Canadian Metalworking

March 2010 • www.canadianmetalworking.com

Industry

Insights

3rd Annual National Benchmarking Survey

22

MACHINING: Evolution of machine tool communications

35 CUTTING TOOLS: Southwestern Ontario

landing gear maker gets proactive about choosing tools for cutting titanium

38 FABRICATING: An electric punch press slashes manufacturer’s energy costs

46

WELDING: Laser welding makes inroads

into new applications

CANADA: A new standard for 6 QUALITY the aerospace MRO market is intended

to help the industry produce higher quality products at lower costs

Very BIG and beautifully engineered

Hurco’s NEW DCX Series.

High Capacity, Dual Column Machining Centers.

Because SIZE is important...

CANADA

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VMX Series High Performance Mills

800.992.7314

Travels Spindle Tools

VM Series U Series (5-Axis) SR Series (5-Axis) General Purpose Trunnion Table Swivel Head, Rotary Table Mills Mills Mills

DCX22 - 40T 86.5″ x 66.9″ x 29.5″ 8k, 10k or 15k 40 CAT (BT) 40

DCX Series Dual Column Mills

Z Series Zone Mills

DCX22 - 50T 86.5″ x 66.9″ x 29.5″ 6k 40 CAT (BT) 50

HTX Series Horizontal Mills

Machines shown with options. Information may change without notice.

DCX32 - 50T 126″ x 82.7″ x 36.2″ 6k or 10k 40 CAT (BT) 50

TMX Series High Performance Lathes

TM / TMM Series General Purpose Lathes

KOMPAKT

Plasma Systems The design of the HACO KOMPAKT is based on a long experience in the field of CNC Plasma Cutting Machines. The large range of tables sizes and Plasma Cutting Sources (conventional as well as high-definition), means that we can offer you the perfect machine for your specific application.

The Haco KOMPAKT is manufactured to the highest standards. The optimum price/quality ratio of the Haco KOMPAKT translates itself into a profitable investment.

HACO PRESS MASTER Press Brakes

• SIMPLE • FAST • ACCURATE • RELIABLE Affordable Bending Solutions • Capacities: 44 to 450 Tons • Bending lengths: 5’ to 20’ • Equipped with: • Synchro type Depth Axis (X1-Y2) • Heavy Duty Two Axis Back Gauge (X-R) (R-Height control) • Manual Adjustable Crowning Table • N.A. Style Top & Bottom Tool Clamping

Optional : • CNC Crowning • ATS 9000 2D Graphic Control • Different Style of Tooling Clamping

CNC PUNCHING MACHINES

HYDRAULIC PLATE BENDING ROLLS

HYDRAULIC SHEARS

CNC PLASMA CUTTING MACHINES

KINGSLAND IRONWORKERS

CORNER NOTCHERS

HYDRAULIC PRESS BRAKES

HYDRAULIC PROFILE BENDING MACHINES

HACO CANADA INC.

www.hacocanada.com

Mississauga Office

2550 Dunwin Drive, Mississauga, Ontario L5L 1J5

Tel: (905) 828 1087 Fax: (905) 828 2062 sales@hacocanada.com

CELEBRATING MATSUURA’s

75th ANNIVERSARY

Special Sale Pricing on ALL In-Stock Models!

ELLIOTT – CANADA’S LEADING MACHINE TOOL DISTRIBUTOR INQUIRE ABOUT: SPECIAL PRICING! EXTENDED WARRANTY! EXTENDED PAYMENT TERMS! APPLICATION SUPPORT! OFFER EXPIRES JUNE 30TH, 2010

Five Axis Machining Center

Five Axis Multi Tasking Machining Center

Vertical Machining Center

Horizontal Machining Center

Matsuura – Manufacturer of HIGH PERFORMANCE Machine Tools Elliott – Renowned for 60 YEARS of unparalleled SERVICE and APPLICATION SUPPORT Elliott Matsuura Canada Inc. 2120 Buckingham Road Oakville, Ontario, L6H 5X2 Tel: 905-829-2211

sales@elliottmachinery sales@elliottmachinery.com .elliottmachinery www.elliottmachinery.com

www.canadianmetalworking.com | volume 105 | no.2 | march

FABRICATING/PUNCH PRESSES & TOOLING

38 A PRESSING NEED

A sheet metal fabricator’s green focus and investment in an electric press generates 40% electrical savings.

automation

FABRICATING/LASER MARKING

43 MOVING TARGET

New approaches and technologies, such as “on the fly” and fiber laser marking, are opening new doors for laser marking.

12

fabricating

46 GOING MAINSTREAM

INDUSTRY REPORT/TRANSPORTAION

Laser welding is becoming cost effective for mainstream welding applications.

12 MOVING AHEAD Machine tools

Trains, buses and ships are moving again and industry experts see a brighter future.

WELDING/LASER WELDING

EXPANDED QUALITY COVERAGE Between page 26-27

BUSINESS REPORT/NATIONAL BENCHMARKING SURVEY

18 INDUSTRY INSIGHTS

Business Report

Despite a challenging economic climate, manufacturers are more optimistic about 2010 and beyond, reveals Canadian Metalworking’s 3rd Annual National Benchmarking Survey.

6 SETTING HIGH STANDARDS

A new standard for the aerospace MRO market is intended to help the industry produce higher quality products at lower costs.

MACHINE TOOLS/MILLING

22 TECHNOLOGICAL LEAP

MEASUREMENT/IN-LINE

The advantages of migrating from Serial to Ethernet communications on the shop floor. tooling

8 LAYING IT ON THE LINE

In-line measurement is a cost-effective way to maintain process capabilities, says in-line expert, Peter Detmers of Mitutoyo Canada.

MACHINE TOOLS/MATERIAL HANDLING

28 HANDLING COSTS

Tips on cost-cutting ways to automate material handling on the shop floor.

Quality Canada asks Ned Espy of Beamex how calibration and calibration software can improve quality management.

31 CUTTING CLASS

Cutting tool suppliers’ innovative solutions are helping manufacturers overcome titanium challenges.

SOFTWARE/CALIBRATION

9 CALIBRATION GUIDANCE

CUTTING TOOLS/MILLING

quality control

SPECIAL REPORT/AEROSPACE

> > > > > > > > > > > > > Departments > > >

CUTTING TOOLS/SPECIALTY TOOLING

35 SMOOTH LANDING Welding

Southwestern Ontario landing gear maker gets proactive about choosing tools for cutting titanium.

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5

Editor

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Anthony P. Viner

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>>>>>>>

Editorial

upfront

Arranged Marriages According to some social studies, arranged marriages are less likely to end in divorce than marriages based on love.

Similarly, a study of the longevity of partnerships between manufacturers and parts suppliers might reveal that the “arranged” ones would be less likely to end in “divorce” than those based on price alone.

Unfortunately, in the current economic climate, manufacturers want to cut costs to become more competitive and one way to do that is to negotiate lower prices with parts suppliers. And as many parts suppliers know, there is only so much cost you can cut out of parts production before you begin to compromise on quality.

When parts suppliers find themselves in these situations, it’s a doubleedged sword; not only do they stand to lose the business with the manufacturer, but they can also be labelled unfairly as a poor quality supplier.

To combat this, parts suppliers must come up with strategies that highlight the important role they can play in a manufacturer’s success.

Magna stands out as one example of how a parts supplier can become an integral partner for a manufacturer. Magna’s model of complete vehicle component assemblies has been well received by its customers and the company has managed to build strong relationships with some of the big automotive manufacturers. When Magna’s initial successful bid for control of General Motors Co.’s Opel/Vauxhall operations became known, some of Magna’s automotive manufacturing customers questioned whether they could do business with the parts supplier who would also be a competitor. Yet, Ford Motor Co.’s chief financial officer Lewis Booth publicly said that it could still work with Magna even if it held ownership in a rival automaker. In a September 11, 2009, online news story at www.plasticsnews.com, Booth said “Magna’s a good supplier. We like working with them and we’ll manage the issues as they come up.”

Another example is CTS, the parts supplier who supplied the now infamous gas pedals that caused the initial recall of several of Toyota’s models. Instead of becoming an adversary and pointing fingers at Toyota, it worked closely with Toyota to make new pedals. And as USA Today writer James R. Healey noted in a January 29 online article, “working through the recall could strengthen ties to Toyota. By acting as a partner— helping design a replacement pedal assembly for one—rather than as an adversary, CTS could earn more Toyota business.”

The two examples I’ve cited are from the automotive market, but the approaches these parts suppliers have taken can be adopted easily by suppliers to the aerospace and defence, medical, resources and energy markets.

Become an integral partner to your customer and chances are your marriage is less likely to end in divorce.

Mary Scianna, Editor

Content copyright ©2010 by Rogers Publishing Limited, may not be reprinted without permission.

GST# R103439444 QST# 1002114875-TQ-0001-MK ISSN: 0008-4379

If you want to comment on editorial in the magazine, I’d like to hear from you, so please contact me. mary.scianna@rci.rogers.com • 461-764-1540 6 | March 2010 | www.canadianmetalworking.com

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Industry news

Elliott Matsuura expands product offering with Samsung machine tools

Elliott Matsuura Canada Inc., Oakville, ON, has expanded its product line following an agreement with Samsung Machine Tool to sell the company’s products in Canada.

Samsung Machine Tool is a certified ISO 9001 and CE metal cutting machine manufacturer that in the past built licensed products for notable machine manufactures as OKK, Mori Seiki, and Toshiba.

“We are confident that the relationship between Elliott Matsuura and Samsung Machine Tools has a bright future. We are excited to see where this partnership will take us,” says Steve Lesnewich, president of Samsung Machine Tool America.

Elliott Matsuura Canada Inc. has been supplying machine tools to the Canadian metal cutting industry since 1950. The distributor carries a full range of metalworking machinery, including EDM machines, machining and turning centres, grinders, metal forming and metrology equipment, horizontal boring mills, vertical turning lathes and other machinery.

Westway Machinery takes on plasma cutting line for Eastern Canada

Westway Machinery, Mississauga, ON, has been named the exclusive sales representative for Eastern Canada for Plasma Automation Inc. and sister company Vicon Machinery LLC, based in Bohemia, NY. Westway will sell the company’s lines of plasma cutting systems, HVAC plasma, liner cutting systems, coil duct processing lines and roll forming equipment.

Westway Machinery specializes in metal forming machinery used in the fabrication, stamping, and HVAC sheet metal industries. The fabrication equipment distributor maintains a large inventory of equipment at its Mississauga location, including hydraulic ironworkers, presses, press brakes, and plate shears.

Spark & Co. to sell Hurco machines in Quebec

Spark & Co., Blainville, QC, has been appointed the Quebec agent for Hurco Canada Ltd., Mississauga, ON. Hurco says that the owners of Spark & Company, Guy Belanger and Ismael Abarca, have extensive experience in the machine tool industry and understand the value of Hurco technology for the Canadian market.

“The professional approach and the relationships they have with their clients are very impressive,” says Joe Poulin sales and operations manager for Hurco Canada. “Their enthusiasm will transpire with our customers and I am very happy to welcome them to the Hurco family.”

Because the aerospace sector is vital to manufacturing in Quebec, the investment Hurco has made in five axis technology is beneficial to many machine shops.

Currently, Hurco has two types of five axis machines, the SR series that uses a swivel head and horizontal rotary table (VMX42SR and VMX60SR), and the U series designed with an integrated trunnion table (VM10U, VMX30U, VMX42U, VMX60U, and VTXU).

Columbia Marking Tools adds Ontario reps to distribution network

Metal and plastic marking equipment maker Columbia Marking Tools, its new division I-Mark, Chesterfield, MI, and Proactive Sales Associates, with offices in Brampton, and Maple, ON, have signed an agreement that will see Proactive selling Columbia’s marking tools in Ontario.

Proactive sales representatives Mike Balfour and Vince Colaluca will be responsible for selling Columbia’s products. Balfour has more than 29 years of experience in the steel fastener industry, while Vince Colaluca has more than 26 years of experience in the same industry.

Columbia Marking Tools and I-Mark design and manufacture metal and plastic marking equipment including stamps, roll marking dies, roll marking and impact marking machines, fully programmable laser, dot peen and scribe marking and UID/2D Square Dot machines, marking machine software, numbering heads and special marking machines. Columbia Marking Tools Inc. and I-Mark are also a certified Cognex Integrator.

8 | march 2010 | www.canadianmetalworking.com

Calendar MARCH 30 American Society for Quality (ASQ) Toronto Section Spring Seminar. webmaster@asqtoronto.org 647-723-3811 APRIL 7 & 8 Mazak Canada open house in Cambridge, ON. 800-668-5449 www.mazakcanada.com 800-668-5449 APRIL 7 Five axis machining seminar at Camplete Solutions, Waterloo, ON. With presentations from Elliott Matsuura, Emuge, Camplete, M&H Inprocess. Tim Franklin tfranlin@elliottmachinery.com 905-829-2211 May 10-12 Excellence in Manufacturing Consortium (EMC) National Manufacturing Conference in Hamilton, ON. conference@ emccanada.org 866-323-4362 May 17-20 Montreal Manufacturing Technology Show (MMTS) at Place Bonaventure in Montreal, QC. Organized by SME Canada. www.mmts.ca 888-322-7333

people Darren Carroll is the new direct sales manager in Canada for MC Machinery Canada, Richmond Hill, ON. He will be responsible with leading sales efforts for multiple Mitsubishi product lines and for providing better support to the sales team. He has extensive knowledge of Mitsubishi product lines and previously served as Hirschmann Engineering and VP of EDM operations at MC Machinery Canada.

>>>>>>>

shop talk

Have you ever gone on a trade mission to another province or country? Did it bring in new business?

“Yes. We participated in an industry specific ‘Road Show’ in the USA. A market survey and invitation to identify industry leaders preceded the events. Suppliers with related technologies participated and technical presentations were done to relatively small audiences. New business, both at the time and later did result.”

-Debbie Blowe, systems manager, Vibra Finish, Mississauga, ON

“Yes and yes. Harbour has gone on trade missions to Alberta, Alabama, Spain, Korea and various other countries. We did get some business out of some of these trips, however, it is not usually the trip that gets you the business—it’s the follow-up trips and relationships that you develop that bring in new business. I personally use these trade missions as more of a fact-finding mission then a ‘get business’ trip.”

-David Glover, co-owner, Harbour Advanced Machining, Windsor, ON

“We have thought about it, but have not done one yet. It kind of seems we are always too busy. I like the idea of Paris though. I haven’t paid $6.00 for a cup of coffee since I had my honeymoon over there.”

-Rob Muru, president, A-Line Precision Tool, Toronto, ON

“We have not done the trade mission thing. We have not felt we had the money or the personnel to support it properly.”

“No, we haven’t. I have never seen any information in regards to these trade missions.”

-Larry Stuyt, co-owner, Ontario Laser Cutting, Tillsonburg, ON

“Yes, we have done a trade mission to Alberta in order to break into the gas and oil industry. Unfortunately, this industry was not as responsive as we hoped. We did not achieve as much success as we anticipated and found greater fortune on our own. That being said, I found the trade mission to be a great asset to better our knowledge in other industries.”

-Adriano Oppio, vice president, Classic Tool & Die, Oldcastle, ON

“We went to the oil fields in Alberta.

Didn’t get any business out of it. I worked in Alberta for a few years, so we got some work that way [through my contacts].”

-David Foscarini, president, Mecon Industries Limited, Scarborough, ON

-Peter Alden, co-owner, Wessex Precision Machining, Ayr, ON

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INDUSTRY REPORT/TRANSPORTATION >> By Nate Hendley

Moving Ahead Trains, buses and ships moving again; industry experts optimistic about future Bombardier Transportation made a big splash at the recent Winter Olympics in Vancouver, providing free streetcar service for residents, visitors and athletes during the games.

The streetcars in question—borrowed for the occasion from Belgium—were new FLEXITY models.

Besides being bi-directional, said streetcars offer electric single and double sliding doors, room for 50 seated or 128 standing passengers and extremely low floors (only 30 – 35 cm above the track). Low floors make boarding considerably less strenuous, especially for wheelchair bound or babycarriage pushing passengers.

According to BT (a branch of Montreal-based giant Bombardier and the largest supplier of rail equipment and services in the world), the FLEXITY models on display in Vancouver are “the first 100 per cent low-floor streetcars in North America.”

Should these new streetcars become popular with the public, there’s a good chance you’ll be seeing them across Canada in the very near future.

The Vancouver demonstration was a vivid example of the extreme importance of transportation in a country as huge as Canada. At present, Canada boasts nearly 50,000 kilometres of railway track, 243,000 km of coastline (giving us the longest coastline in the world) and 900,000 km of roads.

Servicing this vast network of track, waterway and paved road is a huge fleet of trains, ships and buses. While the recession has battered the transportation sector, industry experts remain relatively optimistic, citing technological developments, a rebounding economy and possible massive government spending.

Arguably, rail is the most important component of the transportation sector, in terms of both passenger and freight traffic. Canadian railways carried a record 72.3 million passengers in 2008, an increase of 6.5 per cent from the previous year. The picture for freight—which is measured in “revenue-tonne-kilometres (RTK)”—was not as positive. Railways hauled 346.5 billion revenue tonne kilometres of freight in 2008 a decrease from 2007 when RTK stood at 361.6 billion. Interestingly though, operating revenues for railways were up, hitting $11.197 billion in 2008, versus $10.704 billion in 2007.

The Ottawa-based Railway Association of Canada (RAC) believes freight travel hit bottom in the summer of 2009 and is now recovering.

“We’re optimistic that 2010 freight travel figures will look better than 2009 figures. This is a general reflection of our 12 | march 2010 | www.canadianmetalworking.com

forecast in terms of the economic performance of Canada as a whole in 2010 being stronger than 2009. The longterm forecast for rail is positive,” states Robert McKinstry, manager of policy and economic research at RAC. Industry officials base this optimism on international and domestic developments.

The Canadian Association of Railway Suppliers (CARS) of Ottawa predicts that China might spend an astronomical $120 billion this year to expand its railway system. CARS executive director Jay Nordenstrom dismisses fears that Asian companies will siphon railway manufacturing and supply jobs away from Canada.

“Canadian companies still have a very strong reputation for top grade quality products and top after-market service” that Asian firms can’t match, says Nordenstrom.

Economic nationalism might also benefit the industry. In June 2009, for example, Toronto city council ratified a $1.2 billion contract with Bombardier Transportation to replace 204 old streetcars. The streetcars (officially called “light rail vehicles”) will be built at Bombardier facilities in Thunder Bay, ON. Bombardier estimates the project could generate 5,700 jobs, most of them in Ontario—good news for the province’s hurting manufacturing sector.

Developments in Ottawa have also proven beneficial for the railway sector.

In the 2008 budget, the federal government boosted the depreciation rate for new and rebuilt locomotives from 15 to 30 per cent. CARS, RAC and other groups are currently lobbying for this tax break to be extended to freight rail cars.

Ottawa also launched a seven-year, $33 billion “Building Canada” fund in 2007, which targets public transit for additional financial support, along with highways, green energy and safe drinking water.

If railway experts are optimistic, things aren’t as sanguine in the shipbuilding sector.

Industry Canada counts 749 ship and boat building companies in Canada, most of them based in British Columbia, the Maritimes and Ontario. Federal government figures indicate 8,231 Canadians worked in this sector as of 2007 (the most recent year statistics are available), a decrease from 1998 when 10,407 people were employed in ship/boat building.

There are some glimmers of hope, however. The federal government, for one, has been making noises about buying new ships for the coast guard and navy.

Ottawa’s Joint Support Ship program, launched in June

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INDUSTRY REPORT/TRANSPORTATION

2006, and budgeted at $2.9 billion, aims to build three multirole vessels for the Canadian navy with a target delivery date for the first vessel in 2012. If Ottawa is to be believed, the Joint Ship program might merely be the start of a huge investment in ship building.

“The government will invest in building and maintaining an effective new federal fleet of ships for maritime security and services. Over the next 30 years, the government will need to build some 50 large vessels with an estimated value of over $40 billion. The government of Canada will consult with Canada’s shipbuilding companies and key shipbuilding stakeholders,” reads a government of Canada report.

“The government has not placed any new substantial build orders for ships since the mid-1990s ... the demand for new ships, as well as the need for refit and repair of the federal fleet, will sustain thousands of jobs for Canadians over the coming decades,” the report continues.

To show they mean business, Ottawa held a Shipbuilding Forum on July 27 - 28, 2009, with various interested parties, including the Shipbuilding Association of Canada.

As for the future, it all depends what federal authorities do.

“If the government puts money [into the sector], it’s 񡑘񡑗񡑣񡑔񡑁񡑖񡑩񡑱񡑨񡑢񡑦񡑱 񡑀񡑕񡑙񡑀񡑡񡑰񡑱񡑦񡑤񡑥񡑔񡑥񡑓!񡑀񡑀񡑅񡑂񡑆񡑂񡑄񡑃񡑀񡑀񡑄񡑓񡑈񡑐񡑀񡑠񡑙񡑀񡑀񡑠񡑤񡑧񡑦񡑀񡑄 very good.

If the government sits on its hands, it’s not

good,” states Cairns.

Bus manufacturers have been having a considerably better time of it. The Orion VII diesel-electric-hybrid bus, as manufactured by the Orion company in Mississauga, ON, has proven to be the most popular vehicle of its kind in the world. The bus provides better fuel economy and fewer emissions than traditional gas-powered vehicles.

In September 2009, Daimler Buses North America (which owns Orion) marked their 3000th order for the Orion VII. Many of these vehicles have ended up on Canadian streets: Toronto is now home to Canada’s largest fleet of hybrid buses, with 560 units ordered and 150 delivered. The city has the second largest hybrid bus fleet in North America, a point of pride for high ranking officials. During Earth Day celebrations in 2006, Toronto Mayor David Miller noted that “Toronto’s air quality and the health of Torontonians continue to be serious concerns. Adding hybrid buses ... is another example of how we are greening our fleet.”

Mississauga Transit ordered 15 Orion VII diesel-electric hybrid buses and 20 clean-diesel buses in October 2009.

Mississauga is one of over 260 North American cities serviced by the Orion VII. Next up from Daimler are new, improved lithium-ion batteries for the Orion VII and lowfloor buses.

Now Methods brings you KIWA Japan – the industry’s most expandable

The transportation sector continues to offer opportunities for machine and metal shops. Mecon Industries in Scarborough, ON, for example, recently completed a small project for the Toronto Transit Commission (TTC).

“We supplied them with press brake tooling and we built some custom pieces for a couple of other metal bending machines where tooling was hard to find,” says president David Foscarini.

The tooling ended up in the TTC’s forge and sheet metal shop in Toronto, for use in city buses. Mecon was approached by the TTC to take on the project.

Mecon, which has 15 employees and specializes in metal stamping, also did two “design and build projects” for National Steel Car, a major railway freight car manufacturer based in Hamilton, ON. “Some of the parts were for a horizontal bending machine, and the other pieces were for a tube bending machine,” says Foscarini of the “semi-custom” jobs Mecon did for National Steel Car.

Classic Tool & Die in Oldcastle, ON, has also been “trying to penetrate the bus sector,” says company vice-president, Adriano Oppio. “In the past, we had success manufacturing tooling for this sector and have not seen any [work] for a while. We are currently trying to re-establish our past business relations.”

As for the future of transportation in Canada, watch for more hybrid buses, low-floor streetcars and buses, high-speed trains and possible investment from Ottawa in public transit and new ships.

While the automotive and aerospace sectors tend to get most of the attention in metalworking circles, industry experts urge their peers not to overlook trains, buses and ships.

“Transportation will always be an important part of our industry. As the population increases, so does the need for transportation. It is a growing industry that is sometimes overlooked,” says Oppio. CM Nate Hendley is a freelance writer based in Toronto.

With KIWA’s exclusive in-the-field expandable tool and pallet technology, feature-rich package and affordable price, the profits of horizontal machining are now easily within your reach: Expandable – Easily expands as your business grows, from a 2 pallet machine with 120 tools, to a 6 or 8 pallet machine with 220 tools.

Scalable – The KH-41 and KH-45 feature a 400 mm pallet. The KH-45 has an ample work envelope of 29.5" dia. x 39.4" h and the KH-41 features a compact footprint and an envelope of 21.7" dia. x 33.5" h.

Valuable – Loaded with features, speed, accuracy and rigidity plus reduced set-up time.

Reliable – Japanese quality, exclusively imported and backed throughout North America by Method’s industry – leading application expertise, service and support.

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From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction.

Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call 800.446.7738 or visit www.widia.com. ©2009 Kennametal Inc. l All rights reserved. l A-09-02229

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>> >

BUSINESS REPORT/NATIONAL BENCHMARKING SURVEY >> By Mary Scianna

Industry

Insights Despite a challenging economic climate, manufacturers are more optimistic about 2010 and beyond, reveals Canadian Metalworking’s 3rd Annual National Benchmarking Survey The dark and stormy clouds that hung over the North American manufacturing industry in 2008 erupted into a tsunami in 2009. And yet for two consecutive years, manufacturers have continued to see the rays of light amidst the gloom, according to the results of Canadian Metalworking’s 3rd Annual National Benchmarking Survey.

The survey, fielded in January and February 2010, was conducted online with 121 manufacturers of metal products who are involved in metal fabrication and/or metal chip removal. The margin of error is +/- 7.5 per cent, 18 times out of 20.

Survey participants ranged from executive management to plant floor personnel, but the majority of participants were decision-makers including 48 per cent who are executive management, and 30 per cent who are purchasing personnel. Plant and production people represented 22 per cent of survey participants.

Outlook for Manufacturing in 2010 Many factors came together in 2009 to create a dismal year for manufacturing. The recession, the Buy American policy, Canada’s fluctuating dollar, and the ongoing influx of inexpensive offshore imports contributed to declining revenues for manufacturing companies across the country.

And for those manufacturers who had the good fortune to actually grow in 2009, a lack of access to credit created a roadblock for plant expansion and machinery and equipment purchases.

Despite these obstacles, most manufacturers are optimistic about the outlook for 2010 and beyond. Asked about their overall outlook for the first quarter of 2010, close to 50 per cent are “somewhat positive” while 14 per cent are very positive. One quarter of participants say they are “not very positive” while only 7 per cent say they are “not at all positive.”

The results of the survey also reflect the resiliency of many manufacturers in Canada. There is debate that 2009 was a tough year for manufacturers and most companies 18 | March 2010 | www.canadianmetalworking.com

say revenues and profit margins slid. Indeed, more than half (51 per cent) of survey participants said that 2009 revenues decreased when compared to 2008. And yet there were some that managed to buck the trend; 23 per cent said revenues increased, and 21 per cent said revenues stayed the same.

For those that saw revenues increase, more than one quarter, 26 per cent of participants, generated profits of between $100,000 to $500,000. Another 32 per cent had profits of less than $100,000. There were some shops that managed to generate profits of more than $1 million; just over 8 per cent enjoyed profits in the range of $1 million to $5 million.

Asked about expectations for profit margins for 2010, again optimism reigned with 40 per cent saying margins will increase, 31 per cent saying they’ll stay the same and 27 per cent expecting a decrease.

Purchasing Intentions Ask machinery and equipment suppliers about sales in 2009 and the likelihood is that they would say sales dropped off sharply early in the year but began a slow climb up late in the year. Survey results similarly point to an ongoing slow upward climb. In the next 12 months, 16 per cent of participants who identified themselves as fabricators say they plan to purchase automation equipment, 9 per cent plan on purchasing punching machines, another 7 per are looking at plasma cutting, 6 per cent intend to purchase laser cutting machines while 4 per cent are considering abrasive waterjet machines.

Only 2 per cent of participants are considering stamping machines, while 5 per cent plan to purchase press brakes.

On the chip shop side, purchases of milling machines, lathes/turning machines and machine tool software/controls updates are tied, with 12 per cent of survey participants indicating they plan to purchase one of the three.

Perhaps the brightest light in the survey is capital expenditure for 2010. 30 per cent plan to increase capital spending this year, while 48 per cent say it will stay the same. Only 21 per cent plan to decrease it, but that’s down almost half from those in the 2009 survey, 40 per cent, who

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BUSINESS REPORT/NATIONAL BENCHMARKING SURVEY said they planned to decrease capital spending.

In the next 12 months, do you plan to purchase…

OPTIONS

In your opinion, what is the single greatest challenge facing our industry today?

“

Loss of manufacturing base in North America.

Overall competitiveness in a very tight marketplace where other vendors are arriving on the scene from out of province and internationally where they have taken advantage of rules, regulations and labour rate stuctures that give them certain advantages over local suppliers.

The Ontario government and their paper burden as well as the most draconian rules governing manufacturing in North America making Ontario the most expensive place in North America to manufacture.

Overseas outsourcing and the opening up of the global marketplace.

Flood of offshore low quality products.

Fluctuation in the economy and material pricing.

Lack of skilled labour.

The high Canadian dollar is killing value-add for companies in manufacturing, farming, forestry and fishing.

20 | MARCH 2010 | www.canadianmetalworking.com

TOTAL

PER CENT

O1

Milling machines

5

11.90%

O2

Lathes/turning machines

5

11.90%

O3

Multi-axis

3

7.14%

O4

Multi-tasking

1

2.38%

O5

Automation for machine tools

2

4.76%

O6

Machine tool software/controls upgrades

5

11.90%

O7

Quality control monitoring/ measuring equipment & devices

11

26.19%

O8

None of the above

9

21.43%

Question Total: 42 • No Response: 1

In the next 12 months, do you plan to purchase…

OPTIONS

TOTAL

PER CENT

O1

Press brakes

5

4.95%

O2

Punches

9

8.91%

O3

Laser/punch combo machines

0

0.00%

O4

Laser cutting machines

6

5.94%

O5

Abrasive waterjet machines

4

3.96%

O6

Plasma cutting machines

7

6.93%

O7

Stamping machines

2

1.98%

O8

Automation for fabricating equipment

16

15.84%

O9

Quality control monitoring/ measuring equipment & devices

17

16.83%

32

31.68%

O10 None of the above Question Total: 101 • No Response: 3

QUALITY CONTROL: THE TOYOTA FACTOR? What Canadian manufacturers may lack in innovation, they seem to be making up for in quality. For the third consecutive year, participants said quality control was the most important manufacturing technology used in their facilities. What’s interesting is that more manufacturers recognized quality control this year than in the 2008 survey. 71 per cent of participants said quality control was the most important method or process in their facility, while in 2008 only 64 per cent cited it as the top item.

When asked what type of equipment, systems or processes they planned to purchase in the next 12 months, chip shops and sheet metal fabricators both selected quality control monitoring/measuring equipment. More than one quarter of participants identified as chip shops, 26 per cent, planned to purchase quality equipment, while 17 per cent of fabricators indicated the same.

As in our 2009 survey, ISO and Lean Manufacturing were the top two quality systems that manufacturers use in their operations. Close to 46 per cent said they use ISO and almost 41 per cent said Lean was the main quality system. Lean is

Which of the following quality systems do you use in your shop?

OPTIONS

TOTAL

PER CENT

O1

Six Sigma

13

10.74%

O2

Lean Manufacturing

49

40.50%

O3

Kaizen

18

14.88%

O4

SPC-Statistical Process Control

15

12.40%

O5

ERP-Enterprise Resource Planning

21

17.36%

O6

ISO

55

45.45%

O7

Other (please specify)

9

7.44%

O8

None of these

32

26.45%

Question Total: 121 • No Response: 2

“

making some inroads compared to last year when only 35 participants selected the quality system.

While we can’t know for certain, the Toyota recall fiasco may have had some influence on the increased focus on quality control as the incident was a reminder to all manufacturers of what can happen when quality goes bad.

GEARING UP TO COMPETE IN 2010 AND BEYOND

One common factor the National Benchmarking Survey revealed in 2008 and 2009 was that manufacturers were slow to embrace new technologies—e.g. automation, robotics and cellular manufacturing—to become more competitive.

Indeed, the percentage of manufacturers that said they used robotics and automation in their operation actually decreased in 2009 from 2008. That seems to be changing, perhaps in part because of the recession, which has been a tough wake-up call for many manufacturing businesses in Canada. In 2009, 35 per cent indicated they use automation, while in this year’s survey it’s close to 40 per cent.

Last year, Canadian Metalworking had the opportunity to attend EMO Milano, the world’s biggest metalworking trade show. “Smart” technology--tools that help machinery and equipment worker faster and smarter—were prevalent. So in our 2010 survey we asked participants if they use smart tools (identified in the survey as software tools to facilitate the improvement of a machining system). Close to 24 per cent said they use such tools in the machine shop. CM

Which of the following tools do you use in the shop?

OPTIONS

TOTAL PER CENT

O1 CAD/CAM/CAE systems

82

67.77%

O2 Cellular manufacturing

25

20.66%

O3 Automation

47

38.84%

O4 Computerized maintenance management

24

19.83%

O5 Robotics

22

18.18%

7

5.79%

29

23.97%

6

4.96%

21

17.36%

O6 Vibration or thermo-graphic O7 Smart technology (e.g. software tools to facilitate the improvement of a machining system) O8 Other (please specify) O9 None of these Question Total: 121 • No Response: 2

What kinds of business strategies and management tools do you use to overcome challenges?

Our business has evolved to become more of a service provider in the manufacturing division and we are doing more repair and rebuilding work than actual new manufacturing, since we can offer better cost control and scheduling and can react to unanticipated situations at our customers’ facilities. We have not been able to overcome the challenges of meeting other suppliers’ prices head to head.

Go into products where quality and complexity eliminate the offshore garbage from the competition.

We are implementing continuous process improvement. Working closely with our suppliers, and our employees to find the best possible way to make our process as value-added as possible.

Examples of the tools we are using: 3D software; CNC equipment; training; 5S; Lean manufacturing tools which we modify and apply to the job shop environment.

”

www.canadianmetalworking.com | MARCH 2010 |

21

>>>

MACHINE TOOLS/COMMUNICATIONS >> By Graham Young

Technological Lead The advantages of migrating from serial to Ethernet communications on the shop floor There is a technological shift going on out on the shop floor that is allowing machines to communicate directly with corporate information systems, generating big benefits for companies by increasing their operational efficiency.

Applications are available that provide real-time machine monitoring, acquisition of Overall Equipment Effectiveness (OEE) metrics, dynamic computer-aided machining, automatic synchronization of part programs, DNC, work order scheduling, and central control of machine operations.

These issues have been solved in two ways. The first approach is to use a single PC with one port DNC software working through manual switch boxes. This option is cheap to set up but more costly over the long term due to inefficiency and uncertain reliability. Time is wasted in finding the program, setting up the switch, and walking back and forth from the machine to the PC. In some small shops, where program changes are infrequent, operators

Why Make the Leap?

The Internet has changed how the world gets its information: it’s all about easy access. Manufacturing machines that communicate via serial ports run the risk of being not connected to the information highway and consequently being an unproductive asset. If these machines could be refurbished with advanced communications technology, a company could avoid spending millions on new machines.

Furthermore, extracting operational information from all its machines, both new and old, would permit a company to optimize its manufacturing processes. Companies that have moved to the Ethernet report a significant improvement in efficiency and cost savings.

The Evolution of CNC Communications The first NC and CNC machine tools were programmed by hand directly on the control. Thereafter, machines were loaded with a punched Mylar tape that allowed the running and storage of programs. In the late 1980s and early 1990s, CNC machines with RS232 serial ports for communications with computers appeared. Programs were stored on a PC, backed up or called up remotely, and easier to manage.

Older machines were converted from tape to serial port communication by a Behind the Tape Reader (BTR), which converted the tape format to RS232 serial format and allowed controls without a serial port to connect to a PC. Some CNC controls (such as the Fanuc 6) had both serial and parallel ports but still required a BTR to drip feed in Direct DNC mode. Nevertheless, this approach was so successful that many of these controls and machines are currently still in use.

One way to upgrade older CNC equipment is to install a PC at every machine, a solution adopted by many shop floors today. This approach solves the main weakness of RS232 serial port technology, which is the length of the cables required. The longer the cable, the slower the Baud rate (2400), and the greater the risk of damaging interference.

Flow control issues and other cable interactions can lead to data loss. However, the harsh environmental conditions of some shops can cause PC failures that interrupt operations.

Maintaining large numbers of PCs on the shop floor is time consuming, costly, has inherent security concerns, and requires IT personnel.

22 | march 2010 | www.canadianmetalworking.com

must locate supervisors to make the transfer. The second approach is to use a single PC with multiple port serial cards. This solution simplifies the communications protocol but is risky because only one PC is involved. All cables lead to one location, and the malfunction of any part of an interface card, power supply, PC hardware or OS means that the entire system goes down. A further disadvantage of the multiple port serial card solution is the length of the serial cables (perhaps hundreds of feet long) that may be required to connect the PC to the CNC. Such extended cable lengths frequently require a lower baud rate to ensure data reliability, resulting in increased program load times that reduce machine runtime availability.

Today, such problems can be solved using the Ethernet.

The newest CNC machines are equipped with TCI/IP Ethernet ports, and some of these machines can use FTP servers such that external DNC software is not required for basic

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MACHINE TOOLS/COMMUNICATIONS

file transfer. It is thus common to find in one shop different machines using different communication systems. This multiplicity creates a management issue for plant personnel because more than one system must be maintained.

A solution is to convert older RS232 serial CNC controls to Ethernet and wireless Ethernet connections. However, older serial port-based DNC software often requires additional drivers that can interfere with data integrity and connectivity. In addition, many serial-to-Ethernet conversions are jury-rigged using off-the-shelf components that were not designed with CNC equipment and shop floor conditions in mind, and may require power from 110 volt sources that are not always present in the CNC cabinet.

These ad hoc solutions thus produce high failure rates in the field.

Benefits of Ethernet Conversion Complete and purpose-designed tools that convert serial port to Ethernet communications have several immediate advantages over older technologies: •The CNC becomes an individual node on the corporate network and is not directly connected to a PC. •The network infrastructure can include standard offthe-shelf switches and routers.

•Standard Ethernet cables are used instead of expensive proprietary RS232 cables; cable length becomes irrelevant and surge damage is a concern of the past.

•Data transfers occur at the maximum speed of the CNC control’s ability to receive data.

•Data transmission is secure.

•The PC or server that hosts the DNC software only needs to see the TCP/IP address of the CNC machine. If that PC or server or network fails, any other PC or laptop with the appropriate software back-up can assume the DNC server role with little or no delay.

•There is no single point of failure that will shut down the shop DNC network. A laptop can connect to the CNC if necessary.

•Newer PCs and laptops do not have RS232 ports but all have Ethernet connections.

•The hardware is not control-dependent and is easily reinstalled on new machinery.

In almost all cases, the conversion of serial port to Ethernet communication instantly increases speed, reliability and productivity. For example by increasing the Baud rate from 2400 to 9600, program transfer time is reduced by 75 per cent. This time savings alone often repays the conversion cost.

PRODUCT REPORT AgieCharmilles

GF AgieCharmilles’ Mikron HPM 800U high performance machining centre offers dynamic, three axis milling for the aerospace and automotive industries.

Equipped with directly driven circular and swiveling axes, the machine can be used for a range of applications, including complex mould making, heavy roughing and precise finishing.

chip removal rates. Other features include doors that can be opened out wide to enable unrestricted access to the working area, as well as scratchproof windows that allow a clear view of the machining area.

All tools are visible in the machine due to the inclusion of a tool magazine with a front made entirely of glass. Users also benefit from the inclusion of the latest generation Heidenhain iTNC 530 digital control system, which offers an Ethernet connection for fast CAM data flow, free contour and parallel programming, advanced high speed functions and an optional mobile hand wheel that brings users close to the cutting point if required. www.gfac.com/us

the ULTRASONIC chip removal, also allowing efficient machining of hard and brittle materials, such as glass ceramics and special synthetic materials. Obviously, also highspeed milling of demanding metals, such as titanium and chrome-cobalt are covered by the machine‘s range of performances.

DMG

The machine features stable construction and a simultaneously operable, circular swiveling table with water-cooled direct drives and three axis clamps. The increased accessibility allows users to load and manually secure smaller parts on the table with ease. The machine is also equipped with a dual drive in the Y axis for increased stability, as well as a superior spindle technology from StepTec to deliver high quality 3D surfacing results and exceptional 24 | march 2010 | www.canadianmetalworking.com

DMG has developed the ULTRASONIC 10 as a pure dental machine. Knowing that the available space in dental laboratories rarely meets industrial standards, it was important to minimize the machine‘s footprint. The result is that not more than 21.5 sq ft are required to install it, it features clearances of 31.5 x 70.9 in. (800 x 1,800 mm) for transportation and it allows the machine to be moved through normal room doors.

In addition to its compact dimensions, the machine concept of the ULTRA-SONIC 10 also takes into account the technical requirements encountered in dental technology. The decisive factor here being

The flexibility of the machine when it comes to material selection is paired with its versatility in producing complex geometries.

The integrated rotary table swiveling through -15° and +120° lends the machine a 4th and 5th axis, thereby allowing extreme undercuts.

The small round blank automation unit PH2|4 inside offers space for another four raw material holders without requiring additional space. When fully loaded, this small automation system permits unmanned production for more than 60 hours.

Three variants of the PH2|120 automation system are available:

Automating the Network: DNC and Direct DNC An example of a device that connects serial ports to the Ethernet is Memex Automation’s Mx1053 Universal Network Interface (UNI) with the accompanying Ax2200HS product.

The Mx1053 UNI configures access to the Ethernet for the serial ports of older machines as well as for many new machines that only have RS232 serial ports. The Mx1053 UNI is shop-hardened, not control-specific, and will operate with any CNC RS232 serial port. Forward-thinking companies like Goodrich Aerospace have used the Mx1053 UNI for several years. Similarly, Halliburton, the world’s second largest oil field service company, has adopted this technology for their CNC machines.

The Mx1100E UNI is a BTR version that facilitates Ethernet conversion for tape reader-based CNC controls that are still in service. Although these machines are easily configured with older serial-only DNC software (such as NetDNC), new heights of integration are achieved when the Mx1100E and AxDNC software are used. This new advanced DNC program not only handles traditional serial communications but also has built-in functionality for TCP/IP-based controls. For those newer controls that use FTP, AxDNC has a built-in FTP client that automatically synchronizes with the main server. AxDNC has an additional

•1 2 round blanks and 150 finished part magazines (on pallets or without) • 20 round blanks, 120 finished part magazines and 80 glass ceramic blocks (on pallets or without) • 250 glass ceramic blocks (not palleted) As such, the dental laboratory can design the large automation solution to meet its individual requirements and optimally adapt the system to its own production. www.dmgamerica.com

parts, so the last thing they want is to stop production to remove chips. Haas redesigned the chip pans and reviewed coolant flow in the new VMCs to reduce chip buildup and efficiently flush chips into the auger trough for removal. For high volume production applications, the 2010 Haas VF-1 through VF-6 VMCs are available with optional chip removal systems that combine multiple side augers with either a front discharge auger or a belt-type conveyor to move chips out of the

Kiwa

Methods Machine Tools Inc. has introduced the KIWA-Japan KH-41 horizontal machining centre. The KH-41 has a simple, compact, efficient design that’s only 60.2 in. (1,530 mm) wide. Despite its small size it can handle a wide variety of workpieces, providing an ideal entry-level factory automation solution.

Haas

Haas redesigned its entire VF product line to incorporate a wide range of enhancements, making Haas VMCs better than ever. To ensure smooth, precise motion control, the 2010 Haas VMCs use next-generation digital servomotors and high-resolution encoders on all axes. Combined with significant software and motor-control advancements on the new machines, these yield higher accelerations and better surface-finish performance than ever before. With an eye toward preventing chip and coolant egress during machining, Haas invested considerable effort up front to optimize the enclosures on the new VMCs, paying close attention to panel fit, service access, and internal routing of plumbing and cables. The result is a far better enclosure and a much simpler overall design that thoroughly contains chips and coolant, while increasing reliability and simplifying service.

People buy CNC machines to make

machines faster and easier than ever.

For 2010, Haas engineers reevaluated the machines to make everything the operator touches work even better. For example, the machines’ windows and doors are now stiffer, move more smoothly, and close tightly.

The new Haas thin-design control pendant mounts directly to the enclosure, providing a lighter but more stable operator interface than the previous version. www.HaasCNC.com

It offers a feature-rich package with cost-effective pricing, bringing the profits of horizontal machining within a job shop’s reach. It has a full rotary B axis and can be installed in the same space as a vertical machine. With a 400 mm pallet machine, this HMC can accommodate a wide variety of workpieces, including large workpieces up to 21.7 in. in diameter x 33.5 in. high.

The KIWA KH-41 offers unparalleled performance-to-value in horizontal machining, says the company. The machine design emphasizes maximum space utilization, rigidity, and speed, at an affordable price.

The simple, fast ATC technology with drum www.canadianmetalworking.com | march 2010 |

25

>>>

MACHINE TOOLS/COMMUNICATIONS

Continued on page 27

advantage over the freeware that is commonly used for FTP transfers: the AxDNC allows security-controlled user access so that management can restrict operator access to specific folders and functions. The result is a shop environment in which one application serves all the equipment and is secure, simple to use, and easy to maintain and back up.

Automating the Automation: Advanced OEE and Machine Monitoring The increase in speed and data flow volume facilitated

by Ethernet use allows manufacturers to upgrade their information exchange and retrieval. Two crucial areas are OEE metrics and real-time machine event monitoring.

An example of a device that tracks these parameters is Memex’s Ax9150 Universal Machine Interface (UMI) with optional I/O boards, including the Ax650 CNC interface board and the Ax750 Fanuc interface I/O link board. These devices streamline DNC communications while gathering pertinent data directly from the machines. Unlike a software solution, the Ax9150 UMI does not depend on inserted D-Print

commands or other program manipulation. Through its I/O links, the Ax9150 UMI collects data in real-time directly and electrically from the CNC. These data can then be fed to OEE, ERP, MTConnect and OPC-compliant software programs to provide a complete picture to management of the machine’s operations and usage. During drip feed, the G-Code is read and interpreted as it is being run by the control.

Automation of data collection and reporting eliminates tedious and inaccurate manual data entry of machine events. Production planning ERP software (such as that from JobBoss, Baan or SAP) can be integrated with the CNC directly in a two-way bi-synchronous link. The data flow can also be adapted to the needs of customized software and databases that are unique to individual manufacturers.

Actual experience in the field has shown that use of the Ax9150 UMI allows manufacturers to manage assets more effectively such that productivity gains of 5-20 per cent are achieved. With the current economy and competitive global environment, every avenue of efficiency improvement and cost reduction must be accessed. A

PRODUCT REPORT style design provides speed, accuracy, rigidity, and reduced cycle time. The 1G+ acceleration is standard on all axes. www.methodsmachine.com

Makino

Makino’s new S56-5XR vertical machining centre blends high performance, hardmilling with multi-axis capabilities for the perfect combination of accuracy, speed, flexibility and productivity. Similar to the S56, the S56-5XR is suited for applications requiring high spindle speeds, fine surface finishes and hardmilling. The machine’s five axis functionality delivers exacting accuracy in contoured parts, and enables five-face

The machine’s X, Y and Z axis linear motion guides support rapid traverse and cutting feed rates of 1,575 ipm (40,000 mm/min). Its 40 taper, 13,000 rpm spindle provides the ideal combination of speed and rigidity to hardmill high quality surface finishes in demanding applications. As an option, the S56-5XR can be equipped with a 20,000 rpm spindle featuring Makino’s patented spindle technology for further productivity.

The machine is equipped with a standard 20-tool (30-tool optional) magazine and automatic tool changer to reduce setups and further maximize the machine’s flexibility and utilization, through unattended machining capabilities. The S56-5XR incorporates Makino’s Super Geometric Intelligence (SGI.4) servo control for smooth surfaces, even in high feedrate machining of complex shapes. SGI.4 software helps reduce cycle times in three dimensional parts by as much as 40 per cent. www.makino.com

Matsuura

machining that eliminates setups, reduces lead times, improves quality, and cuts costs.

The S56-5XR is equipped with a 40 x 20 in. (1,000 x 500 mm) worktable, with associated travels of 36 x 20 x 18 in. (900 x 500 x 450 mm). Its table mounted tilt / trunion provides full, five axis capability while the remaining table surface can be used for three axis work.

26 | march 2010 | www.canadianmetalworking.com

The CUBLEX-25, released in 2005, featuring a maximum work size of 250 in diameter x 250 mm high and maximum loading capacity of 40 kg, and the CUBLEX-42, released in 2008, with a maximum work size: 420 in diameter x 350 mm high and maximum loading capacity of 200kg have already proven themselves globally in many industries (aircraft, automobile, medical equipment, etc.)

To meet the market demand for a larger

machine, Matsuura has developed the CUBLEX-63, making this the third machining center in the CUBLEX Series. This machine has the capability to machine workpieces of maximum work size of 630 diameter x 450 mm high with a maximum loading capacity of 350 kg.

The new multi-tasking machine enables milling, turning and grinding (optional) and a significant increase in customer’s process integration. Using Matsuura’s proven five axis machining centre as a base, the high speed precision milling capability is second to none, claims the company. A new direct-drive motor is a new feature for the rotary table axis (C axis). This direct-drive combines high speed and high accuracy for milling, together with high-speed rotation (1,300 min-1) for turning. www.elliotmachinery.com

Mazak

The Nexus Series II vertical machining centres are single column, bed-type machines with three, four, or five axes. The Nexus Series models are available with 15 or 30 Horse Power, CAT 40 spindle taper, 30 Tool

Continued from page 26

major aerospace manufacturer, Héroux Devtek, has taken this philosophy to heart and has recently instituted a corporate roll-out of a totally integrated OEE + DNC solution from Memex for all its machines at all its plants.

This group has already seen benefits from real-time alerting, centralized scheduling, program control and accurate reporting that have significantly increased their overall operational efficiency.

Today’s manufacturing environment demands an increased flow of data and information that legacy serial communication software and hardware simply cannot supply. Migrating from serial ports to the Ethernet is the solution. Conversion to Ethernet communication is cost-effective, has a short ROI period, and provides the easiest path to reliable shop floor information and increased operational efficiency.

Manufacturers with an eye on the bottom line should look at this technological leap to maximize the utility of their most valuable assets, their shop floor machines. The added-value provided by Ethernet technology will ensure a competitive edge and a successful business in today’s global environment. CM Graham Young is the technical sales manager at Memex Automation Inc., Burlington, ON. www.memex.ca

automatic tool changer (ATC) with 1.3 second tool-to-tool change time, and top spindle RPM of 12,000 or 15,000. Model ranges offer X, Y, Z travels from 22.05 x 16.14 x 20.08 in. (510 x 407 x 510 mm) to 41.34 x 20.08 x 22.08 in. (1,050 x 510 x 560 mm) and table sizes from 35.43 x 16.14 in. (875 x 410 mm) to 51.18 x 21.65 in. (1,299 x 550 mm). Table workload capacity from 1,100 lb. (499 kg) to 2,640 lb (1,197 kg) is standard. The HS model versions offer higher spindle speeds and faster rapid travel and feed rates. www.mazak.ca

Okuma

The Okuma MA-H Series of horizontal machining centres deliver high productivity without compromising accuracy, claims the company. Built on the Thermo-Friendly Concept that employs a thermal deformation compensation system, these machines achieve machining dimensional change of less then 8µm over time.

High speed production is achieved through: • Stepped column ways providing excellent feed rates and a rapid traverse of 60 m/min while maintaining an ultra rigid machining platform; • Quick 50 taper tool changer (2 sec T/T) with a tool magazine capacity up to 320; • Speedy two-pallet automatic rotary pallet changer.

• Unparalleled accuracy is delivered through Okuma’s Thermal Active Stabilizer System – TAS, a high precision indexing table; and a highly rigid threepoint supported bed.

These horizontal machining centres are ideal for use in a variety of industries, Available in four sizes (MA-400H, MA500H, MA-600H and MA-800H) the MA-H series features a wide selection of available spindles and the operator-friendly THINCOSP control, a true PC, Windows-based platform with open architecture, plug and play USB capability and 40GB of memory. www.okuma.com www.canadianmetalworking.com | march 2010 |

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MACHINE TOOLS/MATERIAL HANDLING >> By Nate Hendley

Handling Costs Tips on cost-cutting ways to automate material handling on the shop floor Thinking about automating your material handling equipment?

Here are some points to ponder:

1.

Look for hidden benefits

Instead of grousing about the premium price of automatic material handling equipment, think about hidden benefits instead. While everyone knows automation can reduce labour costs, it can also save shop owners money in less obvious ways.

“A lot of times when people look at automating, they don’t really look at the overall costs. A lot of businesses don’t understand their actual costs. They don’t understand the effect of absenteeism, of breaks, of injuries, or heating their shop during second and third shift,” notes Tom

Sipple, Handling Technology Leader for material handling technologies, at Motoman in Dayton, OH. “You need better lighting and airflow for manual operations, whereas robots don’t really care if the lights are on or not,” adds Dale Arndt, Engineering Manager at FANUC Robotics Canada Ltd., in Mississauga, ON.

2.

Automation = greater reliability, flexibility and quality

“Automation allows you to have much more consistency in terms of output. We’ve had people tell us, ‘The most valuable thing about automation is I can depend on it. I can plan to run a particular part tomorrow morning at 8 o’clock and I actually do it … because I don’t have the intervention of a human on third shift who made a mistake, didn’t flip a part when they were supposed to, crashed a tool.’ Automation

PRODUCT REPORT ABB

ABB Robotics has developed a hybrid system integrating articulated robot automation with a linear gantry, delivering a unique combination of cost efficiency and performance benefits. The new IRB 6620LX is a five axis overhead robot arm mounted on a linear axis, providing improved flexibility, faster cycle times and an extended working range for machine tending, material handling, assembly and many other industrial applications.

With a 150 kg (330 lb) payload and large scalable work space, the IRB 6620LX offers greater versatility and cost effectiveness compared to customized linear handling systems, says ABB. The linear axis can support up to two robots, and provides the ability to serve several stations or machines simultaneously or in programmed coordination, resulting in high productivity and machine utilization.

To merge the articulated and linear technology ABB removed the first rotational axis from the robotic arm, enabling it to be mounted either upside down or sideways on the linear axis. The linear gantry acts as 28 | march 2010 | www.canadianmetalworking.com

the first axis of the robot, providing the same agility as a standard 6-axis robot. The linear axis can range in height from 2.5 to 4 m (8 to 13 ft) and in length from 1.8 to 33 m (6 to 108 ft), and saves floor space by elevating the robot(s) over the work area. This inherent flexibility allows the system to be adjusted to serve different applications, and enables quick and easy changeovers.

For many applications only one robot will be needed to replace the numerous complex material handling components typical of standard linear systems, offering further cost savings and reduced maintenance. The IRB 6620LX can be readily fitted or adapted to existing production lines and the support legs can be configured to suit the system specs and available floor space.

The use of standard, well-proven technology guarantees the highest possible performance and reliability. The unparalleled speed and acceleration on the linear axis secures the shortest possible cycle times with highest possible accuracy, even at large distances and with a full payload. The high performance is delivered as a result of sophisticated mechanical engineering and ABB’s state-of-the-art motion control technology, TrueMove and QuickMove.

The new robot is available with the ABB IRC5 robot controller. www.abb.com

Edge Technologies

The new Rebel V-65 Servo is a compact, economically priced short bar loader that

features a 5-65 mm diameter capacity range for feeding spindle length round, square, hexagonal and shaped bar stock into CNC lathes. With a large magazine capacity

allowing for long unattended operation, the bar loader combines the advantages of auto bar loading with a small footprint and an affordable price tag. While processing the bar there is no contact between the bar stock and the loading magazine, so high speed machining is possible with the use of a properly sized lathe spindle liner. The loading storage capacity is 650 mm (25.6 in.) deep. Bars are loaded from the rear of the bar feeder and are then lowered into the feeding channel by urethane guides, eliminating the potential for marring of the surface of the bars. Bar stock with lengths up to 1,200mm (48 in.) can be loaded by the V-65 Servo. The maximum bar length is determined by the spindle length of the lathe and the chucking package. The bar stock is loaded into the main spindle of the lathe by a linear feed mechanism with a servo and encoder. This allows for the feeding of the bar stock into position with the use of a fixed bar stop or accurate position. A quick

ABB says its articulated robot, linear gantry combination delivers greater working range, cycle times and flexibility.

removes [human error] in a lot of cases,” says Sipple.

Greater reliability means shop owners can introduce lights out production, if they haven’t already. Automatic material handling equipment can be used around the clock, on weekends or on extra shifts, without having to pay overtime to aggrieved workers.

On the other hand, automation is also handy for shops that aren’t busy 24 hours a day. Automatic machines can be left to “sit idle for a day or week, which is very hard to do with human labour,” notes Arndt.

Automation can boost a shop’s bottom line quality as well.

FANUC’s M-10iA series, (designed for palletizing, picking,

and accurate adjustment mechanism sets the correct height for the lathe’s centerline according to the bar’s diameter for precise loading into the spindle liner. The V-65 Servo comes equipped with 3 pusher rods to cover the full range of diameters.

The Rebel V-65 Servo features a Mitsubishi PLC controller and a push button screen interface with a LCD display. Feed force is automatically set by the controller after the bar diameter is entered into the conversational touch screen control. The user-friendly multi-line display and operation station includes information to allow rapid setting and productive operation of the loading process. www.edgetechnologies.com

Fanuc Robotics

FANUC Robotics America Inc. has introduced the new M-3iA intelligent, parallel-link robot designed to maximize speed and flexibility for assembly, small part handling and picking applications.

The M-3iA robot is a larger version of the company’s M-1iA robot introduced last year. Available in a four- or six-axis model, the M-3iA offers the same unique parallellink structure, is lightweight and portable, and accommodates payloads up to 6kg. In addition, it has the largest work envelope of any robot in its class (1350 mm x 500 mm).

The six-axis model has a three axis, patent-pending wrist for complex assembly tasks, enabling the robot to pick up and insert parts at simple or compound angles, and

packing and packaging) are equipped with a 2D vision cable built right into the robot arm.

The presence of vision sensors make it “very easy to extract production data—‘Did all the welds get done? Did all the dispensed material get put down?’ It becomes easier to acquire that data and make sense of it, and stop production if something is going out of whack. Whereas previously you might do an end-of-the-line inspection, now you might do a robot-to-robot inspection,” says Arndt.

3.

Automation = more floor space

“Generally a manual operation will take more floor space than an automated operation,” notes Arndt.

Indeed, by using compact-sized automatic material handling machines, shop owners can open up floor space for additional equipment, storage and/or workers.

FANUC Robotics offers several lines of diminutive material handling robots. The M-10iA, for example, has six axes, a 10 kg payload and a weight of only 130 kilos. The M-10iA can be floor, wall or even ceiling mounted, thus saving more space.

Another compact automatic is Motoman’s SDA10D slim dual arm robot, used for assembly, packaging, handling,

twist parts into place, similar to the flexibility offered by a manual operator.

A four-axis M-3iA has a singleaxis wrist for simple assembly and high-speed picking operations, offering speeds up to 4000 degrees per second. In addition, a hollow wrist allows hoses and cables to be routed internally, which minimizes wear and tear on the tooling cables. The M-3iA, like all FANUC robots, operates with the company’s latest R-30iA controller with integrated intelligent functions. www.fanucrobotics.com

Motoman

Motoman’s new MH-series high speed robots feature a flexible design, allowing them to be used for many applications, including material cutting, handling and welding.

The long reach of the MH50 model with a horizontal reach of 2,061 mm (81.1 in.), and a vertical reach of 3,578 mm (140.9 in.), the extended reaches of the MH50-20 (horizontal reach 3,106 mm/122.3 in., vertical, 5,585 mm/219.9 in.) and MH50-35 (horizontal reach 2,538 mm/100 in., vertical reach 4,448 mm 175.1 in.) make these robots ideal for processing of large parts.

In many cell layouts, the extended reach models can eliminate the need for an external

track, decreasing system cost and simplifying programming. Internally routed cables and hoses maximize system reliability, minimize interference and facilitate programming. Wide work envelopes with small interference zones allow the robots to be placed in close proximity to workpieces and equipment, reducing floorspace requirements. The robots have brakes on all axes and can be floor, wall or ceiling mounted for layout flexibility. www.motoman.com

Prab

PRAB/Monlan’s Enviro 1200 increases the life of expensive tooling as well as improves the surface finish of your end product. A three-stage filtration system can recycle cutting fluids and coolants down to 1 micron clarity.

In addition to the benefits of fluid filtration, the Enviro 1200 conveys wet chips from the point of

production. A low profile design integrates into most individual machining centers. Payback of the system can occur in as little as nine months. www.prabmonlan.com www.canadianmetalworking.com | march 2010 |

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MACHINE TOOLS/MATERIAL HANDLING

machine tending and part transfer. The machine can take 10 kg per arm, with 15 axes of motion (seven per arm plus a single axis for base rotation). Each arm has a 720 mm horizontal reach and a 1,440 mm vertical reach. The robot arms can work together or on separate operations. The floormounted SDA10D weights only 220 kilos.

“The neat part about that is that it allows you to have two arms, 15 axes of motion in a footprint about the size of where someone would stand,” says Sipple, of the SDA10D. Space savings in automatic bar feeders can be just as dramatic. As Rick Bauer, national sales and operations manager for Edge Technologies in St. Louis, MO, points out, many manual bar feeders are loaded from the side or rear. In practice, this means that “even though the footprint of the machine may only be 16 to 18 feet long [you may require] 24 feet to actually load the bar,” says Bauer.

Automatic bar feeders from Edge Technologies, by contrast, load “right over the top of the magazine … you put the material in, just like a piggy-bank slot,” he explains.

Bauer points to the FMB Turbo 5-55 automatic bar feeder which comes with “a space saving double-pusher design … the Turbo 5-55 comes in two configurations: one to feed 12 foot bars and for even more space saving, a six foot model is available.”

4.

Use automation for easy tasks and multiple jobs

Some shop owners like to automate the most difficult tasks in their firms so a human doesn’t have to do them.

Bad strategy, say automation experts, who recommend

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letting workers handle complex jobs while machines tackle tasks “which have high return and are easy to automate,” says Arndt.

The whole point of automating, after all, is to boost productivity, which is hard to do if your automatic equipment is being used for complicated, time-consuming jobs.

Here’s another tip: “In order to get better capital justification and return on investment, one thing that customers are doing is using the robots for more than one task. So they might run one part during one shift, then instead of letting it sit idle, they will run another part on another shift and basically try to get the utilization and justification higher,” adds Arndt.

5.

Minimize labour

6.

Ask for an automation audit

Automation allows shop owners to minimize their labour costs, which puts them in an excellent position to compete with low-cost offshore companies.

A single human welder, for example, can control “two or three welding robots” at the same time, which hugely increases work output, says Arndt. “You are effectively multiplying the skills [of your workers],” he says.

Motoman’s new DX100 Controller can support up to eight robots and 72 axes at one time. The DX100 also offers “an energy saving mode—so in essence [a robot attached to the DX100] goes into sleep mode if not in operation,” states Sipple.

Before you make any purchases, ask the makers or distributors of automatic material handling equipment to gauge your automation needs. Many companies will provide this service gratis, and will either inspect your plant in person or have you fill in a survey regarding your operations.

FANUC, for example, will send inspectors into plants that lack automation to observe their current equipment setup then make appropriate recommendations.

Edge Technologies offers a similar service, peppering potential customers who approach them with questions about their automatic bar feeder needs: “[We ask] ‘What are the lot sizes? What type of machine tool are you running— Swiss or fixed headstock? What type of material is it—round, hexed, shaped or profiled?’ And that kind of helps us get the party started,” says Bauer. CM

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Nate Hendley is a freelance writer based in Toronto. www.edgetechnologies.com www.fanucrobotics.com www.motoman.com

2010 PCT Carbide

30 | march 2010 | www.canadianmetalworking.com PCTV4.indd 1

FANUC’s M-10iA robot performs a material removal operation on a plastic part.

12/14/09 9:55:04 AM

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CUTTING TOOLS/MILLING >> By Jack Kohane

Cutting Class Cutting tool suppliers’ innovative solutions are overcoming titanium challenges consumers and government regulators for Dubbed the “space age metal,” titanium lives hotter and more powerful engines led to the up to that title because of its broad variety development of ‘super stainless’ alloys or of applications as a component material super alloys.” for everything from military missiles to For instance, while these strong mobile phones. In its purest form, titanium and heat-resistant alloys can increase is a strong, lustrous, corrosion resistant engine life, allowing smaller engines to (including sea water and chlorine) transition do the work of larger ones, improving metal with a silver colour. The amazing fuel efficiency, and decreasing operating metal can also be alloyed with iron and costs, Vetrecin points out that they also aluminum among other elements, to take their toll on cutting tools. “Their heat produce strong but low density (lightweight) resistance leads to higher temperatures at alloys for aerospace (jet engines and the tool tip, increasing the chance of tool spacecraft), industrial process (chemicals breakage and shortened tool life.” and petrochemicals, desalination plants, As the high temperature strength pulp, and paper), of the super alloys increases, forces automotive, as well as exerted on the insert’s cutting edge jewelry and cell phones. also increase. Cutting tools made “Alloys, the class of C-2 carbide grades that can easily act of metals, have been machine many titanium and developed to ‘stay nickel-based alloys develop together,’ they are crushed cutting edges ductile so they don’t and severe notching break apart easily,” at the depth-of-cut explains David line when machining Vetrecin, rotating tools today’s alloys. The product manager for latest micrograin Iscar Tools Inc., Oakville, carbides, however, have ON. “Because of its great Iscar’s high speed milling (HSM) much higher compressive strength-to-density ratio adjustable endmills strength and hardness than titanium alloy, most often and facemills improve milling of aluminum, non-metallics, traditional carbide grades, at referred to as a super cast iron and hardened steel. only a small cost in toughness. alloy, is ideal for aircraft Tool life is improved, as is reliability of applications.” But this property plus of performance. Consequently, they resist titanium also has a downside, he adds. the common failure modes in super alloy Super alloys represent a range of nickel, machining much more effectively than do iron, and cobalt-based alloys developed traditional carbides. for applications requiring exceptional Part geometry of materials used with mechanical and chemical properties at high increasing regularity in aerospace—such temperatures. Most of the superalloys in as titanium, aluminium, steel and stainless, the modern aerospace industry are used often with thin walls and of complex to make power turbines (jet engines) and shape—pose a range of metallurgical related components. The remainder is and machining challenges, including low earmarked for the chemical, medical, and machinability of expensive new types of construction industries for applications materials (titanium-555-3, Carpenter 465 demanding high temperature properties (stainless), and composites; and high in addition to exceptional corrosion or surface demands such that the surface oxidation resistance. generated with the cutting tool must have “Unfortunately, almost every good integrity to withstand a given number metallurgical change made to enhance of flying hours. these alloys also makes them more difficult “Aluminum is being reduced in aircraft to machine,” remarks Vetrecin. “Originally, structures, replaced by titanium and CFRP steels and stainless steel alloys were used in (Carbon Fiber Reinforced Plastics),” notes aerospace application, but the demand by

Best Practices: Titanium Machining Titanium presents a unique set of machining problems, but many of these problems can be alleviated or eliminated by adhering to some best practices, say suppliers.

• Use low cutting speeds and feeds recommended by the machine manufacturer.

• Temperature is not affected by feed rate so much as by speed, and the highest feed rates consistent with good machining should be used.

• Use large volumes of recommended cutting fluids.

• Use the abrasion and heat-resisting cutting tools recommended in the tables.

• Replace cutting tools at the first sign of wear. Tool failure occurs quickly after a small initial amount of wear.

• Never stop feeding while the cutting tool and work piece are in moving contact. Allowing a tool to dwell in moving contact causes work hardening and promotes smearing, galling, seizing and tool breakdown.

These recommendations should be used as a guide and results may vary slightly with various machines and material input.

www.canadianmetalworking.com | march 2010 |

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CUTTING TOOLS/MILLING

Kevin Burton, application manager, milling and deep hole drilling products, Sandvik Coromant in Mississauga, ON. “This trend means heightened production investments in complex machines featuring advanced machining strategies. It also requires enhanced production planning allowing for no mistakes.”

Focusing on the general machinability of titanium super alloys, Burton emphasizes that it is poor compared to both general steels and stainless steels, which places special demands on the cutting tools, he says. “Titanium has poor thermal conductivity; strength is retained at high temperatures, which generates high cutting forces and heat at the cutting edge. Highly-sheared, thin chips, with a tendency for galling create a narrow contact area on the rake face, generating concentrated cutting forces close to the cutting edge. A cutting speed that is too high produces a chemical reaction between the chip and the cutting tool material, which can result in sudden insert chippings/breakages.”

Thus, cutting tool materials should have good hot hardness, low cobalt content, and not react with the titanium, Burton continues. Fine-grained, uncoated carbide is usually used, and he urges machine operators choose tools with a positive/open geometry with good edge toughness.

One such tool, is Sandvik Coromant’s CoroMill 690, a long edge cutter for titanium milling of aerospace components. It has four cutting edges for 2-D profile operations. Every insert

pocket has a threaded coolant hole prepared for a nozzle for high pressure coolant delivery to enhance chip evacuation.

It’s used for face and plunge milling, where cutting forces are primarily directed towards the spindle, providing stable cutting action that’s almost vibration free. A 10˚ entering angle produces a thin chip, enabling a feed per insert of up to 4 mm per tooth, when operating tangentially.

Nickel- and cobalt-based super alloys should be approached much the same as titanium, but for the most part, they are better at dissipating heat so more aggressive cutting tactics can be applied, observes Dale Hill, applications engineer for Greenleaf Corp., Saegertown, PA. “Unlike titanium, ceramic cutting tools can be applied on most nickel and cobalt alloys,” he states, adding that this means that ceramic tools can be applied at very high cutting speeds, sometimes up to eight times that of carbide tools.

Hardened surfaces left by previous cutting actions cause aggressive wear at the section of the cutting edge. This is known as depth of cut notching and usually becomes the main tool failure mode when machining at high cutting speeds. Programming techniques, like varying the depth of cut, are applied to combat depth of cut notching.

Greenleaf supplies two ceramic grades for turning and milling heat-resistant super alloys: whisker-reinforced ceramic grade WG-300 for general turning and milling, and coated whisker-reinforced ceramic grade WG-600.

PRODUCT REPORT Emuge

Emuge Corp.’s tapered end mills are designed for the machining of specific components in several key manufacturing segments including automotive, aerospace, energy and HVAC. The end mills are tapered in shape, with an accurate ball nose capable of completely machining impellers, blisks, turbine blades and tire profiles without a single tool change during three axis and five axis operations.

Iscar

ISCAR’s new HM90 APCR 220605-CS grooved inserts put an end to chip jamming problems in rough milling of aluminum, where chips can pile up like snowballs. They are a part of ISCAR’s growing HELIALU HM90 line of inserts tailored specifically for aluminum milling.

especially well with ISCAR’s new HM90 EAL/FAL…22 aluminum rough milling cutters. Besides reliably clearing chips, the inserts conserve power and reduce chatter in long-overhang setups.

The inserts feature a cavity on the bottom to ensure correct mounting in cutter chip pockets equipped with standard spring pins. For optimum chip control, ISCAR recommends using the HM90 APCR chipsplitting insert only in cutters with an even number of flutes. This will substantially decrease the volume of chips, compared to inserts which do not have a chip splitter. www.iscar.ca

Sandvik Coromant Offering an application-specific solution, these tools are available in a wide range of sizes. Uncoated designs are able to mill aluminum and specialty steels including nickel-chrome steels and Inconel. End mills with a TiALN coating can machine steel materials at up to 45 Rc as well as cast and non-ferrous metals.

The tapered end mills are available in two standard forms, one with shorter flute lengths for increased rigidity. In addition, special tools made to customer specifications are offered. www.emuge.com 32 | march 2010 | www.canadianmetalworking.com

With two grooves pressed into each polished cutting face, the inserts split aluminum chips into a manageable size for easy, reliable evacuation despite the application’s characteristic high chip volume.

The 22 mm inserts, each with two edges, are designed to optimize metal removal over the full range of aluminum roughing conditions, from high power/low speed to high power/high speed. They work

Sandvik Coromant has launched two new grades to tackle the extreme demands of titanium milling. Together these grades amount to a new level of reliable, long lasting performance, says Sandvik. Grades S30T and S40T are available for a variety of CoroMill cutters for face, shoulder, long-edge and high feed milling, plunging, profiling and slot milling.

S30T has been developed with productive titanium milling in focus. It combines the properties of micro-grain carbide and a wear resistant PVD coating.

This enables sharp cutting edges that resist fatigue and micro-chipping and result in

Emuge’s new line of end mills are designed for dental prosthetics manufacturing.

“Titanium and other “difficult to machine alloys” are tough for everyone to cut and to my knowledge, there is no silver bullet,” agrees Stephen Jean, milling products manager at Emuge Corp., West Boylston, MA. “The same properties that make these materials desirable for use in various harsh environments contribute to the difficulties in machining them. Everyone wants to cut faster and better, but due to the potential for these materials to work harden from the heat and stress which results from an increase in speed, the recommended cutting speeds are relatively low.

And while marginal gains in speed can be achieved through refinements of machining strategies and the use of high

cutting edges that are preserved for longer times in cut at higher cutting speeds.

Grade S40T for difficult conditions S40T is developed for difficult conditions.

It combines high toughness cemented carbide with a thin CVD coating. The result is a grade that withstands vibrations and other difficult cutting conditions for longer times in cut. The wear is predictable, making the cutting edge gradually duller without breaking. www.coromant.sandvik.com

Tungaloy

Tungaloy’s new line of hybrid end mills combine the benefits of solid carbide end mills and the economy of indexable tools. The new line includes EPH, which offers high accuracy and low cutting force for high productivity, similar to a solid carbide end mill. EVH is a centre cutting, multifunctional tool for slotting, drilling, helical drilling, ramping and shoulder milling. EXH is a super high feed, centre

quality end mills, violations of this cutting “speed limit” will ultimately lead to a drastic increase in tool wear and a corresponding drop in productivity.”

To tackle titanium, as well as cast iron and steel materials up to 44Rc hardness, Emuge developed its MULTI-Cut line of solid carbide end mills. Due to its progressive edge profile and variable helix technology, MULTI-Cut end mills can achieve material removal rates five to ten times that of conventional end mills in some materials, claims Emuge.

Three MULTI-Cut tool configurations are offered, including a short design for optimum stability in slotting operations and two long designs; one with extended flute lengths for deep pocket milling and the other with longer shanks for extended reach applications. Tools come in 4-20 mm and 1/8-1 in. diameter sizes.

According to Jean, a veteran in the mouldmaking field, “those with experience working with conventional steels or in high-speed or high productivity machining environments, may need to reconsider what constitutes success when machining super alloys. Successful machining in this area is less about reducing machine time and more about effective machining and increasing tool life. My best advice for machining titanium and other difficult materials: Be patient and be realistic.” CM Jack Kohane is a freelance writer based in Toronto.

cutting tool that will improve productivity in a variety of machining applications, says Tungaloy.

These tools are available in sizes starting

at 0.39 in. diameter. The tools offer the performance and versatility of solid carbide with the economy of an indexable tool.

Insert grades are available for steel, stainless steel, cast iron and aluminum. www.tungaloyamerica.com

Widia

New additions to the WIDIA Victory M1200 series of face milling cutters and inserts, part of the new WIDIA Victory platform of advanced milling, turning, and holemaking tools, are providing superior results for manufacturers working in steels, stainless

steels, high-strength steels, cast irons, and now even non-ferrous materials. In addition to the hugely successful M1200 face-milling range, there are new WIDIA grades and geometries specifically for machining aluminum and non-ferrous materials and a new member to the popular series: the M1200HF face-milling system.

M1200HF (High Feed) is a unique tooling solution that accepts standard M1200 HN .09 inserts already available today, but, by utilizing machining science to incorporate a chip-thinning effect, can achieve extraordinary metal removal. Features and benefits for the face milling system include excellent chip forming and evacuation capabilities, high feed load capability, and superior accuracy of insert positioning, allowing for excellent tool life and surface finish. www.widia.com www.canadianmetalworking.com | march 2010 |

33

NEWS: PRODUCTS AV AVA EVAILABLE B ILA FROM MARCH 01

Milling titanium?

You need S30T and S40T Not one but two new grades to tackle the extreme demands of titanium milling. Together these grades amount to a new level of reliable long lasting perfor mance. And they are available for a large selection of milling cutters.

CoroThread速266

CoroMill速316

Now with two unique grades for threading

Integrated tool holders with exchangeable-head coupling.

CoroMill速490

Sharpen your competitive edge

The wind power industry has a bright future.

With new insert size 14

Think smart | Work smart | Earn smart

www.sandvik.coromant.com

Call your local Sandvik Coromant Productivity Engineer at 1-800-268-0703 today or visit us at www.sandvik.coromant.com/ca to locate your local authorized distributor.

>>>

CUTTING TOOLS/CASE STUDY >> By Daryl Angier

Smooth

Landing Kitchener landing gear maker gets proactive about choosing tools for cutting titanium

Heroux Devtek’s cutting tool supervisor John Miller, right, with machinist Ron Hall in front of the Toyoda FA 800 HMC they used to perform the testing of cutting tools for machining Ti-555-3.

Manufacturers looking for examples of how to stay competitive in today’s tough market would do well to consider the case of landing gear maker Héroux Devtek. When the Kitchener, ON-based company decided it wanted to improve its capabilities in machining titanium, management took a uniquely proactive approach to selecting the tooling. Rather than simply relying on information provided by its cutting tool suppliers, the company worked with universities and performed its own research to test the tooling from five different suppliers in a scenario that had all the drama of a reality TV show. The results of the testing have allowed the company to improve its capabilities and become more aggressive with

quoting, keeping work in Canada that might otherwise go elsewhere.

The bulk of the business at Héroux Devtek’s Kitchener landing gear division

is making components for medium to large-sized commercial aircraft. The 100,000 sq ft location has over 170 employees working on more than 40 CNC machines, many of them massive bridge-style machining centres for making parts up to 12 ft long and can take up to 60 hours to machine.

Like most manufacturers serving the aerospace sector, the company has become adept at machining titanium, which has become the material of choice for many landing gear components because it can handle extreme loads and is less dense than traditional steels.

The latest generation of titanium alloy is Ti-5Al-5Mo-5V-3Cr-0.5Fe, commonly abbreviated as Ti-555-3 (or “triple five three”). The expensive alloy is notoriously difficult to machine and can be only cut relatively slowly, in the range of 60-80 SFM as compared to 80-100 SFM for Titanium 10V 2Fe 3Al (commonly abbreviated as 10-2-3) or less than half the 180 SFM speed for Titanium 6AL-4. What’s more, 555-3 will chew through vast amounts of carbide inserts in the process. When the company decided that it wanted to start using more of this material, John Miller, Héroux Devtek’s cutting tool supervisor, started out by soliciting information from his suppliers about the kinds of speeds and feeds their latest and greatest tooling would be capable of when cutting this material. That’s when things got interesting.

“We were using information given by tool suppliers because we’d never cut this material. The information we received was so varied that we needed to see for ourselves. So we decided to base our decisions on data driven information,” he says. www.canadianmetalworking.com | march 2010 |

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CUTTING TOOLS/CASE STUDY

Miller’s goal was to compare the tooling from various companies in as unbiased and scientifically objective a fashion as possible. To achieve this, the company worked with Steve Trieber and Eugene Ng of McMaster University in Hamilton, ON, to set up the testing protocol and record and compare the data.

Miller and his team (which also included Héroux Devtek’s general manger Jack Curley and engineering manager Dan Sidhu) then invited 18 different tooling companies to provide information on their experience with cutting the 555-3 and what tooling they would recommend. From the initial 18, 10 companies agreed to participate in the experiment. Miller and company then whittled the list down to five—Sandvik, Kennametal, ATI-Stellram, Walter and Seco—basing their decision on a matrix of factors including North American service and support capabilities and real world experience with the material.

Next, they designed what Miller calls the “phantom part”; an imaginary

Multiples of the “phantom part” made of Ti-555-3 that Heroux Devtek designed for the testing.

The part contains many of the machining challenges that might be encountered in a real part to be made from the material.

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component comprising various engineering challenges for the tooling in terms of speeds and feeds, angles and depths of cut. “No one part is going to have all the issues,” explains Miller. “We used our current tooling practices to machine it and we called that our base case.”

The testing was conducted at the Kitchener facility on a Toyoda FA800 horizontal machining centre with a 50 hp spindle. To obtain the testing data, Trieber and Ng equipped the machine with a dynameter—a plate that attaches to the fixturing and records the forces being placed on the part and the machine during cutting.

They also used a digital microscope to measure the wear on the inserts.

Finally, a team of engineers from each company brought in their tooling to the Kitchener facility one by one over the course of five days. And just like on a reality TV show (call it “Canada’s Next Top Cutting Tool”), each one had their expectations shaken a little after the testing was completed.

“Nobody came in and did well on everything. Everybody seemed to have their own niche,” says Miller. “Some of them had good coating but their base carbide was not so good. We were

“The information we received was so varied that we needed to see for ourselves.

So we decided to base our decisions on data driven information.â€? per cent improvement, we’re looking at redoing the way we getting to the point where cutters were melting down. Cutters machine titanium components.â€? were failing. Some cutters would be freer cutting, in other It’s an approach that is sure to keep HĂŠroux Devtek at words, to take the exact same depth of cut with one cutter, it the forefront of the landing gear manufacturing sector. CM would produce less forces than another cutter.â€? www.herouxdevtek.com Miller notes the importance of factors like the radial clearance of the cutting edge for getting freer cutting. “The freest cutting tool, as in the one that generates the lower forces, is better for us, simply because the machine can push it and you’re not putting that much stress into the part.â€? / ĂŠ 1// ĂŠ

Miller also emphasizes that the experiment did not produce a single “winnerâ€? and that HĂŠroux Devtek is using the tooling from all five companies to machine 555-3. “They were all incredibly impressed with the test as well. They said they’d never seen anything like it. They were all incredibly professional, incredibly resourceful and they were all great to work with. It was beneficial to all.â€?

At the start of the process, Miller had a very clear goal in mind. “We want to be number one at cutting titanium. Right now we’re very good at it. But we want to be the most profitable, the most robust, and have everything data driven.�

A careful and controlled examination of tooling practices was only the first step towards that goal.

For next steps, Miller and HĂŠroux Devtek plan to take the same approach to every other part of the process, including coolant, fixturing and especially the machine. “A good machine is made up of the base, the servos, the spindle motor, the damping of the machine. We’re going to approach the machines the UĂŠ >ViĂŠ Ă€ Ă› } exact same way we did the tooling.â€? *Ă€i Ă• ĂŠ VĂ€ ĂŠ Ă€> ĂŠ- `ĂŠ >Ă€L `iĂŠv ÀÊ }iĂ€ Not surprisingly, Miller’s proactive UĂŠĂŠ }Ă€>Ă› }ĂŠ/ Ăƒ / ĂŠ viĂŠ> `ĂŠ VĂ€i>Ăƒi`ĂŠ ii`ĂƒĂŠ> `ĂŠ-ÂŤii`ĂƒÂ° approach to improving his company’s UĂŠĂŠ *Ă€ w iĂŠ Ă€ }ĂŠ >Ă€Ăƒ capabilities at machining titanium is Ă• `Ă€i`ĂƒĂŠ vĂŠ- âiĂƒĂŠ ĂŠ-ĂŒ V ° UĂŠĂŠ -**É -*/ĂŠ/ Ă€i>`ĂŠ Ăƒ informed by courses he took at York UĂŠĂŠ 1 `iĂ€VĂ•ĂŒĂŠ Ă€ Ă› }ĂŠ/ Ăƒ University to obtain his Six Sigma

Ă•ĂƒĂŒ ]ĂŠ >ĂŒĂ•Ă€iĂŠ> ` ivĂŒĂŠ > `i`ĂŠ/ ĂƒĂŠ Ă›> >L i° Black Belt certification.

UĂŠĂŠ 1 ĂŠ Ă?ĂŒiĂ€ > ĂŠ/ Ă€i>`ĂŠ Ăƒ “In that course, one of the things UĂŠĂŠ >V ĂŠ > viÀÊ Ă€ }ĂŠ >Ă€Ăƒ / ĂŠ> `ĂŠ/ they taught was you can improve

>ĂŒi`ĂŠ/ Ăƒ UĂŠĂŠ ĂŠ Ă€ }ĂŠ-ĂŒ>Ă€ĂŒ }ĂŠ>ĂŒĂŠĂ¤Â°Ă¤ÂŁxÊ > iĂŒiĂ€ anything by 20 per cent. But if you ĂŠ-ĂŒ V ° redo the process, now you’re going UĂŠĂŠ V iĂŠ> `ĂŠ-ĂŒĂ•LĂŠ V iĂŠ ĂŒiĂ€ > ĂŠ/ Ă€i>` }ĂŠ/ Ăƒ after a much larger improvement.

And that’s the reason for taking a step back, looking at what we’re doing, - / ĂŠ 1// ĂŠ/"" -]ĂŠ ° and instead of trying to make a 10-20 ££äÊ7°Ê >ĂƒĂžĂŠ-ĂŒĂ€iiĂŒĂŠĂ‰ĂŠ- ĂŠ6> iĂž]ĂŠ ĂŠ ĂŽĂ¤ĂˆxÊÉÊnää°ÎnΰÓÓ{{ÊÊÉÊnäx°xn{° ĂˆĂ“ Ê­v>Ă?ŽÊÉÊ v JĂƒVĂŒ Ă•Ăƒ>°V ĂŠĂ‰ĂŠĂœĂœĂœÂ°ĂƒVĂŒ Ă•Ăƒ>°V

"7ĂŠ 6 ĂŠ ĂŠ 7ĂŠ / " ĂŠ ĂŠ*," 1 /-t

www.canadianmetalworking.com | MARCH 2010 |

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FABRICATING/PUNCH PRESSES/CASE STUDY >> By Jack Kohane

A Pressing Need A sheet metal fabricator’s green focus and investment in an electric press generates 40% electrical savings Sheet metal spray booth manufacturer Global Finishing Solutions is intent on being a green manufacturer. So when the company’s US manufacturing operation in Osseo, WI, decided to revamp its fabricating operation, it wanted equipment that could help it cut energy consumption.

Global Finishing’s Canadian operation is based in Barrie, ON. The company services its main clientele, the aerospace sector, by providing finishing equipment and a service roster spanning conceptual design, engineering, research and development, to manufacturing and technical support.

The industrial products division at GFS supplies some of the latest technological innovations in open-face paint booths, powder coating booths, industrial burn-off ovens, process and curing ovens. “Whether it be woodworking or metal forming, liquid coating or powder coating, application or burn-off, we manufacture the finest finishing equipment available today,” states Jonathan Barrick, marketing manager for the Canadian sales and design engineering arm of GFS. “Our unique ‘modular’ approach allows our customers to choose which components they need, while GFS consultants help tailor these components to the requirements of each client.”

In the growing area of auto and truck refinishing, R&D at GFS is working to improve automotive paint booths for new levels of performance and efficiency. “We’re proud to be the exclusive provider of paint booths for all major auto manufacturers’ shop equipment programs, and GFS has forged strategic relationships with all major coating and paint manufacturers,” boasts Barrick.

A key component of the GFS business plan is integrating the latest in sheet metal fabricating technology into its paint booth and 38 | march 2010 | www.canadianmetalworking.com

oven manufacturing cycle. “We’re an environmentally conscious company, and when we buy new equipment we choose to invest in ‘green’ machinery,” says Barrick. “We are always on the lookout for ways to reduce our environmental impact while also increasing production efficiencies.”

And that’s what compelled GFS to purchase a new Murata Motorum 2558 Servo-Drive turret press, now installed at its Osseo, WI, facility, the corporate

previous turret we had.”

Purchased from Gladwin Machinery, a fabrication equipment dealer in Menomonee Falls, WI, the new turret was shipped to the sprawling 143,000 sq ft GFS plant and made operational in quick time.

Larry Will, operations manager for GFS at Osseo, recalls how he and his management team selected the premier press. “In August of 2008, I put in a submission for money for a

The Murata press is 100 per cent electrically operated and uses about 70 per cent less energy than other turrets, says Jonathan Barrick, marketing manager for Global Finishing’s Canadian sales and design engineering arm in Barrie, ON.

and industrial manufacturing headquarters for North America.

Barrick is big on the benefits it brings to GFS. “The press is 100 per cent electrically operated, using about 70 per cent less energy than other turrets with similar capabilities,” he points out, adding that the usage of servo motors in place of hydraulics means there’s no need for the use of messy oils or refrigerant coolers. “That significantly reduces the environmental impact of the turret’s operation. In addition, this new turret is much more efficient in its operation when compared to the

new turret. In July (2009), we started the process of machine selection and we were thorough in looking at other types and brands of machines during our buying process. We strove to have a certain amount of commonality with our existing equipment for the ease of our operators and maintenance department.”

By early October Will had made his selection and placed the order for the Motorum 2558, receiving the machine on October 26th. By the morning of October 28th his production crew were making parts on the new equipment,

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FABRICATING/PUNCH PRESSES/CASE STUDY

already outpacing the three other CNCs on the shop floor.

Those parts are made of 18 gauge steel, galvanized, stainless steel, and aluminized steel sourced from Central Steel & Wire Co. in Chicago, and from Viking Materials Inc. in Minneapolis, MN. The new servo motor ram drive concept in punch press technology not only offers higher productivity in an eco-friendly working environment, it makes high speed and low noise punching possible by controlling acceleration and deceleration of ram drive and by controlling ram power during punch stroke.

Will gives several reasons why he purchased the Murata 2558. “I knew the direction that I wanted to go based on past experience with Murata Wiedemann. They make good equipment, as do many other manufacturers, but the main difference in my mind is service and their service is outstanding, and downtime is critical to our organization.”

Due to the time sensitivity of his business, he can’t shut down for a day.

Will says he needs the equipment up and running consistently to produce quick-ship products.

“This machine gives us everything we need in a turret. It has a large turret configuration with four auto-index stations, several of the AI stations are large and allow for a long separating tool to be used. Its equipped with a 60 in. throat that allows us to run 5-ft material without having to reposition.

We’ve noticed a huge increase in the processing speed over an older machine that was replaced.”

The Motorum 2558 has been designed to help raise productivity via an auto-index speed up to 180 rpm, a punch rate of up to 400 hpm, and process integration of bending, forming, and tapping. Among its main features: downward extrusion up to 2 mm; forming with upward thrust; turret bending height as high as 20 mm; a servo motor with 25 metric ton (27.5 US ton) punching capacity; and a punching accuracy of +/- 0.1 mm (+/- 0.004 in). The reinforced single piece design with triple box construction affords more precise tool alignment under full tonnage punching.

And the thick Meehanite turret has burnished bores that guide the punch 40 | march 2010 | www.canadianmetalworking.com

PRODUCT REPORT Ferric Machinery

The Procon coil punching machine available in Canada through Ferric Machinery has the ability to process complex parts cost effectively. Once the metal sheet is introduced into the machine, the machine produces automatically without the need for continual supervision.

The company says that the coil punching machine offers savings in labour because of its automation and ability to work operator-free. The product does not need to be manually separated from the sheet, allowing for additional labour savings.

Procon says that the costs of a complete coil system, including decoiler, straightener and punching are much lower than in a sheet metal punching machine with automatic loading and unloading system. And the machine allows for easy management of sheet metal stocks.

The feeder on the machine is equipped with two mobile grippers for optimum feed cycle times. The feeders can be used on raw and prefinished materials, with or without protective film.

The material in the machine runs along the X axis while the tool moves along the Y axis. The hydraulic punching head enables punching speeds of more than 800 punches/min. Fabricators can also rotate the tool for maximum flexibility.

Punching is achieved with the use of what Procon describes as an “intelligent hydraulic hammer” that offers precision positioning and punching in milliseconds.

The coil punching machine is available in six models, depending on the type of punching head and the width of the coil.

For example, the PX 20/1-0800 features a punching capacity of 20 tons, can accommodate coil widths of 50 to 80 mm and coil thicknesses from 0.6 to 3 mm. The PX30/2-1550 has a punching capacity of 30 tons, is equipped with two punching heads, can accommodate widths from 200 to 1,550 mm and material thicknesses from 0.6 mm to 1.5 mm.

The coil punching machines are equipped with a CNC M9500 controller, RoBoPunch firmware, a Windows-based machine software allowing instructions to be stored in the hardware. www.ferricmachinery.com

Mate Precision Tooling

Mate’s new AMX Thick Turret ABS tooling offers the replacement alternative fabricators have been waiting for and provides what the company describes as “100 per cent worry free compatability” with AMADA ABS assemblies and holders.

Fabricators also have the flexibility of using AMX punches with Mate’s ULTRA TEC Tooling System. Mate incorporated advanced metallurgy and lubrication delivery systems to prevent galling, slivering, and slug pulling Features include precision gun drilled ABS channels on A and B station punches, and standard external spiral lubrication grooves ensuring uniform fluid flow for friction-free punch-to-guide operation.

AMX A and B-station stripper guides are available for A and B-station punches, and a the stripper opening incorporates blips for ABS compatibility. The guides are hardened and ground for maximum precision and long life and offered in two styles: o rounds, with internal keyway; and o shapes, with multiple precision keyways. Edges are rounded to minimize sheet marking.

AMX C, D, and E strippers are fully compatible with AMADA ABS systems, relieved to allow 0.078 (2,00) extra grind life and also feature rounded edges for minimal sheet marking. www.mate.com

Peddinghaus

Peddinghaus Corp. has designed a patented original concept for the fabrication of plate, angle, and channel,

the “REVOLUTION” Anglemaster.

The new Peddinghaus Revolution Anglemaster utilizes a unique rotating punch press that is implemented in processing each leg of angle. The revolving design offers flexibility to fabricators when part marking, loading material, and processing plate.

Key features include: • A revolving punch press design; what the company describes as a “ground‐breaking revolving punch press” used for part marking, and punching both legs of angle.

• The triple tool punch press is an A 144 (130 metric) ton punch press complimented by a triple tool punch assembly used for processing each leg of angle, greatly reducing the time required to manually change tooling. In the rare occasion where tool change is needed, the punch press returns to a vertical position for easy access to the tool assembly.

• The punch press boasts a 169 (153 metric) ton shear.

• The SignoPlate Part Stamping System features 44 characters loaded into a new plate style design for hard stamping part numbers on material. The part marking system rotates with the punch press and is capable of marking either leg of angle.

• The new CNC/PC control panel configuration allows fabricators to access both a CNC control and PC computer at the machine control panel for fast and efficient part modifications.

• Fabricators can expect to process angle up to 8°—8°—1 in. (200°—200°—25 mm), plate up to 12°—1 in. (300°—25 mm), and Channel up to 12 in. (300 mm) wide. www.peddinghaus.com

Prima Finn-Power North America

Finn-Power has recently introduced the Finn-Power C6 LST. The 20-station, 33-ton C6 servo hydraulic turret punch press allows 60 in. x 120 in. (1,500 x 3,000 mm) sheet processing without repositioning.

The modular LST construction consists

of a loading device with integrated sheet separation and double sheet detection, stacking device for component removal and stacking and an unloading device for skeleton removal. Multiple loading and unloading table configurations are available to tailor to individual production needs.

The LST is connectable to all storage and retrieval or material management systems.

The machine is a compact automatic sheet loading and part sorting system. It loads sheets to the machine, picks up the parts from the machine and stacks them to the programmed coordinate on the stacking table. Loading capacity is 6,614 lb (3,000 kg). Punched parts are picked up in front of the turret by using a programmable vacuum gripper. Parts are sorted and stacked on the moving table to the programmed position.

the fascia of the multi-press head, you will find a built-in shear that can make cuts of any length, creating a highly compact, high-performance, multifunctional system to surpass the capabilities of ordinary turrets.

Other major upgrades found in the new S4X include a new hydraulic power pack that reduces power consumption by 30 per cent, an optional cartesian stacker, and the expanded ability to incorporate any and all types of feeding connections.

The S4X punch/shear, like all Salvagnini machines, is based on the lean philosophy of batch one production, few or no tool changes, optimum warehouse management, reduced work-in-process and just-in-time production. www.salvagnini.com

TRUMPF There is a choice of two models. The long model can be equipped with up to four moving tables. The short model can be equipped with two moving tables. www.finnpower.com

Salvagnini

Salvagnini America’s latest generation of Salvagnini S4 punching and shearing machines is the Salvagnini S4X for 2010.

The most visible departure from former S4s is a redesigned manipulator, powered by two pairs of rotary electric motors. The first pair employs rack and pinion kinematics driven by new handover control logic, while the second pair uses two ball-bearing screws directed by gantry control logic to position the sheet. The new manipulator enables the S4X to offer exceptional processing speed, reduced cycle times, increased productivity, and improved accuracy.

The punch press retains Salvagnini’s patented stationary, multi-press head that eliminates the in-cycle stops for tool changes that limit turret press processing speeds. All of the S4X’s 96 punching tool stations are live and ready to simultaneously punch, countersink and emboss parts with a speed and precision unmatched by competitive machines, says Salvagnini. Also, beneath

TRUMPF’s TruPunch 5000 is already recognized throughout the industry as being best in class for its speed, productivity and ability to produce work pieces with minimal scratches, says the company. However, the latest generation of the machine provides even greater flexibility—thanks to its increased speed and the new active die option, which virtually eliminates scratches during processing.

With the active die, each time the sheet is positioned, the die is lowered slightly so that it does not contact the sheet. The moveable die also expands the forming possibilities of the machine since the total distance between the table and punch can be used. In addition, the active forming stroke from below the sheet increases the machine’s flexibility because larger tools may now be used; even marking from underneath is now possible.

In addition, the punch press operates about 10 per cent faster than its predecessor, with 1,400 strokes per minute www.canadianmetalworking.com | march 2010 |

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FABRICATING/PUNCH PRESSES/CASE STUDY

The Murata press can handle parts up to 7.87 in. x 6.30 in. (200 mm x 160 mm).

holders throughout the stroke. The bi-directional turret positions each tool as the table positions the sheet.

Hardened bushings guide turret index pins for more accurate positioning.

General specifications for the 2558 include: a stainless steel (with urethane ball transfers) tabletop style; and approximate machine dimensions of 205 in. (5,200 mm) width, 222 in.

(5,644 mm) length, 89m in. (2,250 mm) height, and a table height of 38.6 in.

(980 mm). The part size is a maximum 7.87 in. x 6.30 in. (200 mm x 160 mm), and a minimum 1.18 in. x 3.15 in. (30 mm x 80 mm).

Due to its servo motor drive mechanism, the 2558 differentiates itself from most other turret presses as an eco-machine, one that uses the energy it needs only at the time of punching, and uses regenerated energy generated at the time of braking. Thus running cost is reduced.

“We really like the savings that we see on our electrical bill,” says Will, who estimates he has achieved close to 40 per cent electrical savings on the servo turret, as compared to more traditional hydraulic turrets. “Bringing the Murata 2558 on board not only helps conserve energy and saves us money, it also makes this a good “green” decision that fits in perfectly with our focus on greening our physical work environment and operations.”

Assessing the capabilities and performance of his 2558, Will admits he’s pleasantly surprised. He’s impressed by the machine’s lightning fast nibble rate of 800 hpm, its power to punch 400 hpm on 1-in. centres, and maximum axis speed of 4,921 ipm. With the larger nibbling/parting stations he 42 | march 2010 | www.canadianmetalworking.com

can run 3-1/2-in. parting tools instead of 2 in. as before, meaning he can reduce parting operations by almost 50 per cent. All in all these attributes add up to the Murata punching out parts twice as fast as Will’s older machines.

“With a larger turret configuration we can keep the turret populated with pretty much all of our tools, eliminating most of the downtime due to having to change tools,” observes Will, who says he’s also seeing greater life in the punches because of less turret wear.

“Any time you replace an older machine with a new machine, certain things automatically occur,” adds Will. “Maintenance issues disappear resulting in less downtime and more predictable shop routings. Thanks to the additional throughput, we find ourselves running more parts across this machine than the other turrets in our plant.”

Asked if he’s happy with his new Murata 2558, Will replies, “absolutely.” CM Jack Kohane is a freelance writer based in Toronto.

PRODUCT REPORT for medium format and 1,200 strokes per minute for large format. This means 200 more strokes without using more energy. The TruPunch 5000 can process a maximum sheet thickness of 0.3 in.

There are two other ways in which the machine is fast: It takes only 2.8 seconds to change tools, and only 0.3 seconds to change the tools within the MultiTool. As a result of weight-optimized components and tool cartridges, the X axis accelerates to a maximum speed of 3.9 ipm at .79 in. per second.

Another special feature is the gantry drive of the Y axis. Two separate motors are controlled synchronously without a mechanical connection, to create speed and accuracy.

Working range (X,Y) is 100 x 50 in. (2,540 x 1,270 mm) and 120 x 65 in. (3,048 x 1,651 mm), respectively.

Punching force is 25 tons and maximum simultaneous XY speed is 4,600 ipm.

The punch press can be automated modularly with a variety of components, such as the SheetMaster and a cart system with belt drive or tracks, for the automatic loading and unloading of sheets, as well as the GripMaster, which removes and stacks scrap skeletons. The ToolMaster tool storage unit has up to 70 additional spaces and, TRUMPF compact and universal storage systems offer flexible solutions for automated production. www.us.trumpf.com

Wilson Tool

Wilson Tool has upgraded its Wilson High Performance (HP) line of punch press tooling.

These new upgrades are designed to further increase productivity, precision and durability.

The new HP2 spring packs deliver best in class features for small station driver assemblies. HP2 spring packs enable fast, accurate punch length adjustment in .005 increments with no tools or buttons. They also offer greatly improved length adjustment on punches, tool-less guide removal and maximized stripping pressure.

The company has modified its punches to ensure that the maximum grind life of each Wilson HP punch matches or exceeds all other competitors. Enhancements were also made to WB tool steel to ensure that Wilson’s standard tooling is the toughest, most durable in the industry.

“It is our goal to make tooling that helps our customers be as productive as possible,” says Chris Lawless, Wilson Tool’s vice president of operations. “The upgrades to our HP product line are simply the latest in a long history of innovations by Wilson Tool that advance tooling technology to help fabricators improve the quality of their parts and achieve their lean manufacturing goals.” www.wilsontool.com

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FABRICATING/LASER MARKING >> By Jack Kohane

Moving Target New approaches and technologies, such as “on the fly” and fiber laser marking, are opening new doors for laser marking In today’s competitive environment, it’s essential for metal product manufacturers to leave their mark, literally. Whether it’s a company logo, trademark, material specifications or serial number, manufacturers rely on laser marking to etch critical information onto a part for traceability.

Laser marking has been used for decades, but in recent years, suppliers have introduced new approaches and new technologies to improve the process.

“The benefits of laser marking are many,” says David Gibson, president of Automation Systems & Integration Inc., Mississauga, ON, which designs and builds custom laser marking equipment. “The mark is a noncontact, stress free, permanent mark that is easily readable by either the human eye or the lens of a character recognition camera,” he explains, adding that almost anyone who requires a permanent on their product can use laser marking.

Compared with other marking technologies, such as ink jet printing and mechanical marking, laser marking outshines them all. Among laser’s laudable attributes are its low operation cost (no use of consumables) and consistent quality.

“The technology has been to the development of smaller laser marking systems for both static marking and “on the fly,” where the mark is placed while the product or part is moving,” says Gibson, allowing lasers to be used in very tight areas (some optical scanheads can be as tiny as four sq in).

One innovation launched by Automation Systems & Integration is a portable laser marker which is equipped with a laser head measuring 10 in. x 7 in. x 8 ½ in. (254 m x 178 mm

Automation Systems & Integration’s David Gibson and wife Diana with the new portable laser marker.

Right: A close-up view of the product.

x 216 mm) deep, and weighing about 6 lb (2.7 kg), and a control box that is 19 in. x 19 in. x 6 ½ in. (483 mm x 483 mm x 165 mm) deep and weighs about 25 lb (over 11 kg.). The core of the machine is a fiber laser system. “Quite often a customer will want to mark large parts or parts which are already assembled onto a machine and are therefore not easily presented to a laser marking station,” notes Gibson. “A portable laser can be carried to the part so the part can be marked in location.”

Portability may light the way for increasing interest in this technology, but ease of use and cost effectiveness remain key advantages, according to Brian Hilliker, the Watrerloo, ON-based sales manager for FOBA in North America.

“By using integrated vision systems such as the FOBA IMP camera system for automated position detection and marking/engraving alignment, scrap is reduced and processes are made much more efficient,” says Hilliker. “Also, easier to operate machines for laser marking and engraving are required, those that better integrate into customer’s machine processes/process flows and thus eliminate expensive manual labour processes.”

Hilliker also heralds the launch of FOBA’s DP2UV, a diode laser marker that broadens the engraving scope www.canadianmetalworking.com | march 2010 |

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According to Peter Grollman, into the ultra violet range. Its resonator national sales manager for TRUMPF design has laser power in the medium Inc., in laser marking with solid range of 2 W with a wavelength of 355 state lasers there are three different nm. “It’s an air-cooled laser with long technologies: Nd-YAG lasers, Vanadate life laser crystals, and small beam (Nd-IVO4) and Ytterbium (used in fiber diameter, which means less lasers). servicing,” he remarks.

Nd-YAG and Vanadate laser Another plus propelling technology, which have the best the laser marking market TRUMPF’s TruMark 2010 fiber laser. beam quality, are particularly wellis the focus on accurate suited for marking small features— traceability. “People are such as tiny data matrix more obliged to codes—on small surfaces. mark their parts Nd-YAG produces the highest today,” says Toch laser peak power and makes Uk, technical it the most versatile manager for North laser marking America with the technology for Charlotte, NC, a wide range branch of French of materials firm, Technifor. including metal, “Imagine the plastics and ceramics. confusion, and FOBA’s DP2UV diode The Vanadate recall implications, laser marker.

“The TruMark 5020 performs well laser shines with if two suppliers are producing above our highest expectations, its superior pulse-to-pulse stability similar parts with no identification primarily due to the flexible and pulse durations down to 10ns. It indicating who made the part or programming of pulse is the ideal laser source for marking when.” Laser marking is permanent, duration and pulse stress parts, such as thus discouraging tampering and energy,” says on those found in counterfeiting, adds Uk. For example, Peter Grollmann. the aerospace it can mark nearly invisible data matrix David Gibson industry where codes on parts (down to 0.004 in. or 0.1 of Automated lowest heat affected mm) to identify the manufacturer.

Systems and zones (HAZ) are To address this need, Technifor Integration says the specified. recently introduced its TD412 YAG laser marking market Also, the fiber laser, offering a marking speed of up to is set for unparalleled laser is firmly 2.5m/sec. The unit’s enhanced beam expansion. “The entrenched into the quality creates thin marking lines and growing requirement for laser marking market marking precision without burrs, and traceability is driving the and covers a broad has high peak power for high contrast Technifor’s TD412 YAG laser. market at a frantic rate,” range of applications. marking capability. The TD412 is he insists. “New laser With its long pulse equipped with a user-friendly marking technologies have resulted in lower durations it performs well on metals for program (software) with intuitive cost laser marking systems. “Lasers deep engraving and annealing. It can graphic interface providing traceability have become affordable for everyone, also be used on many plastics. functions (including serial numbers, regardless of the company’s size,” he In fact, with the introduction of the variables, date codes, UID syntax), and states. CM TruMark 5020 fiber laser, TRUMPF bar codes (DataMatrix and QR codes). provides a complete product range “Other technologies can’t match this www.automationsystems.ca with various power levels and offers breadth of automated finesse and www.technifor.com the right laser for every application. effectiveness,” emphasizes Uk. www.us.trumpf.com 4548 CStrip 178x38 (L) AW.pdf

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laser welding >> By Robert Mueller

Going Mainstream Laser welding is becoming cost effective for mainstream welding applications 2010 marks the 50th anniversary of the first working laser (pulsed ruby laser by T. Maiman, May 16, 1960). By the early 1970s, almost all of the lasers currently in commercial application had been invented. Scientists and engineers have spent the last 40 years refining and improving upon the concepts demonstrated in those early days, with the goal of making lasers that are more stable, efficient and easier and more practical to use. Today, lasers penetrate all aspects of modern life, from CD and DVD players to telecommunications, medical instruments and laser pointers.

Processing of metals started shortly after the first demonstration of the laser. The first ruby lasers produced very powerful pulses, too powerful to measure with most optical sensors of the day. Researchers resorted to placing razor blades in front of their lasers, and counting how many blades the laser could drill through. This unofficial unit of measurement was called the Gillette. Maiman’s first laser produced 1 Gillette pulses; within months, scientists were assembling 4 Gillette lasers.

An early laser gear welding system. Photo courtesy Trumpf GmbH.

By the early 1970s, lasers were being used commercially for cutting, drilling and welding, usually for applications where no other process would work. The lasers and laser processing systems were large, complicated, and difficult to operate and maintain. Few applications or manufacturers could justify the cost and effort required to install and operate laser processing systems, but a few applications were very successful. Pulsed Nd:YAG lasers were used to hermetically weld electro-mechanical relay cans for military and aerospace applications. The same basic technology is still used in the hermetic welding of heart pacemakers and other implantable devices. CO2 lasers were being used to cut sheet metal and weld automotive transmission gears; applications that are still important today. Laser drilling of turbine blades and combustor shrouds to provide film cooling in jet engines was well established. Today, engines for military or commercial jets may have over one million 46 | march 2010 | www.canadianmetalworking.com

laser-drilled holes in each engine. These early applications thrived because there were few, if any, other methods capable of performing the task. Laser processing was considered the method of last resort; if every other possible method failed, try a laser.

Laser Beam Metal Vapor Plume Melt Pool

Schematic picture of the keyhole laser welding process.

Keyhole Weldment As lasers were developed into industrial devices, and engineers tested and developed laser welding applications, several advantages of laser welding over traditional welding methods were observed. The qualities of several welding processes are compared in Table 1 (see page 51). The summary for laser welding would be an effective, high quality process, with a higher capital cost than the traditional methods. With the higher cost comes higher productivity, so laser welding is still cost competitive if you can use the process capacity laser welding provides.

MIG welding, TIG welding and resistance welding methods are still the predominant methods for metal joining, often because they are the most appropriate method for the task. But increasingly, laser welding methods should be considered, not just on technical merits, but also for their economic benefits. The capital cost of lasers and laser systems has dropped significantly over the last five years.

Applications that were technically viable, but not cost competitive using laser welding, may now favour the laser approach. The latest generation of lasers are also surprisingly energy efficient (a term that was never mentioned in the same sentence as laser in years past), with electrical to optical power conversion efficiencies of over 25 per cent for laser diode pumped disk and fiber lasers, and approaching 40 per cent for direct diode laser systems. Lasers are well known for their efficient generation of weld metal (process energy input per unit of weld interface area), but coupled with their improved wall-plug efficiency, laser welding may be among the most energy efficient welding methods.

The narrow laser beam at focus forces the user of laser welding to provide a well fitted joint, so the beam can melt both faces to be welded. Applying laser welding to assemblies

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that have been designed for other welding processes, such as GMAW or resistance welding, usually causes problems as the joint often does not have the correct fit-up for laser welding.

If a manufacturer wants to change to a laser welding process, they should be prepared to redesign the weld joint. The best time to introduce laser welding is during a new model introduction or major product redesign.

LASER WELD PROCESSES Laser welding has many applications, from micro-welding of wire leads onto hard disk drive read heads, using lasers smaller than Maiman’s prototype, to welding of heavy plate using 10 or 15 kW of laser power. Over this tremendous range of power, the basic principle of laser welding remains the same: a laser beam is focused onto the material surface to create a melt pool and keyhole, and then the beam is scanned along the joint to create a weld.

Welding of automotive transmission gears is still a major application for laser welding. The low heat input of laser welding means low weld distortion so that fully finished gears may be assembled without further post-machining. As cars get smaller and lighter, there is more pressure for smaller, more compact transmissions, and more demand for laser welding to assemble these dense gear trains.

Tailored blank welding has become another major application for laser welding. A tailored blank is formed from two or more metal sheets, joined edge-to-edge prior to stamping. The concept is to put strength where it is needed

The laser tailored welded blank process, and a sample blank and stamped component. Photos courtesy of Powerlasers Ltd.

in the component, and remove mass in areas where it is not needed. A tailored blank is obviously more expensive than a simple, single-thickness blank, but the tailored blank can save parts, such as reinforcement brackets, and their assembly operations, producing a net saving in the final product.

Several specialized laser welding processes have been developed in recent years that broaden the range of applications for laser welding.

Remote Laser Welding High power, high beam quality lasers may be used to perform remote welding. In remote welding, a long focal length lens is used, and then the beam is directed to the work surface by a pointing mechanism, using one or more moveable mirrors

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laser welding

and/or mechanical movements. The result is the ability to perform many welds over a large area with minimal move time between welds, typically under 0.1 second between welds. Remote welding directly competes with resistance spot welding. Robotic resistance spot welding typically takes three seconds to move to a location and make one weld.

Remote laser welding typically produces three welds per second, with each weld having equal or better mechanical properties than resistance spot welds.

A cut-away view of a remote welding head, and one second time exposure of several remote welds.

Cut-away view courtesy HighYAG GmbH.

The capital cost of a remote welding cell is higher than a simple resistance spot welding cell, but the productivity of the cell is also much higher. Costing studies show that remote welding is cost competitive with robotic resistance spot welding when the annual number of welds to produce exceeds 10 M welds/year. With effective material handling, a single remote welding system is capable of producing 30 M welds/year in a two shift operation. Operating at capacity, a remote laser welding cell costs about one cent per weld (capital and operating costs).

Remote welding has gained significant acceptance in the European automotive industry, replacing resistance spot welding in stampings assembly and on the body line.

Significant opportunities exist for remote welding in North American automotive manufacturing. Other manufacturing sectors using high numbers of spots welds, such as office furnishings and major appliances, would also benefit from remote welding.

Hybrid Laser Welding Laser welding is almost always performed as an autogenous process (no filler wire addition), as there is not enough heat to consistently melt the wire and maintain a stable melt pool. Without filler metal, the joint preparation must be tight to prevent underfill and a concave weld bead. This limits the use of laser welding in many applications where the up-stream manufacturing processes (shearing, stamping, and others) cannot maintain the tight tolerances required for laser welding. Hybrid welding overcomes this limitation by combining laser welding with MIG welding to give a process with the best features of both. Hybrid welding is fast and gives good penetration, like laser welding, and also has the gap bridging and filling capability of MIG welding. The laser stabilizes the MIG arc, producing a better weld faster than MIG could do alone. High power hybrid welding is capable of single 50 | march 2010 | www.canadianmetalworking.com

Advertisers Index Table 1. Comparison of Welding Methods Category

Parameter

Advertiser

Process

Comments and Effects

Laser Electron Beam GMAW GTAW Resistance

Process

Speed Depth to Width Ratio Heat Input to Part Access Contact with Part Atmosphere

++ + + ++ + +

++ + + + + -

+ 0 - 0 - 0

- 0 - 0 0 0

0 - + - - +

Productivity Single pass welding Low distortion, Small HAZ Single sided, Line of sight access Non-contact, no contamination Air or Shielding Gas or Vacuum

Efficiency

Process Effiiency Electrical Efficiency Compatible with Automation

+ 0 +

+ 0 -

- 0 +

- 0 +

++ + +

Convert process energy to weld metal Wallplug efficiency of process High productivity

Cost

Capital Cost Running Costs Reliability Fixturing

- 0 + +

- 0 - -

+ + + -

+ + + -

+ + + 0

Equipment purchase costs Personnel, consumables, floor space Equipment up-time, maintenance time Cost and complexity of tooling

Quality

Hermetic Welding Real Time Quality Monitoring Environment: Noise, Fumes

+ + +

+ 0 0

- - -

+ - -

- - -

Fluid or gas-tight seams Monitoring or closed-loop control of process Noise, weld smoke, sparks

Page

IMTS Show 19 Canadian Welding Bureau (CWB) 50 Esab 49 Fein Canadian Power Tool 47 Flow International Corporation 45 Haas Automation, Inc. 11 HACO Canada Inc. 3 Horn USA Inc. 7 Hurco Canada Ltd. 2 ISCAR Tools Inc. 54 Jesse Engineering Co 36 Elliott Matsuura 4 Methods Machine Tools Inc. 14 MMTS Show (SME) 13 Reid Supply Company 27 Retention Knob Supply & Mfg. Co. 50 Rofin-Baasel Canada Ltd. 9 Sandvik Coromant Company FLP, 34 37 Scientific Cutting Tools, Inc. Seco Carboloy Inc. 23 SigmaTek Corporation 48 Strippit, Inc. 44 30 TNT Tools Inc. TRUMPF Inc. 39 Tungaloy Canada, Ltd. 53 WIDIA Kennametal Inc. 16 YCI Inc. 10 Quality Canada

Carl Zeiss IMT Creaform Inc. Minitab, Inc. Mitutoyo Canada Inc. Renishaw (Canada) Limited 8CMM20186 01/07/2008 Romquest Technologies Corp.

7 10 12 2 08:194 AM 10

A schematic view of the Laser-GMAW Hybrid welding process (image courtesy EWI), and a sample cross section through a 0.5 in. thick hybrid welded specimen (image courtesy CSTPQ).

pass welding of structures that would take GMAW welding three or four passes to complete. Hybrid welding reduces edge preparation requirements (no edge bevelling) and the higher speed reduces heat input to the part and therefore reduces weld distortion.

Hybrid welding is most effective on long welds, where the increased weld speed gives a substantial increase in system productivity. Current and potential applications include ship building, pipe and beam manufacturing, pipeline welding, and long welds in automotive and truck body

manufacturing, such as frame rails and similar structures.

Laser welding has come a long way from its first commercial applications 40 years ago. Laser welding is now routine in many specific applications, but there is still great opportunity to expand the use of laser welding, and reap the benefits in new industrial sectors. CM Robert Mueller is the senior laser solutions engineer at Nutech Engineering Inc., Milton, ON. www.nutech-engineering.com

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Metal...works/NEW MARKETS >> By Chris Kania

Banking on Expansion Looking for new growth markets? Consider expanding into the US Canadian businesses looking to grow revenue in new markets have a unique opportunity to invest in the US. Expanding a business to the US now will position many Canadian companies favourably for an economic recovery.

Canada and the US are the world’s largest trading partners, sharing a highly integrated economy. Unlike many overseas locations, the US offers the full spectrum of advantages, starting with the most basic: a population that is nearly ten times the size of Canada, the use of Western business models, English as a first language, a stable political climate and quality labour assets.

Connect with field experts in the US I strongly recommend that the first step in any expansion is to seek the advice of organizations that specialize in helping companies grow their business in the US. Throughout the US, economic development organizations offer Canadian companies a range of expert advice free of charge. Some groups, like Buffalo Niagara Enterprise (www.buffaloniagara.org) have representatives in Canada who will meet right in your own office. This arrangement provides a single point of contact to a roster of experts in every key area imaginable: site selection, HR, accounting, taxation, insurance, legal issues, patents and trademarks, financial services, real estate, utilities and corporate incentives.

Select the right type of US bank There are far more banking institutions in the US than in Canada, providing borrowers many financing options. US banks range in size from the super-large banks, which operate in nearly all states, to regional banks, such as M&T, to small community banks serving individual cities.

Look for a bank with experience serving Canadian customers. Ensure they understand the intricacies of cross-border finance and the region under consideration for expansion.

52 | march 2010 | www.canadianmetalworking.com

Expanding Canadian companies should work with a bank that has the ability to easily visit the Canadian headquarters.

This allows the bank to have a full understanding of an operation.

Manage float time In the US there is a relatively heavy usage of cheques and mail for invoicing and payments. The US cheque clearing process takes one-to-three business days which introduces the concept of “float” time into the business cash flow.

Canada generally has same-day clearing.

with a US “Work

bank that can visit your Canadian head office.

”

To reduce float, many US companies use their bank’s lockbox service. With a lockbox service, the bank collects customer payments from the post office, processes the deposits and sends the deposit information for updating of the accounts receivable records.

Organize payments to employees and vendors For payments to vendors and employees, consider using Automated Clearing House (ACH) and controlled disbursements.

An ACH offers a cheaper alternative to sending wires. It should be noted that an ACH originating in the US can only be sent to a bank account in the US. Controlled disbursement products itemize cheques clearing a company account each day and maximize the use of excess funds in an account. Excess daily cash can be used to save interest expense by reducing loan balances.

Develop a currency hedging strategy Most expanding companies in the manufacturing and distribution industries tend to keep their money

in US dollars to finance their US operations.

Choose a bank with hedging strategy experience to mitigate exchange rate risk.

There are a number of Canadian manufacturers that provide human resource functionality to their US affiliate that is predominantly a sales office. On a monthly basis the US subsidiary makes a fixed Canadian dollar payment to the Canadian home office. Since the US affiliate is generating revenues in US dollars, any change in the foreign exchange rates between US and Canadian dollars has an effect on the value of the payment being made. A currency hedging strategy mitigates this risk.

Consider financing options There are many lending services, such as a line of credit, equipment financing, and commercial mortgages, that may be beneficial to a company expanding to the US. For example, equipment leasing can be an attractive alternative for a US affiliate to acquire the latest technology without a major outlay of capital. Companies new to the US may be asked for a personal or corporate guarantee on any loans simply because they do not have an established credit history in the US. While several key differences exist between the US and Canadian systems, the majority of banking is conducted similarly. Along with unparalleled trade and investor relations, the United States stands as a promising market for opportunistic Canadian businesses.

Choosing the right partner bank, one with cross-border banking experience and high-quality service, is critical to navigating the nuances of the market and successfully expanding into the US. CM Chris Kania is administrative vice president and group manager of Canadian Banking at M&T Bank, Buffalo, NY. ckania@mtb.com

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8 LAYING IT ON THE LINE In-line measurement is a cost-effective way to maintain process capabilities.

9 CALIBRATION GUIDANCE How calibration software can improve quality management.

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6

Upfront

Recalls and the Fall from Grace

SPECIAL REPORT/AEROSPACE

6 SETTING HIGH STANDARDS

A new standard for the aerospace MRO market is intended to help the industry produce higher quality products at lower costs.

MEASUREMENT/IN-LINE

8 LAYING IT ON THE LINE

In-line measurement is a cost-effective way to maintain process capabilities, says in-line expert, Peter Detmers of Mitutoyo Canada.

SOFTWARE/CALIBRATION

9 CALIBRATION GUIDANCE

Quality Canada asks Ned Espy of Beamex how calibration and calibration software can improve quality management.

Department

5 News

9

Within days of the first Toyota recall back in January, some competitors, secretly gleeful of the fast-growing Japanese auto maker’s fall from grace, were quick to offer Toyota car owners the opportunity to trade in their vehicles for their own brands.

Toyota’s woes only increased with subsequent recalls, but so too did those of Ford and Honda who issued recalls based on growing concerns about the quality of some of the components on their vehicles.

Industry analysts and media commentators voiced their opinions about what went wrong with Toyota and its prized quality system. One of the most interesting comments came from a January 27 commentary in The Economist suggesting that Toyota’s drive to become the biggest carmaker in the world compromised its quality system. Indeed, Toyota has been dealing with recalls since 2005. The recent massive recalls on millions of vehicles were simply the culmination of the company’s furious race to the top.

Much can be debated about what went wrong with Toyota and its manufacturing processes, but more importantly, the company’s unfortunate fall from grace should serve as a reminder to other manufacturers: quality systems can fail and to prevent such failure, manufacturers must continually evaluate their quality systems to ensure they meet the evolving needs of the company and of the marketplace.

Indeed, Larry Coté, president of Kaizen Institute Lean Advisors in Ottawa, says that in its race to be the biggest, Toyota forgot about what made it a success in the first place; it’s reputation for quality.

“They forgot that there are three legs of a stool—cost, quality and productivity.

Toyota went after volume and it succeeded but at the cost of hurting its brand. The company has to go back to what made it great before and start thinking again the way it taught everyone else to think—put the customer first and be able to do more with less, but being able to do it better and faster and at less cost.”

In a nutshell, Toyota got complacent and over-confident.

Whether Toyota can regain the confidence of consumers and build a stronger reputation for quality and reliability remains to be seen. As it takes steps to recover from the damage to its reputation, Toyota may well become a case study—for itself and for others—in how a company that fell from grace regained its status as a world leader in quality.

Mary Scianna, Editor

If you would like to comment on editorial in the magazine, please contact me. I’d like to hear from you.

416-764-1540 • mary.scianna@rci.rogers.com Editorial Editor Mary Scianna

Measurement Testing & Inspection Software Management

416-764-1540 mary.scianna@rci.rogers.com Managing Editor Daryl Angier 416-764-1508 Daryl.angier@rci.rogers.com Art Director Jill Nelson 416-764-1518 jill.nelson@rci.rogers.com Junior web prodcer Jessica Mirabelli 416-764-1316 jessica.mirabelli@rci.rogers.com Production Manager Jim Howser 416-764-1684 james.howser@rci.rogers.com Circulation Manager Bibi Khan 416-764-1450 bibi.khan@rci.rogers.com Business

Volume 3 | Issue 1

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Industry news Quality Canada, NQI partner on seminar

Quality Canada Magazine and the National Quality Institute are joining forces to host a webinar on the cost of quality.

“We often think that the cost of quality is out of our control,” says Adam Stoehr, vice president, educational services for the National Quality Institute. “The truth is that controllable prevention costs can help us minimize unfortunate failure costs. NQI is so pleased to partner with Quality Canada Magazine to offer this webinar that will change the way you think about the costs of quality.”

The webinar will help participants learn new strategies to improve the cost of quality. Participants will also have the opportunity to learn about research conducted by the University of Waterloo, which analzes the differences between the cost of quality for service and manufacturing organizations.

The webinar is slated for Tuesday April 27, at 12 Noon EST. For registration details, visit NQI’s web site at http://www. nqi.ca/training/course_details.aspx?id=267 or contact Quality Canada Magazine’s editor Mary Scianna at 416-764-1540

Rapid prototyping gets new name, language

Rapid prototyping or layered manufacturing now has a new universal name and language—additive manufacturing—thanks to a collaboration between the Society of Manufacturing Engineers and ASTM International.

“Rapid prototyping has meant different things to different manufacturers. It means quick prototyping to one and layered manufacturing to another. Now it’s called additive manufacturing,” explains Brent Stucker, PhD, a member of SME’s Rapid Technologies and Additive Manufacturing (RTAM) Community and an associate professor of mechanical and aerospace engineering at Utah State University.

In an effort to eliminate the

confusion over terminology, design, testing methods, materials and processing differences, SME’s RTAM community approached ASTM to develop the industry’s firstever standards.

ASTM, in turn, formed the Committee F42 on Additive Manufacturing, including members of the RTAM community, to write new standards. The initial result is the publication, “Standard Terminology for Additive Manufacturing Technologies,” now available for purchase online. Prior to this publication, the lack of consensus within the additive manufacturing community often boiled down to something as basic as the name of the industry itself.

Stucker, who is also the chairman of Committee F42 says that terminology standards “will help clarify

communications” especially in industries like medical manufacturing and aerospace where consistency is a must.

And according to ASTM, these new standards will “allow manufacturers to compare and contrast the performance of different additive processes” and “enable researchers and process developers to provide repeatable results.”

Innovation, quality can work together, report says

A new report from the American Society of Quality (ASQ) dispels the belief that quality and innovation can’t mix.

ASQ profiles two major companies—DuPont and Procter & Gamble—as examples of how quality and innovation can work together.

These two companies have managed to successfully integrate creativity-generating functions and R&D and product development with regular process management structures and practices.

DuPont uses a variety of Six Sigma methods as well as Stage-Gate, a business development process that encourages consistency and speed. The aim is reduced waste in the design, development and commercialization of new products.

“There’s no reason why Six Sigma should hamper innovation—if used properly,” says Liz Keim, past president of ASQ who coaches businesses in quality management.

“Companies need to understand that quality process tools aren’t appropriate for all pieces of a job and should carefully analyze where they can best benefit the bottom line.”

A major driver of its innovation for Procter & Gamble is a mix of quality processes that provide

structure. Two major examples are Future Works, an organization of multidisciplinary teams that seek innovation opportunities outside of existing business units, and Corporate Innovation Fund, which focuses on high-risk, high-reward ideas.

“More than any other factor, systems are the way we avoid dependence on ‘eureka!’ approaches to innovation,” says Robert McDonald, P&G chief operating officer. “We select innovation projects, allocate resources and ultimately bring the best innovations to market with highly disciplined processes and systems.”

For details, visit ASQ’s web site at www.asq.org/2010/01/ innovation/fresh-thinking-oninnovation-and-quality.pdf.

CALENDAR

March 30: ASQ Toronto Section Spring Seminar in Toronto. webmaster@asqtoronto.org 647-723-3811 March 31: Automotive Parts Manufacturers’ Association Environment and Energy Conference in Guelph, ON. info@apma.ca 416-620-4220 April 15: ASQ Windsor Section monthly dinner meeting at the Caboto Club, Windsor, ON. 519-252-8383 www.asqwindsor.org May 10-12: Excellence in Manufacturing Consortium National Manufacturing Conference in Hamilton, ON. conference@emccanada.org 866-323-4362 May 17-20: Montreal Manufacturing Technology Show at Place Bonaventure.

888-322-7333 www.mmts.ca For more events, visit Quality Canada’s sister web site at www. canadianmetalworking.com

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Quality Canada March 2010 5

SPECIAL REPORT/AEROSPACE |

By Nate Hendley

Setting High Standards A new standard for the aerospace MRO market is intended to help the industry produce higher quality products at lower costs Leon Dodd, corporate director of quality and flight safety, at StandardAero, sounds like a proud father when he talks about his company’s latest achievements in quality standard certification. One of the largest independent aerospace companies in the world devoted to maintenance, repair and overhaul (MRO), StandardAero boasts more than 4,000 employees working at branches based around the world, including Winnipeg.

“Our Winnipeg facility achieved AS9110 accreditation in the summer of 2009. A team of eight key individuals worked for well over a year and a half on a gap analysis, procedural rewrite, internal self-audit by the StandardAero team and corrective actions from the self audit in preparation for the DNV accreditation audit. DNV arrived thereafter conducting a week long audit and the Winnipeg facility passed with flying colours,” exclaims Dodd, who works at StandardAero offices in Maryville,TN. “Out of the 10 major [company] site locations, StandardAero now has four that are AS9110 accredited and one site will remain accredited to ISO 9001/2000. The remaining five sites are in various stages of certification qualification,” Dodd continues.

The new standard Dodd is referring to—AS9110—is specifically for the maintenance, repair and overhaul sector of the aerospace industry. As developed by the International Aerospace Quality Group (IAQG, a cooperative global organization devoted to providing aviation and space products and services to aerospace firms), AS9110 is based on ISO 9001. It also incorporates elements of the previous standard, AS9100, which applied to all branches of aerospace.

The IAQG, which is also responsible for maintaining and revising the standard, released AS9110 in June 2009.

DNV, the company referred to by Dodd, is a certification firm headquartered in Olso, Norway. It is currently one of a handful of companies able to accredit aerospace firms to the AS9110 standard.

AS9110 emphasizes quality, reliability, safety, customer satisfaction, risk management, project management, and configuration management, and contains new measures to combat counterfeit parts. Aerospace suppliers with AS9110 certification face fewer audits from OEMs. Companies that get 6 | March 2010 | Quality Canada

certified to AS9110 can also be listed in the Online Aerospace Supplier Information System (OASIS), an international database of accredited firms. “The OASIS database allows for the sharing of audit results.The data that is shared is referred to as tier one data [and] is not confidential,” explains Mario Langlois, director of quality assurance and quality control at Bombardier Aerospace.

The motivation behind AS9110 is to promote “true global aviation, space and defence industry cooperation and harmonization, reduced duplication and waste, higher quality products at reduced cost, and open sharing of best practices,” says IAQG. “AS9110 total system implementation has helped StandardAero focus on part, process and service improvements corporate wide,” says Dodd. “We have teams all over StandardAero working on continuous improvement projects and have demonstrated results financially, in turntime, cost-reductions, defect reductions and product risk reductions. AS9110 has helped us focus on integration of personnel, tooling, procedures, lighting and ergonomics to ensure that the work we do is airworthy when it leaves our shops.”

As Dodd notes, getting AS9110 certified is not easy.The process begins with an optional pre-assessment. Stage one is a document review. Stage two is an on-site initial audit using a checklist and scoring system. Should the company pass the audit, then AS9110 certification is issued. Certified firms then have a choice of annual or semi-annual auditor surveillance.

The new standard is making waves among a large portion of aerospace firms. According to the Aerospace Industries Association of Canada, the aircraft MRO sector accounted for over $3 billion in aerospace revenues in 2008 and employed 17,000 workers at 1,110 certified aircraft maintenance organizations.Total aerospace revenue and employment in 2008 came to $23.6 billion and 80,000 workers, respectively.

StandardAero is not the only aerospace company with Canadian branches that has become AS9110 certified.

Magellan Aerospace’s Orenda division in Mississauga, ON, which handles MRO work, has also been accredited for living up to this high standard.

“The driver behind [certification] was that our customers were requiring that we were certified,” explains Karen YoshikiGravelsins, director of environmental quality and continuous improvement for Magellan Aerospace, Mississauga, ON.

SPECIAL REPORT/AEROSPACE Orenda was certified by Intertek, a British accreditation in-progress levels in the production cells dropped by 90 per firm. All divisions at Magellan—including Orenda—are also cent and the level of effort required to manage the business certified to the older, across-the-board standard, AS9100. decreased dramatically.The twice-a-day production meeting Because Orenda was already AS9100 certified, getting AS9110 (attended by 15 people) was eliminated, as were the nearly accreditation was merely a matter of “tweaking” a few constant build schedule changes.” procedures, says Yoshiki-Gravelsins For information on AS9110, visit International Aerospace “The coordinator from each of the divisions is responsible Quality Group’s website http://www.iaqg.org. QC for all the continuing improvement type of activities,” Nate Hendley is a freelance writer based in Toronto. explains Yoshiki-Gravelsins. “[Improvement activities] are broken down into Lean activities and Six Sigma activities.

Under Lean, we do Kaizen events, like accelerated improvement workshops.

These are corporately done, every quarter, at a different site. We bring in individuals from different divisions so not only does the division [hosting the workshop] benefit, but other divisions are taking back lessons learned.”

The goal of these accelerated improvement workshops is to reduce lead time and inventory, she states.

Magellan has also embraced 5S (five “S”) principles.This is another Japanese workplace methodology aimed at boosting quality and lowering costs.

The five “Ss” in question are: sorting, straightening or setting in order, sweeping or systematic cleaning, standardizing and sustaining the discipline.

“On the 5S side, we have standardized checklists we use at all our divisions ... there are a number of criteria that have to be met [and] a scoring system for each of the five elements. So basically with 5S, various [teams] within the facility are The value leader just got striving for the highest score.To create more productive. enthusiasm, we have little competitions The new CONTURA G2 navigator combines our amongst different areas within a facility as popular CMM with the superb mechanical properties well,” says Yoshiki-Gravelsins. of the VAST XT Gold sensor and the navigator scanning StandardAero also utilizes a 5S strategy, engine to give it even better throughput and accuracy. as well as non-AS9110/AS9100 quality standard programs such as continuous improvement and Lean manufacturing.

In 1989 StandardAero implemented product-focused production cells and simple visual control systems. Dodd adds that “in 2007, StandardAero completed another milestone by designing and Helical Scanning Tangential Approach implementing continuous flow lines in one of its turboprop business units and designing a unique pull system in the same business unit’s component repair Elliott Matsuura Canada Inc cell.The business unit inventory value Metrology Department was reduced by approximately 50 per Call: (905) 829-1188 cent, while on-time delivery performance www.elliottmachinery.com increased by a similar amount.Work-

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Quality Canada March 2010 7

IN-LINE MEASUREMENT

Laying It On The Line In-line measurement is a cost-effective way to maintain process capabilities Quality Canada speaks with Peter Detmers of Mitutoyo Canada about the merits of in-line measurement.

Q

What is in-line technology?

[Peter Detmers] A coordinate measuring machine (CMM) is a device for measuring the physical geometrical characteristics of an object.This machine may be manually controlled by an operator or it may be computer controlled. Measurements are defined by a probe attached to the third moving axis of this machine. Probes may be mechanical, optical, laser, or white light, among others. In-line measurements are done for many different reasons, including an increase in throughput based on the number of measurements required and better control by cell operators to ensure product being made meet specs before bad parts are made, improvements in productivity through less scrap, less down time sorting parts, and assurance that parts are within spec before they get shipped to customers.

But frankly, this sometimes leads people to avoid in-line since the idea of automation brings up many obstacles.

Cost is certainly one obstacle, as well as complexity of some manufacturing cells based on number of machines, and types of processes. Complexity of the part being produced can also be an obstacle.

Q

What are the quality measuring tools (CMMs, lasers, etc.) you would use for in-line measurement in a manufacturing environment?

There is a wide range of goods on the market today used for in-line applications. The machines are available in a wide range of sizes and designs with a variety of different probe technologies.They can be operated manually or automatically through 8 | March 2010 | Quality Canada

computer/software control. They are offered in various configurations such as benchtop, free-standing, handheld and portable. Some of the most typical for in-line measuring applications are surface finish equipment, roundness measuring, vision systems, form measuring, laser micrometers, not to mention various small tools that can be integrated into measuring systems to perform quality checks and offer flexibility for various applications that can be integrated into the manufacturing line.

Q

What are the main advantages of in-line measurement versus off-line measurement?

In-line measurements assist in maintaining process capability by allowing measurements to be made at the time the part is made. Data is then available to machine operators to make necessary corrections to maintain the quality of parts. We have done projects where the in-line measurement data is monitored and the offsets are automatically fed to machine controllers to improve the process capability. Other aspects to in-line measurements is that part sorting, good, bad or warning can be determined immediately, ensuring that only good quality parts are released to customers.

Q

Is it cost-effective to go with an in-line measurement system?

This would certainly depend on the reason for deciding to go in-line.

What is the cost of scrap parts? What is the cost of shipping bad parts?

What are the costs in time and labour of measuring offline versus inline.

Many of our systems, from CMM, to form measuring to Vision, are not part dependent, meaning when you experience an engineering change, you simply modify the part program and production continues. If the part itself

changes, for instance the production contract of part x is three years, when you bid on the next version of part x, if you have a flexible gauging solution, the cost of measurement for the next generation contract is less.

Q

What are the key considerations a manufacturer should take into account for in-line versus off-line?

In many cases the decision is based on the number of parts to be measured.

What throughput is required? Is it feasible to meet the quantity by transferring parts to an off-line area?

What are the specs involved? If the part tolerance is too tight then in-line may not be practical or even possible.

What is the capability of the process to maintain good quality parts? If a process is very capable, the sampling rate will likely be low such as a couple of parts per hour. However if the process is very difficult to maintain, greater part inspection is required.

Can the measurements be fed back to machine controllers to make the necessary adjustments to improve part quality? What is the overall costs, relative to the off-line method in time, labour, etc.

Q

Is it essential to have automation on a line for in-line measurement?

It is not essential and in some cases, due to costs or other factors, not even preferable. However, we have done many projects, some with automation and some without, and both have challenges that can be overcome with proper planning and expertise. Moving parts around is actually the easy part.

The “decision making” after the parts are measured is really where most of the complexity comes from. QC Peter Detmers is national sales manager for Mitutoyo Canada Inc., Mississauga, ON. www.mitutoyo.com

SOFTWARE/CALIBRATION

Calibration

Guidance

Quality Canada asks Ned Espy of Beamex, a supplier of calibration software for manufacturing, how calibration and calibration software can improve quality management

Many manufacturers use calibrators as part of their in-line measurement processes on the manufacturing plant floor, but may not use software to process the data. Do you think calibration software is an important component of calibration on the manufacturing plant floor?

There are many benefits for manufacturer’s that have focused on testing “in-situ” vs. on the bench and then taking advantage of software when it comes to calibration. Minimizing risks associated with complete removal of an instrument/transmitter compared to creating quick-connect methods and temporary isolation methods offers obvious benefits and also saves man hours for calibration technicians. By leveraging software, planning and organization see immediate benefits, management is assured that critical work is being done and instead of having the plant’s “calibration program” in someone’s head, procedures are documented so that all associated personnel work from a common platform and new employees can assimilate quickly to the program.

In today’s current environment, many manufacturers may be hesitant to invest money in calibration software. Can you briefly explain the business argument for investing in calibration software?

There obviously must be a business justification to purchase calibration software. In some cases, calibration documentation is required to meet regulatory requirements (ISO 9000, for example) and the justification is simply to stay in business. However, when evaluating solutions, one of the biggest ROI factors will be automation–are there time savings, can more work be done with less manpower, can work methods be simplified or made safer, can product quality be improved, is throughput increased or are there process efficiency gains via improved calibration methods?

While manufacturers are hesitant today to invest in new technologies, many are interested in automating processes. Can you please explain the benefit of automating calibration practices? What would be required and what kind of investment would it mean for a company?

The previous question focused on software, the other side of the equation is to look at available hardware technology. If current methods include having a technician carry around a clipboard or laptop out into the field along with a bucket of test gear (multi-meters, simulators, test gauges, function generators, etc.), this represents a high level of hardware inventory, is complicated and requires quite a bit of training. Investment into a documenting, multi-function calibrator may appear to be high, but over time the cost of ownership is lower, the technician only has to carry around a single device and work methods/training is greatly simplified. No matter who performs the work, it is always done the same way and with proper metrology.With a correct approach, most users can achieve a one to two year payback. Further savings can be achieved because most companies are conservative and “over calibrate” by analyzing intervals and optimizing work schedules. A second round

Checklist: Choosing the Right Software

Here’s a convenient list of questions from Beamex that you should consider when purchasing calibration software.

• Is it easy to use?

• What are the specific requirements in terms of functionality?

• Are there any IT requirements or restrictions for choosing the software?

• Does the calibration software need to be integrated with the plant’s existing systems?

• Is communication with smart calibrators a requirement?

• Does the supplier offer training, implementation, support and upgrades?

• Does the calibration software need to be scalable?

• Can data be imported to the software from the plant’s current systems?

• Does the software offer regulatory compliance?

• What are the supplier’s references and experience as a software developer?

Source: Beamex Inc.

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Quality Canada March 2010 9

SOFTWARE/CALIBRATION of savings are realized if the average calibration interval is lengthened.This allows for the same amount of work to be done by less people or technicians can complete scheduled work earlier and are available for other maintenance tasks.

standard and new calibration methods need to be developed to maintain these technologies. Software must be open and have the ability to integrate into enterprise platforms and corporate information systems.

If you had to summarize Best Practices, can you please identify the five most important ones for calibration?

1. Use of traceable standards with 4:1 uncertainty ratio, calibrator:process.

2. “Say what you do, Do what you say, Record what you did, Check the results, and Act on the difference” is a summary of ISO 9000 or cGMP standards/ practices.

3. Develop and refine good practices such as a “Quality Manual.”

4. Use a “common sense” approach for establishing system parameters.

5. Constantly re-evaluate and strive for incremental improvements.

How will these changes impact how manufacturers use and view calibration and calibration software?

Manufacturers will have to evaluate and prioritize their needs as it is difficult to implement a massive change.

I would look for system flexibility and modularity where critical needs can be met today but there is room for growth and improvement.

What are the most important changes you see occurring with calibration and software in the next few years?

Sensing technology is constantly improving to where calibration equipment must become more accurate.

Digital and wireless communication is becoming the EMISSION

Why use software for calibration management?

In self-evaluating needs, consider at least these issues: • Planning and decision-making capabilities; • Organization requirements; • Execution and implementation of a new system; • Documentation requirements; • Analysis needs. QC Ned Espy, consulting director, has been with Beamex Inc., Marietta, GA, since 1995 and has more than 20 years of experience dealing with process instrumentation applications. www.beamex.com

SPECTROSCOPY

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