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Sustainable Manufacturing By Remanufacturing Using Wireless Technology In Metrology May - June 2013

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May-June 2013

CUTTING EDGE 26 Inserting Intelligence Into Metal Cutting

Adding cleverly designed mechanisms and features around the insert and its holder can go a long way in helping it keep pace with the advancements in machine tool technology. Contributed by Hadas Zeira, Iscar


Metalworking Fluids: Better Understanding For Better Usage

Asia Pacific Metalworking Equipment News (APMEN) spoke with Patrick Brutto, senior technical service and development specialist for Dow Consumer & Industrial Solution, on the finer points that affect the performance of metalworking fluids. By Joson Ng


Cooler By The Minute

Coolants play an enormous role in manufacturing by facilitating heat dissipation. With increased production loads however, manufacturers are looking for a solution to hasten the cooling process, which could potentially be found in nanofluids. By Sherlyne Yong


Case Studies: Use It Right

Using the right metalworking fluid is proven to improve tool life and productivity. By Nadia Hofer, Blaser Swisslube



Wireless technologies have brought a change in the metrology industry by providing flexibility and better performance. By Shruti Khanna, Hexagon Metrology

As the push for manufacturing productivity increases, so too will the rise of wireless technology in the metalworking industry. By Shahnawaz Abdul Hamid

Change. Evolve. Transform — Go Beyond Wireless Technology


asia pacific metalworking equipment news May-Jun 2013

Wireless Technology: The Next Stage In Manufacturing Automation

FormJoinCut 46 Choose The Right Gouging Tool For Weld Repair

The decisions behind the selection of a gouging tool can be a multi-faceted one. By Erik Brine, Hypertherm

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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.


Multi-Wire Weld Processes For More Economical Welding

Tandem welding can produce more flexibility and better performance. By Dipl Ing (FH) Franz Joachim Roßmann, for Fronius


Case Study: Arm Twisting In Quality Control

Engineering tolerance — you are either within or out of it. Measurements however, can benefit from a little flexibility in the form of measuring arms. By Yoshihiro Iida, Faro Japan


The Mould & Die Industry To Change With The Times

Augustine Quek analyses the fortunes of the mould and die industry in this special focus.

Executive Zone 58

Contribute To Sustainable Manufacturing With Remanufacturing

Remanufacturing has subtle differences when compared with terms like repair and reconditioning. However, its potential benefits when applied correctly can be considerably more substantial. By Joson Ng


08 Business News 75 Product Finder 79 Exhibition Programmes 80A Product Enquiry Card 4

asia pacific metalworking equipment news May-Jun 2013


Demand For Motorcycles To Exceed 134 Million Units

The number of motorcycles will increase due to rising standards of living and higher petroleum costs. By Lee Steinbock, industry analyst, Freedonia Group


Bringing It A Level Up

The oil and gas industry has been employing contact and non-contact level sensors to automate and streamline the production process, which has led to enhanced accuracy and efficiency. By Sherlyne Yong

EVENTS & EXHIBITION 64 Event Review: MTA 2013

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: 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


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Event Preview: Manufacturing Expo 2013 Event Preview: Manufacturing Surabaya 2013 Event Preview: MTA Vietnam 2013 Event Preview: JEC Asia


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Editor’s Note Published by:

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managing director Kenneth Tan editor Joson Ng

business development manager Randy Teo

senior sales manager Derick Chia

sales manager Melvin Wong

We were often told to live within our means and not to overspend. Living frugally makes a lot of sense as someone who makes $3,000 a month cannot afford a rent of $4,000. This concept is simple to understand in financial terms but when it comes to manufacturing, things get a little cloudy. In this issue of Asia Pacif ic Metalworking Equipment News, we revisit the issue of sustainable manufacturing. It is a constantly evolving subject, where the definition of the term can take on many forms. In addition, there always seems to be more to add on to the concept as time goes by, be it a new research or simply new takes on the philosophy. There is perhaps no good way to define sustainable ma nufacturing. Therefore, it is best to leave things as that because sustainability can mean different things to different people in different industries or countries. What most people can agree on

is the perceived value of sustainable manufacturing, ie: how can we benefit from it? Whatever the motivations of pursuing sustainable manufacturing are (monetary or environmental), the prize for those who are successful in sustainable manufacturing are the ones who go home with both trophies. At Asia Pacific Metalworkin g Equipment News, we adopt a more quantifiable approach in looking at this abstract issue, ie: by analysing sustainable manufacturing’s individual constituents. In this issue, we choose to look at remanufacturing, a concept that is perhaps not quite fully understood at this point in time. As such, we hope to raise awareness on the difference between repair, reconditioning and remanufacturing. Although this is just a small part in unravelling the mystique of sustainable manufacturing, it is the all important first step.

editorial assistant Sharifah Zainon graphic designer Jef Pimentel circulation executive Samantha Tan

contributors Hadas Zeira Patrick Brutto Sherlyne Yong Nadia Hofer Shruti Khanna Shahnawaz Abdul Hamid Erik Brine Dipl Ing (FH) Franz Joachim Roßmann Yoshihiro Iida Augustine Quek Lee Steinbock 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

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chairman Stephen Tay group executive director Kenneth Tan

Joson Ng Editor



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asia pacific metalworking equipment news May-Jun 2013

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Business News APEC Growth To Gradually Accelerate: Analysis

Surabaya, Indonesia: Economic activity in many APEC member economie s wa s adversely affected by heightened concerns about the Euro area’s sovereign debt issues and weaker trade last year. But growth in the region in general appears to be improving and is set to gradually accelerate which could provide a boost to the world economy. The gross domestic product of APEC economies is forecast to rise 4.2 percent in 2013 and 4.7 percent in 2014. By contrast, growth in the region was unchanged year-onyear in 2012 at 4.1 percent, reveals a APEC Economic Trends Analysis. APEC Trade ministers will meet under this backdrop in Surabaya, Indonesia. The analysis

was produced by the APEC Policy Support Unit to help ministers gain a greater understanding of the broader economic environment in the region. “There are ongoing concerns about t he he a lt h of public finances and the banking system, especially in Europe, as well as price pressures on property and stock markets,” said Dr Hew who is the director of the APEC Policy Support Unit. “Moderated indust r ia l production, an increase in trade restrictive measures and the reduced availability of trade finance adversely affected global trade last year. By October 2012, the value of global exports barely grew from the level seen in 2011,” he added.

We a ke n i n g t r a d e w a s a particular challenge for small, open APEC economies. Gross domestic product growth among them slowed to 1.7 percent in 2012, less than half of their rate of economic expansion in the previous year. “Activity in some large APEC e co n o m i e s r e m a i n s b e l ow optimum levels but is steadily improving,” noted Dr Alan Bollard, executive director of the APEC Secretariat. “This, combined with the continued resilience of emerging economies in the region due to strong domestic demand and investment, is contributing to a more favourable growth outlook for the short to medium term.” G loba l t rade app e a rs to be getting a lift from these developments. The volume of world imports increased 4.1 percent year-on-year in January 2013 which was the indicator’s sharpest increase since September 2011. The report states that finetuning the pace and composition of fiscal adjustment packages, attention to capital flows and actions to strengthen financial markets and institutions are needed to keep APEC economies moving in the right direction. It also calls upon policymakers to support the channeling of capital inflows towa rds productive infrastructure investment.

Pratt & Whitney To Advance Additive Manufacturing Research East Hartford, US: Pratt & Whitney has partnered with the University of Connecticut to establish one of the most advanced additive manufacturing laboratories in the US, the Pratt & Whitney Additive Manufacturing Innovation Center. This facility will be used to further additive manufacturing R&D. Additive manufacturing is the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. Materials are added, versus the traditional subtractive method such as computer numerical controlled machining, to precise geometries determined by CAD drawings. 8

asia pacific metalworking equipment news May-Jun 2013

Said Paul Adams, Pratt & Whitney's chief operating officer: "Additive manufacturing is complementary to traditional methods by enabling new innovation in design, speed and affordability. It is necessary to build the next generation of jet engines. We are currently using additive manufacturing to build complex components with extreme precision for the flight-proven PurePower commercial jet engine." The company invested more than US$4.5 million in the Pratt & Whitney Additive Manufacturing Center and over the next five years will invest more than US$3.5 million in the facility.

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ABB To Acquire Power-One Zurich, Switzerland: ABB has agreed to acquire PowerOne. The transaction would position the company as a leading global supplier of solar inverters — the ‘intelligence’ behind a solar PV system — to a market forecasted by the International Energy Agency to grow by more than 10 percent per year until 2021. This rapid growth is being driven by rising energy demand, especially in emerging markets, rising electricity prices and declining costs.

Power- One has one of the market’s most comprehensive offerings of solar inverters, ranging from residential to utility applications, and a broad global manufacturing footprint. It also has a power solutions portfolio that is adjacent to ABB’s power conversion business. The transaction is structured as a merger and is subject to the satisfaction of customary closing conditions, including approval of Power One's shareholders at a special meeting and receipt of customary regulatory approvals.

HSBC China Manufacturing PMI Shows Modest Improvement In Operating Conditions

Richard Mallinson, London, United Kingdom

Beijing, China: After adjusting for seasonal factors, the HSBC Purchasing Managers’ Index (PMI) — a composite indicator designed to provide a single-figure snapshot of operating conditions in the manufacturing economy — posted 51.6 in March, up from 50.4 in February, signalling a modest improvement. Operating conditions in the Chinese manufacturing sector have now improved for five consecutive months. Production levels increased for the fifth month in a row in March. The rate of expansion accelerated from February to a solid pace, the second-fastest in two years. Behind the rise in output, total new orders rose solidly, and for the sixth month in a row. A number of respondents attributed growth to strengthened client demand. Meanwhile, new export orders also increased, albeit marginally. 10

asia pacific metalworking equipment news May-Jun 2013

Volu me s o f out st a nd i n g business declined for the second successive month in March. The rate of backlog depletion was broadly unchanged from February, and remained slight overall. Staffing levels, however, were relatively unchanged from the previous month. Suppliers’ deliver y times lengthened in March, following a slight improvement in February. That said, the rate at which vendor performance deteriorated was slight, with just over six percent of panellists recording longer lead times. A number of respondents linked the deterioration to increased orders placed at vendors. Average input costs faced by manufacturers decreased, following a five-month period of inflation. However, the rate of reduction was marginal, with a number of respondents citing

lower raw material costs. Output charges set by manufacturers also declined in March, and for the first time since last November. The rate of discounting was modest, with approximately 10 percent of panellists lowering tariffs. A number of respondents attributed the fall to a combination of passing on lower input costs to clients and competitive market pressures. Purchasing activity in the manufacturing sector rose for the sixth successive month. Growth quickened from February to a solid pace that was the third-strongest in two years. Meanwhile, stocks of purchases fell modestly for the second month in a row. Increased input buying and the depletion of stocks were both associated with increased production at plants. Finally, inventories of finished goods increased for the first time in six months, albeit marginally. A number of respondents attributed the rise to increased production on the back of stronger client demand. Commenting on the China Manufacturing PMI survey, Hongbin Qu, chief economist, China & CoHead of Asian Economic Research at HSBC said: “China's recovery continues, mainly driven by the gradually improving domestic demand conditions. The decline in input prices suggests a modest pace of demand recovery and moderating inflationary pressures. This, plus the lingering external headwinds, implies the Beijing policy makers should keep a relative accommodative policy stance in place.”

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Kuka Systems Becomes Number One Automotive Systems Supplier In North America Sterling Heights, US & Augsburg, Germany: Kuka Systems Group has acquired the plant engineering business of privately owned Utica Companies of Shelby Township, a welding equipment specialist and supplier to the automobile industry. With this transaction, t he comp a ny b e come s t he number one ma nu factur ing systems supplier to the North American automotive sector. “This acquisition follows our strategy of being number one or two in our respective markets. It not only adds new customers, but will enable us to continue our profitable growth in North America and in Asia,” says Dr Till Reuter, CEO of Kuka AG, the holding company that owns Kuka Systems Group. “With this acquisition Kuka Systems is leveraging its technologies,” says Lawrence A Drake, president and CEO of the company. “Moreover, our customers will benefit from an expanded manufacturing footprint, talent pool and knowledge base with greater economies of scale. It also stresses our leadership in welding and other joining technologies.” The Utica acquisition primarily covers automobile assemblyrelated assets in southeastern Michigan. Kuka Systems will absorb Utica’s body structure business that builds car body assembly lines and subsystems — as well as products like laser welding heads, net form and pierce systems for high accuracy in joining body sections, standard press room automation for metal stamping and hang-on technologies for installing doors, hoods and other parts on assembly lines. 12

asia pacific metalworking equipment news May-Jun 2013

Steel Closes The Weight Gap On Aluminium

Steel auto body structures in the near future can be as lightweight as today’s aluminium bodies

Brussels, Belgium: The latest in a continuing series of research studies suggests that steel auto body structures in the near future can be as light as today’s aluminium bodies, while meeting all crash performance standards and at comparable cost of current steel structures. The studies also address critical manufacturing challenges, showing that car makers can form and fabricate sophisticated steel designs, therefore accelerating implementation of this technology into production vehicles. Adding to a weight reduction of 35 percent in its initial FutureSteelVehicle design, the steel industry’s most recent studies boost the mass savings to 39 percent, compared to a baseline steel body structure carrying an internal combustion engine, adjusted for a battery-electric powertrain and year 2020 regulatory requirements. The optimised FSV body would weigh just 176.8 kg, putting steel on par with today’s aluminium production designs. An industry database of current production vehicles (A2mac1) shows these light-weight, Advanced High-Strength Steel (AHSS) body structures, designed to carry heavier electrified powertrains, fall in line with the lightest internal-combustion-engine aluminium vehicles, and are on par with other concepts featuring multi-material solutions. The study results show that by incorporating FSV technology, car makers can avoid pursuing more costly alternatives involving competing materials and multi-material designs to achieve their goals. “Our latest light-weighting projects show the continuing potential of steel and demonstrate how car makers can take advantage of steel’s design flexibility and use AHSS to meet their difficult challenges for improving fuel economy and reducing green-house gas emissions,” said Cees ten Broek, director, WorldAutoSteel, the automotive group of the World Steel Association. The two most recent studies, called 'FSV Final Gauge Optimisation' and 'FSV Near-Term Front Longitudinal Rail Shape' streamlined the FSV design and devised alternative geometry (for the front rails), respectively. The former led to an additional mass reduction of 11.6 kg, compared to the initial FSV design, bringing the total weight savings to 39 percent. The latter validates two different, but comparable, front rail designs, expanding the range of solutions available to car makers in the near term.

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Shell Boosts Production For Chemicals Customers In Asia

L-R: Lee Tzu Yang, Lee Yi Shyan and Graham van’t Hoff

Singapore: Shell has indicated the investments made at its Singapore site will add to its portfolio of manufacturing facilities and boost its chemicals footprint in Asia. The company has taken a final investment decision to build petrochemicals production units on Jurong Island to supply customers in the region. The investments will be built over some 35,000 sq m of land. They include a high-purity ethylene oxide purification column with an initial capacity of 140,000 tonnes per annum (tpa) and two world-scale ethoxylation units with a combined capacity of 140,000 tpa. Official groundbreaking was officiated by Singapore’s senior minister of State for Trade & Industry and National Development, Lee Yi Shyan; executive VP of Shell Chemicals, Graham van’t Hoff; and chairman of Shell Companies in Singapore, Lee Tzu Yang.

ThyssenKrupp Sets Milestone In Nanjing Germany: ThyssenKrupp is now opening a truck crankshaft factory in the Chinese metropolis of Nanjing. The factory in China, built at a cost of roughly US$190 million, will close a gap in this important market. ThyssenKrupp Engine Components will produce up to 345,000 crankshafts a year. Dr Heinrich Hiesinger, CEO of ThyssenKrupp AG, underlines the importance of the investment for the strategic development of the group: “We are focusing firmly on the markets of the future. China is an attractive market for our high-tech products and services. ThyssenKrupp has a longstanding partnership with China’s auto and engine manufacturers. With our engineering expertise we are helping the Chinese auto industry meet demand for ‘more’ mobility through the use of ‘better’ technology in the vehicle. This applies particularly to meeting increasingly stringent environmental standards.” Nanjing is the location of choice for the production of truck crankshafts as the Yangtze region is home to the key electrical, petrochemical, iron and steel, energy, auto and engine industries. In addition, numerous Chinese and international engine manufacturers have located in the east of China. With its site in Nanjing, the company will be in an even better position to develop and manufacture attractive solutions and products for its customers. 14

asia pacific metalworking equipment news May-Jun 2013

Rio Tinto Minerals Launches Asia Technology Centre UK: Rio Tinto Minerals has opened the Asia Technology Centre (ATC) in Suzhou, China. It joins research facilities in the US and is fully developed with laboratories, offices and work spaces. Construction of the centre, designed for LEED silver certification for energy efficiency and low environmental impact, began in March 2012. It was completed in November 2012. The ATC provides important internal capabilities in glass and ceramics, metals and advanced materials, and agriculture and specialty chemicals to support the company's R&D expansion in Asia. The company's R&D strategy is to partner with customers, universities, government laboratories and other centres to pursue commercially relevant innovation. Rio Tinto Minerals president and chief executive Xiaoling Liu said: "Asia is the largest and fastest growing market for borates in the world, accounting for 50 percent of global demand. Refined borates play an important role in promoting higher standards of living and addressing energ y and food shortages. We are proud to partner with respected companies and research organisations throughout Asia to provide reliable, consistent innovation now and into the future."

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Walter Builds Regional Competence Centres

Mirko Merlo

Tübingen, Germany: Walter is building regional competence centres in Europe, America and Asia, so that customers around the world can be served quickly and competently. The new centres will become particularly important for technically demanding customer projects in which, until now, the national subsidiaries have had to rely on support from Walter's headquarters in Tübingen. With the

regional expansion of its competence centres, the specialist for precision tools is underlining its position as a competence leader in metal cutting. From now on, the three regional competence centres for Europe, America and Asia will provide the national sales companies in their region with support. Advice can generally be offered in the language of the country and, due to its close proximity, projects can be completed more quickly and efficiently. “Our customers operate in an increasingly global environment and the competition that prevails in countries such as China, India and Brazil is very dynamic,” says Mirko Merlo, president of the Walter Group. “With 34 Walter subsidiaries, we are represented worldwide in all of the important markets. However, when it comes to the expertise in specialist and industry-specific solutions, the national subsidiaries around the world have been dependent on our experts in Tübingen for a long time. With the new regional competence centres, our customers have direct access to our specialists.”

Global Experts Poll: Economic Confidence Up Significantly In Second Quarter Geneva, Switzerland: Confidence in the world economy has increased significantly over the past three months, according to experts polled by the World Economic Forum. The Economic Confidence Index rose to 0.48 from 0.43 on a scale of 0 to 1 during the first three months of the year, amid an easing of the Eurozone crisis and belief that the world economy may have avoided a double-dip recession. The score puts the index back in neutral territory for the first time since it fell into low-confidence territory in the third quarter of 2012; it marks a return to its most Intermach (Thailand) May 16-19

recent peak during the second quarter of 2012. However, the index did not break into positive territory above 0.5. “It looks as though the worst is over and experts are not too worried about a double-dip recession of the world economy,” said Martina Gmür, senior director of the Forum’s Global Agenda Council, of the poll of 304 global experts. “But, while the economic index has seen an improvement over three consecutive quarters and is now back at its peak from one year ago, it is worth remembering that, back then, the Eurozone crisis was

Metaltech (Malaysia) May 21-25

MTA Vietnam 2013 July 2-5

already in full swing; and the index has so far not crossed over into positive territory.” Thirty- one percent of respondents said they are either ‘confident’ or ‘very confident’ about the prospects for the global economy, compared to 23 percent in the first quarter. The remaining respondents were almost equally split at about 34.5 percent on whether they are ‘neutral’ or ‘not confident or not at all confident’ compared with 34 percent and 43 percent the previous quarter, respectively. The indices tracking confidence in global governance and global cooperation made similar significant improvements over the past quarter.

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asia pacific metalworking equipment news May-Jun 2013


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

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Memory, Foundry & LED Markets Drive Fab Spending In SEA Singapore: Increased spending in NAND and flash by Micron, LEDs by Philips and Osram, and continued investments by Globalfoundries will create new opportunities for equipment and materials suppliers in Southeast Asia. For the Southeast Asia region, capital equipment investment will see some pickup in the second half of 2013 followed by a strong recovery in 2014. Overall front-end fab equipment spending is expected to double next year from US$810 million in 2013 to US$1.62 billion in 2014. Foundry and Memory are the two major sectors that invest most in the region. The Southeast Asia region’s capacity growth for front-end fabs shows two percent increase this year and an expectation of higher growth (eight percent) in 2014, exceeding overall global capacity growth of five percent according to the Semi World Fab Forecast. The growth will mainly be driven by the

memory sector, specifically from NAND flash capacity as Micron gears up for further expansion at its Singapore NAND flash facility next year plus ongoing capacity conversion from DRAM to NAND flash at Fab 7. Singapore is emerging to become the third largest NAND flash manufacturing country in the world by the end of 2014. The conversion and the expansion proje ct s w ill dr ive relate d semiconductor investment in the region in 2013 and 2014. For the assembly and test sector, Southeast Asia has long been the focal point of the industry with a large installed capacity from both IDMs and OSATs. This position contributes to the region being the largest packaging materials consumption market in the world, representing a market size of US$6.6 billion in 2013 and US$6.8 billion in 2014. The region’s back-end equipment investment remains

significant with over US$1 billion spending each year throughout 2012 to 2014, accounting for about 17 percent of worldwide share according to Semi. Aside from manufacturing capacity, Southeast Asia region is now e x tending it s va lue proposition to IC design and R& D a rea s w ith more joint development projects between multi-national corporations and local institutes. Semi expects to see a more robust semiconductor ecosystem arise from the region as a result of these endeavors and as companies seek ready access to customers throughout AsiaPacific and South Asia. Currently, Singapore has 14 wafer fabrication plants, including the world’s top three wafer foundries. The country also has 20 semiconductor assembly and test operations, including three of the world’s top six outsourced assembly and test companies. There are about 40 IC design centres, which comprise nine of the world’s ‘top 10’ fabless IC design companies.

Machine Tool Orders Suffered Negative Q1 In Italy Italy: For the first quarter of 2013, the machine tool order index, processed by t he S t u d ie s Depa rtment of UCIMU-Sistemi Per Produrre, showed a 9. 8 percent decrease against the same period of the previous year. In particular, the dome stic order index showed a 35.9 percent decrease compared with the first quarter of 2012. As far as exports are concerned, the index of orders showed a 4.6 percent decrease, a downward trend that has now continued for four consecutive quarters. Luigi Galdabini, president of UCIMU-Sistemi Per Produrre, said: “These latest results clearly demonstrate that the loss of competitiveness that the 18

asia pacific metalworking equipment news May-Jun 2013

political situation is forcing on the whole country is having a strong impact on the industrial sector. The halt in machine tool investments, indicates a progressive and unavoidable loss of competitiveness of the whole country. Without the acquisition and the replacement of production machinery, user sectors will be unable to face the challenge of foreign competitors, whose investments in advanced technologies, although slightly slower than normal, will enable them in the short term to align themselves to us as far as production capacity and quality are concerned.” He added the contraction in manufacturing is directly linked with the decrease of domestic consumption and the failure to update existing equipment. There are however some positives in the export area. “Until now, we have seen that exports have been able to hold their own, thanks to a well thought strategy, but also to the organisational and financial ‘sacrifices’ of our small and medium companies, which do not receive any public support. However, the survival of the enterprises cannot rely infinitely on exports,” he added.



Singapore To Improve Energy Efficiency Of The Industry Sector

Mckenna71, US

Singapore: In an effort to improve Singapore’s energy efficiency and competitiveness, the National Environment Agency ( NE A) has introduced mandatory energy management requirements for large energy users in the industry sector. These requirements will come into effect under the Energy Conservation Act (ECA). The industry sector accounts for more than half of Singapore’s energy demand. In particular, the large energy users in this sector can play a major role in

the national efforts to make Singapore more energy efficient. The large energy users affected are those with business activities that consume more than 54 terajoules of energy annually in at least two of the three preceding years and whose business activities are attributable to manufacturing and manufacturing-related services; supply of electricity, gas, steam, compressed air, and chilled water for airconditioning; or water supply and sewage and waste management. From April 22, 2013, these companies are required to register themselves with NEA and appoint one or more energy managers to monitor and manage their energy consumption. The companies are also required to report their energy consumption and provide information on processes resulting in greenhouse gas emissions, and submit energy efficiency improvement plans annually beginning in 2014. These requirements affect some 170 companies which operate around 200 large energy consuming premises. To ensure the feasibility and practicability of the detailed requirements, NEA has conducted one-to-one industry consultations and briefings for these companies since the beginning of last year.

Strong Domestic Demand Drives Growth In East Asia Pacific Singapore: Driven by strong domestic demand, economies of developing East Asia and Pacific continue to be an engine of global growth, growing at 7.5 percent in 2012 — higher than any other region in the world, says the World Bank in its latest analysis of the regional economy. As the global economy recovers, the report projects that regional growth will rise moderately to 7.8 percent in 2013 and ease to 7.6 percent in 2014. “The East Asia and Pacific region contributed around 40 percent of global growth in 2012, and the global economy continues to rely on the region’s growth, with investor confidence surging and financial markets remaining solid,” said World Bank East Asia and Pacific VP Axel van Trotsenburg. “Now is the time for countries to focus on helping the remaining poor, with more and better quality investments to 20

asia pacific metalworking equipment news May-Jun 2013

accelerate inclusive growth.” Fiscal and monetary policies to b o ost con su mpt ion a nd i nve st me nt he lp e d su sta i n growth in 2012 across the region, with middle-income countries performing particularly well. Developing economies excluding China grew 6.2 percent in 2012, up from 4.5 percent in 2011. In China, growth slowed to 7.8 percent in 2012 due to rebalancing efforts, while real disposable income of urban households rose by more than nine percent, supporting household consumption, which contributed 4.4 percentage points to GDP growth. China is projected to grow 8.3 percent in 2013 and eight percent in 2014. Risks emanating from the Eurozone and the US have declined since the middle of last year. The World Bank’s baseline projections for global growth are for a modest

expansion of 2.4 percent in 2013 and a gradual strengthening to three percent in 2014. While still fragile, there are signs of a turnaround in real activity in high income economies. As such, external demand for the East Asia and Pacific region’s exports will stabilise this year. The most recent numbers on industrial pro duct ion a nd pro ducer’s expectations confirm continued solid growth. Movements in high-income country currencies, such as the yen, are likely to affect trade and investment flows in the region in the short term. Some countries, notably suppliers of parts to Japanese industry and countries with considerable Japa nese investment could gain, whereas countries that compete directly with Japan in third markets may face some headwind in the short run. The report added that a

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BusinessNews return to sustained growth in Japan would benefit the region as a whole. A s t h e g l o b a l e co n o m y recovers, an emerging issue is the risk of overheating in some of the larger economies. The latest numbers suggest that, if global demand continues to revive, some major economies may reach the limits of their current production capacity, as the output gap has closed in those countries. “Most countries in developing East Asia are well prepared to absorb external shocks, but continued dema nd - boosting mea sure s may now be counterproductive, as it could add to inflationary pressures,” said World Bank East Asia and Pacific chief economist Bert Hofman. “A strong rebound in capital inflows to the region induced by protracted rounds of quantitative easing in the US, EU and Japan, may amplify credit and asset price risks.” In East Asia and the Pacific, overall economic management has been effective in dealing with the global economic crisis, which has enabled the region to remain resilient and sustain growth. The challenge for policy makers now is to build on these strengths and address short and long term challenges with smart policies: Policymakers need to continue to be vigilant to react to shocks in the world economy, but be prepared to withdraw stimulus as the world economy recovers. For countries that show some signs of inflationary pressures, it would be a good time to rebuild policy buffers. Several countries need to manage strong capital inflows by maintaining an appropriate macro policy mix, sufficient flexibility in the exchange rate and macroprudential policies. Most countries could increase productive capacity by investing in infrastructure and human capital, paving the way for continued high and equitable growth. 22

asia pacific metalworking equipment news May-Jun 2013

Siemens Recognised By General Motors As Supplier Of The Year For 2012 Germany: General Motors recognised Siemens’ Product Lifecycle Management (PLM) software business unit as one of its best global automotive suppliers during its 21st annual Supplier of the Year awards ceremony. “The honour of receiving the GM Supplier of the Year award with such consistency is a tribute to our team’s dedication to customer success, and a direct result of our two companies’ close working relationship,” said Chuck Grindstaff, CEO and president, Siemens PLM Software. “We are proud of our partnership with General Motors and look forward to the future as our software technology continues to help GM design, build, and sell the world’s best vehicles.” The company was one of 83 suppliers recognised by GM who have consistently exceeded their expectations. This is the fifth time the company has received the Supplier of the Year award, and the third time in the last four years. The award is given to less than one percent of GM’s approximately 18,500 suppliers around the world. The award is chosen by a global team of GM purchasing, engineering, quality, manufacturing and logistics executives.

Bombardier Transportation To Supply Trains To New Delhi

New Delhi, India: Bombardier Transportation has won an order from Delhi Metro Rail Corporation (DMRC) to deliver the Cityflo 350 mass transit solution for the upcoming extensions to Delhi Metro’s Line five and Line six. The extensions are part of Phase III of Delhi’s metro expansion plan. Increasing the reach of the two lines which are already operating with the Bombardier Automatic Train Protection (ATP) technology, the new sections will further improve passenger transportation options in this city. The contract is valued at approximately US$47 million. The extensions will add almost 35 km of double track and 23 stations to the existing 39 km in operation and are due to be completed in 2016. Bombardier’s project scope includes the design, manufacture and commissioning of the integrated train control and signalling system, including control centres, trackside and onboard equipment.

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BusinessNews Automotive / Aerospace

Honda Cars India To Start A New Phase Of Growth

New Delhi, India: Honda Cars India Limited (HCIL) has announced a new plan for growth for the company’s business in the Indian car market. Building on its vision for the Indian market,

HCIL announced an investment of Rs 2500 crore (US$461 million) in its Tapukara plant in Distt. Alwar, Rajasthan to build an assembly line for cars with an annual installed capacity of 120,000 units, a diesel engine component production line and a forging plant. With the objective of strengthening and providing products which exceed diverse customer expectation with more speed, the company changed its global organisation structure from Apr il 1, 2013 a nd ha s

appointed Yoshiyuki Matsumoto, managing officer, Honda Motor Company as ‘Representative of Development, Purchasing and Production in Asia & Oceania Re g ion’ who w il l b e ba se d in India to control all Asia & Oceania Region. The assembly line and forging plant is scheduled to be ready within 2014. Combined with the capacity of the new plant, the company's total installed production capacity will be increa sed to 240,0 0 0 units/ annum in 2014.

Amadeus: Asia Is The Largest, Fastest-Growing & Most Competitive Market For Air Travel

Nina Chantrasmi, Bangkok, Thailand

Madrid, Spain: An analysis from Amadeus Air Traffic Travel Intelligence solution reveals that worldwide air traffic volume grew five percent between 2011 and 2012, with Asia being the largest, fastest-growing and most competitive market for air travel. The analysis shows that Asia experienced year over year growth of nine percent between 2011 and 2012, followed by Latin America, at six percent. 24

asia pacific metalworking equipment news May-Jun 2013

Among other key findings, the study reveals Asia as the market with the highest airline competition. Seventy-five percent of the region’s air traffic is operated by three or more airlines and 27 percent by five or more airlines, making this a region with a very intense competition in all its air travel routes. This contrasts sharply with other regions such as the Middle East and Europe where just half of all air traffic on its routes is operated by three or more airlines.1 The analysis also shows that 22 percent of all global air travel is concentrated on just 300 origin and destination ‘super routes2’, each of which carries over 1 million passengers annually. Furthermore, 69 percent of all global air travel is made on major routes with 100,000 annual passengers. In terms of connecting air traffic, the analysis shows the Middle East as a strong performer, with the three key airports of Doha, Abu Dhabi and Dubai all showing high connecting traffic volumes. For instance, when taken as a group the three airports now serve roughly 15 percent of all air traffic volume that goes from Asia to Europe and from Europe to the South West Pacific. Furthermore, Europe-Asia traffic routed via the Middle East is growing at roughly 20 percent per annum. Note 1. For the purposes of this analysis an airline is considered to be ‘a competitor’ if its market share exceeds five percent for the given traffic being analysed. Therefore if a booking is made and there are four competing carriers vying for the booking, but one has a market share <five percent we would view this as effectively three airlines competing for the business. 2. A route is defined as an Origin and Destination (O&D), that is, an absolute route between point A and point B. Passengers may have connected and flown multiple segments in order to reach their final destination but this is not the point in an O&D analysis. We are interested in travel between an origin and a final destination.

BusinessNews Aerospace

Nextant Aerospace Identifies Potential For Jet Market In Asia S h a n g h a i , C h i n a : N e x t a nt Aerospace (Nextant), maker of the Nextant 400XT, the world’s only remanufactured business jet, believes Asia has the potential to drive sales in the global, entrylevel business jet market over the next decade due to its rapid economic growth and increasing population of high net worth individuals. The entry-level business jet market in Asia has grown rapidly over the last decade with the five years to 2012 seeing a 74 percent increase in deliveries on the previous five-year period (2003 - 2007). Globally, deliveries of business jets grew by just six percent between the same two periods. In spite of this recent growth, the business aviation market i n A sia re m a i n s re lat i ve l y underdeveloped compared to the rest of the world and is likely to continue to grow as its economies and high net worth populations continue to expand. It is for these reasons that Asia has been identified as a core part of the company’s expansion strategy. The company estimates that there is currently one business jet for every 121 individuals with net assets of at least US$30 million in Asia, compared to one for every eight in the USA and Latin America. In Europe, which has the

second lowest density of business jets, there is one jet to every 33 persons with US$30 million or more; still far higher than in Asia. China is the world’s second la rge st economy a nd while expansion has slowed, it recently announced its economic growth target for 2013 is 7.5 percent; far

higher than many economies, and according to a recent report by the OECD, it is on course to overtake the US as world’s largest economy by 2016. This increase in economic activity is likely to increase demand for business aircraft as the number of large companies in the region grows.

Singapore: ST Aerospace has sealed new contracts worth about S$480 million (US$388 million) in the first quarter of 2013. The contracts are for airframe, component and engine maintenance, as well as engineering and development, which will be carried out through its global MRO network.

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May-Jun 2013 asia pacific metalworking equipment news


Cutting Edge

Inserting Intelligence Into Metal Cutting

Adding cleverly designed mechanisms and features around the insert and its holder can go a long way in helping it keep pace with the advancements in machine tool technology. Contributed by Hadas Zeira, manager of marketing communications, Iscar


ver since the invention of the first cemented tungsten carbide inserts in 1927, companies in the field of metal cutting have 26

asia pacific metalworking equipment news May-Jun 2013

endeavoured to reinvent their u se by cre at ing in novat ive geometr ie s a nd chipfor mer de sig ns. The se eng ineering efforts are complemented with

adva nced materia l sciences where substrates are constantly improved and being developed to enable machining u nder harder and tougher conditions. T h e e n d l e s s p u r s u i t to optimise machining processes coincides with technological adva ncements in machine to o l s , w h i c h e n a b l e m u c h faster machining. The modern machining centres have raised the bar for cutting tool manufacturers. They now have to produce highly advanced tool and insert geometries to sustain fast metal removal. In addition, the price of carbide is rapidly increasing on a global scale, which placed pressure on manufacturers to be costconscious with respect to the products which they develop. The two factors mentioned above have re sulted in the production of innovative products. They ex tend the benefits of machining practices to a wider spectrum of applications. For the most part, they enable higher feed rates, yet reduce cutting forces and conserve cutting lubricant, making them suited for todayâ&#x20AC;&#x2122;s high-feed, light-frame machines. Holding Firm A s inser ts a re removable, holding them in place automatica lly become s one of the main factors dictating the performance of the whole cutting operation. It is therefore hardly surprising that many insert manufacturers are now putting in considerable resources in the area of clamping. In the market today, there is a clamping mechanism that can hold double-sided inserts featuring double negative prism flanks. The dovetailed pocket a nd inser t prismatic f la nk s prevent the insert from being lif ted by the cutting force s

CuttingEdge Figure 2a

Figure 1

The cutting forces tend to cause the insert to tilt in lever damp tools Figure 2b

Figure 1: A dovetailed pocket and insert prismatic flanks prevent the insert from being lifted by the cutting forces

resulting in the double-sided dove ta iled pr ismatic f la nk inserts being held in place. Previously, cutting forces tend to cause the insert to tilt in lever clamp tools, whereas in this cla mping method, t he phe no me no n ha s b e e n eliminated. With this clamping mechanism, turning at higher feed rates with a heavier chip load is available to todayâ&#x20AC;&#x2122;s new turning centres. (Figures 1 & 2)

in that family, but match them for t hroughput while using less carbide. It is said that the Eco inserts deliver the same machining rates as their larger counterparts, and feature the same helical- edge, high-rake geometries for lower cutting forces (Figure 3).

Double-sided dovetailed prismatic flank inserts are firmly held in place

License To Speed When machining large parts, the issue of material removal often has an element of speed attached to it. Although fast and efficient material removal is important in all machining processes, the speed factor is arguably more crucial here.

Figure 3: Eco inserts do the same job as their larger counterparts but use less material.

Think Small For Larger Savings For sma ll- sca le turning a nd grooving, wastage occurs when people use larger inserts than are actually required for a particular set of machining parameters. A way to eliminate this waste is actually quite simple, ie: use smaller inserts. These smaller or Eco inserts do the same job as their larger counterparts but use less of the costly carbide. One example in the market today is the Iscar Isoturn Eco inserts. They are smaller than standard inserts

May-Jun 2013 asia pacific metalworking equipment news


CuttingEdge To speed up machining of large parts, typically found in power generation, transportation and heavy industry, the Iscar Heavy Superturn Lomx 402224 - H6P insert delivers secure processing and tool life even under unstable conditions. Capable of a 35 mm depth of cut and a 2 mm/rev feed rate, the tool features a rigid lever lock insert clamping system and uses the tough grade IC8250 inserts. This insert is a suitable solution for large scale turning, which requires high feed performance (Figure 4). The tangential orientation extends tool life by presenting the insertâ&#x20AC;&#x2122;s strongest cross section to the largest cutting force vector so the forces are mainly compressive. High-rake top face geometry, helical cutting edge and the chipbreaker on the insert create a gentler cleaving action, smoother chip exit and cooler running. Heavy Duty Grooving The issue of keeping inserts in position during machining is also important in the grooving segment. As such, there are new technologies designed for this purpose.

Figure 4: It is said that secure processing under unstable conditions is an essential requirement for faster machining.

For deep heavy wide grooving inser ts, a fronta l lock ing mechanism is now available on the Dove IQ Grip to do the job. The inserts feature a rigid dovetail clamping geometry and a locking mechanism with frontal access. It takes a half-turn to clamp/unclamp the insert. Milling Inserts No discussions on machining proce sse s ca n end w ithout

Figure 5: The Heli2000 Chatterfree insert is designed to improve surface finish


asia pacific metalworking equipment news May-Jun 2013

touching on the area of surface finishing. Also an important consideration during the designing stage of an insert, new inserts, particularly those d e p l oy e d i n c h a t te r- p ro n e applications are formulated to improve surface finish. A case in point here is the Heli20 0 0 Chatter free inser t designed to improve surface finish in applications such as long-reach milling. It features an asymmetric design to suppress harmonic vibrations as well as the familiar wiper edge to improve surface finish and ground cutting edges for better perpendicularity (Figure 5). Indexable inserts today offer a capable concept for increasing productivity and profitability when machining all types of materials. The insertsâ&#x20AC;&#x2122; clamping geometries, available in a wide range, assure accurate cutting angles, good chip control, good surface quality, stability, and the possibility for machining all types of materials by use of the latest substrate materials. Enquiry No. 4001 Turn to page 80a or log on to to enquire

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Tech Talk Metalworking Fluids:

Better Understanding For

Better Usage Asia Pacific Metalworking Equipment News (APMEN) spoke with Patrick Brutto, senior technical service and development specialist for Dow Consumer & Industrial Solution, on the finer points that affect the performance of metalworking fluids. By Joson Ng APMEN: Please explain how biocides and amines can influence fluid longevity? Patrick Brutto (PB): Registered biocides increase fluid longevity by keeping growth of bacterial and fungal organisms in check. Without biocides, these organisms will eventually degrade many of the typical components present in the fluids causing performance to suffer. Amines can influence fluid longevity in a couple of ways. First, they help ma inta in optimum pH, enabling the fluid to retain its original performance cha racteristics for a longer period of time. Second, certain amines can improve the way registered biocides perform. This is especially important today, when some of the most widely used biocides are being de -selected due to customer or regional preferences, and/ or regulator y requirements. This is the case for hexahydro1,3,5 -tris-(2-hydroxyethyl)-striazine and other formaldehyde condensate biocides. Amines which enhance the performance of the remaining registered biocides can play a significant role in maintaining overall fluid performance including 30

asia pacific metalworking equipment news May-Jun 2013

corrosion and pH control. An example is Corrguard EXT from The Dow Chemical Company (active ingredient 3 -amino- 4 octanol) which enhances the performance of a wide range of registered biocides. APMEN: It is said that different geographical influences such as water quality, air humidity and temperature can affect the performance of a metalworking fluid. Do you agree with this statement and why? PB: Water quality has a large effect on the performance and longev ity of water- dilutable metalworking fluids. In addition, minerals and anions dissolved in the water can greatly affect metalworking fluid systems. C a lciu m a nd ma g ne siu m cations are often present, which will react with anionic fluid components (fatty acid salts, petroleum sulfonate s, etc.), causing loss of emulsion stability and corrosion control. A nions such a s chloride, fluoride, sulfate and carbonate a re o f te n pre se nt a nd c a n influence the corrosivity of the water. Soft, deionised or Reverse Osmosis (RO) water will usually have a positive impact on fluid

performa nce a nd longev ity, with one major exception: foam development and stability are often more problematic. Water hardness (calcium, magnesium, etc.), usually reduces foam development and stability in part due to formation of water insoluble salts. Softening of the water, which replaces calcium a nd mag ne sium ions w ith sodium ions, or deionisation/ RO treatment which removes almost all ions, enables anionic fluid components to work more efficiently. Unfortunately, this ca n a lso re sult in foa ming. Another strategy for dealing with hard water is to use nonionic fluid components. However in some cases, these materials also cause foam development. Humidity does not have a large impact on fluid performance. However, it can affect the corrosion control of ferrous metals present in machinery and parts. The higher the humidity, the faster the machines and parts will corrode. As temperature increases, the rate of corrosion increases, but higher temperatures also accelerate drying which can potentially offset the higher rate of corrosion.


APMEN: What makes a high performance metalworking fluid? PB: This is a difficult question to a nswer be cause ‘high performance’ is a general term. Different fluid producers and end users will define it differently. My definition of high performance is a f lu id which me et s t he requirements of dema nding operations, where ‘standard’ fluids cannot do the job. This could include applications where difficult alloys (titanium, magnesium, etc.) or part geometries are produced, or where water quality is poor. Another example is longlife fluids, where the end user expects little or no maintenance even in cases where tramp oil and microbial contamination are significant. Enquiry No. 4101 Turn to page 80a or log on to to enquire

Water quality has a large effect on the performance and longevity of waterdilutable metalworking fluids

Patrick Brutto


APMEN: Different metalworking fluids should be used for different materials, machine types and cutting tools. In other words, there is no ‘one size fits all’ approach while selecting a suitable metalworking fluid. Are there any data or studies that can substantiate this claim? PB: There are numerous technical papers and handbooks, such as those published by the Society of Tribolog ists a nd Lubrication Engineers, which discuss the impact of fluid types and components on the various metal forming and metal removal processes. There is a trend to design fluids for multiple operations a n d m e t a l s. H owe v e r, t h i s is only possible to a certain degree. Lubrication and co ol i n g re qu i re me nt s v a r y considerably, and one fluid type cannot possibly meet all the requirements of the wide range of operations and alloys.

May-Jun 2013 asia pacific metalworking equipment news


Cooler By The Minute

Andy Malmin, Ventura, US


Coolants play an enormous role in manufacturing by facilitating heat dissipation. With increased production loads however, manufacturers are looking for a solution to hasten the cooling process, which could potentially be found in nanofluids. By Sherlyne Yong


e ta lwork i n g processes are literally a heated affair with the amount of friction involved in working the piece. While dry machining exists, most other alternatives involve the use of a cutting fluid, which serves to mitigate the high temperatures induced during the machining process. Meanwhile, in light of technological advancements that have enabled faster production, greater loads have driven the need to ha sten the cooling process as well. As limitations exist in conventional liquids, a faster alternative can be found in nanofluids. Coolants ser ve two main purposes in manufacturing â&#x20AC;&#x201D; to cool and lubricate. While the first removes heat, the second reduces heat generation. Typically in the


asia pacific metalworking equipment news May-Jun 2013

form of oil, water or emulsions, these fluids play a pivotal role in multiple machining processes by transferring heat away. It is especially important as excessively high temperatures have the ability to temper with the structure and surface integrity of the work piece, as well as tool life among others. As compared to conventional cutting fluids, nanofluids are more efficacious in the cooling process and are able to provide much faster results as well. Thermal Conductivity Conceptualised within the past decade, nanofluids are a relatively new development that can be utilised in various applications across industries that include biomedical, oil and gas and manufacturing. It comprises a mixture of nanoparticles (ie:

aluminium oxide, copper, copper oxide, gold, silver, silica) less than 100 nanometres in size, which are suspended in base fluids such as water, oil, acetone, decene, ethylene glycol and other biofluids. The mixture has greater heat transfer properties as compared to liquid alone, because it includes solids in the form of nanoparticles, which naturally have better thermal conductivity. For instance, a study found that the addition of copper nanoparticles (less than one percent of total mixture volume) into ethylene glycol increased thermal conductivity of the base fluid from 40 percent to 150 percent. I n fac t, na nof lu idsâ&#x20AC;&#x2122; superiority over conventional liquids can be summed up with three ma in cha racter istics: t h e r m a l co n du c t i v it y, wettability, and viscosity. Thermal conductivity is very much dependent on particle size, its temperature, or particle shape. Different types of particles and base fluids have varying levels of thermal conductivity, and researchers have found it to be enhanced with increasing particle volume. The sensitivity of the mixture is also discovered to be greater for particles made from materials with higher conductivity and base fluids with lower conductivity. This sensitivity is generally more pronounced in nanofluids than base fluids alone. A c i d i t y, a n d e l o n g a t e d particles as opposed to spherical ones, also have a positive effect on thermal conductivity. The same was observed when additives such as surfactants were included in the mixture to prevent the agglomeration of particles into larger ones. Wettability & Viscosity The cooling effects of nanofluids a re a l so mo de rate d by it s


Use In Machining Na nof lu ids hold pa r t icu la r promise in manufacturing, as it has the ability to enhance cooling action and can be utilised for improving various machining processes. This includes milling, drilling, a nd notably so for grinding and turning. As compared to other systems, grinding requires more energy for every unit volume of material removed. Most of this energy is translated into heat that is dissipated at the contact area, which in turn has the potential to

cause thermal damage to the work piece. Not only will this affect quality, production rates will be slowed as well. On the other hand, nanofluids can be used to moderate the existing situation. For instance, it is suited for cooling in creep feed grinding and lubrication in shallow cut grinding. For the latter, this can be achieved through Minimum

Quantity Lubrication (MQL). Likewise, these fluids improve turning operations by providing better lubrication, which helps to alter friction at low speeds. This can be attributed to the flattened or exfoliated nanoparticles. At high cutting speeds, it helps to ease flow, while at low to intermediate cutting speeds, it can penetrate contact surfaces

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wettability and viscosity. It is generally more effective as it has a greater wetting area per volume, and adheres to the contact area more than conventional cutting fluids. Therefore, its enhanced lubrication and heat removal properties are also a result of being able to cover more surface area with the same, or lesser, amount of coolant. Supporting this is a study conducted at the Indian Institute of Technology, where researchers found nanofluids containing one percent volume of aluminium oxide to have greater wettability when compared with water and a conventional cutting fluid. In addition, wettability can be further improved with nanoparticles that are near the liquid-solid surface. Viscosity is directly related to heat removal as well, and is characterised by the level of fluidity. The greater the ratio of nanoparticles to base liquid, the less fluid it will be. Greater viscosity on the other hand, is beneficial for heat transfer as it enables the adherence of nanofluids to contact surface for a longer period of time. Nanofluids can easily be 50 percent more viscous than water. At the same time, most mixtures contain less than five percent of nanoparticles, as too much viscosity could lead to issues such as pumping inefficiency.

May-Jun 2013 asia pacific metalworking equipment news



The use of nanofluids has been touted as an environmentally friendlier alternative to conventional fluids at process level

Damian Searles, Brisbane, Australia

and areas where chipping occurs. On a more fundamental level, nanofluids are useful for raising Critical Heat Flux (CHF), and are reportedly up to three times more effective in doing so than water and oils. This stands true even for the mere addition of less than 0.1 percent volume of particles into the base fluid. A higher CHF is desirable as it slows down thermal damage by encouraging heat dissipation at higher temperatures. Technical Benefits Tool upkeep is a perennial issue in metalworking as tools are often subjected to high temperatures in most processes. Prolonged exposure to heat leads to structural changes in the tool, as it turns soft and becomes more prone to damage. Likewise, this is extended to the work piece, where both structural integrity and surface smoothness are implicated. P ro l o n g i n g a to o lâ&#x20AC;&#x2122;s l i fe inadver tently leads to cost 34

asia pacific metalworking equipment news May-Jun 2013

savings as it eliminates the need to manufacture a new one. Chipping or fractures in the tool are commonplace and accelerated with high cutting wear and stress at the tool edge. In dry machining for instance, tool wear occurs most as thermal changes result in a greater vulnerability to deformation. However, nanofluids serve to retard this process by providing more lubrication. As a result, tool hardness is retained for a longer period and wear is confined to the cutting edge in minimal amounts. Meanwhile, surface smoothness is another favoured attribute as rough surfaces wear faster and are more prone to corrosion. In manufacturing, surface roughness is also difficult and expensive to control, and occurs most severely in dry machining as the tool edge wears more quickly. Presence of the cutting fluids serves to protect the cutting edge, resulting in a smoother machining process and surface. On the other hand, nanofluids greatly improve the wetting properties of rake and flank regions of the tool, which enables better heat dissipation and the retaining of tool hardness. Relative to dry machining or processes using conventional fluid, surface roughness is minimal when machining with nanofluids. Sustainable Manufacturing In light of climate change and limited resources, manufacturers have been integrating sustainable practices into their production cycle where possible. The use of nanofluids has been touted as an environmentally friendlier alternative to conventional fluids at process level. Due to its higher efficacy, less fluid is required to achieve the same cooling effects and this allows a reduction in conventional fluid consumption. With less effort required for waste management, oneâ&#x20AC;&#x2122;s environmental impact is diminished as well. This holds

relevance as there is a greater focus on environmental liability and stricter regulations in place for waste disposal practices. Apart from influencing oneâ&#x20AC;&#x2122;s environmental footprint, the adoption of nanofluids may lead to cost savings as well. Most fluids account for 7 to 17 percent of the total machining costs, which will naturally go down with lessened fluid consumption. Not to mention, waste handling has become increasingly complex and expensive as well. Looking To The Future Despite its k now n benefits, nanofluids are still a relatively new development whose properties require a deeper understanding. As such, more research needs to be conducted to fully unveil the scope of its applications. For instance, its effects on operational health and safety are still undetermined as a proper measurement process is currently unavailable. As a result, measures currently undertaken at the manufacturing site may be inadequate. However, while the small particle size makes it hard to detect, this same consideration also makes it easier for ventilation and might make it easier to remove. At the same time, due to the costliness of production, most manufacturers have not taken to using nanofluids as of yet. Because huge fluid losses are incurred when used for flushing, nanofluids are utilised more for lubrication purposes. However, with greater research and a deeper understanding of how it works, the scope of applications for nanofluids will most definitely expand. A subsequent increase in demand will create a push for developments in the production of nanofluids, which will hopefully, make it more accessible and available to manufacturers. Enquiry No. 4102 Turn to page 80a or log on to to enquire



Case Studies:

Use It Right

Using the right metalworking fluid is proven to improve tool life and productivity. By Nadia Hofer, advertising coordinator, Blaser Swisslube


wo tests were carried out at Blaser Swisslubeâ&#x20AC;&#x2122;s Technolog y Centre to validate the importance of metalworking fluid. When applied accordingly, it can help better chip removal, leading to shorter operating time and reduced tool wear.

Test 1: Deep-Hole Drilling 18 Times Faster The influence of metalworking fluids on the machining process is often underestimated. A project conducted w i t h t h e Te c h n i c a l U n i v e r s i t y (Technische Hochschule) in Aachen demonstrated this very clearly. The aim of the project was to reduce the machining time required to drill


asia pacific metalworking equipment news May-Jun 2013

a deep hole in tempered steel, an operation that took three minutes, while endeavouring to retain the same standard of quality. To optimise these demanding drilling operations, a process of rigorous te sting and adjustme nt was applied to tool, drilling strategy,

Operation: Deep hole drilling, diameter 8 to a depth of 200 mm Pre-machining of pilot hole of same diameter to a depth of 16 mm Material: 42CrMo4 + QT, tensile strength 1,000 MPa Machine type: Mazak Variaxis 500 Tool: Kennametal and Titex drilling tools Cutting parameters: Vc 120 m/ min, f 0.25 mm/per revolution


Test 2: Tool Life Increased Pocket machining with solid carbide millers

machining parameters, metalworking fluid delivery and the metalworking fluid itself. The water-miscible metalworking fluid was pumped through the tool at high pressure (60 bar) to evacuate c h i p s a n d to p r eve n t d ow n t i m e otherwise caused by chip clogging and tool breakage. The key here is to select a metalworking fluid with no tendency to foam, even at high pressures. It is important to prevent a i r e ntr a p m e nt in th e e m u l s i o n, since this is counterproductive to the cooling and lubricating action. Air entrapment also obstructs the flow that enables chips to be cleared effectively. At the end of this project, the original drilling time of three minutes per hole was reduced to 10 seconds, for a depth of 200 mm — an 18-fold improvement in efficiency.

Enquiry No. 4103 Turn to page 80a or log on to to enquire

Another successful project at the technology centre dealt with the machining of a titanium component. Through the use of the optimum metalworking fluid, it was possible to improve the tool life by more than 30 percent in series production, compared to a conventional metalworking fluid. The test project involved milling two identical titanium components. For this, the components were produced on the same Mazak machine, using the same tool, and with a milling program from 3D Concepts. The only difference was the kind of metalworking fluid used. With the conventional metalworking fluid, it proved possible to manufacture one and a half titanium components before tool wear made it necessary to stop production. The solid carbide milling tool had been

Operation: milling (pocket machining) Material: Titanium TiAl6V4 Machine type: Mazak Variaxis 500 Tool: Sandvik VHM miller Cutting parameters: Vc 160 m/min, fz 0.15 mm, ap 25 mm, ae 0.9 mm, tea° 32 (angle of deflection) subjected to extreme stress loading and clear signs of break down on the cutting edges were visible, alongside the normal signs of wear. With a metalworking fluid specifically designed for the machining of titanium, it was possible to manufacture two complete workpieces without reaching the previously defined end of tool life criterion (wear of 0.2 mm) — an improvement in performance.

Enquiry No. 4104 Turn to page 80a or log on to to enquire

The two tests have shown that when the right metalworking fluid is used, good results follow. The real issue here is choosing the right product. In order to recommend a product, the coolant manufacturer needs to know the application and what is expected of the metalworking fluid because even in a same operation, an identical product may not be well suited, due

to different geographical influences such as water quality, air humidity and temperature. In addition, other process situation such as tool quality, machine type and programming of the machine plays a part as well. In other words, every situation needs to be analysed thoroughly first. Enquiry No. 4105 Turn to page 80a or log on to to enquire

May-Jun 2013 asia pacific metalworking equipment news


Software & Measurement

Change. Evolve. Transform– Go Beyond Wireless Technology Wireless technologies have brought a change in the metrology industry by providing flexibility and better performance. By Shruti Khanna, lead consultant — Marketing Communications, Hexagon Metrology


nformation and communication technologies have become increasingly prevalent, social and three dimensional in the 21st century. The use of Internet has become a central element in private and business environment. These new technologies can help connect people, objects and services through physical and virtual worlds. Today, wireless technologies have brought a dynamic change in the metrology industry. Flexibility, easy use, faster performance, newer opportunities and applications are the kind of benefits these technologies provide to the industrial environment. Various wireless technologies such as laser trackers, portable measuring arms, in-process measurement


asia pacific metalworking equipment news May-Jun 2013

sensors and hand tools are now available in the market with each of these products offering their own special benefits and can be selected according to the intended use. Fast Track To Success Metrology companies across the world have adopted wireless technology and are launching numerous products that are enhanced and operate in a smart way. The core objective of this paradigm shift is to create an ideal work environment for the metrology industry. The laser trackers for instance, have been a long-term standard in industrial metrology. These systems lead the field in terms of accuracy and reliability. Modern laser trackers can achieve an

accuracy of 10 μm at a distance of 80 m. Expansion or automation of the system with hand-guided scanners, wireless probes or robot applications open-up a number of possible applications. The effect: rapid and accurate measurements fed directly into production, leading to cost savings and quality improvements. The quality team at Vestas Nacelles says that they have a lot of experience in metrology. Besides a large stationary CMM, they had used two laser trackers for many years. “The time had come to look for new measurement systems,” said Jeppe Nielsen, head of the Measuring Team. “The old laser trackers were still working perfectly. However,

Software&Measurement we wanted to see if there was something faster. The new tool should help us to save time and effort.” The result of the following benchmark and testing phase led to the conclusion that laser trackers were still the ideal solution for the company’s measurement challenges. Armed With High Technology Another wireless technology includes the portable measuring arm, which allows measurements to be ta ken directly in the manufacturing environment, where process improvements are the most beneficial. The attractive price performance of these portable coordinate measuring machines when compared with CAD data or reverse engineering techniques means they are finding use in a wide range of industries.

Booth : D101

The enha nced por table measuring arms with integrated laser scanner are now more rapid compared to previous versions, offering an acquisition speed of up to 50,000 points per second. This means that the user can move the scanner significantly faster across the object to be measured compared to previously, while maintaining high data quality that is typical for such systems. This also applies when the surfaces are difficult to scan, for example with high gloss carbon fibre. Users can now scan up to 66 percent more surface area in the same amount of time as with previous models of these arms with integrated laser scanner. Now, there is also an option for wireless scanning: with the help of the wireless scanning pack, all arms with integrated scanner can be operated via WiFi. In addition,

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Laser trackers have been a long-term standard bearer in industrial metrology

May-Jun 2013 asia pacific metalworking equipment news


Software&Measurement Mobility plus highperformance laser scanning packages make the portable measuring arm an all-purpose 3D measurement tool

the battery system has a facility for replacing the battery while the machine is running, facilitating uninterrupted wireless operation anywhere. Arming Production Floors Mobility, stability, low weight and high-performance laser scanning packages make the portable measuring arm an all-purpose 3D measurement tool. Absolute encoders, which assign an absolute value to each position of the arm, are a unique feature. Initialisation is not necessary. Simply take the measuring arm to the part, switch it on and start measuring. One of the users of this wireless technology, Donovan Barnes of Habitat Industries, Cape Town, South Africa said: “With this technology, we are now capable of CNC machining 40

asia pacific metalworking equipment news May-Jun 2013

simple to complex 3D surface parts and cut our design time down by up to 80 percent. It is a productive tool with almost limitless opportunities.” Elsewhere, Vestas Nacelles has developed a business case and found out that the use of measuring arm has proved to be very beneficial for their business. Mr Nielsen said: “Ordering the measurement, sending the part and getting it back eventually took us days before. Now we have the results in 10 minutes. The measuring arm paid for itself in less than half a year.” The Touch Approach Touch probes and tool setters with radio-wave transmission Self Channel Select (SCS) technology offer precision at a work place. They provide interference free signal transmission between probe and receiver, which is absolutely vital for processr e l i a b l e m e a su r e m e n t s o n machine tools. When using radiowave transmission, the use of a high-penetration frequency range as well as the SCS technology ensures interference free function with a broad transmission range. To u c h p r o b e s m e a s u r e workpieces on milling machines, machin ing ce nt re s, lat he s, turning/milling machines, grinding machines, special machines and robots. Constant production quality also requires the use of reliable accurate tooling. One vital requirement is precise tool data. Touch probes for tool measurement detect tool length and tool radius directly on the machine. Both in small businesses and in middle or large-scale production, workpieces are not only aligned, but geometries are inspected while still on the machine. Touch probes facilitate daily work, reduce manufacturing time and costs, increase the possibilities of modern machines and avoid rejects and rework.

With touch probes, deviating angular positions of workpieces can be exactly determined and automatically compensated. As such, the time-consuming axially parallel adjustment of workpieces becomes obsolete and precision is increased. A l s o, de p e n d i n g o n t he mac h i ne sp e ci f ic at ion, t he workpiece can be adjusted by rotating the coordinate system in the control, or by turning a rotary table, considerably shortening set-up times. In-Process Measurement In tool measurement, the tool data is automatically transferred to the tool table of the control. Periodic tool checks for broken tools or wear create additional production safety. The tool setter will do this job, saving time and increasing reliability. Tool measurement on the machine provides more precise and up to date tool data, since it takes into account the clamping forces of the tool holder and the thermal conditions inside the machine. With proven measuring cycles inside the control, measuring is both quick and safe. This saves cost and setup time, avoids non-machining time and gives high operation and process reliability. Wireless Technology In Hand Wireless probes offer robust and unprecedented stability while transferring data. Moreover, they are provided with a set of technical features unique in the market, such as a synchronised and bidirectional dialogue. They g ua ra ntee fa st a nd reliable measurement, both in a static and in a dynamic mode, even when the instrument is moving or is subjected to accelerations. Finally, the wireless connection contributes to a total freedom and is an asset during translations or rotations of the probe around the part to be measured.


Digital hand-held tools are essential in metrology as they bring advantages in terms of flexibility, readability and reliability

“These new features help increa se the productiv ity substa ntia lly. The reduced, simplified maintenance optimises the employment of resources. The automotive and aerospace industries cannot be mistaken about these innovations and see them as major technological breakthrough,” said Marcel Bila, MD, Tesa. Digital hand-held tools are essential in metrolog y. The c a l ip e r s, m ic rome te r s a nd indicators bring about advantages in terms of flexibility, readability, reliability and traceability and enhance workflows considerably. Keeping in mind the goal of offering centralised solutions, co n ne c t i v it y a nd i nte r face softwares are of major importance. The wireless caliper is a representative example for how customer benefit can be maximised from this wireless interface that allows a smooth and secure data transmission to the PC. Instruments with this technology are equipped with built-in connectivity output which offers a simple ‘plug and play’ connection. Whether using a USB or digimatic connection, data is further processed immediately. At this stage, software that

aligns with these technologies comes into play for data acquisition, made to measure measurement program and statistical data. The software manages simultaneous measurements with different types of instrument, providing measurement protocols, control charts, statistical data, reports and data transfer. Most hand tools, height gauges, inductive probes, roughness testers and setting benches are compatible

with this software and even with a few 3D CMMs. Connectivity is ensured with Opto USB or wireless connectors, available with many instruments. Looking at the field of 1D inductive probes and related electronic interface, metrology companies h av e d e v e l o p e d h i g h - te c h solutions that open up widereaching options for the user: the versatile use of the wireless probes guarantees a high grade of flexibility in multi-gauging applications. Flexibility is the key to most wireless technologies in the precision measurement industry. Responding to direct market needs, measurement equipment companies are looking for ways to optimise the functionality of measurement and inspection e qu ipme nt. T he y i nte g rate wireless options in their portfolio in order to measure all things in all ways and use a wide range of wireless technologies to reduce inspection time and costs. Enquiry No. 4201 Turn to page 80a or log on to to enquire

In-Process Measurement: The VW Way Volkswagen produces injection moulds and dies for large parts and key components at the company’s own Components Toolmaking Division. To ensure the contour accuracy and precision of the workpieces, they are measured using touch probes and software. The process is carried out when the workpieces are on the machine and they are only removed when they have been verified. This promotes smooth-running operations and significantly shortens the overall production process. In an interview with Dirk Strümpfler, head of the Components Toolmaking Division, he explained the key role which component toolmaking plays at Volkswagen and the responsibility it carries. “The speed and quality of our company’s toolmaking division must be second to none. It means large volume throughput accompanied by a very high level of quality.” This high quality standard calls for permanent efforts in production. The quest for optimisation ultimately led to the use of touch probes and software. Now the workpieces can be measured at any time, meaning that if necessary, they can be reworked while still clamped on the machine. Time consuming second clamping operations, which previously meant loss of accuracy, extra production complexity and was difficult to plan, are now a thing of the past. “Now the workpiece is unclamped only when we know it is right,” commented Mr Strümpfler.

Enquiry No. 4202 Turn to page 80a or log on to to enquire

May-Jun 2013 asia pacific metalworking equipment news



T The Next Stage In Manufacturing Automation

Lora Williams, North Andover, US

Wireless Technology:

As the push for manufacturing productivity increases, so too will the rise of wireless technology in the metalworking industry. By Shahnawaz Abdul Hamid


asia pacific metalworking equipment news May-Jun 2013

he advent of wireless technology of late has been relentless, affecting not ju st t he mo der n developed world, but developing countries as well. In a recent repor t by the Inter nationa l Te l e c o m m u n i c a t i o n U n i o n ( I T U ), it i s e st i mate d t hat there a re six billion mobile subscriptions worldwide, with a third of these coming from India and China alone. It is not just indiv idua ls who are riding this wave of wireless telecommunication and networking, but businesses a s w e l l . To d a y, t h a n k s to offshoot technologies that the wireless world has generated, cloud computing for instance, businesses can work smarter and more efficiently. To illustrate, fishermen in Bari, Italy, have recently turned to cloud computing to access a virtual ‘fish market’, allowing them to sell their catch directly from their fishing boats. This helps to reduce an oversupply of fish, since they are better aware of the real-time demand from wholesalers and restaurants. S u c h te c h nolo g y — a nd the subsequent elimination o f i ne f f ic ie nc y i n t he dat a collection process — can mean significant savings if repeated for the metalworking industry, as companies push for greater productivity. The days when workers are restricted to a certain work area to provide timely inputs using a network computer will soon be a thing of the past. Instead, the future will allow workers the flexibility to do this from just about anywhere. Communicate Better, Reduce Costs To d a y ’ s m a n u f a c t u r i n g e nv i ro n me nt i s co n s t a nt l y cha nging. With tougher competition, more government

Software&Measurement Frequency Identification (RFID), regulation and a shrinking pool the corporate office of a company of qua lified workers, it ha s can now keep track of project become increasingly important deliverables in a remote factory that manufacturers improve or warehouse. worker productivity. This paves the way for a One vital aspect of reduction of ma nufacturing productivity is communication, and hiring costs, as companies both interna l a nd ex terna l. site their corporate offices in Communication, whether in developed countr ie s where the form of inventory data or t he re is a re ady supply of design review feedback, is often managerial talent and business needed to be circulated quickly infrastructure, while leaving throughout the company. With large - scale metalworking or wireless broadband, there is manufacturing operations in now improved data visibility, developing nations w ith a n allowing for better collaboration abundance of low-cost labour. across all levels of management. This can also lead to greater Implementation Issues transparency, which reduces Theoretically, a company in the need for highly- qualified Singapore that manufactures personnel to travel frequently meta l fittings, for insta nce, to ensure ma nu factur ing could source for its engineers objectives are met. Through a n d te c h n i c i a n s f r o m t h e the combination of wireless APMEN_ASIA_3406_13159_EMO Hannover 2013 08.03.13 10:53 Seite 1 re lat ive ly e duc ate d lab ou r infrastructure and Radio APMEN_ASIA_3406_13159_EMO Hannover 2013 08.03.13 10:53 Seite 1

pool found loca lly, a nd use wireless technology to transmit impor ta nt information or monitor production processes in Malaysia, Thailand or China, where general workers would be more readily available. While the idea may sound feasible, its implementation may not be as straightforward. In such an environment, safety breaches may be likelier, resulting in needless incidents. To counter this, it may be necessary for machines of the future to work sma r ter, ‘sensing’ when a n operation is done in an unsafe ma n ne r, a nd automat ic a l ly shutting itself down. CCTV monitoring may also b e come t he nor m i n ma ny factories and plants, allowing for easier monitoring of workers as they go about their metalworking processes. Nevertheless,


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May-Jun 2013 asia pacific metalworking equipment news



Solutions For The Oil & Gas Industry While the wireless technology described in this article may seem like an image from the distant future, there already exist current business practices which leverage on the solutions available today. In the oil and gas industry, RFID technology has in recent years been used to automate several important inventory applications, allowing companies to minimise downtime due to shortages in parts. R F I D ta gs a re b e com i n g more preva le nt in such a n environment, given their ability for significantly greater data capacity over other prevailing, older models, such as bar code labels. In addition, RFID tags can

In the world of wireless technology, static control rooms like this one may become obsolete Alaa Hamed, Cairo, Egypt

current network speeds may be insufficient to allow clear images on a smooth feed, with it only being possible in the future with further technological gains. In addition, other non engineering issues also need considering. Would workers work as well without supervisors to ma nage a nd guide them? Would they be as motivated and stringent with a companyâ&#x20AC;&#x2122;s standard operating procedures? If worker performance falls in the absence of supervisors and other management staff, savings from such wireless monitoring may count for little.

be read without a line-of-sight reader, making them easier to use and more efficient. There are already several areas within the industry which have benefitted from the use of RFID. The monitoring of installed pipelines can now be done with fewer employees, and does not have to be as time-intensive and expensive as it once was. Using RFID tags on flanges, gaskets and bolts of a pipeline, operators can tell how old each part is, its maintenance â&#x20AC;&#x2DC;historyâ&#x20AC;&#x2122; and if it needs to be repaired or replaced. This reduces incidents of pipeline leakages and other catastrophes.

With offshore platforms moving further and further from land, tracking workers and assets has become more important.

Kasey Houston, Placentia, US


asia pacific metalworking equipment news May-Jun 2013

R F ID ha s a lso a llowed for the wireless track ing of personnel working in hazardous environments. In the event of an emergency, safety managers can quickly ascertain if all the workers on board a rig or platform have been safely evacuated. They can also determine where missing workers are, allowing for quick rescues which may have been impossible before. While wireless technology may not be fully embraced by all the industries related to meta lwork ing, its potentia l is undeniable. A s the world grows ever sma ller with increasing globalisation, and as competition grows ever more intense, only time will tell how quickly companies adopt this technology. While it may certainly makes processes and machines work smarter, there is still much that needs to be done before it can make a firm impact on the world of metalworking. Nevertheless, if and when it does, the savings accrued from efficiency and productivity will be significant. Enquiry No. 4203 Turn to page 80a or log on to to enquire


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Choose The Right Gouging Tool For

Weld Repair

The decisions behind the selection of a gouging tool can be a multi-faceted one. By Erik Brine, product manager, Manual Systems, Hypertherm


elding is the process of joining two pieces of metal together by fusing the surfaces with a filler metal brought to a molten state by the heat of a welding arc. Since weld failures can be catastrophic, such as in a ship or bridge, most welds must be free of defects to ensure good quality. The most common weld defects are cracks, inclusions (trapped gas or other contaminates such as slag and rust), and incomplete weld penetration or fusion. When these defects are found, they must be removed and replaced by a new weld. This is typically done by grinding or gouging. When it comes to speed and productivity, gouging is the preferred method for the quick and easy removal of welds. Besides weld repair, gouging is commonly used for scrapping or dismantling, as well as ‘back-gouging’, which is the process of removing the slag layer for multiple-layered welds. Several metal gouging solutions exist in the market today, and selecting the right technology allows engineers to remove and repair welds with greater ease. In Asia, hand grinding, carbon arc and plasma are the most widely used gouging technologies. And although carbon arc has long been


asia pacific metalworking equipment news May-Jun 2013

seen as a sufficient gouging system for a variety of needs, plasma is fastbecoming the gouging solution of choice as technology improvements in recent years have made it easier to use and more productive. Gouging Methods In carbon arc gouging, an electric arc is generated at the tip of a carbon or graphite electrode. Heat generated then melts the metal, and the molten form is removed by a blast of air to form a groove. This process can be used on mild steel, cast iron, nickel alloys, copper, and aluminium, but is not suitable for stainless steel, which will corrode if gouged using a carbon arc. Pla sma goug ing involve s blowing an inert gas out of a nozzle at a high speed. At the same time, current from a power supply forms an electric arc through the gas, ionising the gas

Plasma produces smooth, clean and consistent gouges

to create a plasma arc. A plasma arc can gouge and cut any electrically conductive material, and is most frequently used on mild steel, stainless steel and aluminium, giving plasma an advantage over carbon arc. Plasma systems can also gouge or cut metals that are dirty, painted, or rusted. With this basic knowledge about carbon arc and plasma, companies in Asia may be able to instantly decide on which gouging system to use based on their critical business needs. But for more specific factors such as ease-of-use, pollution, cost and productivity, this article explores the comparisons that companies should consider before deciding whether carbon arc or plasma is the best way forward. Ease-Of-Use & Gouge Quality In recent years, the ease-of-use of technical processes has been gaining importance as a key decision factor in Asia, primarily because it minimises training, improves safety, and ultimately increases profitability. Comparing carbon arc to plasma, operators are able to get used to the latter much more easily. When using a carbon arc for gouging, it is difficult to control the electric arc. So, it is not uncommon to have too much metal removed or to wind up with extra carbon deposits on the base metal. This is the case even for experienced operators. Plasma, on the other hand, requires just some practice in order to achieve

Plasma is able to gouge and cut a wider range of materials

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a smooth, clean, consistent gouge. Consequently, secondary operations, such as grinding, are often not required to improve the gouge surface finish when plasma systems are employed. Also, plasma is able to gouge a wider range of metals. It is suitable for both ferrous and nonferrous material that is electrically conductive, as well as metal that is in any condition. Carbon arc gouging, however, can only be carried out on limited types of metals. This means that welders who utilise plasma systems need only to use a single equipment to work on a variety of metals, while carbon arc users may have to switch between systems, depending on the material types they are working on.

Cost & Productivity The initial capital cost of a carbon arc gouging system is generally lower than that of a plasma system. However, because plasma is typically able to gouge four

times as fast as carbon arc is able to, with little or no grinding needed for clean-up, the cost per part produced is smaller. Also, consumables for plasma systems are able to last a longer time. Considering all these factors, plasma gouging becomes the more economically efficient option. In addition, plasma systems can be used not just for gouging, but for cutting as well. End-users have the potential to derive greater value from their equipment and may more rapidly realise a positive return on their investment in plasma. In Asia, carbon arc and plasma gouging are both well-established processes for gouging metals. Each has its own advantages and challenges, and choosing between the two depends on individual companiesâ&#x20AC;&#x2122; specific business needs. Enquiry No. 4301 Turn to page 80a or log on to to enquire


Pollution Providing a safe work environment is of increasing importance to

manufacturers in Asia. For carbon arc gouging, the air blast often vaporises molten metal into fine droplets, producing excessive fumes. These emissions may consist of metal vapour, carbon dust, and metallic by-products, which can cause health problems. With plasma gouging, on the other hand, liquefied metal is pushed out of the groove in a milder manner, so less fumes are produced. In addition, carbon arc gouging, like mechanical gouging, is relatively loud. Although ear protection is recommended for plasma gouging, plasma is a quieter alternative that is typically 5 to 10 decibels lower.

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May-Jun 2013 asia pacific metalworking equipment news


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he development of new weld processes for use in mechanical engineering, shipbuilding and vehicle manufacturing has always centred on the need to boost productivity. In the past, particular attention has been paid to shortening the welding times by increasing the welding speed, and/or to minimising the amount of postweld machining and straightening work needed in the welding of large cross-sections of thickwalled plates. Alongside single -wire processes with higher deposition rates, such as submerged-arc and electroslag welding, efforts have focused on developing systems for welding with several electrodes simultaneously. These systems are called the double -wire and tandem welding processes. The greatest adva ntage of both ty pe s of two-wire process lies in their significantly higher deposition rate and welding speed, and lower thermal input. A further advantage of welding with two wires in a shared weldpool is that the weld-pool is larger, and solidifies later. Also, two-wire processes make it possible to increase the gap-bridging ability by turning the welding torch sideways, allowing broad wetting to sidewalls in the top pass with no need for oscillation. Simultaneous welding with several electrodes has long been established as an economically efficient method of high-performance welding. In practice, however, it has become apparent that users have difficulty identifying the correct parameters. The reason lies in the complexity of the welding systems and processes that have been available until now. Before going into that, we take a look at some of the differences between double-wire and tandem welding processes. 48

asia pacific metalworking equipment news May-Jun 2013

Multi-Wire Weld Processes For

More Economical Welding Tandem welding can produce more flexibility and better performance. By Dipl Ing (FH) Franz Joachim RoĂ&#x;mann, for Fronius

Double-Wire Welding In double-wire welding, otherwise known as parallel-wire welding, two wire electrodes are melted off using a shared torch in which both wires are at the same electrical potential. Depending on the power requirements, welding is carried out either with a shared power source or with two separate ones. Separate control of the weld processes is not possible in either case because only one common

voltage is available for use as a control variable. T he t wo e le c t ro de s a re therefore only melted off at an approximately equal wirefeed speed. This high deposition rate is not needed in all welding applications, for instance, on lap-welds with small seam crosssections. However, thermal input is still high despite the faster welding speed, and this can make work more difficult.

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Figure 2: CMT Twin process sequence when the pulsed-arc and CMT processes are combined

Figure 1: The CMT Twin tandem welding system has two independently functioning digital power sources

The high welding speed can also cause problems in itself, such as undercutting. To prevent this, the arcs must be set as short as possible. On the one hand, it is not possible to control dip-transfer arcs in double-wire welding. On the other hand, when the arc is longer, there will be more interference. As such, negative effects such as spattering and process interruptions are almost impossible to prevent. Tandem welding is the better alternative here. Tandem Welding Unlike in double-wire welding, tandem welding always uses two mutually insulated power sources and a torch with isolated current conduction. In this way, all common types of arc (diptransfer, spray and pulsed) can be combined in one and the same system. Each arc voltage can be measured separately and used as the control variable. For ma ximum stability, a tandem welding process that (eg: TimeTwin) synchronises two arcs used in pulse welding in a 180 degree phase opposition is used. Although the wirefeed speeds can be diverged here, this is only possible within comparatively narrow boundaries. Due to the phase displacement, the weld-pool stays quieter in TimeTwin — there is less spattering

than in double-wire welding or conventional tandem welding, and the arcs are more stable. Tandem processes are generally characterised by lower thermal input than double-wire processes. With some welding-tasks, even this decreased thermal input may still be a problem. Fillet welds are a good example: if the weld-pool becomes too fluid, the seam will sag when welding is performed on larger seam cross-sections in the PB position or in out-of-position work. In these welding positions, process stability also suffers. Cases such as these call for a more stable process in which the thermal input is even lower and can be precisely adjusted. More Flexibility & Control In Tandem Welding Fo r a p p l i c a t i o n s i n w h i c h greater process stability and uninterrupted control of the weld process across the entire power range are required, a tandem welding system may be more suitable (Figure 1). This welding system is equipped with two digital power sources that work completely separately from one another. This allows the weld processes to be individually a d j u s te d to t h e d i f f e r e n t applicational requirements in each case, and also means that — within the given physical limitations —

any wirefeeder can be chosen. As a result, widely diverging wirefeed-speeds can be set. It is even possible to utilise entirely different weld processes. This twin-wire solution allows users to exploit two Cold-Metal-Transfer (CMT) processes, or combine a GMA pulsed-arc welding process (‘Lead’) with a CMT process (‘Trail’), all within one single system (Figure 2). A characteristic feature of the CMT process is that the electrode is moved rapidly back and forward, in a controlled manner, while welding is in progress. The short circuit (when the electrode touches the weldpool) initiates the reverse motion of the electrode. After a defined arc-burning duration has elapsed, the wire changes direction and is moved back towa rds the workpiece. Unlike a pulsed or spray arc, the droplet is now detached in a controlled manner during the short circuit. In CMT, the arc length is subject to little or no fluctuation, as the wire is retracted by a defined distance independently of the stickout. The heat input is significantly less compared to a conventional diptransfer arc, as the short circuit is not broken under high current-flow (as it would be in a conventional diptransfer arc), but at a low amperage when the wire is retracted. May-Jun 2013 asia pacific metalworking equipment news


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Figure 5: The picture shows a pipeline seam in which a 19 mm steel plate has been welded in the PB position, in three passes.

Figure 4: CMT Twin lets users achieve ‘textbook’ results when welding a6 fillet welds in the PB position.

Figure 3: A fillet weld welded at the lap joint of two 2 mm steel sheets.

5 mm

1 mm

2 mm This controlled shedding of the droplet into the weld-pool means that little or no spattering occurs, making the process even more stable in comparison with conventional (pulsed) arc processes. In CMT Twin, these positive properties can be combined with the advantages of a GMA pulsedarc welding process: for example, the first (‘lead’) wire electrode can achieve deep penetration with a pulsed arc and/or a high welding amperage, while the following (‘trail’) electrode works in CMT mode and fills the seam as needed, with reduced wirefeed speed and heat input. As the CMT Process exerts less arc pressure on the weld-pool, with the result that the weld-pool remains quieter, there is less disturbance of the pulsed-arc process on the ‘lead’ electrode. This, in turn, allows the pulsing to be kept shorter and with higher power (= deep penetration). The resulting welding speeds are high. In the case of a fillet weld welded at the lap joint of two 2 mm steel sheets, they can be as fast as 4 m/min (Figure 3). Due to its lower thermal input, the tandem welding system performs better than conventional tandem processes in terms of gap-bridging ability as well. The que stion of which combination of processes should be chosen for the weld system will depend on the requirements 50

asia pacific metalworking equipment news May-Jun 2013

applying to each different welding task, in terms of welding speed, deposition rate and gap-bridging. For fillet welds needing to be welded in the PB position or outof-position, it is best to combine a pulsed arc (‘lead’) with the CMT process (‘trail’). This combination lets welders achieve ‘textbook’ results, even when welding a6 fillet welds in the horizontalvertical (PB) position (Figure 4). Compared to conventional tandem processes, combining the pulsed-arc and CMT processes in this way, with all other parameters remaining the same, decreases the thermal input by between 10 and 20 percent. The thermal input from a CMT-CMT combination is even lower still, meaning that new areas of application can now be opened up for tandem welding. To give one example, CMT Twin allows out-of-position welding of root passes (Figure 5) that would either be impossible with other welding processes, or not economical. Butt-welds can also be welded much more efficiently, as the weld-pool is quieter and the deep penetration on the ‘lead’ electrode lessens the risk of fusion defects, meaning that a smaller included angle can be chosen. Easy To Handle To ensure a good weld right from the very beginning, (in CMT Twin) the ‘trail’ electrode does not start work until the ‘lead’ electrode process has stabilised

and the power source for the ‘trail’ electrode has received a start-up signal. The high process stability and lower level of reciprocal influencing have made it possible for Fronius to draw up optimised characteristics for various applications. These coordinate the processes for users, making it much easier for them to identify the correct parameters. Conclusion C M T Tw i n c o m b i n e s t h e advantages of TimeTwin and CMT in one system. Compared to conventional two-wire processes, the advantages are high process reliability, seam quality, gapbridging ability, speed, and the fact that only minimal post-weld machining is ever needed. Thanks to these performance attributes, the ta ndem welding system delivers better welding results than conventional double-wire or tandem processes. This is seen particularly clearly when joining light-gauge sheets at high speed because the heat input do not exceed the optimum. The welding system also stands out for its ease of handling. All these many capabilities make the welding system suitable for use in the automotive and supplier industries, in shipbuilding and mechanical engineering, and in the power generation field. Enquiry No. 4302 Turn to page 80a or log on to to enquire


Industry Focus

Arm Twisting In Quality Control

Engineering tolerance â&#x20AC;&#x201D; you are either within or out of it. Measurements however, can benefit from a little flexibility in the form of measuring arms. By Yoshihiro Iida, marketing manager, Faro Japan


ost-wax casting is a mould part process that has been gaining popularity amongst manufacturers in recent years due to its pliable nature in producing small lots in short timeframes. The technique permits reproduction of intricate metal objects through multiple steps, allowing several mould parts to be assembled to form a product, removing the need for a machining process after casting. One company that specialises in producing precise parts using the lost-wax casting process is Kingparts, based in Fukuyama Cit y, Hiroshima Prefecture, Japan. The company handles the entire production process from start to finish, which begins with the design of metal moulds, to mould making, casting, finishing, and delivery. 52

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Typically, the parts produced are used in areas such as general industrial machinery, electronic & electrical products, machine tools, medical devices, automobiles, aircraft, measurement instruments, food manufacturing devices and defence equipment. Shape Measurement In Quality Assurance In an effort to improve on casting technology, the company has invested in R&D in recent years. They increased spending on capital investment by acquiring a wax mould making machine, a core firing furnace, a vacuum heat-treating furnace, and a lost core device. This resulted in a new die casting technology using ceramic core. T he te ch nolog y to ok around three years to develop,

Difficulty: Gantry-type measuring machines were not capable of capturing all the fine details of objects with irregular curved surfaces.

Solution: The usage of portable 3D measurement arm with multiple axis-of-rotations that emulates the versatility of a human arm.

Conclusion: Efficiency of the measuring process was improved and it opened up new opportunities for the company.

as the company had to overcome technical difficulties of varying degrees â&#x20AC;&#x201D; including the precision of joining mould and core, as well as core flexure control. But as soon as Kingparts had some success with resolving the technical issues, interest in the new casting technology picked


Lost-wax casting process: mould making by using robots

up and the company started to receive a larger volume of orders from existing and new customers. However, the company ran into a new problem after its initial success. They had to measure complex curved surfaces of parts on objects for quality control, which called for the implementation of a metrology solution. At that time, the company ow ned a few ga ntr y- ty pe measuring machines to perform 3D measurements. The drawback of these machines was that it was incapable of capturing all the fine details of objects with irregular curved surfaces. As such, the company chose to farm out the measurement jobs. This process proved to be time-consuming and cumbersome for product creation. A s production using the new die ca sting technolog y gained pace, the demand for 3D measurements increased. In anticipation to growth in orders, there came an increasing need for the company to possess its own non- contact measuring equipment that would enable it to conduct its own quality checks. A decision was then made to acquire a portable 3D measurement arm with multiple axis-of-rotations that emulates the versatility of the human arm.

Improving The Measuring Process The measuring arm in this case is the Faro Edge. With it, the company’s technicians are able to measure objects that could not be accurately captured using traditional tools. This has a positive impact on quality improvement as the deployment of non-contact 3D measurement arm permits intricate die making, leading to precision die casting reproduction. In the pa st, using the traditional gantry-type m e a s u r i n g to o l s r e q u i r e d the object to be turned over, moved a round or mea sured with the aid of a jig. Repeated benchmark measurements were also necessary. But with the portability and flexibility of the measuring arm, cumbersome processes are no longer needed. This improves the efficiency of the measuring process and reduces measuring time. In addition, issues like storage space for the jig, prolonged production time and cost have also been eliminated, leading to the emergence of other benefits. They are time-savings and costsavings since the company no longer has to outsource the measurement jobs.

Wax pattern making machine

Extending The Reach To enable mass production, the company has assigned dedicated personnel to perform measurements using the arm as opposed to having two employees operating it on top of their other duties. The focus placed on the measuring arm is not surprising given that the company has greater plans for it rather than just pure measurement. Shunichi Kimura of Production Control Division explained: “It’s now possible for us to perform evaluation of objects such as turbines and ceramic cores. This could not be achieved with traditional techniques before. I’m looking forward to applying this technology to the next project that involves measurement of moulds or products with irregular curved surfaces such as wings.” With an eagerness to take on new tasks involving the use of non-contact 3D measurement instrument, he added: “We have received orders that require us to perform reverse engineering. Even though the number of projects is very small at the moment, I look forward to using the Faro Edge more for this new field in the future.” Enquiry No. 4401 Turn to page 80a or log on to to enquire

May-Jun 2013 asia pacific metalworking equipment news



The Mould & Die Industry To Change With The Times

Augustine Quek analyses the fortunes of the mould and die industry in this special focus.


ould a nd die a re the cornerstone of mass production and industrialisation in modern societies, and one of the tools necessary for industries to run mass production. They are widely applied in the automotive, instrument and meter, electronics, home appliance, aerospace and petrochemical industries. A s the se products a nd equipment consist mostly of parts, units (sub-assemblies) and components, which are used in


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large volume, mould and dies are supplied virtually to every company manufacturing such equipment, products, parts and components. Moulding, in the modern sense, began in the early years of the 20th century and progressed rapid ly a f te r t he 193 0â&#x20AC;&#x2122;s i n industrialised countries. The i ndu st r y e x p a nde d rapid ly in the 1940s because World War II created a huge demand for inexpensive, massproduced products.

Accuracy Of Mould As die and mould help in the fabrication of parts and components, their accuracy subsequently determines the accu rac y of t he pa r t s a nd components manufactured. For example, the notched tap of aluminium cans used in package beverages poses a danger to consumers. These cans are finished within the accuracy of 1 micron, while the accuracy of the corresponding mould is in the magnitude of 0.1 micron.


Mould and die are widely used for the automotive industry

Local Connection One characteristic of the industry is that customisation of the mould and die tends to be done locally. Tool-making requires extensive collaboration with the customer, due to the high degree of production customisation. Therefore, a high frequency of interaction between mould and die makers and their customers is necessary, with face-to face discussions usually essential. With the need for these frequent business meetings, it is natural for manufacturers to prefer contracting tooling suppliers located near their facilities. In addition, the industry also traditionally consists of many family-owned companies accustomed to servicing nearby manufacturers. All these factors add to a situation whereby the companies are not particularly ready to compete in a rapidly globalised environment as they could not adapt quickly enough to foreign competition.

Globalisation â&#x20AC;&#x201D; A Disruptive Trend? However, globalisation is making this traditionally competitive business even tougher. As a result, die and mould makers must rethink both their short-term and long-term strategies. According to the International Trade Administration (ITA), US Department of Commerce estimated 60 percent of stamping dies and 40 percent of plastic moulds are employed directly or indirectly by automakers around the world, making them particularly reliant on the transportation market. However, automotive makers around the world are shifting their manufacturing facilities to overseas locations while US automakers, particularly General Motors and Ford continue to wea ken. These trends have negatively impacted the US mould and die makers, particularly small, family-owned shops. In fact, according to several sources, an estimated 150,000

tooling jobs have been lost in North America since 2000 due to offshoring. Additionally, the US injection moulding machinery market has shrunk by almost 50 percent over the last five years, according to ITA. Furthermore, this industry is extremely capital intensive. Highly sophisticated machine tools and manufacturing te chnolog y a re cr it ica l for toolmakers to reduce labour costs and to improve efficiency. Traditional strategies no longer suffice because of the rapid spread of offshore outsourcing, not only in the purchase of tools, but also relocating part of the production to lower cost countries in Asia such as China and India. Mould and die manufacturers who face massive cost pressure outsource not just to follow their customers but also to serve new customers in the target markets. According to the ITA, cost savings from 40 percent to 70 percent are possible, but the process of finding the right supplier of mould tool and mould material is intense and the necessary input is very high. Mould & Die In China The relocation of mould making companies to China has caused the rapid development of automotive, home appliance and IT industries in China. Between 2005 and 2011, the Compound Annual Growth Rate (CAGR) of mould output in China reached 9.7 percent, while that of sales registered 12.6 percent, according to China Mould and Die Industry Report, 2011-2012. The report also revealed that the mould and die output of China saw a slight increase to 9.82 million sets in 2010, compared to 9.7 million in 2009. With the export value totaling US$2.196 billion, up 19.15 percent over the preceding year, trade surplus was realised for the first time. In fact, statistics showed China has the third largest mould industry in the world based on May-Jun 2013 asia pacific metalworking equipment news


IndustryFocus There are more mould makers specialising in high-growth market segments such as military and defence in a bid to differentiate themselves from low cost competititors.


total output, after Japan and the US. According to International Mould Association secretarygeneral Luo Baihui, the Chinese mould and die market is expected to reach CNY350 billion (US$56.5 billion) in 2015, with total sales in 2011 reaching CNY164 billion. Currently, automotive and electric appliances already account for over 80 percent of the entire market. For example, the total number of auto parts needed to be moulded for a car is about 4,000 sets, with total value of CNY200 to 300 million, while a refrigerator requires about 350 sets of moulds in all, which has a value of about CNY4 million. Presently, major mould and die companies that relocated and have established a presence in China are mainly Japanese automakers and enterprises, including Toyota, Toshiba, Sharp, Honda, Mitsubishi and Fuji. Other mould manufacturers from Japan that have also accelerated their business development in China include Ogihara, Kuroda and Uyemura-Solar.

to products, sought niche markets, and increased mouldmaking capabilities. Similarly, mould making machines will become increasingly sophisticated in the areas of processes, technology, and specialisation. For example, Makinoâ&#x20AC;&#x2122;s highspeed machining centres can mill and make moulds out of the hardest steels (60+ HRC), eliminating grinding and polishing in the process. Its Super Geometric Intelligence (SGI.4) controls, allow long, complex mould programs to be processed at fast speeds and with high levels of accuracy and finish. The company claims that the control can help reduce the highdefinition 3D milling of dies and moulds by an average of 15 percent compared to previous versions of this technology, resulting in a reduction of some cycle times by as much as 30 percent. Forging dies that once required eight setups, 40 machine hours and a six-day leadtime can now be executed with a single setup and completed under four hours.

Mould & Die Manufacturing I n orde r to t h r i ve i n t h i s competitive environment, die and mould makers have mostly specialised in particular areas, beefed up services, added value

Tackling The Niche Market To combat low-cost overseas competition, mouldmakers can specialise in high-growth market seg ments such a s medica l, domestic automotive, packaging

asia pacific metalworking equipment news May-Jun 2013

and military & defence. For example, medical moulding is an ideal process for more sophisticated mould manufacturers to specialise in because of the complexities of working with local regulators. It also is becoming more important as the population ages and requires more medical care. Therefore, the more technologically advanced countries, such as Japan, the US and Germany, can still maintain leading positions in various niches. With their wellestablished R& D capabilities and design capacities, the highprecision and complex nature of mould and die development is still better understood and improved upon in these countries. The globalisation of markets is the most important feature in todayâ&#x20AC;&#x2122;s mould industry. Successful mould making companies are facing the challenges head on by diversifying their die and mould markets in order to find new business. They are also transforming in order to strengthen their overall competitiveness. On a grander scale, the mould and die industry will continue to restructure itself to become more dynamic and global in order to compete for business and survive. Enquiry No. 4402 Turn to page 80a or log on to to enquire


Executive Zone

Contribute To Sustainable Manufacturing With

Remanufacturing Remanufacturing has subtle differences when compared with terms like repair and reconditioning. However, its potential benefits when applied correctly can be considerably more substantial. By Joson Ng


here are plenty of ways to define sustainability and sustainable manufacturing. Likewise, there are also different motivations to pursue sustainable manufacturing. A noble definition of sustainable manufacturing by the National Council for Advanced manufacturing is that it ‘meets the needs of the present without compromising the ability of future generations to meet their own needs’. Living within our means seems to be the message here but the bottom line is that it is a tough task to quantify what is sustainable and what is not. In a presentation on remanufacturing, which is a subset of sustainable manufacturing, D r Ta n B o o n K i a t , s e n i o r industry development manager, S u st a i nable M a nu fac t u r i n g Centre, SIMTech spoke at length on the impact of remanufacturing and various considerations that should be undertaken before a business goes down the path of remanufacturing. Disrupting Traditional Beliefs With New Concepts Reduce, reuse and recycle are three terms that are commonly heard and preached. In order to achieve sustainable ma nufacturing, three new terms like recover, redesign a nd re m a nu fac t u r i n g we re introduced, and for good measure too a s t here have be en a n increasing number of disparaging 58

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voices heard questioning the virtue of recycling. In terms of industry ecology at least, recycling may not be what it seems. “Recycling may not be good because you are dumping a lot of energy back into the material in order to get raw material,” said Dr Tan. “Most of the time, it does not work. As such, many companies are struggling to make recycling viable for business,” he added. He pointe d out remanufacturing can be used instead a s rema nufacturing concepts harness the potential of the remaining material (old part) and the carbon footprint used

to remanufacture a part is lower compared to recycling a part. Identifying The Distinction Although remanufacturing is not a new term, it always seems to have a thin mysterious veil wrapped around it. It may be the subtlety of the term but the unfortunately thing is that without understanding and appreciating the differences between terms like recycle and remanufacturing, it is difficult to practise let alone benefit from remanufacturing. “ R e m a nu fa c t u r i n g i s a n innovative model rather than a progressive reduction model like lean and green manufacturing. In

executiveZone lean manufacturing, there is more bias towards waste reduction. Green manufacturing on the other hand, leans towards the environment.” According to Dr Tan, some companies may see green manufacturing as a sacrifice and as a result, the adoption rate is not high. In a bid to illustrate what remanufacturing is, Dr Tan took time out to define repair and recondition. According to him, repair refers to returning the broken or faulty components to a usable condition. Warranty issued for repair is generally much less than that of new components. Reconditioning is usually applied to worn parts that are not yet critically damaged. Again, it is restored to a partial functional state. In remanufacturing, parts are returned to a full functional state with full warranty. These

In terms of industry ecology at least, recycling may not be what it seems. parts can come from both worn and damaged parts. Application Is Key The talk on remanufacturing and its benefits is well and good but it would be ultimately counterproductive if it cannot be applied properly. Remanufacturing is said to be suitable for parts that have high intrinsic values. Good examples would be aerospace parts, machine tools and train rolling stock. Asia Pacific Metalworking Equipment News understands that large machine tools are prime remanufacturing examples because there are “plentiful

amount of materials left at the machine’s end of life,” according to Dr Tan. Staying in metalworking, he said companies are also trying to look into the remanufacturing of cutting inserts due to the scarcity of tungsten carbide. Challenges Of Remanufacturing “Remanufacturing was initially done to reduce costs of automotive parts, not for sustainability,” said Dr Tan. The commercial aspect of manufacturing is a very real one and it can force businesses to prioritise long term financial viability over the fundamental

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May-Jun 2013 asia pacific metalworking equipment news



Dr Tan said there is no fix model for remanufacturing that is guaranteed to work

Jay Lopez, Philippines

According to Dr Tan, recycling requires a lot of energy, which makes the recycling business unsustainable for some companies

noble values behind sustainable manufacturing. It is therefore realistic to consider the financial ramification of remanufacturing. “A s a business challenge (remanufacturing), you do not have the certainty of a used product coming back to you if you do not have control of the whole value chain,” said Dr Tan. In order to get around this problem, he said it is better to design for core collect, ie: calculated ways to get back the used products in order for remanufacturing to take place. On the operational front, even when a supply of used parts is secured, it is often difficult to control the frequency and quantity of supply. As such, planning for different types of manufacturing equipment can be challenging because of uncertain demand. In addition, the decision to scale up or down production hinges on core collection demand, on top of existing demand from customers. These uncertainties result in complicated production planning and execution. The last few challenges to overcome are technical in nature. A typical remanufacturing process starts with the dismantling of 60

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the component, followed by the sorting and cleaning of individual p a r t s, i n sp e c t ion, a nd t he identification of parts that cannot be used anymore. Refurbishing comes next before assembly and quality control. After which, the final part is delivered. During the disma ntling a nd inspection sta ge s of remanufacturing, a lot depends on the experience of the skilled workers in identifying components. This reliance is also seen at the inspection stage. Since it is too expensive to rely on equipment like the CMM, a worker’s judgment is called into action. Finally, some remanufactured parts may have different dimensions, causing problems in assembly. The challenges mentioned do not address some other issues faced by certain manufacturers. I n S i n ga p o r e fo r e x a mp l e , sp e c ia l i se d pro ce s se s l i ke machining, coating and heat treatment need to be outsourced because the technology level needed in remanufacturing is usua lly higher tha n norma l m a nu fac t u r i n g, p ote nt ia l l y creating another problem as transportation and other human factors come into play.

Carry Out Remanufacturing On Your Own Terms Like a tailored shirt, remanufacturing will fit nicely if measurements are done correctly and fitting is done properly. Most important of all, the person wearing the shirt must already have a clear picture how he wants his shirt to be. I n c o n c l u s i o n , D r Ta n said: “There is no fix model for rema nufacturing that is guaranteed to work. Same models may work for some industries in some countries but it won’t work anywhere else. Other factors like legislations also play a part. There is no one size fits all solution in remanufacturing.” He said it is better to list down favourable conditions and identify the types of models proven successful in order for a company to decide whether it should go into remanufacturing. Fina lly, he a lso revea led SI M Te ch ha s in a re se a rch stage a Remanufacturability A s s e s sm e nt S t u d y to h e lp comp a n ie s de c ide t h rou g h various factors to see whether a product, component or module is worth remanufacturing. Enquiry No. 4501 Turn to page 80a or log on to to enquire


Demand For Motorcycles To Exceed 134 Million Units The number of motorcycles will increase due to rising standards of living and higher petroleum costs. By Lee Steinbock, industry analyst, Freedonia Group


he globa l ma rket for motorcycles, including ele c t r ic a l ly - p owere d machines, is forecast to expand 7.2 percent annually to 134.5 million units in 2016, when industry revenues will reach US$90 billion. The Asia Pacific region, which predominantly utilises small and inexpensive motorcycles, will continue to dominate worldwide demand, representing 84 percent of all units sold in 2016. These and other trends are presented in World Motorcycles, a study from The Freedonia Group. World sales of motorcycles will be stimulated by rising standards of living in developing nations. China will remain by far the largest national market, with India and Indonesia also important based on large populations with the means to purchase inexpensive motorcycles. There is a strong correlation between average income levels and motorcycle demand up to a certain point. In emerging economies, strong growth in

There is a strong correlation between average income levels and motorcycle demand up to a certain point. motorcycle sales is triggered once certain per capita income thresholds have been reached. Light Motorcycles Lead The Way Due to the superior fuel efficiency these machines provide compared to automobiles and other light vehicles, motorcycle demand gains will also be supported by higher petroleum costs. Fu r t her more , a reb ou nd from the 2007-2009 recession in developed countries like the US will lead to higher product sales, particularly of medium and heavy motorcycles, as economic conditions become more favourable and consumers begin to purchase these expensive recreational items again. As a result, medium and heavy Internal Combustion Engine (ICE)

motorcycles will account for nearly 20 percent of 2016 demand in dollar terms, even though they will make up less than two percent of global unit sales. Light motorcycles will remain the single largest ICE product segment in unit terms because they offer a mix of the best attributes of smaller (lower cost) and larger displacement models (more power). ICE sco oters, mop e ds, and motorbikes will comprise approximately one-third of total product sales in 2016, supported by their low cost and easy maneuverability in congested urban areas. Sales of electric bicycles (e-bikes) and electric motorcycles (e-cycles) are expected to grow roughly in line with ICE motorcycle demand through 2016. Enquiry No. 4601 Turn to page 80a or log on to to enquire

May-Jun 2013 asia pacific metalworking equipment news


Ryan Lackey, Palo Alto, US


Bringing It A

Level Up The oil and gas industry has been employing contact and non-contact level sensors to automate and streamline the production process, which has led to enhanced accuracy and efficiency. By Sherlyne Yong


n todayâ&#x20AC;&#x2122;s processing plants, control loops have been incorporated into production pro ce sse s to e n ha nce productivity while saving time. Each loop is responsible for one part of the process, such as controlling temperature levels or flows, and a typical plant can have a combination of up to hundreds and thousands of such loops. The entire production process is streamlined with the addition of these automated enhancements, with one example being level sensors. Level sensors can be used across a variety of industries, which includes the aerospace, automotive, mining, construction, medical, food and beverage as well as the oil and gas industry. It is part of a metrology system that facilitates automation by mea suring substa nce levels and transmitting the data to a controller, which then sparks off a set of actions. Suitable for measuring levels of liquids, solids and slurries, level sensors can be categorised into two types, by either measuring point or continuous values. The former is mostly used for detecting excessively high or low levels, by measuring whether levels are


asia pacific metalworking equipment news May-Jun 2013

above or below a particular point. Continuous level sensors, on the other hand, measure the exact amount of substance as long as it is within the specified range.

sensors are just some types of instrumentation used for these applications. Both can be used for measuring point or continuous values.

A Well Oiled Process Level sensors are markedly utilised in the petrochemical and oil and gas industries. It is employed during the oil refinery process, in addition to storage and transportation. Most of these level sensors are used for safety purposes. For instance, it can be used to check the amount of rain or groundwater that has seeped into a basin, by measuring the proportion of oil and water. This helps to determine whether the facility is a danger to the environment. O t her f u nc t ion s include inventory control, mud logging, leakage monitoring, overfilling protection and automatic tank gauging. It is also used to detect and pump out water during the oil distillation process so that the distillate does not get polluted. The ability to measure substance levels within various parts of the process has resulted in a greater accuracy and accessibility to realtime information. Ultrasonic and radar level

The Sonic Boom Ultrasonic sensors are widely used in measuring the levels of liquids, particularly so as it is a non-contact medium that senses liquids with high viscosity, as well as slurries. It is also favoured for the combination of high functionality and low cost. It is suitable for the oil and gas industry as the instrument does not have any direct contact with the compounds, which are mostly volatile, and are therefore less prone to failure as well. The basis of ultrasonic sensors are making use of high frequency sound waves to determine the level of substance, through the time taken for the echo to bounce back to the sensor. The distance of the sensor from the fluid can then be calculated using the speed of sound. However, a disadvantage of using ultrasonic sensors is that measurements might not be truly accurate. As the reflection of sound waves are affected by variables

Features such as moisture, temperature and pressure, allowances and corrections have to be applied to the level measurement for increased accuracy.

are generated down the rod, or equivalent, which causes a change in impedance in the dielectric qualities of the measured fluid. This results in a wave reflection, and the transit time of the pulses are used to measure liquid levels. This method is more efficient as the signal is less degraded by external circumstances, such as the presence of obstructions. However, due to it being contact-based, there is a risk that the probe might be damaged or corroded. Within the oil and gas industry itself, level sensors have many different uses, from pure tank gauging to the separation of immiscible liquids. As such, the type of level sensor that should be employed depends very much on the specific application it is used for. Enquiry No. 4602 Turn to page 80a or log on to to enquire


Microwave Sensors Instead of using sound waves for level detection, an alternative sensor exists that uses electromagnetic pulses. Known as the microwave or radar sensor, this form of instrumentation retains the benefits of ultrasonic sensors without its pitfalls. For instance, it is impervious to temperature and vapour, and is therefore suitable for use in environments that are moist or warm. The use of electromagnetic energy has also enabled the use of these sensors in vacuums, as air molecules are not required. There are basically two types of microwave level sensors, the

first of which is non-invasive and measures distance based on the frequency of reflected signals, while the other is invasive and uses a probe to direct the microwave to the bottom of the vessel. The non-invasive method can be separated into the FrequencyModulated Continuous Wave (FMCW) type or the pulsed timeof-flight method. The former sends a linear sweep at a fixed bandwidth and time, and the frequencies of the reflected and transmitted signals are combined to form an accurate measure of liquid level. Pulsed timeof-flight works on a similar principle to ultrasonic sensors by measuring distance based on the time the pulse is reflected. Alternatively, the invasive method, otherwise known as guided-wave radar, is based on time-domain reflectometry. Hundreds of thousands of pulses

May-Jun 2013 asia pacific metalworking equipment news


Events& Exhibitions Event Review:

MTA 2013


ver 12,50 0 trade attendee s including trade visitors, exhibiting staff, conference delegates and speakers, and members of the press visited M TA 2 013 o v e r f o u r d a y s . Responding to the Singapore government’s urge to adopt a d v a n c e d te c h n o l o g y a n d complex machinery in order to improve productivity and capabilities, precision engineering and manufacturing sectors in Singapore are moving away from low value mass manufacturing and towards servicing high value industries that require complex equipment and machinery. Industry players need the latest technology and know-how to level up their capabilities to meet the demands of these industries. It is therefore not surprising to see a fair bit of new technology and launches at the show. 3D printing is one example. An emerging technology that has been earmarked by the government as the future of manufacturing, the technology is beginning to attract interest among local organisations. Toh Cher Lek, R&D Director of New Kinpo Group, who came to the show to source for 3D printer


asia pacific metalworking equipment news May-Jun 2013

suppliers commented: “MTA allowed me to find new 3D printing suppliers and vendors, and was a great platform for me to learn about the latest in 3D printing and also a new type of 3D printing — 3D metal printing. Exhibitors were reputable, professional and efficient in their dealings.” Generating Sales As the four-day event drew to a close, ‘Sold @ MTA’ signs proudly adorned many of the machines on display at the show floor. “We brought a mixture of grinding, turning and cutting machines to MTA2013. So far we have sold six out of seven machines to automation and precision engineering companies. A ltoget her we made ab out S$800,000 (US$647,000) in sales, we are extremely happy,” said Simon Teo, director of ST Machinery. Some other exhibitors who managed to secure business transactions at the show include Accrington Precision Machine Tools, A nhui Krras Machine Tools, DKSH Technology, EHN & Land, Flexspeed, Gustav Gockel M a s c h i ne n fa b r i k , H e x a g o n Metrology, Ichi Seiki, IM Machinery Asia, J-Tech Machinery, Makino, Mitutoyo, Newserv Machinery,

Pryor Marking, Rotec Singapore and Taipei Industries. Good Results Overall, William Lim, project director for machinery events at Singapore Exhibition Services, organiser of the show gave it a success rating of 8 out of 10, and full marks for the quality of visitors. This is because senior technical engineers from industry big wigs and key buyers such as Amtek Precision Technology, B e c ton D ick in son Me dic a l, Cameron, GE Aviation, Hamilton Sundstrand, Honda, PerkinElmer, Pratt and Whitney and SMB Switchgear & Engineering among many others were seen combing the show floor. W it h a se le c t ion o f 5 0 0 exhibitors from 31 countries and regions exhibiting their latest products, visitors to the show were in the prime position to expand their business networks and form business partnerships. The show will return from April 14 – 17, 2015 at Singapore Expo. Singapore Expo Singapore April 9 – 12, 2013 Enquiry No. 4701 Turn to page 80a or log on to to enquire


Hexagon Metrology: Coming Together As One

Unisig To Expand The Oil Tool Market In Singapore

Jeff Price Leong Kim Huat (L) & Lim Boon Choon ‘Exposure’ is the key word for Hexagon Metrology at MTA2013. According to Lim Boon Choon, VP of Hexagon Metrology Asia Pacific, it is important for a company that has numerous brands under its umbrella to be seen as a single entity. He said: “It is very important for our customers to see our new machines and to see us as one Hexagon. Many may know us from the days gone by as Leica or Brown & Sharpe but the branding is now Hexagon Metrology. As a company, we own all these technologies and companies.” He then went on to say that MTA is an important show for metrology and it is essential to be involved. New Technologies On Show The focus placed on this event has seen the company bring three new machines to the show. “We are displaying a number of machines over here for the first time. For example, one of them is our vision machine (Optiv Lite). We have a line of vision equipment that can be used for vision inspection,” he said. APMEN understands that the Optiv Lite is a vision measuring machine used for non-contact inspections accurate to the micron level. The camera based measurement machine can also switch to a contact mode for tactile measurement.

Another new product at the show is a shop floor CMM. Leong Kim Huat, GM of Hexagon Metrology Asia Pacific said: “The 4.5.4. SF CMM is one for the shop floor. It can operate in harsh environment as the temperature requirement is not as high.” The final new machine at MTA2013 is the Global Performance 3.4.3. According to Mr Leong, it is for minute parts that require high precision. He said: “The Global Performance 3.4.3. is a CNC CMM, which is suitable for electronic components that are small and precise.” In addition to the machines, the company is also featuring a measuring device with a twist as Firoz Khader, regional director for precision measurement instrument, Hexagon Metrology Asia Pacific explained: “This year, we are launching a product called the Twin-Cal (Tesa Wireless Interface Caliper) IP67 electronic caliper. It is a radical departure from the traditional connectivity solutions. The customer buys one product but with it, he has an evolutive solution as well. This is due to the fact that he is not only buying a system that allows him to do simple measurements; he buys an option as well. As such, he does not have to buy another product when he needs connectivity to send data some months down the road.”

Enquiry No. 4702 Turn to page 80a or log on to to enquire

Exhibiting for the first time at MTA is Unisig, a company that manufactures deep hole drilling systems. Jeff Price, VP, sales and marketing of Unisig, told APMEN in detail what his company is all about. He said: “We produce two types of machines. The B Series is used for the drilling of large diameter on-centre holes. They use BTA toolings like solid, trepanning and counter boring tools.” The other machines in use in the Singapore market now are used for drilling small diameter off centre holes with gun drill tooling. He said: “We have the USK and the USC series machines that are used for small diameter holes off centred up to 200 times the diameter of the depth in some cases.” Business In Singapore Mr Price revealed he was at the previous edition of MTA two years ago. It was then that the company decided to exhibit at the show, because they saw the market in Singapore becoming more oil & gas related and it was gradually moving from the traditional realm of electronics. The strong market for oil tool production in Singapore is an exciting prospect for the company and Mr Price expressed hopes to expand the oil tool market and help customers develop processes for deep hole drilling when required. In conclusion, he said: “We are excited about helping people be more competitive.”

Enquiry No. 4703 Turn to page 80a or log on to to enquire

May-Jun 2013 asia pacific metalworking equipment news



Improving Efficiency Through Measurements

Lenox Ready To Contest The Bandsaw Market

Erick Fantini On display for the first time in Singapore is Vici Vision’s MTL 300, an optical measuring machine for cylindrical parts like shafts. The machine is dedicated to the measurements of parts directly on the shop floor, said Erick Fantini, sales manager of Vici & C. Measuring par ts directly on the shop floor is a concept of measurement designed to optimise the production. This philosophy, as aptly pointed out by Mr Fantini, should not only focus on providing quality inspection, but also improve efficiency in production. He added that the machine is capable of inspecting roundness, run-out and cylindricity in addition to other static or geometric measurements. The data collected can later be used to set up a CNC lathe. The value in doing so, according to Mr Fantini, is to prevent rejections and downtimes during production. This is a pertinent point as far as he is concerned, because he noticed a trend of producing cheaper parts with higher quality. In terms of reliability, the machine has a step-master to constantly correct variations. The mechanical construction of the machine, according to Mr Fantini, also adds to its stability. He said: “The machine has one axis movement, so basically you don’t get the same trouble that you have while on the CMM. In addition, we have anti-vibrating feet and the exposure time of the camera is quite fast.”

Enquiry No. 4704 Turn to page 80a or log on to to enquire


asia pacific metalworking equipment news May-Jun 2013

Vincent Chai New at MTA2013 is the Contestor XL bi-metal band saw blade from Lenox. Featuring a high-speed steel on the edge tip according to Vincent Chai, sales manager (Bandsaw) Malaysia, Singapore & Vietnam of Lenox, the blade is said to be capable of longer life. “This bimetal bandsaw would be different from the M42 but equivalent to the M51 (grade). It is also hardened, has higher wear resistance and less susceptible to fatigue stress,” he said. Designed for large and difficult-to-cut metals like titanium and Inconel, the blade mostly targets the oil & gas industry. It is also suitable for the aerospace industry where again, the difficult-to-cut metals come into play. Mr Chai also revealed that the company carried out some tests and the blade fared well. “There is more than 30 percent increase in tool life when comparing with our top bi-metal series,” he said. Finally, he said

the Contestor XL will be available around the world in the beginning of June this year. Satisfied Exhibitor Mr Chai is one of many exhibitors that have commented on the quality of leads they received during the show. “I like MTA Singapore, most of the people that come in here are looking for specific things that are related to metal. Some 80 percent of visitors actually need something from here. In Singapore (MTA2013), I can find people from India, Indonesia, Middle East and Europe,” he said. Mr Chai’s glowing assessment of the show can probably be attributed to the number of enquiries he received, which stood at an excess of 50 (on the third day of the event). He also remarked that most enquiries were made by existing and potential users, and he is confident that his distributor is capable of providing a one stop solution for his customers in Singapore.

Enquiry No. 4705 Turn to page 80a or log on to to enquire

ƒ Supports ASEAN as a Manufacturing Hub ƒ The One and Only Show for Automotive Parts Manufacturing ƒ 4 Specialized Trade Exhibitions for Parts Makers

20- June 2013 23 BITEC, Bangkok Thailand

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Event Preview:

Manufacturing Expo 2013


anufacturing Expo 2013 will be back at BITEC, Bangkok from June 20 – 23, 2013. According to the organiser, manufacturing technologies from 1,500 brands and 22 countries will be presented at the show. The A SE A N Economic Community (AEC) is fast becoming a reality. ASEAN countries are adapting their laws and regulations for seamless integration and more than 70 percent of this work is already done. The world recognises AEC as a single market and the economic power of over 600 million people in one of the fastest developing region of the world. To this end, manufacturers in ASEAN are gearing up their plant processes to make their technologies world class and competitive, in order to emerge as regional leaders. Thailand has concentrated its energies into developing the automotive industry and the country is fast approaching the goal of becoming the world’s eighth 68

asia pacific metalworking equipment news May-Jun 2013

largest auto makers when annual vehicle production reaches 2.5 million vehicles. Auto production in 2013 is already predicted to reach 2.4 million vehicles and major brands are expanding production, to meet growing domestic and export demands. Various needs of Thailand’s and the region’s automotive industry like metal, non-metal parts, rubber parts, plastics parts, assembly technologies, electronics and others, are met by Manufacturing Expo 2013. This show brings the latest technologies to visitors who are ASEAN’s leading manufacturers, and subcontractors of components and parts for the automotive and electronics industries. Manufacturing Expo 2013 includes four U F I approved events: InterPlas 2013, InterMold 2013, Automotive Manufacturing 2013 and Assembly Technology 2013. In addition, four co-located shows: Industrial Components & Subcontracting, a sourcing hub for industrial parts; NEPCON Tha ila nd 2013, a n event on

assembly, measurement, and testing technologies for electronic ma nufacturing; Surface & Coatings 2013, a show on surface treatment, paints, and coatings; and Furnitech 2013, an exhibition for the furniture manufacturing industry provide the linkages among the various parts and supplies to enable industries to find all they will require within a single event. This year, the pavilions are la rger with more attractive displays. Leading is ‘Top of the Best’ Pavilion, which showcases mould making technologies from 10 leading brands. Manufacturers will be able to see — for the first time in ASEAN the latest technologies in high-speed milling, grinding, wire cutting, and multitasking turning among others. In addition, there are four other featured pavilions: Chemical & Raw Material Zone, organised for the first time, where global suppliers of chemical and raw materials in plastics production will present materials for manufacturers to choose; Material Handling, on material handling technologies, equipment and accessories; Factory Automation, on factory automation, electrical & power transmission technology; Industry Energy Efficiency, on energy efficiency management technologies for manufacturing industry. Complimentary activities such as the business matchmaking program, manufacturing gallery, automotive summit are designed to offer business visitors effective tools to expand their networks, and develop new businesses.

BITEC Bangkok, Thailand June 20 - 23, 2013 Enquiry No. 4706 Turn to page 80a or log on to to enquire

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Event Preview:

Manufacturing Surabaya 2013


anufacturing Surabaya 2013 has reached a milestone in integrating end to end manufacturing and production solutions, according to the show organiser. With over 300 participating companies from 23 countries, it is easy to see where this optimism comes from. Scheduled to be held from June 12 – 15, 2013, at the Grand City Exhibition and Convention Center, the show will showcase a range of exhibits supporting multiple industrial sectors.


asia pacific metalworking equipment news May-Jun 2013

Ma nufacturing solution providers such as A k yapak, Autonics, Eka Maju Mesinindo, First Machinery, Fusheng, Gunung Cendana, Hidroliksan, Hydrotech Machinery, Kawan Lama, DMG/ Mori Seiki, Multi Mayaka, Multi Pratama, Nord, Otano, Somagede and many more will take part. On the international front, two group pavilions from World Trade Center Ta ichung a nd Taiwan Association of Machinery Industry will present exhibits from automation & material handling to plastics & packaging,

tools & hardware, mould & die and machine tools. The notable pre sence of international exhibitors once again reinforce east Indonesia’s image as a major manufacturing centre with significant investments and developments. The event is fully supported by Ministry of Industry, Indonesian Mould & Die Industry Association (IMDIA), Indonesian Machine Tool Industries Association (ASIMPI), Indonesian Woven Polyolefin Ma nu fac tu rers A sso ciat ion (GIATPI), Indonesian Packaging Federation ( IPF ), Indonesian Automotive Parts & Component Industries Association (GIAMM) and Indonesian Precision Tooling Industry Association (AIPPINDO). “We are delighted with the strong support rendered towards the event from technology companies both locally and internationally. Manufacturing Surabaya recognises the integrated nature of manufacturing production across various sectors. With a diverse range of technologies and solutions, it serves to provide a convenient platform for manufacturers to identify effective solutions on their production needs,” said Maysia Stephanie, senior project manager, PT Pamerindo Indonesia, the organiser of the show. The exhibits on display at the show will range from machine tools and metalworking technologies to automation & control solutions, gas engines, marine equipment & services, oil & gas processing equipment, cutting & welding gear, test & measuring equipment as well as tooling. Together, they serve the marine & shipbuilding, electrics, power and oil & gas sectors. Grand City Exhibition and Convention Center Surabaya, Indonesia June 12 - 15, 2013 Enquiry No. 4707 Turn to page 80a or log on to to enquire



Event Preview:

MTA Vietnam 2013


TA V ie t n a m 2 013 w ill be held from July 2 – 5, 2013 at the Saigon Exhibition & Convention Center (SECC) in Ho Chi Minh City. Into its 11th edition, the event has proven to be the Vietnamese manufacturers’ procurement ground of choice, as manufacturers from Vietnam will be presented with the latest technologies and services in precision engineering, machine tools a nd meta lwork ing presently available in the global marketplace. Since its inception in 2005, the show has seen increasing and continued support from local and international manufacturers. Some of the key international brands are: Agie Charmilles, Amada, Bystronic, Carl Zeiss, Chin Fong, DMG/ Mori Sek i, Flow, Hexagon Metrology, Haas, Hurco, HwaCheon, Iscar, Mazak, Mitsubishi Electric, Mitutoyo, MST, OKK, Okamoto, Sodick, Studer and Trumpf. International Interest The event has also received strong support from international trade bodies and government agencies, leading to an increase in size of group pavilions this year. To date, there are 11 group pavilions from eight countries and regions. They include Germany, I t a l y, Ja p a n , S out h Kore a , Singapore, Taiwan, Thailand and the UK. Vietnam Manufacturing Climate Attenda nce at t he event has been steadily increasing, 72

asia pacific metalworking equipment news May-Jun 2013

reaching a record number 10,000 attendees in 2012. The sight of group delegations arriving in droves from notable companies are testament to the bright and promising outlook of Vietnam’s manufacturing landscape. A ro s y m ac ro - e co no m ic picture of single digit inflation, lower interest rates and a strong and stable local currency has resulted in imports growing by 10 percent and exports rising by 24 percent year-on-year in the first two months of 2013. The Vietnamese processing and manufacturing industry has also remained the most attractive for foreign investors. Foreign Direct Investment (FDI) into Vietnam’s manufacturing and processing sector has been rising in recent years, the percentage of FDI dedicated to projects in manufacturing and processing increased from 40 percent of the country’s total pledged FDI in 2010

to 48.5 percent in 2011 and 69.9 percent in 2012. The manufacturing industry in Vietnam has seen a shift from low value verticals such as textiles to more high-tech, high value manufacturing. The year 2012 saw international brand names such as Fuji Xerox, Samsung, Nokia and Intel investing more into their manufacturing facilities in Vietnam. In addition, the world largest mobile phone vibration motor manufacturer Nidec Seimitsu Corporation from Japan has built its first factory in Vietnam which was completed at the end of 2012.

SECC Ho Chi Minh City July 2 – 5, 2013 Enquiry No. 4708 Turn to page 80a or log on to to enquire


Event Preview:

JEC Asia H

sustained growth in the construction, aeronautics, automotive, windpower, oil & gas and EEE (electrical and electronic equipment) sectors in Asia over the next five years,” says Frédérique Mutel, JEC Group president and CEO. Japan In Focus The event this year will see Japan as the country of honour. The country’s advancements in the automotive sector will be placed in the limelight during the show. Some pertinent features of the Japanese composite industry are: - Ranked number one in Asia top 10 (excluding China)

- Carbon & Bio based Materials - Efficiency (Equipment & Process) - Aeronautics, - Automotive, - Marine, - Wind Energy, - Oil & Gas

- A n a n n u a l c o m p o s i t e s production of 523,000 tons - A fully integrated value chain - World-class level local players Suntec Centre Singapore June 25 – 27, 2013 Enquiry No. 4709 Turn to page 80a or log on to to enquire


appening between June 25 – 27, 2013, at the Suntec Centre Singapore, is JEC Asia. According to the show organiser, the JEC Group, the show is riding on the wave of growth in the composite market. Based on the survey carried out by the organiser, the Asian segment of the composites market has experienced high growth rates at around 6.9 percent per year since 2002 and should reach up to 50 percent of the global production of composites by 2015. “The market is increasingly in demand of advanced composites for a wide range of applications. We believe composites will see

Main Topics On JEC Asia 2013

May-Jun 2013 asia pacific metalworking equipment news



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Dassault Systèmes: Accelerating Time To Market Dassault Systèmes has developed an industry solution experience for high tech companies called HT body. Based o n t he comp a ny ’s 3DExperience platform, the solution helps electronics manufacturers accelerate the design and the delivery of high-quality and differentiated electronic devices. Focused on the enclosures and chassis that are the first and most obvious hallmark of electronic devices, the product captures consumers’ demands and enables differentiated product innovation to boost design creativity of electronics manufacturers and to keep them directly on target for a best-selling product. With the product, companies can quickly respond to external events, such as the way the public feels about a certain model or design and rapidly adapt their plans as needed.

May-Jun 2013 asia pacific metalworking equipment news


ProductFinder Esco Tool: Pipe Beveling Tools

Mitsui Seiki USA: Providing Precise Performance

A f u l l l i ne of pip e b evel i n g weldi n g e nd prep tools that combine rigidity with a wedgelock cutter head and blades that produce a thick chip without cutting oils is available from Esco Tool. Esco Millhog Pipe Beveling Tools pull a thick chip without cutting oils to promote weld integrity and faster fit-up by providing a precise end prep that is superior to hand grinding. Producing any angle of prep from 37.5 to 10 degree and compound bevels, these tools incorporate the EscoLock wedge-lock cutter head and proprietary blade featuring a radical chip breaker which gets under the material and directs heat away from the surface.

T he H U 6 3 E X hor i zonta l mach in ing ce nt re from Mitsui Seiki USA is engineered to boost metalworking productivity through a combination of precision, power, and torque. The 17,000 kg machine has a footprint of 2,900 mm x 3,180 mm, with X, Y and Z axes travels of 900 mm, 800 mm and 800 mm respectively. According to the manufacturer, the machine offers X, Y and Z axis positioning and repeatability accuracy of +/- 0.001 mm and B axis (rotating the 630 mm sq pallet) accuracy of +/- 2 sec with repeatability of +/- 1 second. In addition to precision, the machining centre also offers good power and torque.

Enquiry No. 4802

Turn to page 80a or log on to to enquire

igus: Combining Stability, Air-Tightness & Speed

Rofin: Next Generation Fibre Lasers

With the R4.1- Light product family, igus is presenting energy tubes developed for to o l i n g m a c h i n e s , which combine the most important requirements such as stability, air-tightness and speed of assembly. With the product, the compa ny ha s developed a solution which scores on the basis of its air-tightness despite its stability/weight ratio. The energy tubes of the product range provide chip protection and stability despite weighing 25 percent less than comparable types. The first version to hit the market is the R4.38L with an inside height of 38 mm. Further sizes, with 31 mm and 48 mm inside height, are to follow shortly. The manufacturer says the light energy chains offer one of the smoothest interiors energy tubes have ever had across all sizes.

Rofin has developed the FL 020, the first model from this series. Smaller, more compact and easier to use best describes the performance and design enhancements. The 2 kW fibre laser, that can be equipped with up to four fibre outputs, comes in a smaller, wall-mountable housing, with simultaneously improved fibre handling and with reduced water requirement. All fibre lasers from the FL Series are efficient and offer good beam qualities. Through the use of switchable optical fibres with diameters from 100 Îźm up to 800 Îźm, the beam quality can be precisely adapted to the processing task.

Enquiry No. 4803 Turn to page 80a or log on to to enquire


Enquiry No. 4804 Turn to page 80a or log on to to enquire

asia pacific metalworking equipment news May-Jun 2013

Enquiry No. 4805 Turn to page 80a or log on to to enquire




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May-Jun 2013 asia pacific metalworking equipment news


ProductFinder Siemens PLM: Reducing Airframe Design Processing Time

The Syncrofit 13 software by Siemens PLM now has a fastener layout and part sizing functionality. It helps airframe engineers reduce the time to generate fastener patterns, perform initial part sizing, validate designs and adapt to subsequent design changes by as much as 40 percent. This version eliminates the need for manufacturing engineers to manually verify if fasteners in an airframe structure are properly consumed according to plan and that the assembly meets design requirements. Another pertinent point of the software sees the expanded integration with Siemens’ Teamcenter portfolio. Enquiry No. 4806 Turn to page 80a or log on to to enquire

TaeguTec has expanded the Chase2Hepta family series of cutters with a right-handed, neutral and wiper inserts which will cover a range of applications. The sharp –ML geometries of the XNMU 0906 ANTRML insert with a full length helical cutting edge is suitable for milling steel under unstable machining conditions such as weak fixtures and clamping, long tool overhang and work pieces with weak cross-sections. The neutral insert, XNHU 0906 ANTN-ML, is suitable for cast iron machining in unstable machining conditions. For those looking for good surface finishing in milling applications, the company also introduced the XNHU 0906 ANTN-W wiper insert which has two right-handed and two left-handed cutting edges. Enquiry No. 4808 Turn to page 80a or log on to to enquire

Sutton Tools: Cutting In Harmony

Walter: Improving Tool Life With Colour

S u t t o n To o l s h a s de ve lop e d t he VA Harmony Endmill. It has been engineered specifically for milling s t a i n l e s s s te e l s a n d super alloys — such as austenitic grades 304 and 316, duplex grades, as well as inconels 718 and 725. The EndMill is aimed at companies producing equipment for the oil & gas, aerospace, food & beverage, medical and marine industries. According to the manufacturer, the Endmills are available in diameters from 6 to 20 mm. It features an ultra-fine micro-grade carbide base material, which offers the wear resistance for highperformance milling applications. The product also employs a Balzers Oerlikon Helica multi-layer coating, designed specifically to work with the characteristics of carbide tools.

Color Select, a cutting tool material from Walter, combines optimal service characteristics with simple wear detection. Field tests have shown that tool life has, on average, been increased by almost 100 percent. The improved microhardness and its toughness add to the cutting tool material’s increased performance. At the same time, the coating thickness is thinner than on the previous cutting tool material. Another feature is that the indexable inserts are coloured in standard ISO colours, which gave the cutting tool material its name. This means they are recognisable and the risk of a mix-up is reduced.

Enquiry No. 4807 Turn to page 80a or log on to to enquire


TaeguTec: Wider Cutting Range

asia pacific metalworking equipment news May-Jun 2013

Enquiry No. 4809 Turn to page 80a or log on to to enquire

Us it s

21 – 25 Metaltech 2013


BITEC Bangkok, Thailand UBM Asia

22 – 25 MTT 2013


PWTC Kuala Lumpur, Malaysia Tradelink

Us it s

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Jakarta International Expo Jakarta, Indonesia ECMI

Jakarta International Expo (JIExpo) Jakarta, Indonesia PT Wakeni



Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo


2–4 Aluminium China 2013 Shanghai New Int’l Expo Centre Shanghai, China Reed Exhibitions (China)

2–5 MTA Vietnam 2013

Us it s

SECC Ho Chi Minh City, Vietnam SES

Us it s

4–6 Vietnam Manufacturing Expo 2013

10 – 12 Metalex Vietnam 2013



Us it s

SECC Ho Chi Minh City, Vietnam Reed Tradex


23 – 25 Indo Automotive

12 – 15 Manufacturing Surabaya 2013

Suntec Centre Singapore JEC Group

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo

ICE Hanoi Hanoi, Vietnam Reed Tradex

November 13 – 15 Oil & Gas Indonesia 2013

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo

20 – 23 Metalex 2013


Us it s

25 – 27 JEC Asia

Us it s

4–7 Mining Indonesia

Us it s

BITEC Bangkok, Thailand Reed Tradex

December 4–7 Manufacturing Indonesia


16 – 19 Intermach 2013


BITEC Bangkok, Thailand UBM

Us it s

BITEC Bangkok, Thailand Reed Tradex Vi


Us it s


20 – 23 Manufacturing Expo 2013

BITEC Bangkok, Thailand UBM

16 – 19 Sheet Metal Asia 2013



16 – 18 Subcon Thailand 2013



Exhibition Programmes

Us it s

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo

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: • Tel: +65 63792888 May-Jun 2013 asia pacific metalworking equipment news


Advertising Index Page No.

Enquiry No.

Agathon AG



Benign Enterprise Co Ltd



Bystronic Pte Ltd



Carl Zeiss Pte Ltd



Dees Hydraulic Industries Co Ltd



Delcam PLC



DMG Asia Pacific Pte Ltd



EMO 2013



Fritz Studer AG



HAAS Automation Inc



Heimatec GmbH



IFM Electronics Pte Ltd






JEC Composites (JEC Asia 2013)



Kennametal Inc



Lico Machinery Co Ltd



LVD Company NV



Messe Dusseldorf Asia (Wire & Tube 2013)



Optical Gaging (S) Pte Ltd



PT NT Indonesia



PT Pamerindo Indonesia (Manufacturing Surabaya 2013)



Reed Tradex Company (Manufacturing Expo Thailand 2013)



Renishaw (Hong Kong) Ltd



Seco Tools (S.E.A) Pte Ltd



Singapore Exhibition Services Pte Ltd (MTA Vietnam 2013)



Sodick (Thailand) Co Ltd



Suhner Abrasive Expert AG



Sumitomo Electric Hardmetal Asia Pacific Pte Ltd



Taegutec Co



Taiwan Machine Builders and Accessory Buildersâ&#x20AC;&#x2122; Association (TMBA)



Taiwan Takisawa Technologies Co Ltd



Techtown Pte Ltd



The Grieve Corporation



Tungaloy Singapore (Pte) Ltd



Vision Wide Tech Co Ltd



Walter AG Singapore Pte Ltd



WIKUS Sagenfabrik Wilhelm H Kulmann GmbH & Co KG



Yih Chuan Machinery Co Ltd




Manufacturers and advertisers that are featured in this issue will send you free information about their products and services. Fill up the Product Enquiry Form on-line at

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asia pacific metalworking equipment news May-Jun 2013

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No. 4 2013

The Engineering Journal For Manufacturing,Automation & Quality Control

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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?

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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?

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❑ 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

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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

StuderTechnology –

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

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

DKSH Technology Pte Ltd 37, Jalan Pemimpin #02-04 Singapore 577177

DKSH Technology Co., Ltd. E-Town 2 Building 1st fl oor, 364 Cong Hoa Street, Ward 13 Tan Binh District, Ho Chi Minh City, Vietnam

DKSH (Thailand) Limited 30th Floor, Thanapoom Tower 1550 New Petchburi Road, Makkasan, Rachathewi Bangkok, Thailand 10400

DKSH Technology Sdn Bhd No. 14, Jalan Bersatu 13 / 4 46200 Petaling Jaya Malaysia

h City MTA Viet nam , Ho Chi Min 02. – 05.0 7.20 13 Hall A, Stand AE5 -3

Fritz Studer Ltd CH-3602 Thun Telephone +41-33-439 1111 Telefax +41-33-439 1112


The Art of Grinding.

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

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

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

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

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

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

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

APMEN May-June 2013  

Asia Pacific Metalworking Equipment News

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