of the VFX6 indexable end mill for machining of Titanium Alloys Mitsubishi Materials Corporation has recently released a new indexable end mill series, VFX6, that is dedicated to the machining of Titanium Alloys.

In the Aerospace Industry, the use of Titanium alloy components is widely used. Titanium alloys has a machining characteristic in which the heat generated during machining generally concentrates around the cutting edge, leading to problems such as welding along the cutting edge that can easily lead to chipping. Additionally due to the heat generation premature cutting edge failure due to increased wear can also become a major problem. With these problems in mind the VFX6 series was designed to ensure effective chip disposal, by removing the chips effectively away from the cutting edge welding can be reduced. This is achieved by the use of effective coolant that can be supplied right to the cutting edge where it is needed the most. This is done using coolant nozzles that can be interchanged to suit the coolant pressure of the machine in use. Additionally the insert configuration uses tangential located inserts that enable to increase the tools overall rigidity making it suitable for high load machining applications. In order to reduce the cutting edge temperatures a uniquely designed insert geometry has been employed, also a brand new PVD tool grade, MP9030, has been developed to obtain a high balance of both wear and fracture resistance. This whole combination of insert geometry, tool grade and tool design enables the VFX6 to be able to achieve metal removal rates of up to 400cm3/ minbased on a dia. 63mm.

MMC Hardmetal (Thailand) Co.,Ltd.

8th Floor Regent House Building, 183 Rajdamri Road, Lumipini, Pathumwan, Bangkok 10330, THAILAND Tel: 66-2651-9800 Fax: 66-2651-9803 Home page or contact our regional distribution centres below. Singapore (Representative office) 33 Ubi Avenue 3, #05-14 Vertex, Singapore, 408868 Tel: 65-6634-8250 Fax: 65-6634-8257

http://www.mitsubishicarbide.com

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When Things Get Complicated,

Scan It

The complex shapes and tight tolerances of today are part of the natural evolution in engineering. Luckily, measurement instruments have also undergone their own transformation over the years to keep up with the changes. By Neven Jeremic, Hexagon Metrology, marketing and communications

T

echnological progress in the manufacturing processes has meant that more daring body shapes can make the leap from the designers’ drawing board to the assembly line. In the not-so-distant past, cars had relatively simple, square shapes, with individual parts fitting to one another along more or less straightforward lines. On the other hand, modern cars boast far more complex shapes than the cars of the past. The task of inspecting how these parts fit to one another has gotten increasingly more complex as well. The Body- In-White ( BI W ) Rollout and Process Optimisation

44

metalworking equipment news April 2011

Department at Daimler Bremen t a c k l e s e x a c t l y t h a t t a sk : it is entrusted with the job of inspecting how the various body parts fit to one another. More importantly, based on their measurements, feedback is given to the production facilities so specific, targeted adjustments can be made on the tools. The Search For A Perfect Fit Operational engineer Henning Siemers is involved in BI W measurement and inspection tasks. He explains: “Our job is to assure dimensional accuracy of the entire BIW. Of course, every BIW consists of many individual parts, and they

must all fit perfectly. Our primary duty is to inspect the entire BIW, both individual parts and the whole vehicle, including the panel gaps, and then analyse the data we get. DIFFICULTY: Shape complexities of today’s cars and the ever-increasing tolerances have pushed manual measuring instruments past their effective range.

SOLUTION: Adaptation of laser scanners and software programs that allows immediate results.

CONCLUSION: Improvement in the quality and speed of part analysis.


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Based on the analysis we perform, we then go back to the production facilities and make adjustments to the tools and make sure that what comes out is an automobile whose parts fit together flawlessly.” In the pa st, Mr Siemers’ d e p a r t m e nt h a s re l i e d o n hand- operated measurement instruments. However, the shape complexity of today’s cars and the ever-increasing tolerances that have pushed such instruments against their limits. He continues: “Viewed in retrospect, cars used to be made of almost square-like segments which used to fit nicely together without much hassle. Nowadays, cars are much more curvy, with round areas suddenly changing shapes and meeting other panels at all kinds of angles and lines. Plus, the much higher requirements for the nearly seamless fit between individual

panels mandate that we work with very tight tolerances.” Using Laser Scanning Armed with a Leica T-Probe/ T-Scan system, the company has used it to measure panel gaps, examine part curvatures and inspect reference holes. In addition, Mr Siemers has also been busy testing different applications for their scanning system. “One of the applications we have found is inline calibration. In the past, BIWs were inspected by being placed inside a grid station and measured using conventional CMM equipment. When you have 150 pallets and want to measure with high tolerances, you’re quickly reaching the limits with traditional methods. That’s why we wanted to be able to measure inline, both the pallets and the tools. Another application of interest to us is the

inspection of the entire robot path, and this is something we plan on doing in the near future.” More Info For Good Analysis After the implementation of the scanning system, Mr Siemers feels the quality of part analysis has improved as he has access to more information. As such, he is able to get to the root of a problem quickly. In addition, using a portable prob e to c a r r y out t ac t i le wireless measurement allows the team to measure twistable parts like the hood. The team uses the probe for quick measurements to get a rough idea about the condition of a part, saving time in the process as it will take them longer to realise the hood is twisted if they jump straight into scanning. MEN Enquiry No. 3203

ENQUIRY NO 010

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Form

Welding:

All The

Jason Conlon, Belfast, N.Ireland, UK

Fireworks

W

46

Viewing welding in its individual segments, it is clear the joining process has come a long way since its inception. By Augustine Quek

elding is a process that joins two or more pieces of materials permanently. The materials in question are usually metals or thermoplastics. They are bonded by the coming together or fusing in both materials. The process is carried out by melting the workpieces and adding a filler material to form a pool of molten material. After cooling under pressure, a strong joint is formed. In welding, there are many energy sources available. They are gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. Some of the welding processes are arc welding, gas welding, energy beam welding, resistance, and solid-state welding.

shielding gas during welding. Another form of arc welding involves using a continuous wire feed as an electrode and a shielding gas in a semi-automatic or automatic process, called Gas Metal Arc Welding (GMAW), also known as metal inert gas or MIG welding. Since the electrode is continuous, welding speeds are greater for GMAW than for SMAW. On the other hand, Flux-Cored Arc Welding (FCAW), uses wire consisting of a steel electrode surrounding a powder filled material. Although the cored wire is more expensive than the standard solid wire and can generate fumes and/or slag, it permits even higher welding speeds and greater metal penetration.

Arc Welding Using an electric arc between a base material and an electrode, arc welding is one of the common welding processes around today. Employing a semi-inert or inert gas, the weld area is protected from contamination to a certain extent. A common form of arc welding is the Shielded Metal Arc Welding (SMAW), also known as Manual Metal Arc Welding (MMA) or stick welding. This uses a steel electrode rod that is covered with flux that produces carbon dioxide as a

Solid-State Welding Deviating from the notion of melting, some solid-state welding methods heat the metals until they are in the plastic phase, ie: till they are ‘soft’ enough to be joined. One popular example of solidstate welding involves the usage of ultrasonic. Ultrasonic welding applies high-frequency ultrasonic acoustic vibrations and high pressure locally to connect thin sheets or wires made of metal or thermoplastic. There is no melting; instead,

metalworking equipment news April 2011

the weld is formed by introducing mechanical vibrations horizontally under pre ssure. U ltra sonic welding is commonly used for making electrical connections out of aluminium or copper, and it is also a very common polymer welding process. Friction Stir Welding (FSW) is a solid-state process which utilises frictional heating combined with forging pressure to produce highstrength bonds. The process uses a non-consumable, cylindrical, shouldered tool to join two or more materials. The tool is rotated and forced against the materials to be joined, creating a plastic layer around the tool. Conventional friction-stir tools consist of a pin and a shoulder. The pin is plunged into the material to be joined and stirs the material at the joint interface. The shoulder remains in contact with the top surface and generates additional heat while constraining the plasticised material that is flowing around the pin. FSW offers many advantages, including little distortion and a significant reduction in consumable costs. Most important of all, it has fewer process elements to control such that a fully automatic process requires only one operator. The technique has been used in cases where traditional arc welding cannot be done, without compromising its mechanical properties on aluminium alloys. Laser Welding Energy beam welding, showcasing high energy density and deep weld penetration commonly uses either a laser or electron beam, and have become quite popular in high production applications. Both capable of minimising the size of a weld area, the difference lies as such where laser beam welding employs a highly focused laser beam, while electron beam welding is done in a vacuum and uses an electron beam.


fab&form

Extremely fast and easily automated, both processes are highly productive. The ability to weld from one side and allowing making welds possible where accessibility poses an issue, gives this process an edge over more conventional techniques although it is more capital intensive. Laser welding usually imparts less heat overall than conventional methods, because the power is more concentrated at the point of weld. Lower heat reduces distortions and the size of the heat-affected zone. In fact, practically every industry today, from consumer products to medical devices and avionics use laser welding. T h i s ha s me a nt g re ate r improvement in laser technology, with higher power and higher beam quality, translating into deeper and faster welding. For instance, RofinSinar has introduced CO2 slab lasers

that no longer use moving parts to generate the beam, and do not use consumable optics. Instead, the laser uses high frequency between two water-cooled electrodes (slabs) to stimulate the laser gas. The optical resonator is formed by the front and rear mirrors and the two electrodes. The heat generated in the gas is dissipated by the water-cooled electrodes (diffusion cooling). As a result, the conventional gas circulation systems involving roots blowers or turbines are not required. Another recent advancement in the last few years is the rapid introduction and acceptance of the fibre la ser, in which t he ac t i ve ga i n me d iu m i s a n optical fibre doped with rare - earth elements such as erbium, ytterbium, neodymium, dysprosium, praseodymium, or thulium.

A solid-state laser, it features a doped fibre-optic cable that is excited (pumped) by diode lasers. It delivers high power with no moving parts and little maintenance. Fibre laser welding have several advantages. The fibre’s wave guiding properties reduce or eliminate thermal distortion of the optical path, typically producing a diffractionlimited, high-quality optical beam. Fibre lasers can be focused to small spot with extremely long focal lengths, as such, remote laser welding capabilities with fibre lasers are highly enhanced. The benefit of large standoff in the order of 1 to 2 m increases the work area multifold over conventional robotic systems. Fibre lasers are compact compared to rod or gas lasers of comparable power, because the fibre can be bent and coiled to save space. MEN Enquiry No. 3301

ENQUIRY NO 061

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C

MT sta nds for Cold Metal Transfer. In the conte x t of welding, ‘cold’ is a relative term of course. Nevertheless, the fact is that in this process, the workpieces to be joined – and above all their weld zones – remain considerably ‘colder’ than they would do in conventional GMA (Gas Metal Arc) welding. The reduced thermal input leads to advantages such as low distortion and higher precision. This, however, is just one of the distinguishing features of this GMA technology for automated and robot-assisted applications. The other significant benefits for users include the higher quality of the welded joints, freedom from spatter, the ability to weld lightgauge sheet from 0.3 mm, and the facility for joining both galvanised sheets and steel to aluminium. By ‘higher quality’, what is meant here is higher uniformity and reproducibility and as a result, fewer rejects. As well as for welding, the technology is also suitable for use with brazing processes. The Process The CMT process is based on the dip-transfer arc – or rather, on a deliberate, systematic discontinuity of this arc. The result is a sort of alternating ‘hot-cold-hot-cold’ sequence. This ‘hot-cold’ process greatly reduces the arc pressure. In a normal dip-transfer arc, the electrode is deformed while being dipped into the weld-pool, and melts abruptly at high dip-transfer arc current. In contrast to this, the CMT process is characterised by a wide process window, and by the resulting high stability. T h is is i mp or ta nt whe n the welding torch is abruptly reorientated, for example. There are three striking criteria which differentiate the CMT process from the familiar dip-transfer arcprocess: The wire motions are incorporated into the process48

metalworking equipment news April 2011

Cool Weld A

To

Way

Cold welding can be misleading at times because of its name but the benefits that come with the technology have no ambiguity attached. By Gerd Trommer, for Fronius

control; the thermal input is diminished, and the metal transfer takes place without spattering. The key point is that the motions of the wire have been integrated into the welding process and into the overall control of the process. Every time the short circuit occurs, the digital process-control both interrupts the power supply and controls the retraction of the wire. This forward and back motion takes place at a frequency of up to 70 times per second (approximately 70 Hz). The wire retraction motion assists droplet detachment during the short circuit. The conversion of electrical energy into heat is both a defining feature and a sometimes critical side-effect of arc-welding. By ensuring virtually current-free metal transfer, the CMT process reduces the amount of heat generated.

Also, the controlled discontinuation of the short circuit leads to a low shortcircuit current. Owing to the i n te r r u p t i o n i n t h e p owe r supply, the arc only inputs heat into the materials to be joined for a very short time during the arcing period. Until now, ‘spatter-free’ arc welding has been somewhat wishful thinking – at best, an ideal to be aimed at. This is why people have preferred to use the term ‘low-spatter’. The notion of ‘spatter-free metal transfer’ is the result of the two coordinated effects: The forward and back motion of the wire, and the controlled short circuiting. Applications which were hitherto impossible, or only possible with a great deal of difficulty, are now common practice.


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The Applications T h e C M T te c h n o l o g y s e t s some standards in the welding engineering field. Indeed, the combination of integrated wire motions, reduced thermal input and freedom from spatter means that welding and brazing can now be used for certain applications which used to be ‘off limits’ to them, as well as delivering benefits such as higher productivity and lower costs for rejects and postweld machining. These advantages are complemented by the high gap bridgeability, leading to better manageability of automated processes, and are underscored by the flawless appearance of the joining weld. Several fields of application are worthy of mention:

from a thickness of as little as 0.3 mm. This means that aluminium sheets can now be welded with no need for any tools for clamping and holding, or for preventing drop-through or burn-through. • In the past, aluminium-to-steel joints have only been possible using laser welding – and with major limitations, at that. CMT technology has achieved

another of its development goals here: Both the metallurgical join and the appearance of the seam are convincing. In principle, the technology offers an alternative to automated or robot-assisted GMA processes for joining thin sheets. This is also true with regard to the base and filler metals used. Enquiry No. 3302

CMT Advanced Technology: The Next Step The technology allows adjustable deposition rates by way of positive and negative process cycles, making it possible to join super-high strength steels with sufficiently high deposition rate yet with low thermal input. In addition, the polarity of the welding current is fully integrated into the process-control as well. Further advantages include targeted thermal input, higher deposition rate with no increase in heat input and with minimal distortion. MEN

• Light-gauge sheets can even be ‘butt-welded’ or ‘butt-brazed’

Enquiry No. 3303

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Business In

Vietnam

The measures in place to help streamline the process of starting a business in Vietnam will no doubt provide much impetus to those who want to be part of the rapid growth. By Michael E Neumann

Steven Tay, Singapore

O

nce an agricultural civ ilisat ion ba se d on rice cultivating, Vietna m ha s shed its tag of one of the poorest country in the region to one with the highest growth. This can be directly attributed to the economic reforms in the 80s. The country’s GDP growth in 2010 was estimated at 6.78 percent against 2009, of which the first quarter GDP grew by 5.84 percent; the second quarter by 6.44 percent; the third quarter by 7.18 percent and the fourth quarter by 7.34 percent. According to ‘The FactBook’ the population of Vietnam stands at 90,549,390. With 69.3 percent of its population in the 15 - 64

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metalworking equipment news April 2011

years bracket, there is a young population to drive the rapid economic growth. Growth To Continue But Difficult Business Conditions Loom Led by a strong construction se ctor, Viet na m’s re a l G DP grow th came in better than expected in 2010. In a market re p o r t , ‘ V i e t n a m B u si n e s s Forecast Report Q2 2011’ by Business Monitor International, going forward, domestic demand is expected to remain robust on the back of rising wages and improving consumer sentiment. In light of a good Q4 2010 result, the report states the forecast of real GDP growth will

be adjusted upwards from 5.5 to 6.3 percent for 2011. Despite the genera l upsw ing in the economy, business conditions are expected to remain difficult as lending rates remain elevated in the short-to-medium term. As such, businesses with tight profit margins in particular could struggle to stay profitable if they fail to pass on higher production and financing costs to the consumer. Businesses may begin to face financing difficulties should lending rates continue to climb over the coming months. Steel Production Closer to metalworking, the steel production sector in Vietnam has also posted good results in


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the country. A news report in Vietnam Business News reported the Vietnam-Australia steel joint venture (Vinausteel) had produced 2.2 million tonnes of steel after its 15-year operation in Vietnam. T he comp a ny ha s had a total revenue of VND17 trillion ( US$815 million) since 1995. Mov ing for wa rd, Vinausteel has raised its investment and capacity of its steel plant to U S $ 4 0.0 2 m i l l io n a n d ove r 20 0,0 0 0 tonne s of steel per year from the initial of US$12.7 million and 180,000 tonnes. Land Of Opportunities? The burgeoning metalworking sector in Vietnam has drawn many international machine tool makers to set up offices there. The movement towards Vietnam has not gone unnoticed. According to another report

from Vietnam Business News, Christoph Miller, MD of EMO Hannover said that Vietnamese mechanical engineering businesses would have more opportunities to seek export markets and new link-ups with foreign partners. In a report by the International Fina nce Corporation, the countr y ha s sta r ted e a sing business start-up. It created a one-stop shop that combines the processes for obtaining a business and ta x license by eliminating the need for a seal for company licensing. In addition, the processes of permitting, property registration and credit information sharing have b e e n i mprove d . A 5 0 percent reduction in the cost to register newly completed buildings, along with the transfer of the authority to register

buildings from local authorities to the Department of National Resources and Environment, made dealing with construction permits easier. Finally, borrowers are allowed to examine their own credit card and correct errors, improving the credit information system. As such, the country earned a spot among the 10 most-improved economies and moved up 10 places in the global rankings on the ease of doing business, to 78 among 183 economies. Though there are some fears of inflation, the positive economic momentum is powering the nation forward. With new systems to help streamline the process of starting a business, there is a belief that Vietnam will be one of the fastest developing countries in Asia. MEN Enquiry No. 3401

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ENQUIRY NO 078

Laser

April 2011 metalworking equipment news

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Focus

Holding Uneven Aircraft Parts

In Place

I

Combining vacuum clamping with integrated controls is the way forward for holding large aerospace parts. By Maren Roeding, PR manager, Witte Far East

n the aerospace industry, almost all savings potential has been exhausted to a large extent. The aim now is to achieve further weight reduction during machining o f a lu m i n iu m a l loy s wh i le simultaneously improving process or quality. Aircraft companies are increasingly viewing chemical milling as time-consuming and environmentally unfriendly. Due to the very large part dimensions involved in aircraft design, (eg: skins up to 3 x 12 m) special fixtures, which exhibit high f lex ibilit y w ith rega rd to range of parts, have to be developed for holding such parts on machining centres. Since in the aerospace industry where thin-walled, light metal alloys are used and conventional clamping methods are often ruled out from the start, vacuum clamping technology represents a suitable alternative. A large variety of different standard vacuum systems are available, which covers many ranges of application. These are however more suited for small 52

metalworking equipment news April 2011

to medium work piece sizes. For part dimensions of several square metres, custom-built solutions are necessary. The Task With such undertaking at hand, knowledge in aerospace parts fixturing and vacuum clamping technology is essential. The synergies of these two ranges of expert knowledge now flow into custom-built fixturing for large aircraft parts. The specialist requirements consist mostly of building a fixture into an existing CNC machine and integrating control procedures. The case in hand involves complex clamping equipment, on which large uneven raw sheets of aluminium are fixed and machined. The clamping unit was integrated into a gantry type machine. Clamping Unit The parts are typically several metres long, rough and uneven aluminium sheets with thicknesses ranging from approximately 9 - 50 mm. Such heavy sheets must be machined on both sides in order

to achieve the necessary weight reduction and accuracy. The difficulty consists of flattening down these relatively thickwalled, bulky, uneven parts for clamping and machining. Because a lot of effort is required to do this, a solution combining a vacuum clamping system with a hydraulic stamp is required. The equipment comprises ma in ly of a vacuu m chuck mounted on a substructure with linear guide units, an integrated portal with a hydraulic stamp and a control unit. Since relatively heavy milling work with a high cutting degree is involved, a grid type vacuum chuck was the obvious choice. This type of system is considered a classic in vacuum clamping technology and is pre-destined for simple shaped work piece geometry with a rough surface. Grid chucks offer maximum holding force a lso for non machined part surfaces. These chucks are available in different shap e s a nd si ze s whe reby grid distance can be designed according to part requirements. Sp e cia l cha rac ter ist ic s of this chuck are 32 separate clamping areas and a defined slot configuration for O-shaped seal. The vacuum surface measures 2,000 x 7,500 mm and is divided into eight segments. Each segment consists of four individually operated, automatically monitored clamping areas with 50 suction bores. The clamping areas are activated via numerical controls and the electrical vacuum valves via a bus system. Slots in the chuck enable insertion of O-shaped seal, which seals off the part when vacuum is applied and also when surfaces are uneven. Filters inserted into the suction holes reduce penetration of chips and waste during milling. Addit iona l tapp e d hole s allow the use of mechanical clamps and stops. It is possible


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to clamp several smaller parts simultaneously thereby increasing effectiveness of the system. Working Process Loading of parts to be machined onto the chuck is done by vacuum pads. In order to flatten the uneven parts onto the clamping su r face, a hydraulic sta mp integrated into the gantry is used. The bridge moves to different positions on the aluminium sheet and the hydraulic stamp presses it down segment by segment onto the chuck. The gantry with stamp have a maximum speed of 15 metres per minute and help to counter unevenness within the sheet metal, which has ensued during production. A maximum force of two tonnes downforce can be created by the press. W hen vacuum is applied from underneath, the sheet meta l is held in position. Additional mechanical clamps along the side can be mounted in threaded holes at regular intervals, which hold the part along critical edge areas. Light ba rriers on both sides of the equipment prevent enda ngerment of ser v ice personnel when the hydraulic stamp is in operation. Machining starts after the stamp has pressed a part flat on the machine table and it is securely held by vacuum. In the first step, pre-machining of raw material takes place in order to obta in a n optima l surface for clamping processes for further machining steps. For machining the second side the part is turned over and laid with machined side downwards onto the vacuum chuck into a flat position. The hydraulic stamp is reactivated, the part pressed down again segment by segment on the chuck and the corresponding vacuum clamping areas activated accordingly. Now further machining steps 54

metalworking equipment news April 2011

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can be carried out. The part is thinned a nd the pockets milled. The finished parts have a wall thickness of only 1, 2 mm with tight tolerances, over the entire length of up to 7.5 m, in accordance with aerospace requirements. Coolants are necessary for m i l l i n g pro ce s se s but m ay cause damage to the pump. T h e y a r e d i r e c te d i n to a n integrated liquid separator with separation capacity of up to 100 litres per hour. By dividing the chuck into eight segments each comprising of four vacuum plates, sheet metal of different dimensions can be clamped and machined. Clamping and milling programs a re automatica lly activated according to the respective part size. Pre-requisite conditions for smooth operation are clean, deburred and dry aluminium sheets, where outer dimensions do not exceed 7,500 x 2,000 mm. During the total operation

the accuracy of the system plays an important role. The set values for evenness and parallelism of the vacuum chuck over entire length and width may not b e e xce e de d eve n during the press process. The division of the vacuum chuck into eight segments makes the unit maintenance friendly. The vacuum equipment developed by Witte monitors a nd reg ulate s a ll functions a u t o m a t i c a l l y. S h o u l d a pump fails, one of the others a u t o m a t i c a l l y t a k e s o v e r. Working reliability is therefore guaranteed and even if power is interrupted, parts always remain positioned and clamped. Pressure difference switches monitor the vacuum system in dif ferent place s a nd a re integrated into the emergency stop system to react to the smallest irregularities. As such, part clamping are made safer. Enquiry No. 3501

Under The Microscope: Vacuum Clamping Technology Vacuum clamping technology is preferably used when machining thin-walled parts from non magnetic materials like aluminium, non-ferrous metals, titanium, steel, plastic, wood, glass, ceramics, graphite and more. This technology is suitable for almost all kinds of machining (Turning, milling, grinding, drilling, engraving, polishing and eroding). The parts are clamped very gently and quickly. As such, clamping times can be considerably reduced. In only one clamping process, up to five sides can be machined vibration-free. Also problem-free milling of pockets and cutouts is possible. For different requirements, types of machining, part shapes and materials – a range of vacuum clamping technology is available. Individual components can be combined on a modular principle depending on requirements.

Market Development The demand for vacuum systems is increasing, as a result, vacuum clamping technology is continuously gaining in significance. With the trend going to lighter materials and thin-walled components, the only economically viable machining processes are the ones using vacuum because of new materials and weight saving thin-walled design. MEN

Enquiry No. 3502


ENQUIRY NO 076


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Making A

CleanWithBreak

Waterjet Commercial and military aircraft manufacturers are increasingly using composites in their structures, making waterjet cutting a desirable technique in the industry. By Marjorie Millay, product manager, Flow

B

oeing Commercia l Airplane Group, the manufacturer of commercial airplanes, began to expand their use of composites on the 777 aircrafts to include the horizontal stabilisers and the vertical fin. Manufacturing large structural components from composites presented several challenges to the manufacturer. For example, the horizontal stabilisers of the 777s nearly equal the area of the 737’s wing. With the 787 aircraft, even more parts are made of composites including wing and fuselage skins, wing leading edges, spars, and the rudder. Carbon Fibre Reinforced Polymer (CRFP) is the primary composite chosen and is difficult to machine. The graphite fibre provides the strength and stiffness required and the polymer matrix holds those fibres in place. But these two materials have very different qualities. In addition, because of how the composite material is made, machining may work well with plies running in one direction but not in another. Using typical metal cutting tools would not work when cutting composite materials. “Metal cutting is a matter of shear force that

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actually peels away material,” explains Mark Saberton, chief engineer at Flow International. “But composites are best cut by fracturing their surfaces at high speeds; peeling those away risks tearing. It is similar to wood being bent. Do it slowly and you get a jagged edge when it breaks. However, when it’s snapped quickly, the break is clean.” Messy Problems Manufacturers encounter numerous proble m s whe n m ac h i n i n g composites with routers including: slow cutting feed rates with two to three passes to complete a clean edge, rough edges that require secondary operations to achieve a quality finished edge, and excessive amounts of noise generated by the machinery. Also, the material is so abrasive that tools wear quickly; creating heat that can melt the polymer and destroy some very expensive parts. In addition, graphite fibre turns to powder when cut and must be collected and controlled. “That dust is a health problem,” says Mr Saberton. “It can cause a black lung-

type disease similar to what miners get. It’s also electrically conductive and can destroy electronics.” Getting The Abrasives Into The Jet Prior To Cutting Boeing had been using abrasive waterjets extensively for cutting aluminium and other metals that could not have a heat affected zone because it hardened the edge and cause micro-cracking when bent. Recognising their use of composites in airplane manufacture was rapidly expanding, they decided to find a better way to cut and drill composites. The technology uses ultrahighpressure intensifier pumps capable of pressurising water up to 94,000 pounds per square inch. The abrasive jet cutting process draws garnet into the water stream using a combination of gravity and the vacuum caused by the Venturi effect of that extremely fast/high pressure water’s kinetic energy (produced by going through the very small cutting head area). The water passing through the cutting head creates a vacuum and entrains the garnet abrasive


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into the waterjet stream, enabling it to cut virtually any material. However, there is a very small delay in that entrainment, so pure water contacts the material before the abrasive-filled water can begin the erosion process. This is not a problem with tough materials such as Inconel or Titanium, but with composites or laminates, delamination is a strong possibility. For edge trimming, this is not difficult to overcome, just start the jet stream off to the side of the piece and move the cutting head in place. However, for drilling, this is not an option. Flow designed UltraPierce to draw the garnet into the cutting head before the water starts, immediately entraining abrasive particles into the jet stream.

reaction to mechanical forces, edge delamination and airborne dust. Unlike routers, when cutting composites with an abrasive waterjet system, the direction the material is being cut, whether with or against the grain or even the ply orientation, has no impact on the surface finish. Router bits dull during the cutting process thereby generating

heat and causing the finish to deteriorate. An abrasive waterjet is always sharp so there are no fibre pullout or exposed fibres (whiskers). “An abrasive waterjet has a high fracture speed of Mach 2 and can cut four times faster than a 10 mm router bit turning at 15,000 rpm,� explains Mr Saberton. MEN Enquiry No. 3503

Better Edge Quality Abrasive waterjet cutting eliminates many of the problems inherent with traditional methods of machining composites such as

ENQUIRY NO 064

Watering Down Fixturing Cost Boeing had historically used fiveaxis routers to machine composites with fixtures holding the parts in place. Since each skin part had its own contour, the company built a separate fixture for trimming each part. The extensive fixturing was required because of the substantial mechanical force exerted on the part by the router. W i t h a b r a s i v e w a te r j e t machining, a non-contact cutting technique, it creates less than 2 kg of vertical force while cutting. The absence of these mechanical forces has kept the company’s fixturing requirements to a minimum. As such, the Stringer Trim machine utilises six waterjet nozzles to contour 72 different stringers for the 787 aircraft. One flexible fixture replaces 144 separate fixtures that would be required for conventional machining. This stringer machining centre processes the stringers at a rate one-tenth the time it takes a five-axis router with rotary tools.

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features

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Solid Edge Product Launch

APMEN was at the launch of Solid Edge ST3 to find out more on the CAD software product that uses synchronous technology to improve design, validation and collaboration. By Joson Ng

W

ith its global launch in the US in October last year, the ST3 made its way to Singapore, bringing with it the benefits of synchronous technology. In his opening speech, Go Say Tiam, VP of the Velocity series, Siemens (Asia Pacific) presented the pertinent points of the product to the participants. According to him, the product accelerates design creation by eliminating design pre-planning and reduces the need for physical prototypes through wider range of simulations. Live demonstrations by Siemens engineers showed new features of the product and how synchronous technology helps cut down time in making Engineering Design Changes (ECO). Marina Mandarin Singapore March 15, 2011

A User Community: Intuitively Yours Go Say Tiam (L) and Rajiv Ghatikar (R) at the launch

At the recent product launch, Solid Edge ST3, from Siemens PLM, is touted as a CAD software program that ‘delivers ideas from 1,000 customers’. With this philosophy of engaging users and drawing inspiration from them, the notion of a user community is very much on the forefront of the company’s strategies in R&D. The importance of having a user community is highlighted 58

metalworking equipment news April 2011

by Go Say Tiam, VP of the Velocity series, Siemens (Asia Pacific). He said: “The community is the cornerstone of our R&D endeavours in my opinion. Recently, while on a roadshow in the US, our R&D team interacted and learnt from our customers what improvements they would like to see in the future.” In addition, Mr Go also touched on the popularity of new media

and the pertinent question to ask, according to him, is how to use the Internet as leverage to build up communities. The next step would be creating an avenue to extract information from the user base. To him, there are two ways to go about doing it. “We have a Global Technical Assistance portal called G Tech in short. This is one way we capture requests online. G Tech is accessible by all Solid Edge users who possess a web key upon purchase of the product. With it, he/she can log on to our bulletin boards where people share openly their opinions,” said Mr Go. In cases where language is potentially a problem, the company’s massive network of partners plays a crucial role in obtaining customer feedback. He said: “In South Korea, sometimes it is difficult for users to engage other international users in G


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Tech because of the language barrier but their voice is heard through our partners who can log on as well. In the end, the number of feedback we get is fairly balanced across the regions we operate in.”

The Only Way Is Forward

What Do You Like About ST3? ST: What I like about the ST3 is we have taken the disruptive approach in CAD technology. I have seen all three releases and the current version is the one with the most impact. Right now, we are marrying the traditional platform (things that the users are familiar with, for instance, the way of design) with synchronous technology. As such,

greater adaptability is achieved. RG: I like the simulations aspect of the software as it allows the user to do some basic validations. That is powerful because they can then track any potential issues at the point of design.

Enquiry No. 3601

The uncompromising route on innovation and improvement points only to one direction.

In The Pipeline… The makers are currently lining up ST 4 for a summer release in the US this year.

ysia 11, Mala ECH 20 METALT 011 y2 4~8 Ma nd 2318 ta iland Hall 2, S 11, Tha ACH 20 INTERM y 2011 a 19~22 M tand Q12 ,S Hall 102

ENQUIRY NO 056

Changes and updates are unavoidable in today’s world of technology. This is the point that Rajiv Ghatikar, VP and GM of Siemens PLM (ASEAN/ Australasia) would like to drive home. “In this world of technology, if you don’t keep up, you are going to be left out,” he said. New product introductions into market sometimes face a cer tain a m o u nt of in e r ti a f r o m u s e r s. In order to address that issue, the key is to make a product that is easier to use. Said Mr Ghatikar: “People may see two things when a new release approaches the market; that is the prospect of re-training and upgrading of hardware systems. But if the product is much easier to work with, it is easier to convince people.” In addition, with Asia taking a more prominent role in the manufacturing world, more designing demands will be on the designers in Asia. With China and In dia a s th e le adin g m a r ke t s fo r the company in Asia, Mr Ghatikar used the Chinese automakers as an example. He said: “The challenge for the future is to design cars that are more compact and fuel efficient. If they are unwilling to upgrade, they will be left out.”

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exhibitions

A New Sheriff In Town

The Henry B Gonzalez convention centre was a scene of technological advancements, creative interaction and for some, a place to catch up with old friends. Be it users, resellers, partners and employees of the company, they all bore witness to the power of 3D designing. By Joson Ng

T

he SolidWorks World (SWW) 2011 kicked off with new CEO Bertrand Sicot on stage where he shared the product roadmap of the company with more than 4,500 attendees at the general session. With the commitment to support three platforms – online, desktop and mobile, Mr Sicot assured users that the company would always have locally installed desktop application CAD, data management or simulations. He also gave participants a brief introduction to SolidWorks n!Fuze, the company’s first online offering. According to Mr Sicot, the tool “levels the playing field for smaller company and individual users by making it easy to upload or share designs.” The online PLM product is planned for release in Q2 of 2011. The product is geared towards companies that do not currently have a formal PDM or PLM system. It is an entry-level design sharing tool that allows companies to share files anywhere in the world with anyone including suppliers, clients, remote personnel, and contract workers. Enquiry No. 3701

Failure Is Not An Option The keynote speakers this year included Captain Jim Lovell, Apollo 13 commander, NASA and Gene Kranz, mission control director, NASA. The pair recounted their experience and shared with the crowd

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how they successfully solved certain engineering problems through pure wit and steely resolve.

Enquiry No. 3702

Taking over from Jeff Ray is Bertrand Sicot, who has grand plans to bring the company to new heights. He shared with APMEN his goals, management philosophy and his personal thoughts on SWW. With over 15 years in the 3D mechanical CAD market, Mr Sicot feels it is time to explore something new. “We believe that we can go into the adjacent markets after spending many years in the 3D mechanical arena. By doing that, it gives us a playing field that is much wider,” he says. Moving out of a traditional area of expertise can be daunting for some but for Mr Sicot, it is a path where he will not walk alone as he is a real fan of teamwork. The word ‘team’ is high on Mr Sicot’s mind, he says: “TEAM for me is Together Everyone Achieves More. I am a big believer of team efficiency, anyone who has worked with me knows that.” A veteran of SWW, Mr Sicot is only one of a few who has attended all 13 installments of the show. For him, the show represents something close to his heart. He says: “There are three days where you have a lot of energy and knowledge exchange. People are unified by one passion, ie: designing things. This is easy to tell with the number of user breakout sessions. After 13 SWW, it is amazing to see the energy level higher every year, which is something special that we have and I need to make sure we keep it.”

Enquiry No. 3703


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Image-Ads_54x240 28.07.10 08:55 Seite 1

The R&D Guru

Drawing Inspirations From Everywhere In R&D, the team is tasked to come out with innovative features for every new release. According to Mr O’Malley, inspirations can be drawn from anyplace, from anybody. “We have a good mix of ideas from users and from our developers. When there are suggestions from users and a

Q&A With Ved Q: With a new CEO in place, will there be any change in the company’s policy towards Asia Pacific in terms of budget allocation? Ved Narayan (VN): Absolutely not, if anything, it is going to increase. We are viewing the region as the fastest growing market. We will have more resources available. Q: What are the company’s plans for Asia Pacific in 2011? VN: This year, it is essential to grow even faster and APAC is the right market capable for that kind of growth we are looking for. We will continue to develop new products and technologies. In addition, we are looking to

large enough demand for this particular feature, we will take it on board for our new release,” he says.

Driving Force “I can tell you it is not a few big customers driving development, it is a big class of small users and big users driving it,” says Mr O’Malley, as he explained the force behind developmental works. The concept of users’ community is central to the company’s many initiatives, including R&D. Though product development is important, it is also prudent to cast an eye on their competitor according to Mr O’Malley. He says: “There are definitely good products out there, I do not discount them.”

Leading in modular fixturing

Enquiry No. 3704

expand the reseller base. It is our strategy to cover more industrial sectors. Q: Asian and US users – how do they differ? Would you say the US users are more enthusiastic and the Asian users more conservative? VN: Yes and no, depending on the part of the user group you are talking about. There is a difference in terms of energy level. The American users are generally more eager, participative but also more critical. That is a good thing actually because, for us to improve, we need to know what are the good, bad and the ugly. When it comes to a typical Asian user, if a certain feature does not work well for them, they are not openly critical; we need to go talk to them. I get very concerned when a user is only telling me good things.

Witte Far East Pte Ltd 1st Level•13 Joo Koon Crescent SGP-629021 Singapore Tel.: +65-6248 5961 Fax: +65-6898 4542 Email: info@witteasia.com www.witteasia.com

Note: Ved Narayan is the VP of Dassault Systèmes SolidWorks (Asia Pacific)

Enquiry No. 3705

Cert– No.: LA – 2007-0394C

ENQUIRY NO 122

One of the original developers of SolidWorks, Austin J O’Malley, the executive VP of R&D has seen his fair share of success and failures. In R&D where setbacks are common, it is important to recover quickly from it. “When we encounter any setbacks, we need to look at the lessons learnt, regroup and build from it. In addition, it is important to work as a team. We consider failure as a team. In order to avoid making the same mistakes, we have devised checklists deployed at critical junctures during the development stage like the ones pilots use. It is a simple thing used by us to eliminate human error,” he says.

Witte. Perfect Fixturing.

April 2011 metalworking equipment news

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EVENTs&exhibitions

T

he 2011 installment of Metaltech returns to the Putra World Trade Centre where approximately 30,000 sq m of total exhibition area (gross) is expected to be filled by some 1,500 exhibiting companies. Also at the event are two sub events. They are the Welding Technology Exhibition 2011 (WeldTEK) and Automation Te c h n o l o g y E x h i b i t i o n & Conference (Automex). This year, 10 nation pavilions are participating, no doubt one of the reasons why the organiser is expecting some 25,000 trade visitors. The exhibits on show include CAD/CAM systems, prototyping systems, metal cutting machine tools, sheet metal processing and metal forming, moulds and dies, metrology equipment, forging and castings equipment, surface and heat treatment, finishing equipment, hardware and power tools, welding and fastening equipment, robotics, industrial automation, factory automation and process automation.

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2011

Event Preview:

Metaltech

The event is endorsed by Malaysia External Trade Development Corporation (MATRADE), the Global Association of the Exhibition Industry (UFI) and Tourism Malaysia Sirim Berhad. In addition, it is supported by SME Corporation Malaysia, Selangor and Federal Territory Machinery Merchants Association (SAFMA), Singapore Manufacturers’ Federation (SMa), National Institute of Compressed Air Malaysia Berhad (NICAM), Malaysia’s Hardware,

Machinery and Building Materials Dealers’ Association (MHMBA), North Malaysian Small and Medium Enterprise Association (SAMENTA), Taiwan Machine Tool and Assessory Builders’ Association (TMBA) and Welding Institute (Malaysia) Berhad. Putra World Trade Centre Kuala Lumpur, Malaysia May 4 - 8, 2011 Enquiry No. 3706

Product Highlights

Goodway Machine: High Speed CNC Turning Centres

62

Gravotech: Marking Without Noise

Built to withstand rigorous high production turning, the ribbed, one-piece, thermally balanced bed and casting parts of the G L S -15 0 0 C N C turning centre are of ‘meehanite’ casting. The 30 degrees true slant bed design further provides support for the headstock, turret, and tailstock, as a result, creates the rigidity needed for long-term high precision turning and efficient chip removal. Other features include fully enclosed splashguards that keep chips and coolant contained and an auto lubrication system that shuts down during idling to prevent waste.

Technifor’s scribing machines use a hardened pin to mark the surface of components. Compared with micro-percussion, scribed marks have a smoother, more continuous appearance. The marks therefore benefit from a higher quality appearance and the marking process is quieter. The range of XF510r scribing solution is complete with an improved control unit, the UC500. It offers speed, precision and quality without the noise. The scribing machines are available in three sizes with their respective marking areas: XF510Cr – marking area 40 x 50 mm, XF510Sr – marking area 80 x 50 mm and XF510Dr – marking area 160 x 50 mm.

Enquiry No. 3707

Enquiry No. 3708

metalworking equipment news April 2011


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Product Highlights

J&L Tech: Tribometer

Metaltech 2011

MicroRep Precision: Vertical Bench Top Optical Projector

Having a large measuring c a pacit y, the V B 40 0 by Starrett has the versatility to be at home in many differing working environments. It is suitable for high volume, low batch production or on routine component sampling, appropriate for the general purpose tool room. In fact the projector can be found wherever there is the need to verify and measure complex shapes, hole patterns and where accuracy, ease of use and speed are of the essence. Designed with surface illumination options, the projector can be configured to match exact measuring requirements.

Enquiry No. 3709

Enquiry No. 3710

ENQUIRY NO 051

The tribometer by J&L Tech measures the degree of frictions or abrasive wears in machine parts. As most of machineries contain moving parts such as bearings, gears, slides, and shafts, and the optimal operation of mechanical devices are greatly influenced by the smooth movements and durability of such moving parts, it is essential to precisely understand and restrict or adjust, if necessary, frictions and abrasive wears in order to ensure the reliability and durability of machinery parts. Equipped with a high resolution load cell, a precision feedback system and built in temperature and humidity sensors, the meter is an equipment which satisfies the needs of industries.

April 2011 metalworking equipment news

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Metaltech 2011

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Product Highlights

Neoframe: CAD Made Easier

ZWCAD 2011 is a CAD software program with a cost-effective solution for the entire workflow, from the very beginning to the very end of projects, with innovative, collaborative, and customisable features. The program ensures compatibility with mainstream CAD software and operating systems. It also allows the removal of boundaries from communication and cooperation and lastly, it provides flexible customisation. Now the program is available in 15 different languages, including Chinese Simplified, Chinese Traditional, Czech, English, French, German, Italian, Japanese, Hungarian, Korean, Polish, Portuguese, Spanish, Russian and Turkish.

The dimension uPrint Plus 3D printer by Stratasys provides engineers and designers stronger functional models with finer feature detail and improved surface finish. In addition, the machine has a small footprint for true desktop use. Featuring an 8 x 8 x 6 inch build envelope and prints in 0.254 mm or 0.33 mm resolution, parts and models are produced in the ABSplus material. It is also possible to print in solid colours. The machine is suitable for the automotive, electronics, electrical appliances, telecommunications, toys and medical industry.

Enquiry No. 3711

Enquiry No. 3713

SolidCAM: Integrated CAD/CAM Solutions

64

Starsysjaya: Rapid Prototyping Machine

Tungaloy: Serrated Cutting Edge For Obtaining Small Chips

SolidCAM software provides CAD/CAM integration, with singlewindow integration and full associability to SolidWorks and Autodesk Inventor. The integration ensures the automatic update of tool paths for CAD revisions. The SolidCAM 2011 has improvements in all functionalities, including turning and mill-turn. It launches a machining technology, iMachining, that could save up to 70 percent of machining time and increase tool life. The technology has four specific goals: a simplified user experience, optimised tool paths, efficient cutting and consistently higher material removal rates. By this, it brings efficiency to higher levels for CAM users.

Roundsplit family of milling cutters can carry either round inserts with a serrated cutting edge or regular round inserts. The cutters from Tungaloy provide four indexing options for the serrated insert, while there are eight for the round. One advantage of using the cutter is that it produces small chips. The smaller the chip, the less likely that it will be re-cut and therefore chip evacuation is improved. The end mill diameter range is from 32 to 50 mm and the face mill diameter range is from 40 to 160 mm.

Enquiry No. 3712

Enquiry No. 3714

metalworking equipment news April 2011


ENQUIRY NO 065


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Event Preview:

Intermach 2011

I

ntermach 2011 brings high-tech machinery and technology from around t h e w o r l d . I t p ro v i d e s a competitive edge for manufacturers in terms of costcutting, improving production and value for money. Over the past few years, manufacturing capabilities have improved and technology permits customised automation using flexible modular techniques and integrated software. Now in its 28th year, the show has become a catalyst for Asia’s manufacturing machinery industry. Recently it has been

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metalworking equipment news April 2011

strengthened by two other colocated shows – Subcon Thailand and Sheet Metal Asia 2011. Other Shows Subcon Thailand has emerged as one of the important regional events in the ASEAN region today. It is now a central meeting point for manufacturers and subcontractors. Since it began four years ago, the annual exhibition covers a broad cross section of industry like automotive, packaging, air -conditioning, electrical and electronics. Subcon also features over 300 subcontracting

companies and a business matchmaking program that links manufacturers to suppliers and vice versa. In addition, there is a buyer’s village at the show where companies put their subcontracting needs in the spotlight for all to see. Over at Sheet Metal Asia, visitors will be able to see the technologies that help raise the industry to new heights. The show provides a complete range of sheet metal fabrication and equipment for inspection under one roof. Equipment at the show includes lasers, water jets, TPP and more. There are also


ENQUIRY NO 071


EVENTs&exhibitions

opportunities to meet one-on-one with knowledgeable experts. Good Reach Intermach 2011 will provide hundreds of exhibitors and thousands of visitors with the range of high-tech machinery and technology designed to help companies achieve new levels of production. It also provides a whole spectrum of information through seminars, conferences and networking events, all directed to one of the largest gatherings of business executives, plant managers, engineers and decision-makers in the region. BITEC Bangkok, Thailand May 19 - 22, 2011

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What To Expect At The Show

• Projected attendance of 35,000 visitors from some 40 countries. • VIP access for visitors to attend important seminars and conferences at the show. • A display of machinery from over 1,000 of the world’s manufacturers. • A complete range of machine-tool technology for the mould and die industry. • Complete range of sheet metal fabrication and equipment on display under one roof. • Complete showcase of sheet metal fabrication machinery. • Over 280 subcontractors at Subcon Thailand 2011. • Business match-making opportunities that link buyers, manufacturers with the right subcontractors. • Buyer’s village and presentations for advice, procurement policies and more.

Enquiry No. 3716

Enquiry No. 3715

with the only BPA audited metalworking magazine in the Asia Pacific region. What is BPA? BPA Worldwide audits the circulation of primarily business-to-business and consumer magazines

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MTA Malaysia 2011

T

he back end of 2010 saw Malaysia post a double-digit growth in the manufacturing sector by 11.4 percent, amounting to some RM4.9 billion (US$1.6 billion) to a record of RM48.1 billion as compared to RM43.2 billion the previous year. This increase was generated by the growth in sales value of 75 industries (64.7 percent) out of 116 industries covered in the Department of Statistics’ survey. Five major industries whose sales value increased notably were identified. They are the manufacturing of refined petroleum products (38.7 percent), manufacturing of other basic industrial chemicals (33.5 percent), rubber remilling and latex processing (77.0 percent), manufacturing of semi-conductor devices (11.7 percent) and manufacturing of plastics in primary forms and of synthetic rubber (43.1 percent). Show Facts Given this outstanding growth, 70

metalworking equipment news April 2011

MTA Malaysia 2011 will be a good platform for various industries in the manufacturing sector to come together and do business in a country that has one of the best economic records in Asia. In conjunction with Metaltech 2010, the show in 2010 successfully attracted 1,200 exhibitors from 22 countries, 21,923 trade visitors and six international group pavilions (China, Germany, India, South Korea, Singapore and Taiwan). The show is supported by MATRADE and other trade associations namely Malaysia Mould and Die Association (MMADA), Singapore Precision E n g i n e e r i n g a n d To o l i n g Association (SPETA) & Taiwan Machine Tools and Accessory Builders’ Association (TMBA). Putra World Trade Centre Kuala Lumpur, Malaysia May 4 – 8, 2011 Enquiry No. 3717


ENQUIRY NO 024


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Product Highlights

72

DMG: Simultaneous Machining In Five Axes

Global Excel Tools: Solid Carbide Drills

The DMU 65 monoBlock from DMG offers the entry into the high-tech world of simultaneous machining in five axes. In its flexible extension ranges encompassing the three-axis machine with its 1,000 x 650 mm table and the five-axis version with its dynamic swivel-type indexing table, the machine masters all disciplines in milling technology – from roughing through to finishing at a high level. With its 7.5 sq m footprint it is a compact machine. The universal modular system offers a number of possibilities like different motor spindles, table variants or preferred controls.

The carbide tipped drill is most commonly used for drilling carbon fibre-GRP and in some cases the drilling of laminates in aluminium and carbon has been successful particularly when using controlled feed drill units. The flexibility in the manufacture of carbide tipped drills enables long reach with relatively small diameters. Standard range of diameter is between 2.5 mm to 15 mm.

Enquiry No. 3718

Enquiry No. 3720

Dynacast: Precision Zinc Parts

LAG: New Generation Press Brake

The high strength and hardness of zinc alloy means that it is a suitable alternative to be machined, pressed, stamped and fabricated. Benefits of precision die-casting include high volume costeffective production with consistent quality and cost savings by eliminating costly post-casting operations. In addition, complex net shaped parts with tight tolerances can be manufactured with lower tool cost and longer tool life.

LAG has developed the design of press brake, which differs from a traditional unit. This generation of press brake, the GBS model, has a rigid structure that eliminates the misalignment of the bending axis. The top beam, which is fixed to the side frame, slides on eight linear guides. This eliminates friction while allowing constant precision during descent movement and precise positioning for the entire stroke. Furthermore, the GBS is a versatile machine. This product can also bend bigger sized plate by a single operator and upon request, it is possible to adapt to automation applications.

Enquiry No. 3719

Enquiry No. 3721

metalworking equipment news April 2011


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Product Highlights

Trumpf: Skeleton-Free Processing

The UPV-3 is designed to meet the growing demands of surface finish (up to Ra 0,03 um) and shape accuracy in the machining of tungsten carbides used in the manufacturing of tooling for precision stamping, fine blanking, and powdered metal forming. This machine is also capable of processing complex cutting tools and cutting tool inserts made of PCD, or polycrystalline diamond.

The TruPunch 3000 is the resource-efficient universal machine from Trumpf, which for the first time ever, works without producing a scrap skeleton. With its intelligent handling of small parts, the machine can process sheets up to 6.4 mm thick virtually scratch-free. This innovation made processes more reliable, increases material utilisation and is user friendly. Also the cut-up metal scraps simplify the logistics and can then be sold at higher prices. This universal machine is not only compact and resource efficient, but it also gently handles materials for a scratchfree metal processing.

Enquiry No. 3722

Enquiry No. 3723

ENQUIRY NO 073

Newline: Dielectric Wire EDM

April 2011 metalworking equipment news

73


Parting

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Shot

Journey To A

Cleaner Future

Electric and hybrid vehicles will take over the cities. By Fraunhofer.

N

ew concepts are needed for individual and local public transportation. In the large-scale project ‘Fraunhofer System Research on Electric-Powered Mobility’, researchers are developing solutions for mobility of the future. The first results have now been presented. The city traffic of the future will be different: buses will not be the only vehicles propelled by electricity, hydrogen or a combination of hybrid propulsion methods. One of these vehicles of the future is the AutoTram. A streetcar as agile as a bus, it combines the benefits of both vehicles – with no need for rails or overhead contact lines, the ‘bustrolley’ rolls on rubber tires and follows a simple white line on the road surface. Charging Up The Tram Unlike cars, which remain parked for an average of 23 hours a day, buses and trams are in motion all day long. Which does not leave much time to recharge the batteries. One solution approach for the AutoTram involves fast-charge docking stations positioned at the stops along the route. Current can then be drawn at every third or fourth stop. The requisite amount of energy must be recharged in just 30 to 60 seconds at more than 1,000 amperes and 700 volts. Accomplishing this in such a short period of time requires super-capacitors. 74

metalworking equipment news April 2011

Researchers are working to develop the modules required: for instance on energy storage units based on double-layer capacitors, on high-performance converters and on contact systems for the transmission of current. Unlike batteries, double-layer capacitors – also known as ‘supercaps’ – have a high power density. Those capacitors ensure that the charge can be quickly stored. Dr Ulrich Potthoff, department he ad at I V I , offers a v iv id explanation on how the principle works: “Batteries take their time charging. You can compare this to a big bathtub with a small spigot. Capacitors, on the other hand, quickly take up the charge, like a small bathtub with a large spigot. However, they can only store a smaller quantity of energy.” Combined Effort His colleagues at the Fraunhofer Institute for Integrated Systems and Device Technology IISB are contributing developments for the power-electronic components, such as a direct voltage converter that adjusts the voltage level. These DC/DC converters are needed to link the double-layer capacitors with the drive train. Also decisive in this regard are materials that can withstand transmission of high levels of current. The surface of the contacts must be very stable and wear-resistant. “The se newly developed

concepts must be coordinated with one another so they will harmonise with all of the other components. At IVI, we are incorporating the modules into the overall tram system and configuring the interfaces,” Dr Potthoff explains. This also includes the lithium-ion battery systems for electric vehicles. Experts have been working to advance the batteries and electrical systems. These systems need to be safe, durable and efficient. Usually, the battery system consists of several hundred cells, and these do not always discharge at the same rate. And if individual cells should fail or no longer deliver the intended performance, this can take a toll on the entire battery. T he indiv idua l cells a re controlled using an overarching energ y-management system. Project manager Dr Matthias Vetter of the Fraunhofer Institute for Solar Energy Systems ISE, who coordinates the project, explains the basic principle involved: “Within a few fractions of a second, the electronics measure the current, the voltage in the individual cells and the temperature and use these parameters to derive values for the battery’s state of charge and health. This way, a determination can be made for each cell as to whether there are any threats of overload, deep discharge, excessive heating or premature aging.” MEN Enquiry No. 3801


productfinder

ENQUIRY NO 072

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Surplus Machine Tools and Factory Equipment used by a Leading Automaker

Machine Tools formerly used by a Major Automobile Manufacturer

For Sale by Negotiation:

Location: Europe

AMAZING TECHNOLOGIES

3D Multi-Axis Laser Cutter and SERVO Bender (NO hyd.oil)

Private Treaty

Axial Forming • Chipless Metal-Forming Process Innovative Spline Forming Technology No Chip, No Scrap, No Cutting, Save Material & Process Application for: • Automotive • Aerospace • Medical Industries

For further information, please contact: INGO WEYAND Tel: +49 (173) 7187000 Email: ingo.weyand@go-dove.com To view and bid on the lots, please visit

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Creative Machinery Enterprise

Block 3015 Ubi Road 1 #04-214. Singapore 408704 Tel: +65 6746 5959 Fax: +65 6745 7163 Email: sales88creative@gmail.com

ENQUIRY NO 048

ENQUIRY NO 079

Featuring • WALDRICH COBURG 17-10 GM 250 NC Gantry Mill • WEINGARTEN / KRUPP Deep Drawing Press Line • DROOP & REIN FP 65/2 Ke N8 Double Gantry Profiling Machine • INFRATIREA AFP 160 2NC Horizontal Boring and Milling Machine • SCHULER P2E2Sqs 400/2,2/04 Cutting and Stamping Press Line • ZEISS PSM601424 Double Column Measuring Machine • SMG HTTP 150- 3100/1600 Hydraulic Tool Tryout Press • INGERSOLL BOHLE B120DC EDM Machine (Qty 3) • & lots more…

April 2011 metalworking equipment news

75


ProductFinder Haas: Versatile Y-Axis Turning Centres

76

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Lico Machinery: High Performance Turning Centres

The Haas DS-30 Series Y-axis turning centres combine dual-spindle turning with Y axis, C axis, and live tooling to create powerful ‘done-in-one’ machining solutions for any shop. The opposed spindles support fully synchronised turning, and allow on-the-fly part pass-off to reduce cycle times. The machines provide 4” of Y-axis travel (±2” from the centreline) for off-centre milling, drilling, and tapping, and come standard with high-torque live tooling and a servo-driven C axis for versatile 4-axis capability. They are available in standard and super speed configurations.

The LNT-S Series of CNC automatic lathes by Lico Machinery and the LNT-S Multi-Slide CNC automatic lathe produce high productivity and performance. Installed with Siemens-840D multi-slide CNC System, up to five tools machining is possible in a fast cycle time. In addition, turret installed on a heavy duty X-Z-slide is available for all turning and milling operations. One position of the turret is installed with a pick off device, which works as a sub-spindle. Finally, the bar capacity is 36 mm, 42 mm, 51 mm and 65 mm.

Enquiry No. 3901

Enquiry No. 3903

Heimatec: Quick Change System

Objet: Personal Desktop 3D Printer

Heimatec has developed the u-tec, a quick change system that allows economical operations without compromising on precision. The system provides high power transmission by polygonal drive and is suitable for use with collet nuts, with internal and external threads. It also produces saving potential for tooling, because it can be used with all standard Heimatec holders, standard collets or u-tec adapters and requires only a minimum set up time.

Objet Geometries has developed a family of desktop 3D printers (Objet24 and Objet30). The company has also held a technology demonstration of advanced materials featuring clear transparency, high-temperature resistance and ABS-like quality simulating engineering plastics. The printers are part of the company’s family of affordable, easy to use 3D printers, making high-quality 3D printing convenient for the office of every designer and product engineer. The Objet24 is suited to the office environment, providing low-cost 3D printing without compromise on model detail or functional versatility. On the other hand, the Objet30 is capable of printing a range of materials making it suitable to a number of applications.

Enquiry No. 3902

Enquiry No. 3904

metalworking equipment news April 2011


productfinder

ENQUIRY NO 068

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10 to 6,000 Ton Capacity DEES' Taiwan and China Factories are all ISO-9000 Certified

DEES HYDRAULIC INDUSTRIAL CO., LTD. TAIWAN HEADQUARTERS / FACTORY: Tel.: +886-2-2601-8661

Fax: +886-2-2601-8936

E-mail: sales@spc.com.tw

www.deesgroup.com.tw

ENQUIRY NO 057

ENQUIRY NO 040

1600 tons Front Runner with 2 x 1000 tons and 2 x 800 tons

April 2011 metalworking equipment news

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productfinder

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Seco: Cermet Grades For Surface Finish & Tolerance Applications

78

Sutton Tools: High Performance Endmills

The uncoated TP1020 and the PVD-coated TP1030 cermets from Seco are both versatile and forgiving when it comes to a demanding surface finish in steel and stainless steel applications. These Ti(C,N)-cobalt based cutting materials have been re-designed and optimised to generate the desired surface finish. Both are easy to apply in steel and stainless steels while the surface finish remains predictable. The TP1020 cermet grade is suitable for reliable control in surface finish critical applications with limited cuts and cutting data while the nanolaminate PVD-coated TP1030 cermet grade adds a new dimension to versatility and predictability at simultaneous high demands of productivity, dimensional tolerance and surface finish.

The R35/38 Harmony endmills by Sutton To o l s r e p r e s e n t s te c h n o l o g i e s t h a t provide improvements in both performance and tool life. Available in both PMHSS and carbide, they overcome vibration, through a combination of tool design, micro geometry, material and coating, without the need to sacrifice productivity. A combination of a flute helix and various optimisations with regard to the end-teeth geometry provides a stable/chatter free cutting action. A 35 – 38 deg unequal flute helix reduces the harmonic build up in the workpiece, resulting in smooth chatter-free milling in various types of milling techniques, increasing productivity.

Enquiry No. 3905

Enquiry No. 3907

Studer: High-Precision, Fast & Cost-Effective

TMT: Rigid & Reliable CNC Lathe

The S41 CNC universal cylindrical grinding machine by Studer is characterised by technology and costeffectiveness. The machine grinds with higher precision, paired with a greater metal removal rate. In addition the longitudinal and cross slide, as well as the swivel axis for the wheelhead are equipped with electric direct drives, which move to the working position much more quickly and precisely. The features of the S41 include, for example, the solid, rigid and more thermally stable machine bed made of Granitan S103. The formula of this mineral casting is designed for optimal grinding operation conditions.

High performance CNC lathe TL-42 series from TMT features high rigidity and reliability. The machine’s box way design offers a flexible, accurate and efficient solution for medium and high productivity applications. The positioning accuracy on X/Z axis is ±0.005 mm while the repeatability accuracy is 0.005 mm. In addition, the servo-driven eight-position turret takes only 0.1 second indexing time to the next adjacent position. The 7.5 kW AC digital spindle motor powers the machine with 75 Nm torque via a 6” spring collet or a 6” hydraulic chuck.

Enquiry No. 3906

Enquiry No. 3908

metalworking equipment news April 2011


ENQUIRY NO 080

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37

054

Kuka robot automation (m) sdn bhd

59

056

LICO MACHINERY CO LTD

73

073

LVD COMPANY nv

41

077

MAWEA INDUSTRIES SDN BHD

77

040

Mitutoyo asia pacific pte ltd

49

066

MMC HARDMETAL (THAILAND) CO LTD

43

053

NATIONAL INSTRUMENTS

17

050

Newell rubbermaid (m) sdn bhd

65

065

OBJET GEOMETRIES AP LIMITED

35

067

OPTICAL GAGING (s) PTE LTD

31

060

PT PAMERINDO BUANA ABADI (MANUFACTURING INDONESIA SURABAYA 2011

79

080

REED TRADEX COMPANY (INTERMOLD THAILAND 2011)

69

121

SECO TOOLS (S.E.A) PTE LTD

01

001

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2011)

71

024

SOLIDCAM LTD

57

064

Sumitomo electric hardmetal asia pacific pte ltd

53

069

TAIWAN TAKISAWA TECHNOLOGY CO LTD

63

051

TSUNGLIN MACHINERY TECHNICAL CO LTD

15

074

TUNGALOY SINGAPORE (PTE) lTD

39

059

WALTER AG SINGAPORE PTE LTD

09

168

WENZEL ASIA PACIFIC PTE LTD

29

075

Winterthur scheleiftechnik ag

15

049

YAMAZAKI MAZAK SINGAPORE PTE LTD

IBC

070

Yih chuan machinery industry co ltd

75

072

KENNAMETAL INC

80

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metalworking equipment news April 2011

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o Bo th No 22 2:A

Exhibiting in MTT Expo 25th ~ 28th May 2011 in Jakarta

1

Quick Turn Smart 150S FZ (8�) (Production scheduled in May 2011)

Vertical Machining Center VCS 430 FZ (Production scheduled in August 2011)

Made in Singapore

Tel : +65 6862 1131 Fax : +65 6861 9284 Email : Lee_weili@Mazak.co.jp Website: www.mazak.com

ENQUIRY NO 070


Our complete portfolio. Your complete satisfaction.

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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 www.widia.com.

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APMEN April 2011