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Making the Cut With Water get moving with mobile manufacturing Event Preview: Metalex 2012 October 2012

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ISCAR TAIWAN 395, TAIWAN Da Duen South Rd. ISCAR 395,Taichung Da Duen408 South Rd. Tel +886 Taichung 408(0)4 247 31573 +886 31530 Tel Fax +886 (0)4(0)4 247247 31573 Faxiscar.taiwan@msa.hinet.net +886 (0)4 247 31530 iscar.taiwan@msa.hinet.net

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ISCAR VIETNAM (Representative ISCAR VIETNAM Office) Room D 2.8, Etown (Representative Office)Building, 364 Cong TanBuilding, Binh Dist., Room D 2.8,Hoa, Etown HoCong Chi Minh 364 Hoa,City, Tan Binh Dist., 84 8City, 8123 519/20 HoTelChi +Minh 8 8123519/20 521 TelFax+ +84848 8123 iscarvn@hcm.fpt.vn Fax + 84 8 8123 521 iscarvn@hcm.fpt.vn

CV MULTI TEKNIK Ruko GsaTEKNIK Blcok B No. 8 CV MULTI BN-BP, City8 Ruko GsaPodomoro Blcok B No. JL.Letjen S.parman Kav.28 BN-BP, Podomoro City Jakarta Barat 11470 Indonesia JL.Letjen S.parman Kav.28 Tel +Barat 62 2111470 29206242/44/45/59 Jakarta Indonesia Fax + 62 21 29206243 Tel + 62 21 29206242/44/45/59 multi@centrin.net.id Fax + 62 21 29206243 multi@centrin.net.id

SINO TOOLING SYSTEM Blk 502, Jurong SYSTEM West SINO TOOLING Ave502, 1 #03-813 Blk Jurong West Singapore 640502 Ave 1 #03-813 Tel + 65640502 6566 7668 Singapore Fax ++65 656566 65677668 7336 Tel sinotool@singnet.com.sg Fax + 65 6567 7336 sinotool@singnet.com.sg

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ENQUIRY NO 065

www.secotools.com


Contents October 2012

CUTTING EDGE 26

Hardware & Software Solutions To Thread Turning Challenges There are hard and soft approaches to making an impact on threading success. By Don Halas, Seco Tools

32

Automotive Industry: Thread Carefully

Better threading technologies are now required for the automotive industry. Contributed by K Ravikumar, Komet Group

TECH TALK 34

Mobile ERP: Mobilising Your Competitive Advantage

The manufacturing industry must literally ‘get moving’ in order to compete in today’s ever mobile arena. By Craig Charlton, Epicor (Asia Pacific)

SOFTWARE & METROLOGY 38

Cloud Computing: The Future For Design & Manufacture? It is clear that the possibilities of mobile technology and Cloud computing are in their infancy. With a bit of creative thinking these technologies can make a difference in design and manufacturing. By Jeff Jaje, Sescoi USA

42

Why The Cloud Changes Everything

Design software programs for manufacturers can now leverage the Cloud’s flexibility to deliver better cost efficiency. By VR Srivatsan, Autodesk

46

CAD/CAM & Cloud: Anywhere, Anytime

Engineering and product design can happen anywhere in the emerging mobile world. By Bertrand Sicot, SolidWorks, Dassault Systèmes

SHEET METALWORKING 48

52

Doing things the unconventional way has served a water jet cutting job shop well. By Volker Albrecht, for Bystronic

Here are some eco and budget friendly tips for increasing waterjet productivity. By Nancy Lauseng, Jet Edge

Blasting Away Conventions

2

metalworking equipment news October 2012

Optimise Your Waterjet Cutting System

INDUSTRY FOCUS 56 Made-In-Japan: Monozukuri

Products made in Japan have spread far and wide. Companies have set up production bases in many countries, training the local labour force what is means to manufacture products the Japanese way. By Michael E Neumann


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Laser | Bending | Waterjet bystronic.com ENQUIRY NO 174

Bystronic iPhone + Android App

From 15 October we will be presenting our latest innovations‌ and much more.


Contents October 2012

58

Japan & Beyond

We take a look at the technologies and products coming out of Japan and how the country tries to engage Vietnam, one of the fastest growing economies in Southeast Asia. By Joson Ng

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.

EXecutive ZONE 62 Conveying The Right Message

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

Away from common themes in metalworking like ‘technology’ and ‘efficient manufacturing’, APMEN touches on the subtle art of marketing with the help from Iscar’s Hadas Zeira, marketing communications manager to see how it is gaining importance quickly with the rise of new media. By Joson Ng

IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE.

FEATURES 64

THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

Manufactured In Taichung

Making improvements to established technologies is one of the ingredients for success for many first generation Taiwanese machine tool and component makers. Today, these family-owned companies are venturing further beyond the shores of Taiwan, some with technologies and radical manufacturing concepts fully developed in-house. By Joson Ng

INDUSTRY Endorsements SPETA

Singapore Precision Engineering and Tooling Association (SPETA)

66

Federation of Asian Die & Mould Associations (FADMA)

To automate its manufacturing process for shredding rollers, HSM has installed a radio touch probe on a turning and milling centre. The radio technology ensures reliable data transmission, permitting a reduction in set-up and machining times. By Winfried Weiland, Blum-Novotest

Federation of Malaysian Foundry & Engineering Industry Associations

Shedding Away Machining & Set-Up Times

68

More Machine Tools Wanted In China

Demand for machine tools in China is to grow over 14 percent annually through 2014. By The Freedonia Group

Regulars

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

metalworking equipment news October 2012

EVENTS & EXHIBITION 70

• Event Preview: Metalex 2012 • Event Preview: Manufacturing Indonesia 2012 • Event Preview: Aerospace Exchange 2013

80

Refer to Advertising Index

pg

For Advertiser's Enquiry Numbers

Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

Taiwan Association of Machinery Industry (TAMI)


ENQUIRY NO 169


editor’s

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note

Published by:

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

Reg No: 199908196C

managing director Kenneth Tan editor Joson Ng

josonng@epl.com.sg

business development manager Randy Teo

randyteo@epl.com.sg

senior sales manager Derick Chia

derickchia@epl.com.sg

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

When the LCD monitor hit the market, it spelt the end for CRT. After a brief stay at the top, it was knocked off its perch by LED monitors. Nowadays, smart TVs are in vogue. This trend or the insatiable thirst for something new and improved, so salient in the consumer world, is also rumbling slowing in the background of the manufacturing world. The main reason for this movement from old to new is ironically mobility itself. Mobility in manufacturing is now thought to be the new norm; it is no longer something that offers a competitive edge. There is understandable inertia in the manufacturing industry where people tend to err on the side of caution. However, with mobile devices like smart phones and tablets penetrating all aspect of our lives, having mobility in manufacturing is no longer that difficult to imagine, even for those most rooted to the tradition ways. With this, new terms and policies began to emerge. Terms like BYOD or ‘Bring

Your Own Device’ for the more uninitiated is becoming common. It is a business strategy whereby employees bring their personally owned mobile devices to their place of work and use them to access privileged company resources such as email and various databases. Even as some struggle to cope with the new concept of mobility or BYOD, more concepts or technologies are waiting to pounce. Clouding the issue further, some may have heard the term ‘cloud’ more frequently in recent years. The proverbial fluffy white stuff manifests itself as a service that is delivered over a network (typically the Internet) in the manufacturing industry. Like the CD or DVD that took out the good old cassettes and video tapes, the wave of change cannot be stopped as we are all governed by market forces. As the saying goes, every cloud has a silver lining, and we wait with bated breath what that might be.

irenetow@epl.com.sg

contributors Don Halas Orly Dupont K Ravikumar Craig Charlton Jeff Jaje VR Srivatsan Bertrand Sicot Volker Albrecht Nancy Lauseng Michael E Neumann Hadas Zeira Winfried Weiland The Freedonia Group board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 098/06/2012 PPS 840/09/2012 (022818) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

chairman Stephen Tay group executive director Kenneth Tan

Joson Ng Editor

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

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

6

metalworking equipment news October 2012


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Walter AG Singapore 20 Science Park Road, #01-04A / 05, Teletech Park Singapore Science Park II, Singapore 117674 www.walter-tools.com www.youtube.com/waltertools www.facebook.com/waltertools

ENQUIRY NO 039


Business News

www.equipment-news.com

Walter Develops A Digital Tool Library

Tübingen, Ger ma ny: Under the name Walter e-Library, the Tübingen-based specialist in precision tools presents an app for the iPad. This app will help users to find the right tool for the application in question. The general catalogue (available i n 17 la n g u a ge s) ha s b e e n loaded into the digital library

followed by other catalogues and information material. The app is available now in Apple's App Store. The user can either view the media installed in the digital library online, or load it onto a dedicated ‘shelf’ within the e-Library app, and therefore also be able to view it offline as well.

The general catalogue in the Walter e-Library app presents many functions that make it easier for the user to search for the right tool and find useful information about it. For example, the user can navigate via a series of links from the table of contents directly to the required applications such as turning, drilling, threading or milling.

Fritz Studer Recognises Innovative Grinding Technologies

Fred Gaegauf, MD Fritz Studer AG, (right) hands the award to the winner Dr Josef Mayr

8

metalworking equipment news October 2012

Stuttgart, Germany: Studer has given out its Fritz Studer Award, a research prize at the AMB exhibition in Germany. With the theme ‘Assessment and compensation of the temperature sensitivity of machine tools’, Dr Josef Mayr from the ETH Zürich, Institut for machine tool and manufacturing (Switzerland), won the Fritz Studer Award 2011. The key aspects of Dr Mayr's research work form the basis for considering the temperature sensitivity of machine tools. He dealt with the measurement, assessment, calculation and compensation of the temperature sensitivity of machine tools. He also developed the Finite Difference Element Method (FDEM), a combination of the Finite Difference Method (FDM) and the Finite Element Method (FEM), during his dissertation. This method enables efficient calculation and evaluation of the thermal effects on machine tools. A notable feature is the possibility of evaluating shifts at the tool control point with reduced, small models, as a result of which the FDEM is also suitable for calculating compensation values. The applications of the award were received as early as the winter of 2011 and they were assessed by a jury. The decision criteria for assessment included, for example, the ease of implementing the findings in the machine industry, novelty and idea of the research work, scientific content, form and correctness of statements and results.


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businessnews

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Over 28,000 Aircraft Needed In The Next 20 Years: Airbus

Rui R, Portugal

Toulouse, France: Airbus’ latest Global Market Forecast (GMF) identifies a need for some 28,200 passenger and freighter aircraft (of 100 seats or more) between 2012 and 2031 worth nearly US$4.0 trillion, reconfirming an upward trend in the pace of new aircraft deliveries. Of these, over 27,350 will be passenger aircraft valued at US$3.7 trillion. Passenger traffic will grow at an average annual rate of 4.7 percent in the next 20 years, during which some 10,350 aircraft will be replaced by new efficient models. By 2031 the world’s passenger fleet will have expanded by 110 percent from slightly over 15,550 today to over

32,550. In the same period, the world’s freighter fleet will almost double from 1,600 to 3,000 aircraft. Emerging economic regions will represent more than half of all traffic growth in the next 20 years. Increasing urbanisation and the doubling of the world’s middle classes to five billion people is also driving growth. By 2031 mega cities will more than double to 92 and over 90 percent of the world’s traffic will be between or through these points. “Aside from growth in international traffic, by 2031 four of the world’s biggest traffic flows will all be domestic — US, China, Intra Western Europe and India — and these account for a third of world traffic,” says John Leahy, Airbus chief operating officer customers. “In 20 years from now, China’s domestic passenger traffic will overtake the US domestic traffic to become the number one traffic flow in our forecast. Aviation is not just essential for international commerce, but also for domestic economies too.” Asia Pacific will account for 35 percent of all new aircraft deliveries, followed by Europe and North America with 21 percent each. In value terms, the single biggest market is China followed by the US, UAE and India.

China Need Over 5,000 New Planes By 2031

Beijing, China: Boeing projects that China will need 5,260 new commercial airplanes valued at US$670 billion over the next 20 years. China is forecast to be the second largest market for new commercial airplanes. "It's impressive that over 75 percent of the demand in China will be for growth instead of replacement," said Randy Tinseth, Boeing Commercial 10

metalworking equipment news October 2012

A irpla ne s V P of Ma rketing. "Sustained strong economic growth, growing trade activities and increasing personal wealth are some of the driving forces." The company predicts that small and intermediate twinaisles, such as the Boeing 787 Dreamliner and 777, will account for a significant part of future deliveries. These airplanes are expected to be the highest value

segment, making up 48 percent of the market in value with some 1,190 new deliveries anticipated. "We expect Chinese carriers to experience rapid international expansion over the next 20 years, with an annual increase rate of 8.9 percent on average. That's not only because the market demand is growing, but because Chinese carriers now have the capability and resources to compete in the tough long-haul international market," Mr Tinseth added. Tourism in China will also help fuel a strong demand for singleaisle aircraft, with total deliveries of single-aisle airplanes reaching 3,650 through 2031. Mr Tinseth said the 737 Max family will allow the company to continue to deliver fuel-efficient, capable airplane with the lowest operating costs in the single-aisle market. Worldw ide, the compa ny projects investments of US$4.5 trillion for 34,000 new commercial airplanes to be delivered during the next 20 years.


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 6 Helical cutting edges for 90 degree cutting  Dovetail mechanism clamping provides increased security and insert clamping  Internal coolant supply

304 Yonggye 4-ri, Gachang-myeon, Dalseong-gun, Daegu 711-864, KOREA Tel: +82-53-760-7640 Fax: +82-53-768-8055 http://www.taegutec.com Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Egypt _ Finland France _ Germany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Malaysia _ The Netherlands _ New Zealand Norway _ Pakistan _ Philippines _ Poland _ Portugal _ Romania _ Russia _ Serbia _ Singapore _ Slovakia _ Slovenia _ South Africa Spain _ Sweden _ Taiwan _ Thailand _ Turkey _ Ukraine _ United Arab Emirates _ United Kingdom _ U.S.A _ Vietnam

ENQUIRY NO 171

TaeguTec Ltd. World Headquarters


businessnews

LiuGong & ZF In JV Liuzhou, China: ZF and the construction equipment manufacturer LiuGong intensify their cooperation by building a joint venture. The company will produce wheel loader axles that are tailored for the requirements of the Chinese market. In the long run, approximately 190 employees will be working at Liuzhou Axle and more than 30,000 of the newly designed axles will be delivered to the joint venture partner LiuGong and the third market. “Our cooperation with LiuGong strongly shows the ‘Design to Market’ strateg y which has been consistently followed by ZF, especially in the field of OffHighway Systems,” says Wilhelm Rehm, member of the Board of ZF. “Together with our partner LiuGong, we have developed a product which exactly matches the requirements of the Chinese market,” concludes Mr Rehm. The joint venture will strengthen ZF’s activities in China. “During the past years, the country has experienced a rapid development of construction machinery,” explains Dr Stefan Sommer, CEO of ZF. “More than half of the worldwide wheel loaders are produced in China. A considerable amount of machines are also being exported abroad from there. The impressive export rate, in particular, represents a big challenge since it frequently leads to market fluctuations. With the new joint venture company, ZF will continue its growth in China,” says Dr Sommer.

Delcam Adds 40,000th Customer

Birmingham, UK: Delcam has added its 40,000th customer — Lifetime Products. “Lifetime Products is a manufacturer, with products sold in more than 70 countries,” said Delcam North America president, Glenn McMinn. 12

metalworking equipment news October 2012

www.equipment-news.com

Solid Edge ST5 Unveiled In Singapore

Singapore: Engineering Computer Services (ECS) has unveiled the Solid Edge ST5 software in Singapore at Bugis+ on August 23, 2012. Speaking at the opening ceremony, Victor Chia, president of the ECS said: “Most of us have to do more, all of us have to churn out two to three times the volume of work we used to do within the same seven or eight hours. So essentially, I think tools make a very important companion to productivity. Having not only the right tool, but the ability to adapt to the tool, will make it work for you.” Synchronous technology is one such tool that has become increasingly relevant in the current economic climate. According to Mr Chia, most companies are now improving and innovating on existing products rather than coming up with an entirely new product. As such, Siemens PLM has introduced an upgraded version of the software. As a show of commitment to its customers, the company has plans to launch an improved version each year. In this fifth installment, the software is equipped with 1,300 productivity enhancements and comprises additional and improved features such as the solution manager, multiple design bodies, symmetric dimension edit, slot feature, hole placement improvements and recognition, assembly relationship enhancements, multi-body support, as well as thermal studies among others.


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businessnews

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APEC Region Trade Still Outperforms World

Vladivostok, Russia: Trade in the APEC region continues to outperform the rest of the world, weathering global economic uncertainty, according to new APEC Policy Support Unit (PSU) research that was presented to APEC Ministers during their meeting in Vladivostok. Growth in the nominal USD value of merchandise trade for APEC economies moderated to 4.6 percent in May 2012, down from 12.1 percent growth in December 2011 due to weak global economic activity and deflated traded good prices. But it was enough to remain at the top of the heap, by comparison. The rest of the world contracted by 5.6 percent in May 2012. “Though trade performance varied across the region in the first half of 2012, due to weak global demand and sharp falls in commodity prices, APEC members’ economic growth has been fairly robust and resilient,” said PSU director, Dr Denis Hew. “Foreign direct investment across APEC economies is also encouraging,” he added. As a whole, the region accounted for nearly half of the growth of global FDI inflows in 2011. Economic activity in the APEC region is expected to

remain relatively robust in the medium-term, despite trimmed growth forecasts caused by increased uncertainty abroad. Based on International Monetary Fund data, member economies’ real GDP growth is on pace to accelerate from 4.1 percent in 2011 to 4.2 percent in 2012 and 4.5 percent in 2013, keeping ahead of the rest of the world. APEC members’ economic growth and their trade and investment flows could be significantly impacted by downside risks related to the external environment. However, there are steps that can be taken to help mitigate the risks, the report suggests. Proposed steps, supported by the business community, include reiterating the pledge to maintain free and open markets, and renewing the pledge to withdraw existing restrictive measures and resist new protectionist measures to bolster the global economic recovery process. “APEC should also continue to monitor trade and investment measures by member economies,” Dr Hew said, building on the commitment made by ministers in Singapore in 2009.

SKF Breaks Ground On Northeast Asian Distribution Centre Gothenburg, Sweden: SKF broke ground on a regional distribution centre located in the WaiGaoQiao Free Trade Zone in the northeast part of Shanghai. The centre will support the entire Northeast Asia Pacific region and joins the 14

metalworking equipment news October 2012

global network of SKF regional distribution centres already located in North America, Latin A merica, Europe, a nd A sia. This centre will be the first SKF warehouse built according to the LEED Gold building certification.

The distribution centre is a fully automated warehouse with a 30 m high automatic storing and retrieval system and will be fully operational in 2013. The total investment will be around SEK 100 million (US$15.2 million).


businessnews

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Singapore Growing As A Manufacturing Hub

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ENQUIRY NO 103

Singapore: The 19th edition of MTA, to be held from April 9 – 12, 2013, will see trade professionals hailing from all facets of Asia’s diverse manufacturing sectors converging on one platform. In tandem with industry’s progress and demands, the show will be focusing on three core vertical sectors — aerospace, medical technology and oil & gas. Market numbers obtained from the Economic Development Board of Singapore are testaments to Singapore’s rising prominence as Asia’s key manufacturing hub. The medical technology segment grew by 14.5 percent in July 2012 as compared to the previous year; higher output from rig building and ship building activities lifted the marine & offshore engineering segment to a gain of 5.9 percent; and the aerospace segment rose seven percent from a year ago with higher demand for engine manufacturing and repair jobs. With rising need for equipment and technological capabilities for highly demanding manufacturing environments, the show will offer industry buyers a selection of products and solutions specifically fashioned for these sectors.

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October 2012 metalworking equipment news

15


Meet Tight Delivery Times Now more than ever, increase cutting conditions and enhance machining efficiency! If you have needs like these , Okuma’s intelligent technologies can help! We’re not happy with our current cutting conditions and want to improve them, but... We don’t know how far we can increase spindle speeds. We start getting chatter and feel anxious about the results We’re working with material we’ve never machined before, but... We don’t know the best spindle speeds...

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

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

Machining Navi M-i (Intelligence) Machining Navi automatically switches the spindle speed to the optimal setting. In other words, the system measures the vibration and calculates the optimal spindle speed, automatically integrating the process of modifying spindle speed commands.

Machining Navi Garners 4 Awards

Machining Navi productivity improvement technology acclaimed in various countries 2011 Japan Society of Die/Mold Technology (Incentive Award)

Awarded to outstanding papers presented at the die engineers meeting and die technology workshop.

2010 Japan Society of Mechanical Engineers Medal (Technology)

presented by JSME to encourage further advancements in Japanese mechanical engineering and industry.

2010 MM] Award (Germany)

Given by leading German technical journal Maschinemarket for innovative products and technologies.

2011 Innovation Award (France)

presented to innovative products reviewed by prominent French technical journals.


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Honda Develops Technology To Weld Steel To Aluminium Front subframe

Conceptual diagram of FSW of dissimilar metals

Tokyo, Japan: Honda Motor has announced that it has developed a technology for the continuous welding of the dissimilar metals of steel and aluminium and applied it for the first time in the world to the subframe of a mass-production vehicle, a key component of a vehicle body frame. The company will adopt this technology first to the North American version of the 2013 Accord and will expand application sequentially to other models. Striving to reduce vehicle weight in order to increase fuel economy, the company focused on Friction Stir Welding (FSW) and developed a technology for the continuous

welding of steel and aluminium. This technology generates a new and stable metallic bonding between steel and aluminium by moving a rotating tool on the top of the aluminium which is lapped over the steel with high pressure. As a result, the welding strength becomes equal to or beyond conventional Metal Inert Gas (MIG) welding*1. This technology contributes to an improvement in fuel economy by reducing body weight by 25 percent compared to a conventional steel subframe. In addition, electricity consumption during the welding process is reduced by approximately 50 percent. It also enabled a change in the structure of the subframe and

the mounting point of suspension, which increased the rigidity of the mounting point by 20 percent and also contributed to the vehicle’s dynamic performance. Furthermore, the company established a method to apply this technology to mass-production vehicles. Conventionally, FSW required use of large equipment, but Honda developed a FSW continuous welding system applied to an industrial robot. This system also can be used for aluminium-to-aluminium welding and as a result, the welding system with the same specifications can be used for production of a fullaluminium subframe. The company also developed a non-destructive inspection system*2 using an infrared camera and laser beam, which enables an in-line inspection of the bonding location for every unit. *1 A welding technique most commonly used for welding of identical materials such as steel-to-steel or aluminiumto-aluminium *2 A system that evaluates quality without actually destructing the parts

Hyundai Eyes Chinese Commercial Vehicle Market Seoul, South Korea: Hyundai Motor Company held a groundbreaking ceremony at its Chinese commercial vehicle joint venture, Sichuan Hyundai Motor Company (Sichuan Hyundai), in Ziyang City, Sichuan Province. “Sichuan Province is at the centre of the nation’s program to develop China’s western regions, and the auto industry — mainly driven by commercial vehicle makers — is expected to grow dramatically in the region.” said Jiang Jufeng, governor of Sichuan Province. “By building a new plant in the region, Sichuan Hyundai bypasses its competitors and quickly becomes a leading commercial vehicle manufacturer in China.” The company is a 50-50 joint venture between Hyundai Motor Company and China’s Sichuan Nanjun Automobile Group (Nanjun Auto), with an investment of around CNY3.6 billion (US$569 million). The plant is scheduled to be completed by the first half of 2014 with an annual capacity of 150,000 units. Equipped with full-cycle production facilities of press, welding, painting, assembly as well as an engine plant, the plant will produce China-exclusive 18

metalworking equipment news October 2012

truck models. The plant is designed to flexibly expand its capacity up to 300,000 units according to market demands. Sichuan Hyundai plans to produce buses initially at Nanjun Auto’s existing production plant after adding and improving production facilities, and aims to increase bus sales with new models in the future. By 2014, the company will roll out a total of 160,000 units (150,000 trucks, 10,000 buses) to become a major commercial vehicle automaker in China. China is the world’s biggest commercial vehicle market, with 4.03 million units (3.54 million trucks, 490,000 buses) sold in 2011, a figure that is expected to grow to 4.71 million units by 2017. With the establishment of Sichuan Hyundai to operate the entire process from production to sales, Hyundai will continue to strengthen its efforts to become a leader in the promising market. Through establishing a full commercial vehicle lineup, expanding facility investment and introducing new models, the company plans to sell 170,000 units to raise its market share to 3.6 percent by 2017.


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A Successful H1 For Gildemeister Bielefeld, Germany: Gildemeister has increased order intake, sales revenues and income. Order intake rose at the end of the first six months to €1,188.4 million (US$1,540 million) (+22 percent; previous year: €971.6 million). Sales revenues reached €916.8 million (+18 percent; previous year: €774.6 million); the order backlog surpassed the billion mark. EBITDA amounted to €64.7 million (previous year: €47.6 million), EBIT reached €45.4 million (previous year: €32.5 million) and EBT rose to €38.2 million (previous year: €2.1 million). As at June 30, 2012, the group reports earnings after taxes of €26.2 million (previous year: €1.5 million). Future business performance will become more volatile. Order intake in the third quarter will be more restrained due to seasonal factors. In the second half of the year, the company predicts good performance. The boost is expected to come from the international autumn trade fairs starting in September — the IMTS in Chicago, the AMB in Stuttgart, the BIMU in Milan and the JIMTOF in Tokyo. The Asian markets, America and the Eastern European markets are developing positively. Willingness to invest is continuing to decline in the Southern European markets as a consequence of the euro debt crisis. Q2 Results Sales revenues in the second quarter reached €465.0 million (previous year: €397.2 million). Domestic sales revenues incre a sed by 35 percent to €36 8.1 million; t he g roup’s international sales revenues rose by nine percent to €5 4 8 .7 m illion. T he e x p or t share amounted to 60 percent (previous year: 65 percent). Order intake rose in the second quarter by 11 percent to €583.3 20

metalworking equipment news October 2012

million (previous year: €525.7 million). In the first half year order intake amounted to €1,188.4 million (+ 22 percent); it was €216.8 million higher than the previous year‘s period. Domestic orders rose overall by five percent to €396.5 million (previous year: €376.8 million). International orders grew by 33 percent to €791.9 million (previous year: €594.8 million). On June 30, 2012, the order backlog within the group amounted to €1,079.9 million (+40 percent on the previous year’s date). The company was also able to improve its results of operations in the second quarter. EBITDA rose to €36.1 million (previous year: €29.7 million), EBIT reached €26.6 million (previous year: €22.1 million) and EBT rose to €23.2 million (previous year: €1.6 million).

Automotive

GM China’s SAICGM-Wuling JV Sells 1 Millionth Vehicle

Shanghai, China: SAIC-GM-Wuling (SGMW) sold its 1 millionth vehicle this year in China for the fourth consecutive year. It is the earliest the General Motors China joint venture has reached the milestone. In 2011, SGMW sold its 1 millionth vehicle in October. Through the first eight months of 2012, SGMW sold an average of 3,500 vehicles every day, up 15.2 percent from the same period in 2011. The joint venture was established in 2002 by GM China, SAIC and Wuling Motors. It has been actively expanding its commercial and passenger vehicle portfolio while boosting its overseas business.


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Yamazaki Mazak To Expand Its Operations In Singapore

Singapore: Yamazaki Mazak (Singapore) held a groundbreaking ceremony on July 30, 2012 as part of the company’s fifth expansion plan, which includes an extension of the existing production plant, in addition to the setting up of a technology centre. Speaking at the ceremony, Norihiko Shimizu, VP of Yamazaki Ma zak Corp said: “These investments are proof of our strong belief that the manufacturing industry has a bright future either in advanced manufacturing countries or in emerging regions.”

Upon its completion in December 2013, production capacity at the plant will be enhanced by 60 percent to a total of 130 units per month, which includes CNC lathes and vertical machining centres. At the same time, the technology centre is poised to be four times larger than the present centre at 1,249 sq m and will be equipped with multi-tasking machines. Primed to aid the oil and gas, semiconductors, aerospace and medical technology sectors, the centre aims to further the development of metal cutting processes.

According to Chang Chin Na m, director of Precision E ng ine er ing at Singap ore’s Economic Development Board, the manufacturing industry in Singapore is evolving with a greater focus on advanced manufacturing and re-manufacturing. Riding on the rise of Asia, the country’s manufacturing output grew by 7.6 percent in 2011 and contributed to 20.9 percent of the total GDP, said Mr Chang. Further citing the Precision Engineering (PE) sector as the backbone of the manufacturing industry, he revealed that PE output grew by 14.6 percent to S$27 billion (US$22 billion) and generated S$7 billion in added value for the industry, which was in part supported by an environment conducive to manufacturing. “The expansion of Yamazaki Mazak Corp in Singapore will therefore be expanding our manufacturing ecosystem further,” said Mr Chang, who stressed on the benefits of having a good manufacturing foundation as Singapore engages in the design and manufacture of high mix low volume equipment, and the production and supply of technology-intensive PE components.

Sutton Tools Enters North American Cutting Tool Market US: Sutton Tools and CIMtek LLC have used IMTS 2012 to launch the cutting tool manufacturer’s e n t r é e i n to t h e N o r t h A m e r i c a n c u t t i n g tool market. Globally, Sutton Tools has been competing for over 20 years, with a presence in Australia, Asia, and the European markets. With this launch into the North American market, the company has fully integrated global logistics, with inside sales, technical support, and warehouse operations in Cheboygan, Michigan. Concurrently, in the US, the manufacturer has formed a strategic partnership with their North American sales partner CIMtek LLC, assuring field sales and application support throughout the entire US. 22

metalworking equipment news October 2012


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Kyocera To Establish Manufacturing Plant In India Kyoto, Japan: Kyocera Corp will start construction of the Kyocera Group's first ma nu fac tu r ing pla nt in India — aiming to further strengthen the company's i n du s t r i a l c u t t i n g to o l business. On September 3, a groundbreaking ceremony was held in Jamshedpur, Jharkhand, India for the building which will house the new manufacturing company, Kyocera CTC Precision Tools*1. “Today, we are conducting the groundbreaking ceremony with plans to complete the plant in June of next year in order to further expand our business and allow more customers to use our industrial cutting tools,” stated Kyocera Corp president Tetsuo Kuba during a speech given at the groundbreaking ceremony. In India, the market for automotive and general industrial machinery is rapidly expanding, with fundamental growth also seen in infrastructure-related industries including energy, railway and road construction. Based on these circumstances, it is expected that the market for industrial cutting tools will continue to grow at an average of 10 percent annually — which is the highest level out of all the newly developing countries. Moreover, with the foray of more automotive manufacturers into India, price competition is intensifying, leading to a priority for purchasing domestically made products. The company currently operates sales offices in four cities in India including Gurgaon, Chennai, Bengaluru (Bangalore) and Pune. Furthermore, in June of this year, the company also established a technical centre for cutting tools in Gurgaon to support the needs of local customers by providing a technical support system. With the establishment of a three -pillared structure for manufacturing, sales and technical support in the growing Indian market, the company aims to expand sales of cutting tools in India to JPY7 billion (US$89 million) annually within five years*2 . *1 Kyocera CTC Precision Tools was established through a joint venture by Kyocera Corp's wholly-owned subsidiary dedicated to sales in the Asia-Pacific region, Kyocera Asia Pacific, and industrial cutting tool manufacturer, CTC (India). *2 Sales of industrial cutting tools in India only.

Tüv Süd Disseminates Information On Testing & Inspection Singapore: Tüv Süd held a Tüv Süd PSB Testing, Inspection and Certification Conference 2012 on September 13, 2012 to disseminate latest information regarding testing and inspection procedures. Ta k i n g t h e f o r m o f a du a l - t rac k co n fe re nce , t he conference discusses various topics related to two industries, namely the healthcare and rail transport industry. Over at the rail transportation track, Sundar Thirunavukkarasu, principal c o n s u l t a n t , R a i l We l d i n g Services of Tüv Süd PSB spoke about the various defects that can be found on rail welds. He then talked about the NDT methods like ultrasonic testing, ma g ne t ic pa r t icle te st a nd radiography that are available to detect the defects. Although as a whole, they can detect planar, surface and volumetric defects, they have limitations when used indiv idua lly. He then introduced the phased array ultrasonic test that can be used to discover planar and volumetric flaws.

Manufacturing Technology Orders Slowed In July: AMT U S : Ju ly U S ma nu fac t u r i n g te c h nolog y orde rs tota l le d US$449.69 million according to AMT — The Association For Ma nu fac tu r ing Te ch nolog y. T h i s to t a l , a s re p o r te d by compa nie s pa r t icipat ing in the USMTO prog ra m, wa s down 2.3 percent from June and down 10.5 percent when compa red w ith the tota l of 24

metalworking equipment news October 2012

US$502.33 million reported for July 2011. With a year-to-date total of US$3,132.23 million, 2012 is up 5.4 percent compared with 2011. “It is typical for orders to slow during July and August. That slowdown is even more pronounced in summers ahead o f I M T S (t he I nte r n a t io n a l M a nu fac t u r i n g Te c h no lo g y

S h o w) a s m a n u f a c t u r e r s attending the show wait to take their manufacturing technology ‘shopping lists’ with them to C h i c a g o ,” s a i d D o u g l a s K . Woods, AMT President. “ W it h m o re t h a n 9 0,0 0 0 registrants for IMTS this year, we fully expect order activity to come back strong in the months after the show.”


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Cutting

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Edge

Hardware & Software

Solutions

To Thread Turning Challenges

There are hard and soft approaches to making an impact on threading success. By Don Halas, manager of threading products, Seco Tools

T

h re a d i n g b e c o m e s a critical operation when you consider that more often than not it takes place at the end of the machining process. So, the component that has undergone so many other operations is now very near the end, and thereby relatively expensive. Mistakes at this stage of manufacturing are costly, both in time and money. Important considerations for those involved in thread turning are quality of the thread, chip control, tool life and getting parts out the door. But, the ultimate test is simply that the gauge goes on the component. Everything else can be a given, but if the gauge does not go on, then you are starting over. Gauging, in many cases, can be done right on 26

metalworking equipment news October 2012

the machine and is the physical proof that the threadform is correct. To get quality threads, proper chip control and long tool life requires operator skill, advanced tooling and application expertise. As with anything, variations and slight deficiencies in any of these areas can have a rather dramatic effect on overall productivity. To that point, recent innovations in both tooling and programming are offering manufacturers real advantages and are removing some of the more long-standing challenges to consistent thread turning. Direct Press Inserts Indexable tooling has long been adopted for a range of thread turning and offers basic advantages of productivity and

economy. Carbide inserts have multiple cutting edges and can be ground for optimum edge preparation to provide the best chip control for various threadforms and materials, especially impor tant when machining softer stainless steels. To make an insert with precision ground edges, it requires a secondary operation that increases the cost to produce the insert for the cutting tool manufacturer. Until recently, this was the norm. Continuous advancements in cutting tool manufacture, however, have given way to new technologies like direct press inserts. Direct press inserts are just that, a complex shape and precision edge that is produced as the insert is pressed and sintered. The threadform identification can also be permanently marked on the insert to prevent any confusion that sometimes happens, with disastrous results, on the shop floor. The carbide substrate is then coated through methods like Physical Vapour Deposition (PVD) with layers of (Ti, Al) N and TiN to provide long and predictable life. The result is two-fold: no further need to grind the insert’s cutting edge, and less expensive to produce — a cost advantage of roughly 20 percent that is passed onto the user. As for the concept of complex shapes, it is now possible for a cutting tool manufacturer to produce such a highly-engineered cutting edge and chipbreaker that users can machine more with fewer inserts. In fact, as little as three insert styles (chipbreakers) can cover 80 percent or more of all thread turning in steel and stainless steel materials. Holding It Together Tooling innovations do not stop there. A ver y common problem that has been hard to determine lies not with the insert, but with the toolholder.


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Hexagon Measurement Technologies Sdn. Bhd Tel: +603 5632 8900 Fax: +603 5632 8955 contact.my@hexagonmetrology.com

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

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Thailand

Hexagon Metrology (Thailand) Ltd. Tel: +66 2361 3695 to 9 Fax: +66 2746 9607 contact.th@hexagonmetrology.com

Vietnam

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

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


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Figure 1: Modified flank infeed - for CNC and conventional machines

Figure 2: Flank infeed - for CNC and conventional machines. Choose flank infeed when modified flank infeed cannot be used

In cases where the gauge just would not go on properly at the end of the operation, and insert wear appeared to be normal, application experts began looking at the holder. They found that over time the holder could become compromised enough that the insert would begin to rock slightly in the pocket and cause the threadform to go out of tolerance. This was especially true in coarser pitch operations where cutting forces were relatively high. To combat this, a new style holder has been engineered that features two key advancements, a carbide pin in the back of the pocket and a strong D-style clamp. The resulting combination is that the insert is held more tightly in the pocket. Together, this design ensures rigid insert holding, minimised vibration and predictable thread turning performance. Understanding The Variables Perhaps the biggest of all challenges

for repeatable, quality thread turning, is not tooling-related, but programming. Although many machine tool controllers have canned threading cycles built in, they are based on machining for the masses and oftentimes do not represent the best methodology for the numerous threadforms and pitches. Every detail, including material and treatment, has to be considered when establishing the best machining parameters. Having said that, there are four variables to understand and determine in order to get the most from your operations. They are helix angle, anvil, infeed method and number of passes. The helix is basically (making) a spiral on the workpiece. The proportion between diameter and pitch gives the helix angle. The anvil is a separate seat underneath the insert that protects it and sets the angle (side-to-side) from zero to five degrees. This is what helps tilt the insert to chase Threading becomes a critical operation when you consider that more often than not it takes place at the end of the machining process.

28

metalworking equipment news October 2012

the thread and prevents rubbing on one side and cutting on the other. A one-degree anvil is the most common choice and represents as much as 80 percent of all threading applications. But, coarser pitches may require up to three degrees or more to achieve the correct (constant) cutting pressure. When the proper chip load is achieved, users can expect 30 percent increases in tool life and better thread quality. Conversely, incorrect anvil selection will result in the improper cutting forces, leading to more rapid insert wear and threads that may not match the gauge at the end of the day. Infeed method is basically how the insert addresses the workpiece as it enters the cut. Depending on whether your machine is a CNC or conventional, there are four infeed methods: radial, flank, alternate flank and modified flank (see figures 1 - 4). The most consistently productive and reliable choice is modified infeed as it does the best job of maintaining constant chipload on both sides of the thread during the cut. Determining the proper infeed method can improve tool life by 30 to 50 percent especially when threading high-temperature alloys. The last of the four big issues is number of passes. It speaks for itself, but if improperly calculated, will result in the rubbing of insert cutting edge and compromises thread quality. There are numerous tables of information regarding the proper selection of number of passes based on pitch, threadform


CuttingEdge

Figure 3: Radial infeed - for conventional machines and multi-tooth inserts

Figure 4: Alternative flank infeed - for CNC machines

and material. This can become daunting, so the important issue to understand is that the infeed depth will vary as the machining progresses from pass to pass in order to, once again, maintain the proper chipload. These four variables are complex as they interrelate. To properly determine them can be challenging, especially for newer inexperienced operators, but doing so will have the largest impact on threading success.

Balancing The Need For Price & Quality To remove the guesswork, and to greatly simplify the programming process, there are now software packages provided by cutting tool manufacturers that bypass many phases of the CNC canned cycle to most accurately determine all of these variables. The resultant program can then be directly loaded to your machine tool CNC, and a new level of thread turning confidence can be achieved.

A d d i t i o n a l l y, t w o g o a l s of thread turning that seem d i a m e t r i c a l l y o p p o s e d a re currently being pursued — price and quality. On one hand is the constant pressure to be price competitive by controlling costs as much as possible. In short threading production runs of var ying pitches, many shops are looking to partial profile inserts. With this type of insert, operators can produce multiple pitches with the same insert and simplify (or reduce) stocking requirements. To accomplish this, the nose radius of the insert is sized to suit the smallest profile within the range. The operator then varies the infeed depth and the helix to produce the desired thread. To do this and meet the quality needs of the customer often require a fairly experienced and skilled operator.

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October 2012 metalworking equipment news

29


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When circumstances are different, such as larger production volumes and operators of varying skill levels, it is recommended that full topping inserts are used. With a full profile insert, only one tool is needed to produce the entire thread, including the proper radius on the thread itself and no deburring is required (see figures 5 and 6). On the other hand, the customer-driven need for higher quality threads (smaller tolerances) will likely force manufacturers to continue to improve their performance. In most cases, if all parameters are properly identified and executed upon, manufacturers can expect to achieve a class three fit with the high quality cutting tools. Currently, roughly 30 to 40 percent are holding this tolerance, with two industries leading the way — military (and commercial) aircraft with UNJ threadforms, and oil field with large ACME threadforms. In both cases the need for very tight tolerances is Figure 5: Full profile — By topping the thread, the workpiece need not be premachined to the exact diameter and may be a little oversized. The threading operation is simplified since only one tool is needed for the entire thread (no subsequent deburring is needed).

Figure 6: Partial profile — Covers a wide range of thread pitches, which simplifies stock-keeping. Requires a correct workpiece diameter prior to threading. The nose radius of the insert is sized to suit the smallest profile within the pitch range of the insert.

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metalworking equipment news October 2012

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Oil-Drilling Industry: New Twist On Threading By Orly Dupont, international application engineer for Seco Tools & Don Halas Oil-drilling companies depend on long stretches of steel piping to form what are known as ‘strings’ to reach down deep into oil wells, and machined, robust couplings that connect the individual string sections. Coupling reliability is paramount and depends heavily on precision internal threading. Coupling threading has traditionally involved multiple-pass push-threading with right-hand tooling systems. Unfortunately, generating internal threads with this method involves long cycle times and unnecessary manhours, due mainly to the process’s inefficient handling of chips. Faster Method A new process developed by Seco is single-pass pull threading, and it shaves 40 s off the typical one-minute cycle time of threading oil pipe couplings, which adds up when some companies produce hundreds of thousands of couplings each month. Additionally, the method improves chip control and increases productivity by 50 percent. The process applies a left-hand tooling system with multi-tooth, chaser-style threading inserts that are pulled through to direct cutting forces into the beds of the turning centres used to machine the couplings. The inserts are reliable and wear resistant for higher cutting speeds. Going Deeper Robust couplings, made from Group 4 and P10 steel and higher cobalt compositions, are becoming more common as oil-drilling companies are now going deeper into the earth and hitting acid beds that quickly break down standard steel. Seco designed its singlepass system specifically for handling these tough materials and other various grades and types of steel.

A c u s to m - b u i l t , h e av y - d u t y toolholder bar, which can range in size from 6” to 9” in diameter depending on the size of the coupling, keeps the single-pass cutting insert securely in place during the threading process. The mechanical chipbreaker’s through-theholder high-pressure coolant also assists with chip control and ensures long tool life when producing coupling sizes ranging from 2.875” to 14” in diameter. Push & Pull With the traditional push method, an operator cutting a thread with three to five passes must stop the cycle, stick a hook down into the part, pull out the chips and then restart the cycle. Without high-pressure coolant running through the chipbreaker, operators will see large, stringy chips that require continuous removal, creating an increase in man-hours. If not removed during the process, the chips will be re-cut, causing unnecessary tool wear and slowed cycle times. The pull technique, on the other hand, efficiently removes the chips and drops them into machine tool chip beds, eliminating the problem of chips packing back into the coupling ID. There is no need to interrupt production cycles. The system’s high-pressure coolant also breaks the chips down, making them more compact as opposed to the large, stringy chips that can cause safety issues and major problems with machine tools. In fact, the system can break long 12” stringers down to tiny half-inch segments, and even smaller.


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Enquiry No. 7001 Turn to page 80a or log on to www.equipment-news.com to enquire

continue to apply pressure on price competition; quality requirements from customers and end users will only go up; and the challenges, from a manufacturing point of view, to meet those demands would not get any easier either. MEN Enquiry No. 7002 Turn to page 80a or log on to www.equipment-news.com to enquire

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Making Right Machines Available It is important to note, however, with the new single-pass threading, coupling manufacturers must have the right machine to reap the process benefits. Old or mediocre equipment is not capable of handling the process, and retrofitting outdated machines will not work. Shops need to have newer, rigid machines — 30 to 50 hp spindle motors and well-made, strong jaws in the chuck — that are capable of handling the forces that come with performing just one threading pass. Furthermore, it is recommended that machines have at least 1,000 psi to accommodate the high-pressure coolant that is necessary for properly breaking down large, stringy chips. A lot of the newer machines already offer high psi levels, but if not, it is an easy upgrade. Over the years, there has not been much advancement in the manufacturing of couplings for the oil-drilling industry, or even discussions on how to improve the process. The development of s in gl e - p a s s th re a din g h a s increased the productivity of what could be considered ‘old-school’ machining and provided coupling manufacturers a valuable tool for meeting the growing demands of the oil industry.

critical to the performance of the equipment, as well as safety and environmental concerns. To achieve these, and all of the other key issues that face thread turning operators require careful planning and the use of the latest technology in both tooling and programming. In all likelihood, manufacturing from developing markets will

Live Tools for turning centers

When it comes to thread forms, the oil field industry typically uses two types: the 8 API/RD and buttress. Often used for shallower wells, the 8 API/RD thread requires only a single pass of the new process, whereas the buttress thread involves two passes to create a tight hydraulic seal. Keep in mind, however, the traditional push threading method would take three or four passes on a buttress thread. The new method can also accommodate licensed thread forms, which are better suited to handle the powerful forces that come with deeper drilling.

October 2012 metalworking equipment news

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Automotive Industry:

Thread Carefully Better threading technologies are now required for the automotive industry. Contributed by K Ravikumar, GM Asia Pacific, Komet Group

I

n the machining of automotive components, thread manufacturing would appear to account for a comparatively small share of the entire volume of cutting work involved. Under closer scrutiny, however, it becomes clear that, with the quantity of threads to be manufactured, selecting the right machining techniques can deliver considerable savings. To manufacture internal threads on the engine, on its attachment parts and on the drivetrain, any of a variety of techniques could be employed. Making the right choice depends on the batch size and material, the machine used and the requirements for the fastener, such as whether the thread should finish close to the bottom of the hole or whether the start of the thread should have a full profile turn.

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metalworking equipment news October 2012

Modular tooling systems are suitable for multiple uses

Thread Milling One alternative to the conventional tapping process is thread milling. Both of these machining techniques involve cutting the material. Another option is thread forming, a process in which material is displaced rather than removed. As a result, there are no chip-removal problems and there is no costly cleaning of components to remove swarf. The threads are produced without interrupting the grain flow of the material being machined and its surface is compacted, resulting in a smoother finish compared to one achieved with tapping. Under

static load, the strength of the formed thread is identical to that of a cut or milled thread but greater under dynamic load. For this reason, thread forming — if feasible given the ductility of the material used — has proved to be a popular technique for fastening points that will be subjected to high load. Tapping and forming are supported by all machines. Milling, however, requires a CNC machine capable of helical interpolation. During this process, the threads are created in a circular motion, with the rotating tool simultaneously moving axially at a rate equal to


CuttingEdge

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TC76_DIGILOG_Blum_1-3_EN.pdf 1 22.06.2012 14:36:24

Frequently Used With large batch sizes, components are often machined on transfer lines, which restrict thread manufacturing options to tapping and forming. Here, there are usually basic feed units in the individual machining stations linked in series or in a loop. While HSS taps were used in the past, they tend to be made from solid carbide today. These taps have a substantially longer tool life, which enables cost savings to be realised not least because fewer tool changes mean shorter machine downtimes. Other tools that are highly attractive from a design point of view include thread formers.

Stiffer Challenges To Come In contrast to mass production, component machining, particularly in the automotive industry, has become ever more marked by considerable model variety and faster innovation cycles. This, in turn, has led to decreasing batch sizes. At the same time, the desire to reduce machining times has generated demand for ever faster machines with higher rotation speeds. In addition, modern component designs are placing increasing demands on the properties of threads and the way in which they are produced. As wall thicknesses become thinner, effective thread depths must increase or threads must be manufactured without the typical entry burr. There are the special challenges presented by specific materials or machining techniques, such as cutting with minimum quantity lubrication or dry machining.

TC76-DIGILOG

C

M

Y

CM

MY

Current Trends The trend, therefore, is towards production on CNC machining centres, which can be used as standalone machines or linked to form a chain. With these machines, it is possible to implement and exploit superior thread milling technology and all the advantages it has to offer. The prerequisite to this, however, is that the machine must support helical interpolation. N o w a d a y s , t h i s f e a t u re is available on the majority of machines and, in isolated cases where it is not, it simply needs to be activated. These machines also enable the use of combination tools, which can perform not only axial but also circular operations. They provide scope for accomplishing as many tasks as possible with a single tool. MEN

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the thread pitch. In the process, the thread mill plunges into the core hole exactly down to the programmed thread depth. There is none of the overrun typical of conventional tapping and, in contrast to taps and thread formers, thread mills do not have a lead chamfer. This means that thread milling can produce a thread down to the bottom of the hole without the need for any secondary operations. In addition, different tolerances can be machined using the same tool or different dimensions with the same lead. No chip root is left inside the finished thread and a higher-quality surface is achieved by comparison with tapping. If the machine is able to offer high rotation speeds, considerable time savings can be achieved in the machining of large threads or thread milling in aluminium. Short chips and instantly adjustable and repeatable thread depths help to ensure a reliable threading process. Another advantage is that relatively large threads can be milled in cored holes directly. No finish machining of the core hole is required. Virtually all materials can be machined and the tools are regrindable.

October 2012 metalworking equipment news

33


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Talk

Mobile ERP:

Mobilising Your Competitive Advantage The manufacturing industry must literally ‘get moving’ in order to compete in today’s ever mobile arena. By Craig Charlton, senior VP and GM, Epicor (Asia Pacific)

N

o longer something that offers a competitive edge, having mobility in the workforce today is a competitive necessity; particularly in certain vertical sectors such as the metalworking industry. The vast majority of mediumsized businesses already utilise the benefits of an Enterprise Resource Planning (ERP) system to optimise and improve organisational processes and cut costs. Enter enterprise mobility, which is all about flexibility, providing easy access to information and processes to employees wherever they are located. It can encompass everything from the integration of mobile phones into a corporate telephone system, to vertically oriented solutions involving the quick delivery of productivity enhancing information to people in the field, the factory and in the warehouse.

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metalworking equipment news October 2012

Mobility Works The Internet and mobility play an essential part in the daily lives of the information-hungry global economy, but how do you make ERP mobile? Furthermore, how do you use mobility to the benefit of the metalworking industry and other manufacturers? The image of the traditional ERP system does not match with today’s powerful mobile devices and flexible, scalable software solutions. The traditional image has become outdated. There is a new set of technologies which enable ERP with ‘Enterprise Mobility’. Organisations are gaining benefits from adoption of enterprise mobility. ‘Enterprise Mobility’ improves employee performance and increases productivity by ensuring employees access to data from your ERP system at all times and in all locations. Inventory tracking is improved by labelling and scanning

Craig Charlton

inventory to achieve optimum traceability and to make immediate adjustments during counting, leading to improved confidence in your enterprise data; you know your stock levels are accurate and can therefore make better business decisions when buying and selling products. Material handling and visibility on the plant floor is also improved. The use of mobile solutions allows an organisation to track Work In Progress (WIP) and eliminate the need to go back into large systems to search for products. A company can search through their products at the tip of their fingers and be confident that their delivery estimates will be accurate. The Advantages Of Enterprise Mobility Businesses regard enterprise mobility as a key investment because it can help them:


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Mobility in the workforce and access to company data and customer information in real-time is a competitive necessity in vertical sectors like metalworking.

• Field Service solutions with modern and robust mobile technology with purpose built applications for field-based teams. Field Service provides both connected (wireless) and disconnected (local device storage) support with real-time or scheduled synchronisation. Mobile field service gives field service engineers access to comprehensive role-specific functionality alongside synchronised ERP data. With it, users can: - Receive and update rosters of service call jobs

• I m p ro v e s e r v i c e q u a l i t y levels — provides mobile field representatives access to relevant functions and data so that they can deliver on-thespot, real-time information to customers • Operate more efficiently — allows organisations to reclaim time previously lost to travel and connectivity issues, build deeper business relationships and improve productivity • Gain a competitive advantage — provides instant access to data, including pricing and inventory levels • Extend business borders and enter new markets — enables an ability to transact business where it happens, regardless of location or connectivity • M a k e e m p l o y e e s m o r e productive — increases the cost effectiveness of mobile technology (the ability to access and work with essential information) A Different ERP Mobile ERP offers organisations the option for lightweight access and ability to work with 36

metalworking equipment news October 2012

information within their ERP system through un-tethered wireless Web browsers, on a variety of common mobile devices like laptops, iPads or smart phones. With the rapid expansion of mobile devices, you should m a k e s u re t h a t y o u r E R P solution can handle deploying information and transactions to these devices seamlessly. The technology used should allow ERP applications to run as smart clients or Web clients, or on mobile devices, all from the same source code. This will ensure that customisation and user personalisation remains intact, whatever the user interface. As well as making general ERP applications available on mobile devices, some ERP vendors will have specific mobile solutions for vertical sectors like metalworking which contain departments that are very mobile-centric. Mobile solutions for these vertical sectors include: • Handheld, MES (Manufacturing Execution Systems) which offer support for on-premise/local mobile tools such as vehicle mounted PCs, rugged shop devices, handheld inventory tools, and barcode scanners.

- Process service call jobs, tracking labour, inventory, materials and equipment in a configurable workflow - Specify OH&S, QA, customer approval forms using a simple graphical tool - Update service call status in ‘real-time’ - Operate ‘offline’ on a local SQL database when not connected - M a n a g e s c h e d u l e a n d allocation using the ‘Schedule and Dispatch’ option Mobility in the workforce and access to company data and customer information in realtime is a competitive necessity in vertical sectors like metalworking. Mobile solutions can support more customers, transactions, and products, and maintain a wider range of business partner relationships. Starting with an ERP system that can seamlessly deploy information and transactions to these devices is crucial to realising the full benefits of mobility in the field, factory and warehouse. MEN Enquiry No. 7101 Turn to page 80a or log on to www.equipment-news.com to enquire


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Metrology

Cloud Computing:

The Future For Design & Manufacture? It is clear that the possibilities of mobile technology and Cloud computing are in their infancy. With a bit of creative thinking these technologies can make a difference in design and manufacturing. By Jeff Jaje, marketing & business development manager, Sescoi USA

I

n one way or another most internet users are already using Cloud computing. By posting on social media sites, putting videos and images on YouTube and Flickr, and using web based email services such as Gmail or Hotmail, personal and business data is being stored and processed at a central location on servers operated and maintained by these suppliers. Most of this use has grown organically with the convenience of mobile computing offered by smartphones and tablets, and the need for mobile working and fast personal communication.

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metalworking equipment news October 2012

Keeping It Local Over the past 20 years or so, PCs have become increasingly powerful, so the natural way of supporting increasingly complex software products such as CAD/ CAM, PLM, and ERP has been to run the application locally, on the desktop, and store the data either locally or on a central server on the customer’s premises. For highly complex applications, such as automotive or aerospace design, teams of engineers work together across a supply chain on sophisticated management systems developed by CAD/CAM companies

to synchronise data and manage design change. These systems can manage updates from multiple sites, which may be in different time zones, from suppliers such as mould makers and seat manufacturers as well as the OEM customer itself, who is likely to be continually improving its design in partnership with its suppliers. To add to the complexity, the functions of CAD/CAM, ERP, PLM and other processing-hungry software is co-dependent on these types of tasks, building up a whole range of management and engineering information such as cost models, delivery capability, structural integrity, manufacturing performance and the finished design itself. To manage these complexities, companies frequently use a Virtual Private Network (VPN). This provides security, the ability to login from remote locations, and the ability to share certain data with suppliers and customers. The disadvantage is that it needs a very significant investment in skills and hardware to maintain the system at peak performance and ensure safe and reliable backup of data. Even then, this type of system is not entirely foolproof as it still relies on users operating the system properly, and not compromising security through the use of unsecured means of accessing data, in Wi-Fi hot spots for example. Before PCs, engineers will remember that the only way of getting sufficient computing power for complex CAD/CAM systems was by using a mainframe computer and a series of dumb terminals on each engineer’s desk. The mainframe provided the storage and power to carry out the complex calculations required by design and manufacture, and the local network offered the communications speed to the terminal to update graphics and send and receive commands from the local keyboard.


software&metrology

The Clouds Gather‌ With Cloud computing, the model is moving back to the mainframe arrangement, but with some added advantages. One of the main benefits is that hardware, storage and security is the responsibility of the Cloud supplier. It is no longer necessary to have expensive servers and support staff, or to continually upgrade equipment and software to maintain the system and provide sufficient storage space. This can produce some big savings and ensures that the technical side of the configuration is properly and professionally set up. Data backup is also more secure. Firstly, it is off-site and secondly, it will have plenty of redundancy built in so that it will provide more resilience in the event of catastrophic failure. For software upgrades, Cloud computing also makes it simpler to have the latest

versions of the software being used, as it only needs to be installed once instead of on every individual PC, ensuring everybody is using the same release and therefore improving compatibility. Mobile working across the Internet is certainly much easier with the Cloud because, with a fast connection, engineers can work from any location using much less powerful devices as all the processing is taking place on the Cloud supplier’s servers. So, why is not everyone using the Cloud already? The simple answer is connection speed, security fears and resistance to moving to a SaaS (Software as a Service) model. Security need not be so much of an issue, as companies can elect to have a private Cloud configuration. This gives them nearly the same capabilities and security arrangements found on a

VPN which, as explained above, is only as secure as its users, giving similar risk levels. F u r t h e r m o re , t h e re a re encryption methods available which will make any data sent across the internet indecipherable, which provides an extra level of security. For some applications, even these precautions may not be sufficient, so individual users need to talk to their customers to find out what extra checks are needed for a satisfactory mode of operation. A Speed Issue Many companies purchased their CAD and CAM software outright, and maybe just pay for upgrades, or continue to use an older version of their software. Many smaller design and manufacturing places are not early adopters of SaaS, which is the model most cloud computing programs take.

ENQUIRY NO 139

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October 2012 metalworking equipment news

39


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The Cloud is a good place for CAD/CAM data backup

Speed of connection and connection reliability are far more important issues. For applications which only need to move relatively small amounts of data, Cloud computing works very well and, in most cases, any breakdown in internet connection is usually only very short term. For software such as CAD/ CAM, which needs to transfer large quantities of data quickly so that, for example, graphics can be updated instantly, low speed connections will make the system virtually unusable. Companies like Fujitsu are addressing this by compressing data as it goes across the Internet, mitigating some of the speed problems. To give an idea of the size of the problem, a medium sized CAD/CAM file for a mould consists of about 3 Gb of data. This includes the stock 40

metalworking equipment news October 2012

model, dozens of cutter paths, B-rep and tessellated data. Anyone who has tried to use Google Earth and waited for the picture to update will appreciate how slow it would be to modify and update designs of this size across the Internet. Akamai, the network giant, reports that average global network speeds are 1.7 Mbps. However, some countries are already making big strides with South Korea in the lead with 12 Mbps followed by Hong Kong (9 Mbps), Japan (7.8 Mbps) and Romania (6.3 Mbps). At the moment, it seems clear that trying to work with CAD/ CAM files and processing them on a Cloud server exclusively is not going to work. However, technology is changing at an amazing rate. Higher mobile speeds with 4G are just one example, so it is likely that it will become possible in the future.

How CAD/CAM Fits Into All This? So, is there an application for Cloud computing in CAD/CAM? The area where there can be a significant advantage is in data backup. Processing of files can still be done locally on the user’s PC, but files can be retrieved and stored at the beginning and end of a session on a Cloud server. Backups should also include the software configuration such as .INI files, post processors, custom documentation, custom scripts, tool libraries and holder libraries. Data storage services are available from companies such as Amazon, and encryption from companies such as TrueCrypt, giving users a secure and low cost solution. Other possible uses of the Cloud include live monitoring of machines. For ‘lights out’ machining, companies may want to have a live video link so that they can see what is happening in the workshop from home. Setting this up through Cloud computing is quite simple and cost effective. Similarly, for moving and sharing large files, companies frequently set up FTP connections. The same result can now be achieved with Cloud services like DropBox, where you can leave a password protected file for collection by customer or supplier. For mobile devices, Apps help users to do simple tasks quickly and effectively. Splitting some frequently repeated CAD/CAM tasks into simple elements could be a way forward for making more use of the Cloud. Companies need to maintain tool libraries and reorder tools as they are used or broken, or when there are new requirements. Doing this through an App which updates the tool library, places the order and checks on delivery and dispatch, could be one example of how this could be used in practice. MEN Enquiry No. 7201 Turn to page 80a or log on to www.equipment-news.com to enquire


ENQUIRY NO 180


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ompanies across the board in the metalworking industries face continuous pressure to lower cost, improve productivity, enhance quality and accelerate time-tomarket. The quest for innovation in products and internal processes is essential for success. A s p ro d u c t c o m p l e x i t y increases within the metalworking industry, many manufacturers find themselves faced with the need to perform more comprehensive computations in order to manage products from their initial conception to the end of their useful life. To this end, many have gone beyond the use of design software for simulation and analysis — to investing in Product Lifecycle Management (PLM) solutions, often with disappointing results. While design software promises design optimisation, PLM takes things further, promising manufacturers a cradle-to-grave view of their products and the processes to create them. The vision is one of improved quality, collaboration and response to market dynamics, and reduced waste and process inefficiency.

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metalworking equipment news October 2012

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Why The Cloud Changes

Everything Design software programs for manufacturers can now leverage the Cloud’s flexibility to deliver better cost efficiency. By VR Srivatsan, MD, ASEAN, Autodesk However, this highly appealing vision has been difficult to achieve, as most traditional PLM software takes months, even years, to implement fully, and is complex and costly to maintain. It is understandable then, that after seeing the limited success rates of larger counterparts, small and midsized manufacturers have chosen not to deploy PLM solutions. Enter the era of modern cloud computing, where hosted services promise to make powerful design software and enterprise solutions accessible to manufacturers of all sizes. With cloud computing technology, manufacturers are now able to access these solutions as a hosted service on a flexible, agile

and affordable platform. Depending on the needs of the organisation, cloudbased solutions offer the same opportunities to streamline design and planning processes as their traditional counterparts, with the added benefits. High Performance Computing By leveraging the computing power available in the Cloud, teams of engineers are able to perform multiple complex analyses and simulations to improve speed and accuracy in making decisions, while allowing designers to remain productive on their own local systems.


ENQUIRY NO 165


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processes — whether in design and engineering, order workflows or an end-to-end solution covering every imaginable process.

Cloud-based design software programs allow the sharing of complex layouts and assembly designs, so that clashes and space constraints can be remedied before they become on-site issues.

Rapid Deployment & Low Maintenance Requirements Cloud-based solutions are almost instant-on offerings, able to go live quickly with the rollout handled by a vendor that focuses on enabling a speedy payback. Similarly, maintaining the solution is also handled by the vendor, with most upgrades included automatically, reducing the burden on IT staff. Roulunds Braking, a manufacturer of friction materials in the automotive industr y, deployed Autodesk PLM 360 to manage new product development data across the globe. Approximately 50 users were given access to the latest design schedules and modifications. “The ability to rapidly deploy the system and provide all users with access to real-time data has significantly minimised development errors and improved 44

metalworking equipment news October 2012

development time. I’m able to configure the system to work just how we want it, with no software development experience and little or no outside consulting help,” said Mark Lawrence, development engineer at Roulunds Braking. Low Total Cost Of Ownership As a hosted service, cloud-based solutions are easy to implement, and do not require installation or in-house hardware or technical support to deploy. Such solutions also typically run on commodity hardware, thereby reducing cost of acquisition and ownership significantly. Flexibility & Scalability Deployment in the cloud means that solutions can be tailored in purpose and scale to accommodate varying numbers of users, and to address specific business

Improved Collaboration With cloud-based solutions offering users real-time access to data anytime and anywhere, even from mobile devices, complex processes that require access or input from members of crossborder teams can be easily managed. This helps streamline and improve collaboration for teams working remotely. Feige Filling, a manufacturer of filling machines, leverages the power of cloud-based design software for customer reviews. They share complex layouts and assembly designs with customers, so that clashes and space constraints can be remedied before they become onsite issues. This virtual evaluation can be done across borders, in realistic and immersive 3D, rather than multilayered 2D that can be difficult to interpret — a critical factor that has helped the company win more business. Perhaps the most appealing attribute of cloud-based solutions to the new user is the unique ability to easily test-drive the solution. The solutions’ subscriptionbased, scalable nature offers less risky pilot programs. Naturally, the need to tailor one’s software solutions to fit seamlessly into the organisation’s workflow remains. These barriers are lowered now that cloud solutions are growing in variety and functionality, with potential benefits that can be reaped by manufacturers of all sizes. The gateway to the cloud is now open for all players looking to get ahead with the help of advanced software solutions, and the time to explore the possibilities in the cloud has arrived. MEN Enquiry No. 7202 Turn to page 80a or log on to www.equipment-news.com to enquire


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CAD/CAM & Cloud:

Engineering and product design can happen anywhere in the emerging mobile world. By Bertrand Sicot, CEO, SolidWorks, Dassault Systèmes

I

magine a sales engineer at a lunch meeting with a customer, looking at a tablet computer displaying a 3D solid model of a product on which two other engineers are working on. The customer tells him that he is interested in the product, but needs a variation on the original design. The engineer modifies the product to his specifications during lunch. He is also able to reassure the customer that the modification would not affect the product’s performance, that the parts to meet the customer’s requirements are available, and that his company’s production line can accommodate them without any inconvenience. With the knowledge that his company can produce the customer’s variation without extraordinary costs, the engineer sends the specifications to the product development team and signs a deal with the customer on the spot. Making The Connection The concept sounds simple — put engineering data, knowledge and processing power where business occurs, which could be on sales calls, the shop floor, or someplace on the road. While business has been mobile for years now, product development has been tethered to desktops since the computer-aided design era began. Processing requirements and the cost of applications for designing, 46

metalworking equipment news October 2012

testing and manufacturing products meant that only a fraction of product design could be performed in the field. The serious tasks, such as major modifications, simulations, and performance optimisation, had to wait for engineers and designers to return to their desks, where they had access to wired networks and enough computing power to operate the full range of software they needed to complete their work. Being out in the field — on a shop floor, or on a customer site — meant being cut off from the computing assets needed to perform every facet of the job. Lack of processing power and application functionality are obvious drawbacks to being away from the office, but not the only ones. Engineers and designers working with customers or partners in the field are also largely cut off from each other — or more specifically, each other’s data. They can communicate through e-mail and cell phones, but do not have direct access to all of the definitive data for a given product. Design engineers onsite with a customer are unable to determine the effect a late-stage design change has on tooling, machine layout, or production costs. And the product manager on the road cannot approve those changes without accessing the corporate network or PLM system. Gearing Up For The Shift New mobile computing paradigms make portable devices a gateway

to a new collaborative model where everyone connected to product development can access all of the latest data on a project. From calling up the most current design iteration for a sales meeting to modifying the design in real time, emerging ‘cloud computing’ infrastructures will eliminate boundaries to fully-mobile product design. Applications are moving from the desktop to the Internet, making it possible (in theory, at least) to design in 3D on any device with an Internet connection. Over the next few years, purposebuilt applications and viewers will bring product designs to all of the platforms that your employees, partners, and customers use — including desktops, mobile devices, and browsers — with experiences appropriate to the platform. New delivery models will provide on-demand access to software, processing capacity and data storage, ensuring that mobile designers and engineers always have the right tools for the job, regardless of where they are. The result will be increased creativity, greater productivity, and livelier, more interactive collaboration. E n g i n e e r s a n d p ro d u c t designers’ careers are built around knocking down barriers through the design of new and improved products — products that perform better and more efficiently, at lower production costs, and with minimal impact on the environment. Yet, they have had to accept limitations on their creativity and collaboration because the primary tools kept them in the office even though much of what they do occurs somewhere else. Desktop CAD software freed product design from high-powered workstations by putting essential design tools on everyday PCs. Mobile engineering takes the next step, putting those tools where products go from design to reality. MEN Enquiry No. 7203 Turn to page 80a or log on to www.equipment-news.com to enquire


ENQUIRY NO 176


Sheet

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MetalWorking

Michael Meier

Blasting Away Conventions

Doing things the unconventional way has served a waterjet cutting job shop well. By Volker Albrecht, for Bystronic

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metalworking equipment news October 2012

O

vercapacity costs money, at least according to standard commercial principles. This is not the case at a Swiss company called Waterjet AG, a cutting job shop for the production of parts using waterjet cutting. In the company, dead capital ensures a stable position in the market and good returns. “It is our recipe for success that we work with overcapacity and a large materials warehouse and as a result, are always in a position to be able to deliver,� says Walter Maurer, the co-founder of the company. The shop provides a wide range of machines such that each part can always be cut on the most suitable machine. The


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Mr Maurer’s approach, to cut high-quality parts quickly and also to deliver at short notice pays off.

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The correct production facilities and approach, in which the focus is on industrial solutions, have allowed the company to become the leading waterjet cutting shop.

Michael Meier

spectrum ranges from what is currently the largest waterjet cutting system in Switzerland, a Byjet L 8030 with an 8 x 3 m cutting table, through to several Bystronic machines for standard formats that are predominantly equipped with two cutting heads. Running A Tight Ship In the shop, although overcapacities exist on paper, the machines are used efficiently. With personnel costs running at 60 percent, the objective is to produce as much as possible with only a few people. The work force is used optimally. This starts with a sort of clocking of the order processing, so that the work steps of the employees and the cutting times mesh with each other. This means that two operators can control three machines. They are supported in part through process automation components. For example, one 50

metalworking equipment news October 2012

Michael Meier

Byjet 3015 is equipped with a shuttle table, and the Byjet L uses a concept consisting of separate cutting zones. With it, cutting can take place in one zone of the cutting table, while in another, loading or unloading is carried out. Furthermore, exchangeable cassettes that can be lifted out using a crane facilitate the removal of the cut parts. Above all, during the night and at weekends, the capacity of the waterjet machine, in spite of its vast cutting area, is not only used for large parts. At these times the machine is loaded with several different sheets and operated in the lightly-manned mode. If an unexpected problem should arise, the process monitoring reliably switches the machine off. Furthermore, auxiliary devices are used, with which the cut parts are held in place in the skeleton using dots of easily removable

glue. As a result, there is no longer a need for micro tabs, which would subsequently have to be ground away. Mr Maurer thinks in terms of industrial solutions and these are aimed at the continuous improvement of the processes. One example: ‘clogging’, which refers to the accumulation of abrasive in the cutting head. This cannot be completely eliminated with waterjet cutting — but it can be minimised. Mr Maurer uses high-quality abrasives and clean water and carries out regular maintenance on the high-pressure pumps. The fact that the cutting nozzles are changed every two days ensures additional reliability in the work processes. Keeping Things Fresh M r M a u r e r m a ke s r e g u l a r investments in new machines. “From a commercial point of view,


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this could perhaps be viewed as an error of judgment, but we earn money with the excess capacity,” he says. Additionally, he keeps the machines at the highest technical level, and gaps in the machine portfolio can be filled. He assumes that ever y investment adds additional competence and as such, creates added value. Making Money With Complicated Solutions “Waterjet cutting is a technology that can do everything,” says Mr Maurer. As such, as a waterjet cutter, one has to remain open to everything and be creative. Based on his experience, the added value lies with complexity. Very elegant solutions are to be found, for example, in medical technology, aerospace or in general industry, where the

material has to be cut without therma l stress. Lightweight construction materials such as Carbon-Fibre Reinforced Plastics (CFRP) are also increasingly being used. Mr Maurer also sees ample potential in the micro sector. He is convinced that anyone who is able to position themselves in good time in this sector can differentiate themselves from the competition and earn good money. He reports growing oppor tu nit ie s in combine d processing, which lies in the subsequent processing of the cut parts. As one example is a brass gauge in which a 0.3 mm slot had to be cut. Using waterjet cutting, this is no problem. Such processing of finished parts today already account for 25 percent of the orders at his company. Mr Maurer’s approach, to cut

high-quality parts quickly and also to deliver at short notice pays off. For example, he has been successful in competing with laser cutting in the cutting of aluminium sheets. Also large quantities of copper, high-alloy steels, and thick stainless steel are processed. Additionally, there is titanium and what are known as hightech materials such as CarbonFibre-Reinforced Polymer (CFRP). To process these, five of his machines are equipped with mechanical drill spindles. These prevent individual layers from peeling off during piercing. The correct production facilities and approach, in which the focus is on industrial solutions, have allowed the company to become a leading waterjet cutting shop. MEN Enquiry No. 7301 Turn to page 80a or log on to www.equipment-news.com to enquire

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Optimise Your Waterjet Cutting System Here are some eco and budget friendly tips for increasing waterjet productivity. By Nancy Lauseng, marketing manager, Jet Edge.

W

ith time and money tighter than ever, waterjet shops around the world are looking for ways to maximise their waterjet systems’ productivity and profitability without breaking the bank on capital investments. Waterjet industry veterans Jeff Schibley and Bradley Schwartz of Jet Edge recently offered some helpful insights on how to increase waterjet productivity and minimise waste. According to them, there are numerous ways to increase waterjet productivity, including deploying pressure pumps that can reach up to 90,000 psi (6,200 bar), multiple-head systems that can include a dozen or more cutting heads, mirroring programs that can cut large parts twice as fast by using two cutting heads, and nesting software that can maximise parts per sheet or plate. Ancillary equipment can also be added to waterjet systems to increase their productivity, including abrasive removal systems, garnet recycling systems, chiller and closed loop systems, dual pressure valves, height sensors and pneumatic drills. Turning Up The Pressure For years, 60,000 psi (4,100 bar) was the standard operating pressure for most waterjet shops, but in the last five years, X-Stream pressure

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cutting technology has made an entrance into the waterjet world. With pressures exceeding 90,000 psi, waterjets can increase cutting speed up to 50 percent, depending on the material. By cutting faster, the systems use less power, water and abrasive, reducing operating costs as much as 40 percent. “Increasing pressure is where we can see tremendous efficiencies in the abrasive waterjet cutting process,” said Mr Schibley, who serves as Jet Edge’s Great Lakes regional manager. “By pressurising to higher pressures, we get faster acceleration of the abrasive and we get more efficiency in the cutting process.” An example is NASCAR’s Michael Waltrip Racing (MWR). MWR has seen productivity gains since upgrading their waterjet intensifier pump to an X-Stream pressure pump. Since the upgrade, the team has been able to reduce its waterjet operating hours from 60 to 65 hours per week to 40 to 50 hours per week, saving on labour and overhead. “We’ve been seeing, across the board, a 35 percent improvement in cutting speed, plus we are using about 25 percent less garnet abrasive, and we have reduced our costs by 30 percent,” said Nick Hughes, MWR’s technical director. “As an example, our spindles,

which are one of our more complicated steering parts and cut from 2” 4140 steel, used to take 50 to 55 minutes to cut at 60,000 psi. Now we are cutting them in 30 to 44 minutes. Before we got the waterjet, it used to take three or four hours to rough cut them on a band saw. I also should note that about the same time we upgraded our pump, we changed suppliers for our spindle blanks. They use a much harder material that requires a slower cutting time. The new pressure pumps offset the increased cutting time.” “Another good example of a reduction in machining time would be our upper control arm plates that attach our front suspension arms to the chassis. These are cut from 1.5” thick steel and took about 1 hour and 25 minutes to cut two with the double heads and the old 60 KSI pump. We can now cut two in about one hour with the double heads and the 90 KSI pump.” Select The Right Waterjet Pump Before investing in a waterjet system, ask the waterjet manufacturer to perform a test cut, Mr Schibley advised. Most waterjet manufacturers provide free test cuts using material supplied by the customer. The test will help you determine how many cutting heads are necessary to reach a desired throughput and how much horsepower is required to supply the proper amount of water to each cutting head. It also will determine the most efficient orifice/nozzle combination, pressure and abrasive feed rate for a given application. “We cut the part to determine how much energy is required,” Mr Schibley noted. “As an example, you say, a .010/.030 orifice/nozzle combination at 60,000 psi made my part, but not as fast as I want. Well, I can run two .010/.030 nozzles with a 50 hp pump or I can run four .010/.030 nozzles with a 100


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hp pump, or I can run six .010/.030 nozzles with a 150 hp pump.” “If I’m cutting much over ¾” thick material, I’m probably going to want to put a 50 hp of energy into that nozzle. I’m going to run at least a .010/.030 at 75,000 psi (5,200 bar) or a .015/.045 at 60,000 psi. Depending on the throughput is how we determine the horsepower. If I run one head, I need 50 hp, if I’m running two heads, I might need 100 hp to feed the proper amount of water to that nozzle,” he said. Multi-Head Systems The quickest way to make a waterjet system more productive is to add multiple cutting heads to the system, Mr Schibley noted. “Look at most successful job shops and what are they running?” he asked. “They are running two heads, three heads, four heads. That’s generally because we burden

a machine with overhead costs and General and Administrative costs (G&A) based on that machine. We don’t burden each cutting head, so when we start putting multiple heads on a machine it allows us to prorate our G&A costs over a greater number of parts per cut.” he said. Mirroring — Cut Large Parts Twice As Fast Adding optional mirroring capabilities to a waterjet system can be a huge time saver, said Mr Schwartz, who serves as Jet Edge’s Pacific regional manager. Mirroring capabilities allow waterjet operators to cut large parts simultaneously with two cutting heads, doubling productivity and freeing the machine and labour for other projects. Precision Waterjet Concepts of Pequot Lakes, USA, is one example

of a shop that is saving time and money by mirroring parts with a mid rail gantry system that also features programmable head spacing. “We cut a lot of extremely large parts and we can save a lot of time and money by mirroring,” said Joe Quaal, Precision Waterjet Concepts president. “Fifty percent of the time, we are mirroring. The programmable head spacing also saves us 10 to 15 minutes per job on set up time.” Nesting Software — Maximises Material “A good nesting program is very important for any system, especially if you are looking at material that costs quite a lot and you’re doing high volume,” Mr Schwartz said. “You can look at the efficiency of the nesting software and just conservatively see a five percent savings. Nesting will give you a huge amount of cost savings in a year.”

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sensors are also a necessity in running underwater cutting operations since the operator cannot monitor the “stand off distance” between the nozzle and material, he added.

Height sensors help operators to overcome fluctuations in material flatness

Nesting software saves money and increases productivity by maximising the amount of parts that can be cut out from a piece of material. Pneumatic Drill Pneumatic drills are an inexpensive accessory that can speed up waterjet processing time by predrilling material that is sensitive to delamination, such as polycarbonate or fiberglass, Mr Schwartz explained. The programming sequence will first run the drill, pre-drilling at desired locations, then switch to the waterjet to finish the part. This increases productivity by allowing waterjet operators to quickly predrill and cut sensitive material without using a slower low-pressure pierce or long lead in cut to the part. Height Sensing According to Mr Schwartz, contact height sensors allow waterjet operators to overcome significant fluctuations in material flatness by maintaining a constant automatic standoff from the material. As a result, waterjet operators achieve optimum cut quality, tolerance, taper and speed without having to monitor the standoff. Height sensors also can be programmed to avoid previously cut parts that may have tipped up after being cut. Height 54

metalworking equipment news October 2012

Dual Pressure Valves For shops whose work requires them to frequently raise and lower pressure or do frequent low pressure pierces, there are cost-effective solutions available to lessen wear and tear on pump components and reducing downtime. “In dual pressure cutting, we want the ability to peck our way through material ever so gently with lower pressure water, and then as we get that hole in there, we can increase the pressure,” Mr Schibley explained. “But when you take a waterjet pump and you ramp that pressure up and down, what occurs? Number one, when we ramp and load up and down on the electric motor, it uses more electricity. It also causes us to fatigue our high pressure components faster. High pressure components are designed to be at maximum pressure. They like being at 60,000 psi, or 75,000 psi, or 40,000 psi, whatever your system runs at. What they don’t like is being at that pressure and suddenly being depressurised. It’s that action that creates fatigue.” To overcome the wear and tear of dual pressure cutting, a dual pressure valve can be used, Mr Schibley explained. The valve allows waterjet operators to raise and lower water pressure independent of the waterjet pump. “This allows us to reduce the pressure at the cutting head without having to ramp our pump up and down,” he explained. Green Accessories Waterjet has always been considered an eco-friendly technology, but it is becoming even greener as more shops invest in green accessories that are not only good for the

environment, but also good for their bottom line. Closed-loop filtration systems are perhaps the greenest of all waterjet accessories. They allow waterjet shops to filter, cool and recycle water, eliminating the need to dump it down the drain. A must in desert environments, closedloop filtration systems are now required by many municipalities and for ISO-9000 certification. They also provide a great option for waterjet shops that do not have a floor drain. Garnet is by far the costliest operational expense of a waterjet system. Abrasive waterjets go through 0.5 to 1.5 pounds (0.25 to 0.68 kg) per minute of the abrasive material, which can cost US20 cents to more than US40 cents per pound, depending on grade. The good news is, garnet can be effectively recycled. Garnett Gerke of GO H20 of Edmonton, Alberta, Canada, uses a garnet abrasive recycling system to reclaim 50 to 70 percent of his garnet. He mixes used garnet with new garnet and has seen no reduction in cutting speed. He recovered the cost of his recycling system in one year and now uses it to recycle abrasive from two waterjet machines. Mr Gerke explained that he had to come up with a way to remove the garnet from his tank and reuse it to minimise downtime for shoveling out the tank and reduce disposal costs. “In our first two years, we had had to shut down every 7 to 10 days to clean out the tank,” he recalled. “We would be down 8 to 12 hours. We had a sump truck come in and pump out the tank and haul the garnet off to the landfill. The first year, he charged US$400 per visit. Two years later, it was three times the cost.” If you have high disposal costs in your area, it can definitely be worth it to recycle the material, Mr Schwartz noted. “Only about 30 percent of the


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Maintain Your System You can equip your waterjet shop with all the latest productivity accessories and the biggest pump on the market, but if you do not maintain your waterjet system properly, your productivity could suddenly drop to zero. The most important thing you can do to maximise productivity is to maintain your system properly. “I had a customer who never changed their hydraulic oil or hydraulic filter,” Mr Schibley recalled. “They had over 4,000 hours on the original hydraulic fluid and all of a sudden, their pump stopped. The hydraulic oil broke down over a period of time and it gummed up the directional control valve. Had they been changing their filters regularly

hole to continue weeping water out until it cuts a groove in that high pressure component, now you have to spend a lot of time lapping it out or you have to replace that component. In order to minimise the cost of ownership and minimise the maintenance and downtime, proper maintenance is important.” MEN Enquiry No. 7302 Turn to page 80a or log on to www.equipment-news.com to enquire

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Abrasive Removal Systems — Stop Shoveling! Abrasive removal systems are a must for high-volume shops. They all but eliminate the need to shut down production to shovel out a tank. Shops with an abrasive removal system might only have to shovel their tank out once a year to remove large material drops, versus several times a month if they do not have an abrasive removal system and run 24/7. “Abrasive removal systems will allow for 24-hour operation seven days a week by pulling the abrasive out of the tank and discharging it into a receptacle,” Mr Schwartz said. “It keeps the tank stirred up and keeps the abrasive suspended. In the water, it will bring the abrasive out through a centrifugal separator and discharge into a tank and into a bag filter. When that fills up, you just pull the full bag out and put an empty bag in.” Abrasive removal systems can be added to existing waterjet systems.

and changing their hydraulic oil as recommended, they would not have had hydraulic oil breakdown and a clogged directional control valve which stopped the process from working.” “You hear some people complain about how high the cost of maintenance is; ultra-high pressure only becomes high maintenance if you neglect it. If you allow a weep

©

abrasive is actually doing the work and the rest is going right into your tank,” he explained. “You can reclaim this.”

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Industry

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Focus

Made-In-Japan:

Monozukuri

Products made in Japan have spread far and wide. Companies have set up production bases in many countries, training the local labour force what it means to manufacture products the Japanese way. By Michael E Neumann

Kimubert, Kobe, Japan

T

here are many Japanese terms synonymous with modern manufacturing. Words like seiri, seiton, seiso, seiketsu, and shitsuke of the 5 S system come to mind. The list describes how to organise a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items, and sustaining the new order. Muri (overburden), mura (inconsistency) and muda (to eliminate waste) are another three words used in the Toyota Production System ( TPS) to 56

metalworking equipment news October 2012

organise manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. Now add ‘Monozukuri’ to the list of Japanese words used in manufacturing. It is a word that is foreign to many in Southeast Asia. For those who have heard about it, the meaning of the exotic word resonates in so many levels that it is almost impossible to have a firm grasp of its importance. It is said only those with knowledge of the Japanese language can fully explain its nuances. For us who do not, we have to

make do with this definition. In Japanese, the words mono (thing) and zukuri (process of making), when taken together literally mean the process of making or creating things. The word however, has a more intense meaning; monozukuri is about having a state of mind, the spirit to produce not only excellent products but also have the ability to constantly improve the production system and its processes. Using this unique spirit as a guiding principle, Japanese products have gone on to achieve worldwide fame with names like Toyota and Sony instantly recognisable. In the world of metalworking, Japanese products also have similar reputation of having good quality and advanced technology. T heir p opu la r it y ca n b e easily shown in their export figures. According to figures from Japan Machine Tool Builders Association (JMTBA), the total value of machine tool orders from October 2011 to May 2012 has been hovering around JPY 97.4 to 115.98 billion (US$1.2 to US$1.4 billion). Bringing ‘Monozukuri’ To Asia The manufacturing industr y may be facing challenges at the moment, but this has not stopped Japanese companies from expanding outside their home country. Although the expansion is due to both a weak domestic market and the need to gain market share in developing nations, the companies have brought with them the spirit of ‘Monozukuri’. J a p a n E x t e r n a l Tr a d e Organization (JETRO) carried out a survey on business conditions of Japan’s small and mediumsized parts suppliers and their challenges for expansion in Asia. Some 170 Japanese parts suppliers (50 in Japan, 120 overseas) and 57 non-Japanese parts suppliers for cars, machines and electric and


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Monozukuri is about having a state of mind, the spirit to produce not only excellent products but also have the ability to constantly improve the production system and its processes

Steve Jurvetson, Menlo Park, USA

electronic goods took part. The result showed that due to the continued decrease in stable domestic demand associated with the overseas production shift by major manufacturers, the surveyed SMEs have strengthened efforts to develop and expand their business overseas including other parts of Asia. This action invariantly involves the training and imparting of knowledge and experience. Some of the firms educate and train local employees in Japan for a few years, then utilise them as a core in establishing business in Asia. This helps ensure the Japanese way of production. The SMEs have also adopted locally-produced materials once they meet Japa nese quality standards, which have no negative influence on the safety and function of production. New Investments Here a re some exa mples of overseas expansion by Japanese firms where k nowledge and pro duc t ion philosophy a re transferred to the locals. Honda Malaysia Sdn Bhd (HMSB), a Honda automobile production and sales joint venture in Malaysia, has started the construction of

its second automobile production line at the existing auto plant in Malacca, Malaysia. On the second line, which is scheduled to begin operation before the end of 2013, the company is planning to produce mostly small-sized vehicles and hybrid vehicles. The a nnua l production capacity of the second line is planned to be 50,000 units, doubling the company’s overall production capacity from the current 50,000 units with the first line to 100,000 units. The total investment on the second line

is expected to be approximately JPY 8.68 billion, and HMSB is planning to hire approximately 700 associates when the second line becomes operational. Other Expansions A pa r t f rom A sia , Japa ne se machine tool compa nie s have expanded elsewhere as well. Mazak Corporation has announced that it will expand the company’s North American manufacturing plant in Florence, Kentucky. This expansion will allow for increased production and support of new and additional Ma za k machine models in Kentuck y, a nd increa se the facility’s potential production capacity to 200 machines per month to meet surging customer demands. Completion of the expansion is set for the later part of 2013, although some facets will be completed by December 2012. With Japanese companies spreading their wings far beyond the shores of Japan and their production bases setting up in more locations worldwide, the term ‘monozukuri’ is well on its way to becoming better understood. Enquiry No. 7401 Turn to page 80a or log on to www.equipment-news.com to enquire

Japanese Market Watch According to JMTBA, the total machine tool orders have increased. In 2011, total amount of orders reached JPY1,326.2 billion, up 35.5 percent over 2010. Demands are driven by foreign orders, propelled by Asian countries and the US. In 2011, total amount of foreign orders amounted to JPY904.6 billion, up 34.8 percent over the year before. It was derived from this figure that orders from Asia have set historical highs for two straight years amounting to JPY505.5 billion in 2011. Domestic orders are also on the rise. In 2011, it amounted to JPY421.6 billion, up 37.1 percent over the previous year. Looking forward, the May 2012 figures from JMTBA showed although total orders have exceeded JPY100 billion for four consecutive months, it is necessary to keep a close watch on the effects on the investment climate caused by instability in the European economy and the slowdown of China’s economy. MEN

Enquiry No. 7402 Turn to page 80a or log on to www.equipment-news.com to enquire

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& Beyond

J

apa ne se machine tool, equipment and products have a reputation of quality but at the same time, price can work against them. In developing countries whereby entry-level machines or technologies are sometimes in demand, this presents a challenge. Hiroto Kobayashi, director, manufacturing and environment industry department, Japan External Trade Organization (JETRO) however, firmly believes quality is still key. “Japanese products are made with high technology. They are durable as well and I believe this will be an advantage and a springboard to gain a fair share of the Asian market,” he said. Despite having faith in the quality of the products, he conceded marketing is still a factor. For JETRO, it includes helping Japanese companies showcase their product in overseas exhibitions such as MTA Vietnam. “We have taken part in MTA six times. This year, we have 20 booths in our pavilion. To help the exhibitors, JETRO has absorbed a third of the cost of the booth and its decoration,” he said. Some of the notable exhibitors this year include Kito Seiki Seisakusho and Segawa Tool Service. The former supplies milling units of metal cutting tools and precision metal 58

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We take a look at the technologies and products coming out of Japan and how the country tries to engage Vietnam, one of the fastest growing economies in Southeast Asia. By Joson Ng

works. The latter manufactures cutting tools, end mills and drills for the automotive and mould making industry. S t ay i n g i n V i e t n a m , M r Kobayashi feels that Japanese products have a big role to play in the market, which possesses much potential. He concluded: “In Vietnam, there are many small companies, but the supporting industry for big Japanese automotive makers is not extensive enough. There are not enough tier one suppliers at the moment. As such, we are promoting the export of better products and technologies to the Vietnamese market.” Other Collaborations According to Re e d Trade x , organiser of Metalex Vietnam, JETRO has co - organised the Vietnam Supporting Industries

Forum in Ho Chi Minh City to serve as a learning platform for all leading industrialists across Vietnam about how supporting industries in Vietnam can stay co mp e t it i ve i n t he A S E A N Economic Community, to be implemented in 2015. The keynote speech was on the ‘Overview of Vietnam Manufacturing Industry Development’. The panel presentation focused on ‘Working together: Growing together; Expanding Vietnamese Supporting Industries by Reaching Japanese Standard’, ‘How to reach Japanese Production Standard and QC system?’ by Japanese Automobile Manufacture and ‘How to Increase Efficiency of Vietnamese Supporting Industries’ by Japan International Cooperation Agency (JICA). MEN Enquiry No. 7403 Turn to page 80a or log on to www.equipment-news.com to enquire


ENQUIRY NO 085


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Japanese Product Highlights

Kitamura: Horizontal Machining Centre

Mitutoyo: Surface Roughness Measurement

Kitamura has developed the Mycenter-HX800iL horizontal machining centre. Rigidity in construction, accuracy and handcraftsmanship combine to make this machine suitable for large part machining requiring a larger work envelope and a higher degree of precision. The machining centre is suitable for the automotive, aerospace, heavy construction, oil field and power generation industries. A work envelope (work size of Ø59.1” x 59.1”), pallet size of 31.50” x 31.50”, is suited for heavy-duty, oversize part machining.

Mitutoyo Corp has developed the Surftest SJ-410 series, a line of SJ-series portable surface roughness testers for managing surface roughness on-site, featuring greater precision and performance with the ability to switch between skidded and skidless measurement. It offers two options for X-axis measuring ranges, (25 mm and 50 mm), and an array of detector ranges of 800, 80 and 8 μm, at resolutions of 0.01, 0.001, and 0.0001 μm respectively. Two drive units are available: the SJ-411 has a straightness accuracy of 0.3 μm and drive length of 25 mm, and the SJ-412 has a straightness accuracy of 0.5 μm and a drive length of 50 mm.

Enquiry No. 7404 Turn to page 80a or log on to www.equipment-news.com to enquire

Sumitomo Electric Carbide: Cast Iron Turning With Ceramic Grades

Sumitomo Electric Ca rbide cera mic grades emphasise a dynamic balance between wear resistance and toughness in rough turning and milling of cast iron. Developed using a patented microwave sintering process, the SN2000K and SN2100K are suitable in machining a broad range of cast iron materials. These ceramic grades exhibit the right amount of wear resistance and toughness to produce grades for cast iron turning and milling. The SN2000K grade is fit for high speed general turning and finishing applications in cast iron. This grade promotes long tool life and wear resistance through its hardness and increased toughness. With its high shock and impact resistance, the SN2100K is suitable for rough turning and milling of gray cast iron applications. Enquiry No. 7405 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 7406 Turn to page 80a or log on to www.equipment-news.com to enquire

Tungaloy: Productive Shoulder Milling

Further extending its range of milling products, the Tungaloy Corp has now added to its DoRec series of shoulder milling cutters with the introduction of the DoRec18. The tool is available in JIS, ISO and ANSI designations. Capable of improving productivity levels by over 80 percent when compared to its rivals, the tool can increase feed rates due to its extra thick insert design. This thick insert design not only improves metal removal rates but also improves fracture resistance to provide the end-user with longevity and consistency from its shoulder milling processes. With a maximum depth of cut value of 16 mm, it is an effective shoulder milling cutter series for semi finishing to rough machining of steels in the general machining industry sectors. Enquiry No. 7407 Turn to page 80a or log on to www.equipment-news.com to enquire


ENQUIRY NO 185


Executive

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zone z

Right Message

Conveying The

Away from common themes in metalworking like ‘technology’ and ‘efficient manufacturing’, APMEN touches on the subtle art of marketing with the help from Iscar’s Hadas Zeira, marketing communications manager to see how it is gaining importance quickly with the rise of new media. By Joson Ng APMEN: What is your marketing philosophy? Hadas Zeira (HZ): At Iscar, the motto is ‘Being global is being local’. The company has subsidiaries in over 50 countries around the globe, providing services at all levels to assure that the customer always receives technical support, products and services, punctually and with satisfaction. The vision which guides our marketing philosophy is to increase productivity and profitability for the customer. APMEN: How important is marketing in today’s metalworking world? Do you think metalworking products can sell themselves? HZ: As in any other business sector, marketing plays a role to ensure that we convey the message in the most effective manner. Marketing themes always emphasise and portray features of the new tools and innovations which a given company introduces. In essence, if products are unique and distinguished, to the extent that the enduser becomes more profitable by using the tools correctly, the tools may sell themselves. This is where marketing is used, to create this awareness and to secure the customer’s ongoing confidence that he is doing the right thing by using the right products. APMEN: With digital marketing on the rise, what kind of adjustments do you have to make to your marketing plans? HZ: The smartphones, tablets and the Web 2.0 provide new platforms, alongside the common use of paper, to convey and implement marketing messages. We invest heavily in these new forms of communication, as our customers gain substantial benefits using these new systems in real-time. Surveys conducted by Iscar among its customers reveal that the metalworking industry is also inclined to make use of digital marketing trends. It is all part of the quest for sustainable productivity. 62

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APMEN: Social media is widely used today. Is it a standalone marketing tool, or do you see it complementing traditional marketing techniques? HZ: We provide ‘tangible’ engineering and technical support by physical presence and verbal consultation. In addition, electronic catalogs, online parametric tool advisors, Webinars, YouTube videos and demonstrations are widely used. All are gaining popularity, and all provide added value to customers. Tools such as Twitter and Facebook are secondary for our customers in the context of gaining valuable information. APMEN: Out of the marketing tools available, which do you think is the most suitable for the metalworking industry? HZ: One of the major marketing assets is being able to face customers at live events, such as exhibitions and seminars. In these times, trade shows have become the right platform to engage face-to-face contact with customers to strengthen personal and business ties. In addition, national and international seminars have proven to be a good method to interact on a personal level with customers. This reinforces the B2C form of communication. Moreover, the new marketing age makes it possible to improve interaction with customers by use of the web, email and other types of social media. All facilitate bringing closer the line of interaction with customers, and some — such as seminars and actual demonstrations — improve a continuous long-term interaction with customers and endusers, by sharpening the line of visibility between our products, technologies and solutions, and the customers’ ultimate needs. MEN Enquiry No. 7501 Turn to page 80a or log on to www.equipment-news.com to enquire


ENQUIRY NO 167


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Manufactured In

Taichung Making improvements to established technologies is one of the ingredients for success for many first generation Taiwanese machine tool and component makers. Today, these family-owned companies are venturing further beyond the shores of Taiwan, some with technologies and radical manufacturing concepts fully developed in-house. By Joson Ng

T

aichung, situated roughly in central Taiwan, is known to be a place where its people are creative about the food they eat. They can lay claim to the invention of Bubble Tea (milk tea) and Suncakes (pastry). Unknown to many, it is also a place where many Taiwanese machine tool makers have chosen to set up shop in. The Taiwanese machine tool industry is heavily influenced by their Japanese counterparts, with many companies adopting the Toyota Production System (TPS) as their modus operandi in manufacturing. It is also not uncommon to see manufacturers picking the best features in European or Japanese made machines, and making improvements upon it in their R&D laboratories. 64

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The manufacturing cluster of Taiwan has grown steadily over the years and has garnered more international attention as Taiwanese machine tool and accessory manufacturers, with their spirit of ingenuity, continue to manufacture and export their products to many parts of the world. This growth has led to the birth of Taiwan International Machine Tool Show (TMTS), an exhibition in Taichung organised by Taiwan Machine Tool & Accessory Builders’ Association (TMBA). To have a better understanding of the manufacturing climate i n Ta i c h u n g , A s i a P a c i f i c Metalworking Equipment News (APMEN) visited four plants in the area. They were Hiwin, Victor Taichung, Chmer and Keyarrow.

The Spirit Of Innovation An interesting point to note is almost all the plants have the uncanny ability to create s o m e t h i n g n e w, b e i t i n a technological or business sense. Wu u - S h y o n g Wa n g , t h e chairman of board of Chmer, an EDM manufacturer, stated the company invests some five percent of its annual revenue and allocates 40 of its 300 employees into R&D. This investment has paid off with the development of the EDM maker’s very own CNC controller. In addition, the company also derived their system from the TPS, TQM and TPM s y s t e m s . Called the Chmer Production System, it allows an ‘E-administrated’ factor y


Features

with e-bulletin and temperature control. As a result, the temperature of the production floor is maintained at a cool 26 deg C in their spacious new plant. Lean Manufacturing Keyarrow on the other hand, has kept things compact. In fact, they had their production area reduced by half in order to streamline their production. In spite of this, APMEN understands that they have tripled their p r o d u c t i o n c a p a c i t y. T h e component supplier for machine tool manufacturers produces sheet metal machine guards, chip conveyor, and telescopic covers. They take lean manufacturing very seriously and some might say, literally. King Wang, the president of the company revealed that back in 2008, he decided to cut cost

by 50 percent, something that many thought was not possible. Eventually, after about a year, they managed cost reduction of 35 percent. Although the objectives were not met, Mr Wang feels that changing the mind sets of his employees is important. That laid the foundation for more improvements. Said Mr Wang: “It takes us now three to five days to manufacture a telescopic cover from its raw form in Taiwan. Some 80 percent of our covers only require four hours to assemble.” This has resulted in the company’s capture of a 75 to 80 percent market share in Taiwan. In addition, this also meant that the company can produce upon order, enabling them to adopt a zero stock policy, which can be attributed to the Keyarrow Production System that uses a

‘one piece flow’ strategy that sees no ready products on hand, smaller quantity, diverse orders and by order production. Proximity Rules The company also has a peculiar concept in order to create a ‘winwin’ scenario with its customer. They believe in setting up an in-house factory within their c u s t o m e r ’s m a n u f a c t u r i n g plant, so they could save on transportation cost and also avoid damages that might occur during the process. The result is a lower price for customers but the same profit margin for the company. Mr Wang said the company currently has an in-house factory in Kaohsiung, the southern port city of Taiwan and in Kunming, China. MEN Enquiry No. 7601 Turn to page 80a or log on to www.equipment-news.com to enquire

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October 2012 metalworking equipment news

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Features

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Shedding Away

Machining & Set-Up Times

To automate its manufacturing process for shredding rollers, HSM has installed a radio touch probe on a turning and milling centre. The radio technology ensures reliable data transmission, permitting a reduction in set-up and machining times. By Winfried Weiland, marketing manager, Blum-Novotest

H

SM is a manufacturer of various document shredders and presses for material disposals. Whether document shredders or crushers, a large proportion of the products manufactured at HSM’s production department have rollers, which draw in and shred the material. A complete ra nge of machining centres is available for manufacturing these rollers, some of which are deeply grooved and mesh with each other when fitted or are equipped with knife edges. The machining centres are fitted with bar stock and then run their program more or less automatically. Top Quality Required “The demands on the quality of the rollers are very high: if two rollers with 0.65 mm wide grooves are

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meshing with each other to cut up paper into the finest strips, the smallest tolerances are required — after all, the rollers are not designed to touch each other when rotating. To achieve these accuracies, the rollers are first rough-machined, then its initial cut is measured and the adjustment parameters for final machining calculated,” says Marcus Winter, foreman in the Mechanical Production Department and divisional head of Turnery. This is carried out for every individual roller. Previously, the machine had to be stopped in the middle of machining. One alternative would have been to finish machining completely with no measuring and re-adjustment, but then scrap would have been higher. Last but not least, the enforced stoppage of the machine disrupted

the workflow and costs time, because at HSM one worker operates two, and in the case of large-run production, even three machines. Eliminating Error Today, the TC63-30 touch probe from mea suring technolog y provider Blum-Novotest is kept in the tool shop. If a measurement ha s to be performed on a n automate d ba sis b e fore or between machining stages, the touch probe is simply exchanged like a tool and the relevant measuring points collected. Data is transmitted via radio. The probe is supplied with power via two lithium batteries which, at a normal capacity utilisation of five percent, provide power for approximately four months. The readings are relayed via infrared or — as is the case at HSM — via radio to a receiver in the workroom. HSM had also been working for ma ny ye a rs w it h Blu m laser measurement systems, for example, for checking tool cutting edges in unma nned production or for the length and radius measurement of tools. Probes have also been used in the machining centres — at the start with infrared transmission. These a re reliable but, especially in the machining centres on which the rollers are produced, placing the infrared receiver is very difficult. As the turning and milling centres have swivel heads, it is virtually impossible to guarantee free line of sight in every position between the touch probe and the receiver. This is why the specialists ordered the first radio probes. Instead of transmission via the channel hopping method or channel allocation, which is the market norm, the probe transmits its data using the BRC technology promoted by Blum. The advantage of this technique lies in the fact that every bit of a radio signal is transmitted over a large frequency range, making the


Features

transmission particularly immune to parasitic inductions. “Radio touch probe systems usually require 10 ms and more to transmit the switch signal. In practice, however, what happens is that users measure with a different measuring speed than the one with which the system was calibrated, as a result, significant measuring errors can occur. The reason for this can either be the user’s fear of a collision with the workpiece or the mistaken belief that a lower measuring speed means a more precise measurement. As BRC technology only requires 2.5 ms for the transmission, this error can be virtually eliminated,” explains Erhard Strobel from Blum-Novotest’s Technical Sales Department. This is confirmed by HSM’s experts, who enjoy interferencefree transmission using the radio

probes. It also has a direct payoff, because if the data transmission fails to work, the system comes to a halt and the operator would then have to intervene manually. The company aims to generate the complete test record while machining is being carried out and to file it in SAP so the rollers would not have to be taken first to the quality assurance department to check for machining errors but could continue to be machined directly. Durable & Efficient The probes are resilient not only to mechanical stress but also during the measurement process. Because the saying ‘First clean, then measure’ is actually true. However, it does not matter for the probe as it will not be affected by cooling lubricant. In addition, the probes can be

used flexibly due to its modular construction and can be used with very light extensions made of carbon even at measuring points, which are very difficult to access. “Our entire collaboration with Blum - Novotest is ver y positive. Set- up times have fallen considerably due to the probes, in some cases by over 50 percent. Previously, for zero point recording and measurement of the initial cut, the machine had to stop and the operator had to measure by hand and enter the values into the machine control, a process which was also prone to error. Now measurement is integrated into machining and we can manufacture efficiently in three shifts with multi-machine operation,” says Mr Winter. MEN Enquiry No. 7602 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 086

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More

Machine Tools Wanted In China

D

emand for machine tools in China is projected to grow 14.2 percent a nnually to CN Y389 billion (US$61 billion) in 2014. This strong growth will bolster China’s current position as the world’s leading consumer and producer of machine tools. Both supply and demand will benefit from a number of government policies set forth in the 12th Five-Year Plan. Economic goals in the plan that are especially salient to the machine tool industry are the development of Strategic Emerging Industries (SEIs), which will receive beneficial government treatment and the push for ‘Indigenous Innovation’. The se a nd other trends, including market share and pro duc t se g me ntat ion, a re presented in Machine Tools in China, a study from the Beijing office of The Freedonia Group, a Cleveland-based industry market research firm. High- end equipment manufacturing is designated as one of the SEIs and will be extensively promoted by the Chinese government. Advanced machine tool manufacturing is an important segment of high-end

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Demand for machine tools in China is to grow over 14 percent annually through 2014. By The Freedonia Group

equipment manufacturing, and as such, the industry will benefit from subsidies offered by both the central and local governments for research and development. Sales of high-end machine tools will also benefit from favourable tariff policies that will promote the sales of domestic products. China plans to be an innovationoriented society by 2020 and a variety of megaprojects have been introduced to achieve the goal, including the development of CNC machine tools, which will focus on serving key industries, such as aviation equipment, shipbuilding, motor vehicles and generating equipment. Major Markets In China The major markets for machine tools in China are industrial machiner y a nd e qu ipment, t ra n sp or t at io n e qu ip me nt ,

primary and fabricated metals, and electrical and electronic equipment. Industrial machinery is the la rgest ma rket for machine tools due to the extensive use of various machine tools in numerous segments of the industry. Tr a n sp o r t a t i o n e qu ip m e n t manufacturing, the second largest market, has been supported by the explosive development of the automobile industry in China over the past decade. Metal cutting machine tools form the largest product segment, which is about three times larger than the metal forming segment. Demand for machine tool accessories is projected to increase at an annual rate of 16.1 percent to 2014, faster than both metal cutting and metal forming machine tools. MEN Enquiry No. 7603 Turn to page 80a or log on to www.equipment-news.com to enquire

China plans to be an innovationoriented society by 2020 and a variety of megaprojects have been introduced to achieve the goal


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EVENTs&exhibitions

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Event Preview:

Metalex 2012

A

s a driver that has been empowering the advancement of ASEAN’s metalworking industries, Metalex 2012 will be a technological compass for the region’s manufacturing technology with the largest exhibit space and the highest number of exhibitors who will debut their latest offerings across the show floor. The show, which had served regional industrial community for the last 26 years, will showcase an array of machinery by 2,700 global brands for 68,000 international buyers. Under the theme ‘The Future of ASEAN. The Plus of High Precision’, the event is a platform for global technology providers to debut their latest offering in Thailand and Asia. Some examples are: • CNC Machine with pre-tension x double anchored ball screw • W i r e c u t t i n g m a c h i n e with automatic threading device and high speed submerged cutting • CNC jigborer that offers highprecision for mould surface up to three microns • Double column machining centre with automatic BC head

Exhibitors At The Show Some of the highlighted brands at the show include ABB, Carl Zeiss, Agie Charmilles, Haas, Hexagon, Hwacheon, Iscar, Mazak, Mitsubishi, Mitutoyo, DMG/ Mori Seiki, Nikon, Okamoto, Okuma, Sodick, Taegutec, Trumpf, Tungaloy and Renishaw, who will showcase the Equator, a gauging system.

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metalworking equipment news October 2012

• High-precision tool presetter with maximum resolution of 488 x 486 pixels, diameter of 400 x 400 mm, and measuring precision of one micron. New Knowledge For Tomorrow There are also many activities lined up during the show such as technical forums, business match making sessions and product presentations. This year will see the Metalex Nano Forum return for its second edition, showing participants nanoenhanced technology for the metalworking industry. Others can explore collaboration opportunities and promote the manufacturing quality of the mould and die industries in the ‘Japan – Thai Mold & Die Symposium’ which is the only event that Japanese Society of Die and Mould Technology (JSDMT) host outside Japan. The Asian Welding Federation (AWF) is also having a meeting

with AWF high-ranking members from 13 countries across Asia in a bid to enhance the welding excellence. For those eager for business leads, the business matchmaking program allows participants to plan ahead in order to make the most of their visit by making available an online preappointment service. Finally, a session catered to products making their respective debuts, the ‘First-Time-in-ASEAN Te c h n o l o g y P re s e n t a t i o n s ’ allows the expansion of strategic visions with new knowledge and technological experiences through on-site conference sessions.

BITEC Bangkok, Thailand November 21 – 24, 2012 Enquiry No. 7701 Turn to page 80a or log on to www.equipment-news.com to enquire


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The organisers of the show have been conducting roadshows across ASEAN countries to attract visitors to the show in order to add to the internationality of the event, which already boasted the participation of 10 international pavilions. According to Chainarong Limpkittisin, MD, Reed Tradex Company, the roadshows visited countries like the Philippines, Singapore, Vietnam, Malaysia and Indonesia. The shows were sponsored by Thailand Exhibition and Convention Bureau (TCEB). With the Thai economy estimated to grow for machinery and metalworking industry in 2012, there is bright export potential for all ASEAN markets. It is believed that the market for machinery and metalworking technology in Asia will grow by 20 percent this year, making the roadshows a good tool to drive these messages across and foster good working relationship between ASEAN nations. The organisers have stated during the roadshows that foreign visitors will have special privileges like attending international forums such as Machine Tools Summit — Innovation of machine tools and metalworking with high precision technology and the Nano Metalex Forum free of charge.

Enquiry No. 7702 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 177

Metalex Roadshows

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EVENTs&exhibitions

M

anufacturing Indonesia 2012 is scheduled to return from December 5 – 8, 2012 at the Jakarta International Expo Centre, Kemayoran, Jakarta. The manufacturing technologies and solutions event, which is into its 22nd series, is anticipated for the innovations and capability advancements expected to be showcased on the show floor. Once again, the manufacturing event in Indonesia will occupy all nine exhibition halls. To cater for increased space demands, an additional temporary structure has also been added. In total, the show is expected to gather over 2,600 exhibiting companies from 40 countries. National and regional pavilions committed include China, Germany, Japan, South Korea, Russia, Singapore, Taiwan, Turkey, the UK and the US. Machine Tool Indonesia in particular, has set a good growth pace with participation from players such as DMG/Mori Seiki, First Machinery, Jaya Metal Teknika, Leeport, Trumpf and Somagede Indonesia endorsing the event as the industry platform to partner manufacturing developments in Indonesia. Simultaneously, Industrial Automation & Logistics Indonesia, Tools & Hardware Indonesia and Fastener & Fixing Indonesia, have grown in tandem to add credibility to the Manufacturing Indonesia series as an end to end manufacturing event, facilitating heightened engagements between solution providers and users, buyers, as well as trade professionals. “With its focus on innovations and capability advancements, the Manufacturing Indonesia series has emerged with strategic significance to the manufacturing community,” said Maysia Stephanie, senior project manager for the organiser, PT Pamerindo Indonesia. “Production bandwidths are

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www.equipment-news.com

Event Preview:

Manufacturing Indonesia 2012

expanded and indeed, substantial purchases are transacted over the duration of the show,” she added. The show is supported by Ministry of Industry, Republic of Indonesia, Association of Metalwork and Machinery, Indonesia Precision Tooling Industry Association, Indonesian Automotive Parts & Components Industries Association,

Indonesian Machine Tool Industries Association and Indonesian Mould & Die Industry Association. Jakarta International Expo Centre Jakarta, Indonesia December 5 – 8, 2012 Enquiry No. 7703 Turn to page 80a or log on to www.equipment-news.com to enquire


EVENTs&exhibitions

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AAIS

A

eroSpace eXchange (ASX) 2013 is back for its third edition, with more in store for delegates and exhibitors alike. From February 27 - March 1, 2013, the Singapore Expo Hall 6 will become the showground for aerospace suppliers across the value chain, making for a show that promises value-add to participants. Riding on the successes of the previous editions, the ASX has since been expanded to offer the industry an enhanced platform to showcase their capabilities. Reflective of the new ASX, the show’s name in itself has been changed from Aerospace Supplier eXchange to AeroSpace eXchange, illustrating the show’s broadened focus. An integral part of the show, the ASX 2013 Conference has been enhanced since its first two shows, with new conference tracks developed in addition to the wellreceived AeroSuppliers track that has been a focal point since 2009. The 2013 edition will now include Aviation Security and Civil & AeroDefense MRO conferences, with further plans to incorporate Training & Simulation and Space & Satellite into future editions of the show. In addition, the Leadership Forum will make its debut at the show. Enhancements To The Show The show will boast a bigger showground as compared to its

Event Preview:

Aerospace Exchange 2013

predecessors. Some 10,000 sq ft of floor area — almost three times the size of previous shows — will be occupied by exhibitors, conference halls, networking and meeting areas to cater to the many aspects of the show, as well as the needs of exhibitors and delegates. A new feature of the show will be a demonstration area for exhibitors to showcase their products and for delegates to witness live demonstrations onsite. On the need for an expanded and enhanced show, Dr Aloysius Tay, chief executive, Association of Aerospace Industries (Singapore), said: “From industry feedback, we saw the need for a show that focuses not just on tier three and four suppliers, as the show was originally intended for, but one that also showcases suppliers across the entire aerospace supply chain. As Singapore continues to maintain itself as the aerospace hub of choice in the region, it is important that all companies that make up the aerospace ecosystem here in Singapore continue to profile themselves to stay competitive.” The show is expecting an estimated 8,000 visitors, and organisers are optimistic that about S$6 to 8 million (US$4.9 to 6.6 million) worth of contracts will be signed at the show. Leadership Forum The ASX Leadership Forum will occur on the second and third days of the event. It will cater to aviation leaders across the value chain including regulators, associations

and HR professionals, and will focus on how their roles can be enhanced to address pertinent challenges in the industry. It will also include panel discussions to allow for an interactive and engaging session between speakers and delegates. International Aviation Association Leaders’ Meeting The International Aviation Association Leaders’ Meeting will highlight the roles that associations and regulators play in the growth and development of the aviation industry. Current trends, challenges and good practices will also be discussed. The meeting will also touch on manpower trends that will set the stage for the second day of the Leadership Forum, which will go in-depth to explore issues relating to the next generation aviation professional. Next Generation Aviation Professional (NGAP) Conference The NGAP Conference is an extension of the NGAP initiative recently raised by the International Civil Aviation Organization (ICAO). Having touched on manpower issues on the first day of the forum, the conference will go into greater depth and bring to the forefront the challenges of attracting and retaining young talent, and other manpower challenges facing the global industry today. Singapore Expo Singapore February 27 - March 1, 2013 Enquiry No. 7704 Turn to page 80a or log on to www.equipment-news.com to enquire

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The Evolutionary Journey Of APMEN 1986

The Beginnings Established in 1986, Asia Pacific Metalworking Equipment News or APMEN started with readers mostly in Southeast Asia.

2008

1990-1999

2000-2006

2004

2007

The Tough Times The early years were tough with the Asian Financial Crisis in the 90’s. With the help from the metalworking fraternity, the magazine survived to go on an unprecedented growth.

Keeping Our Numbers Real The years 2000-2006 saw the print version became the first metalworking title in Asia to be BPA audited. In addition, the APMEN website was launched in the year 2000.

The Electronic Age — Extended Reach For Advertisers In 2004, APMEN went digital, giving birth to eAPMEN. Today, we are proud to report eBook readership of 28,000.

Hitting The Road Since 2007, a number of regional shows were established thanks to the rapid development of the industry. These new shows provide a massive boost in our subscription numbers.

2011

2012

New Franchises The launch of APMEN’s Vietnam Guide Book in 2008 was a proud moment for us because it gave what our readers in Vietnam what they have been calling out for. Following that, MEN Indonesia was launched in 2011 to cater to the burgeoning economy in the archipelago, bringing the best of APMEN in Bahasa Indonesia.

2013

The Present Today, we have over 38,000 qualified subscribers from all over Asia Pacific, making us truly regional. Our eBook is also now available in iOS and Android enabled platforms.

The Future We have new products coming your way in 2013. They are VidzAds and DigiAds, giving you good value for money.

We may have increased in size but the cost of advertising with us has gone down. Our CPM is only US$90, making us a quality publication with the lowest cost and highest ROI. Join us in this journey of growth and be part of this metalworking tradition in Asia Pacific today!

apmen@epl.com.sg Tel: (65) 6379 2888 • Fax: (65) 6379 2805 www.equipment-news.com


Product Finder

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Delcam: Software For Inspection & Reverse Engineering

Delcam has released the 2012 R2 version of its PowerInspect software for inspection and reverse engineering. This includes enhancements to the inspection capabilities and also continues the development of the reverse engineering capabilities introduced earlier this year. The main enhancement in this area has been an expansion of the digitised curves capabilities to create a powerful re-engineering and modelling tool. Improvements to the inspection functionality include a simplified procedure enabling users to calibrate the probe assembly by probing a single point anywhere within the measuring envelope. Enquiry No. 7801 Turn to page 80a or log on to www.equipment-news.com to enquire

The NLX2500/1250 is a CNC lathe with a 10-inch chuck for machining long workpiece with a maximum turning length of 1,255 mm, which is extended 550 mm from the present NLX2500/700. The machine, produced by Mori Seiki uses rigid slideways with damping performance on all axes and a coolant circulation technology for its bed to control thermal displacement. In addition, a variety of option such as loader and steady rest contribute to increasing the productivity of shaft workpiece. Other notable feature is its energy saving ability where power supply for a spindle motor, servo motors and a fan inside the electrical cabinet can be stopped in the shutdown mode. Enquiry No. 7802 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 168

DMG/Mori Seiki: Rigid & Precise CNC Lathe

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productfinder

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Morgan Technical Ceramics: High Temperature Bimorph Range

Dormer: Expanded Tap Range

Dormer has expanded its multi-application threading program with the introduction of titanium nitride coated taps, which provide improved wear resistance and increased productivity. Available in DIN or ISO standard in both spiral point and spiral flute geometries, the taps will be of interest to anyone performing threading operations in steel, alloy steel, stainless, copper or aluminium. The surface treatment provides high hardness combined with low friction properties. This ensures considerably longer tool life and better cutting performance over uncoated taps. All spiral flute geometry taps feature a three radii flute profile with a constant rake angle that facilitates the creation of narrow, regular chips. This, combined with adequate flute space, results in negligible chip congestion.

Morgan Technical Ceramics is extending its electro ceramics portfolio, with the launch of a range of high temperature piezoelectric bimorph components, suitable for sensor and actuator applications in the fields of aerospace, automotive, medical and general industry. The components are two-layered PZT (Lead Zirconate Titanate) devices, which feature a formulated core created from high temperature conductive epoxy glue. They can operate in continuous temperatures of up to 180 deg C, which represents half the Curie temperature of the piezoelectric materials. The bimorphs are available in a variety of sizes and configurations including squares, rectangles and discs. Sizes range from 6 to 74 mm in length and 1 to 43 mm in width.

Enquiry No. 7803 Turn to page 80a or log on to www.equipment-news.com to enquire

Mobil Industrial Lubricants: Advancement For Higher Performance Mobil advancedtechnolog y g re a se s are designed to offer extended regreasing inter vals, longer equipment life, and greater productivity. When it comes to lubricating a wide range of machinery, greases are required to provide the necessary protection to improve productivity and reduce costs. Mobil’s greases — whether mineral or synthetic — can help provide better equipment protection and extended grease life, and enable problem-free operations. They are based on mineral and synthetic base fluids in combination with patented thickener technology and synergistic additive systems. These greases are designed to meet a variety of operating conditions in both industrial and mobile equipment, including extreme applications such as high and low temperatures; water contamination; heavy or shock loads; or variable speeds. Enquiry No. 7804 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 7805 Turn to page 80a or log on to www.equipment-news.com to enquire

Renishaw: Extended Flexibility The XR20-W rotary axis calibrator by Renishaw features bearing and encoder technology as well as Bluetooth wireless technology. This design has enabled the reduction in size and weight of the equipment compared to the outgoing RX10. At just over 1 kg, the unit has achieved that goal, which has advantages for ease of use and applications flexibility. A separate mounting base enables simple, fast and easy centration and fixing, while adapters supplied with the main unit allow fitment to a variety of rotary tables and axes, including lathe chucks and spindles. The rotary axis calibrator includes ‘built in’ retro-reflectors, with separate alignment targets on the reverse side of the retro-reflector housing. Together, these features ensure faster set-up and minimise alignment errors that can lead to measurement errors. Enquiry No. 7806 Turn to page 80a or log on to www.equipment-news.com to enquire


productfinder

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SIC Marking: Fibre Laser System

chip protection energy, data, media dirt resistant...hot

igus® Singapore Pte Ltd 15 Shaw Road #03-02 Singapore 367953 asia-sales@igus.com.sg

ENQUIRY NO 186

A range of integrated laser i 103 l-g meets marking needs on plastic or metallic parts which are subjected to close tolerances or very high rates of production. The choice of the fibre laser technology allows it to be more compact. As a result, its integration into production line is easier. The laser is noted for its high speed of execution, due to optic fibre and sources going from 10 to 50 W. It can also guarantee up to 100,000 hours without maintenance fees. Using the laser, SIC Marking has developed a controller, the fibre unit. Pertinent feature of this controller is its stand-alone function, doing away the need for a PC. With the system, all marking types like alphanumeric, datamatrix, logos, deep or superficial are possible. Enquiry No. 7807 Turn to page 80a or log on to www.equipment-news.com to enquire

Adaptable SUHNER power tools – for difficult tasks and special shapes. Handy and with good torque characteristics.

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

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

ENQUIRY NO 081

ENQUIRY NO 159

www.suhner.com

October 2012 metalworking equipment news

77


productfinder

www.equipment-news.com

Suhner: Lightweight Fillet Weld Grinder

Walter: Indexable Inserts With PVD Coating

Efficient tools for working stainless steel are adopting a more important role in metal construction. The UKC 3-R fillet weld grinder by Suhner is an addition to the company’s range of special tools for abrasive stainless steel working. The fillet weld grinder is suitable for hard-to-access fillet welds — a problem zone often encountered for example on vessels and railings. Weighing at 1.8 kg, the equipment’s rated power input is 500 W and its speed range is 1,400 to 3,300 rpm. For minimised tool weight and optimised manoeuvrability, a low long-neck angled head was developed. This long-neck angled head is made of diecast aluminium. The high reduction is obtained with two-stage gears. The first gear stage is a parallel helical gear pair for smooth running with low noise emissions. The second stage is a palloid tooth system.

Walter has developed the manufacturing technology enabling a further increase in the high-temperature wear resistance of PVD aluminium oxide coatings without simultaneously having to accept any compromise in toughness. The improved cutting tool material is coming on the market under the name Tiger•tec Silver PVD. A quartet comprising four cutting materials for recessing, grooving and parting off operations are designated as WSM13S, WSM23S, WSM33S and WSM43S. The cutting material WSM13S is suitable for use in stable machining. The cutting material WSM43S is appropriate for unstable clamping arrangements and machining conditions. The middle variants WSM23S and WSM33S cover the intermediate range.

Enquiry No. 7808 Turn to page 80a or log on to www.equipment-news.com to enquire

TaeguTec: Double Sided Inserts For Heavy Turning

Yih Chuan: Articulated Head Machining Centre

TaeguTec has developed the Top Duty series of inserts to give users the advantage of using double sided inserts in heavy turning without compromising on performance. The CNMD/SNMD 19/25/32 mm inserts are designed with different chipbreakers on both the top and bottom sides. On the top side, the manufacturer’s roughing HT, HD, HY and HZ chipbreakers make it suitable for heavy turning applications. On the bottom side, a finishing chipbreaker for DOC <5 mm designed with a flat face provides stability during roughing with the top face

V H - 11 9 U i s a n articulated head machining centre develop e d by Yih Chuan. It can support 4+1 for five-face machining, and also manages five axes simultaneously by adopting different controllers. The machine is fitted with programmable articulated head (A axis), featuring cost effectiveness on large workpieces’ machining compared to machines with tilting rotary table design, whose working range are greatly limited due to the tilting design where the customer can only work with a small area. The embedded Ø700 mm C axis plus high torque build-in spindle motor supplies 17 kW power with maximum speed of 15,000 rpm, no counter-weight balancing system prevents structural jerking that hampers cutting performance on surface finish.

Enquiry No. 7809 Turn to page 80a or log on to www.equipment-news.com to enquire

78

Enquiry No. 7810 Turn to page 80a or log on to www.equipment-news.com to enquire

metalworking equipment news October 2012

Enquiry No. 7811 Turn to page 80a or log on to www.equipment-news.com to enquire


Exhibition Programmes

2012-2013

October

4–6 Metalex Vietnam

7 – 11 TMTS 2012

27 Feb – 1 Mar ASX 2013

23 – 27 EuroBlech 2012

21 – 24 Metalex

March

GTIEC Taichung, Taiwan TMBA ricky@tmba.org.tw www.tmts.tw

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

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

Exhibition Grounds Hanover, Germany Mackbrooks Exhibition info@mackbrooks.co.uk www.euroblech.com

December

November

5–8 Manufacturing Indonesia 2012

1–6 JIMTOF 2012 Tokyo Big Sight Tokyo, Japan JMTBA www.jimtof.org

6 – 10 China International Industry Fair 2012 SNIEC Shanghai, China www.ciif-expo.com

2013 January 24 – 30 Imtex 2013

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

7–9 Indonesia Oil & Gas Expo 2012

Balikpapan Int'l Sport Arena Balikpapan, Indonesia Fireworks info@asiafireworks.com www.indonesiaoilgas.com

February 20 - 23 Indometal

7 – 10 Indo Aerospace 2012 JIExpo Jakarta, Indonesia www.indoaerospace.com

Jakarta Int'l Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

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

To be considered for inclusion The Editor (APMEN) in the calendar of events, Eastern Trade Media 1100 Lower Delta Road, EPL Building, #02-05, send details of event to:

Singapore Expo Singapore AAIS asx@aais.org.sg www.asx.sg

5 – 10 TIMTOS

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

26 – 29 Inapa 2013

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

April

9 – 12 MTA 2013

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

May

16 – 19 Intermach 2013

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

21 – 25 Metaltech 2013

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

Singapore 169206 Email: josonng@epl.com.sg Tel: +65 63792888

www.equipment-news.com October 2012 metalworking equipment news

79


Advertising Index Page No.

Enquiry No.

AGIE CHARMILLES (SEA) PTE LTD

41

180

Advertiser ASSOCIATION OF AEROSPACE INDUSTRIES (SINGAPORE) (ASX 2013)

69

175

BENIGN ENTERPRISE CO LTD

59

085

BLUM PRODUCTION METROLOGY PTE LTD

33

181

BYSTRONIC PTE LTD

03

174

DEES HYDRAULIC INDUSTRIAL CO LTD

77

081

DELCAM PLC (INTERNATIONAL DIVISION)

05

169

DMG ASIA PACIFIC PTE LTD

FC

182

EVERGREEN INTERNATIONAL CORP. (TAITRA) / TIMTOS 2013

63

167

EVERISING MACHINE CO

47

176

EXXON MOBIL

43

165

FACTORY AUTOMATION TECHNOLOGY CO LTD

29

173

FRITZ STUDER AG

IBC

160

HAAS AUTOMATION INC

09

158

HEIMATEC GMBH

31

172

HEXAGON METROLOGY (THAILAND) LTD

25

166

HPMT INDUSTRIES SDN BHD

39

139

HURCO (S.E.ASIA) PTE LTD

19

183

IDEMITSU LUBE (SINGAPORE) PTE LTD

21

162

INGERSOLL-RAND SOUTH EAST ASIA (PTE) LTD

49

111

Igus Singapore PTE LTD

77

186

ISCAR LTD

IFC

184

KENNAMETAL INC

BC

128

LICO MACHINERY CO LTD

67

086

LVD COMPANY NV

37

161

NEWELL RUBBERMAID (M) SDN bHD

35

163

16/17

179

OPTICAL GAGING (S) pTE lTD

45

125

PAMA SPA

55

113

OKUMA TECHNO (THAILAND) LTD

80

www.equipment-news.com

REED TRADEX COMPANY (METALEX THAILAND 2012)

61

185

RENISHAW (HONG KONG) LTD

23

054

SECO TOOLS (S.E.A) PTE LTD

01

065

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2013)

75

168

SUHNER ABRASIVE EXPERT AG

77

159

SUTTON TOOLS PTY LTD

15

103

TAEGUTEC CO

11

171

TAIWAN TAKISAWA TECHNOLOGY CO LTD

53

058

TECHTOWN PTE LTD

51

164

TUNGALOY SINGAPORE (PTE) lTD

13

170

WALTER AG SINGAPORE PTE LTD

07

039

WENZEL ASIA PTE LTD

71

177

WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG

27

178

YIH CHUAN MACHINERY INDUSTRY CO LTD

65

080

metalworking equipment news October 2012

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

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

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ASIA PACIFIC METALWORKING

No. 7 2012

The Engineering Journal For Manufacturing,Automation & Quality Control

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CNC Machining Milling Gear Cutting Grinding Stamping Shearing

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1912 – 2012 STUDER – a 100 year success story. METALEX, Bangkok TH 21 – 24 November 2012 Hall 102, Booth J09

DKSH Technology Pte Ltd 37, Jalan Pemimpin #02-04 Singapore 577177 claus.bressmer@dksh.com

DKSH Technology Co., Ltd. E-Town 2 Building 1st floor, 364 Cong Hoa Street, Ward 13 Tan Binh District, Ho Chi Minh City, Vietnam daniel.meyer@dksh.com

DKSH (Thailand) Limited 30th Floor, Thanapoom Tower 1550 New Petchburi Road, Makkasan, Rachathewi Bangkok, Thailand 10400 weilun.tsao@dksh.com

DKSH Technology Sdn Bhd No. 14, Jalan Bersatu 13 / 4 46200 Petaling Jaya Malaysia claus.bressmer@dksh.com

Fritz Studer AG CH-3602 Thun Telephone +41-33-439 11 11 · Telefax +41-33-439 11 12 www.studer.com

ENQUIRY NO 160


WIN WITH WIDIA

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

WIDIA VariDrill

tm

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

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

ENQUIRY NO 128

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

APMEN Oct 2012  

Asia Pacific Metalworking Equipment News

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