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Productive Machining Laser Technology Aerospace Outlook January - February 2013

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Contents January-February 2013

CUTTING EDGE 24 Benson Foo On Productive Machining…

The technical manager of Seco Tools Singapore tells APMEN what it means to be productive. By Joson Ng

28

Tools For Better Productivity

Increasing machining productivity is like an art with many different subtle considerations. By Dr Moshe Goldberg, Iscar

TECH TALK 30

The Route To Greater Efficiency

Optimal production planning requires highquality tool and technology data. This in turn allows a consistent production process with fewer errors, lower machine downtimes and ultimately, higher productivity. By Ralf M Haassengier, for TDM Systems

33

Enrico Krog Iverson On Industrial Robots…

The CEO of Universal Robots gives his take on the role of robots in today’s manufacturing environment. By Joson Ng

SOFTWARE & METROLOGY 34 Take A Closer Look At Medical Parts

Advanced software makes vision and multisensor inspection a mainstream tool for medical part analysis and inspection. By Marc Stalker, PC-DMIS Vision

FormJoinCut 38 The Source Of Fibre

Asia Pacific Metalworking Equipment News (APMEN) takes a look at what is making waves in sheet metalworking. By Joson Ng

2

asia pacific metalworking equipment news Jan-Feb 2013

INDUSTRY FOCUS 41

MTA2013 Supports Singapore’s Position As Asian Aerospace Hub of Choice

42

Singapore Plots A Stable Flight Path

The Singapore aerospace industry is expected to cruise even with some light turbulence expected ahead. By Joson Ng

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Contents January-February 2013

44

Diamond Is Aerospace’s Best Friend

Diamond is the only realistic cutting tool material for the economic machining of fibre composite materials, given the strength of the glass and carbon fibres in resin laminates. Contributed by Jaslin Huang, Walter AG Singapore

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.

FEATURES 46

Special Report: EuroBlech 2012

Asia Pacific Metalworking Equipment News (APMEN) goes to Hannover, Germany to gauge the pulse of the sheet metalworking industry. By Joson Ng

52

Ferdi Töngi On The Future Of Sheet Metalworking

The rise of Asia and the acceptance of fibre laser will accompany the evolution of sheet metalworking, which will increasingly see branding and after sales service as a differentiator. By Joson Ng

56

DMG/Mori Seiki: Market Development Grew 5.2% Worldwide, More To Come

With production plants being commissioned in all corners of the globe and machines making their debuts at various trade shows worldwide, it is clear for all to see that the partnership between the two companies is flourishing. By Joson Ng

60

Market Outlook: Beyond 2013

Metalworking is essential in many industries. We take a look at the fortunes of these industries in 2013 and beyond as we try to draw our own conclusions how the metalworking world would fare in the coming years.

Big Movement On The Nanoscale Nanotechnology is poised to stake a bigger claim in the next few years in the manufacturing environment as more advancement can be expected from this field. By Joson Ng

EVENTS & EXHIBITION 64 Event Review: Metalex 2012

Thailand may be the regional automotive powerhouse but it is not known as a producer of metalworking machinery or technology. Its tradeshows are however shop windows for many international brands to exhibit their most relevant products for the Southeast Asia region. By Joson Ng

Event Review: Manufacturing Indonesia 2012

The number of national pavilions at the show is a sure sign of international interest in the manufacturing market of Indonesia. By Joson Ng

Workplace Safety And Health Conference 2012

62

Event Preview: Indometal 2013

It takes more than a good product to gain a significant foothold in the bandsaw market. By Joson Ng

TIMTOS Supplement 73

Making The Cut

Regulars

08 Business News 91 Product Finder 95 Exhibition Programmes 96A Product Enquiry Card 4

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asia pacific metalworking equipment news Jan-Feb 2013

96

Refer to Advertising Index

pg

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 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)

Federation of Malaysian Foundry & Engineering Industry Associations

Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

Taiwan Association of Machinery Industry (TAMI)

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Editor’s Note Published by:

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

Before You Toss Out That

Old Calendar…

Reg No: 199908196C

managing director Kenneth Tan editor Joson Ng

josonng@epl.com.sg

business development manager Randy Teo

randyteo@epl.com.sg

senior sales manager Derick Chia

derickchia@epl.com.sg

sales manager Melvin Wong

As we replace our calendar that has been sitting on our desk for the past 12 months, do make a special effort to flip the pages and take some time out to reminisce on what happened in the year 2012. In the same spirit, we shall look back on some of the shows APMEN was involved in, and the thoughts they left us. In Asia, APMEN’s curtain riser for the exhibition circuit was the MTA Hanoi in Vietnam. With some 4,000 attendees at the event, the show was described as “exciting” by the organiser SES. April saw the first major show of the year in East Asia as SIMTOS took centre stage; the largest to date in the exhibition’s history with 100,000 sq m of floor space. May saw the focus back in Southeast Asia with the Metaltech show in Malaysia. After a short break in June, the exhibition bandwagon was again in full motion. MTA Vietnam in July reminded people how attractive the Vietnamese market can be in the metalworking industry with a good exhibitor turnout. With laser cutting technology on show in a big way in 2012, it is perhaps a telling sign that Vietnam is ready for something

more sophisticated. A PMEN then travelled to Euroblech, JIMTOF, TMTS, Metalex and Manufacturing Indonesia to round up the busy last quarter of the year. Euroblech saw fibre laser technology come of age. JIMTOF was arguably one of the best attended shows all year with its crowded aisles, both frustrating and enthralling at the same time. The entire supply chain was represented at TMTS, along with the manufacturing cluster of Taiwan, all within a 60 km radius of the Greater Taichung area. As we begin 2013, it is also worthwhile to note that major Asian powers like China, Japan and South Korea have had new leaderships. Although it is too early to say how they will impact the manufacturing industry, there are some positive signs. A look at our special economic outlook feature will tell you that even as the economic ‘fog’, which has so often dampened our spirits since early 2012 refuses to clear; there are silver linings that can provide us with the occasional respite. Finally, on behalf of APMEN, I would like to wish you Happy New Year.

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 Dr Moshe Goldberg Ralf M Haassengier Enrico Krog Iverson Marc Stalker Jaslin Huang 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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asia pacific metalworking equipment news Jan-Feb 2013

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Business News SAIC-GM-Wuling To Build Third Manufacturing Base In Chongqing

GF AgieCharmilles Inaugurates Training Academy

Geneva, Switzerland: Machine tool manufacturer GF AgieCharmilles has inaugurated its GF AgieCharmilles Academy, a training environment. Located at the company's Geneva headquarters, the academy features an enlarged machining centre area with space for training, and an updated metrology area, technical and training labs and classrooms. The enhanced facility and developed academy curriculum positions the company to accelerate and expand training opportunities for applications and service engineers worldwide, and to leverage the group’s expanding knowledge base to the direct benefit of customers. Those customers include tool and mould makers and manufacturers of precision components across a wide range of industrial areas, including aerospace and aeronautics, automotive, medical technologies, Information and Communications Technology (ICT), electronic components, and jewellery and watchmaking.

Shanghai, China: SAIC-GM-Wuling will build a third manufacturing base in Chongqing Municipality to keep pace with the rising demand for its vehicles. The joint venture between GM China, SAIC and Wuling Motors will begin construction of its facility early next year (2013), pending relevant government approvals. The RMB 6.6 billion ( U S $1 b i l l i o n) f i r s t p h a s e is scheduled to open in 2015. The facility will have an annual production capacity of 400,000 vehicles and engines. It will adopt GM’s global manufacturing processes and standards. T he p ro du c t io n b a s e i n Chongqing will give the company a strategic position in southern, northern and midwestern China. It will enable SGMW to reach its production target of 2 million vehicles per year by the end of 2015.

Nikon & A*STAR Institute Of Microelectronics To Set Up R&D Lab In Singapore Singapore: Nikon Corp and A*STAR Institute of Microelectronics (IME), a semiconductor research institute of Singapore, have announced a collaboration with an agreement to jointly set up a R&D laboratory to develop advanced optical lithography technology used in the manufacturing of semiconductor chips. Nikon and IME will collaborate on technologies such as multiple patterning and directed self assembly techniques to drive the extension of ArF Deep Ultraviolet (DUV) dry and immersion lithography down to geometry of 20 nm and beyond, targeting advanced applications including logic, high density memory, embedded non-volatile memory, high-speed electronics and nanophotonics, and nano-electromechanical systems. For Nikon, this is a strategic addition to its capabilities in Singapore. This collaboration will allow the company to tap into IME’s R&D infrastructure, process technology and talent pool to get early insights into its next-generation systems which will 8

asia pacific metalworking equipment news Jan-Feb 2013

shorten time-to-market. It will open opportunities to the company to learn required technology for future process, and continue pushing ArF immersion lithography for several device nodes. The capabilities will enhance and expand IME’s joint collaborations with industry partners, research institutes and universities to develop advanced technologies such as metrology and materials for further technology shrinkage as well as manufacturing excellence.

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BusinessNews

Hwacheon Celebrates 60th Anniversary

Gwangju, South Korea: Hwacheon marked its 60th anniversary on November 1, 2012 with a grand opening of its Technology Centre and an open house. More than 2,000 people attended the threeday event where the company had on display its range of CNC machine tools from vertical turning centres to drill and tap machines, horizontal lathes to mould and die machining centres. The Technology Centre includes

ground floor demonstration space, two higher floors for training and meeting rooms and an auditorium. A portion of its adjacent factory was dedicated to exhibiting 14 new machines during the open house. Klaus Ludwig, International Business Unit leader and VP of Hwacheon Machine Tools said the company is making a greater commitment to its markets outside South Korea with new facilities and machine development backed by

ABB To Expand Press Automation Solutions

Delcam Achieves Record Orders In December

Zurich, Switzerland: ABB has announced the acquisition of Gresin Grupo Estudios Industriales, SAL, a privately owned company that specialises in refurbishment solutions for mechanical presses. The acquisition is in line with the company's strategy to expand its global offering of robotics solutions. Gresin is a player in the area of press automation refurbishments and technology enhancements. T he compa ny de sig ns sub assemblies, retrofit and upgrade packages while it outsources manufacturing. Gresin will be integrated into ABB’s Robotics business unit in the Discrete Automation and Motion division. 10

increased stocking of its machines in markets globally. T he compa ny ’s mach i ne tools are all made in its factories in South Korea and no step in producing, assembly or design is outsourced. They operate eight plants, delivering more than 3,000 CNC machine tools worldwide annually, half of which are installed in South Korea at automotive, die and mould, and machining job shops. Although industrial conglomerates such as Hyundai and Doosan have entered the machine tool market, the company maintains its 20 percent of the South Korean machine tool market. Thirty-seven percent of the company’s turnover comes from overseas — about 38 countries worldwide. Young-doo Kwon, president and CEO of Hwacheon Machine Tools aims to achieve the company’s goal of reaching its 100 -year anniversary. He has expanded investment in R&D and said the company is concentrating more on overseas sales.

asia pacific metalworking equipment news Jan-Feb 2013

Birmingham, UK: Delcam has announced that, in line with the trading update made on December 18, 2012, it achieved a new one-month record in December 2012 for orders of software licences and maintenance contracts. Orders increased by more than 10 percent over the December 2011 figure, completing a record quarter to end the year. The growth came not only from the Clive Martell company’s established markets in the automotive and aerospace industries but also from newer markets, such as the dental sector. There were particularly strong performances by the company’s Beijing and Philadelphia offices, its Italian subsidiary and its South Korean joint venture. Clive Martell, chief executive of Delcam, said: “December is traditionally the best month of the year for our software business and it is encouraging to see that we continue to set new records. I am delighted that Delcam has ended an already strong year on a new high.” www.equipment-news.com


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BusinessNews

SIMTech Launches Productivity Initiative

Singapore: Singapore’s manufacturing industry will benefit from a productivity boost with the launch of the Overall Equipment Effectiveness (OEE) initiative — a move spearheaded by the Manufacturing Productivity Technology Centre (MPTC) hosted at SIMTech. The OEE initiative encourages companies to increase productivity by improving machine utilisation, performance and quality with R&D and the adoption of advanced manufacturing technologies developed by SIMTech. Central to this initiative is a program comprising OEE champion training, OEE assessment, identification of areas for improvement, as well as OEE technologies adoption and nurturing a culture of improvement. The initiative advances expertise through systematic training of the local manufacturing workforce in application of knowledge and technology to raise competency and productivity on the manufacturing shop-floor. The initiative measures how well a manufacturing unit performs in three key categories. They are availability, performance and quality. An OEE score based on these three categories will provide an indication to the company of the relative level of performance against the optimum that can be achieved. To date, CKE Manufacturing, EADS Singapore, Makino Asia, MicroMechanics and Mitsuboshi Overseas HQ have signed up as members of the initiative. They represent different industry sectors from precision engineering, aerospace to equipment manufacturing. These members are gearing to improve the overall productivity and utilisation of their manufacturing assets through the OEE initiative.

Alstom Expands Presence In China’s GasFired Power Generation Market France: Alstom has been awarded a contract by Harbin Turbine Company (HTC) to supply two sets of GT13E2 gas turbine generators for Huaneng Power International’s (HPI) 517 mW Tongxiang combined cycle power plant. The contract is valued at approximately €40 million (US$52.9 million). This power plant is located in the province of Zhejiang. This is the company’s second gas turbine order awarded by HTC within half a year. The two new sets are scheduled to enter commercial operation by end 2013. Alstom already has an existing relationship with HPI and is building a gas-fired power plant in Singapore for Tuas Power Generation (TPG), a fully owned HPI subsidiary in the country. 12

asia pacific metalworking equipment news Jan-Feb 2013

Daimler & Kuka Sign Strategic Cooperation Stuttgart/Augsburg, Germany: Daimler has introduced lightweight robots, originally designed for use in outer space, to an industrial environment. The company has signed a strategic cooperation agreement with Kuka. The partnership focuses on human-robot cooperation to achieve optimisations both for production workers and in manufacturing processes. Employees of both companies a re jointly conducting field tests to explore processes such a s a ssembly a nd in -vehicle screw application. They are also developing systems concepts to make cooperation between humans and robots safe. Direct human-robot interaction makes it possible to employ trendsetting manufacturing concepts, where the lightweight robot acts as a worker's ‘third hand’. The lightweight robot was originally developed by the German Aerospace Center for use in outer space. Its sensitive motorised grippers give it a delicate touch, which enables it to handle objects gently and perform difficult tasks precisely. The robot can be positioned and set up to optimally support workers in terms of ergonomics. As an example, the lightweight robot takes over and performs tiring tasks such as steps that involve handling items overhead. Working with a nd ha ndling the robot is straightforward and intuitive, which reduces programming time and increases the efficiency of ma nufacturing processes. Due to their precise performa nce, lightweight r o b o t s a l s o c o n t r i b u te to enhanced quality. www.equipment-news.com


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BusinessNews Technology News

Better Protection For Forging Dies

Fraunhofer IPT

Germany: Hard or tough — very often, the manufacturers of forging dies must make a compromise here. A technology now makes it possible to combine both characteristics and clearly expand the useful life of forging dies. Forging dies must withstand a lot. They must be hard so that their surface does not get too worn out and is able to last through great changes in temperature and handle the impactful blows of the forge. However, the harder a material is, the more brittle it becomes — and forging dies are less able to handle the stress from the impact. For this rea son, the manufacturers had to find a compromise between hardness a nd streng th. One of the possibilities is to surround a semi-hard, strong material with a hard layer. The problem is that the layer rests on the softer material and can be indented by blows, like the shell of an egg.

Researchers from the Fraunhofer Institute for Production Technology IPT in Aachen, Germany, have now developed an alternative. “The forging dies we have been working on have a useful life that is up to twice as long,” explains Kristian Arntz, head of department at the IPT. “We are using a working material that is less hard and able to handle the impact stress well. We melt the uppermost layer of the material with a laser and introduce a powder into the melt material that is used to chemically alter the characteristics of the material. We have therefore achieved a large degree of hardness in the upper millimeter.” The advantage is that since the characteristics of the outer layer do not change abruptly (as is the case in a deposited layer), but increases in hardness gradually (this is also called a hardness gradient) therefore circumventing the ‘egg shell effect.’

In addition, the particles act like sand paper and prevent the material from wearing off the die. Since the wear only occurs in certain spots of the die, the scientists are altering only these surface areas. They are therefore further minimising the effect the layer has on the impact resistance. Simulations help to calculate the areas that are particularly stressed — and knowledge gained by experience is also applied. To be able to work on the forging dies, the scientists and their colleagues at Alzmetall have developed a machine with which they are able to work on the freeform die inserts and forging dies. The scientists have also developed a software with ModuleWorks that ensures that the laser travels across the surface at a constant speed and that the gaps between the laser paths remain even — otherwise tears would develop in the surface. “This isn’t a problem if the surfaces are straight; however, we had to develop special algorithms for free-formed tools that keep the path distance and the speed constant — even with complex geometries,” said Mr Arntz. The scientists are planning, in a further step, to reduce expensive raw materials such as chromium, molybdenum and vanadium. To date, these materials are present in all forging dies.

Jenoptik Sets Foot In Singapore Singapore: Jenoptik has established an office in Singapore, from where the company will target the Southeast Asian automotive and supplier industries. K Srinivasan, who is also managing the Indian subsidiary Hommel-Etamic Metrology India, was appointed the MD of Jenoptik South East Asia. Elsewhere, Mr Harikrishna is responsible for sales and product support. In addition, Ryan Wang Cheng Hung has been appointed as senior sales and service engineer. Finally, Judy Heng sees to accounting, order processing and logistics. “We will continue to rigorously pursue our course of internationalisation on the principle of being on the ground close to our customers. In the Industrial 14

asia pacific metalworking equipment news Jan-Feb 2013

Mr Srinivasan, MD, Jenoptik South East Asia

Mr Harikrishna, regional sales manager, Jenoptik South East Asia

Metrology division, we are one of only a few suppliers around the world able to carry out global and largescale projects with speed and flexibility. This is a key factor of success in this business,” says the company’s chairman of the Executive Board Dr Michael Mertin. www.equipment-news.com


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BusinessNews

TRUMPF Group

Trumpf Launches Online Resource Platform

Ditzingen, Germany: Trumpf has developed an online resource website. It contains stories about sheet metal manufacturing techniques and includes many helpful hints and information on the company’s technologies. The web site augments the company’s Express customer magazine.

3D Systems To Acquire Geomagic Rock Hill, US: 3D Systems has signed a definitive agreement to acquire Geomagic, a global provider of 3D authoring solutions including design, sculpt and scan software tools that are used to create 3D content and inspect products throughout the entire design and manufacturing process. This acquisition is subject to customary closing conditions, and is expected to close during the first quarter of 2013, after those conditions are met. The combination of Geomagic’s sculpting, modeling, scanning and inspecting software tools with 3D Systems’ portfolio strengthens its 3D authoring platform and positions the company for accelerated growth in the fast-growing, 3D content-to-print space. The transaction adds complementary products and technology, increases the company’s reseller coverage globally and is expected to be accretive to its non-GAAP earnings in the first full year following the completion of transaction.

ExxonMobil’s Forecasts Shift In Global Energy Balance And New Opportunities For International Trade And Economic Growth Ir ving, US: The global energy landscape will evolve significantly as regional demand-and-supply patterns shift in the coming decades, cre ating new oppor tunitie s for inter nat iona l t rade a nd economic growth, says E x x o n M o b i l ’s O u t l o o k f o r Energy: A View to 2040. “Energy is fundamental to our way of life and essential to grow our economy,” said Re x W Ti l le rson, c ha i r ma n and CEO of Exxon Mobil Corp. “Understanding future energy trends is critical for effective policy decisions that ca n help ensure safe, reliable and affordable energy development a n d e co n o m ic g row t h , j ob creation and expanded global trade.” In its a nnua l foreca st, t he comp a ny proje c t s t hat global energ y demand in 2040 will be approximately 35 percent higher than in 2010. Future energ y needs will be 16

asia pacific metalworking equipment news Jan-Feb 2013

supported by more efficient energ y-saving practices and technologies, increased use of less-carbon-intensive fuels such as natural gas, nuclear and renewables, and the development of unconventional energ y sources that were previously inaccessible without technology advances. Oil will continue to be the most w idely u se d f uel, but n a t u r a l g a s — t h e f a s te s t growing major fuel — is e x p e c te d to ov e r t a ke co a l by 2025 as the second most used fuel. Demand for natural gas will increase by about 65 percent through 2040, and 20 percent of global production will occur in North America, supported by growing supplies of gas from shale and other unconventional sources. New technolog ie s w ill continue to be key to development of reliable and a ffordable energ y, which is central to economic grow th

a nd huma n progress, the Outlook for Energy concludes. Significant advancements in oil and natural gas technologies have safely unlocked vast new supplie s, a l re ady cha ng ing the energ y landscape in North America and expanding supplies to help meet growing global energy demand. T he O u t l o o k fo r E n e r g y projects that North America is likely to transition to a net energy exporter by 2025. Over the next two decades, more t ha n ha l f of t he g row t h i n unconventiona l natura l ga s supply will be in North America, providing a strong foundation for increased economic growth across the US, a nd most notably in industries such as energy, chemicals, steel and manufacturing. These resources will also create new opportunities for global trade with countries in Europe and the A sia Pacific region, which are reliant on www.equipment-news.com


Add: 10/F,GIFC,No.1438 Hongqiao Road,Shanghai 201103 China Tel:021- 2208 5112

ENQUIRY NO 016

www.lenoxtools.com asia@lenoxtools.com


BusinessNews international markets to meet domestic energy requirements. The changing landscape and resulting trade opportunities w ill cont inue to prov ide consumers with more choices, value, wealth and good jobs. The forecast projects t h at e ne r g y for e le c t r ic it y generation will continue to be the largest component of global dema nd a nd is expected to grow by 50 percent to 2040. The growth reflects an expected 85 percent increase in electricity dema nd, led by developing cou nt r ie s where 1. 3 billion people are currently without access to electricity. A s the world g radua lly tra nsitions from coa l to clea ner fuels for electricity generation, natural gas, nuclear and renewable energy sources, including wind and solar, will represent a greater sha re of t he g loba l e nerg y mix. Natural gas, which emits up to 60 percent less carbon dioxide than coal when used fo r e l e c t r i c i t y g e n e r a t i o n , will grow the most. By 2040, natural gas will account for 30 percent of global electricity generation, compared to less than 25 percent today. The forecast highlights the importa nt role of efficiency i n he lp i n g b a l a nce e ne r g y d e m a n d w i t h t h e g r ow i n g world economy. Energy-saving practices and technologies, such as hybrid vehicles and highefficiency natural gas power plants, will help countries in the Organization for Economic Cooperation and Development (O EC D) i nc re a se e conom ic output by 80 percent without increasing total energy use. In the transportation sector, t he nu mb er of c a rs on t he road worldwide is expected to approx imately double by 2040, but the fuel demand will actually plateau and gradually 18

asia pacific metalworking equipment news Jan-Feb 2013

decline as consumers turn to smaller, lighter vehicles and technologies that improve fuel efficiency. This Year’s Findings Energy demand in non-OECD co u nt r i e s w i l l i n c re a s e 6 5 p e rce nt by 2 0 4 0 comp a re d to 2 010, re f le c t ing g row ing p ro sp e r it y i n n a t io n s t h a t include more than 80 percent of the world’s population. E le ct r icit y generat ion is expected to account for more than half of the increase in global energy demand over the next few decades. Natural gas, nuclear and renewables will grow to meet rising electricity demand, while coal and oil use for power generation will decline.

Globa l tra nspor tation related energ y dema nd w ill rise by more than 40 percent from 2010 to 2040. The growth is almost entirely from commercial transportation — heav y duty, aviation, marine and rail — as expanding economies and international trade spur greater movement of goods. Evolving demand and s u p p l y p a t te r n s w i l l o p e n the door for increased global trade opportunities. The changing energy landscape in conjunction with an abundance of free trade opportunities will help lead to more choices and creation of value that helps fuel economic growth and improve living standards worldwide.

Heimatec To Engage Asia More Extensively

Taichung, Taiwan: German based Heimatec held its first Asia Pacific Distributor Seminar in Taichung, Taiwan on December 12, 2012. The event was held to upgrade the product knowledge of regional Heimatec partners from countries like India, Malaysia, China, Thailand and Taiwan. Martin Krieger, CEO of the company attended the one-day event. While regional marketing issues and strategies were touched by the GM of Asia Pacific Karl Moessmer, product updates of static- and live tools as well as new design and development were extensively introduced by sales manager Andreas Meyele. Similar events will now be held to upgrade technical skills and knowledge of partners as to provide professional support to an increasing number of regional customers. www.equipment-news.com


TruLaser Series 1000 www.laser-processing-made-easy.com It’s as easy to operate as your CD player at home: just hit play, pause or stop. That’s it. Fits any size facility and any budget. And, you can choose a CO2 or solid-state laser. So whatever you make – make it easy.

ENQUIRY NO 008 TRUMPF_TruLaser_Series1000_EN_220x280.indd 1

21.09.12 11:18


BusinessNews

Dassault Systèmes’ 3DExperience Used To Accelerate Medical Device Time To Market Singapore: Olympus Technologies Singapore, an endoscope manufacturer, has selected Dassault Systèmes’ 3DExperience platform for the development of its medical devices. The ‘Licensed to Cure’ industry solution experience will be deployed to create a single environment, allowing to eliminate scattered processes and data, and to ‘embed’ regulations as an asset, optimising quality and compliance. Olympus Technologies Singapore has standard operating procedures in developing engineering and software system documentation for their medical device manufacturing. ‘Licensed to Cure’ will help them simplify those procedures by providing a single source of information to always get relevant, up-to-date information and establish true collaboration with the same, accurate set of product data. In addition, the company will be able to reduce new product time to market and streamline regulatory filings by creating an end-to-end, traceable and compliant product development process directly linked to quality management.

Bombardier In Partnership With Shanghai Shentong Metro Group

Mike Johnson, Des Moines, IA, US

Berlin, Germany: Bombardier Transportation and Shanghai Shentong Metro Group have formed a joint venture company, Shentong Bombardier (Shanghai) Rail Transit Vehicle Maintenance Company. The joint venture will focus on the repair and maintenance of urban mass transit vehicles in China, offering customers the services of daily maintenance, intermediate repairs, overhauls, refurbishment and technical consultation. The company leverages the respective partners’ competencies in terms of technologies, equipment and businesses to deliver quality, reliable trains that are safe to operate. The synergy generated from this strategic partnership will deliver a new level of after-market service and support in the region. Both parties are committed to a long-term relationship to enhance train performance while ensuring greater revenues for the customers through lower operating costs. 20

asia pacific metalworking equipment news Jan-Feb 2013

Boeing & BMW Group To Collaborate On Carbon Fibre Recycling

Jay Lopez, Philippines

Seattle, US: Boeing and the BMW Group signed a collaboration agreement to participate in joint research on carbon fibre recycling and share knowledge about carbon fibre materials and manufacturing. Both orga nisations a re pioneering the use of carbon fibre in their products. Boeing's 787 Dreamliner is made up of 50 percent carbon fibre material and BMW will introduce two vehicles with passenger compartments made of carbon fibre in 2013. Recycling composite material at point of use and the end of product life is critical to both companies. "This collaboration agreement is a very important step forward in developing the use and end use of carbon fibre materials," said Larry Schneider, Commercial Airplanes VP of Product Development, who represented Boeing at the signing in Seattle. "It is especially important that we plan for the end of life of products made from carbon fibre. We want to look at ways to reclaim and reuse those materials to make new products. Our work with BMW will help us attain that goal." As part of the collaboration agreement, both companies will also share carbon fibre manufacturing process simulations and ideas for manufacturing automation. www.equipment-news.com


BusinessNews

National Metrology Centre To Improve Measurement Capabilities & Standards

Singapore: Ichi Seiki has received the Singapore Prestige Brand Award (SPBA) — Established Brands 2012. This marks the first winner of the SPBA in the machine tool industry. Philip Kia, MD of the company, received the award from deputy PM, coordinating minister for National Security & minister for Home Affairs, Teo Chee Hean at the award presentation ceremony. www.equipment-news.com

NMC launched its M A P initiative to industry partners with a seminar on December 12, 2012. The keynote speaker was well known metrologist, Nobuo Suga, advisor and instructor, Mitutoyo Institute of Metrology, Mitutoyo America Corp.

Success is no coincidencee coincidenc We constantly strive towards that accomplishment heimatec GmbH (Asia/Pacific) 19 B Hillview Ave. phone +65 8112 6550 #01-03 Hillview Park mail kmoessmer@heimatec.com SINGAPORE 669555 web www.heimatec.com

www.heimatec.de

ENQUIRY NO 006

Ichi Seiki Wins The Singapore Prestige Brand Award

consultancy and training, to help ensure laboratories are capable of ma k ing accurate measurements. NMC actively work s w ith our pa r tners to maintain and adhere to the high standards of measurement for industries in Singapore.�

Live Tools for turning and machining centers

Singapore: The National Metrolog y Centre ( NMC ) of Singapore has launched the Measurement Assurance Prog ra mme ( M A P). This programme serves to enhance the measurement capabilities o f a c c r e d i te d te s t i n g a n d ca libration laboratorie s, so as to raise the overall quality benchmarked to international standards. This will help in building a nd st reng t hening confidence among the industry partners in Singapore. The programme further aims to help improve productivity by minimising manufacturing fa u l t s f ro m a r i si n g du e to poor measurements. Accurate me a su re me nt s t ra n slate to efficient manufacturing p ro ce s s e s , l e a d i n g to l e s s waste from the production of defective products. Acting executive director of NMC, Dr Thomas Liew said: “The MAP will provide regular proficiency tests for laborator ie s to ver if y their m e a s u r e m e n t c o m p e te n c y as well as help develop their c a p a b i l it ie s i n co mpl ia nce with international standards. T he M A P w ill a lso prov ide

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BusinessNews

GE & Taiwan Power Sign Wind Turbine Service Agreement

Miguel Saavedra, Spain

Schenectady, US: GE and Taiwan Power Company have signed a fiveyear, Full Service Agreement (FSA) covering 26 GE 1.5 mW class wind turbines operating throughout Taiwan. Under the agreement, valued at nearly US$11.4 million, GE will provide a full scope of services including planned and unplanned maintenance, repairs and spare parts. The agreement guarantees fleet availability of greater than 95 percent. Of the 26 GE wind turbines, 23 are located in Taoyuan County, and three are located in Kenting Township. The fleet contributes more than 110 million kilowatt hours of green electricity to the Taiwan power grid or enough energy for 28,000 Taiwan households.

DNV & GL To Merge H a m b u r g /O s l o , G e r m a ny/ Norway: An agreement has been signed to merge DNV and GL. The new entity will be called DNV GL Group. It will be one of the world’s ship classification societies and risk experts in the oil and gas, renewable energy and power sectors, and among the global top three within management system certification. “The merger rests on a strong strategic rationale, a nd responds to challenges of incre a se d g loba lisat ion, rapid technolog ica l cha nge and the need for sustainable development. Our customers will benefit from an increased ser v ice offering a nd globa l competence base as well as one of the densest networks,” says DNV’s Group CEO, Henrik O Madsen, who will be the CEO of the combined new company. “The merger with DNV supports our long-term goal of being recognised as one of the most respected technical assurance and advisory companies in the world,” adds GL Group CEO, Erik van der Noordaa. The DNV Foundation will hold 63.5 percent, while GL’s owner Mayfair SE will hold 36.5 percent of the shares. The new company, with a combined turnover of s o m e € 2 . 5 b i l l io n ( U S $ 3 . 3 billion), will be headquartered and registered in Norway.

Faro Unveils 3D App Centre Lake Mary, US: Faro Technologies has unveiled the Faro 3D App Center, the company’s online exchange for its Laser Scanner Focus3D software applications. Through the 3D App Centre, Focus3D users and software developers can download and share purposebuilt apps to meet specific scanning challenges. The 3D App Centre reduces costs and simplifies workflows by replacing expensive software packages that perform tasks users may never need. Instead, customers can access and download Faro software apps built specifically to resolve their particular 22

asia pacific metalworking equipment news Jan-Feb 2013

scanning challenges, such as surface or volume calculations. This result in a lower operating cost and an assurance for scanning professionals to get the software they need, so as to perform the right task each and every time. The App Centre also provides a forum for software developers to create and share their own apps with the laser scanning world. Now, thirdparties and other software companies can reach out to Focus3D customers directly, with apps tailored to meet their needs. www.equipment-news.com


ENQUIRY NO 003


Cutting Edge

Benson Foo On Productive Machining… The technical manager of Seco Tools Singapore tells APMEN what it means to be productive. By Joson Ng

Face milling with 16 cutting edges per insert boost productivity and cuts costs

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roductive machining means different things to d i f fe re nt p e ople . For Benson Foo, it is something fairly complex. He said: “Productive machining or productivity as such, is a very general term. There are many ingredients influencing productivity in machining. While we typically focus on the area that we can directly influence with our efforts, ie: the complete cutting tool solution in the machine tool spindle, there are many other factors that need to be taken into consideration to achieve a good result.” O n e p e r t i n e nt fa c to r i s paying attention to the complete machining setup, which entails the machine tool, its available power, stability and agility. The component setup like size, weight and clamping strength is also important. Other factors like geometric access limits, coolant supply 24

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and chip evacuation systems have to be considered, along with the material to be machined and the tool path. At the end of the day, he feels machining strategies and methods need to be balanced with correct cutting data. Balance is perhaps a key word here as Mr Foo explained that there are cross influences everywhere. He said: “Productivity could be defined simply as the highest possible number of correct components over a defined period of time. However, that is most often not the case. If one increases the speed of machining, output increases but so does tool cost as a result of shorter tool life. With cost curves being non-linear, one quickly realises that a balance is needed to find the best output/ cost compromise.”

Lending A Listening Ear In order to strike a delicate balance, Mr Foo stre ssed on the impor ta nce of communication. “We listen to our customers and find out what their manufacturing philosophy is and where they want to place their priorities and then we optimise the machining process from there. Typically, we start with bottleneck operations and work it backwards from there,” he said. Applying a DCR or Documented Cost Reductions system along www.equipment-news.com


CuttingEdge

Benson’s Pick To Increase Productivity • Square 6 shoulder mills with six edges per insert • Double octomill face mill (16 edges per insert)

processes. It can lead to dramatic productivity gains, especially in the so-called difficult-to-machine materials such as aerospace alloys or materials used as oil and gas components. The most important factor is that the high pressure coolant delivery nozzle sits as close as possible to the cutting zone in order not to lose any coolant pressure.

Getting Involved Working to increase productivity often requires close cooperation between users and tool suppliers. Mr Foo felt that it would be ideal if they could be involved from the start. “Typically, we can reduce costs in most applications by good margins. It all depends on the complexity of the job at hand

• Minimaster Plus, a modular end mill system

Enquiry No. 1001 Turn to page 96a or log on to www.equipment-news.com to enquire

Other Factors One definite focus on any cutting operation is the cutting tool, but other toolings and even coolants can have a significant impact on the whole operation. Said Mr Foo: “It is important to look at the complete tool as a single unit, ie: a cutter combined with an arbour, ready to be inserted into a machine spindle nose. The quality of the arbour (holding the cutter) is crucial. Its strength, precision and run-out has a direct impact on tool (insert) life and productivity. A tool that has a large run-out takes ‘uneven cuts’ with constantly changing medium chip thickness (hzm). This results in short tool life, chipping and micro vibrations. The spindle of the machine also has to match the strength and precision of the tool assembly. If any of these links are substandard, productivity is affected.” According to M r Foo, in terms of coolant, there is a trend towards high pressure coolant systems in the industry and such systems can improve chip forming www.equipment-news.com

ENQUIRY NO 019

with a process called ProductivityCost-Analysis (PCA), Mr Foo said these methodologies consider existing solutions, costs and output values while simulating a more productive alternative, reduction in costs and better productivity.

Jan-Feb 2013 asia pacific metalworking equipment news

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CuttingEdge

Machining Tips The feed method — It looks at existing feed per insert/tooth rates, and questions if it can be raised safely without overloading the cutting edge. If it can, it virtually has no effect on cost or tool life but increases metal removal rate ‘free of charge’ so to speak. It is a simple rule and often effective. Correct chip thickness values — The medium chip thickness is an often overlooked factor and it has a tremendous impact on machining efficiency. Besides that, correct cutter placement as well as entry and exit angles are important since they have strong links to premature tool failures. All this assumes that the basics are correct: Tool selection, methods and tool path.

High pressure coolant is delivered straight to the edge to help improve productivity

Enquiry No. 1002 Turn to page 96a or log on to www.equipment-news.com to enquire

Vibration damping can improve surface finish and tool life

and also the prevalent application skill level in a workshop. The best situation is when we are consulted right from the beginning before the component is first machined. We can then consider all above mentioned elements and define a solution set of tooling that works well and predictable right from the beginning. We have cases in the oil and gas industry, large components with hard to reach, deep cavities where we save up to 60 percent of machining time. This is always done with a combination of more suitable tools, better methods and tool paths and correct machining data,” he said. More Than Just Technology Embracing technology is one obvious way to better productivity. 26

asia pacific metalworking equipment news Jan-Feb 2013

However, companies can still achieve good output with better knowledge. Said Mr Foo: “Technology is one part of the business. The equipment is out there and available for everybody. We often see that the human factor is the decisive element that lifts productivity up to the next level. There often is a ‘knowledge gap’ with users that creates a difference between the capacity of equipment and how it is actually being used. If that gap is narrowed or closed, one sees a substantial increase in productivity. We address this with our clients through a STEP education programme, where we provide technology and process insight for metal cutting. This is not to be confused with ordinary product

training. STEP is a technology e du c at io n t h at a l low s ou r customers to get the maximum performance out of modern cutting tools, any tool for that matter, not just ours. It provides insight into the process of metal cutting and creates a deeper understanding on what is actually happening when we machine materials. The way our staffs apply our documented cost reduction system addresses bottlenecks and increases productivity while reducing overall costs.” Productivity in machining in a nut shell is about machining faster and extending tool life while not compromising on quality. The end result is easy to appreciate but achieving productivity requires pay ing attention to details, striking a balance in machining and working together to make the right choices. It may prove to be elusive for some but for those who have the knowledge or know where to obtain the knowledge, the potential rewards will be worth their while. Enquiry No. 1003 Turn to page 96a or log on to www.equipment-news.com to enquire

www.equipment-news.com


ENQUIRY NO 004


CuttingEdge

Tools For

Better Productivity

Increasing machining productivity is like an art with many different subtle considerations. By Dr Moshe Goldberg, marketing technical advisor, Iscar

T

he key to high productivity lies in the tooling and machining strategy that are applied. In this very competitive world, manufacturers are tr ying to increase their productivity constantly. This ongoing challenge entails raising the amount of metal removal volume, which requires boosting feed rate parameters, raising the depth of cut, and maximising cutting speeds. In order to achieve these targets, metal cutting operations should be properly managed and applied in the most effective way, utilising the latest cutting tool technology. The cutting tool factor holds a very important position in the machining environment. Although cutting tools account for only three percent of the total production cost, proper choice can effectively deliver savings up to 15 percent on overall costs. Raising machining performance by 15 to 20 percent can have a p o sit i ve dom i no e f fe c t o n productivity, which will directly contribute to a higher level of profitability and strong competitive position. These objectives can 28

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be achieved, only by combining cutting tools, with an advanced CNC machine tool and smart CAD/ CAM software. Using The Right Metal Cutting Strategy Selecting the right cutting tools and machining parameters can reduce cycle time and result in the total energy per piece consumption. Fast metal removal process not only provides high productivity, but saves energy. In broad terms, the shorter the engagement of the tool with the cut, the more productivity is achieved and more power is saved. This feature can further be enhanced by applying a high specification CAD/CAM system to define the shortest path for the tool, coupled with optimising the machining conditions. Eliminating Vibrations Combining improved performances of shearing mechanism, accuracy, and efficient distribution of cutting forces, while eliminating vibration and facilitating easy chip evacuation will all lead to a substantial reduction in power

consumption, as well as higher productivity. The two main factors that mostly contribute to a high volume of metal removal with minimum energy consumption comprise helical cutting edge geometry and variable-pitch flute configuration. Tools with variablepitch flute configuration represent patterns that eliminate harmonic vibration, known to be the main source for chatter. Whenever vibration or chatter occurs during machining, operators immediately turn down the speed, feed or depth of cut parameters and by doing so ultimately compromise on performance. A better option would be using endmills that are designed specifically to eliminate chatter problems in milling operations, and at the same time produce roughing and finishing simultaneously. Iscar’s Chatter Free Finishred cutters’ variablepitch flute pattern eliminates harmonic vibration, the main source of chatter. This enables faster cutting and finer finish using rough machining conditions. These endmills are useful for low-power machines with ISO40 or BT40 adaptations. The solid carbide version can handle fullslot machining of as large as x2 diameter. Combination of roughing and finishing solid carbide endmill in a single tool, reduce the cycle time, while the four variable pitch flutes, 38 degree helix, medium length; provides vibration free, quality finished surface at rough machining parameters at high load applications. Increasing Turning Productivity The most popular option to raise productivity in turning is by utilisation of the helical cutting edge geometries, in order to obtain high metal removal rate. Inserts with unique cutting edge and rake face configuration, can operate www.equipment-news.com


CuttingEdge at high machining parameters (particularly high feed rate), while exerting low cutting forces on the cutting edge, interfacing with the workpiece and consequently resulting in vibration reduction. According to the manufacturer, Iscar’s insert’s corner has a wiper configuration which produces good surface finish even at high feed conditions, which on occasions can eliminate a finishing cut. The corner angle is 88 degree, which provides increased strength. These helical cutting edged inserts can be accommodated on existing standard ISO toolholders, by a simply replacing the supporting shim beneath the insert. Utilising Chip Thinning Effect For Increasing Milling Productivity A xial chip thinning is often associated with high speed machining, but the same effect could be used to increase metal removal rate with a standard-size endmill run on a moderate-speed machine, when the insert profile blends into a radius. Chip thinning occurs due to light depth of cut that meets the insert along its curve, allowing feed rate to increase. The term ‘high speed machining’, particularly in applications involving steel, often refers to small tools run at high spindle speeds and feed rates with light depths of cut. Despite the light cuts, machining in this way achieves a high metal removal rate by taking the passes very rapidly. By virtue of this effect, the chip thickness is smaller than the advance per tooth. This means that the advance per tooth can be increased, and correspondingly the linear feed rate in mm per minute can be increased even beyond what the high spindle speed already allows. The material meeting the curve of the tool at a point below the tool’s full radius exerts a cutting force that is not entirely lateral, www.equipment-news.com

Fast feed milling tools are often designed to improve productivity while reducing power consumption.

but instead pushes up towards the centre point of the insert. To that extent, only some of the cutting force is directed along X and Y. The remainder is directed along Z, the direction of the spindle, which is the most rigid of the three axes. With correspondingly less force directed along the side of the tool, there is less opportunity for tool deflection, and the cut is more stable. There are fast feed milling tools specifically designed for improving productivity for milling applications, while reducing power consumption. Iscar’s range provides stability and enables machining at high feeds, even for long overhang applications. In addition, the insert is clamped into a dovetail pocket which provides firm clamping. Cutters of that type need to be equipped with coolant holes, particularly when applied to high feed milling, ramping, plunging and helical interpolation applications. Chip thickness is determined by the combined effects of the tool’s axial DOC and radial engagement, as well as its lead angle. A 45 degree lead angle spreads the chip over a longer surface and produces only 70 percent of the programmed chip load. Standard edge preparations for inserts in hard milling applications consist of a narrow land and a light hone. Some applications, such as severe interruptions or workpieces

featuring heavy scale, require a larger land. The feed rate per tooth should be larger than the edge hone to ensure that the tool cuts but does not rub the workpiece and that sufficient chip thickness is achieved. Understanding and controlling the chip thinning phenomenon can boost productivity. Summary A high level of productivity can be achieved by applying the most adequate tooling solution, combined with the appropriate machining strategy and adopting the most advanced features as explained before. The key to high productivity is in the hand of the user, and a strategic decision has to be made whether to adopt this technology, tooling solutions and all other nontraditional machining strategy. In order to remain competitive, machinists a re expected to change the concept, think out of the box, and use the most updated tooling solutions. Implementing efficient machining solutions will contribute to the reduction of cutting forces, distribute these forces effectively, eliminate vibration and facilitate easy chip evacuation. This will ultimately lead to a high volume of metal removal per piece, coupled with minimum energy consumption. Enquiry No. 1004 Turn to page 96a or log on to www.equipment-news.com to enquire

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Tech Talk

The Route To

Greater Efficiency

Optimal production planning requires high-quality tool and technology data. This in turn allows a consistent production process with fewer errors, lower machine downtimes and ultimately, higher productivity. By Ralf M Haassengier, PRX Agentur fĂźr Public Relations, for TDM Systems

30

asia pacific metalworking equipment news Jan-Feb 2013

T

he Siemens fossil power generation business develops technologies for low-CO 2 electricity generation with a high level of efficiency in order to reduce fuel consumption. At the plant in Charlotte, US, some 1,000 employees are involved in the production of components for generators for gas and steam turbines. CNC machines are used for machining, milling, drilling, and to hob and turn turbine blades, rotor blades and housings. According to Klemens Huch, generator operations manager at Siemens Energy, the company is capable of complex production process involving more than 100 machines. The vertical integration and large number of parts to be produced for the widest imaginable range of turbines and generators entails a correspondingly large number of tools. More than 10,000 tools are in use at the machines. These are constructed out of more than 30,000 items. Tools, adapters and fixtures etc, including their technology data, all require clearly structured management in order to avoid duplicate orders and redundancies and thereby, to save costs. Moreover, the data are required for programming. The Path To Digital Manufacturing Until a few years ago, the Charlotte production facility used its own internally developed operating materials management system which had at that time, reached its limits in terms of functions and extendibility. “On the one hand, our old system was incapable of mapping and storing tool graphics. On the other, data maintenance was elaborate and complex. The tool data was incomplete, which rendered them useless for many further processes,� says Mr Huch. This resulted in a scenario that www.equipment-news.com


TechTalk saw unreliable tool selection in the generated NC programs during production. Particularly when it came to the processing of new workpieces on the CNC machines, the machine operators had to proceed very carefully in order to avoid any risk of collision. “Sure, we did even then try to simulate the production process, but the lack of adequate data maintenance for our production equipment management rendered this impossible under real-life conditions and represented an additional process risk,” recalls Eric Graber, manufacturing engineer. This often led to discrepancies between the NC programming and production staff, and mutual acceptance was low. “We could never rely 100 percent on the programs. If we wanted to work with any degree of process stability, we had to run in new processes very slowly to avoid collisions, which were very timeconsuming.” A Paper-Free Factory “Our highest objective was a paperfree factory,” says Mr Huch. Secure, standardised processes were necessary, with digitally stored work and equipment instructions and set-up sheets, to which everyone had access: both in NC programming and work preparation and at the machine itself. Of one thing, the production specialist had no doubt: “At the end of the day, we would only be able to develop uniform and secure production processes and draw up and define production standards if everyone was working with the same up-todate operating materials data.” Once the goal had been set, the team around Mr Huch and Mr Garber went looking for software that could be used to realise digital manufacturing at the company. They eventually settled on a TDM Systems tool data management system, which had been in used in other Siemens www.equipment-news.com

A standard interface with Vericut ensures that the tool data in the production simulation is true to life. Left: the dataset in TDM, right: after transfer to Vericut.

facilities for production equipment management. The fact that the software in its standard modules already met most of Siemens Energy’s requirements was also an advantage. It is possible to store not only 2D and 3D tool graphics, geometry and technology data (cutting speed, feed rate etc) but also work information and set-up instructions in the system’s tool database. Mr Huch was also persuaded by the ability of the software to communicate with other systems: “It was important to us that the system offered good interfaces with up- and downstream systems, such as SAP, CAD/CAM, simulation and presetting systems. This allowed us to integrate TDM without difficulty into our system landscape.” T h e s y s t e m ’s m o d u l a r construction made it possible to plan and implement the introduction of the software step by step. The team decided, as a first step to implement the system’s base module, is the integration into the planning system (CAM and Simulation). As a second step, the application was realised at shopfloor level: inventory management, connection to the Zoller presetter and gauge and calibration control.

This was an advantage also for operations spread over more than one site. Today the team uses the entire range of TDM data and graphic generators for the creation and maintenance of tool data and graphics. “This makes simulation a lot easier for us,” stresses Mr Graber. “We no longer need to transfer tool data manually into Vericut, which is an advantage in saving time and quality.” NC Planning With Integrated Production Experience In turbine manufacturing in p a r t i c u l a r, i t i s e x t re m e l y important to ensure that errors do not creep into processes and tools. Process stability is the highest priority. To enable the enormous number of complex parts to be produced with precision, each year, some 1,500 new NC programs are written for the tool machines. The exact planning and calculation of the individual processing operations in the NC programs are facilitated by staff transferring the tools with their geometrical and technological parameters directly from the tool data management system into the ProE tool library. There, the tools are planned in for each individual processing operation. Jan-Feb 2013 asia pacific metalworking equipment news

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TechTalk

The system is a repository for thousands of work instructions, set-up aids and even set-up photos and graphics, so that the machine operators can use tools and set-up equipment properly.

In the software program, any number of technology sets can be defined for each tool. This permits a detailed definition of the field of applications for an individual tool. This information is also available in ProE via CAM integration. Mr Graber explains his team’s use of the software solution: “The production staff stores data documenting their experience of individual tools and tool lists. In this way an enormous pool of knowledge is created which is accessible to the planning staff.” In the meantime, NC programs are simulated to permit the early recognition of potential collisions. In the process, the data in the software program has a significant role to play in the execution of realistic production simulations. At the end of the day, the virtual simulation is intended to mirror real production processes as closely as possible: this is the only way of recognising and minimising risks. Alongside the tool data, 3D tool graphics can also be transferred into the simulation system. The 3D tool graphics are generated using the TDM Data and Graphic Generator. The team uses 32

asia pacific metalworking equipment news Jan-Feb 2013

the respective programs for drilling, turning, milling and solid round tools. This software tool is used to create tool items in TDM with datasets and 2D and 3D graphics. In this way, the Walter tools used by Siemens can be set up, as the complete Walter standard catalog is available in digital form in the generators. Tool construction takes place almost automatically in the software program, including both 2D and 3D graphics. The created tools can then be ‘enriched’ with the experience values from production: reliable technology data such as cutting parameters for the materials to be machined. In this way, new programs are run quickly and securely, resulting in a continuous improvement in efficiency. It might be more accurate to describe the working method at the company, as network manufacturing. The operators at the shop floor level document their experience in using a tool. This knowledge supports the NC programming in respect of tool selection and calculation of the processing operations. By this means, the planning crew knows which tools are really suited to

particular work processes and which are not. Transparent Tool Circulation For each of the 50 production units, the orders are prepared in a central tool assembly area, ie: the tools are assembled and preset for individual orders, ready for punctual transfer to the machine in question. The machine operators see on their control monitors which orders are next in line for the machine and retrieve the corresponding tool lists from TDM. This way, the operators no longer have to look for their tools; instead they stay at their machines, as they can see that their tools have already been scheduled in. The transparent and up-to-date databases are used by some 50 employees in their daily work. Mr Huch says: “We have standardised production processes which work almost entirely without paper. The central database secures a high, uniform quality standard; the staff on the machines can now rely on the NC programs and work instructions.” Enquiry No. 1101 Turn to page 96a or log on to www.equipment-news.com to enquire

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TechTalk

Enrico Krog Iverson On

Industrial Robots…

The CEO of Universal Robots gives his take on the role of robots in today’s manufacturing environment. By Joson Ng APMEN: What are the types of industrial robots in the market today and what are their typical applications?

APMEN: Please share with us the latest technology in robotics and how it can be applied to metalworking.

robots, ie: robots that are able to work in close cooperation with humans. In recent years, a lot of resources have been invested in the development of safer robots and we now see the first robots in the market, that have been certified to work directly with humans. Naturally such direct cooperation still has a few limitations and depends on the actual application and tool operated by the robot. We a lso see a movement towards robots that are much easier to operate and program — previously it has taken a long time to learn how to program i ndu st r ia l rob ot s a nd on ly large companies have had the internal expertise available. Today we see robots that you can learn to program in a few hours and where the actual operators in the factories can do the programming. Finally we are beginning to see robots with two arms, and systems where it is very easy to coordinate the movements of two or more robot arms. These robots are very well suited for assembly applications in all industries.

EKI: The latest technology, and also a trend for the coming years, focuses on collaborative

APMEN: It is said that the market requires small and flexible lightweight robots to

Enr ico K rog Iver son ( EKI ): There is a very large number of different types of industrial robots in the market today, such as articulated robots — probably the best known type — linear robots, SCARA robots and delta robots. The different types of robots cater to different types of applications. Wit h t he dif ferent t y pe s of robots being available in different sizes, it is fair to say that there are very few industrial applications that cannot be rob ot ise d to day. T he ma i n applications are still welding and material handling and a large number of robots are now used for the loading and unloading of CNC machines. However, we also see a growing number of robots in process oriented applications and assembly.

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cater to the needs of small and medium-sized enterprises. How small are these robots and what are their operating range? How suitable are they for the metalworking industry in Southeast Asia? EKI: It is absolutely true that there is a requirement for small, flexible and easily programmable robots for the SME’s. With new technologies that allow direct interaction with humans and easy programming of the robots, industrial robots are no longer only something considered and used by large companies. The trend for these small and easy to use robots started in Europe, but it is now moving fast across the world. These new type of industrial robots are suitable for the metal industry, as they can be installed in existing factories without changing the factory layout. The lightest and smartest of these robots have even been i n st a l le d d i re c t l y o n C N C machines. With weights as low as 18 kg, they can be moved a rou nd i n t he fac tor y a nd thereby ensure a higher degree of flexibility than the SME’s have been used to so far. Enquiry No. 1102 Turn to page 96a or log on to www.equipment-news.com to enquire

Jan-Feb 2013 asia pacific metalworking equipment news

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Software & Measurement

Take A Closer Look At

Medical Parts

Advanced software makes vision and multi-sensor inspection a mainstream tool for medical part analysis and inspection. By Marc Stalker, global product manager, PC-DMIS Vision

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ccurately va lidating the dimensional specifications of medical parts is a crucial aspect of design and product development. However, medical parts can oftentimes be too difficult to measure with conventional tactile measurement systems. For instance, part features may be too small for, or out of the reach of, hard touch probes. Soft and pliable materials can deform from contact measurement and contact probes might scratch highly finished orthopedic products. Fo r t u n a te l y, v i s i o n a n d ot he r non - cont ac t probi n g technologies let users rapidly collect vast amounts of dimensional information for design analyses and subsequent part validation. The technologies use CAD-based programs that facilitate measurement systems to operate in 2D, 2.5 D, and 3D modes while collecting data that can be used both to validate dimensions and analyse designs and manufacturing processes. These advancements were ha rd - won a s v ision - system software developers spent decades creating proprietary algorithms for accurately capturing images 34

asia pacific metalworking equipment news Jan-Feb 2013

and transforming them into discrete points of data that could be automatically compared to nominals in the CAD model — and that was just the beginning. Current refinements to the software used with vision and multi-sensor metrology systems should be of great interest to medical-device developers. Algorithms Augment Optics A perceived barrier to using vision and multi-sensor measurement systems as primary equipment for medical part metrology has been the idea that adjusting the systems for appropriate lighting, contrast, and edge-detection sensitivity required too much specialised knowledge for the average user in the metrology lab. This may have been true at one time, but it is no longer the case. Many algorithms in vision-measurement software e f fe c t ive ly automate t he se adjustments, a llow ing for consistent measurements from part to part and vision machine to vision machine. The subjectivity of making manual adjustments to optimise contrast is a legitimate concern. Optimising contrast substantially

improves measurement accuracy by improving the vision system’s capability to detect edges and compensate for the tendency of light to bend around the edges of cylindrical surfaces, thereby shortening measured distances. Today, special algorithms automate the adjustment of contrast levels. At the touch of a but ton, t he a lgor it h m makes a series of rapid iterative adjustments until an optimal and stable level of contrast is gained. Another potential source of vision measurement variability is caused by the differences in light sources (halogen or LED) used to illuminate the parts and the ambient lighting conditions in different plant locations. It is easy to correct for these variations when the measurement software includes algorithms that allow users to compensate for these factors just as they would calibrate a probe on a CMM. Unlike tactile probes, cameras do not touch the edge they measure. Therefore, edge detection must rely on the accurate interpretation of data the vision software receives from the camera. Fortunately, advanced vision measurement www.equipment-news.com


Software&Measurement The graphical representation of results in CAD-based vision measurement software allows users to identify features

softwa re ca n tune its edge detection algorithms to account for both the part’s surface and the illumination conditions. Generally, the software uses a dominant edge algorithm to select the edge of a part when using sub -stage illumination. Measuring top-lit parts with a high surface finish is more of a problem. In this case, users can select a specific edge algorithm, which allows the detection of the feature in question based not only on contrast but also its shape and location. If there are grind marks on the part, which might confuse the camera when top lighting is used, the software can apply another type of algorithm that chooses the most dominant edge out of possible candidates in the camera’s field of view. Breaking Bottlenecks Until recently, quality assurance was one of the biggest bottlenecks in medical-device development. Advances in vision and multisensor software now help many h a r r i e d qu a l it y a s su r a n ce personnel keep pace with the frenetic pace of development. Vision systems were www.equipment-news.com

traditionally programmed in a teach-and-learn mode. This meant that while users were developing me a surement routine s, t he machine was not measuring parts. Today’s CAD -based vision software allows the development of part programs off-line, while the vision system continues to measure. This does not mean that programmers must work with unfamiliar software and an unfamiliar interface. The best of the new vision metrolog y software looks the same in online and offline modes. It can also generate a view of the part that accurately simulates what the camera would see if it were working on an actual part. A big advantage of off-line programming is that users do not need to have the physical part in hand. Quality assurance personnel can therefore have programs ready to measure the part as soon as the prototype is complete. In many quarters, offline programming is slashing days from product development cycles. Of course, vision systems can only measure what the camera can see. So, when something obstructs the camera’s view of a feature, another type of probe is

necessary. In the past, this might require removing the part from the vision system and using a different measurement device. In contrast, the software used in advanced, multi-sensor systems lets users collect data using a combination of cameras and other probing technologies on the same machine. In the medical industry, the most common alternatives are touch-trigger probes and whitelight sensors. Sophisticated calibration techniques consolidate t he me a su re me nt s co m i n g from these sensors into a single coordinate system. It makes no difference which type of probe collects the data. In addition, rotary and trundle tables make it possible to present the part to any sensor at an optimal orientation for accurate measurement. Parametric Programming For medica l ma nu facturers making families of parts, the capability to generate parametric programs for their vision systems can help boost productivity. A time-honoured approach used routinely by CMM programmers, parametric programming creates a set of rules that govern the generation of programs for every member of a part family. For each new member of the family, the programmer simply changes values in a table and the software automatically creates the new part. In one example, it took an orthopedic-device manufacturer about 16 hours to create one multisensor system program to measure a single prosthetic. For the 100 parts in the family, it was looking at about 1,600 hours of measurement programming time. Instead, the compa ny spent about 40 hours to write a parametric program, which gave it time ti generate new programs. This cut the cost of programming while helping the quality lab keep pace with product development. Jan-Feb 2013 asia pacific metalworking equipment news

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Software&Measurement

Software including feature-based measurement with target splitting allows users to easily select areas of interest

Other software enhancements b o o s t v i sio n - m e a su re m e nt data-capture productivity. For e x a mple , t he Mu lt iC aptu re technology in PCDMIS Vision software automatically finds multiple features that fit in the same field of view and captures their measurement data simultaneously. Upon completing the measurements in a particular field of v iew, the a lgorithm dr ive s t he ca mera to t he next cluster of features and measures them in the same way. This sequence continues until the inspection program is complete. This approach allows users to measure parts up to 35 percent faster. In addition, best-fit analysis, a tool long familiar to users of conventional CMMs, is being employed with great success on v ision - a nd multi- sensor machines. Be st- fit a lgorithms use t h e d a t a p ro du ce d b y t h e inspection software to group together related features. It then evaluates the ‘composite’ feature for design intent. This approach ca n substa ntia lly reduce the number of good parts rejected during inspection, pa r ticula rly when critica l features of interest are complex 36

asia pacific metalworking equipment news Jan-Feb 2013

and numerous. The approach also provides information that lets manufacturers rework parts with greater precision as well as modifies the manufacturing process to eliminate subsequent problems. Enterprise-Wide Metrology Vision and multi- sensor inspection are now mainstream in medical product development and manufacturing. As such, they can work in a broader enterprise metrology framework that lets dimensional data and analyses be integrated into any phase of development from design through final inspection. Recent advancements further support this holistic concept of medical-device metrology. For example, current software allows engineers to record their design intent in the form of inspection plans and attach these to CAD files. This information is an invaluable aid to part programmers in creating inspection programs. The ‘inspection plan’ approach takes the designer a little additional time but results in multi-sensor and vision system programmers being able to complete their work up to 70 percent faster. Further, the software gives both designers and inspectionsystem programmers access

to change-management tools. These are bidirectional software modules that notify users of a ny thing that a ffects the dimensional characteristics of a part, whether it is a change made by design or by manufacturing. Current vision and multi-sensor systems capture huge amounts of data, which provide a deep reservoir of data for analysis. Medical manufacturers have begun generating vast data clouds for reverse engineering and for dimensional and statistical analysis. Managing this amount of data and making it readily available has forced metrology software vendors to rethink their data storage strategies. Therefore, the latest releases of vision metrology software supports advanced, scalable, open source database technologies. Giving the users analytical tools to access raw data is only half the battle. It is also important to give those who need to be in the know, secure access to information and reports as quickly as possible. As such, web-based reporting and data management software that make it easy to collect data, configure reports, and disseminate information are now available. Enquiry No. 1201 Turn to page 96a or log on to www.equipment-news.com to enquire

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MTA2013_APMEN Jul12_FA(Path).indd 1

ENQUIRY NO 193

9/19/12 10:35:50 AM


FORM Join Cut 

L

aser technologies have many applications in the world today. From the medical industry, all the way to the defence industry, laser technologies are widely used. This is no exception in sheet metalworking as well. In the recently concluded Euroblech, APMEN spoke to two companies involved in the laser cutting business to feel the pulse of the industry as well as to find out what is behind the hype of fibre laser technology. Offering a choice in many performance classes featuring both solid state and CO2 lasers, Trumpf is one company that has a rich history in laser cutting technology. Giving his take on laser cutting technology, in particular fibre laser, Dr Hans-Peter Laubscher, MD of Trumpf (Asia Pacific) said: “CO2 lasers are now known for 20 years or so. Fibre lasers are not really new as well. We started in the late 90s. However, fibre lasers only came into the market in a big way since the last two to three years. With this, many manufacturers are now concentrating their R&D efforts in this segment. The advantage a fibre guided solid state laser is, besides higher cutting speed in thin sheets using nitrogen as assist gas and a wider range of material you can cut with, it also consumes lesser power. With the TruLaser 3030 fiber, we are now in the position to offer a complete range of laser solutions; from the 1000 series, to the 3000, 5000 and 7000 series with either a CO2 laser or a fibre laser. It is now up to the customers to choose a machine based on his particular needs.” LVD, a newcomer in the field of fibre laser cutting machines, is dipping its feet in the increasingly crowded pool of fibre laser technology for the first time at Euroblech with the launch of the Electra FL. While Matthew Fowles, marketing manager of 38

asia pacific metalworking equipment news Jan-Feb 2013

The

Source Of

Fibre

Asia Pacific Metalworking Equipment News (APMEN) takes a look at what is making waves in sheet metalworking. By Joson Ng LVD admitted it has been a long time coming due to extensive development work, he was happy to give his take on their laser technology. “The Electra is our first fibre laser cutting machine. Four years ago at Euroblech, we saw the first fibre laser cutting machines entering the market. By waiting

four years, we have learnt several things. Firstly we have learnt what fibre lasers are good at and what they are not so good at. Secondly, we saw that it was important to develop a machine that had the dynamic capacity to fully exploit the main advantage of fibre laser cutting and that is cutting thin sheet metal quickly. Subsequently, www.equipment-news.com


Form Join Cut 

when we designed the Electra, we started with a blank piece of paper and we designed it to go as fast as the process,” he said. Powered by a solid-state doped fibre laser source, Electra FL provides fast, accurate thin sheet processing of traditional sheet metal materials such as mild steel, stainless steel and aluminium with the added versatility to efficiently process metals such as copper and brass. Increased beam absorption of the 1 μm wave length laser beam by the material provides processing speeds up to twice as fast as a CO2 laser sourced laser in thin sheet metal. The cutting machine features a fibre laser source technology with a wall plug efficiency of up to 30 percent. The maintenance-free fibre laser resonator utilises ‘all in glass’ transmission technology to ensure ‘contamination’ free delivery of the beam to the cutting lens, resulting in no loss of performance due to optic contamination. Breaking Down The Fibre Energy consumption is one of the most important factors in manufacturing as it directly affects cost. Away from the financial considerations, the issue of energy consumption also weighs heavily these days from the environmental perspective as people are placing more emphasis on the impact a pa r ticula r www.equipment-news.com

Dr Laubscher said the advantages of a fibre guided solid state laser are higher cutting speed in thin sheets, a wider range of material suited for cutting and lower power consumption.

manufacturing process can have on the environment. This trend is not lost in fibre laser cutting. Sa id M r Fowle s: “Pe ople are increasingly aware of the economic and environmental type of statements like ‘green footprint’. For a number of years we have been constantly working on increasing the efficiency of power consumption. The power conversion for the Electra is better than the CO2 lasers. Also, you have to compare part costs, material types and surface finishes. It is a complex equation.” He also said that while some of the advantages fibre laser cutting have over current CO2 laser cutting technology are low running costs and increased wall plug efficiency, it is important to note that CO2 laser technology has not been standing still. So the claims of lower costs and efficiencies of fibre lasers must be made compared to the latest CO2 laser sources. Echoing the same sentiments, Dr Laubscher acknowledged that the common concerns for lasers are their efficiency and power consumption. This presents an obvious route for improvements

for R&D engineers. He revealed that the company is undertaking quite a number of measures to lower the power consumption for their laser products, even for CO2 lasers. For example, they have introduced features like the standby mode or more efficient chillers in order to cut down the power consumption of laser. He also felt it is important to consider other factors affecting efficiency. He said: “Coming back to fibre guided lasers, the electrical consumption is one part of the efficiency issue. The other part is how to make use of the potential speed and productivity advantage. It is done by cutting with nitrogen in fusion cutting. Fusion cutting with a fibre laser has a speed and productivity advantage in thin sheet metal with thicknesses up to 3 or 4 mm. However, you are only able to gain this advantage with a significant amount of nitrogen gas, which typically is in the range of 15 to 20 bar. That might be a concern for some customers. They may have to ask themselves questions like ‘Is it cost efficient to spend money on nitrogen gas in order to gain this amount of productivity?’ It is a tradeoff.” Jan-Feb 2013 asia pacific metalworking equipment news

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Form Join Cut 

Mr Fowles: “There is a cut-off point where the technology of fibre laser tails off and CO2 laser takes over.”

Gassy Issue The gas used in laser cutting plays a role in the quality of parts at the end of the process. The issue however, is clouded by economics. Said Mr Fowles: “In fibre laser cutting, there is no need for gas in the beam path. The gas you need is the assist gas. It is typically put around the beam. There are two gases, nitrogen and oxygen gas. You can also use dried compressed air as an assist gas when cutting thin materials in high speed. If you see a fibre cutting machine cutting parts quickly, they are using nitrogen. Nitrogen is mainly for the removal of melted material because you are cutting quickly. The gas is blowing the materials out. The second factor (for using gas) is it will ensure a clean edge. If you want a paint ready edge with no oxide on the edge of the sheet, nitrogen should be used. If you are cutting thicker mild steel, depending on the fibre laser source, (3 or 4 kW), there is a cutoff point where the technology of fibre laser tails off and CO2 laser takes over.” Away from nitrogen gas, Dr Laubscher spoke at length on the role of oxygen and compressed air in laser cutting. 40

asia pacific metalworking equipment news Jan-Feb 2013

He said: “We are doing oxygen cutting for mild steel. As the material has carbon content, it is burnt during the cutting process and the laser in this case is only the accelerator or the facilitator to the cutting process. The heat itself is generated by oxidising the carbon. Oxygen cutting consumes less laser power because you are using the oxidation process as an additional power needed in cutting. Compressed air cutting, on the other hand, is a cheaper variant of cutting with nitrogen gas. This process is a mixture of fusion cutting and oxygen cutting. It will result in burrs and oxidation after processing. The underside of the material will not be as smooth or shiny after cutting compared to oxygen cutting of mild steel.” Not Quite The Perfect Process…For Now With good surface quality and fast cutting speed, some might be tempted to view laser cutting as an ideal process. Although the sentiments on the ground tend to swing in the favour of fibre laser, there are still some chinks in the armour which people should be aware of. “ T here a re not so ma ny disadvantages associated with

laser technology as they (laser cutting machines) are flexible tools. Lasers have come into metalworking from the late 80s and taken over from punching to produce smaller batch sizes,” said Mr Fowles. However, when asked to state a disadvantage of laser, he said: “Laser cannot form; it cannot put a form into a shape. You can solve that by buying a combination machine with a punch and laser. The capital cost of the machine however, will be a factor for many. If you are producing small batches and a variety of different material thickness and intricate shapes, lasers generally do not have that many disadvantages.” Euroblech 2012 could be seen as the show which saw fibre lasers finally come of age. Although currently in vogue, it might be wise to know there are still alternatives, albeit less ‘modern’ ways of making sheet metal parts, like punching. A decision should only be made after considering all factors before deciding if fibre lasers are suitable because when used properly, it can be a real performer but when applied in the wrong areas, it can be an expensive mistake. Enquiry No. 1301 Turn to page 96a or log on to www.equipment-news.com to enquire

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Industry Focus

MTA 2013

A

sia’s aviation industry has witnessed strong growth in recent years, and is predicted to progress even more in the future. The opening of the Rolls Royce facility in Singapore earlier in February 2012 is testament to the growing confidence manufacturers have in Asia’s capabilities to manufacturing high-quality parts. With the delivery of the first Singaporemade Trent aero engine for Airbus A380 on November 28, 2012, it further seals Singapore’s reputation as Asia’s Aviation Hub. In tandem with this industry trend, MTA2013, returning to the exhibition halls at Singapore Expo from April 9 – 12, 2013, is geared

Supports Singapore’s Position As Asian Aerospace Hub of Choice

to impress industry visitors by the unveiling of a specialised group of companies housed within the Capabilities Hub. Solutions For The Aerospace Sector The Capabilities Hub will showcase a cohort of enterprises that serve t h e p re c i s i o n e n g i n e e r i n g industry. These companies will demonstrate their aptitudes in the manufacture of highquality, advanced solutions — all dedicated to meet the e m e rg e n t n e e d s o f A s i a ’s aerospace, complex equipment, medical technology and oil & gas sectors. Serving the aerospace sector,

Onn Wah Precision Machining deals in complex medium-size components in a high-mix, low volume environment, and serves a range of sectors including the aerospace, semiconductor, oil & gas, biomedical and optics. Adding to the show’s exhibitor line-up is Singaporean company JCS Vanetec, which specialises in the manufacturing of 3D compressor airfoils, or vanes, for all sizes of commercial and military aircraft engines. The company’s services include the manufacturing of sheet metal components and offer tool & die turn-key solutions to the local and international gas turbine industry. Enquiry No. 1401 Turn to page 96a or log on to www.equipment-news.com to enquire

Sphinx Tools Ltd. Gewerbestrasse 1 CH-4552 Derendingen

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Phone +41 32 671 21 00 Fax +41 32 671 21 11 www.sphinx-tools.ch

Swissmade tools

ENQUIRY NO 015

Where precision sets standards.

Jan-Feb 2013 asia pacific metalworking equipment news

41


IndustryFocus

Singapore Plots A

Stable Flight Path

The Singapore aerospace industry is expected to cruise even with some light turbulence expected ahead. By Joson Ng

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n a typical takeoff roll, once a plane reaches the ‘V1’ speed, this is arguably known as the speed that the aircraft can no longer stop with the amount of runway left. In a way, this aviation term aptly describes where the Singapore aerospace industry is at the moment. It is currently taking off and it has to lift off no matter what. As to what will happen during the flight, nobody knows for sure but the ‘weather forecast’ for the industry according to Dr Aloysius Tay, chief executive of the Association of Aerospace Industry Singapore (AAIS), is going to be fair for now. “This year (2012) has been generally good. CAGR will probably be 10 percent, like it has always been. With the Seletar Aerospace Park now up and running, 2013 will be better as companies who have been establishing themselves this year (2012) would have started productive operations. Big companies like Rolls-Royce should ramp up production cycles from 2013 as they become more settled in their new home,” he said. Despite several dark clouds on the horizon, namely the Europe debt crisis and the talk of China’s growth slowing down, Dr Tay is confident the industry is poised to weather the turbulence.

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asia pacific metalworking equipment news Jan-Feb 2013

“In fact, the problems in the US and Europe pose good opportunities for Asia. As the US currency is weak, this means purchasing becomes cheaper for us. With Europe being unstable, we see European companies coming here to establish a presence,” he added. For China, Dr Tay feels that the market is “selfsustaining.” He said with increasing affluence in the Chinese society, the demand for air travel will increase as well. The Chinese engineering companies and some of those outside the country will stand to benefit. Technology Trends Dr Tay pointed out a key trend in the industry that will affect the manufacturing job shops in Singapore; it is the usage of composite materials. Said Dr Tay: “We see, in terms of airframes, that we have moved away from sheet metal to composite materials. Therefore, there will be a big demand for skill sets in composite materials. Our workers need to equip themselves with relevant skills as we are talking about bonding rather than riveting now.” Composite materials bring obvious advantages from a designing and application point of view but when it comes to machining, it introduces a new set of challenges. New technologies and techniques will have to be learned quickly in order for local job shops to keep up. Although companies in Singapore are investing in new technologies, they need to use them in a correct manner, according to Dr Tay. “Companies are using five axis machines to manufacture sophisticated parts. However, it is not the technology that we are worried about today. It is the people who handle the technology. For example, workers who can handle three axis machines perfectly may still handle the five axis machines like a three axis machine, resulting in the underutilisation of the technology,” he said. www.equipment-news.com


IndustryFocus He hopes companies will send their operators for training to use their high-tech machines efficiently because it defeats the purpose of investing in new technology when companies are not getting the most out of it.

Productivity Rules AAIS is very active in promoting ‘AeroProductivity’. In his interactions with the industry’s players, Dr Tay has picked up that workflow is an important concept in many of Singapore’s aerospace shops. He said: “In the last two to three years, a lot of shop managers have been talking about processes and systems. Like the metalworking industry, it is the system and the process flows that directly influence output. It is therefore important for us to always ensure our systems and processes are at their optimum productivity levels.” He added that shop managers are looking at the prioritisation of tasks and many shops are now looking at using systems to help them see which tasks are priorities. Besides productivity, repeatability in manufacturing is also crucial. In conclusion, he said: “If companies want to serve the aerospace industry, they need to ensure quality in their products. Accuracy in production is very important because we cannot afford gaps that are not supposed to be there in an airplane. The accuracy of component manufacturers is the key to success.” Enquiry No. 1402 Turn to page 96a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 052

Staying Ahead A stable government, good IP protection, modern infrastructure, skilled workforce and stable currency are some of the strengths of the Singapore aerospace industry according to Dr Tay. However, he did warn that these attributes can be emulated by any country if they wanted to. As such, Singapore needs to better manage cost and manpower issues in order to stay ahead of the chasing pack. At the moment, Singapore is the Asian aerospace hub of choice with many MNCs setting up regional headquarters in the country. Her place as the premier aerospace hub will soon be challenged by neighbours Malaysia and the Philippines who, according to some reports, are eyeing a bigger share in the aerospace market. When asked, Dr Tay expressed some concerns. He said: “In the short term, we should still be viable. However, if we do not try to understand our neighbouring aerospace industries, we will be caught by surprise once they start to unveil what they can do. As such, we should start looking at these countries, their supply chain and explore ways we could collaborate with them to enhance our value. We need to engage them.”

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IndustryFocus

Diamond

Is Aerospace’s Best Friend

L

ightweight and highstrength — these combinations of properties are what make modern composite materials so soughtafter in many industries. High-tech glass or carbon fibre reinforced materials (GFRP, CFRP) are increasingly being used to replace metals such as aluminium alloys, for example in modern aircraft, where more than half of the pipes are now made of composites. The aerospace industr y represents the most significant sector, but composite materials are also being used increasingly in energy production, especially wind energy, the automotive industry and for leisure and sports equipment. It is clear that the increasing spread of fibre composite materials also affects tool manufacturers. “As we have been pursuing a strategy of sector focussing for several years now, we pick up on new trends very quickly,” explains Michael Fink, head of global product management at Walter. “This was also the case 44

asia pacific metalworking equipment news Jan-Feb 2013

Diamond is the only realistic cutting tool material for the economic machining of fibre composite materials, given the strength of the glass and carbon fibres in resin laminates. Contributed by Jaslin Huang, marketing, Walter AG Singapore

with the emergence of composite materials; the industries from which the demand for these materials typically comes are in the sectors we focus on.” Working With Fibre The majority of workpieces to be machined are thin-walled near-net-shape components. One important, if not the most important, machining technique is therefore drilling, to enable the parts to be assembled. For example, cabin parts for aircraft are fitted using rivets, which necessitates the drilling of numerous holes. The requirements of drilling and boring tools are correspondingly high, as cutting these difficult materials is no mean feat. The cutting edges of standard carbide tools, whether coated or uncoated, are very quickly blunted by the strong abrasive effect of the fibres. A harder cutting tool material — diamond — is therefore used for larger series. There are two ways to use these materials. Mr Fink

explains: “We produce our tools — drilling tools and milling cutters — for fibre composite materials either with PCD drill points or diamond coatings.” The machining quality of workpieces made from composites is assessed on the basis of completely different aspects from those made from metals. If the tool does not cut the fibres optimally, this may result in undesirable burrs and delamination, especially at the hole exit. Furthermore, the usual hole tolerances in the IT8 region and in terms of surface finish quality are Ra values of <3.2 µm. Considering the behaviour of the material, these values are not easy to comply with. “The quality required by users is also continuously increasing,” continues Mr Fink, “so our developers are always seeking to optimise our products. It is particularly important to maximise tool life with optimum geometries, as burrs and delamination causes increased tool wear.” www.equipment-news.com


IndustryFocus It is particularly important to maximise tool life with optimum geometries

Vein Technology A complex technique known as vein technology has been known and used since the 1980s for the manufacture of tools with PCD drill points. The PCD drill points themselves are not brazed, but sintered into pre-shaped carbide bodies with specially-designed slits (hence the name ‘vein’). T h e p ro c e s s h a s m a n y advantages: phenomena such as solder failures, which may arise

in the case of directly brazed PCD drill points, are a thing of the past. Tools manufacturers can also be more flexible in terms of cutting edge geometries and helix angles than with standard PCD tools. One particular important aspect for users is that the tools can be reground several times, which increases the cost efficiency. To keep the tendency to delaminate to a minimum, low cutting forces are needed. This

means that the tools are given large rake angles or small cutting angles. Protective chamfers on the cutting edges ensure that stability is not compromised. “To a large extent, the design of the geometry is dependent on the application,” says Mr Fink, “so we work with numerous special tools, such as those typically found in high-tech sectors like aerospace technology. One major challenge, especially in this sector, is presented by sandwich components, in which layers of fibre composite materials and materials with difficult cutting properties, such as titanium alloys, have to be drilled in a single operation.” Some standard tools have been developed in recent years (PCD drills and PCD rivet countersink) to help in this particular area. Enquiry No. 1403 Turn to page 96a or log on to www.equipment-news.com to enquire

WHICHEVER SWISS ST 26 YOU CHOOSE:

Tornos Swiss ST 26 for turned parts up to 25,4 mm. Amazingly affordable Swiss Made quality. Now it pays to invest in high performance and productivity with the new Swiss ST 26. Two totally independent tool systems provide balanced operations, 7 linear axes, 2 C-axes and conversion to a guide-bush-less machine in only 30 minutes. The Swiss ST 26 is equipped with the most powerful and dynamic spindle and counter spindle ever built for this class of machine, allowing extreme machining capabilities. Choose from three turnkey equipment packs: “Starter”, “Advanced” and “Medical”. Your nearest representation: TORNOS Malaysia, Penang, +6(04)-642 6562/6563 TORNOS Thailand, Bangkok, +66 2746 8840-1 www.tornos.com, www.swiss-st.com

MEDICAL STARTER

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AUTOMOTIVE - MEDICAL - ELECTRONICS - MICROMECHANICS

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ENQUIRY NO 007

YOU ALWAYS CHOOSE SWISS MADE QUALITY

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Features

W EuroBlech Special Report:

2012

Asia Pacific Metalworking Equipment News (APMEN) went to Hannover, Germany, to gauge the pulse of the sheet metalworking industry. By Joson Ng

ith the Eurozone c re d i t c r i s i s s e t as an unwitting b a c k d r o p , Euroblech 2012 has proven that the shroud of uncertainties across Europe has done little to quell the appetite of the sheet metalworking industry. Often referred to as the barometer of the sheet metalworking i n d u s t r y, t h e o rg a n i s e r o f the 22nd international sheet metalworking technology e x h i b i t i o n re p o r t e d a n e t exhibition space of 84,000 sq m, and a total of 1,520 exhibitors from 39 countries. The number of trade visitors reached 60,500, which equalled the visitor number of the previous exhibition. They also reported a rise of five percent in the number of exhibitors in the 2012 edition. Finally, the floor space grew by seven percent. The first analysis of the visitor survey showed a significant shift towards highly qualified trade visitors. Some 75 percent of the visitors came from the industry. There were more visitors from the top management, and 40 percent of all visitors came to the show with the definite intention of buying. The exhibitor survey showed t h a t t h e m a i n re a s o n s f o r exhibiting were to approach new markets, attract new customers and present their product. Almost half of the exhibitors (48 percent) and 36 percent of the visitors at this yearâ&#x20AC;&#x2122;s show came from outside Germany. Most important exhibitor countries, a f t e r G e r m a n y, w e re I t a l y, Turkey, China, the Netherlands, Switzerland, Austria, France and the US. Technologies & Trends At Euroblech Blech â&#x20AC;&#x201D; the German word for tin or sheet metal may not be familiar to many in Asia, but

46

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rket Where Manverge Leaders CoLatest

to Unveil ies Technolog tions e Solu to Provid atives rn & Alte ery to Meet Ev Need g rin Manufactu

EMO E IMTS JIMTOF TIMTOS METALEX

The 7th International and Specialised Exhibition on Machine Tools, Metalworking & Precision Tooling, Automotive Engineering and Related Manufacturing Technologies for Indonesia

22 - 25 May 2013

Jakarta International Expo, Kemayoran

for Europe for USA for Japan for Taiwan for Thailand for Indonesia

The strong support and proactive participation of renowned machine tool manufacturers and market leaders clearly reflect a high confidence and expectation towards Indonesia’s industrial development and in particular, on the manufacturing sectors of automotives, electronics, mould and dies, precision parts, machineries, oil and gas engineering, as well as the marine and shipbuilding engineering sectors. Indonesia’s economic growth secured track record as the world’s third best after China and India recently. Great opportunities are abounding for exhibiting companies to contribute significantly to the country’s need for capital goods and technology through their supply and services, as the nation mount up to the next level of development.

Space Booking

1st - come 1st - served

(subject to space availability)

Book OnLine Now

www.mtt-indonesia.com

Supported by :

Organized by :

ENQUIRY NO 005 T : +62 21 7818954 (Indonesia) : +65 65709007 (Overseas) E : exh@mtt-indonesia.com


Features the processing or fabrication technologies associated with it are. APMEN takes a look at the interesting technologies and trends at the show. • Forming Technology Space is often an issue at a factor y. When it comes to large pressing machines, t h i s i s s u e b e c o m e s m o re pronounced. As aptly put by Simon Scherrenbacher, corporate communications f r o m S c h u l e r, “ s p a c e i s e x p e n s i v e . ” To a d d r e s s this concern on space, the company has set their sights on compact designs. At Schuler, the Twin Servo Technology (TST) is one of the latest technologies on offer at the show. This technology f e a t u re s a d r i v e c o n c e p t with two decentralised ser vo motors in the press bed, which enables a more compact design and reduces noise emissions. It also improves both accessibility and rigidity compared to former servo presses. Compared to a conventional SDT (ServoDirect Technology) press, the total space requirement has been reduced by around 30 percent. In other words, the press takes up less space in the stamping plant and also fits in halls with lower ceilings. This compact size also means that the entire press can be insulated with a free-standing sound enclosure. The fact that the drives are located in the foundation already makes sound emissions m u c h l o w e r c o m p a re d t o conventional designs. TwinServo press without uprights also improves access to the die area. The slide movement is handled by four drawrods which apply the press force to the end faces 48

asia pacific metalworking equipment news Jan-Feb 2013

of the slide. Compared to conventional designs, this allows greater eccentric loads. In addition, the maximum press force can be used right up to the bed edge for forming operations. The 30 percent reduction in deflection which the TwinServo press offers, compared to conventional machines, has further positive effects: the blanking shock is reduced, protecting both die and press. This property is additionally helped by the dampening effect of the increased slide mass. Tilting resistance in the feed direction is almost twice as high, and at right angles to the feed direction, it is as much as four times higher.

• Laser Technology Arguably the star of the show, f i b re l a s e r h a s c a p t u re d the imaginations of many, with established names like Bystronic and Trumpf pushing out fibre laser solutions to complement their existing portfolio. There were also numerous smaller companies working with laser producers to bring their fibre laser cutting technology to the market. APMEN understands the number of companies producing fibre laser cutting machines will continue to increase as laser sources are relatively easy to obtain and there are many engineers with the know-how to carry out the integration. Another notable www.equipment-news.com


Features

Some 40 percent of visitors came with the intention of buying.

debutant in this field is LVD with their Electra fibre laser cutting machine. Rounding off its 2D laser portfolio with the TruLaser 3030 fiber is Trumpf. As a flexible standard machine, the solid state laser unit has a laser power of 3 kW. It cuts through up to 20 mm of mild steel, 15 mm of stainless steel and aluminium, and 6 mm of copper and brass. Moreover, the all-purpose cutting unit processes all sheet thicknesses, meaning there is no need for cutting head change. Ermaksan from Turkey b ro u g h t t h e i r f i b re l a s e r cutting machine to the show as well. Called the Fibermak, www.equipment-news.com

the machine is said to provide high speed and efficiency. It also comes with a 17” touch LCD colour screen control. Also at the exhibition, Rofin presented the FL Series that cover all common solid-state laser applications. They are said to be compact, robust, efficient and available with good beam quality. Due to the use of multi-mode optical fibres with diameters of 50 to 800 microns, the beam quality can be configured precisely to the processing task. For applications requiring the highest accuracy and precision, single-mode lasers (up to 1,000 W) allow beam quality of ≤ 0.4 mm x mrad. The fibre lasers are

a v a i l a b l e i n s t a n d a rd o r compact versions. Optional beam switches and power splitters are available in the s t a n d a rd v a r i a n t s , w h i c h allow the operation of up to four workstations with a single laser. This reduces the system downtime and therefore increases utilisation of the laser. • Press Brake Better productivity and green technology are two common taglines for exhibitors at the show. Safan Darley said their E-brake press brakes are made as environmentally friendly as possible. There is no risk of polluting oil and the lower energy consumption means lower CO 2 emissions. They are also 50 percent more energy-efficient than a comparable hydraulic press brake as the machine only consumes energy when the upper beam is actually moving. Better productivity is also the main idea behind LVD’s ToolCell press brake system that features an automatic tool changing system, according to marketing manager Matthew Fowles. He told APMEN in an exclusive interview that the development of the machine was borne out of extensive market research. “The reason we have b ro u g h t t h i s p ro d u c t t o market is because we have s e e n a w o r l d w i d e t re n d , which is reduced batch sizes in manufacturing. This results in shorter lead times and tighter margins. We did s o m e m a r k e t re s e a rc h t o establish the number of tool changes people were doing. Tool changes are driven by the number of batch sizes that you have. Typically, if you have a small batch size, Jan-Feb 2013 asia pacific metalworking equipment news

49


Features you are doing a lot of tool changes. We now know people are being squeezed on their margin, they probably have to make more parts a day in order to make the same amount of money as they were making before,” he said. During their research on the bending process, one of the areas they looked at was human behaviours and from their findings, they managed to formulate a technology that made the process more efficient, ultimately resulting in more bent parts. He said: “Let us look at the inefficiency in small batch production from a bending perspective. The main area of time spent is in tool setting. We designed a machine that contains the tools you need in the machine. As such, there is no need for the operator to go away looking for the tool. The machine automatically changes the tool for the operator. What it enables him to do is to take the part that has been formed and put it aside and load the blanks into the machine.” • Other Technologies Joining is also an important branch of sheet metalworking with the entire hall 13 catered t o re l a t e d p ro d u c t s a n d technologies. A key area in joining is welding and like their sheet metal cutting counterparts, welding equipment providers are also tooting the horn of productivity. The only difference here is that there are more innovations or marketing efforts pertaining to ergonomics. In the area of welding, the i-Torch from Lorch is said to ensure more productivity. The TIG (Tungsten Inert Gas) torch brings welders closer to action by reducing the distance of the 50

asia pacific metalworking equipment news Jan-Feb 2013

The sheet metalworking industry is showing no signs of slowing down.

operating hand to the arc by a full 2 cm compared to standard torches. This ensures greater arc control, more precise torch guidance and more productivity. Fronius on the other hand, combines two independently functioning arc-welding processes in a single process. The twin-wire solution allows users to exploit two Cold Metal Transfer (CMT) processes, or combine a CMT process with a GMA (Gas Metal Arc) pulsed-arc welding process, all within one single system. In metrology, the thickness of materials can be measured by a laser device manufactured by Lap Laser. The Calix XL reportedly has a repeatability of

+/- 0.5 um, measuring frequency of 4 kHz and a measuring range of 30 mm. It uses laser class 2 and is said to be temperature stable. Summary Overall, based on the activities on the exhibition ground, it is difficult to tell that there is an economic crisis brewing on the same continent. The number of new technologies on show is a testament to the confidence shown by machine builders or technology providers that even when things threaten to slow down in an economic sense, the demand for better technologies will always be there. MEN Enquiry No. 1501 Turn to page 96a or log on to www.equipment-news.com to enquire

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Features

Products at EuroBlech 2012 Güdel: Crossbar Transfer System

The roboBeam system by Güdel is characterised by their straightforward and stable mechanics that allow a secure and direct transfer of parts from press to press without intermediate stations. The system is based on a solid-structured linear guidance rail that has been designed for high dynamic loads. The RBS roboBeam Stand alone and the RBC roboBeam Compact press are the two versions available. The former is designed for transfer of large blanks in tandem lines with a distance between the presses of up to 8,500 mm. The latter is designed to be installed in compact presses and enables direct motion of parts between die stations up to a distance of approximately 4,000 mm. Enquiry No. 1502 Turn to page 96a or log on to www.equipment-news.com to enquire

Omax: Bridge-Style Waterjet Cutting Machine

Omax Corp has developed the JetMachining Centre 60120. Suitable for a range of production runs, the bridge-style machine can cut complex parts, measuring up to 1.5 m x 3 m, from materials that range from advanced composites, exotic alloys and glass to traditional metals, rubber and stone. Featuring an X-Y travel of 3.2 m x 1.5 m, the machine comes standard with the company’s Intelli-Max Software Suite, which runs on the Windows 7 Ultimate operating system. The software calculates the velocity of a tool path at over 2,000 points per inch, allowing for complete control over the motion of an abrasive jet, and enabling precise, rapid machining. Enquiry No. 1504 Turn to page 96a or log on to www.equipment-news.com to enquire

Kemper: Indoor Air Purifying System

Vitronic: Image Processing Systems

To keep the health risks to workers in the metalworking industry to a minimum, Kemper has developed a ventilation system for light to medium pollution. The modular push/pull technology employs constant circulation, ensures clean air and keeps working conditions in the workshop safe. A feature which distinguishes the push/pull system compared to conventional spot extraction units is in the uniform, horizontal air flow. By means of extractor tubes, the contaminated air is sucked in (pull), the harmful substances are separated out at the filter cartridges and the purified air is returned on the opposite side of the factory building (push).

Vitronic Vinspec machine vision solutions detect surface flaws such as scratches, notches, dents, bubbles, pores, cavities, spots, and changes in transparency, as well as edge defects such as cracks, burrs, bevel, rounding, and leveling errors. The 2D and 3D camera-based systems are generally installed inline and inspect the surfaces at production speed. In the process, parts with any shape, areas, and contours are recorded reliably — even when the part is not positioned precisely. Defective parts can be detected automatically and discharged in a timely manner. The inspection data is documented as proof for customers and for traceability and it can be used to make targeted process optimisations.

Enquiry No. 1503 Turn to page 96a or log on to www.equipment-news.com to enquire

www.equipment-news.com

Enquiry No. 1505 Turn to page 96a or log on to www.equipment-news.com to enquire

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Features

A Ferdi Tรถngi On The Future Of Sheet Metalworking

The rise of Asia and the acceptance of fibre laser will accompany the evolution of sheet metalworking, which will increasingly see branding and after sales service as a differentiator. By Joson Ng 52

asia pacific metalworking equipment news Jan-Feb 2013

t a press conference held at Euroblech, a trade show for sheet meta lwork ing, Ferdi Tรถngi, CEO and president of Bystronic spoke about four key trends emerging in the world of sheet metalworking. First of all, he mentioned that fibre laser technology is to grow in popularity and eventually take some 50 percent of the market place, changing market behaviour along the way. This shift may already be www.equipment-news.com


Features

Brainstorming Sessions In order to design and build new machines, Mr Töngi said the company devoted some 10 percent of their staff to R&D. In addition, he gave insights on how ideas are generated in his company. “Half the ideas for new products come from market research and half from the R&D department. Also, every two years we organise an idea workshop to generate new ideas. We invite about 10 customers and 10 people with no idea of our business to join 10 members of our R&D team. A jury of four to five people would select the idea which will typically be realised in three years,” he said.

happening judging on the number of companies offering fibre laser cutting solutions, many for the first time at Euroblech. He also spoke about the need to optimise processes and reduce delays. His third prediction sees Southeast Asia taking a leading role in consuming sheet metalworking solutions. In an interview with Asia Pacific Metalworking Equipment News (APMEN), Mr Töngi said: “Asia occupies a little bit more than a quarter of our business in terms of value. It is a tremendous shift if you look at the last 10 years. I believe Asia will go on to 40 percent in the future.” He revealed that in terms of number of units, China is already the biggest market. However, China’s rise is now rivalled by countries from Southeast Asia. “China has been dominating in the last five years but now, Indonesia, Vietnam and Thailand are doing well. I was in Indonesia and Thailand two weeks ago and I realised they are looking for two types of products, mainly big machines to build infrastructures and automobiles,” he added. Staying in Asia, Mr Töngi said www.equipment-news.com

We should differentiate ourselves in terms of services. - Ferdi Töngi

Technologies At Euroblech

The ByAutonom is a laser cutting system developed from the beginning as an autonomous working machine

In the niche market of sheet metalworking, the materials used are different and so are the machines and technologies. Although the solutions are unique to its field, the industry is not immune to market fluctuations, especially for a job shop owner. These challenges are eventually passed on to machine makers and it becomes part of their job to advise their customers what the best way forward is. The current market climate places a lot of strain on profit margins and people do not necessarily have as much resources or time compared to the past. For instance, it is thought that process optimisation is one of the many points in the ever growing wish list of a sheet metalworking job shop owner. Along with this, more power is expected from machines but less manpower is available to operate the hardware. In addition, flexibility and the ease of usage add to the growing difficulties of a sheet metal job shop. To overcome these challenges, Bystronic pushed out 10 new products at the show. They are the ByAutonom, BySprint Pro, BySprint Fiber, BySun, ByJet Smart, Xpert, Hämmerle 3P, Xcite 80 E, ByVision and BySoft 7. The ByAutonom is a laser cutting system developed from the beginning as an autonomous working machine, which together with automation modules such as ByTrans, ByTower and Bycell, can be used for reduced-manning operation. This is also applicable if the type and thickness of the raw material has to be changed. The linear motors accelerate the machine to higher speeds. This is supported by a machine bed and the bridge. Even thick materials are cut faster and better because of a 9 inch cutting head, which is better suited to such orders than a 7.5 inch cutting head. At EuroBlech 2012, the machine won a MM Award. It was awarded the main prize in the cutting category. The Xcite is the next exhibition highlight from the company. It is a press

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Features the company would use BySun, an entry level machine made in China, for the Chinese market and export it to Southeast Asia and eventually India. The company currently manufactures some ¼ of their lasers in China. He said other efforts to engage the region include setting up a sales and service company in Vietnam. The Soft Approach The most pertinent prediction he made was the ‘soft factors’ emerging as key differentiators in the market place. With the adoption rate of fibre laser set to explode in the next few years, many builders are teaming up with OEM laser suppliers to build fibre laser cutting machines. This technology ‘race’ will first result in improvements but eventually reach a technology ceiling. Mr Töngi believes a day will come where there is no longer much to choose between press brakes or laser cutting machines built by rival manufacturers, as they are both as good. Elaborating, Mr Töngi said: “In the past, there is a chance to make differentiation in products. 3 kW is more powerful than 2 kW, everybody understands. This differentiation however, is getting smaller and smaller. Therefore, we must be different in the softer aspect of the business. We should differentiate ourselves in terms of services. This entails a lot of factors. For instance, the customer has to feel comfortable talking to us.” Apart from service, branding is also another major factor. Using the automobile industry as an example, he explained: “If you go to China, which cars are perceived to be good? Most would say German cars, period. The branding must be right as you do not buy a car purely because of its horsepower.” Enquiry No. 1506 Turn to page 96a or log on to www.equipment-news.com to enquire

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The BySoft 7 software simplifies the processes within a factory

The press brake is electrically driven brake that is electrically driven. The manufacturer said the press brake is some 2.5 times faster than a hydraulic pressbrake. Using the Fast Bend+ safety system, the tool can be positioned closely to the metal sheet without the operator being placed in any danger. Only then does the machine switch over to bending speed. Using the Force Dynamic Drive (FDD), the machine bends to within a tolerance of +/- 25 arc minutes and has a repeatability of +/- 0.0025 mm. Described as a ‘new software generation’, the BySoft 7 is a modular CAD/ CAM software with 2D and 3D CAD as well as functions for scheduling and monitoring manufacturing processes. The software program is easy for firsttime users to operate and it simplifies the processes within a factory.

Enquiry No. 1507 Turn to page 96a or log on to www.equipment-news.com to enquire

What Crisis? Ferdi Töngi gives his take on the Eurozone crisis and the financial aspect of his company. “In the past, when you heard of a financial crisis, we try to save money. Now, things are different. The consumers in Germany are still spending money. The biggest impact we have comes from China as orders have decreased,” said Mr Töngi. The Eurozone crisis to Mr Töngi is more of a political issue rather than a business one. Painting an example, he said: “If you see unemployment rate of 50 percent among young people below the age of 25 years in Spain, that is not a commercial issue, it is a political issue.” Focusing on Bystronic, he mentioned the company grew nearly 40 percent from 2010 to 2011. As 2011 performed better than 2012, there will be a reduction in growth. He predicts a growth rate close to 10 percent in 2012.

Enquiry No. 1508 Turn to page 96a or log on to www.equipment-news.com to enquire

www.equipment-news.com


ENQUIRY NO 209


Features

J

DMG/Mori Seiki:

Market Development Grew 5.2% Worldwide,

More To Come With production plants being commissioned in all corners of the globe and machines making their debuts at various trade shows worldwide, it is clear for all to see that the partnership between the two companies is flourishing. By Joson Ng

Dr R端diger Kapitza (L) and Dr Masahiko Mori

56

asia pacific metalworking equipment news Jan-Feb 2013

IMTOF 2012 kicked off on November 1, 2012 at the Tokyo Big Sight. According to the organiser, some 128,674 visitors attended the event over six days. This exhibition is known to be important to the Japanese machine tool companies and therefore, it is not surprising to see them turn out in force. As with the previous edition in 2010, DMG/Mori Seiki occupied the largest exhibition space at the show. Taking up some 2,340 sq m, the company reconstructed a familiar scene that was seen in shows in the US and in Europe in 2012, ie: participation in a big way. Making their presence felt seems to be a strategy that is deployed across departments within the company, be it on the exhibition scene or geographically in terms of the locations of their factories and technology centres. As a press conference chaired by both Dr R端diger Kapitza, chairman of the board of Gildemeister and Dr Masahiko Mori, president of Mori Seiki, the latter took time to drive this point across. He first reported www.equipment-news.com


Features the market development of the partnership in 2012. According to Dr Mori, the regions of Asia, Europe and the Americas saw growth of +6.5, -0.4 and +7.8 percent respectively. This growth, he said, also resulted in greater efficiency in sales and services, cost savings in R&D, easy financing for customers and reduction in procurement cost. Although Europe posted a negative growth, Dr Mori said the company remains confident. “We have high expectations in Europe and we feel the European situation will recover,” he said. His confidence can be easily deduced from the investments made in the continent and the network they have established. According to him, DMG/Mori Seiki Europe has 27 technology centres and 820 employees. Trade Shows & Production Plants Some strategic reasons for establishing a par tnership between the two companies back in March 2009 is to pool together resources and increase the size of the company. As a result, the company can exert more influence over a wider area. This philosophy can also be seen in the company’s investments in trade shows all over the world. Although bigger is not always better, having a significant presence in trade shows is paying dividends for the company. Dr Mori revealed that they exhibited 40 machines at IMTS in the US, taking up some 3,036 sq m of exhibition space. They also exhibited the same number of machines in AMB, an exhibition in Stuttgart, Germany. Finally, they sent 19 machines to BIMU, Italy’s main show in 2012. According to him, the results justified the investment. He said: “We received 200 orders at IMTS, 50 percent DMG machines, 50 percent Mori Seiki machines. At AMB, we received more than 200 orders.” www.equipment-news.com

World Premieres At JIMTOF Occupying the largest exhibition space at JIMTOF with 2,340 sq m, the company showcased 32 machines, including five world premieres.

DMC 65 monoblock

NLX 1500 Y

NLX1500Y/500, NLX2000SY/500 and NLX3000Y/700 all made their debuts at the show and together, they complete the lineup of the NLX series of CNC lathes. The lathes now come with an evolved Built-in Motor Turret (BMT) technology, achieving a maximum rotational speed of 10,000 min-1. The manufacturer also said that the vibration and turret temperature have been reduced, leading to better accuracy. Over at the DMG side of things, the DMC 65 monoblock and the CTV 250 DF were also unveiled at the show. The former comes with an automatic pallet changer for better productivity and flexibility in production. The milling centre is designed for use with 20 pallets (measuring 500 x 500 mm) with 800 kg loads each. The maximum workpiece diameter for this model is 630 mm and the maximum component height is 500 mm. A vertical turn/mill centre for the machining of constant velocity joints in five axes, the CTV 250 DF is capable of a swivel range of +105 to -45 deg. In addition, the swivel bridge of the machine can be equipped with one or two powered tool spindles. This enables the turning and milling tools to be mounted or clamped. Moving forward, Dr Mori said it is inevitable that technologies had to be improved. “We are looking to develop more automation and measuring technologies,” he added.

Enquiry No. 1509 Turn to page 96a or log on to www.equipment-news.com to enquire

Opening Of The Davis Plant

The company has built a new plant in Davis, US. The facility will produce mainly horizontal machining centres for customers in the US and in neighbouring countries. It operates similarly to an automated factory and is said to have a production capacity of 80 units per month. The factory is capable of unmanned operation at night or on holidays due to the use of robots and loader cranes. It adopts a line assembly system. Outline of North American Factory 1 Area: About 89,000 sq m 2 Total Investment: About JPY 5 billion (US$59 million) 3 Production Items: Horizontal machining centre NHX4000, NHX5000 and others 4 Number of Employees: 200

Enquiry No. 1510 Turn to page 96a or log on to www.equipment-news.com to enquire

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Features

Plant Visit: High On Efficiency, Low On Energy Usage Asia Pacific Metalworking Equipment News (APMEN) visited Mori Seiki’s new assembly and machining plant at the Iga campus to see why the plant has been touted as the leading edge machine tool factory.

Dr Mori did not release any sales figures for the BIMU show but he said Italy remains an important market for the company and the partnership will stay in the Italian market. In the area of production, Dr Mori gave an update on the construction of the manufacturing facility in Tianjin, China. Scheduled to start production in September 2013, the 90,000 sq m plant will produce some 100 units of horizontal machining centres per month. He said he expects “no problem despite some political issues” in recent months. Dr Kapitza chipped in with his report on the construction progress of the Russian plant. He said the production facility in Ulyanovsk is expected to start operating at the end of 2013. In Germany, the Seebach plant has opened additional facilities. He said it will produce the MillTap 700 to a rate of 500 per month in its 10,500 sq m facility. Enquiry No. 1512 Turn to page 96a or log on to www.equipment-news.com to enquire

Saving Energy At The Iga Plant

Built at a cost of JPY10 billion (US$125 million), according to Dr Mori, Mori Seiki’s 25,000 sq m assembly and machining plant in the Iga production campus is designed to produce multi-axis machines, among others, to an efficient and efficacious manner. With many energy saving and efficient production solutions and technologies incorporated into the plant, it is easy to see why he calls it a “leading edge machine tool factory in the world.” APMEN visited the bed/column precise processing plant, which boasts a precise temperature control system that keeps ambient temperature within 0.5 deg C of 20 deg C. Opened in April 2012, the plant is divided into a five-face machine area, grinding area and a quenching/tempering area. The plant typically processes a machine bed or column in about four days. Apart from its temperature control, the plant is said to come with earthquake resistance strength and other safety features.

Enquiry No. 1511 Turn to page 96a or log on to www.equipment-news.com to enquire

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There are many systems put in place to achieve better energy savings. High-efficiency heat pump chillers, compressors and lightings are used in the plant. It also has a renewable power generation system and a tracked photovoltaic power generation system, which is said to be 35 percent more efficient than the fixed type. All in all, their energy saving endeavours resulted in an electricity usage of 7,524,000 kWh/year, which was a reduction of 40 percent compared to previous numbers. Another green initiative saw the deployment of a grinding sludge solidification system that separates sludge generated during grinding into metals and cutting fluid so both can be recycled.

Enquiry No. 1513 Turn to page 96a or log on to www.equipment-news.com to enquire

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ENQUIRY NO 014


Features

Market Outlook:

Beyond

2013

Metalworking is essential in many industries. We take a look at the fortunes of these industries in 2013 and beyond as we try to draw our own conclusions on how the metalworking world would fare in the coming years.

Abrasives: China & India Global demand for abrasives is projected to grow 6.3 percent annually to US$44.8 billion in 2015. Advances will be driven by ongoing industrialisation activity in developing areas, rising per capita incomes and consumer spending, growing durables manufacturing output and greater fixed investment activity, especially in the Asia/Pacific region. Such increases in construction and manufacturing activity and per capita incomes will also boost demand for abrasives-containing cleaning and maintenance products in the developing world. The fastest gains will be seen in nations such as China and India. China passed the US to become the largest national market for abrasives between 2000 and 2005, and is expected to account for over half of global demand in 2015. These and other trends are presented in World Abrasives, a study from The Freedonia Group. Superabrasives are quickly gaining favour with manufacturers because of their long life and high performance characteristics. Suppliers of metallic abrasives will benefit from increases in primary and fabricated metals manufacturing output as global economic growth accelerates and industrialisation activity continues in less developed parts of the world.

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Crude Steel: India India is set to become the 2nd largest producer of crude steel by 2015. Venkatesan Subramanian, director, Metals & Minerals, Frost & Sullivan said: “Around 300 MoUs have been signed with various states for a planned capacity of around 488.56 million MT by 2020. The intended steel capacity build-up in the country is likely to result in an investment of approximately INR 5,000 to 10,000 billion (US$91.8 to 183.5 billion) by 2020.” Traditionally, construction and infrastructure sector together have had the highest demand for steel (more than 60 percent) in the country. Indian finished steel production in 2011-12 stood at 70.32 million MT and is forecast to touch 92.29 million MT in 2015-16. “Among steel intensive industries in India, construction registered the highest growth rates over the past consecutive five years. Manufacturing is the second highest steel consumer segment followed by automotive, both of which are poised to witness impressive growth over the future,” he said.

Solar Energy: India According to a recent research report by RNCOS, “Indian Solar Energy Market Analysis”, the solar power sector in India is witnessing a growth. Research findings show solar PV installation in the country is growing at a rapid pace as in 2011-12, and the total capacity addition in solar PV segment stood at around 468 MW. In the future, the cumulative PV installed capacity is anticipated to grow at a CAGR of around 47 percent from 2011 to 2016.

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Features

Buses: China The world market for buses is projected to grow five percent annually to 632,000 units in 2016, approaching US$64 billion in sales. Much of the gains will be attributable to type C school buses, demand for which will skyrocket from 26,000 units in 2011 to 70,000 units in 2016. This increase will largely be driven by market advances in China, where sales of type C buses will expand rapidly from a small existing base because of safety concerns about other types of buses currently used to transport students. Growth in demand for motor coaches, transit buses, and all other buses will, in the aggregate, be much more moderate, averaging 3.7 percent per year through 2016, a pace consistent with longer term trends. These and other trends are presented in World Buses, a study from The Freedonia Group. The Asia Pacific region will register the fastest market advances through 2016 , fueled by robust economic growth and the expansion of urban transit systems, particularly in China and India. China alone will account for 3/5 of all new bus demand between 2011 and 2016.

Electric Vehicles: Japan & South Korea Both Japanese and South Korean automakers are optimistic about commercialising fuel cell electric vehicles by 2015, says Frost & Sullivan. An analysis from Frost & Sullivan CEO’s 360 Degree Analysis of Fuel Cell Electric Vehicle Market in Japan and South Korea finds that Fuel Cell Electric Vehicles (FCEVs) in both countries are expected to increase to 58,100 units in 2020 from 600 units in 2011. Vijayendra Rao, research manager at Frost & Sullivan Automotive & Transportation Practice, Asia Pacific said that the Japanese and South Korean governments play a key supporting role in the commercialisation of FCEVs and most OEMs in Japan and South Korea are likely to be focused on medium segment passenger FCEVs. Finally he added that Honda Motor Japan is expected to be the market leader in the fuel cell electric vehicle market in Japan and South Korea in 2020 with a 41.8 percent market share. South Korea’s Hyundai and Japan’s Toyota are expected to command market shares of 17.4 percent and 17.2 percent respectively.

Aerospace: Singapore Singapore’s aerospace cluster looks set to grow in 2013. Dr Aloysius Tay, chief executive of the Association of Aerospace Industry Singapore (AAIS) said: “This year (2012) has been generally good. CAGR will probably be 10 percent, like it has always been. With the Seletar Aerospace Park now up and running, 2013 will be better as companies who have been establishing themselves this year (2012) would have started productive operations.”

Enquiry No. 1514 Turn to page 96a or log on to www.equipment-news.com to enquire

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Features

MakingTheCut Vincent Chai (L) and Gao-Ya Chen

It takes more than a good product to gain a significant foothold in the bandsaw market. By Joson Ng

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bandsaw may look the same from one another but the difference in performance will soon be evident once cutting begins. Cutting performance in bandsaw varies from different materials and machines but it looks set to improve across the board with the inclusion of carbide, a material widely used in other cutting tools. According to Gao-Ya Chen, director of Marketing APAC and Vincent Chai, sales manager, Bandsaw, Malaysia & Singapore, Lenox, this improvement can be directly attributed to the inve st ment s place d by t he company. Said Mr Chen: “We have been making investments in the US and carbide blade (Tungsten Carbide) is a focus area. We are about to finish all our capital investments including new carbide welding and grinding cells. We hope these ventures will help us capture the carbide market.” APMEN understands that the carbide is similar to what is being used in cutting tools, but the difference is that a carbide cylinder or ball is welded onto the tooth tip of a spring steel backing material and then through various grinding

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operations, the tooth tip is formed. The technology is widely used in developed countries and the trend is starting in Southeast Asia. For those who are only interested in productivity and fast cutting, this will prove to be good news for their production efficiency. “For carbide blades (bandsaw), you basically use it for speed, for fast cutting,” said Mr Chen. Mr Chai also remarked that the bandsaw could yield cutting speeds that are three to four times faster and they are suitable for materials like Inconel and Titanium, which are more abrasive. Finally, he said the tool life would also be improved. Growing Ambition With the future of bandsaw cutting seemingly pointing towards higher speeds, APMEN asked if it is the bandsaw machine makers or the bandsaw manufacturers who take the lead in their industry. Mr Chai said: “Bandsaw cutting machines are getting more precise and powerful. Our blade is like the ‘tyres’ of a car. If the ‘car’ runs faster, we need to produce something that runs fast.” “Hav ing sa id that, some machine builders do test out their

machines with our blades,” added Mr Chen. He feels the relationship between the machine, the bandsaw and the materials being cut is the most crucial to a successful manufacturing process. With that in mind, he described the company’s approach in customer service, which encompasses the same philosophy. He said: “We have a lot of trained technical representatives. They look at customers’ machines, what they are cutting and the problems they are facing. Our goal is to solve the problem and recommend the best blade.” In terms of training, Mr Chai said: “We are active in Asia, in countries like Singapore, Taiwan, Vietnam and Thailand. In addition, we started in the US and Shanghai the Lenox Institute of Technology, a training centre. The goal of the training centre is to give people the hands-on experience. We also run a weld shop training course for operators to weld the bandsaw loops.” Future Plans Mr Chai also revealed plans for Vietnam, where the company is experiencing good growth. “We have recently doubled our local contact there. With many Japanese, Taiwanese and Singaporean customers in Vietnam, there is definitely a market over there. As such, in the next one to three years, we intend to have an office in Vietnam.” This sentiment is echoed by Mr Chen who said the company targets to grow in Asia quickly. APMEN understands they now operate in Asia out of their Shanghai headquarter. Summing up the expansion plans in Asia best, Mr Chai concluded: “We used to have two employees in Asia when we first started in mid 2006. In 2013, this number will be in the excess of 200 employees engaged in helping to bring cutting improvements to user.” Enquiry No. 1515 Turn to page 96a or log on to www.equipment-news.com to enquire

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Features

Big Movement On The

Nanoscale

Nanotechnology is poised to stake a bigger claim in the next few years in the manufacturing environment as more advancement can be expected from this field. By Joson Ng

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peaking at the Nano forum in Thailand recently, Dr M C Roco, senior advisor of Nanotechnology at the National Science Foundation said the development of Nanotechnology (NT) can be classified into two periods. The years 2000 to 2010 are known as Nano1 and Nano2 is the subsequent 10-year period. The period of Nano1 saw foundational knowledge of nature built by controlling matter at the nanoscale and accompanying breakthroughs in science and technology. These discoveries resulted in a better understanding of the smallest structures, uncovering the behaviours and functions of matter at the nanoscale, and the creation of a library of 1D to 4D nanostructures building blocks for devices and systems. There were numerous nanoscale science and technology breakthroughs each year. For example, a notable commercial success was the 90 nm thin film storage (TFS) flash flexmemory by Freescale (2010). Other breakthroughs came in advanced materials, biomedicine, catalysis, electronics and the pharmaceutical field. Nano2 according to Dr Roco, will usher in a period that will witness a shift from ‘passive’ to ‘active’ nanostructure/ nanosystems and see NT more widely used in the industry. “The first few years mainly witnessed empirical work. We have many developments in the metal industry, nanostructure metal and coating, which were www.equipment-news.com

Dr Marinescu (L) and Dr Roco

applied to the electronic industry. In the future, we will start to have multi-functional devices and nano systems,” said Dr Roco. Prof Dr Ioan D Marinescu, the director of Precision MicroMachining Center of the University of Toledo added that the NT community is using molecular dynamic simulation in order to understand the mechanism in nano machining. The next important step is to develop and integrate them into processes in order to benefit the industry. NT & Metalworking With the developments during Nano1 and more advancements expected in Nano2, APMEN asked Dr Roco and Dr Marinescu how these improvements can benefit metalworking. “In the semiconductor industry, you have nano metalworking. For a long time in Thailand, they have been using the nano cutting process. This is one of the first areas that was developed some 20 years ago. Cutting tool is another big area. There are constructors selling hard tools. They use nano coatings in order to increase the life of the tool and reduce the friction between the tool and material. Metal is one of the easiest to work with, as it is better known compared to ceramics and polymer,” said Dr Marinescu. Different Meaning In Different Places The rate of development of NT is different between countries

but taking Asia as a whole, NT is developing fa st. Dr Roco said: “It (NT) has a high rate of development in Asia. Countries like South Korea, China, Thailand, Vietnam and Singapore will have an increased share as they specialise in different areas.” Dr Marinescu felt that it is interesting to see each country deciding to go into different aspect of NT development. For example, he said Taiwan chose to go into the semiconductor industry with NT while Thailand will go into the pharmaceutical, medical and the textile industry. While the scope of development may vary from country to country, they both agreed that NT can play a significant role in Precision Engineering (PE). “Before 1997, NT was a fragmented field and it has different definitions in different fields. For instance, in Japan, electronic devices on surfaces were called NT. In Russia, it was ultrafine aerosol. NT was known in Germany as ultra-precision e n g i ne er i n g. B et we e n 19 97 and 1999, we reformulated the definition of ‘nano’. Now we define nano as a new state of matter like a transitional state from atoms to bulk behaviour where all basic properties of materials and devices are determined. The new definition shows the ways to obtain new properties and functions,” said Dr Roco. Enquiry No. 1516 Turn to page 96a or log on to www.equipment-news.com to enquire

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Events& Exhibitions Event Review:

Metalex 2012

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ike how Thailand is known as the automotive hub of Southeast Asia, the K ingdom ca n also be known as the exhibition hub of the region as far as metalworking and manufacturing technologies are concerned. With at least three major exhibitions happening a year, Metalex is perhaps the one most dedicated to t he metalworking industry. The exhibition may fall behind the likes of JIMTOF, EMO and IMTS in terms of size and the sophistication of the technologies on show, but it is largely known in the industry as the show to go to in Southeast Asia. A trip to EMO may be a real eye opener, but there is a question of relevance that needs to be addressed here. The machines at EMO may be ‘state-of-the-art’ but how relevant is it to a jobshop in Thailand, Vietnam or Indonesia? The issue of relevance may be a complex one but potential buyers in Southeast Asia can let the machine builders make that decision for them as the manufacturers only bring along machines that they feel are suitable for the region, giving shows like Metalex a distinct ‘tailor-made’ flavour. This has 64

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Thailand may be the regional automotive powerhouse but it is not known as a producer of metalworking machinery or technology. Its tradeshows are however shop windows for many international brands to exhibit their most relevant products for the Southeast Asia region. By Joson Ng resulted in many international names being represented by their local partners at the show. It is therefore not uncommon to see one large distributor showcasing products from various brands at their booth. For someone who is visiting a metalworking trade show in Asia for the first time, it may be something new. Like its previous editions, the technological level of the machines and equipment at Metalex 2012 were brought in

with the manufacturing climate of the region in mind. There are no machines that are too simple or too advanced. With some 4,000 items of machinery and technology from 2,700 brands and eight international pavilions at the show, based on the figures released by the organiser, the ne eds of most v isitors a re catered for and it showed in the attendance. A post show report from the organiser revealed a visitorship of 65,216.

Southeast Asia metalworking trade shows have a distinct ‘tailor-made’ flavour

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Events&Exhibitions Christoph Zoller

Mr Kamiya: Machining Navi can help new users better control the problem of chattering Cool Flash

Machine Tools At the 2012 edition of Metalex, A PM E N sp oke to va r iou s exhibitors at the show to see what their offerings for the Southeast Asia region are. In machine tools, Okuma is offering chattering free machining. According to Masahiro Kamiya, operations ma na ger of Ok u ma Te chno ( T ha i la nd ), t he comp a ny ’s Machining Navi can help new users better control the problem of chattering, to better optimise the cutting condition and help fill the ‘experience vacuum’ left by retiring workers. “The state of no chattering is normally found, based on users’ experiences. But with Machining Navi, the machine will find the no chattering zone automatically. This helps in quality, productivity and speed. It increases tool life too,” he said. Productivity is also achieved, a l b e i t i n a n o t h e r w a y, a t Precitrame. Vincenzo Bonavoglia, sales manager, said the Swiss company is trying to introduce m u l t i - f u n c t i o n a l p r e c i si o n machines to the region. “Our machines are integrated with several kinds of machines. As such, it is capable of turning, milling, drilling, reaming and sometimes grinding,” he said. One example of the CNC rotary transfer machine is the MTR 312 designed for the manufacture of www.equipment-news.com

small and medium-sized precision mechanical components. Another Swiss company at the show is Kern. Specialising in micro manufacturing, their machines are said to be capable of +/- 0. 5 µm, according to Udo Reinwald, the company’s international sales director. He talked to APMEN about the Pyramid Nano, a CNC machine that has temperature control for the whole machine, not only the spindle. It also has hydrostatic axes of x, y and z, which allow the machine to achieve precision and good surface finishes. Keep Things Stable & Manageable Tooling and machine producer Haimer exhibited Cool Flash, a tool holder that sends coolant directly to the cutting edge. Alexander Tjioe, VP of Haimer Asia Pacific said: “When you use spindle through coolant, the coolant will start losing focus in relation to the cutting tool edges after certain rpm due to the centrifugal force. Cool Flash has a small slot that will create a pressure chamber, amplify it, resulting in a flow of coolant closer to the shank and to the flute. As such, there will be coolant at the cutting point and the tool will last much longer.” Zoller’s new product at the show also has a direct impact

on productivity but it is less mechanical. GM Christoph Zoller revealed that the company has developed a Tool Management Software (TMS). He said: “With the TMS, engineers can now access the complete tool database, for tools in the production shop. The system helps to speed up the preparation time for the cutting tool and also the performance.” APMEN understands from Mr Zoller that the system is said to have resulted in some 20 percent increase in productivity in general. Heimatec showcased their range of live tools at the show. The company develops, manufactures and assembles static and powerdriven tools. Flexibility is key for their live toolings for CNC machine tools. Karl Moessmer, GM (Asia Pacific) of the company said: “Every machine tool manufacturer has a different kind of system. Our job is to adapt our product to any machine manufacturer.” Cutting Tools In the world of cutting tools, many household names were represented by their respective distributors or partners, as opposed to exhibiting on their own while they were at shows in Europe or East Asia. Malaysia-headquartered HPMT took their aluminium line of cutting tools to the exhibition. Touted Jan-Feb 2013 asia pacific metalworking equipment news

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Events&Exhibitions Eric Koh (R), Hoffmann Group

Taveesak Srisuntisuk: The Optiv multi-sensing machine made its debut at Metalex Steve Bell, Renishaw

to possess the “top three most comprehensive line” in the world for aluminium, Khoo Seng Chee, PA to the MD said: “The range (of this line) goes from 0.1 mm all the way to 25 mm.” He added that with good holder and machines, the maximum tolerance can be +/- 10 µm. Hoffmann Group, a system partner for tools, brought to Thailand a drilling chuck for high speed applications. Fully balanced to a quality of 2.5 G, the MicroClamp drill chuck has a clamping range of 0.2 to 3 mm, concentricity of ≤ 0.01 mm and a transmissible torque of 7 Nm. The product is also capable of a maximum speed of 42,000 rpm. It is suitable for precise and micro-size applications, especially those found in the watchmaking industry according to Eric Koh, GM of Hoffmann Group (Asia Pacific). A Measured Approach T he world of met rolog y is arguably the best represented at the show in terms of participation from the ‘big boys’. Unlike their cutting tool counterparts, the likes of Carl Zeiss, Mitutoyo, Nikon Metrology and Hexagon Metrology, among others, all had a decent sized booth at the show. The manufacturers brought in a good range of equipment, some of them newly launched in Europe back in early 2012. Hexagon Metrology gave the 66

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Optiv multi-sensing machine its Thailand debut at Metalex. “The Optiv 321 has a touch probe and a vision sensor. This is the smallest model. The specimen to be measured can be plastic or metal,” said Taveesak Srisuntisuk, MD, Hexagon Metrology (Thailand). He remarked the machine is more suitable for the electronic industry due to its size. A bigger version with a wider working range is more suited for the automotive industry. Like Hexagon Metrolog y, Wenzel also brought a highly compact machine to the show. The Desktop CT exaCT XS is an industrial computed tomography whereby it not only analyses materials, but also measures dimensions, said CP Chuah, the regional sales manager of Wenzel Asia Pacific. “The machine comes with an 80 kV x-ray power source and covers non-ferrous material,” he added. The Desktop CT is said to have an accuracy of 10 μm, making it suitable for any industry that requires reverse engineering, material analysis and dimensional measurements. At Metalex, Renishaw presented its usual array of measuring probes and equipment. However, what caught the eye was something that was not physically at the show. APMEN spoke to Steve Bell, the GM of ASEAN, Renishaw (Singapore)

to find out more on the additive manufacturing technology that the company is offering. “The technology is like rapid prototyping except it uses metal powder. Rather than just producing a prototype, we can produce real parts in metal. The laser melts the powder and forms the object layer by layer. It is a market we see expanding,” said Mr Bell. Conclusion Show organiser Reed Tradex said they hope to increase visitorship to 68,000 in the 2013 edition. In addition, they plan to expand busine ss horizons in order to get participants ready for opportunities arising from the establishment of the AEC (ASEAN Economic Community) in 2015. While the removal of certain trade barriers and increase in labour mobility within the AEC is expected to bring some benefits to the region, metalworking trade shows such as Metalex will continue to play the role of bridging the technological gap between ASEAN and the rest of the developed world, forming a gateway for many metalworking machine or equipment suppliers. BITEC Bangkok, Thailand November 21 – 24, 2012 Enquiry No. 1601 Turn to page 96a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

T

r a f f i c co n g e s t i o n i n Jakarta is something most people living in the city have to contend with on a daily basis. The gridlock of cars, trucks and motorcycles may raise questions on infrastructure, but it also points pertinently to the rise of the middle class. Fuelled by its burgeoning economy, the city has seen 11.26 percent increase in the number of vehicles, or around 1.35 million units, between 2010 and 2011, according to a report from The Jakarta Post. The number of passenger cars saw a 19 percent increase in 2011, equating to some 206,468 new cars, or roughly 565 new cars purchased per day. The number of new cars and growing economy can partly be attributed to the automotive sector in the country, which c o n t i n u e s to l u r e f o r e i g n investors, including those in the metalworking industry. This trend may not be exactly new, but based on the level of international participation at the Manufacturing Indonesia show at the end of 2012, there may be more investments coming Indonesiaâ&#x20AC;&#x2122;s way. Foreign Participation The 23rd edition of Manufacturing Indonesia was held from December 5 â&#x20AC;&#x201C; 8, 2012, in Jakarta. Although no stranger to international exhibitors and visitors, the 2012 edition seemed to have taken on a greater international flavour and also an increase in size. The show occupied all nine exhibition halls available. The organiser said in order to cater for increased space demands, an additional temporary hall has also been added. In total, the event gathered over 2,400 exhibiting companies from 41 countries. Apart from the usual participating nations, Russia and Taiwan have caught the eye in the 2012 edition for different reasons. For Taiwan, it is the sheer number www.equipment-news.com

Event Review:

Manufacturing Indonesia2012

The number of national pavilions at the show is a sure sign of international interest in the manufacturing market of Indonesia. By Joson Ng of exhibitors. With three different associations bringing exhibitors over to the show, Taiwanese booths were out in force in all halls. Elsewhere, the show saw the Ministry of Industry and Trade of the Russian Federation organising a national exposition to promote the achievements of the Russian industry. The Russian national stand covered some 300 sq m, and represented small, medium and large scale businesses within the industrial sector, as well as the regions of the Russian Federation. Indonesia is pa r ticula rly attractive for Russian manufacturing enterprises. In recent years, commercial and economic relations between Russia

and Indonesia became more active with increased trade flow between the two countries. In 2011, there was a 13.3 percent increase in mutual trade volume, which made a total value of US$2.17 billion. The exhibits in the Russian pavilion included handling equipment, industrial robots, metalworking technology, metal-cutting tools and vehicle manufacturing technology. Metrological Technologies At The Show In metrology, both Mitutoyo and Carl Zeiss took part with significant sized booths despite their exertion at Metalex in Thailand barely two weeks prior. Senior regional sales manager of Mitutoyo Asia Pacific, Desmond Yee told APMEN Jan-Feb 2013 asia pacific metalworking equipment news

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Events&Exhibitions CMM with laser scanner and portable measuring systems are the pertinent technologies on show. He said: “The CMM CrystaApex S has a 3D laser scanning application in addition to the touch probe. Laser scanner provides rapid scanning for inspection or reverse engineering applications. Instead of the touch probe taking points, the scanner can scan the surface in 3D within seconds. It can take up to 40,000 points per second. Another product, the Spin Arm Apex is a portable CMM. There are two applications. One is for probing and another is laser scanning. This is operated manually. The portable CMM is for inspections of parts that are not manufactured to very high tolerances. It (accuracy) can be about 100 µm or better. The weight of this equipment is less than 20 kg. Operators do not need to move it often. As far as operator ease of use is concerned, it is very light weight. One man can carry and set this up. The product is for large work pieces because they generally do not need such high tolerances. Examples are components like the car body and also for big die.” Fellow metrology solution provider Carl Zeiss was also at the show, showcasing new technologies and also existing technologies with a new twist. Shaun Lim, regional division manager (Southeast Asia) of Carl Zeiss said: “We have been showing the Spectrum and G2 for the last two years. This time, we have upgrades in certain areas. We have made controllers more compact. This helps reduce the footprint by an estimation of 25 percent. We have centralised all the control buttons at the control panel, improving convenience.” Mr Lim also said the show marked the first time they were showing the O-Inspect 442, a multisensor-CMM that combines measuring technology with optics. It is equipped with a contact and an optical sensor. 68

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Multi-functional measuring solutions provided by the CMM Crysta-Apex S is in demand in Indonesia

O-Inspect 442 made its Indonesia debut at the show Cost reduction plays a big part in metal cutting and it showed in many features of the cutting tools

Taizo Seno

Cutting Technologies Over at the cutting tools segment, Tungaloy brought their exhibits from the recently concluded JIMTOF to Indonesia. Taizo Seno, sales manager of Tungaloy Indonesia picked out some new products to share. One of them is TetraCut, a grooving tool with fourcornered insert.

“Normally, there are only one to two cutting edges. Four cutting edges result in cost savings.” He added that the tool comes with PVD coating and is suitable for small parts manufacturers in the IT industry. In their milling line, the DoFeedQuad, touted as a high feed face milling cutter, is said to allow www.equipment-news.com


Events&Exhibitions A mixture of gases is fed into the deburring chamber via a gas metering system and ignited by a spark. The temperature of the combustion ranges from 2,500 to 3,300 deg C. The burr reaches its ignition temperature and reacts with the excess oxygen inside the deburring chamber. This leads to a complete combustion of the burr within 20 ms. Various metallic materials, thermoplastics and injection moulded parts without glass fibre content are processable. However, some of the limitations of the technology are that the work piece cannot be larger than the deburring chamber and the material must be oxidisable.

Faster plasma cutting is possible with higher amperage

PCT is expected to change how human and machine interact

reductions in cost. Mr Seno said: “The cutter allows five times higher feed rate than the existing model. Cycle time is reduced, resulting in reduced cost. This is because of a new concept that cuts less but cuts faster.” The concept is achieved by reducing depth of cut and increasing the feedrate. In plasma cutting, Soo Kam Tatt, director, Hypertherm (Asia) said: “Our latest product at this show is the Powermax105. We launched it about six months ago. The system is capable of a production cut of 32 mm. In terms of speed it is slightly faster (than the 1650 model) because of the higher amperage.” Mr Soo added that the 105 has now out-performed the 1650 and price wise, it is not much different, which goes very much along their www.equipment-news.com

philosophy of reducing the cost of cutting metal. Rough Around The Edges Post cutting, parts are usually sharp around the edges and require a smoothing process call deburring. At the show, ATL Anlagentechnik Luhden introduced therma l deburring or TEM ( Thermal Energy Method). It is a process to remove production related burrs from various machine parts which are caused by milling, drilling or other machining methods. The material to be removed is burned due to a chemical reaction between the material and the gas mixture. For this purpose, the work pieces are placed in a bell-shaped deburring chamber which is hydraulically closed by a closing plate.

Automation Technology F i n a l l y, i n t he auto m at io n segment, Beckhoff Automation brought various new products to the show. What caught the eye was the multi touch panel. When asked by APMEN, David Chia, MD of the company was happy to demonstrate the range of application of the product. He said: “One of the new products we are showing is this multi touch panel. We are moving on from the resistive type of technology. We are going into the same type of technology found on smart phones and tablets.” T he technolog y Mr Chia was talking about is PCT, or projected capacitive touchscreen technology. He said that with the electronics interaction behind the glass, constant pushing of a button in a specific position will not affect the sensitivity. “Released in Germany back in April 2012, this technology will start a different approach to HMI,” he added. Jakarta International Expo Centre Jakarta, Indonesia December 5 – 8, 2012 Enquiry No. 1602 Turn to page 96a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Workplace Safety And Health Conference 2012

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untec Singapore International Convention and Exhibition Centre was the host of the second Singapore Workplace Safety and Health (WSH) Conference 2012 held from September 12-13, 2012. The theme of the 2012 edition was ‘Changing Landscapes, Shaping a Progressive WSH Culture’. The show opened to over 750 leaders, experts, and delegates from around the world. Opening Address The opening address was given by Tharman Shanmugaratnam, deputy PM and minister of finance, Singapore. Mr Shanmugaratnam touched on three key points during his speech that affect how we look at workplace safety and health, namely, the evolution in the structure of economic activity, the increasing proportion and participation of older workers, and the continuing advance of technology. Why Now? The event is timely and critical g i v e n t h e u rg e n t n e e d f o r businesses around the world to address pressing WSH challenges. 70

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It will draw focus to a wide range of issues, including striving for strong WSH performance in an increasingly challenging operational landscape; ageing workforce; recognising WSH as a core business consideration; and new workplace risks emerging from fast-pace technological developments and the evolution of the global economy from agrarian based to the manufacturing and service-oriented economy it is today. WSH Initiatives The Singapore WSH Conference witnessed the launch of two key initiatives, namely the CultureSafe progamme, and the ergo@work mobile app. CultureSafe Programme By WSH Council The CultureSafe is a programme that provides organisations with a roadmap to advance their WSH culture through a five step cycle. The programme will help companies progress from a reactive to a proactive culture. The Council has also prepared a set of diagnostic tools that measure a company’s WSH culture maturity

or CultureSafe index. Through the programme, companies will also be able to identify WSH cultural gaps and develop implementation plans. Ergo@Work Mobile App By WSH Institute The WSH Institute’s new mobile application, ergo@work, will enable smartphone users in the increasingly tech-savvy workforce to download the free app from both the iPhone and Android market. The app takes photographs of sitting postures, evaluates and suggests possible areas for improvement as well as provides tips on how to improve postures and carry out simple stretching exercises. The app aims to raise awareness on good ergonomics in an office environment and help prevent work-related health issues due to poor postures. The third Singapore WSH Conference will be held in 2014. September 12-13, 2012 Suntec Singapore International Convention & Exhibition Centre Singapore Enquiry No. 1603 Turn to page 96a or log on to www.equipment-news.com to enquire

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Events&Exhibitions

Event Preview:

Indometal 2013

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esse Düsseldorf Asia and PT Wakeni, the joint organisers of Indometal 2013, have read signs well and set the date for the international metal and steel trade fair for Southeast Asia to be February 20 – 23, 2013. The promising nature of Indonesia’s economy was once again confirmed in July when economic figures for the first half of the year indicated a 6.3 percent growth rate. According to the World Steel Association, demand for steel is expected to grow similarly; they quote a predicted three to six

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percent year-on-year growth for 2012. The growth of the economy is largely attributed to an increased number of investments and an increase in consumption. Most recently, the Indonesian g o v e r n m e n t h a s t r i g g e re d debate in an attempt to promote domestic investment, particularly in ore processing, in order to advance exports of finished higher-value metals. While some are rather sceptical of the increased export taxes, the government’s move is in line with the fact that steel consumption alone grew by 20.6 percent in 2010 and has been growing since.

At an 18.4 percent share, I n d o n e s i a i s r a n k e d t h i rd largest consumer of steel in the ASEAN region. The growing steel consumption contributes to the economy’s growth and economic position in the region. By promoting investments into the sector, the government is now hoping to achieve higher quality production and end products, and ultimately, exports. Event Details The industry’s immediate future will therefore be marked by those changes and it is in these busy times that the organisers will launch the inaugural Indometal in February 2013, a specialist trade fair for the metal and steel industry that will provide opportunities to get a grasp of the current events and innovations. It will also allow professionals and business people from outside Indonesia to explore the market and build relationships. What is more, a complementary platform will be held, adding value to the event by concentrating on equipment, tooling and machinery solutions at Indotools. This sector becomes particularly relevant given the rising demand for machine tools in industries such as automotive or mining. The increase in demand can largely be attributed to the fact that such industries constitute a significant proportion of the country’s growing GDP. In light of the recent changes to government regulation, demand for specialist tools can be expected to increase further as the competitive and substantial need for higher value production and metal endproducts will keep rising. Jakarta International Expo Kemayoran Jakarta, Indonesia February 20 – 23, 2013 Enquiry No. 1604 Turn to page 96a or log on to www.equipment-news.com to enquire

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he 24th Taipei Int’l Machine Tool Show (TIMTOS) will star 960 direct exhibitors who are taking up more than 5,300 booths. Running from March 5 - 10, 2013, the event is cohosted by TAITRA (Taiwan External Trade Development Council) and TAMI (Taiwan Association for Machinery Industry). Since its establishment in 1975, the size of the show and levels of participating products have grown steadily. Along with strong participation from across Taiwan, the established names in the machine tool industry from 17 other countries have also signed up for the event. The event will cover a total space of 90,000 sq m at Taipei World Trade Center hall 1, 2, 3 and the Nangang Exhibition Hall. It is projected that more than 5,500 visitors from overseas and 40,000 domestic visitors will visit the venue. Technology Developments: Taiwan’s Take • Five-Axis Technology Ta i w a n e s e m a c h i n e manufacturers have moved toward more high-end products such as five-axis machines with high-speed spindles and fiveface machines with C-frames or double column structures in recent years. There are typically four types of five-axis mechanisms usually 74

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seen on such machining centres: 1. An additional rotary and tilting table (on three-axis machines). 2. An integrated rotary and tilting/ swiveling head unit (on threeaxis machines). 3. A swiveling or tilting head on the top, plus a built-in or independent rotary table. 4. An integrated rotary and tilting table driven by low inertia motors. The five-axis high-speed, high precision machining centres are suitable production tool for aerospace parts, medical equipment as well as computer and communication components. • Horizontal Machining Centres The cutting efficiency and machine reliability for a horizontal machining centre is extremely critical. Such high expectations include spindle rotation and the axial motion’s acceleration and deceleration, the reliability and speed of the Tool Changer (ATC) and Pallet Changer (APC), the protection of the ATC / APC mechanism (from being damaged by cutting fluid or chips), and thermo deformation control. The accuracy and reliability of both the ATC and APC are two critical challenges. To achieve the optimum performance of the

APC, it is best for the pallets to be mechanically clamped using a ball locking system and accurately positioned by four tapered cones. High pressure air cleans as well as confirms the pallets are seated correctly. The clamping system ensures rigidity under external cutting force conditions. In addition, the modern design of a horizontal machining centre also allows users to expand their pallet capacity and tool capacity in the future. This means it is possible to increase the number of pallet stations as well as the capacity of the tool magazine on the shop floor. Higher productivity is easily achieved by this retrofitting flexibility and it enables long-term unmanned operations or high-efficiency of multi-part, small-lot production. • Vertical Machining Centres Taiwanese vertical machining centres were price-oriented in the past. Today, manufacturers focus on features such as operator comfort and service safety. Additionally, machines nowadays must meet the most stringent env ironmenta l protection standards at different stages, including: 1.Production stage in the manufacturer’s factory. 2. Packing and delivery. 3. Operation at the end-user’s factory with the requirements of low electricity and water consumption as well as low volume of waste. 4. Recycling. Taipei World Trade Center & the Nangang Exhibition Hall Taipei, Taiwan March 5 – 10, 2013 Enquiry No. 1701 Turn to page 96a or log on to www.equipment-news.com to enquire

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Product Finder Adcole: Camshaft Inspection

Esco: Pipe Beveling Tools For Offshore Pipelines

The Adcole model 1304 multi-headed ca msha f t gauge prov ides pa r ts inspection with one minute cycle times, me a su re s 3 ,6 0 0 data p oint s p er revolution, and can be loaded automatically by gantry or manually. Featuring four programmable moving heads and a tailstock with 6” travel, this gauge allows parts access from a touch screen, handles different length parts, and each of the heads can move to a park position for easy access. Incorporating a headstock spindle with glass scale angle encoder systems, the gauge permits on or off line programming. Menu-driven, it has dual Windows 7 computers and can measure 20 different parameters including roundness (LSC, MIC, MZC), diameter (LSC, 2-point), profile, taper, crown, timing angle, velocity, acceleration, runout, and concentricity. Enquiry No. 1801 Turn to page 96a or log on to www.equipment-news.com to enquire

Dormer: Extended Threading Programme

Dormer Tools has added to its threading programme with the launch of a range of taps. Designed to promote a continuous production process in structural grade steels, carbon steels, copper and brass, all taps feature a hard chrome plating. This treatment has the benefit of increasing surface hardness — up to 68 HRc — but also prevents swarf from sticking to the tool. When combined with a geometry designed to provide optimum flute space, this feature promotes negligible chip congestion and, in turn, better productivity. A short thread length generates low torque, meaning the taps can be run at higher operating conditions with no detrimental effect on tool life or workpiece surface finish. Enquiry No. 1802 Turn to page 96a or log on to www.equipment-news.com to enquire

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A line of portable welding end prep tools for beveling pipe ranging from 38 mm ID to 914 mm OD made of hard super alloys, is available from Esco Tool. Millhog Pipe Beveling Tools are fully portable for onsite use and can bevel at any degree of angle including precision ‘J preps’ for automatic welding. Designed for long life and ease of use, these tools require no special operator training. It employs direct-drive bearing supported gears, and use the EscoLock blade lock system with interchangeable cutter blades to bevel, face, and bore simultaneously. Enquiry No. 1803 Turn to page 96a or log on to www.equipment-news.com to enquire

Fronius: High-Speed Welding With Optimum Energy Input

Welding technology provider Fronius International has developed a tandem welding process, the CMT Twin. This twin-wire solution enables users to exploit two Cold-Metal-Transfer (CMT) processes, or combine a CMT process with a GMA pulsed-arc welding process, all within one single system. To do this, CMT Twin comes with two digital power sources that work separately from one another. This allows the weld processes to be individually adjusted to the different applicational requirements obtaining in each case, and also means that — within the given physical limitations — any wirefeeder can be chosen. Enquiry No. 1804 Turn to page 96a or log on to www.equipment-news.com to enquire

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ProductFinder Ifm Electronic: Compact Industrial 3D Sensor

Iscar: Insert With Helical Cutting Edge

ifm electronic has released the first industrial quality 3D sensor that detects objects in 3D. Enabling evaluation of geometrical characteristics such as volume, distance, level or surface area, these functions are suitable for ‘missing goods’ applications. The geometric characteristics of an object are interpreted via two output options. The first is a switch. The other may be set as a second switch point, or configured as 4-20 mA / 0-10 V analogue output.

Iscar has developed the Heliqmill 390 line. It offers a triangular insert with three cutting edges. Available in 10 and 15 mm cutting edge lengths, the insert with three edges has a stronger structure. The cutting geometry of the insert results in a precise 90 degree shoulder and a wiper flat provides good surface finish. The inserts are produced from the Sumo Tec carbide grades and are intended for machining shoulders, slots and planes. In addition, they can be a good choice in milling surfaces, ramping-down or helical interpolation such as pockets or cavities. The tools are available as endmills with shanks and face mills with a central bore.

Enquiry No. 1805 Turn to page 96a or log on to www.equipment-news.com to enquire

igus: Compact Cable Guide For Small Loads igus has developed a lightweight linear guide system that can accomplish several tasks, which were not solved by one single component previously. These include the lubricant-free guiding of a linear movement and the accommodation of pipes and cables. The drylin Q system works like a traditional shaft guide. It is made up of a closed casing, which can be moved linearly on a shaft. However, it does not have a round shaft, but rather a square aluminium profile with an edge length of 7.5 mm. This makes the guide system torsion-proof compared with round systems. Since the aluminium profile is also hollow, it can accommodate protected compressed air, fluid, signal or energy pipes and cables. This hybrid solution allows additional design space to be saved for cable routing, particularly useful for applications in the miniature range such as in laboratory instruments. Enquiry No. 1806 Turn to page 96a or log on to www.equipment-news.com to enquire

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Enquiry No. 1807 Turn to page 96a or log on to www.equipment-news.com to enquire

Kennametal: Shoulder Mill For Small Diameters

As a complement to the Mill 1 platform for finishing operations, Mill 1-7 is Kennametal’s solution for finishing in small diameter milling. This line is engineered to cover ramping, slotting, and plunging for aerospace, energy, and general engineering applications. The tool is for roughing and finishing operations, where small diameter end mills are required. Multifunctional Mill 1-7 cutters can be used for shoulder-, ramp-, slot-, plunge-, and helical milling. The small Mill 1-7 inserts enable the use of higher density cutters rather than larger inserts, providing greater feed and higher metal removal rates. The inserts are designed with elliptical cutting edges that are optimised with a straight 90 degree wall and true zero degree lead, making them capable of replacing SCEM finish machining in certain applications. Enquiry No. 1808 Turn to page 96a or log on to www.equipment-news.com to enquire

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ProductFinder

HOMMEL-ETAMIC Nanoscan Ultra-precision, opto-mechanical measuring system.

JENOPTIK SOUTH EAST ASIA PTE LTD 883 North Bridge Road, # 03-01 South Bank Singapore 198785 www.hommel-etamic.com

Oxford Instruments: Materials Analyser

Panasonic: Handling Robots

Ox ford Instruments ha s added to its handheld XRF analyser X-MET7000 series with the X- MET750 0. The analyser delivers analysis of a variety of materials, including trace elements and light elements (from magnesium) analysis, without the need for helium purge or vacuum pump. It is a suitable screening tool for positive material identification in the metal industries, among other applications. According to the manufacturer, the analyser features a software, reporting tools and long battery life. It also offers an improved, and easy-to-read graphical user interface. Large functional icons make learning how to use the instrument simple and quick.

Panasonic Robot and Welding Systems Europe has released the HS-G3 series of handling robots. It prov ides an additional field of application capabilities within the existing robot product range. Offering a payload capacities of up to 200 kg and a ma ximum working range of 2.66 m, the HS-165 /-200 G3 provides enhanced benefits for production automation solutions requiring work handling. Programming and operation takes place by using the G3 controller and the light weight teach panel â&#x20AC;&#x201D; exactly matching the control method of the G3 Panasonic welding robots. This controller has a 600 percent faster main processor than the previous G2 controller, ensuring the acceleration and deceleration processes occur 10 percent faster than the previous model.

Enquiry No. 1809 Turn to page 96a or log on to www.equipment-news.com to enquire

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The simultaneous high-precision measurement of roughness and contour characteristics, on curved or inclined surfaces, requires a high resolution measuring system with a wide measuring range. The HOMMEL-ETAMIC nanoscan is an extremely precise measuring system, with a resolution of 0.6 nm and a measuring stroke of 24 mm, delivering unprecedented flexibility in a measurement system. Together with the high-precision traverse unit, the system achieves excellent measuring accuracy both in the measurement of microgeometry characteristics and in contours with large measuring strokes.

Enquiry No. 1810 Turn to page 96a or log on to www.equipment-news.com to enquire

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ProductFinder Reis: Welding With Robots

Sumitomo Electric Hardmetal: CBN Grades

Reis Robotics has developed a welding robot, the RV20-10HW with hollow wrist axis in conjunction with a compact welding cell. This robot type is available in six different designs with a payload from 6 to 10 kg and a reach of r= 1.550 to 2.050 mm. The hose pack lying inside reduces the interfering edge, extending the robot work envelope. Optimum processing of complex components in particular is possible. The solution excludes the previous danger of collision of the hose pack with the component or with the weld fixture. This will result in further increase of the system availability, ensures reduced downtimes and lower costs due to wear.

Sumitomo Electric Hardmetalâ&#x20AC;&#x2122;s has developed their next generation uncoated CBN grades Sumiboron BN1000 and BN2000. These grades are produced with a high-purity TiCN ceramic binder, which improves the CBNâ&#x20AC;&#x2122;s overall toughness and heat resistance. According to the manufacturer, BN1000 exhibits the highest wear resistance in any uncoated Sumiboron grade and is developed for high speed machining of hardened steel. On the other hand, BN2000 covers general purpose turning of hardened steel. The grades are available in both single and multi-cornered type inserts.

Enquiry No. 1811

Turn to page 96a or log on to www.equipment-news.com to enquire

Steinbichler Optotechnik: 3D Touch Probe

Walter: Precision Holder For Precision Tools

Steinbichler Optotechnik, a provider of optic measuring and sensor technology has developed a portable coordinate measuring device. The handheld touch probe T-Point CS is designed for easy and efficient single-point measurement. According to the manufacturer, the touch probe measures the selected measuring points quickly and reliably, making it a suitable solution for single-point measurements on building areas such as (trimmed) edges and ruled geometries. The system can be used with conventional measuring probes, which can be replaced. Enquiry No. 1812 Turn to page 96a or log on to www.equipment-news.com to enquire

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Enquiry No. 1813

Turn to page 96a or log on to www.equipment-news.com to enquire

Walter has included a steep taper monoblock adapters in its range of holders. In addition to the already available HSK and the SK modular adapter solutions for accommodating a variety of different machining situations, the range now also includes monoblock designs in sizes SK40 and SK50, as well as BT40 and BT50. The adapters are characterised by the precision of their taper within the smallest of tolerances, which also results in maximum concentricity and clamping precision. A minimum balance quality of G6.3 at 16,000 rpm is guaranteed by the manufacturer. The coolant is supplied either through shape AD (centrally) or B (via the collar). A selection can be made between variants with shell end mill arbour according to shape AK155 and A155, with collet chuck AK300 and Weldon chuck AK170. Enquiry No. 1814 Turn to page 96a or log on to www.equipment-news.com to enquire

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Exhibition Programmes

2013

January

May

Bangalore International Exhibition Centre Bangalore, India IMTMA imtma@imtma.in www.imtex.in

BITEC Bangkok, Thailand UBM www.subconthailand.com

24 – 30 Imtex 2013

February 20 - 23 Indometal

Jakarta International Expo Kemayoran Jalarta, Indonesia Messe Dusseldorf (Asia) shirley@mda.com.sg www.indometal.net

27 Feb – 1 Mar ASX 2013 Singapore Expo Singapore AAIS asx@aais.org.sg www.asx.sg

March 5 – 10 TIMTOS

TWTC, TWTC Nangang Taipei, Taiwan TAITRA timtos@taitra.org.tw www.timtos.com.tw

26 – 29 Inapa 2013

JI Expo Kemayoran Jakarta, Indonesia GEM Indonesia www.inapa-exhibition.net

16 – 18 Subcon Thailand 2013

16 – 19 Sheet Metal Asia 2013 BITEC Bangkok, Thailand UBM www.sheetmetalexhibition.com

16 – 19 Intermach 2013

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

21 – 25 Metaltech 2013

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

22 – 25 MTT 2013

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

June

12 - 15 Manufacturing Surabaya 2013

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

July

2-5 MTA Vietnam 2013 SECC Ho Chi Minh City, Vietnam SES mta@sesallworld.com www.mtavietnam.com

September 4-7 Mining Indonesia

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

November

13 - 15 Oil & Gas Indonesia 2013 Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

December

4-7 Manufacturing Indonesia Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

April

9 – 12 MTA 2013

Singapore Expo Singapore SES mta@sesallworld.com www.mta-asia.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

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009 028

CHIA LERN CO LTD

79

CHI-FA MACHINERY MANUFACTURER CO LTD

77

023

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82

029

DELCAM PLC

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DEES HYDRAULIC INDUSTRIAL CO LTD

93

081

ECMI SERVICES PTE LTD (MTT 2013)

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EVERGREEN INTERNATIONAL CORP (TAITRA / TIMTOS 2013)

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EVERISING MACHINE CO

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GREENLEAF CORPORATION

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HAAS AUTOMATION INC

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JAPAN Ted Asoshina Echo Japan Corporation Tel: 81-3-3263 5065 Fax: 81-3-3234 2064 E-mail: aso@echo-japan.co.jp

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IFM ELECTRONICS PTE LTD

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ISCAR LTD

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052

JOEMARS MACHINERY & ELECTRIC INDUSTRIAL CO LTD

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KENNAMETAL INC

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LICO MACHINERY CO LTD

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MAXMILL MACHINERY CO LTD

90

040

MECATRON MACHINERY CO LTD

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MESSE FRANKFURT (HK) LTD (SIAF GUANGZHOU 2013)

27

004

NATIONAL INSTRUMENTS

15

011

NEWELL RUBBERMAID – LENOX

17

016

OCEAN TECHNOLOGIES CO LTD

84

042

OSCAR EDM COMPANY LTD

85

043

PERFECT MACHINE CO LTD

86

044 045

SESAME MOTOR CORP

90

SHUN CHUAN MACHINERY IND CO LTD

81

046

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2013)

37

193

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2013)

59

014

SINGAPORE ORIENTAL MOTOR PTE LTD

01

051

SPHINX

41

015

TAEGUTEC CO

11

012

TAIWAN TAKISAWA TECHNOLOGY CO LTD

79

047 048

TOP-ONE MACHINERY CO LTD

87

TORNOS TECHNOLOGIES ASIA LTD

45

007

TRADE-LINK EXHIBITION SERVICES SDN BHD (METALTECH 2013)

55

209

TRUMPF PTE LTD

19

008

TUNGALOY SINGAPORE (PTE) LTD

13

020

TUV SUD PSB PTE LTD

07

050

UBM ASIA (THAILAND) CO LTD

23

003

WALTER AG SINGAPORE PTE LTD

FC

001

YIH CHUAN MACHINERY INDUSTRY CO LTD

82

049

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SWITZERLAND Rene Bachmann Mediall SA Tel: 41-56-442 14 40 Fax: 41-56-442 27 77 E-mail: rb@mediall.ch

TAIWAN Robert Yu Worldwide Services Co., Ltd Tel: 886-4-2325 1784 Fax: 886-4-2325 2967 E-mail: sales@wwstaiwan.com

U. KINGDOM Eddie Kania Robert Horsfield Int'l Media Rep. Tel: 44-1663-750 242 Fax: 44-1663-750 973 E-mail: ekania@btopenworld.com

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions. The closing date for placing advertisements is not less than FOUR WEEKS before the date of publication. Please contact our nearest advertising office for more details.

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ASIA PACIFIC METALWORKING

No. 1 2013

The Engineering Journal For Manufacturing,Automation & Quality Control

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(Refer to Advertising Index for Advertisers’ enquiry numbers)

Note: This form must be duly completed and signed.______________ TYPES OF PRODUCTS TO BE PURCHASED IN THE NEXT 12 MONTHS ❍ Cutting Tools ❍ Machine Tools ❍ Software

❍ Metrology

❍ Others_____________

TYPE OF BUSINESS (Please ✔ ONE box only) Do you use METAL in your production/manufacturing process? Do you use machine tools and related equipment? Do you use automation systems & equipment?

❑ Yes ❑ Yes ❑ Yes

❑ No ❑ No ❑ No

YOUR METAL PROCESS USED ? (Please be specific) ❑ 300 ❑ 303 ❑ 306 ❑ 309 ❑ 315 ❑ 318

CNC Machining Milling Gear Cutting Grinding Stamping Shearing

❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310

EDM/ECM Inspection/Measuring/Testing Design with CAD/CAM Drilling/Boring Tapping/Threading Lapping/Honing

❑ 313 ❑ 316 ❑ 319 ❑ 322 ❑ 302 ❑ 305

Forging Rolling Die Casting Welding Turning Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 Others (Please specify)_____________________________________________________________________________________________

YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122 ❑ 123

Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg. Dies & Moulds mfg. Motor Vehicles Parts Shipbuilding

❑ 160 ❑ 180 ❑ 200 ❑ 224 ❑ 078

Design & Consultancy Services Govt bodies, Trade Assns, Exhibitions Cos. Agent/Distributor/Trader of Machine Tools & Accessories Mechanical, Fabrication and all other metal engineering works Others (Please specify)_____________________________________

JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt

❑ 028 Testing & Inspection ❑ 030 Sales & Marketing

❑ 022 Production Engineering ❑ 024 Quality Control/Assurance

❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

❑ 027 Others (Please specify)

Size of company ❑ 001 1 – 10

❑ 002 11 – 30

❑ 003 31 – 50

❑ 004 51 – 100

❑ 005 101+


www.equipment-news.com FAST PERSONAL COPY SUBSCRIPTION FORM INVEST $0.15 PER DAY IN TECHNICAL AND BUSINESS INFORMATION FOR YOUR CORPORATE STRATEGIES IN SOUTHEAST ASIA

Name: (Surname)_ ______________________________________ (Given Name)_ ___________________________ Company: _____________________________________________ Job Title:_________________________________ Address:__________________________________________________________________________________________ Country: ______________________________________________ Telephone No: _ __________________________ E-mail:_ _______________________________________________ Fax No:__________________________________ Signature ______________________________________________ SUBSCRIPTION RATES

Commencing from:

AIRMAIL (1 YEAR – EIGHT ISSUES)

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Date____________________________________

Eastern Trade Media Pte Ltd

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Month

■ Asia Pacific/America/Europe/ Others S$100.00

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United Overseas Bank, Singapore Bank Code: 7375 Branch Code: 037 Account No.: 921-343-851-0 Company: Eastern Trade Media Pte Ltd

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Account Number

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Expiry Date

Signature

TYPE OF BUSINESS (Please ✔ ONE box only) Do you use METAL in your production/manufacturing process? Do you use machine tools and related equipment? Do you use automation systems & equipment?

❑ Yes ❑ Yes ❑ Yes

❑ No ❑ No ❑ No

YOUR METAL PROCESS USED ? (Please be specific) ❑ 300 ❑ 303 ❑ 306 ❑ 309 ❑ 315 ❑ 318

CNC Machining Milling Gear Cutting Grinding Stamping Shearing

❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310

EDM/ECM Inspection/Measuring/Testing Design with CAD/CAM Drilling/Boring Tapping/Threading Lapping/Honing

❑ 313 Forging ❑ 316 Rolling ❑ 319 Die Casting ❑ 322 Welding ❑ 302 Turning ❑ 305 Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 Others (Please specify)

YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122

Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg. Dies & Moulds mfg. Motor Vehicles Parts

❑ 123 ❑ 160 ❑ 180 ❑ 200 ❑ 224 ❑ 078

Shipbuilding Design & Consultancy Services Govt bodies, Trade Assns, Exhibitions Cos. Agent/Distributor/Trader of Machine Tools & Accessories Mechanical, Fabrication and all other metal engineering works Others (Please specify)_____________________________________

JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt

❑ 028 Testing & Inspection ❑ 030 Sales & Marketing ❑ 027 Others (Please specify)

❑ 022 Production Engineering ❑ 024 Quality Control/Assurance

Send this Fast SUBSCRIPTION FORM to Circulation Department, Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-02, Singapore 169206 or Fax: 65-6379 2806 Note: This form must be duly completed and signed.

❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing


ENQUIRY NO 013


WIN WITH WIDIA

How much would you pay for a perfect hole? Not nearly as much as you think.

WIDIA VariDrill

tm

Best price-performance ratio. • Applicable in almost every workpiece material. • Available from 1,0 to 20,0 mm, from 3xD to 8xD. • With coolant or non-coolant. •

To learn more about the unmatched benefits of WIDIA VariDrill,tm contact your local distributor or visit www.widia.com.

ENQUIRY NO 128

©2012 Kennametal Inc. l All rights reserved. l A-12-02818-EN

APMEN JanFeb 2013  

Asia Pacific Metalworking Equipment News

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