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TIMTOS 2013 Review See More With Machine Vision ASX 2013 Review April 2013

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Machining Navi Machining Navi instantly determines the optimal cutting conditions for highly efficient machining. Spindle speed and chatter are linked in a periodic manner, manifesting as alternating ranges with and without chatter. This means that there will be cases in which chatter cannot be suppressed with a reduction in spindle speed, and other cases where increasing the spindle speed will eliminate the chatter . Machining Navi navigates the extremely difficult process of finding the optimal spindle speed value. Machining Navi analyzes chatter and instantly determines the optimal spindle speed.

Machining Navi M-g (Guidance) Machining Navi displays a number of optimal spindle speed possibilities on the screen. The operator can change to the indicated spindle speed with a single touch and immediately confirm the result.

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Contents April 2013

CUTTING EDGE 22 Software Programs Byte-ing Into Grinding

Grinding these days is enabled by software programs as much as the grinding wheel. By Dipl Ing Ira Schroers

24

Case Study: Grinding With Quality & Speed

One company has claimed that it is possible to grind gearshafts faster than ever without compromising quality. Contributed by Christine Isenmann, Erwin Junker Maschinenfabrik

TECH TALK 26

Machine Vision To Facilitate Reliable Production

From the automotive to medtech sectors, manufacturers in Southeast Asia are looking towards better quality control methods. By Didier Lacroix, Cognex

30

Incorporating FPGA Technology In Machine Vision

A graphical programming environment is said to be the key that paves the way for the utilisation of FPGA image processing in vision systems. By Wu Rong, National Instruments

36

Case Study: Optical 3D Inspection Of Weld Seam

Weld seam inspection systems are used to ensure that the required quality standards for welded seams are met in an automobile factory. By Dipl Ing Markus Maurer, Vitronic

SOFTWARE & METROLOGY 38

42

FormJoinCut 46

Reducing cycle time and improving surface finishing is now a software program’s job. By Maggie Smith, Hurco Companies

CNC machining is favoured for its ability to automate large batch processing while maintaining the precision of parts. Yet, it faces the challenge of thermal errors, whose effects could compromise machining accuracy. By Sherlyne Yong

Reducing energy consumption during ‘idle’ time and studying actual power consumption figures can lead to energy-efficient bending. By Matthew Fowles, LVD

Going 'Soft' On Machining

2

Precision Under Heat

asia pacific metalworking equipment news April 2013

Energy Reduction In Bending

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Contents April 2013

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: samanthatan@epl.com.sg

50

Pressing On

Asia Pacific Metalworking Equipment News (APMEN) caught up with technical experts in the metal forming world to talk about the present and the future of metal forming. By Joson Ng

54

The Pressing Issue Of CFRPs

Manufacturing CFRP parts by forming is now a more desirable process. By Simon Scherrenbacher, Schuler

INDUSTRY FOCUS 56

TAMI Optimistic About 2013

By their own admission, 2012 was not a very good year for Taiwan’s machine tool industry. The year 2013 however, is a very different story. By Joson Ng

EVENTS & EXHIBITION 65

Productivity Is Vital For Singapore’s Aerospace Industry

Arguably one of the more competitive industries for Singapore, the aerospace industry needs to do more to maintain their lead in the region. By Joson Ng

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

INDUSTRY Endorsements SPETA

Singapore Precision Engineering and Tooling Association (SPETA)

Federation of Asian Die & Mould Associations (FADMA)

Measured For Accuracy

Many success stories have shown that cutting tubes with lasers offer wider perspectives, both for steel dealers and for job shops that until now have been involved in 2D laser cutting. By Evelyn Konrad, Trumpf

Federation of Malaysian Foundry & Engineering Industry Associations

Event Review: Indometal

Indian Machine Tool Manufacturing Association (IMTMA)

58

Event Preview: Metaltech

The Future Lies In Tubing

Technical Seminar: Automated To Fabricate

When considering automation solutions for sheet metalworking, looking at the big picture helps in better decision making. By Joson Ng

Regulars

08 Business News 76 Product Finder 79 Exhibition Programmes 80A Product Enquiry Card 4

FEATURES 60

asia pacific metalworking equipment news April 2013

Maintaining the accuracy of CMM measurements requires a multi-faceted approach, where precision is dependent on a myriad of factors. By Sherlyne Yong

Event Preview: Intermach 2013 Event Preview: MTT Indonesia

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Refer to Advertising Index

pg

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

Taiwan Association of Machinery Industry (TAMI)

For Advertiser's Enquiry Numbers

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ENQUIRY NO 017


Editor’s Note

Curious CaseOf David

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

In technology, some exhibitors are showing dual spindle machining centre, twin spindle lathe with three turrets and some are also incorporating fibre lasers into sheet metal cutting. Focusing on core strengths like flexibility may be essential, but developing new strengths can enable long term prosperity. In a bid to increase the profile of their companies in an established industry and to possibly squash stereotypes, some companies are willing to invest big and travel far. For example, FFG or Fair Friend Group has revealed that they have the second largest booth in this year’s EMO. Having a second largest booth in any trade show is a statement but going to Europe and Germany in particular, arguably the technology capital of the machine tool world, is nothing short of gutsy. It may be a big statement of intent no doubt, or a marketing master stroke maybe, but this move has shown a new level of maturity in Taiwan’s machine tool builders.

randyteo@epl.com.sg

senior sales manager Derick Chia

derickchia@epl.com.sg

sales manager Melvin Wong

Knowing one’s strength and playing to it is often the advice coaches pass to their charges. This tactic or philosophy has led to many victories for the ‘Davids’ of this world, where they triumphed against all odds while their bigger, stronger, and seemingly infallible opponents flounder. In the machine tool manufacturing world where European and Japanese machines dominate, it is probably fair to call Taiwan’s machine builders ‘David’, in a relative sense. While its pricecompetitiveness is well-documented, the Taiwanese machine tool manufacturing industry is less known for its flexibility. This flexibility is evident at TIMTOS, Taiwan’s answer to IMTS, JIMTOF and EMO. On the business front, the government has lined up various FTAs with many countries across the world, such as Singapore and New Zealand. The government is also actively pursuing other agreements like the Trade and Investment Framework Agreement (or TIFA), the Regional Comprehensive Economic Partnership (RCEP) and the Trans-Pacific Partnership (TPP).

josonng@epl.com.sg

business development manager Randy Teo

melvinwong@epl.com.sg

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

samanthatan@epl.com.sg

contributors Dipl Ing Ira Schroers Christine Isenmann Didier Lacroix Wu Rong Dipl Ing Markus Maurer Maggie Smith Sherlyne Yong Matthew Fowles Simon Scherrenbacher Evelyn Konrad 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. 098/06/2012 PPS 840/09/2012 (022818) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

chairman Stephen Tay group executive director Kenneth Tan

Joson Ng Editor

etm

Eastern

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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Business News Kennametal Celebrates 75 Years

Latrobe, US: Kennametal marks its 75th year as an industrial technology leader, delivering productivity, innovation and performance around the world in the aerospace, earthworks, energy, industrial production and transportation industries. Fou nde d i n 193 8 , Ph il ip McKenna’s breakthrough invention of tungsten-titanium carbide alloys started a company of 12 employees

and US$30,000 in revenues in its first year. Since then, the company he founded — subsequently renamed Kennametal — has grown 100,000-fold to nearly US$3 billion in revenues, serving more than 80,000 customers in over 60 countries. “We drive a strong culture of innovation and performance at Kennametal, starting with k nowle dge able p e ople a nd proprietary material science

to d e v e l o p b e t te r to o l i n g technologies and engineered components for the world’s most demanding work,” said Carlos Cardoso, Kennametal chairman, president and CEO. “Today, we consistently achieve 40 percent or more of sales each year from new products that offer customers at least 20 percent performance improvement.” Named Among World’s Most Ethical Companies The company has been named for the second year in a row as one of the World’s Most Ethical Companies by The Ethisphere Institute, an international thinktank dedicated to the creation, advancement and sharing of best practices in business ethics, corporate social responsibility, anti-corruption and sustainability. Through in-depth research a nd a mu lt i - ste p a n a l y si s, Ethisphere reviewed nominations from companies in more than 100 countries and 36 industries.

Malaysia Government & Private Sector In Partnership To Promote Metrology

Malaysia: In the month of March 2013, Region Suppliers, a distributor o f pre c i sio n me a su re me nt instrument, organised seminars i n Johor B a h r u a nd Kua la Lumpur, Malaysia. According to the organiser, as the seminars were supported by NML – Sirim, this marks the first collaboration between the government and a company from the private sector 8

asia pacific metalworking equipment news April 2013

in promoting the importance of industrial metrology in Malaysia. “We are very honoured to have the co-operation and support from NML-Sirim, who plays a very important role in the dissemination of measurement traceability in Malaysia and ensuring that metrological infrastructures in the country meet the current international standard, which is our

common objective for this seminar,” said Roger Michell, chairman of Region Suppliers Group. More than 150 participants from all industrial sectors attended the event and listened to the keynote speech, which was delivered by Dr Wan Abd Malik Wan Mohamed, principal metrologist/head of Mechanical Metrology Section of NML-Sirim. www.equipment-news.com


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Haas Factory Outlet Singapore Philippines Malaysia

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BusinessNews

Vericut Software Reaches 25-Year Milestone

I r v i n e , U S : C G Te c h , t h e developer of Vericut software has celebrated a quarter-century of developing Numerical Control (NC) program simulation and analysis software. Si nce it s i n it ia l rele a se , Vericut has been constantly

enhanced in-house by a team of software engineers who have many years of experience in the mechanical CAD/CAM industry. I n addit ion to reg ula r e n h a n c e m e n t s to i t s c o r e algorithms, products have been added to optimise feed rates

Quality Control At Your Fingertips G e r m a ny : For production operations, quality assurance over the process chain is indispensible: it is the only way to detect problems at an early stage and lower additional costs. Fraunhofer researchers developed an efficient type of quality control: With a pointing gesture, employees can input any detected defects to car body parts into the inspection system, and document them there. Researchers at the Fraunhofer Institute for Optronics, System Technologies and Image Exploitation IOSB in Karlsruhe engineered the gesture control system on behalf of the BMW Group. In the future, it should supersede today’s test procedures. “Previously, the inspector had to note all defects that were detected, leave his workstation, go to the PC terminal, operate multiple input screens and then label the position of the defect and the defect type. That approach is laborious, time-intensive and prone to error,” says Alexander Schick, scientist at IOSB. The gesture control system, by contrast, improves the inspector’s working conditions considerably, and Fraunhofer IOSB

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asia pacific metalworking equipment news April 2013

and simulate the kinematics of complex multi-axis and multispindle CNC machine tools. The company has also recently re le a se d new pro duc t s for companies utilising automated co mp o site m ac h i ne r y, a n d drilling and fastening machines.

triggers time savings — the employee can remain at his workstation and interact directly with the test object. “If the bumper is fine, then he swipes over it from left to right. In the event of damage, he points to the location of the defect,” says Mr Schick. 3D Tracking Works In Real Time This non-contact gesture-detection system is based on 3D data. As such, the entire workstation must first be reconstructed in 3D. That includes the individual as well as the object with which the operator is working on. “What does the inspector look like? Where is he situated? How does he move? What is he doing? Where is the object? All of these data are required so that the pointing gesture can properly link to the bumper,” explains the researcher. In order to enable gesture control, the experts apply 3D-body tracking, which records the individual’s posture in real time. Even the car body parts are ‘tracked’. When it comes to this, the hardware requirements are minimal: A standard PC and two Microsoft Kinect systems — consisting of camera and 3D sensors — are required to realise the reconstruction. Mr Schick and his team developed the corresponding algorithms, which fuse multiple 2D and 3D images together, specifically for this kind of application, and adapted them to the standards of the BMW Group. The technology can be subsequently integrated into existing production systems at little expense. Scientists could incorporate their effective process into the BMW Group’s system through a specialised interface module. www.equipment-news.com


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ENQUIRY NO 101

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BusinessNews

3D Systems Receives Award

Hexagon Metrology Expands & Relocates In Singapore

Rock Hill, US: 3D Systems has received the Financial Times and ArcelorMittal ‘Boldness in Business’ Award recognising companies, entrepreneurs and individuals who, through bold decisions, drive change, inspire innovation and deliver outstanding economic performance. The company invented the first 3D printing technology almost 30 years ago, changing the way people develop and manufacture their products. Through continuous innovation, 3D Systems’ content-toprint solutions transformed entire industries. According to the award sponsors, winning companies stand out by making the boldest decisions to change their business model, delivering sustainable and scalable economic and social impact.

Singapore: Hexagon Metrology has expanded and relocated its Asia Pacific headquarters to a new and larger space in Singapore. The official grand opening took place on February 18, 2013 with Norbert Hanke, CEO & president of Hexagon Metrology and Claudio Simao, president of Hexagon Metrology APAC inaugurating the office. “We see this move as a positive change towards a bright future for the organisation and its employees. Further, this change reflects our confidence in our ability to continuously grow and provide high quality products, services and support to all our customers,” said Mr Hanke.

Studer Produced 1,000th S33

Switzerland: Studer produced the one thousandth machine in its S33 series in the hundredth year since the company's foundation. The Swiss company celebrated this event during the 16th Indian Machine Tool Exhibition IMTEX,

which took place earlier this year. Back in 1996, the company launched the S30leanPro, which has the ‘All in One’ solution (using several grinding wheels on one and the same machine), and became known as a compact and flexible

universal cylindrical grinding machine with two external grinding wheels and one belt-driven internal grinding wheel. An innovation at this time was the creation of grinding and dressing programs using pictogramming. Over the course of time, marketspecific variants of the S33 were developed. The KC33 was built specifically for the Chinese market, by Körber Schleifring Machinery Shanghai. The favoritCNC was built as a simple variant for the Eastern European and American markets, and the ecoGrinder as the best process-accessible version for the Asian continent.

Visit us at these shows! Intermach (Thailand) May 16-19

Metaltech (Malaysia) May 21-25

www.equipment-news.com 12

asia pacific metalworking equipment news April 2013

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Tungaloy Singapore Pte. Ltd. 31 Kaki Bukit Road 3 #05-19 Techlink Singapore 417818 Tel: (65) 6391 1833 • Fax: (65) 6299 4557 www.tungaloy.co.jp/tspl/

ENQUIRY NO 091


BusinessNews

World Bank To Support Vietnam’s Economic Reforms

Roberto Colonello, Merano, Italy

Washington, US: The World Bank Board of Directors has approved the first Economic Management and Competitiveness Credit for Vietnam, EMCC 1, to help the country with economic management reforms for higher productivity and competitiveness. The EMCC 1, the first of a series of three operations, provides US$250 million concessional financing to support reforms in seven policy areas: financial sector; fiscal policy; public administration and accountability; state enterprise management; public investment management; efficiency of the business environment; and equity and transparency of the business environment. “The EMCC follows on from the successful Poverty

Reduction Support Credit series, and aims to address new challenges that will raise the efficiency and competitiveness of the Vietnamese economy,” said Victoria Kwakwa, the World Bank country director for Vietnam. “I hope that the EMCC series will provide a platform for deepening and coordinating dialogue between development partners and the government of Vietnam with a view to helping Vietnam transition to a new economic growth model, which targets competitiveness and the quality of growth.” Macroeconomic stability is a major priority for competitiveness in Vietnam, and a core objective of EMCC. The EMCC will help monitor macroeconomic policies and ensure that it supports the stabilisation efforts of the government. Public Investment Management, SOE and banking sector reforms are prominent themes under the program, in line with the government’s priorities for structural reforms. In addition, the EMCC prioritises government efforts to streamline administrative procedures and strengthen fiscal discipline because they are critical to productivity and competitiveness.

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BusinessNews

Fab Equipment Spending To Go Up 24 Percent In 2014: Semi San Jose, US: Fab equipment spending for front end facilities is expected to be flat in 2013, remaining around US$31.7 billion, increasing to US$39.3 billion in 2014 — a 24 percent increase. The Semi World Fab Forecast also reveals that in 2013, increases for fab equipment spending will vary by technology node and that fab construction spending will increase an overall 6.7 percent with major spending in China. Despite these adjustments, the overall forecast for equipment spending for 2013 has remained about the same. Depending on macro-economic risk factors, possible scenarios project a range of -3 percent to +3 percent change rate for fab equipment spending in 2013; in other words, hovering around flat. Although the overall outlook has improved, fewer players in the market can afford the rising costs for R&D and upgrading facilities as the amount of money needed to upgrade facilities at the leading edge technologies is immense. The report shows fab equipment spending for 17 nm and below is expected to kick off in 2013 and

increase by a factor of 2.4 to about US$25 billion from 2013 to 2014. Fab construction spending is now expected to increase 6.7 percent with construction spending to reach almost US$6 billion. In 2014, however, construction project spending is expected to contract by about 18 percent. Construction spending is led by TSMC, with seven different projects for the year; followed by Intel. Fab construction spending in China will increase by a factor of four due to Samsung’s mega fab in Xian. Capacity is now forecasted to expand by just 2.8 percent for this year and to improve to 5.4 percent growth in 2014. Excluding 2009, the years 2012 and 2013 show the lowest growth rate for new capacity over the past 10 years. However, pent-up demand is expected for some product types because capacity additions have been cut to minimum levels while chip demand keeps increasing. Capacity additions and equipment spending are expected to pick up in the second half of 2013. In 2014, at least five percent in new capacity will be added and fab equipment spending will increase by 24 percent.

ENQUIRY NO 095

Trumpf AD 14.03.13 11:05

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April 2013 asia pacific metalworking equipment news

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BusinessNews

Malaysian Economy To Expand 5 - 6% In 2013: Bank Negara Malaysia

Lee Pei Rei, Kuala Lumpur, Malaysia

Malaysia: The Malaysian economy is expected to remain on a steady growth path, with an expansion of five to six percent in 2013. Economic activity will be anchored by the continued resilience of domestic demand, and supported by a gradual improvement in the external sector. Private investment is expected to remain robust, driven by capacity expansion by the domestic-oriented firms and the continued implementation of projects with long gestation periods. Investments by the externaloriented businesses is also expected to be higher amid the gradual improvement in external demand, while private consumption is projected to grow at a more moderate rate in the second half of the year, although it will continue to be well supported by sustained income growth and positive labour market conditions. G over nment spending is expected to record a lower growth given the ongoing consolidation of the government’s fiscal position and as the role of the private

sector gains greater significance. In line with the more favourable external sector, gross exports are projected to record a higher growth in 2013 supported by the export of manufactured products. Gross imports are expected to moderate, in tandem with the projected trend in domestic demand. Overall, this is expected to result in a lower negative contribution to real GDP from net exports. As import growth continues to outpace export growth amid the continued deficit in the income account and in current transfers, the current account surplus, while still remaining significant is expected to narrow further in 2013. O n t he suppl y side , a l l major economic sectors are expected to record continued expansion in 2013. The services and manufacturing sectors are expected to be the key contributors to overall growth, driven by the continued resilience of domestic demand and supported by higher international trade activity. Growth in the construction

sector is projected to remain strong, supported by the implementation of major infrastructure projects. In the commodities sector, the growth of agriculture is expected to improve due to the higher output of crude palm oil and food commodities while the mining sector is expected to strengthen following the higher production of natural gas, crude oil and condensates. Headline inflation is expected to average two to three percent in 2013. This inflation projection takes into account the expected higher global prices of selected food commodities and the adjustments to domestic administered prices. Demand-driven price pressures are expected to be moderate. The wider forecast range reflects the greater uncertainty in the external and domestic environment. Given the challenging external env ironment, there w ill be risks to the economic outlooks. The potential re-emergence of instability in the Euro area and slower growth in Malaysia’s major trading partners would affect the Malaysian economy. While pressures from global commodity prices have receded, upside risks from nonfundamental factors, such as adverse weather conditions and geopolitical developments, could push commodity prices higher and adversely affect the growth prospects of economies that are major trading partners of Malaysia. Potential upside to the domestic economy could emerge if the recovery in the advanced economies turns out to be better than expected.

Italian Technology Centre Inaugurated At Pune Italy: Italian Technology Center (ITC), the centre for the promotion of the Italian industry of capital goods, was inaugurated on March 6, 2013 in Pune, India. It was born from a network agreement signed by 11 companies manufacturing machine tools and plastic processing machines. 16

asia pacific metalworking equipment news April 2013

Promoted by UCIMU-Sistemi Per Produrre and Assocomaplast, reference associations for the two sectors which the network companies belong to, ITC is part of the initiatives established by the Ministry of Economic Development and Federmacchine, the federation of manufacturers of capital goods. www.equipment-news.com


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Global Performance 03.04.03

CMS-106 Laser Scanner

Global Performance 03.04.03, a new compact size and flexible coordinate measuring machine (CMM) from Hexagon Metrology. Industry proven ultra rigid structure, advanced motion controller and superior measuring software, ensure high reliability and high performance for the measurement operation.

The CMS 106 laser scanning probe provides many benefits for metrology in a complete and powerful turnkey package via rapid point-cloud capture, including: Feature inspection to CAD (Thin walled/ sheet metal parts), free form surface inspection to CAD and reverse engineering.

The machine is ideal for both single point touching and high-speed continuous scanning of profiles and complex geometries.

The probe is available on Hexagon Metrology GLOBAL, ALPHA, DELTA, LAMBDA & BRAVO CMMs, allowing for integrated scanning operations.

Compact size with high performance

3D point scanning at its best

Indonesia (Representative Office) Hexagon Metrology Asia Pacific Pte. Ltd. Tel: + 65 6463 6242 Fax: + 65 6463 8030 contact.sg@hexagonmetrology.com

Thailand Hexagon Metrology (Thailand) Ltd. Tel: +66 2 361 3695 to 9 Fax: +66 2 746 9607 contact.th@hexagonmetrology.com

Malaysia Hexagon Measurement Technologies Sdn. Bhd. Tel: +60 3 5632 8900 Fax: +60 3 5632 8955 contact.my@hexagonmetrology.com

Vietnam (Hanoi Representative Office) Hexagon Metrology Asia Pacific Pte. Ltd. Tel: +84 4 3936 7935 Fax: +84 4 3936 8069 contact.vn@hexagonmetrology.com

Singapore Hexagon Metrology Asia Pacific Pte. Ltd. Tel: +65 6463 6242 Fax: +65 6463 8030 contact.sg@hexagonmetrology.com

Vietnam (Ho Chi Minh Representative Office) Hexagon Metrology Asia Pacific Pte. Ltd. Tel: +84 8 5445 6665 Fax: +84 8 5445 6660 contact.vn@hexagonmetrology.com

www.hexagonmetrology.com

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BusinessNews

Walter Develops GPS Tool Software Tübingen, Germany: The Walter GPS is now available in version 2.0. This update provides an introduction to machining prismatic workpieces and it is now set for use all over the world because of its multilingual capability. “In order to provide optimum support for both solid carbide and indexable insert tools, it was necessary to redesign our proven tool selection and cutting data software,” explains Dr Peter Müller, GPS project manager at Walter AG. “We are convinced that in this day and age, comprehensive software support for a highperformance tool is essential for achieving maximum productivity,” he adds. “We are therefore not

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shying away from the immense development effort required in order to place a system in the hands of our customers that does not exist on the market yet.” As in the past with TEC-

CCS, Walter GPS will also be developed over the years. The further expansion of the prismatic workpieces in 2013 will also be followed by rotationally symmetric components.

Delcam Thailand Holds On-Machine Verification Event

Jenoptik Wins 2013 Vision Award

Thailand: Delcam Thailand held a two-day event promoting OnMachine Verification (OMV) to local Bangkok manufacturers on March 7 – 8, 2013. The event was hosted by machine-tool supplier Mazak in its Bangkok showroom and supported by Renishaw, which supplied probing equipment for the live demonstrations. Representatives from many of Bangkok’s largest manufacturing companies attended on each day. Each morning included presentations on Mazak’s machine tools, Renishaw’s probing systems and Delcam’s PowerInspect inspection software. The afternoons were run in a workshop format, with delegates provided with initial training in the use of OMV. OMV with Delcam’s PowerInspect allows initial checking of machined parts to be carried out in situ on any CNC machine tool rather than having to transfer them to coordinate measuring machines for inspection. The main advantage is that any mistakes are discovered where they can be corrected — on the machine tool. Repeated cycles of machining and inspection, interspersed with long set-up times on the respective pieces of equipment, are avoided, meaning that overall manufacturing times can be reduced. The most obvious benefit of OMV is for those companies that do not have existing inspection capabilities. Modern machine tools either come with, or can be retrofitted with, probing systems to assist in the set-up of the job. With PowerInspect, this same equipment can be used for verification at little extra cost.

Jena, Germany & Brighton, US: Jenoptik’s Laser Processing Systems business unit of the Lasers & Material Processing division has received the 2013 Vision Award for the JenoptikVotan BIM. This machine is suited for cutting complex 3D metal parts. The laser cutting machine was a product which, among the nominated products, had the biggest potential of solving entrepreneurial challenges using technological innovation. Main criteria for the US Vision Award are innovation, value and impact.

asia pacific metalworking equipment news April 2013

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We have a habit We are convinced our way is the best way to build a machine tool. Entirely by Hwacheon. From castings, box guideways, spindles, gears to sheet metal.

Historian Will Durant once paraphrased Aristotle this way: "We are what we repeatedly do. Excellence, then, is not an act but a habit."

Every day, we follow traditional, craftsmanlike methods for designing and building our very advanced machine tools. That’s what yields the best quality, longest lasting equipment. And that is what we deliver to our customers.

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BusinessNews Aerospace / Automotive

Strong Demand Pushing Commercial Production Rates Higher: Boeing Maria Herrera, Izcalli, Mexico

Orlando, US: Boeing said that strong demand for its commercial airplanes and a healthy backlog are behind the company's decision to keep increasing production rates. "The data tells us the market is strong and will continue to be strong. That's why we're confident as we raise our production rates," said Randy Tinseth, VP of Marketing, Boeing Commercial Airplanes. "Supply and demand will continue to be in balance as we put more airplanes into the hands of our customers." Mr Tinseth spoke at the International Society of Transport Aircraft Trading (ISTAT) Americas conference in Orlando. He said passenger traffic is growing faster than capacity. Utilisation rates and airline load factors are at historic levels. And Mr Tinseth said airlines continue to replace their older, less fuel-efficient airplanes.

"All of these factors play into our decision to ramp up production in a methodical, deliberate way," he said. "We constantly pulse the market to make sure we're exactly where we need to be." Boeing's 737 prog ra m is currently in the process of increasing its production rate to 38 airplanes per month and will go to 42 per month in the first half of 2014. The 777 program just ramped up production to a record high of 8.3 airplanes per month (100 per year) and the 787 program plans to increase its current five per month rate to 10 per month by the end of this year. Mr Tinseth also said industry data shows the economic life of airplanes continues to hold steady. "We've done an exhaustive analysis of the data. Everything tells us that airplanes are long-lived assets and continue to be good investments."

Honda Opens US$71 Million Motorcycle Production Plant Penang, Malaysia: Construction of Boon Siew Honda's one-stop motorcycle production facility, which started in the third quarter of 2011, is now completed and fully operational. The MYR$222 million (US$71 million) one-stop production plant in Batu Kawan, Penang was officiated by Yang Berhormat Dato' Sri Mustapa bin Mohamed, minister of International Trade and Industry Malaysia on March 12, 2013. The facility occupies a 23.7 ha site and is five times larger than the previous Mak Mandin plant in Butterworth with an annual production capacity of 300,000 units. It marks a milestone in the company's plan to consolidate manufacturing, sales, customer service, spare parts and safety riding into one integrated location for management efficiency and greater customer satisfaction. The facility deploys an efficient production system with the use of advanced technologies such as a solar photovoltaic system, high coating efficiency technologies and an efficient electro deposition coating line for volatile organic compounds. The streamlined processes not only increase productiv ity but contribute to greater energy savings and reduction of manpower and material wastage.

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Cutting Edge

Software Programs

Modern software technology has simplify and accelerate the production process in the manufacturing of turbine blades

Byte-ing Into Grinding

Grinding these days is enabled by software programs as much as the grinding wheel. By Dipl Ing Ira Schroers

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or centuries, machines were operated solely by people. For workpiece machining this means the workpiece quality was only ever going to be as good as the machine’s stability and reliability and the operator’s experience and ability. Although it was a laborious task, (eg: in manual tool grinding, every angle and surface to be ground required a new clamping. For each measuring process the workpiece had to be removed from the machine, measured and then re - clamped. Errors could quickly creep in and the reject rate was high) outstanding precision could be achieved with the right person even then. Machining Going Soft The first step towards automation wa s Numer ic Cont rol ( NC ) machines. Their control system read the control commands present on data carriers and converted them into movement sequences. The big advantage back then was

Today’s funnel geometries of a forging die can be produced in a single clamping in just a few minutes using modern grinding software

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asia pacific metalworking equipment news April 2013

by changing the data carrier, (still perforated tape at that time) the machines could be quickly adapted to a new task, which is why NC controls were at first primarily used in machine tools. With advancing technological development, computer technology also found its way into the production process. CNC technology began to assert itself in the mid 70’s. It provided higher flexibility and was the enabler for rationalisation in series and single part production. Thanks to electronic control and software tools, much more precise and complex products can be manufactured cost-effectively today. Through the use of software combined with modern measuring and drive technology, today processes can be operated with high reliability and reproducibility in quality ranges which were still inconceivable just a few years ago. This also applies for the manufacture of stepped and profile tools, for example. Pine tree cutters

Thanks to electronic control and software tools, much more precise and complex products can be manufactured

and thread milling drills as well as micro tools for the medical sector can only be manufactured due to modern software. Modern Software Programs For Grinding Users require programs which will allow them to manufacture complex parts as cheaply and quickly as possible. At the same time the precision requirements on the workpieces are increasing. While 0.01 mm was sufficient a few years ago, today precisions of under 0.005 mm are the rule. For comparison: a human hair is 0.07 mm thick. In order to achieve this precision, application software, hardware and machine control must harmonise with each other. This is only possible if the software developer has the relevant expertise and possesses sound knowledge of mathematics, control technology and grinding technology. With a tea m of sof twa re specia lists, the sof twa re StuderTechnology was developed in around five years. This system stores the company’s entire grinding know-how in a database and suggests the optimal setting for the machining parameters, irrespective of the operator’s knowledge. The StuderGrind grinding software and all other software mo du le s acce ss t his whe n programming a new grinding www.equipment-news.com


CuttingEdge

Whether peel grinding longitudinal contours (left) or pendular grinding prismatic surfaces (right) – modern software can master all challenges

process. The advantages are much specifically for individual workpiece shorter changeover and set-up families. Common to all software times without rejects, and optimal solutions is simple, intuitive production results from the outset. operation and familiar WindowsIt is a similar story at Walter. The based user interface. But these ToolStudio software is available software solutions by no means for virtual programming and mark the end of development. machining, as well as a database of Future Of Grinding knowledge for tool grinding. Is Software? With Grips, Blohm, Ewag and The importance of grinding Jung offer a programming aid software will increase, because for profiling grinding wheels and in future it will be the most develop grinding programs which APMEN_ASIA_3406_13159_EMO Hannover 2013 08.03.13 10:53 Seite 1 important distinguishing feature in can be parameterised application-

competition. Ewag, for example, is working on further standardisation of its software, Walter is focusing on profile tools and regrinding, while Studer, with Studer training and programming, is working on a program which will enable customers to execute ‘grinding dry runs’ on a laptop. Blohm Ju ng is cu r rent ly per forming initia l te sts for the automatic calibration of workpieces using a 3D scan; this will enable the machine to select the appropriate grinding program with the aid of the CAD drawing and then grind the workpiece from the drawing. But one thing is common to all developments: the more complex the software processes running in the background become, the simpler the operation of the machine.

APMEN_ASIA_3406_13159_EMO Hannover 2013 08.03.13 10:53 Seite 1

Enquiry No. 3001 Turn to page 80a or log on to www.equipment-news.com to enquire

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INFO: VDW – Generalkommissariat EMO Hannover 2013 INFO: Verein Deutscher Werkzeugmaschinenfabriken e.V. VDW – Generalkommissariat EMO Hannover 2013 Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY Verein Deutscher Werkzeugmaschinenfabriken e.V. Tel. +49 69 756081- 0 · Fax +49 69 756081-74 Corneliusstraße 4 · 60325 Frankfurt am Main · GERMANY emo@vdw.de · www.emo-hannover.de Tel. +49 69 756081- 0 · Fax +49 69 756081-74 emo@vdw.de · www.emo-hannover.de

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r vee d . o enr avn o h -n aon -ehm

April 2013 asia pacific metalworking equipment news

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CuttingEdge

Case Study:

Grinding With Quality & Speed One company has claimed that it is possible to grind gearshafts faster than ever without compromising quality. Contributed by Christine Isenmann, marketing consultant (Communication), Erwin Junker Maschinenfabrik

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nstead of linking conventional grinding machines, more a nd more automotive manufacturers and suppliers rely on compac t a nd costeffective technology for their crankshaft, camshaft or gearshaft manufacturing. One such company is Getrag Ford Tra nsmissions, one of the largest transmission manufacturers in the world. They have three Jucenter 6L’s installed. With the units, a ma x imum capacity of more than 2 million gearshafts can be reached during

three-shift operations. Within the grinding machine, is a machine concept that is said to support economical turnaround and enables significant potential savings. Keeping Quality & Quantity Up The trend to build transmissions of fer ing sma ller ge a r rat io increments to achieve better fuel efficiency, require new manufacturing machine concepts to achieve higher part accuracies while increasing the equipment’s throughput. Product quality, cycle

New manufacturing machine concepts need to achieve higher part accuracies while increasing the equipment’s throughput.

times, unit costs, output and process reliability must therefore always be at a constant high level. This ethos manifests itself as tangible result — what was earlier ground on three machines can now be achieved in one machine. Throughput is matched by quality. The long-term precision of the machine is enabled by its hydrostatic guide ways and drive systems. The same systems provide dynamic stability and dampening. According to the manufacturer, the Jucenter 6L is the first grinding machine which enables complete grinding of gearshafts in a cycle time of less than 45 seconds. With a machine availability of 97 p e rce nt , (t rad it iona l manufacturing lines using three machines can only reach 91.7 percent) an annual production of 800,000 gearshafts can be produced. Reducing the number of machines also reduces labour costs — an additional benefit. To a d d t o t h e o v e r a l l performance in time, the Junker Operator Panel (EJOP) allows a standardised operating structure o f a l l m a c h i n e s p ro du ce d by the manufacturer. As such, familiarisation phases or retraining are reduced to a minimum. Enquiry No. 3002 Turn to page 80a or log on to www.equipment-news.com to enquire

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asia pacific metalworking equipment news April 2013

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INNOVATIVE BAND SAW BLADES FOR YOUR REQUIREMENTS OF TODAY AND TOMORROW Customised band saw blades and support for higher efficiency With more than 50 years of experience in the development and production of high-performance tools, WIKUS is Europe‘s largest manufacturer of band saw blades and global technology leader in metal sawing. Precision band saw blades from WIKUS represent innovation and productivity with the objective of higher efficiency for the customer. WIKUS is offering you: · Innovative band saw blades, optimised for all kinds of sawing tasks · Competent and individual customer service in the entire sawing process · Cutting tests directly on location of the customer

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Made in Spangenberg, made in Germany.

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Tech Talk

T

he automotive industry in Southeast Asia appears to be starting the year on a good footing. According to Business Monitor International or BMI, a source of specialist news analysis, data and forecasts, Thailand is a major production hub due to its strong export potential. This positive trend is expected to continue in 2013, with automakers increasing investments into the country to use it as an export base. Furthermore, support from the Thai government should continue to boost the industry. Vehicle sales this year are likely to grow 10.3 percent to reach 1.6 million units. With robust demand expected over the ye a r, automotive s producers need to ensure that their facilities are ready to take on higher production volumes. Given the large number of parts and the stringent requirements that are needed for automobile production, effective Quality Control (QC) measures need to be in place. These processes ensure that parts on the production line conform to predefined standards. They also allow parts to be tracked anywhere along the line for traceability and accountability purposes. Challenges On The Line The last 20 to 30 years have seen major improvements being made in Otto and diesel engine technology. Modern day engines give off far less particulate matter and lower levels of carbon dioxide, while providing greater reliability in the detection of operational faults. Where a 2.5 litre combustion chamber was required to produce 180 horsepower, a 1.4 litre chamber today is all that is required. However, in order for the same amount of power to be produced using a lower cubic capacity engine, greater compression is required, resulting in the need for improved engine lubrication. The lower engine cubic capacity results in a reduced clearance in the bearing shells of the 26

asia pacific metalworking equipment news April 2013

Machine Vision To Facilitate

Reliable Production

From the automotive to medtech sectors, manufacturers in Southeast Asia are looking towards better quality control methods. By Didier Lacroix, senior VP, International Sales & Services, Cognex

connecting rod eyes. This creates production challenges because it is difficult for the connecting rod to withstand the stronger forces that are exerted while operating with minimal tolerances. In the manufacture of connecting rods, material temperatures can rise to about 1,280 deg C, which causes the C70 steel to be extremely sensitive to the mechanical shaping processes. One problem is that it is possible for the connecting rod to end up being thicker or thinner than the required size while it is being forged. During the automated forging process, forging displacement occurs under certain conditions. It happens if the upper and lower dies do not accurately correspond within a tolerance, which could range from a tenth to hundredths of a millimetre. Even during the subsequent manual calibration process, occasional temperature

changes in the connecting rod could still cause deviations in its size and weight. This makes Quality Control (QC) a vital part of the entire production process. The rods are first sandblasted and are visually inspected before they undergo a magnetic powder test to detect the presence of possible ultra-fine hairline cracks. Before component parts are directed to a connecting rod, the latter is checked to ensure that its weight is within tolerances of plus or minus six grams. The connecting rods are then fed via a conveyor belt into the optical testing machine. They are detected by a light barrier, where their locations and positions are then transmitted to the tracking system. At the first image processing station, in-sight vision systems equipped with telecentric lenses are used to measure the lengths and widths of the connecting rods, www.equipment-news.com


TechTalk the concentricity of the crank eye, and the engraving. The lengths and widths are determined according to the product specification, based on the ratio of the centre of the crank eye, to an established outer edge reference. If measurements deviate outside the acceptable range, the vision systems transmit a signal to reject the connecting rod. In the image processing station, a vision camera is used to detect additional characteristic numbers on the upper side of the components, by checking 3D imprints that have good Optical Character Recognition (OCR) legibility. The different characteristics are recorded under a combination of different light settings. Light Emitting Diode (LED) background lighting helps to define the contours of components. Engravings and characteristic numbers are recognised under red LED incident lighting. Staying On Track Traceability is another important aspect of QC. Data management on the production line allows ma nu fac tu rers to opt im ise processes and to keep track of quality. Collecting and storing the necessary data on vehicles and related parts can also help to reduce costs. The information also comes in handy for responding promptly and accurately to possible complaints and recall problems. To a c h i e v e a r e l i a b l e traceability program for engine and transmission parts production, manufacturers can turn to 2D Data Matrix Direct Part Marked (DPM) codes. A car transmission can comprise of about 300,000 parts. Key components may include the T/F driver gear, T/F driven gear, differential gear, carrier, O/D clutch, transmission case, housing, valve body, etc. These items need to be tracked throughout the production process. Besides these, key components on the engine make up about 200,000 parts (eg: the piston, www.equipment-news.com

Across technologyintensive industries such as automotive and medical devices production, machine vision is playing an increasingly important role.

cylinder head, engine block, CAM shaft, and crank shaft), and are also traced throughout the manufacturing process and distribution channels. Every day, a particular facility’s co nve nt io n a l t ra n sm i s sio n manufacturing line produces approximately 1,800 units, and its engine line rolls out 1,300 to 1,400 units. The problem was that the facility’s tracking system could only deliver about 97 percent successful read rates or less. And because it was manually operated, it was difficult for the tracking system to match the manufacturing cycle on time. This in turn decreased work efficiency and production yield. There was also the possibility that inappropriate parts may be used if the code read was incorrect, which could cause product defects later on. Since the s-speed transmission parts are typically small, the data matrix codes are also hard to read. Given such a high production rate, an increase in read rates by just two to three percent on these production lines would deliver major benefits. Solution In Sight The solution came in the form of in-sight barcode readers that were deployed on the production lines. The readers are optimised with patented algorithms, which help users achieve read rates of 99 percent or higher, even on the toughest DPM and label-based ID applications.

Each 2D Data Matrix code is read to ensure that the data matches the corresponding part that it is marked on. Production information such as date of manufacture and model number, is then saved on the server. In adopting this solution, the facility has been able to reap benefits such as increased production yield, a reduction of manufacturing costs and improved work efficiency. In another facility, machine vision is also used to detect product defects in the production of electrohydraulic automatic transmission control modules. The system first reads a 2D code on the part that is being inspected. After receiving confirmation from the production management software that it is the correct part, the defect detection process commences. The system checks for the presence of bolts; the positions and distances of contact pins of connectors; and the presence of adhesive tape. Any products that do not conform to predefined standards are removed. The system stores a total of 10 detection positions in a single job file. A Progra mmable Logic Controller (PLC) and a robotarm are integrated into the vision system. When the robot-arm arrives at the assigned position, the vision system sends a signal through the IO module to change product detection positions. The PLC sends a trigger signal for the vision system to capture images and to give a signal after that, to April 2013 asia pacific metalworking equipment news

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TechTalk Machine vision is widely used in the automotive industry

indicate the end of that segment of inspection. The PLC then instructs the robotarm to move to the next position. After completing inspections at all the 10 positions, the vision system sends out signal that indicates the end of the inspection cycle. The results are displayed and sent to the production management software, along with images of any detected defects. Surgery In Progress In the medical devices industry, machine vision plays an important role in the ma nufacture of electrosurgery electrodes. The latter are employed by neurosurgeons and plastic surgeons to cut tissue and cauterise bleeding vessels in a range of different procedures. To ensure that the electrodes fulfil customer requirements, a number of critical dimensional me a su re me nt s ne e d to b e performed. This includes gauging the diameter of the tips to ensure that they are isolinear or parabolic (depending on the specification); measuring taper angle and length, overall length, bend radius, as well as other variables. Performing Checks E l e c t r o d e s a r e i n s p e c te d immediately after a proprietary tapering process called electrochemical pointing. Fixtures of tapered electrodes are cleaned and dried, before being loaded into a machine vision-based system for 28

asia pacific metalworking equipment news April 2013

inspection. The fixture of electrodes is automatically indexed into the inspection zone, where the vision camera is positioned overhead. The vision system captures an image of the needle and performs dimensional measurements in sequence. After an electrode has been inspected, the camera moves to the next electrode and repeats the proce ss. Dimensiona l measurements of each electrode are displayed onscreen, which makes it easy for operators to compare results against specifications. The information is also stored on a database to allow quality assurance staff to collate and provide reports to the customer. This helps to save human resources as the staff do not have to perform additional inspection routines — with less accurate equipment. A fixture of electrosurgery electrodes can be inspected in three to five minutes. When this is completed, the system unloads the fixture and the operator retrieves the parts. Any electrodes that fail to meet the grade are rejected and can be identified onscreen for disposal. Accepted electrode s a re removed, and a corresponding label for each is printed, documenting the inspections for archival purposes. The documentation can be used to highlight any production process inefficiencies and reduces the amount of time needed for quality assurance. It also helps customers to better model their

own processes and assures them about product quality, without them having to perform their own additional internal inspections. All About Quality In the manufacture of small implants such as screws for spinal surgery, manual inspections are becoming increasingly unsuitable. Due to tightening regulations, vision technology is called upon to provide the means of ensuring quality during production. For low volume production, a solution can be found in using a two-axis desktop robot coupled with a vision system. To begin, each implant is placed into the cell of a blister pack. Each batch is identifiable by a code and certain nests may be empty. The products are inspected in their individual nests as they move through the vision system. The camera is located on the robot’s y-axis, and inspection takes place while the blister packs are transported under the camera in the x-axis direction. S e ve ra l i n sp e c t io n s a re made for each nest. A barcode scanner is used to enter data for each batch. Data obtained from the inspection is compared against predefined set values and permissible tolerances. In the event that a faulty product is detected, an alarm is triggered to signal QC personnel to remove the product for manual inspection. Across technology-intensive industries such as automotive and medical devices production, machine vision is playing an increasingly important role. By adopting such solutions in QC, manufacturers can raise the bar for quality and efficiency in their production facilities. In this manner, waste is reduced and human resources can be saved — all while better meeting traceability needs and legislative requirements for product safety. Enquiry No. 3101 Turn to page 80a or log on to www.equipment-news.com to enquire

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Unbeatable Control,

Precision, and Flexibility

Lowering cost, increasing productivity, and shortening design times are just some of the challenges industrial engineers face. The graphical system design approach combines productive software and reconfigurable I/O (RIO) hardware to help you meet these challenges. This off-the-shelf platform, customizable to solve any control and monitoring application, integrates motion, vision, and I/O with a single software development environment to build complex industrial systems faster.

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TechTalk

Incorporating FPGA Technology In

Machine Vision

A graphical programming environment is said to be the key that paves the way for the utilisation of FPGA image processing in vision systems. By Wu Rong, marketing engineer, National Instruments

M

achine vision systems are prevalent across industries to perform imaging-based automated inspections using high speed cameras, sensors and image processing software today. They are commonly used for quality assurance in process control to detect defects, monitor production lines, or track, sort and identify parts. Machine vision systems are also used for high speed visual test inspections that are indeterminable by human eyes such as crash tests in the automotive industry. According to a market report by IMS Research, Asia is poised to be the largest market for machine vision by 2016. Market complexity, rising labour and other costs are driving industries to adopt machine vision in order to keep manufacturing costs down and stay competitive. There is little wonder why machine vision companies continue to invest

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asia pacific metalworking equipment news April 2013

heavily in R&D to help industries improve their productivity. Bridging The Gap Matching ima ge proce ssing w it h c a me ra sp e e d s i s a n inherent problem for high-speed automated visual inspections, and researchers around the world have devoted their time and effort to identify a solution. Advanced algorithms and excellent program s t r u c t u re s we re t wo su c h examples, but these solutions failed to consider the limitations of the hardware computational capability. In traditional cases, the Central Processing Unit (CPU) is more than sufficient to process and analyse acquired images from the camera concurrently. However, with the advent of high-speed image acquisition cameras going over 1,000 frames per second, there is a widening gap to improve the rate of image processing to reduce system latency.

Low latency between acqu i sit io n a nd t he i m a ge processing result is of paramount importance as it impacts the overall speed of the machine vision system. It is now essential to start looking into the hardware components. Field Programming Gate Array (FPGA) technology fills in the missing gap as it frees the CPU to perform its inherent operations by taking over all or partial of the image processing and analysis tasks. Technology companies and R&D institutes have already been evaluating the use of FPGA in vision systems. What Is Field Programming Gate Array (FPGA)? F PG A s a re reprogra mmable silicon chips invented by Ross Fre ema n, t he cofou nder of Xilinx in 1985. Fundamentally, these semiconductor devices contain a large quantity of noninterconnected gates ( logic devices) whose functions are determined by a wiring list which is then downloaded to the FPGA. The wiring list determines how the gates can be interconnected, a nd this interconnection is performed dynamically by turning semiconductor switches on or off to enable different connections. Imagine a printed circuit board with a large number of devices that are not connected. The wiring list determines which nodes are to be connected and this can be done using physical wires soldered to the pins or a wire wrapping tool to connect the devices. However, if the wiring is embedded in the printed circuit board, it cannot be programmed. Software is used to program a FPGA to define and verify the logic functions as well as the expected timing of the signals in the device. A layout tool physically maps the logic devices to specific elements on the chip a nd there a f ter determines their actual wiring. www.equipment-news.com


- one gauge, many applications

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The unique new Equator™ is a versatile alternative to traditional gauging, offering inspection of an unprecedented variety of manufactured parts. It has been developed and proven on the shop-floor with industry-leading gauging users in multiple industries and applications.

Benefits which can be gained by using Equator™ include: • Reduced gauging costs • Robust shop floor measurement process • Reduced production bottlenecks

To see Equator in action call +65 6897 5466 or scan the code

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TechTalk Field Programming Gate Array (FPGA) explained

X1153

Why Use FPGA Image Processing For Vision Systems? F PG A technolog y is a n attractive proposition because you ca n up date mu lt iple hardware functions in the field. Microprocessors have a fixed hardware structure to execute the software whereas FPGA possesses a flexible hardware structure. Programming a FPGA rewires the chip itself so each independent processing task is assigned to a dedicated section of the chip, and can function autonomously. For this reason, FPGAs are highly efficient when it comes to performing repetitive instructions required for DSP or imaging tasks. FPGAs also permit the design of large number of parallel data paths, which can greatly increase the performance for DSP and data streaming applications. The parallel nature of FPGAs makes them appealing for vision because many image processing routines can be broken up into independent, iterative tasks. Consider an operation where each pixel is multiplied by a value. With the resources on an FPGA, many pixels can be multiplied simultaneously, increasing the processing throughput. This parallel nature to vision is also the reason why multicore processors have become s o i mp o r t a n t fo r m a c h i n e vision. Many image processing a lgorithms a re inherently parallel and therefore suitable for FPGA implementations. These 32

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algorithms involve operations on pixels, lines, and region of interest do not need high-level image information, such as patterns or objects in the image. These functions can be performed on small regions of bits as well as on multiple regions of an image simultaneously. The fast loop rate of FPGA also enables fast processing of image data. The FPGA receives image data and processes individual bits using a high-speed onboard clock (up to 100 MHz clock rate), as compared to normal loop rate of 1 KHz in a Windows system. One other benefit of using FPGA is the tight integration of processing and hardware input/output (I/O). In most machine vision systems, a decision will be made based on the result of image processing and a corresponding action will be taken. If a product fails the vision inspection, it will be rejected and removed from the production line. FPGA integrates tightly with the hardware I/O, and a command can be sent to the actuator immediately within the same clock cycle.

When To Use FPGA In Image Processing? F P G A v i sion te c h nolog y i s commonly used for high-speed control applications such as high-speed alignment where objects need to stay within g i ve n p a ra me te r s or h i g h speed sorting production lines where objects need to be sorted efficiently and quickly based on colour, shape, size, texture or other physical features. FPGA image processing can speed up this process with higher quality assurance because it reduces the computational resources required for image analysis. FPGA frees the CPU to perform other operations because it is a hardware resource. CPU intervention is not required to perform the a na lysis, so latency is significantly reduced from preprocessed input to processed output. Figure 1 shows an example of how the FPGA is used to offload resources from the CPU. In this case, the FPGA performs the entire image processing, which results in minimum system latency. Image

Figure 1: Image processing is done in FPGA, freeing up CPU resources in the process

FPGA Camera

Actuator

Acquisition Logic

Memory

CPU

LabVIEW FPGA Inline Processing

Digital I/O

Image Acquisition Device

Memory

Host

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TechTalk information to the CPU can be sent for data storage or image display after processing is completed. FPGA can also be used with a vision system’s processor to perform image pre-processing. Figure 2 shows how to preprocess with an FPGA while the CPU performs the more advanced processing algorithms. In this case, the FPGA performs bit-level processing such as filtering or edge detection. The preprocessed image is then sent to the CPU for image-level processing such as pattern recognition. System latency is still low in this case because the CPU has fewer functions to perform than it does in a traditional vision system. Examples of image processing functions that work well on FPGA are listed below:

Figure 2: Imaging acquisition and preprocessing are done in FPGA. CPU performs more complicated image analysis

FPGA Camera

Acquisition Logic

Memory

CPU

LabVIEW FPGA Inline Processing Memory

Image Acquisition Device

Host

Preprocessing • Image transforms • Image operators • Shading correction • Bayer decoding • Colour space conversion • 1D and 2D fast Fourier Transform • Filtering (smooth/sharpen) • Binary morphology Feature Extraction • Edges, lines, and corners • Binary objects • Colour

FPGA Programming In the past, the roadblock with F PG A te ch nolog y wa s t hat engineers need to have a deep understanding of the digital hardware design in order to master low-level FPGA design tools like VHDL to design the algorithms running on the FPGA chip. This is a challenge for vision engineers who do not have indepth knowledge of machine-level implementation. www.equipment-news.com

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Measurements • Centroid • Area measurements

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TechTalk

Figure 3: This 3D OCT medical imaging system is the world’s first and is developed by the Graduate School of Medical Science, Kitasato University, Japan.

The emergence of graphical High - Level Sy nthesis ( HL S) design tools such as NI LabView has removed some of the major obstacles of the traditional Hardware Description Languages (HDL) design process. The NI LabView graphical programming environment is suitable for FPGA programming because it represents parallelism and data flow, so users who a re b ot h e x p e r ie nce d a nd inexperienced in traditional FPGA design processes can leverage on FPGA technology. FPGA vision technology can be found in many areas, including medical, R&D and manufacturing industries. Medical Industry One of the most exciting examples of using FPGA technology in the medical industry is to boost the speed and efficiency of Optical Coherence Tomography (OCT). OCT is a technique for obtaining sub-surface images of translucent or opaque materials at a resolution equivalent to a lowpower microscope. OCT images reflections from within tissue to provide crosssectional images for further analysis. The OCT technique is already garnering its own following in the medical community because it provides tissue morphology imagery at much higher resolution (better than 10 Âľm) compared with other imaging modalities like MRI or ultrasound. 34

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Figure 4: NI grid captured using three different imaging methods

A typical OCT system uses a linescan camera and special light source to sweep across a tissue and image the surface beneath, one line at a time. Once each line is acquired, the data is scaled and converted to the frequency domain, where the data is further manipulated and combined with other lines to revea l a high resolution, 3D picture of a tissue. Figure 3 shows a 3D OCT me dica l imaging system. Manufacturing Industry For industrial inspection, there are many applications today that use brute force to check for defects over large surface areas. An alternative is to adopt vision systems. An example of a vision system is available from Basler. It is used to inspect sheets of glass for flaws. The system first corrects for lighting variations across the glass, then thresholds the image to extract any particles on the sheets. After that, it analyses the particles to determine the type and severity of the defects. In order to keep up with production, the system uses nine linescan cameras to feed images to nine individual computers. Trying to program, synchronise and coordinate one inspection over nine computers is a challenge that could simply be avoided by connecting all nine cameras to nine FPGA-enabled plug-in boards inside one computer or PXI chassis.

Research & Development In the R&D field, flexible, upgradable and easily maintainable vision systems are highly sought after by many research groups. Department of Physics from National University of Singapore has developed a data acquisition and imaging system for nuclear microscopy based on NI FPGA technology. This system supports several imaging methods to simultaneously acquire image signals and perform pulse height analysis from a variety of ion beam detectors (Figure 4). Conclusion Deploying F PG A technolog y for machine vision systems has numerous advantages. It enables high-speed image processing and its parallel nature allows image processing routines to run simultaneously. Pre-image processing can be done in FPGA to save the CPU resources for other routines and reduce processing time. FPGA can also integrate seamlessly with physical I/Os making it suitable for vision control systems. New or inexperienced FPGA users can also use a graphical programming platform to leverage on the intrinsic advantages of FPG A technolog y to build a complete machine vision system that parallels imaging processing with camera speed and resolve the predicament faced by many industries today. Enquiry No. 3102 Turn to page 80a or log on to www.equipment-news.com to enquire

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TechTalk

Case Study:

Optical 3D Inspection Of

Weld Seam Weld seam inspection systems are used to ensure that the required quality standards for welded seams are met in an automobile factory. By Dipl Ing Markus Maurer, product manager 3D Technology, Vitronic

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n automatic camera-based weld seam inspection can provide advantages to companies that use automated welding. In contrast to a manual, subjective visual inspection by trained employees, an automatic, optical inspection system always works objectively based on individual criteria. Over at the BMW Group’s plant in Dingolfing, Germany, where the 5 Series saloon are produced, welded seams are inspected in the same production cell immediately after MAG (Metal Active Gas) welding is completed. This is necessary in order to inspect key seams which could be hidden during subsequent production processes and as a result, would no longer be accessible for inspection. A handling robot is used to inspect the component; this saves on robotics and the need for a separate cell. The system inspects MAG weld seams on the rear part of the steel body in two different stations. All relevant parameters such as the inspection process, warning limits and inspection 36

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criteria are defined according to the customer’s production requirements at the very start of production. • Inspection At Station 1 The main chassis beam on the rear part consists of 12 welded seams, each 20 to 30 mm long, with six on the right and six on the left. Inspection takes place according to the BMW Group’s specifications for welded seam length, seam surface, seam position, throat thickness, holes, undercuts and pores. To achieve this, a robot moves the main chassis beam along a stationary sensor so that all welded seams can be inspected. The inspection takes 34 s. Feature of inspection station 1: Virowsi, a weld seam inspection system, inspects two parallel MAG welded seams which are positioned very close to one another. This represents quite a challenge for the welded seam inspection software, because there is generally weld-free sheet metal to the left and right of the

seam and the system must locate the edges of the welded seam (seam expansion) easily. Software processes make it possible for even welded seams which are close together to be inspected clearly and reliably. • Inspection At Station 2 At a second station, the weld seam inspection system inspects eight welded seams along with the main chassis beam, (each with a welded seam length of 30 mm) the seam surface, seam position, throat thickness, holes, undercuts and pores. The inspection here takes 16 s. Inspection Results & FollowUp Actions The computer unit processes the weld seam images using evaluation software and depicts the inspection results visually on a customer terminal outside the production cell. Information on the size and position of the defects is recorded and can be used later for tracing a nd pro ce s s opt i m i s at io n . Defining indiv idual warning limit s, for e x a mple, a llows drifting production processes and fluctuations in the product quality to be corrected quickly. All data generated is entered into a database and forms the basis for interactive statistics. Defect hot spots can be localised within the process using a defect frequency chart. This forms the basis for the systematic optimisation of product quality. After inspection, the robot control receives a signal telling it whether the inspection part is to remain in the production process or if it is to be redirected to a separate production cell for reworking. There, a trained employee determines whether and how an inspection part is to be reworked. Enquiry No. 3103 Turn to page 80a or log on to www.equipment-news.com to enquire

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COMPLEX SHAPES

are our specialty ShapeGrabber SG Central Software lets users easily configure scan settings, speed and resolution for ShapeGrabber 3D laser scanners. Quality control operators who use a ShapeGrabber automated 3D scanner perform an inspection simply by placing the part on the scanner turntable and clicking “Run”. The ShapeGrabber scanner automatically scans and rotates the part according to the scan specifications (for example, the density of the scan and the amount of rotation required). The scan can be conducted using default specifications or can be easily customized by the using a user-friendly interface. This generates a “point cloud”—an exact representation of the entire surface area of the scanned part. This point cloud data file is easily imported into the inspection software included with the ShapeGrabber system (Geomagic® Qualify). This data can be quickly compared to a reference file, such as a CAD model or the scan of a known good part, or measurements can be extracted directly from the scan data. An inspection report is then automatically generated—with visual and numerical data—and can be saved or printed. The report quantifies the deviation of the part’s actual shape from the specifications, using GD&T analysis, error maps, tabular measurement, cross-sectional analysis, and more. Optical Gaging (S) Pte Ltd (OGS) offers OGP / QVI non-contact and multisensor metrology systems like OGP SmartScope, QVI SNAP & contour projectors. Over the years, OGS has expanded its metrology solutions with new products such as SHAKE SHR 3D CT (X-Ray) Scanner for non-destructive inspection & measurement and Vici Vision Optical Measuring system for shaft & cylindrical parts inspection.

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Software & Measurement

Going ‘Soft’ On

Machining Reducing cycle time and improving surface finishing is now a software program’s job. By Maggie Smith, media relations manager, Hurco Companies

C

NC motion pla nning includes the ability to smooth the path within machine tolerances, and optimise velocity and acceleration based on the physical limits of the axes. Therefore, to improve cycle times and the quality of a part’s surface finish, a motion system must possess three components: smooth tool paths; good control of velocity, acceleration, and jerk; and a robust control loop to handle real-time disturbances and changing loads. In this field, Hurco has claimed to have developed a software prog ra m t hat of fers a new approach to motion planning. The software system determines the optimal trajectory and feed

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rate to run the tool, which results in reducing cycle time. According to the company, the UltiMotion motion control system can simultaneously reduce cycle time by up to 30 percent or more and improve surface finish quality.

In addition, the motion control system can produce cornering velocity that is 2.5 times faster than conventional motion, 50 percent less machine jerk, and a patented dynamic variable lookahead mechanism that does not require a fixed number of blocks. Instead, the control evaluates the geometry and motion profile and adjusts the look-ahead information to make optimised maneuvers. This look-ahead mechanism is another reason why better surface finish quality can be obtained in a shorter period of time. The entire system took six years to develop and consists of multiple components, including motion planning with double-arc data smoothing, dynamic model compensation with feedback control, and machine geometry compensation. Variable-Length Dynamic Look-Ahead Part of UltiMotion’s optimisation is the Variable-Length Dynamic Look-Ahead system, which looks ahead to plan deceleration and acceleration along an optimised trajectory based on measured characteristics of the machine (dynamics of the a xes). The mot ion cont rol te ch nolog y generates optimal trajectories to achieve the best performance out of the CNC mill. The dynamic look-ahead system does not require a fixed number of blocks like its conventional

Figure 1

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Software&Measurement

To improve cycle times and the quality of a part’s surface finish, a motion system must possess three components: smooth tool paths; good control of velocity, acceleration, and jerk; and a robust control loop to handle real-time disturbances and changing loads. counterpart. Instead, the motion control system changes how far ahead it looks depending on the feed rate and lengths of the blocks (complexity of the part), up to 10,000 blocks. This is the main reason why the decrease in cycle time is dependent upon the complexity of the part and the number of repetitive tasks, such as drilling and tapping. The more complex the part is or the more repetitive tasks required, a greater reduction in cycle time will be achieved. Double-Arc Data Smoothing Another feature that enables the motion control to improve surface finish is double -arc data smoothing. Ta ngentia l arcs replace lines, resulting in smoother motion, and the system uses gradual arc curvature to reduce vibration, which also increases the quality of the surface finish. Ultimately, the motion control software is able to adjust data points within tolerance to compensate for NC round off errors. This technology also expands the performance range of an existing feature patented by the company called SelectSurface Finish Quality (SFQ). With SFQ, users choose either a higher throughput or better surface finish for their application via a simple one-parameter control mechanism. The Hurco control automatically adjusts all of the www.equipment-news.com

internal parameters to achieve the desired result. The UltiMotion system extends the performance range for SFQ to achieve even better surface finish quality for the finish pass and saves more time in the roughing or semi-roughing passes. The Control Loop The control loop component of the software includes feed forward

and feedback. Feed forward is the predicted output gains to the axes’ servo drives to follow the tool path, and is the primary output of the control system. Feedback is made possible by the axes’ encoders that measure actual position and velocity. The feedback control makes small adjustments to servo gains to compensate for real-world conditions. (Figure 1) Rapid Cornering For programs with numerous consecutive rapid moves, the motion control system does not stop between two rapids. Instead, it t ravel s t h rou g h ble nde d corners at very high speeds with only a negligible deviation. This saves a significant amount of time for repeated tasks, such as drilling and tapping. Enquiry No. 3201 Turn to page 80a or log on to www.equipment-news.com to enquire

Figure 2

Case Studies: 3D Solutions Shawn Yates at 3D Solutions in Connecticut, US, realised a 30 percent reduction in cycle time on a job for turbine blades that are approximately 18 inches long by 4 inches wide. The blades are cut from aluminium and took 2 hours and 20 minutes with conventional motion. With no adjustments to the program, the job took 1 hour and 40 minutes when UltiMotion was enabled. Along with the reduction in cycle time, Mr Yates reported a 40 percent increase in throughput, which means he is cutting 1.4 parts for every one he was making before he activated the system, and he also said the surface finish is better (Figure 2).

Enquiry No. 3202 Turn to page 80a or log on to www.equipment-news.com to enquire

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Software&Measurement

M-Tech Lab

The majority of the orthotics M-Tech manufactures are custom designed to a person’s foot UltiMotion endured intensive beta tests before the feature was introduced to customers. M-Tech Lab in Indianapolis, US was one such beta site. President and M-Tech founder Tom Miller said he seeks speed versus accuracy for the type of machining his company does. “We are builders of custom orthotics and we focus on throughput and speed. With the software, we’re seeing 30 to 35 percent faster throughput,” said Mr Miller. The majority of the orthotics the

M-Tech Lab company manufactures are custom designed to a person’s foot, but all of them are elliptical in shape and have contours throughout. UltiMotion handles such complex geometry because the spindle can cut fast in a smooth elliptical motion. The secret to the software program is the advanced trajectory algorithm that generates significantly faster yet smoother motion than conventional motions systems that rely on hardware. Controlling motion with software versus

Another noticeable benefit M-Tech has experienced is the lack of machine jerk hardware is theoretically a simple idea, but development of the software was a complex and comprehensive project. Another noticeable benefit M-Tech has experienced is the lack of machine jerk. “With UltiMotion, our machine runs very fast and we don’t get any jerks,” observed Mr Miller. In the long run, smooth motion reduces stress on the ball screw and minimises the wear and tear on the machining centre’s components.

Enquiry No. 3203 Turn to page 80a or log on to www.equipment-news.com to enquire

Wepco Plastics Established in 1985, Wepco Plastics specialises in short-run prototype injection moulds in aluminium and steel. In the fall of 2008, Wally and David Parmelee (Wepco owners) found themselves at a cross road in terms of milling capacity for their tool room. Should they continue with their current milling technology or invest in the future by purchasing a higher performance machine? They knew this decision would impact their tooling and in-house moulding business for many years. New technology can promote growth, but it can also be a risk since there is always a learning curve. T h e d e c i s i o n to m ove fo r wa r d and invest in new technology proved advantageous for the company. The dualwound 12,000 rpm spindle of the Hurco VMX30, coupled with a motion control system called UltiMotion, reduced total part cycle time by as much as 200 to 300 percent in some cases with no loss of accuracy or finish.

Wepco Plastics According to Mr Parmelee, he thinks the productivity will get better, “We have really started to focus on pushing the machines to see what they can really do. With the software, along with tweaking our post to make segmented or linear moves, we are achieving high feed rates up to 800 ipm. As an example, we had a cut that would have been at least 100 hours long on our old machines that we did in 30 hours, and I believe that we could even cut that in half. We finish cut the cores with a .0469

Wepco primarily focuses on aluminium moulds for prototype and short-run batches end mill and ground back .500 at 100 ipm. We could have easily doubled the speed and achieved the same results, and I don’t have to polish the mould.” These productivity gains yield increased profit margins for existing jobs and additional capacity due to increased throughput. For example, a 30 percent productivity gain turns a 40 hour work week into at 52 hour week in terms of throughput, with zero overtime for labour and zero increase in debt service on the equipment.

Enquiry No. 3204 Turn to page 80a or log on to www.equipment-news.com to enquire

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Software&Measurement

Precision Under Heat CNC machining is favoured for its ability to automate large batch processing while maintaining the precision of parts. Yet, it faces the challenge of thermal errors, whose effects could compromise machining accuracy. By Sherlyne Yong

C

ompute r Nu me r ic a l C o n t r o l (C N C ) h a s become ubiquitous in machining ever since computing technology took flight. A program that uses a series of code and symbols to send instructions to the machines has progressed to become an essential component of modern manufacturing systems, and is especially vital for automated processes. The rise of CNC systems in machining is not without just cause. It provides a bevy of benefits that include greater convenience and efficiency, as well as a reduced reliance on labour. This would inevitably result in cost savings for operators. Nonetheless, its main advantage can be said to be the autonomy it accords to the machining process. It allows for batch processing, where as much as 1,000 parts can be machined continuously. Compared to traditional systems that are heavily reliant on the expertise and skills of operators, CNC machines have greatly reduced the amount of resources consumed in each machining job.

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However, no system is without its challenges. In the case of CNC systems, this comes in the form of errors that stem from geometrical inaccuracies or thermal effects. In this instance, the autonomy of such systems serves as a doubleedged sword, as the lack of human supervision has also made it easier to miss such errors when it happens. Meanwhile, there is a growing need for high precision machining, which is fast becoming a priority as manufacturing moves towards the production of complex and sophisticated parts. It is therefore important that manufacturers are able to meet close tolerances and keep product quality consistent. Accounting for errors through design or compensation will bring them closer to this goal. Types Of Errors Errors in CNC machining are either dynamic or quasi-static. The former describes errors that are dependent on the operating conditions of each machine, and could be caused by structural

vibration, spindle error motion and controller errors. Quasi-static errors on the other hand, refer to errors which may appear in the machine, fixturing, tooling and workpiece at a more gradual pace. This includes geometric, kinematic and thermal errors, in addition to those induced by cutting forces. Faults in individual machine comp one nt s a re k now n a s geometric errors, while kinematic errors are caused by misaligned components. Thermal errors occur when heat sources in the machine to o l c a u s e t h e r m o - e l a s t i c deformations at various contact points. Together, geometric and thermal errors make up the bulk of machining inaccuracy problems. This stands particularly true for thermal errors, which cannot be eradicated completely as the generation of heat during machining is unavoidable. Temperature changes may lead to thermal expansion or the thermal bending of machine elements, which are mainly a result of temperature variances in spindles, ball screws, as well as coolants, which can cause machine structure distortion. Other thermal error sources include heat that is generated f ro m t he c u t t i n g pro ce s s, machine energy loss, the job shop’s environment, people, as well as thermal memory from the previous environment. Meanwhile, positioning accuracy is particularly affected by temperature variances in ball screws. A Heated Issue The prevalence of thermal errors is partly due to the sheer number of triggers, but is further exacerbated with the introduction of complicated machine tools. For instance, it is much harder to quantify and predict thermal deformations in five-axis machines as opposed to its three-axis counterparts. www.equipment-news.com


Software&Measurement In addition, temperature is highly variable and changes according to the working cycle, environment, and even along different parts of the machine tool. This effectively makes it much harder to resolve when compared to other types of errors, which is made more complicated with the inclusion of five-axis machines and their rotary axes. The algorithms used for three axis models cannot be applied as they only consider tool positions, and not tool orientations. The interactions between five axis and three axis machines differ as well. This has made it a challenge to develop efficient calibration methods, and is a roadblock towards the development of robust and accurate prediction models. Nonetheless, thermal formations, and machining errors in general, can be minimised in

two ways — either through error avoidance or error compensation. The former aims to minimise machining inaccuracies by using the design of machines and tools to account for errors during the design and planning stage, or by optimising working conditions to eliminate error sources. However, error avoidance has its limitations; it is virtually impossible to create a machine that effectively prevents all types of errors. It is a complicated process that involves too many parameters. Constantly optimising the infrastructure of a machine or the work environment can also be a costly matter. Doing so, or attempting to do so, might also incur huge costs, especially if the machine has to be constantly updated and recalibrated to be in line with tolerances that are growing increasingly tighter. In contrast to the avoidance

method, which aims to prevent errors from surfacing, error compensation fully recognises the fact that there are errors, before it measures and counteracts it instead. Most times, compensation rather than avoidance is preferred as the changes required in machine design or operating environment may be difficult to achieve. For the same reasons, thermal error compensation is easier to implement and also more cost effective. Compensating For Precision C o mp e n s a t io n i s t y p ic a l l y performed through the use of algorithms, which utilises a holistic rather than individual approach when assessing for errors. Instead of reducing the scale of errors, it focuses on reducing the overall impact that these errors have on precision and the finished part.

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Software&Measurement Error prediction can either be conducted offline or online. In the offline approach, the error is first measured before or after a machining process, and then used to recalibrate the instructions for subsequent processes. T he p erk s of u si n g t h is method are that it is less time consuming and does not require a sophisticated control. However, the machining process has to be highly repeatable in order for the calibration to be accurate. Online compensation on the other hand, does not assume that the process is repeatable. Instead, errors are monitored continuously during machining, and the feedback is utilised simultaneously to alter the process. This allows for inaccuracies to be corrected almost instantly. With the ability to respond in dynamic situations, this method provides greater accuracy and is also suitable for boosting the precision of lower grade machine tools. The main drawback of this method are the convergence speed of neural networks and the approach’s need for copious amounts of sensors and a large database for ‘training’ the networks. Predictive Of Success The foundation of every good compensation model is accurate measurement. Modern CNC systems generally have closed feedback loops, where key information is first collected for error modelling, before it is analysed and then used to predict and circumvent errors.

Modern CNC systems are generally able to react to real time information

Errors in CNC machining are either dynamic or quasi-static

This has set the stage for adaptive controls that are able to react to real time information. Quality of data would determine the efficacy of compensation, for the processing information will be modified based on those inputs and go on to influence the amount of compensation applied. It is therefore pertinent that the measurements attained are accurate and indicative of the machine tools’ thermal statuses. As such, thermal sensors have to be placed at strategic locations where dominant thermal modes can be captured. This is an instance where quality trumps quantity. Using more sensors than necessary is not only costly, but it also creates noise in error modelling. In fact, it has been suggested that sensor placements play a much bigger role. According to researchers at the University of Michigan, sensor locations play a vital role in determining the robustness of a thermal error model, thereby affecting its applicability under different working conditions. Due to the variability and

unpredictability of thermal effects, computational techniques are used to highlight relationships and trends within the collected data. These computational systems include back propagation networks, a r t i f icia l neu ra l ne t work s, regression analysis, and system identification. Correlation can also be calculated using finite element analysis, which is recommended for prediction without conducting experiments. However, error estimation using these systems may be time consuming due to the large amounts of data involved. In response to this, researchers and engineers are on the lookout for methods that helps to trim down computing time. Some have managed to shorten the time taken by grouping sensors together, or by utilising small neural networks. In another case, machining accuracy was achieved even though limited data was used for thermal error compensation. With precision and tolerance requirements looking set to become only more stringent in future years, it is vital that machine tools are able to withstand and compensate for errors that affect accuracy. While much has been done to negate the effects of thermal errors, there is no online or offline system that can deliver all benefits in one package. Instead, the search for a balance between efficacy, timeliness and costs continues. Enquiry No. 3205 Turn to page 80a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 097


FORM Join Cut 

Energy Reduction In Bending

PPEC series hydraulic press brake with frequency convertor

Reducing energy consumption during ‘idle’ time and studying actual power consumption figures can lead to energy-efficient bending. By Matthew Fowles, group marketing manager of LVD

E

co - f r ie nd l y m ac h i ne tools are increasingly the more favoured choices as energy costs escalate worldwide. In addition, users are looking to protect their profit margins and move toward reducing their environmental footprint and becoming more socially responsible in their manufacturing practices. This trend is also seen in sheet metal fabrication, where progress ha s been made in improving the energy efficiency of the bending process and of press brake machinery. In the past few years, the technology of servo electrically driven press brakes has come to the forefront with several new product introductions designed for bending small parts on a compact machine. 46

asia pacific metalworking equipment news April 2013

Also in the spotlight of late are servo electric press brakes in larger formats. These machines are being promoted as consuming less power and as a ‘greener’, more environmentally friendly method of producing bent parts. The ‘Idling’ Issue While electric ram designs are gaining popularity, it is important to note that modern day hydraulic press brakes are not as ‘power hungr y’ as some users may believe. In fact, hydraulic press brakes can rate comparably to electric ram machines when it comes to energy consumption. When considering the overall equation of energy cost, the link to direct part cost and environmental impact, it is important to take into account the reality of most

bending shops. The fact is, the majority of press brakes in any given workshop stand at ‘idle’ 75 percent of the available time; some even more than that. While the causes of this inefficiency are varied, the need to consider technology that can reduce a machine’s energy consumption when at idle is key. Statistically, hydraulically driven press brakes comprise 95 percent of the world market of press brakes because they provide the most flexibility, repeatability and durability in a cost-effective design. So what can be done to improve energy consumption of hydraulic press brakes? Most importantly, if the machine is at idle and the motor remains on then the machine will continue to consume power. Most modern machines have a motor shut off that automatically turns the motor off after a period of time. However, the motor requires a period of time to start up again, which can disrupt production. Ma ny ma nufacturers of hydraulic press brakes are now incorporating several different technolog ie s to reduce the power consumption of hydraulic press brakes, particularly when the machine is at ‘idle’. These technologies include: 1. Frequency convertors for the motor pump 2. Variable flow pumps • Frequency convertors Frequency convertor units are used to ‘slow’ the motor revolution to zero when the machine is at ‘idle’. They also intelligently control the motor’s revolutions in synchronisation to the machine’s different operating modes, which include approach, bending, decompression and idle. S i m i l a r to ‘s to p - s t a r t ’ technology in the automotive www.equipment-news.com


ENQUIRY NO 102


Form Join Cut 

Variable flow pumps enable the machine’s controller to regulate the flow of the oil in the hydraulic system

Frequency convertors allow the machine to be ready for bending as soon as the operator presses the bending pedal

industr y, using frequency convertors means the machine is ready for bending as soon as the operator presses the bending pedal. The advantage of this system is two-fold: energy reduction is dramatic — up to 45 percent energy reduction compared to convention models — and the machine is ‘ready-to-go’ at the touch of the pedal. • Variable flow pumps Variable flow pumps enable the machine’s controller to regulate the flow of the oil in the hydraulic system. By lowering the flow of oil to a minimum when the machine is at idle, the energy consumption of the motor is dramatically reduced with power savings of up to 45 percent, depending upon working modes. Electric Servo Driven Press Brakes Selecting the right machine for the application is also a significant consideration when it comes to controlling and optimising direct part cost. For example, the application 48

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The energy consumption chart shows the difference in energy consumption between a PPEC series hydraulic press brake (main picture of the article) and a conventional machine.

of bending small piece part components — an application that can benefit from the use of an electrical servo driven ram press brake. Often, users employ larger/more costly machines than are required for the bending of such parts. A machine that has a lower price tag, a small footprint, is transportable with a fork lift and offers fast bending speeds and low power consumption is the ideal solution for this application. T he te ch nolog y of t he electrical ser vo driven ram makes the practicality of creating such a machine feasible. It is important to remember that it is not purely the fact that the ram drive is electrically driven and consumes less power that makes this technology a good solution for small part bending. It is that the technology allows a more compact machine to be built with a fast ram drive characteristic. I n a c t u a l i t y, t h e p owe r consumption figures for a smaller size modern hydraulic press brake (ie: 35 ton – 1.5 m) using frequency convertors or a variable flow pump are quite comparable to an electrical servo driven ram system. However, beyond the size

of machine, the motor size required for an electrical servo ram machine to deliver the required bending speeds becomes impractical considering the inertia/motor load ratio. The point is, electric servo driven ram systems should be used for what they are best at, and not simply employed because they are perceived to be ‘green’ and ‘eco’ friendly. Actual power consumption figures tell the story. Conclusion When it comes to selecting your next press brake, do not be swayed by the ‘green’/’eco’ hype; consider the facts. Most press brakes sold in the world are hydraulic because they offer the best mix of flexibility, durability and competitive pricing. Consider electrical servo driven machines for the bending of small parts. But when it comes to the most flexibility, productivity and cost effective bending of medium to large parts, hydraulic press brakes equipped with the latest frequency conversion or variable flow pump technology remain the best price-performance solution. Enquiry No. 3301 Turn to page 80a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 072


Form Join Cut 

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Pressing On Asia Pacific Metalworking Equipment News (APMEN) caught up with technical experts in the metal forming world to talk about the present and the future of metal forming. By Joson Ng

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aterial removal is the basis of metal cutting. Material addition on the other hand, is the chief mechanism behind the slightly newer concept coined as AM or additive manufacturing. Lying conveniently between the two would be metal forming where there is no net gain or loss to a work piece’s mass. In the world of metal forming, plastic deformation is the key or main enabler. Although the term ‘permanently deformed’ often has an ominous ring to it, particularly to someone involved in manufacturing or QC, plastic deformation in this case has helped produced many useful parts. www.equipment-news.com


Form Join Cut 

Developments In Press Machines In the recently concluded TIMTOS show, Seyi demonstrated how low energy consumption is possible in press machines. For example, the numerically controlled die cushion featured in the SD1-300 is said to enable low energy consumption but higher production. According to the manufacturer, ser vo motors double up a s generators during die cushion compression to recapture energy that is normally wasted, making the machine more energy efficient. Kuei- Chang Hsu, assistant manager of the R&D department of Seyi added that apart from being energy efficient, presses integrated with servo technology can also improve productivity. He claimed that in the case of SD1160, it can achieve an increase of productivity by up to 100 percent. Looking forward, Mr Hsu felt that the softer aspect of pressing www.equipment-news.com

would eventually come to the fore. He said: “A user-friendly interface is important as workers c a n not op e rate a comple x interface. In addition, powerful programmability is important.” Elsewhere, Chin Fong, also a Taiwanese press manufacturer, is a keen adopter of ser vo technology. According to them, the advantages of servo press

19 A Hillview Avenue #01-06 Hillview Park SINGAPORE 669554

are better production efficiency as it is possible to select and adopt optimal slide motion curve according to various production requirements. In addition, product stability and precision is improved along with an extension of die life due to low noise and low vibration. Finally, an intelligent feature can be found on their presses.

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Like their counterparts in the metal cutting or material addition world, metal forming has evolved over the years in order to keep up with a n ever dema nding manufacturing world. According to Steve Lin, the chairman of the metal forming machinery committee of Taiwan Association of Machinery Industry (TAMI), he sees all electric technology as a key technological trend in metal forming. He said: “All-electric systems are now widely used in various processing equipment, including presses and forming machines.” L o o k i n g a t t h e r a te o f development and integration of servo motors and controllers i n f o r m i n g te c h n o l o g y i n recent times, this statement only serves to emphasise how servomechanism, along with combination philosophy (eg: punch/laser 2-in-1 machine) have come to dominate developments in metal forming in recent years.

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Dr Berner sees a low volume high mix trend giving rise to the need for modular tools in metal forming

Kuei-Chang Hsu

Their machines are capable of automatically correcting Bottom Dead Centre (BDC) position, retaining BDC repeatability within +/- 0.01 mm. It is important as BDC position can be affected by temperature. Combining Processes Moving from Taiwanese machine builders to a Singapore research institute, A PMEN caught up with Dr Sebastian Berner, a scientist working on forming technology at Singapore Institute of Manufacturing Technology (SIMTech) to find out more on the field of metal forming. Much like the machine builders, Dr Berner’s project also involves combining two metal forming processes, in this case stamping and forming. “We have one project related to combined stamping and forging. We combine stamping, forging and forming processes to take advantage of various processes in order to manufacture more complex product shapes,” he said. This process is said to tap into the advantages of both stamping (low forming load and good tool life) and forging process (good dimensional accuracy and variable wall thicknesses). Applicable to gears, electronic components and biomedical instruments, this technology can potentially improve productivity and reduce material 52

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waste (near net shape forming). This project, along with several others has helped some of the SMEs of Singapore, according to Dr Berner, as his team is able to help setup the production sequence for new products in their client’s facility. In some cases, they have allowed their clients to manufacture parts in-house that were previously bought from abroad. “It’s a cost issue. We made the tool development and process of the whole forming sequence taking into account what machines they have in their machine shop. For one specific product, we achieved 30 percent reduction in cost,” said Dr Berner, summing up his work with Singapore SMEs. Improvements In Metal Forming Away f rom his re se a rch projects, APMEN understands from Dr Berner that in-process measurement in metal forming p ro ce s s e s l i ke b e n d i n g i s something that can benefit the sheet metalworking industry. Giving an example, he said: “In press brakes, checking of bending angles can be done with optical measurement systems.” He also touched on the importance of servo technology citing its advantages. “Servo technology allows the maximum capacity to increase. Its (servo technology) advantages are its different stroke and load curves

Other Notable Forming Research At SIMTech Advanced Spin Forming Technology Spin forming is a metal forming process, which involves one or two rollers moving in the axial or radial direction and simultaneously deforming the peripheral of the axisymmetrical workpiece to the desired shape. Because of its deformation characteristics, spin forming can be used to form ‘hard to form’ or low ductility materials. With the technology, it is possible to manufacture peripheral intricate features such as flange, boss and wheel rim profiles.

that can be applied and used for demands that have a shearing process, which has a different demand on the stroke load curve compared to a drawing process,” he said. Future Trends In the Singapore manufacturing context, Dr Berner sees a low volume high mix trend, giving rise to the need for modular tools. He said: “The tools need to be very flexible due to the number of different components to be manufactured. You have quite often part family, eg: different product line with little difference in cross section shape. One of the focus is to develop tools that are applicable for all this components just by varying the tool setting.” In conclusion, Dr Berner highlighted another trend which could potentially be adopted by machine builders. “Another future trend might be to combine additional process sequences like welding in forming machines. There are some researches going on in Germany where efforts are being made to combine joining technology with stamping technology,” he said. Enquiry No. 3302 Turn to page 80a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 209


Form Join Cut 

The

Pressing Issue Of CFRPs

Manufacturing CFRP parts by forming is now a more desirable process. By Simon Scherrenbacher, Corporate Communications, Schuler

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arbon Fibre-Reinforced Plastics (CFRPs or simply carbon) have been used for the manufacturing of cars for several years now. As the ultra-light and extremely rigid material is much more expensive than steel or aluminium, it is rarely used in mass manufacturing processes. This will potentially change, especially when Schuler, a metalforming solutions provider, now claims that it is offering lines which can economically produce CFRP parts in large volumes. According to the company, the manufacturing of carbon parts is carried out by the RTM (Resin Transfer Moulding) process in which woven carbon fibre mats are placed in a die, filled with resin and hardened by applying heat and pressure. This apparently results in shorter cycle times and improves consistency. “High-pressure RTM presses not only enable shorter cycle times for complex parts with high requirements regarding geometry and rigidity, but also deliver consistently high part and surface quality,” says product manager Raimund Zirn. This virtually eliminates so-called voids, ie: resinfree vacuum pores or gaps within the part or along its edges. In the high-pressure RTM process, resin is injected as quickly and smoothly as possible into the vacuum mould, which opening is just a few tenths of a millimetre. This gap injection process enables the

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resin to spread over the mat with far less flow resistance and therefore with low injection pressure. It then quickly infiltrates the mat before polymerisation is started by heat induction. The Curing Process “The vacuumising, fast resin injection, high resin pressures and tempered dies mean that the gelling process virtually begins with the wetting of the last fibre,” explains Mr Zirn. Curing takes four to eight minutes — the thicker the part, the longer, as the reaction heat cannot be led as easily into the die. Depending on the part, the necessary resin pressures also vary between 30 and 150 bar. Large-surface exterior panels with clamping areas of 3,600 x 2,400 mm require total press forces of 36,000 kN or more. Due to the geometry of the part or cavity surface, the die’s centre of loading is not necessarily in the middle of the press. There are also off-centre forces from the injection positions. “The pa ra llelism control prevents the slide or upper die from tilting during gap injection and therefore ensures smooth and even injection over the entire surface,” he explains. With a positioning speed of 1 mm/s, the presses achieve parallelism values of 0.05 mm in absolute terms with diagonal clamping surfaces of 4 m. The preform and part handling

processes, as well as the necessary die clea ning, account for a considerable part of the RTM cycle lasting two to three minutes. “This largely involves the removal of plastic residues, which mainly stick to the polymer seal located in the lower die,” adds Mr Zirn. On request, however, the manufacturer can fit the RTM presses with two shuttle moving bolsters so that a common upper die can be operated with two alternating and movable lower dies. This reduces downtime to the period it takes to replace the lower dies. Upstroke ShortStroke Presses RTM presses are available in two designs: conventional downstroke machines work with a fixed bed and moving bolster, and a slide whose press force is transmitted via cylinders in the press crown. Parallelism is ensured by four servo-controlled counter pressure cylinders located at the bed corners. These are also responsible for the breakout force needed to counter the adhesive forces and open the die. In the upstroke short-stroke press, the slide only acts as support during the pressing process. From top dead centre, the slide is moved by a drive cylinder to its support position and locked there. The actual working stroke is performed by the bed plate, driven by several short-stroke cylinders. Parallelism is ensured by the servo controlling of these cylinders. The breakout force in upstroke presses is achieved by the withdrawal of the bed plate. “The benefits of the upstroke short-stroke press compared to downstroke designs are the high closing speeds of 1,000 mm/s, the shorter pressure build-up times of under 0.3 s and the significantly lower construction height,” says Mr Zirn. Enquiry No. 3303 Turn to page 80a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 096


Industry Focus Trumpf

The Future Lies In

Tubing Many success stories have shown that cutting tubes with lasers offer wider perspectives, both for steel dealers and for job shops that until now have been involved in 2D laser cutting. By Evelyn Konrad, Trumpf

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ubes are the order of the day. Normally supplied in six-metre lengths, tubing is available in a variety of material qualities, thicknesses and sizes. They are usually round, but square, rectangular and oval cross-sections are often seen. Tubes and profiles are used everywhere, from gym equipment to furniture and on to agricultural machinery. They are also used for simpler structures as well.

Demand is currently outstripping available capacity. There were only a few suppliers using lasers for tube cutting in the past. For those early adopters of laser technology in tube cutting, they have been rewarded by great success. Cost-Effective & Flexible Laser tube cutting is a market with a great and diverse future. Sources say that actively marketing the

new design options available can significantly step up demand for laser-cut tubes and profiles. Many newcomers to laser processing for tubes expand to two-shift operations within a short time. They often invest in a second laser tube cutting machine in just a couple of years to fill a largely unoccupied market niche while cashing in on attractive profit margins. After all, tube cutting opens up new tube design options that are not practical or simply too expensive with conventional processes. In addition, this technology simplifies production work further down the line. Simpler welding equipment and jigs can be used, while costs for the welding operation itself are reduced. Positioning aids with tabs and slots simplify subsequent mounting while encoding prevents assembly errors. The high quality of the cut edges virtually does away with rework and reduces both the number of process steps and timeconsuming tool changes when compared with other technologies. Users can cut expenditures for downstream work such as deburring and assembly. The number of intermediate steps — storage and handling are two examples — can also be kept to a minimum. This saves an enormous amount of time and greatly

In our example, laser tube cutting saves 49 percent in terms of time and 31 percent in part costs. Conventional welding using two separate parts (A). Laser-ready design with folded connections and additional positioning aids (B). Trumpf

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IndustryFocus reduces parts costs in comparison to conventional processes like sawing, drilling and milling.

the geometry of the tubes to be processed with data already in storage. This is how the software prevents disruptions caused by operating errors. T he u n it’s g r ipp ers automat ica lly adapt to t he measured length of the tube. The operator can, of course, still feed individual tubes manually or semi-automatically with a pivoting conveyor. Appearing with the TruLaser Tube 7000 is a swivel-mounted laser cutting head. This permits accurate chamfering, which is a prerequisite for obtaining a close fit between surfaces to be welded. Diagonal cutting at angles of up to 45 degrees opens up more manufacturing options — not only in mild steel but also in stainless steel and aluminium applications. Enquiry No. 3401 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 099

Keeping Unproductive Time To Minimum Laser tube cutting machine with automatic machine adjustment are said to have the ability to minimise unproductive time. Cutting tubes and profiles of up to 250 mm in diameter, with walls up to eight millimeters thick, the TruLaser Tube 7000 is one example. In addition, it has stepped rollers that provide both support and lateral guidance for the tubes to automatically adjust to the diameter of the workpiece. The self-centring clamping jaws also adapt automatically to the tube’s geometry. A FocusLine regulation mechanism keeps the laser’s focal position constant, adjusting it automatically to

suit the type of material being processed and its thickness. The machine’s software activates the laser parameters as necessary, depending on which tube is being processed. All these features combine to turn out parts at consistently high quality. According to the manufacturer, they have also added an unloading station to the machine. Depending on the requirements involved, it can sort finished components and place them on movable conveyor tables, in pallet cages, or in other containers. The LoadMaster Tube unit automates production. Its tube storage magazine will hold up to four tons of raw materials, which the unit feeds into the machine for processing after carrying out a plausibility test. When doing this, the machine’s software compares

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IndustryFocus

Technical Seminar:

Automate To Fabricate

When considering automation solutions for sheet metalworking, looking at the big picture helps in better decision making. By Joson Ng

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anufacturing in Singapore and other Southea st Asian countries is at the crossroads. Singapore in particular is facing the perennial problem of high cost, coupled with mounting social pressures to curb the reliance on foreign workforce. Many larger companies have decided to relocate and enjoy the lower operating cost offered by many developing countries. The rest who are still here have a decision to make. Relocating could arguably help reduce operating cost, but whether it is feasible to move again once the cost goes up in their adopted nation is another issue to ponder. For those who decided to stay or for some reasons are unable to relocate, embracing automation 58

asia pacific metalworking equipment news April 2013

and pursuing higher productivity are their only other viable options. Automation In Sheet Metalworking Trumpf Asia Pacific recently organised an Automation and Productivity Seminar in Singapore to help educate participants on the advantages of automating their operations as well as to highlight the importance of time studies and calculating part cost. Two speakers flew in from Germany to explain how automation can be beneficial in the sheet metalworking context. “Our target is to make our customers more competitive,” sa id Ma rc Sauer, who is in charge of Trumpf’s sales and advising consultant of sheet metal handling systems. With

that in mind, he went on to share with the participants the automation solutions on offer. The automation technologies can be applied in three areas; they are punching/combination machines, laser machines and bending machines. In the three areas, they serve functions like: automatic loading and unloading; automatic sorting of large and small parts; and storage connection. The SheetMaster, arguably the company’s flagship automation solution, is an automatic loading and unloading equipment that ensures raw material supply to the machine is seamless and finished parts are unloaded carefully onto the pedestal. According to the manufacturer, it can help produce medium to large batches in a costeffective manner and it is also easy to upgrade and expand the automation system. Why Automate? High cost and difficulties in implementation are often the perceived notion of automation to the uninitiated. Michael Sellner, also from Trumpf’s sheet metal handling systems, spent about an hour explaining why automation can be a feasible solution against escalating labour and operating costs in Singapore. In his presentation, he quoted common problems customers faced prior to insta lling a n automation system. They are low percent machine running time (actual machining time), high number of operators and high traffic on the shop floor. A f ter implement ing a n automation system, loading and unloading are improved, leading to higher productivity. Some operators are also freed to concentrate on other tasks and automation also results in space saved and better material flow. Enquiry No. 3402 Turn to page 80a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 014


Features

TAMI

Optimistic About 2013

Alan Lu

By their own admission, 2012 was not a very good year for Taiwan’s machine tool industry. The year 2013 however, is a very different story. By Joson Ng

F

or Taiwanese machine tool industry on a whole, 2012 was a slow year. Looking back, many were talking about uncertainties in Europe and the US being the major reasons for the downturn. In Asia, there was also a lull in China’s GDP growth which was also a major factor considering the country, along with Hong Kong, is responsible for some 33.8 percent of Taiwan’s machine tool export. Fast forward to the present, the mood in Taiwan or TIMTOS (a machine tool show in Taipei) in particular, is far more bullish. Hsiu-Tsang Hsu, chairman of TAMI said at the opening ceremony of TIMTOS that with a strong export business, he predicts a good year for Taiwan’s machinery industry. He said: “We are still optimistic when we look at this year (2013). With PMI level for global procurement managers all above 50, the Taiwanese machine tool industry should have room for growth of 5 to 10 percent in 2013.” The air of optimism was echoed by Alan Lu, chairman of the machine tool committee of TAMI. He said at a press conference that although the association is “conservative”,

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they are “positive” about the global market in 2013. “In the European market, we expect to see growth in Germany, the Netherlands, the UK and Turkey. We also expect a five to eight percent increase in Brazil, South Korea, Japan and India, a 10 to 15 percent increase in Russia, Thailand, Indonesia, Singapore and Vietnam,” he added. More R&D To Come At the opening ceremony of the show, president of Taiwan, Ma Ying-Jeou said Taiwan do not have many natural resources and as such, have to depend on innovation and the main way to go about it is by embracing R&D. This point was

Hsiu-Tsang Hsu

brought up again when he talked about the ways for the machine tool industry of Taiwan to improve. Apart from building up SMEs and signing various FTAs to facilitate trade, R&D is another key point. The top management of TAMI is also singing the same tune, affirming the commitment towards innovation. Described as a “long and tough road” by Mr Hsu, he said the “R&D road” taken by Taiwanese builders was made in small but solid steps in pursuit of precision, speed and sophistication. Mr Lu also weighed in on the R&D issue. He said it is important to develop high-end products like multi-tasking machines and fiveaxis machining centres. In order to compete in the global market, they need to present products with their distinctive characteristics and also satisfy the needs of customisation. In addition, he also highlighted the importance of developing solutionbased technologies. Enquiry No. 3501 Turn to page 80a or log on to www.equipment-news.com to enquire

Trend Spotting Here are some notable export figures… Export figures released by TAMI shown that in relation to Southeast Asia, export in 2012 (January to December) rose in Thailand, Indonesia and Singapore by 50.2, 19.0 and 11.4 percent respectively. The increase in Thailand could be due to the rebuilding efforts after the flood which plagued the country in 2011. Malaysia and Vietnam on the other hand registered a -2.3 and -19.9 percent increase respectively in export. Other pertinent figures revealed a major acceptance of Taiwanese products in the US with a 50.6 percent increase (IMTS show possibly a factor). Elsewhere, India experienced an increase of -17.8 percent and China (inclusive of Hong Kong) posted an increase of -3.4 percent.

Enquiry No. 3502 Turn to page 80a or log on to www.equipment-news.com to enquire

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Features

TIMTOS 2013

The Taipei International Machine Tool Show or TIMTOS as it is known in the industry recently held its 24th edition in the Nangang and TWTC exhibition centres in Taipei, Taiwan. With the exhibition space of 100,000 sq m (gross), the 2013 edition is said to be the largest according to the organiser TAMI, the Taiwan Association of Machinery Industry. APMEN takes you on a quick tour of TIMTOS. By Joson Ng

Seeing Double? YCM exhibited a dual spindle machining centre (DV30T) that features two individual tool changers on either side of the machine. The machine is said to save space and improves productivity. It is suitable for the electronic market.

The More The Merrier Victor Taichung’s special offering at TIMTOS is the VTurn Q200, a twin spindle lathe with three turrets. The manufacturer insists that the machine can bring about better efficiency in high volume production. The R&D and modification processes of the nine-axis machine took the company about a year to complete.

Mazak showing what their products are capable of manufacturing.

A Giant ‘Smart Phone’ That Makes The Cut

The folks from FFG showed us the inside of the machine to convince us that it is indeed a machine tool!

With the control interface inspired by smart phones, the MT-310i by Ecoca is a machine tool that resembles a giant smart phone. Operators can also go online with this machine.

www.equipment-news.com

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Features

Grinding Out Results The LGA-2812 continuous generating gear grinding machine comes with an eight-axis close loop servo control system and a direct drive motor to make sure all axes move simultaneously and accurately. Its workpiece spindle can operate up to 600 rpm and the grinding wheel can reach up to 5,000 rpm resulting in gear production efficiency, according to the manufacturer.

Honoured At TIMTOS Chmer left the Taiwan machine tool industry awards as one of the big winners when it bagged the ‘other NC machine tools’ grand champion award and the ‘award of eminence’ for the machining centre category for the Q4025L and HM5042L respectively.

Versatility Is The Way Looking to cement their place as one of the top sheet metal machine tool manufacturer of Taiwan, Tailift has embraced fibre laser and also launched a punch laser combination machine at TIMTOS. The ML2500F is said to be able to fulfill four functions in one machine.

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The Need For Speed Accuracy and speed are the ethos of Akira Seiki according to the company’s chairman, Alan Kludjian. It is therefore hardly surprising when the company exhibited the RMV 500 APC, a drilling and tapping machine that is touted to have the fastest movement in the world. According to the manufacturer, its maximum rapid rate is 96 m/min and the maximum acceleration is 1.6 to 2 G.

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Features

Heavy Metal Shieh Yih Machinery Industry or Seyi brought to TIMTOS the SD1 and SD2 series of straight side direct drive servo press. Touted to provide high torque, rigidity, productivity and formability, the machines have tonnage capacities from 80 to as high as 500 tonf.

Information On The Go The organiser made sure tech savvy visitors were not left out by providing them booth, product and company information while on the move.

Heritage & Evolution With help from certain exhibitors, the organisers were able to show visitors how far the Taiwanese machine tool industry has come.

Standing Out

Enquiry No. 3503 Turn to page 80a or log on to www.equipment-news.com to enquire

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A company that tends to stand out, Keyarrow used their own product (telescopic covers) as building material for their booth. A notable technology on the telescopic cover at the show was the Complex Synchronised Parallel Mechanism or CSPM where it is said to be more durable and less noisy.

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Features

Yih Troun

Enterprise At TIMTOS

A

sia Pacific Metalworking Equipment News spoke with Fei Chen, who is in charge of overseas business development of Yih Troun Enterprise at TIMTOS to talk about the new launches at the show. The word ‘modular’ comes to mind when viewing the products on show. Adopting and expanding the inserts philosophy (whereby a replaceable cutting tip is used a nd cha nged while reusing the tool body) to chamfering and T-slot cutter, Ms Chen told APMEN that their products have done well abroad.

The indexable type design optimises machining efficiency Adopting a changeable cutting tip improves tool life

“Chamfer King is one of our products that has done well in sales in Japan and in Europe. The chamfer tool is traditionally a single piece tool. Now, it has an insert as cutting edge. This results in an increase in tool life,” she said. She revealed the product took about a year to develop and it is available in various cutting range from 4 to 110 mm in diameter. Another pertinent feature is the tool’s ability to balance out vibration during chamfering. This is due to the design and the placement of various carbide tips along the tool surface.

Another product she talked about was the T-Slot UFO cutter. It is a range of indexable T-slot milling cutter, slitting saw and side milling cutter. According to Ms Chen, there is no fear of run out error while using such indexable tools because of the self centring taper design that connects the cutting tool to the shank. The T-slot cutter is said to be available from thickness of 0.5 mm. Finally, the manufacturer claims that the cutter can help increase machine speed by some 300 to 500 percent. Enquiry No. 3504 Turn to page 80a or log on to www.equipment-news.com to enquire

DMG/Mori Seiki At TIMTOS

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t the recently concluded TIMTOS, APMEN spoke to Woody Wang, MD of DMG/Mori Seiki (Taiwan) and asked him what the main technological innovations brought to the show were and his take on the Taiwanese machine tool industry. Looking at the year 2013, he said: “People are generally a little pessimistic. But we are optimistic because our product range is wide, covering various sectors like the automotive, medical and aerospace industries.” A lthough a wide product range is favourable, the quality of individual machines is also important. Recognising this point, he said: “The Taiwanese market demands high precision, efficiency and productivity.” With that in

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mind, he singled out two machines from his booth. The machines were LaserTec40 and NVD1500 DCG HSC. Micky Tan, product manager (new technologies) of Sauer explained further: “For LaserTec, we have incorporated a picosecond laser into the system. The benefit of this laser compared to nanosecond laser, which is common, is the beam spot size, which can be as small as 10 micron. The next benefit is the surface finish it can deliver. Because of its accuracy, picosecond laser can be used not only for ablation, but as a cutting medium as well.” A PM E N understa nds the NVD1500 DCG HSC is a small machine used for the mould and die industry to produce small and high precision parts. This is a suitable machine for Taiwan where the manufacture of 3C components

Woody Wang

is in demand due to the consumer electronics industry there. The NVD1500 DCG HSC has achieved space savings with a machine width of 850 mm. That limited space is packed with various features for high precision, including Mori Seiki’s DCG (Driven at the Center of Gravity). The machine comes with a high speed spindle with 24,000 rpm or optional 40,000 rpm and achieves maximum acceleration rates of 0.8 G (X- and Y-axis) and 1 G (Z-axis). Enquiry No. 3505 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events& Exhibitions

Productivity Is Vital For Singapore’s

Alexander Wallnöfer, Bolzano, Italy

Aerospace Industry

Arguably one of the more competitive industries for Singapore, the aerospace industry needs to do more to maintain their lead in the region. By Joson Ng

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acing strong competition f rom it s ne ig hb ou rs who can offer potential foreign investors lower operating cost, Singapore has seen manufacturing steadily exiting the country in recent years. Bucking the trend however is the aerospace industry, which has seen major foreign investments arriving to prevent a possible vacuum. In fact, the aerospace industry of Singapore can be seen as one of the remaining manufacturing ‘crown jewels’ the country can boast about and by the looks of things, the government of Singapore is pulling out all the stops in order for things to stay the same. Vision & Investment Highlighting its importance at the

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opening ceremony of AeroSpace eXchange (ASX) 2013, Lee Yi Shyan, senior minister of State, Ministry of Trade and Industry and Ministry of National Development said that the Singapore aerospace industry has contributed significantly to the country’s economy. In 2012, the sector achieved a total output of S$8.7 billion (US$7 billion) — more than doubled the output a decade ago. He added that since 1990, the industry has grown at a Compounded Annual Growth Rate (CAGR) of over 10 percent. Revealing the government’s plans for the industry, he said: “Our vision is for Singapore to be an aerospace hub with a co mpre he n si ve ra n g e o f capabilities. To help us achieve this, we are developing the Seletar Aerospace Park to meet the growing and diverse needs of the aerospace industry.” Attracting massive investments in infrastructure is just one of the strategies in place to ensure the aerospace industry of Singapore do not follow the other manufacturing

industries out of the country. Highlighting the importance of productivity is next. Better & Faster In terms of productivity, Mr Lee gave two examples how local companies have embraced and profited from being productive. He said: “ST Aerospace has completed more than 400 Kaizen programs to date, generating more than S$20 million worth of savings for the company. Singapore Aero Engine Services, a joint venture between Rolls-Royce and SIAEC, reduced its engine overhaul turn-around time by 25 percent through its investment in automation. The company now boasts one of the fastest turn-around times in the global Rolls-Royce MRO network. Looking ahead, productivity and innovation must continue to be key drivers of our growth.” With that said, he reminded those in the aerospace industry t hat a S$2 billion Nat iona l Productivity Fund has been set aside by the government to help industries make the switch to higher productivity. Fina lly, a f ter stating the government’s intent and vision, he laid down his marker for AAIS,

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Events&Exhibitions

Maintaining Competitiveness Is Key: AAIS

Lee Yi Shyan

the Association Of Aerospace Industries (Singapore) to help draw up a blueprint for its members to transform itself in the next 10 years, making full use of all the productivity programs and funding available for the industry.

In his welcome address at the ASX 2013 Mr Chong views o p e n i n g c e r e m o n y, C h a r l e s C h o n g , Singapore as a very president of AAIS said the organisation comprehensive MRO hub. sees a lot of potential for upgrading the ae rospace value chain in Singapore. Commenting on the upgrading issue, he said: “This serves not only to maintain our competitiveness on a global scale, but also to enable us to be able to better serve the local industr y, and even overseas aerospace sectors as well.” He also felt that Singapore is already a “very comprehensive MRO hub,” and ASEAN as a whole, has the potential to be “the aerospace value chain hub of the world.” This vision requires considerable amount of commitment and as far as the organisation is concerned, they are not about to look inwards while many other hubs are sprouting in the region. In conclusion, Mr Chong said: “While Singapore has its own strengths, the region has its own too, and opportunities to synergise our capabilities are aplenty.”

Enquiry No. 3601

Enquiry No. 3602

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Conference Report

continent in the long term as worldwide co-leader for composite manufacturing for aerospace with Singapore, Malaysia and China all enjoying good growth.

Frédérique Mutel expects the composite market to double in the next 15 years with Asia leading the way. A total of four conference tracks were put together by the organiser. They are AeroSuppliers, Aviation Security, Civil & AeroDefence MRO and Next Generation Aviation Professional. Over at the AeroSuppliers conference, Frédérique Mutel, president & CEO of JEC Group, talked about the growing influence of composite materials in the aerospace industry. She said the composite market is growing at five percent annually and is expected to double in the next 15 years with Asia leading the way in both value and volume.

An interesting note according to her is that the composite market is linked to the development level of a particular industry. For aerospace, she shared composite materials were only used in the secondary structures 30 years ago. Now, they are getting more popular in the primary structures. Stating that composite use is growing in both military and civil aviation, she said: “Composite in aeronautics will continue to substitute metal, especially aluminium and planes will structurally evolve in the next 20 years using higher share of composites.” Finally, she expressed high hopes for Asia by predicting the emergence of the

Product Innovation Teo Wee Kin, integration manager at the Manufacturing Technology Centre of RollsRoyce Singapore gave some examples of product innovation in aircraft manufacturing. One of them is the shape memory alloy for adaptive control of hot engine components. Product innovative can be directly attributed to the company’s investment in R&D, which reached £919 million (US$1,394 million) in 2012, according to Mr Teo. He also revealed some 475 patent applications in 2012. Other notable endeavours in the area of product innovation came from SIMTech. Dr Sun Zheng, senior industry development manager of the organisation told participants they will develop Additive Manufacturing (AM) capabilities in the aerospace industry with projects expected to be launched in February 2014.

Enquiry No. 3603 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Event Review: ASX 2013 AAIS organised the AeroSpace eXchange (ASX) 2013 Conference & Exhibition at Singapore Expo Hall 6 from February 27 to March 1, 2013. The show featured a showground of more than 7,000 sq ft (650 sq m), showcasing 61 exhibitors. These included aerospace certification bodies, design and manufacturing houses, equipment manufacturers, metrology companies, non-destructive testing houses, precision machining companies, stockists and distributors. Memorandums Of Understanding During the opening ceremony, three Memorandums of Understanding (MOUs) between the A AIS and the following organisations were signed: 1. BSI Group Singapore T his MOU will se e both pa r tie s

collaborating to conduct courses on three management systems, namely ISO 9001 Internal Auditor Courses, ISO 14001 Internal Auditor Courses and OHSAS 18001 Internal Auditor Courses.

its application in the aerospace industry. Areas to be explored include knowledge and education, training opportunities and services for potential industrial projects.

2. German Institute of Science and Technology — TUM Asia With this MOU, the AAIS and TUM Asia will work together to explore opportunities to promote composite technology and know-how to encourage

3. VTOC “Fokker” BV This will involve both organisations pursuing the development of EASA certified classroom based modules and activities for imparting EASA based education programmes in Singapore.

Enquiry No. 3604

ENQUIRY NO 105

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Events&Exhibitions

Measured For

Accuracy Maintaining the accuracy of CMM measurements requires a multi-faceted approach, where precision is dependent on a myriad of factors. By Sherlyne Yong

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ccuracy was the theme of the day at the Zeiss 1D User Workshop 2013, held on March 6 at the Zeiss Metrology Competence Centre, Singapore. Apart from updating participants about the latest software and technology, topics such as CMM maintenance and accuracy were covered as well. In his talk, Sanjay Pillay, senior regional manager of Southeast Asia at Carl Zeiss explained t he re la t io n sh ip s b e t we e n mea surement accuracy a nd its various influencing factors that include the environment, operator, workpiece, CMM, and measuring method. Reducing Uncertainties Influences on accuracy include volumetric uncertainties from CMM geometry, scales, and construction design, or uncertainties that are due to sensors, holders or software. This 68

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includes guideways, bearings and the structural design of the CMM. Because the length measuring system is dependent on the scale, uncertainty can be reduced when thermal effects have been eradicated with the use of glass ceramic scales. Calibration and indexing errors may also occur due to changes in probe angles or heads. The proposed solution for this is to use multiprobes on a fixed head. Software errors on the other hand, can be mitigated by comparing data sets from the machine used to industry benchmarks. Meanwhile, other uncertainties may be caused by the environment, such as humidity, contamination, vibrations and temperature. In fact, temperature a ffects everything from the probe to the work piece and machine, and is by far the largest influencing factor. Temperature fluctuations might also occur, depending on the

amount of heat sources and their positions. In such cases, rotating fans may be used to improve circulation and create an even distribution of heat. Determining The Bend The next major contributor of accuracy a fter temperature is probe bending. Bending is i nev itable a s ever y tac t ile sensor system requires some deflection, a result of force on the stylus, in order to record sensor coordinates. Bending is affected by stylus stiffness, measuring force, extensions and the number of joints in the probe, where lesser joints result in greater stiffness. Likewise, its effects can be reduced by using less measuring force, increasing the styluses’ stiffness by increasing its diameter, or determining the extent of bending during measurement and then compensating for it. Stiffness can be enhanced by using a short, thick stylus as opposed to a thinner and longer one, while bend determination can be calibrated depending on whether it is static or dynamic. For example, passive calibration is conducted for XXT sensor, where concentric scanning with three different deflections is used to determine the stiffness of the stylus, and six points calibration is used for determining the probe tip geometry. For active sensor, tensor calibration is conducted by measuring up to 30 points with two different forces each. Dynamic bend on the other hand, is resultant of both the measuring force and dynamics of the machine (eg: centrifugal force). It can be determined by scanning in three planes at two different speeds, together with tensor calibration. According to Mr Pillay, these capabilities are exclusive to the company’s Vast Gold, Vast XT Gold and option navigator. Enquiry No. 3605 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Event Review:

Indometal

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rganiser for indometal has declared a successful debut. The inter nationa l meta l & steel trade fa ir for Southea st A sia closed on a positive note reporting that 259 exhibiting companies from 26 countries including 70 local a nd Indone sia n - ba sed have taken part. I n addit ion, si x nat iona l groups and pavilions (Austria, China, Italy (2), the UK and Taiwan) and an official group under the Ministry of Industry Republic of Indonesia showcased their products and ser vices as well. In total, some 6,228 targeted and qualified visitors from more than 20 countries attended the show. According to the organiser, the first edition of the show focu se d on t he sy nerg ist ic inter relat ion s of fou ndr y technology, casting products, metallurgy and thermoprocess technology.

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Indonesian Market With the trend in steel production shif ting from mature to emerging economies, and the industry focus on future growth through expanded production, operational agility and efficiency and cost optimisation, Indonesia i s t he ide a l lo c at ion for a specialised trade fair. Commenting on the importance of the Indonesian market, Winfried Resch from the German Engineering Federation ( VDMA) said: “The market is still small and is starting to grow, but the demand definitely exists. That is why it is important to have an exhibition here at the right time.” The VDMA is one of the key association service providers in Europe and offers the largest engineering industry network in Europe. T he World Fou ndr y Organization (WFO) from the UK also saw potential in the exhibition and is planning to join in the 2014 edition in order to take

advantage of the market growth oppor tunitie s in Indone sia. “The British government sees Indonesia as one of the hotspots for the export market at the moment, so they are naturally interested to be present here,” commented Andrew Turner from the WFO. This sentiment was echoed by exhibitors from the Austrian, Italian and Taiwanese Pavilions who have also shown interest in joining indometal 2014. Concurrent Events Held alongside the exhibition were a series of business seminars, conferences and networking sessions. A seminar focusing on the metal and steel industry’s role w ithin the Indone sia Economic Master Plan 2011-2025 was presented. The seminar was organised by the Federation of Indonesian Metalworks & Machinery Industries Association (GAMMA). Another seminar on ‘The Development of Mineral D ow n s t re a m i n I n d o n e si a’ highlighted presentations by indometal 2013 exhibitors as well as industry topics which included: ‘Roadmap of Dow nstrea m Metals Minerals in Indonesia’ and ‘Primary Energy to Support The Development of Smelter Industr y in Indone sia’. The series was attended by some 130 representatives from the metal and steel industry as well as delegates from the Indonesian government.

Jakarta Internatonal Expo Kemayoran Jakarta, Indonesia February 20 – 23, 2013 Enquiry No. 3606 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Event Preview:

Metaltech

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he 19th edition of Metaltech will take place on May 21 – 25, 2013 at Putra World Trade Centre in Kuala Lumpur, Malaysia. With some 25,000 visitors expected to participate, organiser TradeLink Exhibition Services have

managed to bring in some 1,500 exhibiting companies. This year’s event will also witness six national pavilions from Austria, China, Germany, South Korea, Singapore and Taiwan. Endorsed by the Ministry of International Trade & Industry

(MITI), Malaysia External Trade Development Corporation ( M AT R A D E ), t h e G l o b a l Association of the Exhibition Industry (UFI) and Sirim Berhad, the show will be incorporating WeldTek, the Welding Technology e x hibition a nd I ATech, the Malaysia International Robotics & A u to m a t i o n Te c h n o l o g y Exhibition. Together, the show is expected to take up 30,000 sq m (gross) of total exhibition area. Visitors can expect to interact with exhibitors mainly dealing with sheet metal technology, machine tools, software programs, metrology, mould & die, tools and surface & heat treatment technology. Putra World Trade Centre Kuala Lumpur, Malaysia May 21 – 25, 2013 Enquiry No. 3607 Turn to page 80a or log on to www.equipment-news.com to enquire

Products at Metaltech2013 Carl Zeiss: Table-Top Optical CMM

DMG/Mori Seiki: Fast & Precise

T he O - I n sp e c t 322 is an entry level table-top optical CMM from Carl Zeiss. It is equipped with a multi-point contact scanning Vast X XT as well as a 12x telecentric discovery zoom lens from Ca rl Zeiss Microscopy, which compensates for deviations with additional zoom range. According to the manufacturer, true 3D form and position measurements are possible with minimal probing forces.

The first joint development from DMG/Mori Seiki is the MillTap 700 compact machining centre. The productive machine stands out with its patented tool changes (0.9 s tool change times), stable base construction for highperformance milling as well as its Siemens 840D solutionline operate control technology. As the only machine in this segment, the machine can be optionally equipped with a measuring system in X/Y/Z for the best repeatability and consistent precision. Enabling milling and drilling in one setup on a small footprint, the machine is designed for automotive or electronics mass production and will celebrate its Malaysia Premiere at the show.

Enquiry No. 3608 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 3609 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions Products at Metaltech2013 Guhring: Keeping Things In Order

Guhring’s To o l Management Software GTMS facilitate s tool management and brings order to tool storage. Three tool dispensing systems ( TM 326, TM 426 and TM 526) will aim to meet demands through modern, secure and intelligent tool storage and dispensing systems. Every individual tool dispensing system is of modular design. This allows the customer to choose from combinations of drawers, spiral units, pull-outs and compartments, where everything from indexable inserts, drilling, milling and threading tools have their place. Enquiry No. 3610 Turn to page 80a or log on to www.equipment-news.com to enquire

Hexagon Metrology: CMM For Sophisticated Parts

A solution for high tolerance parts and sophisticated m e a s u r e m e n t t a sk s that require the assistance of CAD models, G loba l Per for ma nce come s sta nda rd w it h a touch-trigger probe, temperature compensation, as well as software with CAD capability, training, and warranty. The Performance model also has the added benefit of being upgraded to accommodate a variety of contact and non-contact scanning sensors. The standard package includes Tesastar-sm motorised probe head and Tesastar-mp touch trigger probe; PC-DMIS CAD; FB2 scan capable controller and various accessories. Enquiry No. 3612 Turn to page 80a or log on to www.equipment-news.com to enquire

Hasil Karya: Ermaksan Laser Cutting Machine

Hwacheon: Stable High Speed Cutting

Ermaksan has developed the Lasermak. The laser cutting machine has been described by the manufacturer as a machine that meets expectations in performance, velocity, accuracy, application range, and maintenance costs. In addition, the machine is said to be reliable and strong. Its mono block construction and dynamism is manufactured by combining the company’s 40-year old experience in the sector.

The Vesta-1000 by Hwacheon is said to have a tough machine structure, according to the manufacturer. The rigid C-type machine structure, designed with the help from finite element analysis, minimises any distortion which may occur from changes in machining environment and condition. All axes integrate Roller LM Guide for fast and stable feed. The manufacturer also claims the machine’s spindle is integrated directly into the motor for stable, high-speed cutting. The spindle is greaselubricated and jacket cooled to minimise the thermal displacement and to increase the life of the spindle assembly. Finally, the air curtain design prevents any foreign substances from entering.

Enquiry No. 3611 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 3613 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions Products at Metaltech2013 Mazak: Vertical Machining Centre

Renishaw: Gauging System

The Vertical Centre Smart 430A S (VCS430A S) provides value for a variety of machining operations from heavy duty machining to high-speed machining. With its high rigidity construction and machine control technology, it is designed to provide higher accuracy machining to meet the demands of the various manufacturing industries. Equipped with Mazak Fanuc Controller for EIA/ISO format programs, the machining centre has a table size of 900 mm x 430 mm and is capable of handling a spindle speed up to 12,000 rpm for machine milling operations.

The Equator 300 gauging system by Renishaw is a versatile alternative to custom gauging, offering inspection of a variety of manufactured parts. A l l t he gau g i n g systems are supplied w it h t h e i n du s t r y standard SP25 threeaxis analogue scanning probing module. In addition, the Equator 300 comes packaged with two SH25 stylus holders and two styli. One of them is a straight stylus with 21 mm length and 5 mm ball diameter and the other is a straight stylus with 75 mm length and 8 mm ball diameter. Finally, the manufacturer says the Equator 300 Controller can be ordered pre-loaded with two different levels of software. They are Modus Organiser, which is for shop floor operation and the Modus Organiser and Modus Equator, for programmers.

Enquiry No. 3614 Turn to page 80a or log on to www.equipment-news.com to enquire

Mitutoyo: High Accuracy Digimatic Micrometer

Sodick: Sinker EDM

Mitutoyo has claimed to have developed the world’s first 0.1 um micrometer. Enabling 0.1 μm resolution measurement, the micrometer is suitable for customers who need to make accurate measurements with a hand-held tool. The micrometer utilises the company’s 0.1 μm resolution ABS (absolute) rotary sensor and screw machining technology to reduce the instrumental error to ±0.5 μm, delivering higher accuracy without sacrificing operability. Finally, a rigid frame and constant-force mechanism enable more stable measurement, while the clicks emitted as the workpiece is being measured assures the operator that measurement is proceeding normally.

The AG40L Sinker EDM features Sodick’s Linear Motor Technology. In addition, it features a noflush EDM technology, user-friendly control and zero electrode wear combined with increased machining speed. Some of the notable features are: linear motor drives (X, Y and Z Axes); a 10-year positioning guarantee; glass scale feedback (X, Y and Z Axes); LAN connection port; and energy saving circuit.

Enquiry No. 3615 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 3616 Turn to page 80a or log on to www.equipment-news.com to enquire

asia pacific metalworking equipment news April 2013

Enquiry No. 3617 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Event Preview:

Intermach 2013 I nter mach 2 013 w ill be one of the largest industrial machinery and subcontracting exhibitions in ASEAN, according to organiser UBM Asia ( Thailand). It will host over 1,200 manufacturers and distributors of industrial machinery who will be arriving from 35 countries. Over 4,000 pieces of the latest technology — some of which is being displayed for the first time in ASEAN and Thailand — will be featured. Ke eping up t he p osit ive tone is Sanchai Noombunnam, project director for Intermach a nd Subcon Tha ila nd. He said: “Because of the success enjoyed by our customers in 2012, Intermach 2013 will be about 17.5 percent bigger and the number of exhibitors will be up by 20 percent. We are also expecting to welcome more than 40,000 qualified visitors from 35 countries around the world.” Internationality of the show is not limited to visitors. The organiser revealed that the 2013 edition of the show will play host to 10 national pavilions mainly f rom Jap a n, Ta iwa n, S out h Korea, China and the Czech Republic. ASEAN Supporting Industrie s, Enha ncement of Mould and Die Industr y Competitiveness Project, and Thai Subcontracting Promotion Association will also be featured in their own special Pavilions. In addition, the 2013 show will also have a Japanese Zone spotlighting the country’s top manufacturers of machinery, equipment, and industrial parts. During the course of the show, many activities, presentations and regional seminars will take place. Intermach 2013 will be co-

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Sanchai Noombunnam

located with Subcon Thailand, ASEAN’S international industrial subcontracting event for procurement parts and business match-making. Finally, Sheet Metal Asia 2013 — a showcase o f she e t me t a l fa br ic at io n machinery in the region, will run in conjunction with both shows.

BITEC Bangkok, Thailand May 16 - 19, 2013 Enquiry No. 3618 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Subcon Thailand 2013: Opening The Door To Opportunities

to give them the opportunity to take part in the business matchmaking program online with top-notch quality part manufacturers,” said Narucha Ruchuphan, director, BOI Unit for Industrial Linkage Development (BUILD). Some of the event highlights are: • A full display of industrial parts from 10 countries — over 300 booths. • Activities and pavilions featuring Osaka, Toyoma and Kanagawa from Japan; JETRO Bangkok and part manufacturers from the ASEAN region including the Fastener Showcase; ASEAN Supporting Association booth; Enhancement of Mould and Die Industry Competitiveness Project; and Thai Subcontracting Promotion Association. • B usiness matchmaking with participating industrial part manufacturers. • Buyer’s Village — an area where industrial part buyers display their need for specific parts.

Narucha Ruchuphan

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ubcon Tha ila nd is organised by Thailand Board of Investment (BOI), T ha i Subcontracting Promotion Association, and UBM Asia (Thailand). Now in its 7th edition, the event helps provide meaningful linkage between industrial part buyers and part manufacturers. Major regional and international corporations, industrial part buyers and entrepreneurs from both domestic and international companies from 15 countries will meet with over 300 quality part 74

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manufacturers. In terms of exhibits that will be on show, visitors can expect to see over 2,500 industrial parts in the automotive, electrical appliance, electronic components and machinery industries. “One of the strengths of Thai manufacturing is the quality and capabilities of the supporting and subcontracting industries. Subcon Thailand will provide opportunities for buyer firms seeking sourcing networks in Thailand and ASEAN. The event is expected to attract large corporations from all over Asia

• Buyer presentations — individual presentations from industrial procurement officers who will provide details on their requirements and procurement policies. • Activities and seminars featuring entrepreneurs from ASEAN and international markets.

BITEC Bangkok, Thailand May 16 – 18, 2013 Enquiry No. 3619 Turn to page 80a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Event Preview:

MTT Indonesia

Cut 20P

Hi-Tech 450

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he biennial event MTT I ndone sia retu r n s to Ja k a r ta from May 22 – 25, 2013 at J I E x po. Experts from the machine tool, metalworking and industrial automation fields will be present to lead the audience through their innovations that will no doubt make an impact in today’s manufacturing world. Industry stalwarts such as Makino and Yamazen from Japan, AgieCharmilles and Rollomatic from Switzerland, Citra Naga Cemerlang and Omega Taiyo Teknologi from Jakarta will be exhibiting at the show. Technologies On Show In EDM, AgieCharmilles will exhibit the Cut 20P, an EDM wirecutting unit. The machine handles wire diameters from 0.15 to 0.30 mm and is flexible to satisfy most of www.equipment-news.com

U3

the requirements in the field of general engineering and standard stamping. It also allows a speed cut. These technologies optimise main, second and third finishing cuts, to attain the most common values of surface roughness, like Ra 0.60 μm and Ra 0.35 μm to be achieved in a minimum of time. Elsewhere, Makino will bring fore their U3. With a 3µmRz/ 3pass capability, it cuts faster than other technologies. According to the manufacturer, the mechanical structure of the machines also assures that movements between details will be accurate anywhere within the work envelope. This combination of speed, finish, and repeatability will help increase productivity. Over at the machining segment, Hwacheon Asia Pacific will showcase the Hi-Tech 450,

which has an integrated 45-degree angle bed frame to minimise heat distortion; along with a guide surface and bed design to absorb the vibration sufficiently, to ensure precision at hard turning. All guide surfaces are rectangular and incorporate tack guide to maintain rigidity and accuracy in prolonged operation. The gear transmission system allows for high-torque turning at low speed and also high speed turning. The transmission and the spindle motor are designed separately so that the heat and the vibration generated from the transmission do not interfere with the spindle axis. The exhibition is open to trade and business visitors from 1030 to 1830 hours on all days and admissions are strictly by registration only. Online registration will close on May 18, 2013. Conference As technology advances, the world becomes smaller and everyone is just a touch away in communication, both near and far. With higher technologies and wider choice of alternatives, manufacturing becomes simplified with productivity amplified and quality magnified. Bearing that in mind, t he orga niser w ill r u n t he Techno Seminar alongside the exhibition where the know-how and applications of advanced technologies are explored and revealed in-depth. Complimentary seats are limited and reservations are on first-come first-served basis. Interested delegates are to contact the organiser for more details. JIExpo Jakarta, Indonesia May 22 - 25, 2013

Enquiry No. 3620 Turn to page 80a or log on to www.equipment-news.com to enquire

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Product Finder Aicon: High Resolution Camera Systems

Epson: SCARA Robots

Aicon has developed an optical measuring system called MoveInspect HR and the hand-held MI.Probe. Together, they are said to allow precise and quick measurements. According to the manufacturer, while using common measuring arms, measurement of large objects can be very time-consuming and the repositioning of the arm during the procedure can cause errors. Optical measuring system on the other hand is precise and versatile. It can be used for mobile or fixed application. In mobile use, the carrier is measured on site with the probe. In static use, the system is integrated in a measuring unit. Both applications compare the relevant points with the nominal data. Possible misalignments are signalised and can directly be adjusted online.

With its H8 robots, the first models in Epson’s H series of horizontally articulated SCARA robots are capable of handling payloads up to 8 kg, and are available in models with arm lengths of 450 mm, 550 mm, and 650 mm. The industrial robots are used to transport and assemble parts on production lines particularly in the electronics and automotive industries. According to the company, in high-speed mode, H8 robots operate up to 40 percent faster than their G6 models, and in low-vibration mode they produce 50 percent less vibration.

Enquiry No. 3701 Turn to page 80a or log on to www.equipment-news.com to enquire

Delcam: Feature-Based CAM

Rockwell Automation: Compact Drives

The 2013 R2 version of Delcam’s Fe ature CA M, a feature-based CAM software incorporates a number of stock model options that a llow users to incre a se productivity, improve surface finish and reduce tool wear. Other enhancements in this release include methods for the generation of html set-up sheets, and improvements to turning and turn-mill programming. The software program also incorporates a method for generating html setup sheets. Information can be extracted from the FeatureCAM project to provide a detailed list of the tooling to be used, with an illustration of each tool, together with the dimensions of the initial stock and an image of the finished part.

Rockwell Automation has launched its Allen-Bradley PowerFlex 525 AC drive to help machine builders and end users simplify equipment design and operation, along with speed installation and configuration. Representing the first in the company’s next generation of compact drives, the drive features a modular design in power ranges from 0.5 to 30 horsepower or 0.4 to 22 kW at 100 to 600 volt input. Its embedded EtherNet/ IP, safety, USB programming, energy savings and a variety of motor-control options are suited for machine-level and stand-alone applications or simple system integration. Suitable for a range of applications, including conveyors, material handling, compressors, fans and pumps, the drive provides a variety of motorcontrol options to accommodate open and closedloop applications.

Enquiry No. 3702 Turn to page 80a or log on to www.equipment-news.com to enquire

76

Enquiry No. 3703 Turn to page 80a or log on to www.equipment-news.com to enquire

asia pacific metalworking equipment news April 2013

Enquiry No. 3704 Turn to page 80a or log on to www.equipment-news.com to enquire

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ProductFinder Schuler: Knuckle-Joint Press

Enquiry No. 3705

High-performance drives with flexible shafts from SUHNER - for high torque applications. Flexible and easy to use.

www.suhner.com

SUHNER Abrasive Expert AG P.O. Box CH–5201 Brugg Phone +41 (0)56 464 28 80 info.sae@suhner.com

Shanghai Tong Lee Hardware Pte Ltd. 200 Jalan Sultan #01-01 Textile Centre Singapore 199018 Phone (65) 6291 7288 (5 lines) sales@shanghaitonglee.com.sg

ENQUIRY NO 100

Turn to page 80a or log on to www.equipment-news.com to enquire

Pure power

ENQUIRY NO 083

Knuckle-joint presses with servo drive are flexible machines used in many areas of metalforming technology. Schuler re ce nt l y u n v e i l e d an enhancement of its line, which saw a precision blanking and forming press with a force of 6,300 kN produce parts with a smooth cut ratio of up to 90 percent. The main feature of this range is the vastly improved rigidity of the entire system, which makes it possible to minimise the cutting gap. The resulting parts have very smooth and even cut surfaces with sharply right-angled edges.

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April 2013 asia pacific metalworking equipment news

77


ProductFinder Seco: More Options For Exchangeable-Tip Drills

TaeguTec: Universal Metal Cutting Solutions

Now available with 8xD options, Seco’s Crownloc Plus offers benefits in terms of both productivity and cost effectiveness. The drills incorporate an exchangeabletip system that eliminates the need to replace an entire tool. Instead, when the cutting edge becomes worn, the user simply removes and replaces the tip of the tool with the Crownloc Plus wrench. Crownloc Plus drill bodies contain deep and wide flutes that optimise chip evacuation and contribute to a long tool life. The cutting head tips incorporate optimised geometries and a TiAlN coating to boost performance and wear resistance. Available in diameters ranging from 12.00 to 19.99 mm, the drills are available in 3xD and 5xD options in addition to the 8xD models.

Ta e g uTe c has developed its highspeed steel line of taps t hat prov ide s universal metal cutting solutions on various materia ls. The line offers two different flute geometries for both through and blind-hole applications. The HSSE-cobalt T-Tap line expands the manufacturer’s threading range beyond milling and turning applications with carbide tools to high speed steel. It is said that the tap is suitable for steel, stainless steel and cast iron applications. The material used in the line is offered in three different grades: uncoated, steam tempered or titanium nitride. No matter the coating, the line enables productivity and economy on a wide range of materials.

Enquiry No. 3706 Turn to page 80a or log on to www.equipment-news.com to enquire

Suhner: Grinding Wheels

Walter: Threading Blind Hole In Steel Materials

With its Tigerbite finned grinding wheels, Suhner has developed a solution for effective machining of stainless steel. Working temperature is now lower due to the active grinding layer, which effectively eliminate damage to the surface like discolouration. Compared with conventional roughing or fibre wheels, the grinding wheel makes work a more pleasant and smoother experience. Elsewhere, the Vulcano roughing wheel was developed specifically for machining curved surfaces. Its vulcanised geometry enables the wheel to adapt to all curved surfaces. It is therefore suitable for turbines and blades in power stations. Featuring ceramic grains, this roughing wheel is a product with a removal rate and service life fit for the maximum requirements. With a thickness of 4 mm, the wheel is a flexible roughing wheel.

Walter has expanded the Paradur X•pert P line. The tool can optionally be supplied with a TiN or THL coating. Features such as 45 degree helix angle, chamfer according to form C and a tapered guide ensure thread cutting in blind holes up to a depth of 3.5xD. As a secondary application, the tool is also suitable for Al-Si alloys with an Si content of 0.5 to 12 percent. Except for metric thread M2 to M64 and M2.5 x 0.35 to M52 x 3, it is available in many inch versions (UNC, UNF, UNEF, UN-8, G, BSW). In addition, the catalogue range also contains left-hand thread variants (LH) and variants with interrupted teeth (AZ). The user can also choose from three tool lengths M, L and XL, alongside tolerance classes 4H, 6H, 6G, 7G, 2B and 3B.

Enquiry No. 3707 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 3708 Turn to page 80a or log on to www.equipment-news.com to enquire

asia pacific metalworking equipment news April 2013

Enquiry No. 3709 Turn to page 80a or log on to www.equipment-news.com to enquire

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16 – 19 Intermach 2013

Vi

BITEC Bangkok, Thailand UBM www.sheetmetalexhibition.com Us it s

21 – 25 Metaltech 2013

Vi

BITEC Bangkok, Thailand UBM Asia intermach@intermachshow.com www.intermachshow.com Us it s

22 – 25 MTT 2013

Vi

PWTC Kuala Lumpur, Malaysia Tradelink info@tradelink.com.my tradelink.com.my/metaltech Us it s

Jakarta International Expo (JIExpo) Jakarta, Indonesia PT Wakeni www.indoautomotive.com/contactus www.indoautomotive.com

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Vi

BITEC Bangkok, Thailand Reed Tradex contactcenter@reedtradex.co.th www.manufacturing-expo.com

July

2-5 MTA Vietnam 2013

Us it s

SECC Ho Chi Minh City, Vietnam SES mta@sesallworld.com www.mtavietnam.com

September

4–6 Vietnam Manufacturing Expo 2013

ICE Hanoi Hanoi, Vietnam Reed Tradex vietnammanufacturingexpo@reedtradex.co.th www.vietnammanufacturingexpo.com

Jakarta International Expo Jakarta, Indonesia ECMI mtt@ecmi.cc www.mtt-indonesia.com

23 - 25 Indo Automotive

Us it s

Us it s

SECC Ho Chi Minh City, Vietnam Reed Tradex kasinee.phan@reedtradex.co.th www.metalexvietnam.com

November 13 - 15 Oil & Gas Indonesia 2013

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

20 – 23 Metalex 2013

Vi

Vi

Us it s

October 10 – 12 Metalex Vietnam 2013

Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo www.pamerindo.com

20 – 23 Manufacturing Expo 2013

BITEC Bangkok, Thailand UBM www.subconthailand.com

16 – 19 Sheet Metal Asia 2013

12 - 15 Manufacturing Surabaya 2013

Us it s

Us it s

BITEC Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th

December 4-7 Manufacturing Indonesia

Vi

Us it s

June

Vi

16 – 18 Subcon Thailand 2013

Vi

Jakarta International Expo (JIExpo) Jakarta, Indonesia GEM Indonesia info@gem-indonesia.net www.inamarine-exhibition.net

Vi

2013

2-4 Inamarine 2013

Vi

May

Exhibition Programmes

Us it s

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

4-7 Mining Indonesia

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com To be considered for inclusion in the calendar of events, send details of event to:

The Editor (APMEN)

Eastern Trade Media 1100 Lower Delta Road, EPL Building, #02-05 Singapore 169206 Email: josonng@epl.com.sg • Tel: +65 63792888

www.equipment-news.com April 2013 asia pacific metalworking equipment news

79


Advertising Index Page No.

Enquiry No.

BENIGN ENTERPRISE CO LTD

45

097

BYSTRONIC PTE LTD

03

093

DELCAM PLC

05

017

EMO 2013

23

090

EVERISING MACHINE CO

47

102

FRITZ STUDER AG

IBC

085

HAAS AUTOMATION INC

09

082

HAIMER ASIS PACIFIC LTD

21

107

HEIMATEC GMBH

51

089

HEXAGON METROLOGY ASIA PACIFIC PTE LTD

17

103

HURCO (S.E.ASIA) PTE LTD

FC

088

HWACHEON ASIA PACIFIC PTE LTD

19

087

IFM ELECTRONICS PTE LTD

33

094

ISCAR LTD

IFC

092

KENNAMETAL INC

BC

068

LVD COMPANY NV

41

098

NATIONAL INSTRUMENTS

29

106

NEWELL RUBBERMAID – LENOX

35

056

OKUMA TECHNO (THAILAND) LTD

01

198

OPTICAL GAGING (S) PTE LTD

37

086

REED TRADEX COMPANY (MANUFACTURING EXPO THAILAND 2013)

55

096

RENISHAW (HONG KONG) LTD

31

108

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2013)

59

014

SUHNER ABRASIVE EXPERT AG

77

083

TAEGUTEC CO

11

101

TAIWAN TAKISAWA TECHNOLOGIES CO LTD

67

105

TORNOS TECHNOLOGIES ASIA LTD

43

007

TRADE-LINK EXHIBITION SERVICES SDN BHD (METALTECH 2013)

53

209

14 / 15

095

TUNGALOY SINGAPORE (PTE) LTD

13

091

UBM ASIA (THAILAND) CO LTD (INTERMACH 2013)

49

072

VISION WIDE TECH CO LTD

77

100

WALTER AG SINGAPORE PTE LTD

07

084

WIKUS SAGENFABRIK WILHELM H KULMANN GMBH & CO KG

25

178

YIH CHUAN MACHINERY CO LTD

57

099

Advertiser

TRUMPF PTE LTD

80

asia pacific metalworking equipment news April 2013

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ASIA PACIFIC METALWORKING

No. 3 2013

The Engineering Journal For Manufacturing,Automation & Quality Control

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StuderTechnology –

Winner of the PRODEX AWARD 2012 (CH) Winner of the intec-Preis 2013 (DE)

The Expert for your grinding task Stay in control of the grinding process with StuderTechnology. Profit from the expert know-how from STUDER for a reliable and economical cylindrical grinding process and improve the payback of your universal STUDER cylindrical grinding machine considerably.

StuderTechnology Integrated Fritz Studer Ltd CH-3602 Thun Telephone +41-33-439 1111 Telefax +41-33-439 1112 www.studer.com

ENQUIRY NO 085

The Art of Grinding.


Double-sided insert with up to 12 cutting edges for a more productive cutting process. Higher clearance angles designed in the cutter bodies to permit pocketing, profiling, and 5-axis machining. Three different insert sizes and three topography styles per size, cover any type of material, component, and application. Unique anti-rotation feature for excellent stability with higher feed rates and cutting forces while allowing for user-friendly insert rotation.

Working harder and smarter. That’s Rodeka. That’s Different Thinking. TM

Kennametal introduces a new and revolutionary double-sided round milling insert — Rodeka. TM

It’s capabilities span multiple types of milling operations and workpiece materials, providing the latest double-sided insert technology to increase your productivity with the most efficient cost per edge. Now That’s Different Thinking. That’s Kennametal. Rodeka double-sided round inserts: TM

• Three insert ICs: 10, 12, and 16mm. • Innovative, cutting-edge design increases tool life and reduces cutting forces. • Also offered, Rodeka 8, a tailor-made solution for turbine blade machining. TM

ENQUIRY NO 068 ©2013 Kennametal Inc. l All rights reserved. l A-13-03153

To learn more about Rodeka and the latest machining technologies, contact your authorized Kennametal distributor, call 800.446.7738, or visit www.kennametal.com. TM


APMEN April 2013