Canadian Metalworking

February 2011 • www.canadianmetalworking.com

Taking Stock 4th Annual Benchmarking Survey:

Is the economic storm over?

36

MACHINING Evaluating a new machine

47

CUTTING TOOLS Geometries’ impact on performance

63

FABRICATION Making buses with lasers

73

WELDING 10 TIG tips

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Inside this issue...

Volume 106 | No.1 | February 2011 | www.canadianmetalworking.com

INDUSTRY REPORT

FABRICATING

4TH ANNUAL NATIONAL BENCHMARKING SURVEY

LASER CUTTING

TAKING STOCK........................ 18

A Winnipeg bus manufacturer realizes big savings with new laser cutting machines.

Is the economic storm over?

See what manufacturers think.

18

FLYING WITH LASERS ................... 63

23

WELDING

BUSINESS REPORT

TIG

FINANCE

SHOP AROUND ....................... 23 There are many options for financing your machine tool purchases.

10 TIG PROBLEMS ........................ 73 A visual troubleshooting guide to overcome common TIG welding issues.

OVERSPRAY

MACHINE TOOLS

MANUAL SPRAY GUNS

MACHINING CENTRES

EVALUATING MACHINES .......... 25 Canadian shop specializes in R&D for five axis machining.

BACK TO BASICS ......................... 78 Troubleshooting pointers from industry experts on common powder spray gun problems.

81

CASE STUDY

TURNING POINT ...................... 39 New digs, lathes boost the fortunes of a fledgling Ontario shop.

CUTTING TOOLS

63

MILLING

SHAPELY FIGURES ..................... 47

Do asymmetrical geometries and complex inserts make better cutting tools?

QUALITY ON MACHINE VERIFICATION

CHECK POINTS ........................ 61 On machine verification is a smart way to improve your part measurement process.

PAINT STRIPPING

THE NAKED TRUTH ...................... 81 Can you achieve cost savings with green stripping technologies?

DEPARTMENTS Upfront ............................................... 6 News ................................................. 8 Floor Space ...................................... 16 Metal...Works ................................... 84

Instant access online

ONLINE SUBSCRIPTION SERVICES

84

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Upfront Protectionism Perils When economic turmoil strikes, as it did during the recent “Great Recession,” protectionist sentiments surge.

“There is one thing that could turn a recession into a depression—it is protectionist measures across the world,” said Prime Minister Stephen Harper during a CNN interview back in February 2009 in reference to the US Buy American clause in that country’s massive US $787 billion stimulus package.

Canada eventually won some concessions, giving Canadian businesses limited access to US government stimulus projects, but it didn’t stop the US, Canada or other countries around the world from continuing to pursue protectionist policies.

Indeed, according to Global Trade Alert, an independent trade watchdog set up in 2009 to monitor and analyze trade measures (www.globaltradealert.org), “the upshot for policymakers was that 2009 was much worse in terms of protectionism than previously thought.

Another implication is that there is much more protectionism to unwind in 2010 and as the recovery unfolds,” it noted in a 2010 report.

In Canada, one policy that has come under attack by some European nations is Ontario’s Green Energy Act. When the federal and provincial governments negotiated deals giving Canadian companies access to US government stimulus projects, Ontario exempted its renewable energy policies. The local content requirement rule (which rose from 40 to 60 per cent for solar projects on January 1 of this year and will rise from 25 to 50 per cent for wind projects Jan. 1, 2012) in the Green Energy Act means foreign manufacturers who want to supply the Ontario market with energy products must invest in the province. Hence the recent slew of announcements from many foreign firms about manufacturing investments in Ontario.

Local content is an effective way to ensure investment in a country, but the problem with these types of policies is that in some ways, they are double-edged swords: they improve local manufacturing investment, but they inadvertently hurt Canadian firms—typically smaller and medium sized enterprises—looking to access offshore markets with governments that have their own local content requirements. Some SMEs simply won’t find it economically feasible to set up a manufacturing operation in a foreign market and may end up losing out on export opportunities. That’s not the way to build healthier Canadian manufacturing companies.

Long term, will protectionist policies contribute to sustainable manufacturing growth for Canada or for any other country?

I think Canada would better serve the manufacturing industry by creating a more attractive investment environment (low corporate tax rates, skilled workforce and technological expertise) for foreign manufacturers so they’ll come not because they have to, but because they want to.

MARY SCIANNA, EDITOR

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

6 | FEBRUARY 2011 | www.canadianmetalworking.com

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News Online information hub for CMM users

Canadian Metalworking is launching a new online feature for coordinate measurement machine users.

The CMM online forum will launch later this year on the magazine’s web site, www.canadianmetalworking.com. The magazine is launching the CMM online forum with Bill Reilly, co-founder of Beamsville, ON, Quality Inspection Technologies, a company he co-founded with partner Wayne Jordan 11 years ago, and sister company Elite Tool & Gauge Co., (whose ownership includes a third partner, Allan Malenfant) which applies QIT’s expertise in metrology to gauge design and manufacturing.

part of their continued learning…they have nothing to fear and understand that they have everything to gain by sharing.”

Reilly says the online concept suits the CMM community because “the job of the CMM inspector is most often a solitary position and there are many knowledgeable and experienced inspectors out there, to which most of us have no access.”

To kick-start the forum launch, Reilly and Canadian Metalworking have created a CMM blog on the magazine’s website, “Metrology Matters” (see the most recent blog at www. canadianmetalworking.com) where Reilly will post periodic articles about issues affecting CMM users and their machines, and answer questions from individuals.

A graduate of the Mechanical Engineering Technology program at Mohawk College, Hamilton, ON, Reilly has spent the past 16 years working in the metrology field. He began his career with Burlington Technologies, where he trained under several CMM programmers with decades of combined experience.

Gaining insight into metalworking technologies

Canadian Metalworking Magazine is getting into the futures business with the launch of two new metalworking conferences on the future of metal cutting and metal fabricating.

Slated for November 8, 2011 at the Toronto Congress Centre near the Toronto International Airport, the two conferences will be held concurrently. Each conference will offer two streams; one focused on where metal cutting and metal fabricating cutting technologies are going and the second will examine key management issues.

The one-day conference will include exhibits from key machinery, equipment and service suppliers. Supplier representatives will be available during breaks and at lunch to discuss issues with delegates.

Canadian Metalworking will be posting more details about the event, including presentations and speakers, as information becomes available. Please check our web site at www. canadianmetalworking.com for updates.

New firm aims to boost manufacturers’ competitiveness

Reilly, who approached Canadian Metalworking with the idea, says there’s a need for online information to help CMM users optimize their machines, upgrade their knowledge, share ideas and troubleshoot.

“Running QIT has provided access to literally hundreds of companies in the manufacturing industry over the years and it became apparent that CMM inspection, in so many cases, has become a self-taught skill. The danger in self-teaching is there is usually no one more experienced than you to learn from and although we all learn through making mistakes, you can’t learn from a mistake when you don’t know you’ve made one. Having access to someone more experienced is invaluable when learning a new skill.”

Hence Reilly’s idea to create a community of CMM inspectors to provide access to the knowledge and skill that exists in industry.

Reilly says his goal in developing this online community with Canadian Metalworking is to create “a culture of sharing,” adding “people are hard-wired to share what they know as 8 | FEBRUARY 2011 | www.canadianmetalworking.com

A new Toronto-based company wants to help manufacturers become more competitive and its founder Pierre Huot thinks he has the industrial toolkit to make that happen.

Invisual E. Inc., Toronto, is what Huot describes as a business improvement company for the manufacturing industry.

“I’ve seen many companies that offer products for improving a manufacturing process but these companies don’t offer a holistic approach to the industrial market and that’s what Invisual E. aims to do.

The company’s industrial toolkit of solutions include hardware (e.g. cameras for welding, and thermal weld profiling for NDT/ NDE) and software products (software for automation and controls) integrated into a package and designed to improve manufacturing productivity.

“It’s a hyper competitive environment for manufacturers and we want to bring the toolkits and solutions that can help manufacturers improve productivity, traceability, reduce liability and improve competitiveness.”

Huot adds the technologies Invisual E. offers “are built on a base layer of industrial computing hardware which we configure, test and offer as hardware only or as part of our

e d i b r a C lid o S GS Series Drill • RUN FASTER – with the new wear resistant DEXTM coating!

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News solution package…our approach is to be business improvement specialists. We offer consulting on manufacturing issues, supply software control modules for larger projects, or offer the control software solution.”

TRUMPF Canada launches first laser workshop

TRUMPF Canada plans to holds its first laser workshop on March 30 at its Canadian headquarters in Mississauga, ON. The workshop, dubbed “Face-Off” is an open house event

that will focus on the cutting differences between 2D laser machines with new fiber type resonators and traditional CO2 gas resonators.

“The biggest question in the 2D laser cutting market right now is: fiber or gas? Customers want to know which type suits their specific application better,” says James Rogowski, managing director of TRUMPF Canada. “Here, on March 30th, we will be able to look closely at both types, cut with both and see the results of both.”

Letters to the Editor In your Upfront in the Canadian Metalworking September issue (“Are China’s Growing Pains Our Gain?”): Finally some good news.

“You know it breaks my heart [to see] many shops that have had to close in the last two to three years due to lack of work. Almost every day in the last 16 months I have received an auction off publication where lots of machines, tools and equipment were being sold off like junk.

Not only was the equipment sold but people were laid off. This is lost knowledge—knowledge we gave almost for free to the Chinese as a kickstart to become the world’s biggest ecomony!

And for what? All for the sake of more profit!

Too bad the government did not realize what we lost here. [Instead] it invented some new important taxes to protect our domestic manufacturing industry, plus export our acquired know-how over the past four decades. But luckily the Chinese have to fight with the same problems we have had…unions, rising salaries, working conditions, environmental issues; we entrepreneurs here in the West can only say one thing: Welcome to the club.

So your article was like music in my ears! Hope it will go on in this melody.

Markus Hächler, M-Tech Precision Inc. (Job shop outside of Montreal) There are many subjects that warrant more discussion in terms of what we should be pursuing as the manufacturing sector. For instance, why are we buying seven billion dollars of windmills from Korea (Samsung)?

Why aren’t we designing the tall windmill masts with solar panels on the sides that would go all the way up?

They are supposed to be about 400 ft tall and since the infrastructure will be right there to feed the power into the grid, why not make the most of the power generating opportunity? Four hundred vertical feet of solar panels in shadow free zones seems like it could add significantly when there is not enough wind to effectively generate wind power but abundant sunshine to generate power

10 | February 2011 | www.canadianmetalworking.com

from the solar cells. So this idea would make more effective use of resources at hand. More importantly, why aren’t we building the windmills in our Ontario manufacturing facilities?

We, as manufacturers, need to lobby for our views to be heard. This is vital for our industry, for our workers and for our economic health and survivability. In your wonderful magazine, you have a powerful tool for assembling skilled, knowledgeable people with ideas, resourcefulness and the experience to get difficult jobs done.I think Canadians were destined to be world leaders in many areas and lead the world into a new era of technology, prosperity and most importantly, hope. So we have to do things smarter, better and more efficiently. With our political leaders making seven billion dollar backroom deals with multinational corporations, we will have no future and, as a society, we will be lost.

There is much that needs to be discussed. Let’s strive to make 2011 the year that reason triumphed over maintaining the status quo. Never forget, we are the Canadians! We used to represent the very best of the world. We need to get back to that place.

Best wishes, your editorial friend, Al Rutke, Lasertek, Newmaket, ON I really enjoy your magazine. Recently I have been frustrated by comments from shop owners in your pages and the pages of similar publications complaining about the HST. (e.g. page 15 of your October issue].

These complaints show a basic lack of understanding about how the HST works for manufacturers with sales under $10 million (it saves them money) and perpetuates this mistake.

How can we expect governments to support us when we don’t even understand the support we are being given?

I hope that your magazine will work to combat this ignorance instead of repeating misunderstandings.

Ben Whitney, president, Amro-Tool Ltd., London, ON

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News Two laser cutting machines (TruLaser 1030) will “compete.”

One machine will have a traditional 2500 W, CO2 gas resonator and the other will have a 2000 W fiber delivered resonator pumped from light emitting diodes (LEDs).

Rogowski says customers will be able to see the mechanical differences, the costs associated with both and the cutting quality that can be achieved with these two types of resonators. Test cuts will be timed and then examined by attendees.

“The event will provide answers to those who want to know what a fiber laser is and how it compares to traditional gas lasers,” adds Rogowski.

Live demonstrations of laser cutting and laser marking and presentations on cutting differences are also planned. For more information, email info@ca.trumpf.com or call 800-306-1077.

SMD gets new drilling line

SMD Machinery Inc., Mount Albert, ON, has taken on a new line of drilling machines from Commercial de Maquinaria Aizira S.L. of Valencia, Spain.

SMD has become the exclusive importer and distributor of CMA’s GRD and TRD lines of drilling machines.

New $500,000 welding centre opens doors

Lenox has opened its new $500,000 welding centre at its Mississauga, ON, facility.

The new welding centre will serve industrial band saw blade users in Ontario and Quebec.

Mike Mendrala, senior manager of global welding operations, says the investment has created three new jobs. The centre performs between 200 to 300 welds per day, with plans to double staff and increase output.

From left: Paul Drumheller, logistic leader; Ken Maruk, Weld Centre manager; Paul Bates, process engineer, Global Welding Operations.

Mendrala says the company chose to locate the facility in Mississauga to reach industrial band saw customers more quickly.

“This was always a busy area for us. Even though 2008 was a bad year for manufacturing, we’re coming back,” he says.

Les Payne, executive director for the Canadian Tooling & Machining Association, agrees.

“There has been increased confidence in the industry, although I don’t like to use the term ‘coming out of the recession’ because that implies we’re going back to where we were before it,” he says.

Payne adds investments in areas like technology and skills training will also be important to keep the industry continuously improving.

With files from CanadianManufacturing.com.

12 | FEBRUARY 2011 | www.canadianmetalworking.com

The TRD machine above and the GRD series below, now being sold by SMD Machinery.

Luc Seesing, president of SMD Machinery, says he is in the process of setting up a reseller and agent network in Canada.

“CMA, a long time player in the European market for high quality flexible drilling machines, decided to expand its exposure to North America in 2011. The short term focus will be on establishing a dealer network that is active in fabricating machine sales, but also in the machining part of the Canadian metalworking industry.”

The GRD and TRD series are NC controlled X, Y and Z axis Rapid Drilling machines. Both series have a drilling capacity of 1.0/1.25 in. (24/31 mm) or up to 1.57 in. (40 mm). The GRD is a gantry type NC drilling machine with work areas as small as 10 ft x 48 in. (3 m x 1.2 m) going all the way up to 40 ft x 10 ft.

(12 m x 3 m). The 8.9 kW a-synchronous motor with BT40 tooling adaption will handle two in. holes in mild steel. Heavier capacities (BT50) are available.

The TRD line is a bench-model drilling machine line with a column type head-construction capable of drilling a 1.57 in. (40 mm) hole at a maximum Y direction of 24 in. (609 mm) Table dimensions range from 59 in. x 24 in. (1.4 m x 0.609 m) up to 354 in. x 24 in. (8.9 m x 0.609 mm) “It’s a versatile new drilling concept that provides total flexibility for a variety of vertical drilling operations,” says Seesing.

News People David Toomey is the new president of Komet of Canada Tooling Solutions ULC, a new Canadian subsidiary. A 15 year veteran of the cutting tool industry, he was most recently general manager for Seco Tools Canada. Prior to his position with Seco, he held sales management positions at SGS Tools, Iscar and Pillar Engineering.

Kevin Lorch is the new marketing manager at Sandvik Coromant Canada, Mississauga, ON. He has been with the company for more than 14 years and spearheaded the “Art of Milling” events the company launched in June 2009.

Formerly project manager, business strategies and development for Sandvik Coromant, Lorch came up with the unique concept of the “Art of Milling” to enhance the company’s image in the metalworking industry.

Ken Hurwitz has joined equipment leasing firm Enable Capital Corp., Toronto, as account manager. Hurwitz has an operations background in metalworking and served as operations manager for ten years at Gross Machinery, a former machine tool distribution firm that represented Mori Seiki in Canada before it closed last year. Hurwitz, whose grandfather Harold Gross founded Gross Machinery, had been with the company for 16 years.

Tom Hagan has been appointed milling product manager for Iscar Tools, Oakville, ON. He has been with the cutting tool supplier for 13 years and has served as distribution manager and area sales manager for the Hamilton/Niagara region.

Chris Pilcher has joined IPG Photonics as Canadian sales manager, industrial high power lasers. He has more than 25 years of experience in the industrial laser industry and was most recently employed by TRUMF Canada. Pilcher will lead efforts to expand IPG’s presence in the Canadian automotive and general manufacturing industries.

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www.canadianmetalworking.com | FEBRUARY 2011 | 13

News Multicam’s “Disneyland”

Calendar FEBRUARY 14-18 CWB Welding Supervisor seminar. Calgary, AB. www.cwbgroup.org FEBRUARY 17 CME Small Manufacturing Summit. Mississauga, ON. www.cme-mec.ca FEBRUARY 24 EMC Canada SR&ED information session in Milton, ON. www.emccanada.org MARCH 30 TRUMPF Canada laser workshop, Mississauga, ON. www.us.trumpf.com

When Sean Lawlor, president of MultiCam Western Canada approached his friend and long-time customer Dan Sawatzky to design the interior of the company’s new Langley, BC, facility, he asked for a “Disneyland for CNC machines.”

Each element of the design we created was designed to show the capabilities of the machines they sold,” explains Sawatzky, owner of Sawatzky’s Imagination Corp., a designer specializing in theme signs and environments. “While the bulk of the project was done in our shop, on our own MultiCam CNC router, Sean promised I could play with his new equipment on the showroom floor.”

The lobby features a robotic theme; a massive desk is designed with huge robotic arms (actually lamps) reaching over. The boardroom theme is “under the sea” as evidenced by the large rustic steel beams that support the curved ceiling, a sea-themed LED TV with “gauges” and “dials” giving it “an unknown and mysterious function,” says Sawatzky.

Sawatzky has taken other clients through the facility and says that each client that has seen the MultiCam facility “want us to work the same magic for them.”

Tooling association’s 2011 Board of Directors

At the annual gathering of the Canadian Tooling and Machining Association Annual General Meeting, last October, the association named its incoming 2011 Board of Directors.

Back row, left to right: Ron Spraggett, director (Tipco Inc.), Ted Callighen, director (Schmolz+Bickenbach Canada Inc.), Horst Just, treasurer (H.J. Machine & Pattern Ltd.), David Glover, vice president (Harbour Advanced Machining Ltd.), Robert Cattle, past president (Micrometric Ltd.), Horst Schmidt, director (H.S. Enterprizes/University of Windsor).

Front row, left to right: Emerson Suphal, president (ESS Business Strategies Inc.), Steve Watson, Toronto Chapter chair (Century Tools & Machinery Ltd.), Colin Docherty, Windsor Chapter chair (Clinton Aluminum & Stainless Steel), Ralph Schippanoski, Western Ontario Chapter chair (XL Tool Inc.), and Ryan Wozniak, director (Anchor Danly).

NEW IN CANADA CMA X-Y-Z RAPID DRILL

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News Floor Space Do you broadcast music on your shop or factory floor? Has this improved efficiency?

“Due to the ambient sounds generated by our equipment, background music is not an option at this point. Our offices and the employees’ lunchrooms do have background music. I would say it helps productivity as long as it is only [in the] background and does not become a distraction.”

-Joseph Manzoli, president, Colourfast, Concord, ON

“Yes. On occasion, we broadcast music at the employee’s request. Measuring improvements in efficiency is negligible. However, morale is boosted.”

-Jason Bannerman, president, Xakt Komponents, Brampton, ON

“We do have music on the shop floor. Whether or not it helps with efficiency, I am not sure.”

than the machinery and quieter when the machinery was not running, which forced us to add sensors to automatically adjust the music volume relative to the ambient noise. More cost into the system, and it only proved be more of a nuisance than anything else. In the offices, some of our engineers didn’t like the current music, so they decided to bring in their own radios. I can’t tell you how frustrating it is with three different radio stations playing in the same room. I banned all radios from that point onward.”

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

“I do allow my employees to have radios. I personally do not like having radios in the shop. I find them very

-Brian Wetherall, president, Brotech Industries, Barrie, ON

“We allow employees to have their own radios on the shop floor but we do monitor the music level in order to not interfere with the general work environment. We also do not allow employees to have MP3 players in their ears.”

-Marco Gagnon, co-owner, Gagnon Ornamental Works, Grand Falls, NB

“We do broadcast some music some times. Not sure how to measure if it makes my team more efficient. I find that a working team is happy [when it] feels that management cares about them and supports them in personal and business issues. [This] makes them more efficient. Not sure if the music does [make them more efficient]. I don’t think it hurts, however.”

-Steve Cotton, president, Micro Precision Parts Manufacturing Ltd., Vancouver Island, BC

“Yes we do. We let workers choose what they want to listen to. This does help improve efficiency by lifting the mood and allows the employees to be more productive because of that.”

-Renny Husada, vice president, Yess Products, Surrey, BC

“At one point years ago, we tried to play music on the floor, in engineering and in the offices. This became complete chaos. Firstly, on the shop floor, between the loud machinery, including stamping presses and the paging system, we could not decipher between the music and someone being paged over the intercom. Next, the music had to be relatively louder

16 | FEBRUARY 2011 | www.canadianmetalworking.com

distracting but it doesn’t seem to distract my employees as much as it distracts me. I don’t think [music] helps to improve efficiency but it does help to make the employees feel involved with the outside world. The factory can be very confined at times.”

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

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INDUSTRY REPORT

NATIONAL BENCHMARKING SURVEY

Taking Stock Manufacturers more upbeat about 2011; still wary of long term economic recovery

Canadian manufacturers are more upbeat than ever before about their growth prospects, but wariness about the sustainability of the growing economy has many hesitating when it comes to investing in their businesses, according to the latest findings in Canadian Metalworking’s 4th Annual National Benchmarking Survey.

The survey, fielded in December 2010, was conducted online with 120 manufacturers of metal products involved in metal fabrication and metal chip removal. The margin of error is +/- 7.5 per cent, 18 times out of 20.

Survey participants represent a range of industry sectors, including automotive parts, transportation (rail, truck, bus and ship), aerospace and defence, energy and resources, tool, die and mouldmaking, agriculture, furniture and appliances, medical, electronics and construction.

The largest number of participants are executive management, representing 36 per cent, while What is your overall outlook for the first purchasing and of production operations represent quarter 2011 (January to March)?

What is your overall outlook for the first 21 per cent and 17 cent respectively. quarter of per 2011 (January to March)?

MANUFACTURING OUTLOOK 2011

Lacklustre would be a good way to describe the performance of the manufacturing industry in the first half of 2010. The economy slowly sputtered along and the strong rebound that many were anticipating early in the year didn’t occur until the last quarter.

Despite the rocky economy back in 2009, participants in last year’s National Benchmarking Survey were still fairly optimistic about 2010; 40 per cent forecast their margins would grow; and close to 50 per cent were “somewhat positive” in their outlook for the first quarter of 2010.

That optimism is still present among manufacturers in Canadian Metalworking’s 4th Annual Benchmarking Survey and has been likely influenced by the strong performance of the North American economy.

Two recent industry indicators point to better times ahead. According to the closely watched US Manufacturing Technology report—a good indicator of economic performance in both the US and Canada—manufacturing technology consumption was up a whopping 83 per cent year-to-date in 2010 compared to 2009. In Canada, the Conference Board of Canada’s monthly leading indicator of industry profitability increased 0.6 per cent in Compared to 2009, has your revenue in 2010…

Compared to 2009, has your revenue in 2010…

46.67% 46.67%

6.67% Don’t know

What business strategies or management tools 6.67% Not Don’t 2.50% at know all positive do you use to overcome challenges?

2.50% Not all positive 15.83% Notat very positive

where “Attempt to purchase more from countries 15.83% Not very positive prices are more competitive than52.50% here.”

Somewhat positive 52.50% Somewhat to Very offset 22.50% positivepositive “Using SR&ED government program price difference to offshore competitors. ” positive 22.50% Very “We have found that training and employee input at all levels, while implementing new How likely youTPM to expand into has new strategies likeare LEAN, and others, markets (e.g. regions, sectors such as green been us stay Howhelping likely are youcompetitive. to expand into new technology, etc.) in the next 12 months? markets (e.g. regions, sectors such as green Looking into other andmonths? using technology, etc.)market in theareas next 12 government work share program.

”

“

10.83% Not Not very at alllikely likely In your opinion, what are the21.67% top two greatest challenges facing your business today?

21.67% Not very likely

39.17% Somewhat likely

Offshore competition 58%

39.17% Very Somewhat 28.33% likely likely

28.33% Very likely 18 | FEBRUARY 2011 | www.canadianmetalworking.com

Increased Increased Decreased Decreased Stayed the same Stayed the same

Do you expect your profit margins for this year to…

Do you expect your profit margins for this year to…

41.67% 41.67%

”

10.83% Not at all likely

Rising costs 60%

22.50% 22.50%

28.33% 28.33%

15% 15%

41.67% 41.67%

Increase Increase Decrease Decrease Stay the same Stay the same

e

NATIONAL BENCHMARKING SURVEY

INDUSTRY REPORT

What is your overall outlook for the first quarter of 2011 (January to March)?

December 2010, its biggest one month gain dating back to 2001.

Compared to 2009, has your revenue in 2010…

In the recent survey conducted in December, asked about

What is your overall outlook for the first quarter of 2011 (January to March)?

6.67% Don’t know 2.50% Not at all positive 15.83% Not very positive 52.50% Somewhat positive 22.50% Very positive

Compared to 2009, has your revenue in 2010…

their overall outlook for the is first quarter ofoutlook 2011, more than half, 6.67% Don’t know What your overall for the first 53 per cent, said they were “somewhat 23 per quarter of 2011positive” (Januarywhile to March)?

7% at all positive 46.6Not cent said they were “very positive.” This optimism 2.50% may have been spurred by healthier businesses: 56 per cent of respondents 15.83% Not very positive 6.67% Don’t know said revenues increased in 2010. Of those businesses reporting Increased 3% an increase, 31 per cent said they generated less than $100,000 28.3 52.50% Somewhat positive 2.50% at all positive in profits, while close to 19 per cent enjoyed profits ofNot $100,000 Decreased to $500,000 in 2010.

22.50% NotVery verypositive positive 0% also reflected in15.83% 22.5was Stayed the same The rosy outlook or 2011 participants’ responses about profit margins in the coming year: only 15 52.50% Somewhat positive per cent indicated margins would decrease while 42 per cent expected margins to increase or stay the same. 22.50% Very positive How likely are you to expand into new markets (e.g. regions, sectors such as green Do you expect your profit margins for this year to… technology, etc.)next in the 12 months?

In the 12next months, do you plan to pur

How likely are you to expand into new EYEING EXPANSION markets (e.g. regions, sectors such as green 7% positive With the recession behind them, manufacturers are now 46.6more technology, etc.) in the next 12 months?

How likely are youMilling to expand into new machines markets (e.g. regions, sectors such as green about the future and are focusing on expansion plans.

1.67%Not at all likely 412 10.83% technology,Lathes etc.) /in the next months? Increase turning machines Expansions come in many forms. For some it means broadening the customer base, while for others 2it8.3 includes capital equipment purchases, Increased 3% 21.67% Not very likely Multi-axis Decrease plant upgrades, and new employee hires.

10.83% Not at all likely Decreased Many are considering expanding into new markets; more than 28 per 15% 39.17% Stay the sam Multi-tasking 10.83% NotSomewhat at all likelylikely 21.67% Not 22.50%expand cent said they will “very likely” intovery newlikely markets and 39 the persame cent 41.67% Stayed said “somewhat likely.” And 51 per cent are eyeing the energy (e.g. solar, 28.33% Automation for machine tools 21.67% NotVery verylikely likely 39.17% likely transportation wind) markets, with 25 per cent and 21Somewhat per cent eyeing Machine tool software/ equipment and agricultural equipment markets respectively.

39.17% Somewhat likely controls upgrades 28.33% Very likely Capital expenditures are getting set to rise; 34 per cent of survey Quality control monitoring/ measuring equipment &28.33% devicesVery likely participants indicated they would increase capital spending in 2011, while Do you expect yourcapital profit spending margins for thisremain year to…

57 per cent said their would the same as 2010.

None of the above The average tooling expenditure reported for 2010 was $189,234, however, Which of the following are you considering expanding into?

16 per cent of respondents indicated they spent between $100,000 - $250,000.

0% 5% 10% 15% in 2011, as Top equipment purchases planned for chip removal % Automotive 1.67 In the next 12 months, indicated in the survey, are multi-axis machines4(16 per cent) and lathes/ Increase do you expect any turning machines (16 per cent). Close to 20 per cent of participants said Aerospace facility upgrades/ In the next 12 months, Decrease they planned to purchase machine tool software or control upgrades. On expansions to occur dofabricating you expectside, anyautomation the is the top item manufacturers said they Energy (alternate/green) In the next firm?

12 months, In the next 12 months, do you p 15% for your Stay the same facility to upgrades/ planned purchase in 2011, just over 18 per cent.

7%the top metal cutting 41.6Of do you expect any Energy (oil/gas) expansions to occur Press brakes technologies, 5 per cent said they would be purchasing plasma cutting No, don’t facility 51.38% upgrades/ plan to expand for your firm? machines, 4 per cent said laser and 3 per cent said abrasive waterjet. expansions Punches Transportation equipment to occur While many are considering investing in new equipment, almost half of for your48.62% firm?Yes, plan 51.38% No, don’t Laser/punch combo machines the manufacturers to expand plan to expandin our survey, 48.62 per cent, said they also planned to Medical devices 51.38% No, don’t upgrade or expand their manufacturing operations.

Laser cutting machines plan to expand Agricultural equipment

48.62% Yes, plan to expand

48.62% Yes, plan Other (specify) to expand

Which of the following are you considering expanding into?

GROWTH0% STRATEGIES 10%

Automotive Aerospace Energy (alternate/green) Energy (oil/gas) Transportation equipment Medical devices Agricultural equipment Other (specify) 0%

10%

20%

30%

40%

50%

60%

Abrasive waterjet machines Plasma cutting machines

20%

30% Stamping 40% machines 50%

Just like the real estate mantra, “location, for fabricating equipment location, location,”Automation the manufacturing mantra is Quality control monitoring/ “automation, automation, automation.” measuring equipment & devices And yet for many years North American manuof the above facturing firms have not embracedNone automation as manufacturers in other parts of the world (Europe 0% and Asia) have. That is beginning to change. In our 2009 National Benchmarking Survey, close to 50 per cent selected automation as the top tool used in shops. That number dropped to 39 per cent in 2010 and 33 per cent in 2011. The slight decline is likely due to the recession as many manufacturers cut back dramatically on equipment investments.

Interestingly, while the numbers for automation www.canadianmetalworking.com | FEBRUARY 2011 | 19

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Lathes / turning machines

28.33%

Increased

Multi-axis

Decreased

22.50%

NATIONAL Multi-tasking BENCHMARKING SURVEY

Stayed the same

Automation for machine tools Machine tool software/ controls upgrades monitoring/ have declined, the percentage of participants reporting roboticsQuality control While automation and robotics are obvious ways to become measuring equipment & devices

as tools used in the shop has remained fairly consistent with 23 per cent in 2009, 19 per cent in 2010 and 22.5 per cent in 2011.

Two other tools that have consistently been at the top of the list for shops are CAD/CAM/CAE systems (68 per cent in 2010 and 71 per cent in 42011) 1.67%and quality systems (26 per cent and 38 per Increase cent respectively for 2010 and 2011).

more competitive, investing in employees is also big on manufacturers’ None ofradars. the aboveIndeed, when asked about employee benefits, 63 per cent of respondents noted employee training programs, and 5% reimbursement.

10% 15% 20% 25% it comes to 50 per cent said0%education And when training, 38 per cent reported offering eight to 20 hours of formal training and 21 per cent said 21 to 40 hours.

ofit margins for this year to…

Decrease

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

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

Stay same

41.67%

Press brakes

Milling machines

Punches

Lathes / turning machines

Laser/punch combo machines

Multi-axis

Laser cutting machines

Multi-tasking

Abrasive waterjet machines

wing are you considering expanding into?

0%

INDUSTRY REPORT

Automation for machine tools

Plasma cutting machines

Machine tool software/ controls upgrades Quality control monitoring/ measuring equipment & devices

Stamping machines Automation for fabricating equipment Quality control monitoring/ measuring equipment & devices None of the above

None of the above 0%

5%

10%

15%

20%

25%

0%

10%

20%

30%

40%

50%

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

Press brakes

10%

ur o y k r Ma r o f r a d calen

20%

30%

Conference streams

50%Punches 60%

40%

Laser/punch combo machines Laser cutting machines

Abrasive waterjet machines Plasma cutting machines Stamping machines

Automation for fabricating equipment Quality control monitoring/ measuring equipment & devices None of the above 0% 10% 20% 01 30% 1 r 8, 2 e b m e re Nov s Cent s e r g n nto Co

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FINANCE

BUSINESS REPORT

Shop Around Shopping for a new machine tool? There are many options for financing your machinery purchases

By Tim Wilson .....................................................................................................................................................

The manufacturing sector in Canada is coming out of the recession, and there is renewed interest in creative financing scenarios for Canadian companies. The dollar is strong—and may remain so for some time—which can be a challenge for exporters, but also makes it cost effective to reinvest in machinery. It also means interest rates may stay low, which gives financing companies more options, particularly on the leasing side.

“Leases offer the benefit of a lower down payment requirement over finance contracts, with as little as the first rental payment due in advance, whereas finance contracts often require 20 to 30 per cent down,” says Frank Penkela, leasing services specialist at LeaseDirect Canada Corp. in Calgary, AB. “It is also easier to get standard equipment approved quickly for a lease, with terms offered within a day of a request being made.”

Leasing can give a manufacturer more financial control, in that a bank often reserves the right to call in notes and effectively, control how a business is conducted. Banks can also suffer from a lack of manufacturing knowledge, which means they have more difficulty structuring industry-specific loans.

“The specialized nature of some manufacturing equipment can be a problem,” says Penkela. “The decision makers in credit departments are always looking at the worst case scenario, and assess historical auction results to determine the liquidation values.”

As a result, the more unique the item to be financed, the

more difficult to approve for financing. Given that banks don’t often have this expertise, they are responding by buying large leasing companies. In 2009, for example, the Canadian Western Bank purchased National Leasing, and Scotiabank bought Roynat Lease Finance Inc. (formerly Irwin Commercial Finance Canada).

At the same time, the leasing firms themselves are relying on solid banking relationships.

“We have funding arrangements with both domestic schedule A banks, and the foreign schedule B banks,” says Tom Moore, the owner of Baylore Acceptance Corp., a commercial financial services intermediary in Burlington, ON. Aside from leases, Baylore provides secured loans, conditional sales contracts, as well as business and vendor support programs.

“We also deal with small, independent leasing companies,” adds Moore. “Some of which don’t have troops on the streets, and rely on companies like ours to bring them the opportunities.”

VENDOR PROGRAMS ON THE RISE

An increasingly popular way to finance equipment is through the vendors themselves. These arrangements have distinct advantages in that the vendor is more closely involved in its customer’s success. Here, too, third party financing companies can play a role.

“A vendor program is often an arrangement that establishes first refusal on an opportunity,” says Moore. “A lot of times a www.canadianmetalworking.com | FEBRUARY 2011 | 23

Business Report

FINANCE

vendor can put a manufacturer in contact with someone they can use as opposed to the customer arranging the financing themselves. The advantage for us is that we get to know the equipment; thus we can put a package together on the asset side as well as look at the quality of the credit.”

This can make more sense than having a vendor build those capabilities in-house, while also keeping the relationship closer and more flexible than a traditional bank might provide.

However, a large machine tool vendor like TRUMPF, with global headquarters in Germany, can often do it on its own.

“The standard packages for us include balloon, delayed payment, interest for one year, ramp up payments and special low interest, monthly programs,” says Mike Morissette, sales finance manager, TRUMPF Finance, which is expanding in Canada. “Each has its own advantages for certain companies.”

Morissette says that at present TRUMPF is having a lot of success with small to medium sized manufacturers, many of whom would benefit from several months of skip payments to get the machine off the ground. The company is seeing an increase in demand across Canada.

or the funding source write the lease directly with the customer.”

For Makino, deals are usually over CDN $100,000, rising to about CDN $3 million. The company will do all the legwork for the customer and get the package to the funding organization, which then runs it through its credit model to assure that the risk is acceptable.

Canada’s new economy

In Canada, there is more to the new funding environment than the increasing appeal of leasing. There is also the effect of a strong dollar, and pent up demand from the low refresh rate during the recession.

“It will get to the point where there is no choice but to replace machinery, because automation is so important now,” says Moore from Baylore. “Every company in manufacturing knows that it is wise to upgrade equipment.”

Moore offers the example of a recent deal in which he helped finance a multi-axis machine for a customer. The new machine does the job of two or three previous machines, and requires less labour.

“At the end of 2008 and during 2009 a lot of customers were experiencing difficulties and reporting losses,” adds Scherpenberg. “As a result, equipment was being cannibalized or underutilized. The question now is whether or not to buy new equipment. It’s an easier decision, as many reported profits in 2010.”

The increase in activity has offered new opportunity for Canadian funders, given that Daniel H. Wittlin, president of Enable Capital Corp. and Blue Chip Leasing Corp. many US-based financial institutions were hit hard by the recession and have left the market.

“The decision to offer TRUMPF Financing in Canada was “We are seeing a big increase in activity,” says Daniel H. based on hundreds of requests from current and potential Wittlin, president of Enable Capital Corp. and Blue Chip Leasing customers that wanted TRUMPF to be able to offer a complete Corp. in Toronto. “We are replacing a lot of deals that were package,” says Jim Rogowski, TRUMPF Canada’s managing previously US financed and required pre-payment of HST at the director based in Mississauga, ON. border. We don’t do that: we bill HST monthly and claim it back TRUMPF Finance approves 91 per cent of its applicants, on the life of the lease.” compared to the banking and industry average, which lies The silver lining with the strong dollar is that foreign-made around 67 per cent. Usually the financing strategy is designed equipment is cheaper and rates are low. So far, however, many to allow a company to preserve its borrowing capacity within a Canadian businesses don’t see it that way. bank or lending institution.

“If you ask 100 of our customers if they would rather have 85 cents to the US dollar versus near parity, 95 customers would Financing the risk take the 85 cent loonie,” says Rogowski from TRUMPF. “If the A typical lease assessment will do a deeper dive than a bank loonie is below the 90 cent mark to the US dollar, the amount of conducting a straight loan, which is usually contingent on a solid work coming up from the US is extremely high.” credit history and healthy balance sheet, with less emphasis on With the addition of TRUMPF Finance in Canada, however, asset value and the specific productivity enhancements of the new Rogowski says that his company will now be able to offer machinery. That said, leases are fairly standard in that they run machines for sale in Canadian dollars. For TRUMPF and others, from a few years to five or seven years, with most at fixed rates. the advantage isn’t only on the US side—though less pro“About 90 per cent of our deals are fixed rates, running nounced, the Canadian dollar has appreciated relative to other anywhere in the 5 to 8 per cent range,” says Moore. “With an major currencies as well. “You can get a machine from overseas atypical lease, rates could get higher, with more risk reflected in that is now 20 per cent cheaper than it was a few years ago,” a greater return.” says Moore. “We are now in the position where we can buy from Given the size of the Canadian market, it can be harder anywhere for prices never seen before.” and less cost effective for a vendor to build in-house financing And this is where Canada has a growing advantage over its capabilities. Instead, after doing the footwork the financial major trading partner: suddenly, the tables have been turned, details can be handed off to a financial intermediary. with Canada having the advantage on equipment and asset “We have program agreements with various funding sources acquisition, and the US leveraging a weaker currency to stimuif our customers need financing,” says Tom Scherpenberg of late demand. CM Makino in Mason, OH. “We do it a little differently in Canada than Tim Wilson is a freelance writer based in Peterborough, ON. in the US; we don’t write it on our own paper, but have the bank

“ We are replacing deals that were US financed

and required pre-paymnet of HST at the border...we don’t do that: we bill HST monthly.”

24 | february 2011 | www.canadianmetalworking.com

MACHINING CENTRES

machine tools

Evaluating Machine Tools Canadian shop specializes in R&D for five axis machining

When AgieCharmilles wanted to assess the performance of its new high speed five axis machining centre, it knew which Canadian company could do the job: Miltera Machining Research Corp., Waterloo, ON. Founded in 2007, Miltera specializes in providing research and development services for five axis machining across a range of services. The company’s services are retained by manufacturers and machine tool builders looking to test, validate or refine new technologies. Miltera also routinely helps with implementation of turnkey solutions at manufacturers across the nation.

“We often will get a call from a machine tool builder with a customer who has just purchased its first five axis system,” says Mike Blackburn, president of Miltera. “They’ll retain our services to help organize the total solution, including workholding, tooling, programming and

Miltera Machining Research Corp. specializes in providing research and development services for five axis machining across a broad range of services.

Miltera has recently been using a GF AgieCharmilles Mikron XSM 400U LP to evaluate how five axis performance is impacted by the use of linear motors to drive axes.

www.canadianmetalworking.com | february 2011 | 25

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PRODUCT REPORT operator training. On occasion, we’ll even begin production of the component in our facility and then transfer it over to the manufacturer as they become comfortable with the process.”

It is because of Miltera’s extensive experience in five axis machining and close ties with machine tool builders, that it’s frequently rewarded with the opportunity to work on unique cutting edge projects.

So in 2009, GF AgieCharmilles contacted the company about performing testing and analysis of a new model of five axis machine, the Mikron XSM 400U LP. Miltera was the only non-Swiss company invited to participate in the evaluation of the new technology.

“It’s very difficult to test wholly new technology in an actual production environment,” say Blackburn.

“Obviously anything that represents a significant step forward in terms of innovation holds the potential of running into problems in its early stages. For the most part, we’re not actually doing production runs at Miltera, which allows us a greater flexibility in working with a new type of machine, should any kinks arise. When GF AgieCharmilles approached us about the Mikron XSM 400U LP, we were very excited to participate in the field testing process.”

To begin its evaluation of the new machine, Miltera set it up next to a somewhat similar model, the Mikron HSM 400U. The most prominent difference between the two machines is the Mikron XSM 400U LP’s use of linear motors to drive the axes, as opposed to a more traditional ballscrew system. Comparison between the two machines began with simple cutting exercises, machining blocks of various materials using a range of cutting data and recording the results. Following extensive testing along these lines, Miltera started producing actual parts on both machines.

Miltera has access to a wide range of actual part designs because of its unique partnership with the University of Waterloo. A team of students at the university operates a racing team in the Formula SAE Series. This program calls on teams of college students to design, build and race their own racecar. As a sponsor of the Formula

AgieCharmilles

The Mikron HSM 500 is a vertical machining centre that provides three axis high speed milling in a compact design.

Capable of machining cubic workpieces up to 200 kg, the HSM 500 is designed with the operator in mind.

The machine is equipped with an HSK-E40 tool interface and a vector controlled motor spindle for short run-up and brake times and high torques at low speed.

To ensure a high speed spindle output of 13 kw at 42,000 rpm with over 4.2 Nm torque, the HSM 500 is also outfitted with ceramic hybrid ball bearings and liquidcooled stator jacket and bearings.

The base is made of mono-bloc polymer concrete with high vibration damping properties for strength and rigidity for high speed machining. The single casting construction also improves machining accuracy, producing better thermal stability for excellent workpiece surface quality and minimal tool wear. The machine is fitted with absolute optical linear scales on the X, Y and Z axes that operate with a measuring step of .02 µm to guarantee incomparable positioning precision.

The machine is equipped with a large sliding door to give access from three sides, as well as a side window for maximum monitoring of the milling process. It also offers a low loading depth, access to the tool changer and an easy-toclean work area.

User friendly features for use in the workshop, including Smart Machining Modules, operate sensors allowing machinists to utilize the Advanced Process System (APS) for monitoring and recording spindle vibrations. The iTNC 530 Heidenhain control system provides operators with free contour programming, freely definable sub-programming and pre-set work cycles for automation during unmanned hours. www.gfac.com/us

DMG/Mori Seiki

The NTX2000 is the latest machine from DMG/Mori Seiki. The new mill turn centre is the newest model in the company’s X-Class, a new line that made its debut at IMTS in Chicago, IL, last September and at JIMTOF in Tokyo, Japan in late October.

The NTX2000 is a compact integrated mill turn centre with a maximum workpiece size of 660 mm x 1,540 mm. Suitable for complex and high precision machining for parts in the aerospace, medical equipment and semi-conductor industries, the machining centre features key Mori Seiki original technologies such as DDM (Direct Drive Motor), ORC (Octagonal Ram Construction), and BMT (Built-in Motor Turret).

The machine also offers high productivity. Since spindle two has the same specifications with spindle one, machining processes can be flexibly assigned to each spindle. The high speed drive of a tool spindle with a feedrate of 40 m/min maximizes the advantages of a distance between centres of 1,500 mm, claims the company.

Also, the ORC supports the tool spindle movement in the Y axis direction. Since the Y axis structure located close to the cutting point consists of slideways, it allows for heavy duty cutting with less vibration.

The tool spindle is equipped with a built-in motor with output of 18.5/11 kW, equivalent to that of a 40 taper machining centre.

To prevent thermal displacement in the spindle centre, spindle one of the machine is designed to maintain its centre in the same position, with a headstock whose front shape is symmetrical to the X and Y axis directions.

The machine also is equipped with the MAPPS IV operating system. The combination of automatic programming software and ESPRIT CAM software allows the machine to handle complex machining programming.

The NTX machine comes in six models to meet different machining needs. www.dmgmoriseikiusa.com www.canadianmetalworking.com | FEBRUARY 2011 | 27

machine tools

MACHINING CENTRES

SAE team at the University of Waterloo, Miltera machines many of the parts required for the car. The team receives free components for its design. Miltera receives access to real-world complex parts that demand impeccable levels of quality.

“We became involved with University of Waterloo because quite a few of our employees, including myself, are alumni of the school,” says Blackburn. “It gives us a really great opportunity, as these parts feature great geometries and have to perform in demanding race conditions. We’re able to do a lot of research into five axis machining by participating in this program.”

Using racecar components in the testing of the Mikron XSM 400U LP quickly validated some of the data gathered in previous stages of evaluation. Namely, without any adjustments to cutting data, cycle times on the new machine were approximately 10 per cent shorter, on average, than on its predecessor. Additionally, parts were coming off the machine with improved surface finishes.

| february 12011 | www.canadianmetalworking.

28schunk.indd

PRODUCT REPORT Feeler

Methods Machine Tools Inc. has introduced high performance Feeler vertical machining centres featuring extensive engineering

by Methods. The VMC line includes the HV-Series, VB-Series and VMP-Series.

“The rugged, reliable Feeler VMC line is now further enhanced with design and engineering by Methods,” says Paul Hurtig, Feeler product manager, Methods Machine Tools Inc., the exclusive North American distributor.

The HV-800 and HV-1000 models offer

high performance machining featuring 1G X axis acceleration and 1.9 second tool change time in 800 mm or 1,000 mm X axis travels. Roller guideways are on the X and Y Axes. A 15,000 rpm, 30 HP direct drive, 40 taper spindle, Fanuc 18i-MB Control with 4th axis and 30-tool automatic tool changer are standard.

The VB-Series VMCs are heavy duty boxway machines featuring a high torque, two stage gearbox and spindles from 15 HP – 30 HP, available in 40 or 50 taper. Models include VB-900, VB-1100, VB-1300, VB-1400, VB-1650, VB-1900 and VB-2200. X axis travels range from 900 mm - 2,200 mm (35 in. – 87 in.), Y axis travels range from 610 mm – 1,000 mm (24 in. – 39 in.) and Z axis travels are from 600 mm – 800 mm (24 in. – 31.5 in.).

A 30-tool automatic tool changer and Fanuc 0i-MD control are standard.

The VMCs range in weight from 3,000 kg (6,600 lb) – 22,000 kg (48,400 lb) and include a two year warranty. www.methodsmachine.com

7/29/10 2:22:24 PM

MACHINING CENTRES

First

The First V2000 vertical machining centre, available in Canada through Heinman Machinery, Mississauga, ON, features a new Y axis bridge design that uses three guide rails to improve machining accuracy and increase machine strength and stability during heavy cutting applications.

The newly designed double column machining centre is also equipped with a new Z axis slide that uses the same linear guideway with C guide rail blocks on the Y and X axes, allowing for faster feed rates.

Another improvement is a larger door opening for better access for loading and unloading of parts and for easier setups.

The machine is equipped with a 15,000 rpm spindle direct drive that runs continuously at the maximum rpm.

Other key improvements include a bigger spindle motor and an enlarged saddle and rigid head structure. The sturdy Meehanite cast iron construction allows for machining of a variety of large parts. All ball screws are preloaded, offering higher accuracy. www.heinmanmachinery.com

Hardinge

Hardinge’s GX 1000 is the newest version of the Bridgeport GX vertical machining centre designed with the Okuma OSP P200 control, drives, motors and encoders.

Rick Simons, president and CEO, Hardinge Inc., says “the addition of the Okuma control option for our GX 1000 machine enhances product offerings for our distribution partner. We will also continue to offer the Bridgeport line with the Fanuc I Series control to serve our diversified customer base.

The design characteristics ensure Bridgeport 40-taper spindle GX-Series vertical machining centers deliver long term accurate and reliable machining performance.

These VMCs include a stiff and thermally stable spindle, a rigid C frame fixed column design, and fixed pre-tensioned doublenut ball screws on all axes. The unique

Bridgeport designed linear guide and guide truck configuration provides added stiffness, damping and surface contact area. The machine is configured with three guideways and five guide trucks on both the X and Y axis; two guideways and six guide trucks on the Z axis.

GX-Series machining centres feature a powerful spindle motor for aggressive cutting capabilities. A 15 kw (20 hp 1 min) spindle drive is included on GX 480 and GX 710 machines; GX 600 and GX 1000 machines feature a 15 kw (20 hp) drive; GX 1300 and GX 1600 machines feature an 18.5 kw (25 hp) drive. The rigid spindle design includes four angular contact bearings at the front and one roller bearing at the rear for optimum performance and long life. The noncontact magnetic encoder design eliminates noise and vibration, while providing more accurate spindle orientation feedback.

The high speed spindle option is ideal for mould and fixture work when machining hardened materials, as well as high speed cutting of aluminum or magnesium alloy.

Through-spindle coolant is available as an option to supply coolant to the cutting edge at 20 bar (300 psi), allowing faster speeds, enhanced deep hole drilling and blind pocket milling.

The OSP control on the GX 1000 has another advantage for service and support requirements. With the machine and the electronics both being supported by the distributor, customers have the advantage of a single source supplier. When a service technician is dispatched, their knowledge on the entire machine becomes invaluable in saving time and expense. www.hardinge.com

Haas

Constant improvement is a way of life at Haas Automation. The company is always looking for ways to improve its CNC products and give more value to its customers.

MACHINE TOOLS

Normally, these incremental improvements are rolled into production without fanfare; the customer simply gets a better machine.

In 2010, however, Haas redesigned its VF product line to incorporate a wide range of enhancements, making Haas VMCs better than ever, claims the company.

Haas engineers reviewed all aspects of the machines, including motion control, coolant containment, chip evacuation, ergonomics, and serviceability, then made improvements, and put everything into an all-new package.

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 optimized 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 better enclosure and a much simpler overall design that contains chips and coolant, while increasing reliability and simplifying service.

Because people buy CNC machines to make parts, the last thing they want to do is stop production to remove chips. Haas redesigned the chip pans and reviewed coolant flow to reduce chip buildup and efficiently flush chips into the auger trough for removal. For high volume production applications, the New Generation VF-1 to the 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 machines faster and easier than ever.

Haas machines have always been designed from the operator’s and programmer’s points of view. 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, www.canadianmetalworking.com | FEBRUARY 2011 | 29

MACHINING CENTRES

machine tools

PRODUCT REPORT and close tightly. The new Haas thin design control pendant mounts directly to the enclosure, providing a lighter, more stable operator interface than the previous version, and there’s a convenient storage compartment behind the pendant. www.HaasCNC.com

Hurco

Impellers represent one of the many types of demanding parts Miltera produces in its research into five axis technologies.

“Any time you have a mechanical connection without an interference fit, there’s going to be some play in it,” says Blackburn. “With ballscrews this translates into some backlash.

Using linear motors to drive machine movement eliminates this and you get a better surface finish as a result.

The linear motors are also much more responsive, improving cycle times.”

While the benefits of using linear motors quickly became clear, there were some concerns about how the machine would perform in long, demanding applications. Linear motors generate considerably more heat than ballscrews and motors, presenting an obvious challenge in the area of thermal control. “The Mikron XSM 400U LP’s base really helps eliminate the heat problems,” says Blackburn. “Instead of going with cast iron, GF AgieCharmilles has used polymer granite for the base of the machine, which resists any distortion due to heat. Additionally, the machine’s thermal management system, ITC (Intelligent Thermal Control), does an incredible job at compensating for any temperature deviation within the machine tool.”

While the machine provided 10 per cent reduction in cycle time with little changes to existing programs, Miltera was able to achieve even more impressive results with testing and optimization of cutting data. In some instances, cycle times were reduced by as much as 25 per cent. Overall, the results showed

Hurco expanded its VMX series to include larger machines.

The VMX64 and the VMX84 are the largest machining centres in the VMX Series with travels of 1,625 x 864 x 762 mm (64 x 34 x 30 in.) and 2,133 x 864 x 762 mm (84 x 34 x 30 in.) respectively, and rapids of 709 ipm. Both the VMX64 and VMX84 have large door openings to accommodate easy loading/unloading.

The machines are designed for easy overhead crane access to load large, heavy parts or fixtures and the oversized work cube lets customers schedule a wider variety of work. As with all Hurco machine tools, the VMX64 and VMX84 feature the integrated Hurco control powered by the newest version of WinMax software.

The Hurco control supports conversational and NC programming equally well, which gives shop owners the flexibility they need to be more productive and more profitable. www.hurco.ca

Kiwa

The Kiwa Japan KH-55 horizontal machining centre, sold in Canada by K&K Productivity Solutions, Cambridge, ON, is a heavy duty HMC with a full range of features designed to accommodate precision machining of a wide variety of large work components. Having the largest work envelope in its class, the 50-Taper KH-55 can machine work pieces of up to 900 mm x 1000 mm (35.4 in. x 39.4 in.) high, and 750 kg (1,650 lb) in weight.

Large component machining requires

exceptional machine tool rigidity, which the KH-55 provides with a box-type structure where the bed, column and spindle head are symmetrically designed to uniformly absorb force. The column also has an elevated X axis roller guide design which increases rigidity while reducing column weight.

High speed features offer maximum production efficiency. Spindle speed is 10,000 rpm, with a spindle acceleration time of 2.95 seconds and deceleration at 3.32 seconds. Tool-to-tool and chip-to-chip times are 1.8 and 3.8 seconds, respectively.

The KH-55 features a full rotary B axis and will also be available with a 15,000 rpm, 40-Taper spindle as an option.

New features include Spindle Thermal Displacement compensation to ensure accuracy and stability, and a Ballscrew Cooling System that regulates oil temperature, minimizing thermal expansion.

In addition, a comprehensive tool management program provides information such as tool number, life, status and feed rate. Other specifications include an X-Y-Z stroke of 800 x 800 x 800 mm (31.5 x 31.5 x 31.5 in.), a 500 x 500 mm (20 x 20 in.) pallet size, rapid traverse of 60m/min (2,362 ipm), 47 HP direct drive spindle and an easy-to-use FANUC 31i-A CNC control. www.kkpcnc.com

MAG

MAG’s modular HMC 1250/1600 Series features a new 180,000-position A axis tilt-spindle for five axis horizontal machining on large aerospace and energy parts.

The HMS1250/1600 Series now includes six spindle options to suit specialpurpose or general machining requirements.

The new 6000 rpm/46-kW (61.6-hp) tilt-spindle joins an all-around 10,000 rpm/ 56-kW (75-hp) spindle, high speed 24,000 rpm spindle, high-torque 2600 www.canadianmetalworking.com | february 2011 | 31

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machine tools

MACHINING CENTRES

clear benefits to successfully integrating linear motors into a five axis machine. “There’s no doubt that the linear motors offer significant operational benefit,” says Blackburn. “We could consistently and reliably achieve levels of accuracy and surface finish that were comparable or better than attained with previous machine models, while greatly reducing cycle times. With the vital role of productivity in today’s manufacturing world, that’s really a significant development.” CM www.gfac.com www.miltera.com

4

PRODUCT REPORT Nm/80-kW (1918 ft lb) spindle and two live spindles (110 or 130 mm diameter). The high torque spindle is suited for aerospace titanium cutting, while the live spindles extend W axis reach by up to 800 mm (31.5 in.), enabling deep cavity milling to high precision with shorter, more rigid tool lengths. Standard on the live spindle, MAG’s exclusive Z axis thermal compensation software dynamically offsets spindle growth to maintain tight tolerances.

The series is engineered for high precision, high productivity machining of large aerospace, power generation, pump, valve, and off-road equipment parts.

Designed for extreme application flexibility, the machine offers maximum 3000 mm (118 in.) work-zone swing, 2050 mm (81 in.) work-height capacity and 7000 kg (15,400 lb) pallet load capacity. Major machine components, including the X bed, Z bed and column, are cast ductile iron, with 1250 x 1600 mm pallets, headstock and rotary table housings of gray cast iron.

A modular design provides a range of machine travels, 60 to 120 tool magazines and two control choices.

The new HMC offers 56 to 80 kW (75 to

th-axis part positioning FOR MEDICAL & AEROSPACE DD100 Direct-Drive, Super-Precision® High-Speed Rotary Indexer Quick setup on any brand of machining center using a Hardinge Servo Control !

SUPER-PRECISION ±3 arc/sec accuracy, ±2 arc/sec repeatability

ZERO-BACKLASH, DIRECT-DRIVE Some serious part cycle time reduction!

HIGH-SPEED Speeds up to 600rpm as true 4th-axis or up to 700*rpm using the servo control!

GRIPPING FLEXIBILITY Accepts collets, expanding collets & step chucks with a collet closer. Jaw chucks & fixture plates mount directly on the spindle!

HARDINGE B R I D G E P O RT HAUSER JONES & SHIPMAN KELLENBERGER TSCHUDIN

* 700rpm@230V, 450rpm@120V Factory-Direct Sales & Engineering Support

800.843.8801 shophardinge.com hardinge.com VID

videos.hardinge.com 34 | february 2011 | www.canadianmetalworking.com

107 hp) spindle power, 35 kN (7870 lb) Z axis thrust, and a rigid, full contouring hydrostatic rotary table. Rotary table positioning accuracy is ten arc seconds, repeatable to five arc seconds. Positioning accuracy of the tilt spindle is four arc seconds, repeatable to two arc seconds.

Meeting industry needs for tighter part tolerances and greater machining accuracies, the HMC Series comes standard with linear scale feedback in X, Y and Z axes, providing 8 micron (0.0003 in.) positioning accuracy and 5 micron (0.0002 in) repeatability. As well, heavy duty hardened and ground roller guide ways enable a rapid traverse rate of 40 m/min (1575 ipm) with high acc/dec rates, double the load capacity and nearly 10 times the wear life of ball-type ways, claims the company. www.mag-ias.com

Makino

Makino’s a81M horizontal machining centre is designed for machining tough and hard materials. It is suitable for large diameter

MACHINE TOOLS

MACHINING CENTRES

PRODUCT REPORT boring and face milling on such challenging materials as stainless steel, titanium, titanium alloys, inconel, ductile iron, cast iron and CGI (compacted graphite iron).

The unique, high torque and high thrust spindle on the a81M provides unparalleled productivity and reliability for a machine of this type, which helps customers reduce costs from manufacturing operations. It has a quick tool-to-tool time of only 1.7 seconds, with a similarly quick chip-to-chip time of 4.2 seconds.

Industries such as aerospace, diesel engine, construction equipment, oil field components and pump and compressor manufacturing will all benefit from the a81M. The machine is particularly suited for long reach and large diameter boring operations requiring a high torque, particularly at low rpm. For applications such as tapping, where a significant amount of spindle stopping, starting and reversal occurs, the Makino high-torque spindle on the a81M is significantly faster and has less idle time.

The integral drive spindle of the Makino a81 greatly outperforms all other spindles on the market due to the nature of its efficient design, which provides significantly higher torque at a low rpm. This proprietary design combines the optimum blend of speed and superior rigidity necessary to take aggressive cuts.

The spindle has no corresponding loss

of acceleration and deceleration. The quick acc/dec ranges are from 4.4 seconds to 3.8 seconds at 8,000 rpm.

The machine has an X, Y and Z axis of 900 x 800 x 1,020 mm (35.4 x 31.5 x 40.1 in.). It has a rapid feed rate and cutting feed rate of 1,420 ipm (36 m/min) in X and Z axis and a 1,182 ipm (30 m/ 36 | FEBRUARY 2011 | www.canadianmetalworking.com

min) in Y axis. It has a 630 mm (25 in.) pallet able to handle workloads of up to 4,900 kg (10, 800 lb).

The thrust capacity has 25 per cent more axes thrust than the previous a81 machine. The centre trough hinged conveyor provides for fast and effective chip evacuation. The machine also has a 40-tool ATC as standard. www.makino.com

Matsuura

The Matsuura five axis vertical machining centres with multi-pallet systems for full lights-out production capability represent the industry’s most advanced multi-tasking technology, according to the machine builder’s distributor in Canada, Elliott Matsuura Canada.

The Cublex multi-process technology

provides five axis milling, vertical and horizontal turning, and optional grinding capabilities, all in one high performance platform.

The two new Matsuura models include the Cublex–35 PC32, featuring a 350 mm (13.8 in.) diameter x 240 mm (9.5 in.) high maximum work size and a 32 APC system.

The machine offers a maximum loading capacity of 60 kg (132 lb) on its tilting axis table. Its expandable automatic tool changer (ATC) features a standard 320-tool base with 520 tools as an option. X, Y and Z axis travel is 570 mm/410 mm/525 mm (22.4 in./16.1 in /20.1 in.) on the Cublex-35.

The larger Cublex-63 PC-18 features a maximum work size of 630 mm (24.8 in.) diameter x 450 mm (17.7 in.) high and up to a 18 pallet APC system, or it can be added to a full flexible manufacturing system (FMS) production line system. The 63 model is constructed with a trunnion style direct drive A/C axes and has a load capacity of 350 kg (772 lb). A standard

320-tool ATC is expandable to 520 tools. The 63 X, Y and Z travels are 760 mm/845 mm/660 mm (30 in./33.3 in. /26 in.)

Both machines have high accuracy, reliability, and numerous ATC and APC options. The Cublex-35 is equipped with a 25 HP/20,000 rpm direct drive spindle, and the Cublex-63 comes with a 22 HP/12,000 rpm (20,000 rpm optional) direct drive spindle. The Matsuura G-Tech 840DI is standard on Cublex Series machines.

The 35 model features a 3,000 rpm direct drive C axis. The 63 model offers a 1,300 rpm direct drive C axis, the highest C axis rotation speed in its class. www.elliottmachinery.com

Mazak

Mazak’s Multi-Tasking Integrex e-670H II offers productive machining of large, complex shaft workpieces. The machine offers simultaneous five axis machining, allowing parts with tapered holes, blisks and spiral bevel gears to be machined in one setup.

The e-670H II includes a powerful 1,000 rpm, 60 hp spindle for turning and C axis control. It also has a 50 hp, 10,000 rpm integral motor milling spindle that rotates 240° in the B-axis. To support full multi-tasking processes, the e-670 II comes standard with a 40-tool magazine for storage and retrieval of turning, milling, drilling, and tapping tools.

Options can increase the storage

capacity to 80 tools. The e-670H II offers a maximum machining diameter of 1,070 mm (42.13 in.) and a spindle bore of 250 mm (10.2 in.).

The new Mazak MX Hybrid Roller Guide System is integrated into the VCS 430A to deliver levels of durability and reliability that result in long-term accuracy.

The hybrid roller guide system increases vibration dampening to extend tool life, handles higher load capacities, accelerates

MACHINING CENTRES

and decelerates quicker to shorten cycle times, consumes less oil for “Greener” operations, and lasts longer with less required maintenance.

Hardware advances in the Mazak Matrix CNC control include powerful internal computing speed to support 16 million pulse encoders on each linear axis for sub-micron resolution and new servo control technology that minimizes vibration.

Powering these advances is a 64-bit, twin-engine CPU that reduces cycle times for machining complex surfaces up to half versus the previous CNC control.

New software capabilities make Matrix CNC control easier and safer to program and operate. A unique Voice Advisor verbally informs operators of safety alarms and switch settings in manual operation.

Enhanced Visual Machining creates crisp 3D simulations to aid the operator in identifying and correcting any interference conditions and running part program cycle simulations while the machine is operating.

Mazak has also developed intelligent software functionality, pushing the envelope further for reliable and precise machine performance.

Active Vibration Control uses extensive look-ahead technology from the Mazak Matrix control to optimize the servo acceleration and deceleration values in anticipation of rapid changes in direction.

This intelligent function delivers smoother finishes, better accuracy, and longer tool life. www.mazakusa.com

Mitsui Seiki

Mitsui Seiki’s “Vertex” high precision line of vertical machining centres just got bigger with the addition of a new, larger machine, the Vertex 750-5X. In response to requests from existing

customers and the precision component marketplace, the new Vertex 750 offers the following benefits for high performance machining: work envelope of X axis 750 mm, Y axis 800 mm, Z axis 700 mm (29 in., 27 in. and 31 in.); weight capacity 500 kg (1100 lb); small footprint 2200 mm x 3740 mm (87 in. X 147 in.); hand-scraped casting for high geometrical accuracy; rapid traverse rate of 48 m/min (1890 ipm) feed rate of 20 m/min (787 ipm); an integrated trunnion offers fourth and fifth axes with maximum work size of 950 mm diameter and 650 mm high; 15,000 or 25,000 high stiffness spindles with 40 taper or HSK63 tool types; ergonomic access for loading and operation; and Fanuc 31i CNC with the latest Fanuc features for multi-axis contouring.

According to Mitsui Seiki, the accuracy of the Vertex line rivals its best jig boring equipment and offers the machining performance of its larger machining centres.

Typical applications for this model include aerospace components, moulds and dies, and other precision components. www.mitsuiseiki.com

Okuma

The new Okuma MB-H Series of horizontal machining centres provides a unique combination of high speed and power in a small footprint and delivers high productivity without compromising accuracy. Utilizing a high speed spindle and fast APC and ATC, the machines reduce non-cutting time as well.

Built on the Thermo-Friendly Concept that employs a thermal deformation compensation system, the machines are able to predict and counter thermal deformation, improving accuracy.

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 •1G acceleration •Speedy two-pallet automatic rotary pallet changer •15,000 rpm spindle (on the MB-4000H and MB-5000H) •Optional expandable tool matrix allows for quick tool changes using 81 to 285 tools Accuracy is delivered through Okuma’s Thermal Active Stabilizer System (TAS), a high precision indexing table, and a rigid

MACHINE TOOLS

three-point supported bed.

These fast horizontal machining centres are ideal for use in a variety of industries, including the mold/die and automotive industries.

Available in three sizes (MB-4000H, MB5000H, and MB-8000H) the MB-H series feature the operator-friendly THINC-OSP control, a true PC, Windows-based platform with open architecture, plug and play USB capability and 40GB of memory allowing easy connectivity of complementary and peripheral equipment. www.okuma.com

Toyoda

Toyoda Machinery’s latest entry to its vertical machining centre line is the Stealth series, offering unparalleled value and performance, claims the company.

Featuring hardened box ways built upon

a frame and bed made out of a single piece of high grade Meehanite Cast Iron, the new VMCs are manufactured with precision handscraping. Equipped with powerful spindle options, the machine is engineered to maneuver through challenging materials and deliver precise, long-lasting accuracy. They’re are available with: an X Stroke of 900, 1,100, 1,300, or 1,500 mm; a Y stroke of 650 mm; and a Z Stroke of 600 mm. Also standard is a full featured Fanuc Oi MD control and lift-up chip conveyor. www.toyoda.com www.canadianmetalworking.com | FEBRUARY 2011 | 37

TOYODA MACHINERY

HIGH PERFORMANCE MACHINING CENTERS

STEALTH Vertical Machining Centers are the new evolution in job shop performance. Engineered to precisely maneuver through challenging materials and deliver long-lasting accuracy. Reinforced by Toyoda’s unsurpassed service and support.

Table Dimensions: X: 1,100mm, 1,300mm, 1,450mm, 1,650mm Y: 650 mm Z: 600mm

FIVE AXIS VERTICAL MACHINING CENTER Equipped with high performance spindle with tilting headstock, Toyoda’s UA2090 5 Axis Vertical Machining Center offers superior structural rigidity essential to achieving precision and lasting performance for demanding applications.

Table Dimensions: X: 2,150mm Y: 900mm Z: 900mm

THE FASTEST, MOST POWERFUL, & LARGEST WORKPIECE IN ITS CLASS HORIZONTAL MACHINING CENTER The FH1250SX delivers high accuracy and precision on a large scale. Toyoda’s SX Series machines bridge the gap between boxway and high speed machining and excel at machining a wide range of materials.

Pallet Size: 1,250mm

Cutting Feed Rate: 42m/min

Spindle Torque: 600Nm

MACHINING CENTRES/CASE STUDY

MACHINE TOOLS

Turning Point

New digs, lathes boost the fortunes of a fledgling Ontario shop

By Nate Hendley .................................

2010 was a big year for Martec Precision, a machine shop in Brampton, ON. The company moved into more spacious quarters and purchased a new lathe from Japanese machine tool giant Okuma. The combination of more space and more lathes has been a boon for the fledgling firm, which continues to grow despite the lingering effects of a brutal recession.

Martec’s success is all the more impressive when you consider the firm’s humble origins and initial brush with disaster. The company is owned by Dawson Marks, who runs it with his wife, Marlene.

“I always wanted to own my business,” recalls Dawson, citing his motivation for launching the firm.

Originally from Nova Scotia, Dawson came to Barrie, ON, in 1980, where he picked up a job with Rockwell International. At the time the company was building a pipeline for Alberta. A self-taught machinist, Dawson spent a quarter-century working for Rockwell and other firms before starting Martec with Marlene.

Buying equipment was the first step towards becoming an entrepreneur. To this end, Dawson and Marlene attended the 2005 CMTS show, and came away impressed by Okuma.

“I had known Okuma from being in the industry.

When I was first introduced to the machines as a young man, I liked the aspects of it … the tight tolerances they held. They had lots of horse power and were reliable,” says Dawson.

The Marks purchased a new Okuma ES-L8 lathe from EMEC Machine Tools, an Okuma distributor based in Mississauga, ON. The ES-L8 CNC two axis lathe comes with tailstock and features a fully automatic SMW 2200 series bar feeder for production runs, three jaw chucks, a 12 station V12 slotted turret and a spindle speed of 4,000 RPM. Maximum turning s. diameter is 12.25 in. (311 mm) with maximum ce an er of their tight tol chines because ma turning length of 18 in. (547 mm). ma ku O of n on Marks is a fa Lathe in hand (along with a saw and a Martec’s Daws www.canadianmetalworking.com | FEBRUARY 2011 | 39

MACHINE TOOLS

MACHINING CENTRES/CASE STUDY

compressor), the Marks opened Martec’s doors in February 2006, in a Brampton business park.

Disaster struck right away. Dawson and Marlene had launched their firm with the expectation of a work order that would cover the cost of their lease and equipment.

“Once we got the [ES-L8] machine on the floor, the customer informed us that business had slowed down and they were pulling that job off of us. So we had a shop but no work,” recalls Marlene.

This setback didn’t stop the company for long, however. Thanks to Marlene’s determination and Dawson’s reputation as an expert machinist, the newborn firm survived. Marlene got on the phone or sent flyers to almost every machine shop in Brampton and nearby Mississauga, ON. “I told them what had happened.

We were very honest. I said it was my husband’s dream to start a business (but) we lost our first job before we got going and is there any chance you could help us. Give us an opportunity to quote some work. A handful of people said,

‘we’ll give you a chance.’ Some of those customers are still with us today,” states Marlene.

It helped that Dawson was well regarded for his high precision work and ability to maintain tight tolerances.

“He’s known as the ‘MacGyver of machining’,” laughs Marlene, referring to the 1980s television character who fought crime with make-shift machinery he slapped together on the spot. “A lot of people will call upon Dawson … [when] they’re having troubles or challenges. He hasn’t found a job he is known as the oblem.

Dawson Marks pr Martec founder chining” who can handle any hasn’t been able to handle.” ma “MacGyver of At first, Dawson worked full time for another firm, toiling at from Okuma. The lathe features three Martec in the evening and on weekends. After three months, he was able jaw chucks, a 12 station V12 slotted to quit his outside job and concentrate turret, spindle speed of 4,000 RPM and all of his energy on Martec. Around the a 20 HP spindle drive. It has a maximum same time, the firm purchased a second turning diameter of 12.25 inches and a lathe, “because we found enough work to maximum turning length of 18 inches. warrant it,” states Marlene.

Six months after opening, the Marks The Marks bought a new ES-L10 lathe hired their first employee. They also

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MACHINING CENTRES/CASE STUDY

Martec’s team inc ludes Marlene M with light blue sh arks (centre) irt, and Dawson Marks, far right.

made some wise business decisions such as concentrating on aerospace and mining while avoiding automotive. Because of this, Martec didn’t suffer when the North American auto industry imploded.

“I think that’s what saved us in the recession. We didn’t have one [big] customer in automotive,” states Marlene.

By mid-2010, the company had three lathes, a mill and a 1997 Okuma Cadet-V4020 vertical machining centre equipped with a 4th rotary axis (all from

Okuma) and was looking to expand. In July 2010, the Marks purchased a new Okuma lathe, a Heritage Series ES-L811 CNC turning machine.

“I’ve always been a lathe man. I can make more parts on a lathe than on a mill,” states Dawson.

That said, the new lathe comes with milling capabilities. It also has 12 live stations with VDI 30 tooling types, 6,000 rpm and 5.3 hp capabilities. It offers X axis repeatability of +/-0.002 mm and +/-0.003 mm repeatability on the Z axis.

The C axis provides programmable rotary position and C axis feed for use of driven tools on the workpiece. The machine tool comes with a bar feeder interface, electric spindle orientation and two controlled axes. It is also equipped with Okuma’s THINC-OSP control.

Installation and training were provided by Okuma and went smoothly.

Okuma doesn’t offer a set training period: “Rather than saying, ‘You get five day’s training and that’s it’, we train the customer until they are fully proficient.

That way they get the most out of [their machines] and usually purchase their

MACHINE TOOLS

next machine from us also,” states Bill Mara, president of EMEC Machine Tools.

According to Dawson, the new Okuma ES-L811 CNC turning machine was up and running within two days of its arrival.

“The milling feature in the new lathe enables us to complete more features of a part in one operation, greatly improving production times. With some jobs, depending on the type of material, we can run this machine ‘lights out’ on its own, 24 hours a day. An operator would only be required to load the material into the barfeeder four times a day, remove turnings and monitor for quality … production on that machine [can top] 2,400 parts in a 24 hour period,” says Dawson.

Dawson primarily uses the new lathe for doing aerospace parts and moulds.

He says the new lathe has boosted productivity by 15 per cent. While current revenues are a company secret, Martec has grown considerably since their first year of operation, when it grossed $350,000. It also added staff, growing from six last year to 11 this year.

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MACHINING CENTRES/CASE STUDY

An over view of

“I think that’s what saved us in the recession. We didn’t have one [big] customer in automotive.”

While the new lathe made Martec more productive, the company now faced a space problem. Their 2300 sq ft headquarters had become too small for the operation. Employees had to turn sideways to get between machines, Marlene recalls. Fortunately, a larger space was available in the business park.

The new digs offered 4600 sq ft of room, which seemed adequate to the task.

Martec moved in September 2010 and was functioning one month later.

The shop floor in Martec’s present location is 50 ft wide, 22 ft tall and extremely clean and well

MACHINE TOOLS

Martec’s shop.

organized. Tools are neatly hung and drawers bearing labels indicating contents abound.

Martec’s current workload is divided evenly between aerospace, moulds and mining. They still do custom jobs and retain something of a job shop atmosphere. Late last year, Martec hired a quality control manager in the hope of becoming ISO certified. The company now boasts 11 employees, including Dawson and Marlene.

The Marks want to continue growing the business at an even pace. Plans have been made to purchase new machines—from Okuma, of course.

The Marks are thinking planning to purchase a new mill, despite Dawson’s preference for lathes, to accommodate the growing milling end of their business.

Ironically, Martec’s new quarters have turned out to be less roomy than anticipated.

“Once we got in here and got our machines over and set up, we looked at it and thought, ‘Wow. It’s already looking small.’ In hindsight, we probably should have taken the triple unit that was available,” states Marlene.

Indeed, the Marks are already talking about taking over another unit in the business park.

“We are ready for expansion,” notes Dawson, proudly. CM Nate Hendley is a freelance writer based in Toronto and a regular contributor. www.martecprecision.com www.emecmt.com www.okuma.com www.canadianmetalworking.com | FEBRUARY 2011 | 45

MILLING

CUTTING TOOLS

Shapely Figures Do asymmetrical geometries and complex inserts make better cutting tools?

By Tim Wilson ......................................................................................................................................................

Milling geometries can have a big effect on cutting performance, and given the range of factors, getting it right can be tricky. When choosing an insert the operator needs to consider how the material, grade, coating, and edge will interact. Decisions can then be made as to whether a multipurpose tool will work, or if something more specialized is needed for a higher sheer.

“At Ingersoll we have targeted edge preps and geometries for specific material groups,” says Konrad Forman, milling products manager at Ingersoll Cutting Tools, Rockford, IL. “We have multi-purpose geometry, too, which allows for different grades and edge preps.”

Though Forman is clear that this approach is not suited for all applications, Ingersoll’s multi-purpose products are nonetheless part of a strong trend toward multi-radial geometry, wherein a single insert can handle a range of angles. Specifically, the company’s S-Max technology can cover an array of tangential milling requirements.

“With the S-Max you can cover a broader spectrum of materials without specific target geometries,” says Forman.

“Now a single insert houses the majority of cuts–you don’t need a whole drawer.”

The caveat is that multi-purpose Emuge cutting tools. geometries also involve compromises.

As a result, repeated high sheer, double-positive applications with the same material, such as aluminum, would benefit from a more specialized approach to improve throughput.

AN ANGLE ON A COMPLEX WORLD

There is a wide variety of milling operations in the field, which means there is plenty of territory to cover when it comes to discussing the machining process.

“Porcupine, side and face milling—there is a lot of technology going in to making a modern milling cutter,” says Robert Humphreys, field application engineer for Walter Tools in Canada.

And there are a wide variety of cutting tool suppliers, including customized tooling suppliers such as Carbide Concepts Inc., Stoney Creek, ON, a 30-year-old custom cutting tool manufacturer. Mac Mackenzie, CEO, says his small Canadian-owned firm can create any geometry a customer requires. He claim the company offers “unique” solid carbide high feed milling cutters. Carbide Concepts is the sales and marketing arm of Epic Tool Inc., the manufacturing company also owned by Mackenzie. As of March 1, 2011, Carbide

Concepts will be amalgamated into Epic Tool.

“We manufacture our high feed tools with positive cutting edges from a series of continuous changing radii, leaving no tangent point to produce wear. Our geometry allows the chip to flow upwards quickly and smoothly, allowing heavier chip loads which result in high feed rates. The geometry includes a chip thinning factor that allows the milling tool to generate all cutting forces upwards towards the machine spindle, eliminating vibration and tool deflection.”

Whether it is on the face, up against a shoulder, machining across a clear surface, or a lead angle on a square shoulder, the range of materials also adds to the complexity of inserts and geometries now available.

“It used to be that inserts were essentially flat, with the rate and angle controlled by the pockets or cut,” says Humphreys. “Today geometries at the top of the insert have variations from five, to 18 or 20˚ positive.”

This trend away from tools that were more or less symmetrical has been occurring over the past few years, with variations in flute geometry now able to bring definite advantages.

“For example with a four flute tool, where the flutes are set at standard 90 degree intervals, we might see 88 and 92, or 87 and 93,” says Stephen Jean, milling products manager at Emuge Corp., West Boylston, MA. “This helps to minimize vibration, allowing the tool to run more smoothly, and contributes directly to more effective machining and longer tool life.”

A blended radius tool creates a peak and fall that breaks the rhythm and reduces vibration. As an insert comes around and engages, it takes a small amount of material that increases as the tool gets into the cut, then decreases on the way out.

“This creates a parentheses-shaped chip,” says Forman from Ingersoll. “It is very smooth running, minimizes the vibration, and allows you to go faster with less vibration, heat, friction, and wear.”

This increased sophistication allows operators to reduce any movement that isn’t directly related to the spinning, lowering the chance of fracture and premature tool breakdown. With these advances a tool can be more rigid and robust, with more force driven out of it. With hard milling, however, it is important not to be too aggressive.

“The optimal helix angle varies depending on the material types,” says Rich Maton, supervisor of engineering and planning at Sumitomo Electric Industries, Mount Prospect, IL. “At www.canadianmetalworking.com | FEBRUARY 2011 | 47

cutting tools

MILLING

Sumitomo we offer a 30° helix for some of our general purpose cutters, but for hard milling at HRc 50-60 we offer a 50° helix.”

Web thickness—essentially the distance across the end mill from the bottom of the flutes—is also an issue. The thicker the web, the stronger the tool.

“In hard milling applications, the web is usually thicker to have a more rigid tool, and the feed rate is generally slower per tooth, so the flute is shallower,” says Maton. “In aluminum applications, the material is easier to machine, so the feed per tooth is higher, creating more chips and requiring deeper flutes and a thinner web.”

High sheer must account for chip flow

High sheer is important in modern milling cutters, with CNC machines running smaller cutters at higher speeds. There are more passes at lower forces, which can then allow for more adaptable tools.

“With a positive geometry there is not too much cutting force down into the component,” says Humphreys from Walter.

“It will help reduce those axial forces, but the rigidity of the component has to be taken into consideration—you need to know that the surface will not move or vibrate underneath the supported cutting edge.”

Walter has its Xtra·tec shoulder, face, slot and side milling cutters. Specifically, the F4080 octagon cutter has eight cutting edges per insert, with a wide range of application types. The company also has porcupine cutters and the F4041, which has four cutting edges per insert, as well as a unique spiral-shaped indexable insert.

“We put lumps and bumps on the inserts to improve chip flow,” says Humphreys. ”You don’t want too many pockets; it can’t be too tight or else there will be chip jamming; you need clearance to get the thing out.”

Kennametals’ helical milling cutters.

With aluminum you tend to have a narrow core and deep fluting, whereas a harder material will have shallower fluting.

A harder material will have a lighter chip load, which permits more flutes, he adds.

“People should not be lured into a false sense of security with the multi-purpose approach,” confirms Forman from Ingersoll. “The end user needs to make sure that multi-purpose is acceptable, because a specific edge can deliver lower overall costs. The risk is that you can be penny wise, pound foolish, and multipurpose yourself out of business.”

Making the right decision

The key question is whether or not the focus is on one material group, or if the 48 | february 2011 | www.canadianmetalworking.com YG-1.indd 1

1/25/11 2:05:43 PM

MILLING

cutting tools

appealing design from a cost efficiency perspective.”

And new players are getting into the action, with OSG Canada introducing its Phoenix Indexable cutting tool series to the Canadian market early in 2011.

“We are entering into the indexable carbide market offering a variety of products including square shoulder, button and high feed endmills and face mills,” says Craig Ramsey, product manager for OSG Canada in Burlington, ON. “As part of the Phoenix line we will also have our PFB Finish Ballnose series end mills for 3D contour milling applications.

These cutters feature an extremely accurate radius as well as excellent insert pocket accuracy for improved tool life and surface finish.”

But, as with other experts, Ramsey notes that the correct helix angle on the insert, though important with regard to putting heat into the chips and off of the work piece, is not the whole story.

“Insert geometries are only part of the puzzle,” says Ramsey. “Carbide substrates and coatings are also critical in making the proper insert choice for specific applications.” CM

Sandvik Coromant’s CoroMill 40 cutting tools.

approach is more generic. Given the recent hard times, some shops have found it easier to weather the storm with a more adaptable technology, the hope being that they can invest in precision tools when the economy improves.

“There are some areas where the long haul can support a generic approach, but there are also applications that consume an enormous amount of carbide. You shouldn’t go into it blindly,” says Forman.

Ingersoll is fine tuning its high feed technology to get more teeth per diameter, thus getting more out of each insert. These are ultra fast, shallow applications for 40 taper machines.

“The quiet revolution is in delivering the full range of radii and geometry to smaller and smaller diameters,” says Forman.

“The customers need this high sheer technology. They also want more cutting edges per insert, and lower costs per edge. This is why we have two-sided technology, with a mirror image four and four octagonal design, or even five and five; it makes for an

Tim Wilson is a freelance writer based in Peterborough, ON. www.carbideconcepts.com www.emuge.com www.ingersollcuttingtools.com www.osgcanada.com www.sumitomotool.com www.walter-tools.com

THE CUTTING EDGE We use Premium Micro grain solid carbide for longer tool life and increased feeds and speeds.

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Hardened steel head features proprietary mechanical attachment... no annealing from brazing heat Pocket keeps chips away from machined surface Fits into SCI standard QHC coolant tool holders Inserts lapped and ground to fine finish for maximum chip flow Available in right-hand and left-hand versions Bars stocked with or without locating flat...

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cutting tools

MILLING

PRODUCT REPORT ATITI Stellram

ATI Stellram’s new XE solid carbide endmill is designed for machining exotic and difficult to machine materials.

The geometric design features deep flutes and robust high helix cutting edges, the result of what the company says is its continuous improvement program in aerospace machining.

The tool is designed to run faster, run cooler and, with through tool coolant and deep flute design, evacuate chips more efficiently, claims ATI Stellram.

The XE endmills feature a longer shaft for maximum clamping and reach to help minimize vibration.

The endmills are manufactured from a tough, high wear resistant submicron substrate, and are coated with PVD Nano TiAlN. The design of the endmills enable the tool to slot and profile to higher radial and axial engagements and run at higher surface speeds and feeds in the most difficult to machine materials. www.atistellram.com

BIGIG Kaiser

Emuge

Emuge Corp.’s new series of endmills, TiNox-Cut, provide exceptional tool life when machining challenging materials. They offer a dependable cutting solution for nickel alloys like Inconel and Stellite, all grades of titanium, and tough stainless steels like Super Duplex, materials used extensively in the aerospace, power generation, medical, chemical and food industries, among others.

“The demand for parts and components machined from these materials is on the rise, but the same special properties, like high heat, chemical and abrasion resistance, that make these materials desirable for use in extreme-service applications, also make them difficult to machine,” says Stephen Jean, milling products manager, Emuge Corp. “Typically, these materials burn up cutting tools. Now, with TiNox-Cut end mills, Emuge has something to combat this.”

The new endmills feature a high heat resistant, lubricious coating and an optimized cutting edge design. This provides long tool life by minimizing friction and efficiently evacuating chips, which is important in tough, long-chipping materials. In addition, the tools are made from an extra tough carbide grade to maximize wear resistance.

BIG Kaiser Precision Tooling Inc. has expanded the Kaiser Kab modular tooling system capabilities to include the ultra rigid high feed C-Cutter Mini chamfer mill line from BIG Daishowa Seiki.

The new C-Cutter Mini Kab Type delivers multi-functional cutting, including chamfering, back chamfering and even light face milling.

Its design permits 45˚ chamfering for diameters .866 in. to 2.441 in., and is suitable for use on steel (including stainless), cast iron, aluminum and other non-ferrous materials. The newly introduced SE (Sharp Edge) insert type prevents burrs and is recommended for stainless and mild steel applications.

The new modular connection makes the C-Cutter Mini much more versatile since it can now be used with existing Kaiser Kab1/ Kab3/Kab4 shanks, extensions and reductions. The Kab connection delivers performance advantages including strong face to face clamping forces for maximum rigidity, repeatable seating precision and moderate vibration dampening effect due to friction between the mating components. www.bigkaiser.com 50 | february 2011 | www.canadianmetalworking.com

For maximum effective cutting lengths, the endmills feature reduced neck diameters. Offering superior machining repeatability and safety, the new endmills combine a tight, h5 shank tolerance with a specially roughened surface finish to maximize tool holder clamping potential.

They’re well suited for roughing and finishing operations. The tools consist of three designs: two four flute variations for both roughing and finishing, and a five flute extra long finishing tool.

TiNox-Cut roughing/finishing endmills are available with flat ends or with a selection of corner radii. For more efficient chip evacuation, the four flute endmills are available with internal coolant/lubricant capability. The roughing/finishing versions are available with a serrated profile for effective chip breaking during roughing operations.

The five flute finishing endmills are available with various corner radii, and feature length-to-cutting diameter ratios of 3 times D and 4 times D. The design offers added stability and minimal deflection in long reach applications.

The endmills range in diameter from 6 mm – 20 mm, depending on the design. www.emuge.com

MILLING

cutting tools

PRODUCT REPORT Greenleaf

Greenleaf Corp. has introduced its new line of Excelerator Ball Nose Mills. The ball nose endmills are the only complete line of ball nose cutters designed to use both ceramic and carbide inserts in the same qualified cutter bodies.

The unique cutter geometry, combined with Greenleaf’s ceramic or carbide inserts, offer better performance, longer tool life and superior cutting action over competitors’ mills across a wider spectrum of materials, claims the company.

The insert geometry prevents excess tool pressure at high metal removal rates and has the edge strength to shear material without smearing. Greenleaf’s WG-600 ceramic and G-925 carbide inserts maximize tool life when machining a wide variety of difficult materials including nickel and cobalt-based super alloys, hard steels, soft steels, stainless steels, titanium and more.

The Ball Nose cutter line is available in standard and extended lengths. www.greenleafcorporation.com

Horn USUSA

The Dah tool system is available in wear resistant SA4B carbide grade for face milling, pocket milling and circular milling of steel, cast products and aluminium.

With cutting edge diameters of 20, 25, 32 and 40 mm, they expand the Horn product range to include larger diameters and higher feed rates with deeper cutting depths.

The titanium nitride (tiN) coated holders with internal coolant supply are available as end mills with the Weldon tool holder and as industry standard threaded connection cutters with the MD holder design. It has a cutting depth of 1.2 mm and feed rates of up to 3 mm per tooth. All milling cutters can be equipped with the same indexable inserts, cutting tool costs. www.hornusa.com

Iscar

Iscar’s11 mm profiling insert does the job of a bigger one, enabling finer pitch cutters for smoother profiling and lower chip loads. On a 50 mm diameter cutter, six of the new Helido H400 RNHU 1205 inserts can fit in a pitch circle that normally accommodates just five standard 12 mm inserts.

Key applications include die and mould and blade profiling for the aerospace and powergen industries. It can improve any milling operation and should be preferred wherever standard 12 mm profiling inserts are used.

The design secret of the Iscar H400 RNHU 1205 insert is that it isn’t quite round. Each face has four 6 mm radius cutting edges separated by a flat. The result is that the insert itself measures just 11 mm across and performs like one a millimeter larger. The smaller the insert, the more you can fit into a given size pitch circle.

Depending on priorities, the user can translate this difference in diameter to higher table feeds, finer finish or longer edge life.

Made from tough Sumo Tec grades, the inserts are double sided, with each edge providing a 120o active area. The adjacent flats prevent insert rotation in the Helido cutter’s rigid dovetail seat pocket. Despite the negative axial orientation needed to create a double sided insert with its extra edges, the cutting presentation angle is 10 o positive as in standard round profiling inserts.

Cutters for the new inserts feature coolant delivery to each individual insert, extending edge life even when running difficult stainless steel or superalloys. Insert grade choices are available to cover steel, super alloys and stainless steel. www.iscar.com

Kennametal

Kennametal’s Beyond platform of high performance tooling products continues to garner exceptional reviews from Kennametal customers.

Due to higher metal removal rates and extended tool life, these products are resulting in productivity improvements of 30 per cent or more for a broad spectrum of metalworking users, according to the company.

“Depending on the application, field tests have shown up to 300 per cent of improvement in tool life,” says Osny Fabricio, Kennametal senior product manager.

Kennametal has taken another step forward with its new Beyond Blast, which debuted at IMTS 2010. By channeling coolant through the insert, at the interface of the milling cutter and insert, Beyond Blast delivers coolant directly where the tool cuts the material, ensuring more efficient coolant delivery, heat transfer, and lubricity. www.canadianmetalworking.com | february 2011 | 53

TM

More than just the right tool — the ultimate solution. That’s Beyond Blast.

©2010 Kennametal Inc. l All rights reserved. l A-10-02451

TM

Beyond Blast technology uses low-pressure conditions to offer high-pressure performance

Through-channel coolant, delivered at the cutting edge, results in twice the tool life of standard inserts

Delivers superior performance on Titanium and high-temperature alloys, using either high- or low-pressure coolant systems

Effective thermal management results in reduced cutting temperatures, improved lubricity, superior chip control, and longer tool life

That’s Different Thinking.

At Kennametal, innovation follows vision. Our revolutionary products are inspired by asking “what if?”

The solutions that follow — like our Beyond Blast through-coolant inserts — deliver remarkable results in the world’s most demanding machining environments.

TM

A cutting-edge insert that delivers coolant precisely at the cutting edge. Now that’s Different Thinking.

That’s Kennametal.

TM

To learn more about your productivity gains using Beyond Blast technology, call 800.446.7738 or visit www.kennametal.com.

CUTTING TOOLS

MILLING

PRODUCT REPORT Optimizing high speed milling applications is a task aimed at maximizing a company’s milling productivity and reducing manufacturing costs. Improving speeds (sfm/Vc) and feeds makes a big difference, as does achieving maximum metal removal (MMR). Intelligent coolant application is key. Mechanical cutting generates frictional heat. At high cutting speeds, the rate at which heat is absorbed by the tool increases with velocity. To optimize performance, tools must be adequately cooled.

Proper coolant flow means improved tool life and higher maximum effective cutting speeds for a number of reasons. When not properly cooled, the insert will heat up rapidly, which shortens tool life. In many cases, the workpiece can heat up significantly, too. This negatively affects surface finish and dimensional control, causing a failure mode typically called plastic deformation.

Traditional flood coolant jets are uncontrolled and wasteful.

This is because they are aimed at the cut, but often hit behind the cutting zone. Instead of making cutting more efficient, this can actually add to problems by pushing chips back into the cut, increasing chip friction and accelerating tool failure due to increased chip recutting. Custom high pressure systems (1,000 psi or higher) engineered to address this situation can cost tens of thousands of dollars to install and maintain. Even ultra high systems delivering coolant in excess of 4,000 psi have been observed emerging in specialty applications. With Beyond Blast,

COOL BREEZE UTILITY SERIES Solid Micro-Grain Carbide End Mills Coated Variable Helix End Mills for Materials up to 55HRC • Coating for improved lubrication and high hardness • Special cutting edge design provides high rigidity • Flute design promotes efficient chip evacuation • Cool Breeze tight tolerances Diameter

L.O.C.

Chamfer

O.A.L.

Price CAD

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2 ½” 2 ½” 2 ½” 3” 3 ½” 4” 4”

$9.99 $14.99 $17.99 $29.99 $52.99 $79.99 $144.99

Komet

With the Komet Quatron hi.feed milling cutters, the company is replicating the success of its proven Kub Quatron drills in a new range of milling cutters. For roughing operations, this tool variant enables machinists to use the four effective indexable inserts for both drilling and plunge milling.

Among the key features are the four Quatron indexable inserts that the company says are remarkable for the number of cutting edges and rapid removal of high chip volumes. These properties are now available in the new Quatron hi.feed milling cutters. The indexable inserts also have a radial cutting action, which affords a higher degree of flexibility in plunge and pocket milling by comparison with two or three-edged inserts.

Machinists who need to cut deep grooves or large cavities in their workpieces often opt for plunge milling due to the dimensions or cutting capacities of the tools or the performance of the spindle inside the machine. Rather than boring with the use of multiple boring tools, it is possible to achieve various diameters and complex contours in one roughing operation by milling with an axial and a horizontal feed. The milling cutters can use the same indexable inserts for drilling and milling. The BK8425 coating extends tool life. The cutters can be used for steel, cast iron and stainless materials. www.komet.com

Sandvik Coromant

Sandvik Coromant has developed a new range of small CoroMill Plura ball nose endmills for profiling in medium hard to hard steels.

C.N.C. VARIABLE HELIX: 4 Flutes 10% Co, 0.6µm grain size

www.pctcarbide.com Phone: 888-398-9449 2011 PCT CARBIDE

56 | FEBRUARY 2011 | www.canadianmetalworking.com 01 TNT Tools.indd 1

coolant is delivered through the insert, at the interface of the milling cutter and insert, delivering the best of both worlds.

Beyond Blast is available for both turning and milling applications. www.kennametal.com

1/6/11 10:10:39 AM

MILLING

The endmills come in diameters from 0.1 -0.12 mm (.004 in. - .0047 in.) and are perfectly suited for all small die and mould, electronic fibre optic connector and medical tooth implant manufacture, where high precision is important.

Produced in a fine grained solid carbide grade with multi-layered PVD coating, the tools have a geometry design which prevents the radius from deteriorating from uneven wear. The long neck of the tool allows for good accessibility especially in pocket milling. www.sandvik.coromant.com/ca

Seco Tools

Seco Tools Canada has enhanced the performance of its entire Turbo Mill family of square shoulder milling cutters through a new nickel-based surface coating that approaches HV700 on the pre-hardened cutter bodies for longer life, better tolerances and a more durable surface. For the user, this translates into increased reliability, higher precision machining and better chip evacuation and control.

The Turbo Mill offering is a comprehensive and versatile square shoulder milling product line that can slot, ramp, contour, plunge, pocket mill and perform both circular and helical interpolation. There is a choice of 13 carbide grades, three PCD tipped grades and five geometries suited for a variety of materials including steel, stainless steel, cast iron, hardened materials, high temperature alloys and non-ferrous materials. Turbo’s inserts feature an optimized edge, advanced helix angle, large wiper flat and a strong, positive rake angle to allow high productivity.

Available Turbo products include: Nano Turbo in 3/8 – 1.5 in. diameters (10 - 40 mm), offering an alternative to both HSS and solid carbide; Micro Turbo in ½ – 3.0 in. diameters (12 – 100 mm) for light duty, high precision applications; Super Turbo in ¾ – 10 in. diameters (20 – 250 mm) for general purpose square-shoulder milling applications in a wide range of materials and applications; and Power Turbo in 1.0 – 10 in. diameters (32 – 250 mm) for heavy duty, maximum metal-removal applications.

Combimaster interchangeable heads are available for all Turbo sizes. For live spindle machines, Capto adapters for Combimaster heads are available to further extend the flexibility of this tool system. Close and coarse pitch version cutters are also available. www.secotools.com

Tungaloy

Tungaloy has introduced a leap forward in high feed milling.

Tungaloy’s new DoFeed mini is in a class of its own called “super high feed milling”. The DoFeed mini is a high feed tool that offers a high density pitch allowing for super high feed rates. As an example this tool is available in a one inch diameter with five teeth. The high positive geometry on the insert allows for higher feed rates while decreasing the spindle load. This means even low horsepower machines

CUTTING TOOLS

can take advantage of super high feed milling. The innovative geometry of the insert allows for economical four cutting edges per insert. The new “Premiumtec” coating technology applied to these inserts allows for extended tool life, higher speeds and is applicable to a wide range of materials from steel, tool steel and even titanium. The tool itself has an innovative pocket design that protects the unused edges on the insert from chipping. These tools are available in sizes starting from 5/8 in. diameter in regular, long and extra long lengths. www.tungaloyamerica.com

Walter Valenite

The new WKP35S grade for milling of steel and cast iron is the latest product introduction from Walter Valenite. The new grade uses a new CVD technology that for the first time provides the hardness (wear resistance) of CVD grades and the toughness (crack resistance) formerly realized only in PVD grades. The company claims WKP35S improves surface speed rates on average of 20 per cent.

The CVD technology benefits manufacturers by providing up to 80 per cent higher tool life on wet milling applications versus existing grades, up to 30 per cent higher tool life on dry milling applications versus existing grades, and up to 20 per cent higher cutting speeds.

Unique attributes of the Tiger-tec Silver include: •Silver-Colour – Silver colored clearance face easily detects tool wear and indicates the proper time to index to extend insert life.

•Edge Preparation – Exclusive edge preparation process provides a smooth rake face and cutting edge. This means you get consistent tool life for predictable machining.

•Top Surface – Coated surface is “polished smooth” in a unique, patented, post-coating process. This process results not only in a smoother surface, but increased edge strength by relieving inherent stresses in the coating. www.walter-tools.com/us

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 with steels, stainless steel, high strength steels, cast iron, and now even non-ferrous materials, claims the company. In addition to the successful M1200 face milling range, the M1200HF (High Feed) face milling system and M1200 Mini now extend the series.

M1200HF (High Feed) is a unique tooling solution that accepts www.canadianmetalworking.com | FEBRUARY 2011 | 57

cutting tools

MILLING

PRODUCT REPORT

standard M1200 HN .09 inserts already available today, but by utilizing machining science to incorporate a chip thinning effect, can achieve extraordinary metal removal. “This design allows for feed rates of up to 14X higher feed per tooth versus even our highperforming standard M1200,” says Josef Fellner, global product manager, indexable milling team.

“With 12 cutting edges, the Widia Victory M1200 series offers many cutting edges per insert, which all perform at higher speeds and feeds while achieving lower power consumption due to superior design versus other double-sided platforms available today. It’s a proven best-in-class system, and these new options really complement the series.”

The M1200 Mini offers the same 12 cutting edges and higher performance results of the M1200 series but in a smaller size (up to 3.5 mm maximum depth of cut). Extremely capable in aerospace, transportation, and general engineering applications, the M1200 Mini offers easier cutting at higher speeds and more metal removal at lower power consumption.

Features and benefits 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

YG-1

The X5070 is a new generation of nano-grain carbide endmills from YG-1 designed for machining hardened materials in the 50-70 HRc hardness range.

The company notes the endmills were produced to fill a large gap between the “normal” carbide and the premium products, and are designed to increase tool life when machining the upper range of hardened materials.

Its polished cutting surface means these endmills can also be used to substitute for many grinding operations.

The fine nano-grain and uniform carbide particles provide better wear resistance, claims the company, leading to prolonged tool life. The cutting tools feature a hot hardness material heat barrier that permits a higher cutting temperature and provides great hot hardness at the tool/chip interface.

The geometry of the endmills includes higher corner end strength and a unique process that the company says improves cutting corner smoothness. A special blue coating allows for the machining of hardened parts (over 4500 HV) and provides high thermal stability against oxidation (1200ºC) and a low coefficient of friction against steel.

The endmills are suitable for dry cutting and clean machining processes, which help reduce coolant costs. www.yg1usa.com 58 | february 2011 | www.canadianmetalworking.com

Passion.

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ON MACHINE VERIFICATION

Quality

Check Points On machine verification is a smart way to improve part quality

By Philip Smith.......................................................................................................................................................

Problem

Imagine that your machine components weigh 2,000 kg or more.

The inspection process of such a large part is not easy; the part must be removed from the machine, be transported to a co-ordinate measuring machine (which could be at your facility or on the other side of town), get in-line and then, possibly days later, it could be found to be dimensionally flawed only then having to be reworked. This whole process is time consuming, risky and expensive.

The above situation is not unusual, irrespective of whether the part weighs a few grams or tons. The ability to check the part while it is still on the machine is advantageous from a time and cost perspective. If such a system could also produce a report detailing component features, size, deviation from tolerance and GT&D functionality, this would be of benefit too.

to sound and the machine to stop. Investigations into what has caused this deviation and subsequent actions can then be taken.

Timing

On machine verification can be a time consuming process.

Where many features are to be inspected on a component, a choice must be made between sacrificing cutting time on the machine tool and getting critical component information quickly.

Machine condition

By utilizing a machine mounted 3D touch trigger probe and suitable software, it is possible to achieve on machine part verification. However, before implementing such a program there is a serious technical issue which must be addressed to ensure the process is reliable.

The 3D touch trigger probe does not actually measure and relies on the integrity of the machine position data to calculate feature size, so the machine performance is paramount.

I often hear the very valid comment, “if I measure on the machine and the machine is wrong then my part is wrong and the probe data is too, but we wouldn’t know.”

Regular machine checking as part of a preventive maintenance program can highlight any machine positioning or axis issues before they negatively impact the part. Using analytical devices such as a laser interferometer and telescoping ballbar, axis information such as orthogonality, linear compensation, angular and straightness deviations, can be checked and corrected, ensuring the component is cut correctly and that when measured on the machine using a 3D touch trigger probe, the data obtained is reliable.

Artifact comparison

One additional tool we can use to check all is well with the machine and process is “artifact comparison.” This is an extremely simple technique where something of known size is mounted on the machine. This “something” could be a scrapped component, a ring gauge or datum sphere. What is vital is that the artifacts’ dimensions and machine position is known accurately and has been verified to a high degree of certainty on a device such as a CMM. During the on machine verification process, the artifact is measured and the feature size/position is compared to the known size/position stored in the machine controller. Any deviation outside of an acceptable threshold causes an alarm

Machine checking using analytical devices can highlight machine positioning or axis issues before they negatively impact the part.

Inspecting too many features (which do not have a critical effect on the process for this or future components) will result in too much time being used on the machine, reducing capacity for additional parts to be produced.

Inspecting too few features will result in critical problems remaining unidentified, and many of the corresponding benefits of detecting failures on the machine may be lost.

Solution

Select the critical features to be measured and reported, according to a set of criteria.

Features should be reported: • Where the failure of a feature would be indicative of a more serious process fault (e.g. the final feature machined with each tool).

• When the position or dimension of a feature is dependent on other measured features or ‘in process’ calculations. CM Philip Smith is technical sales manager with Renishaw (Canada) Ltd., Mississauga, ON. www.renishaw.com www.canadianmetalworking.com | february 2011 | 61

LASER CUTTING

FABRICATING

Flying with

LASERS

A Winnipeg bus manufacturer realizes big savings with new laser cutting machines

By Judy Waytiuk ...................................................................................................................................................

When New Flyer Industries purchased its first laser cutting machine in 1997, it didn’t take long for plant management to recognize that the technology would go a long way towards improving manufacturing efficiency.

“Not long after we had our first TRUMPF, we knew it was definitely the way to go in terms of safety, quality and technology,” says Scott Simpson, New Flyer’s primary operations superintendent. New Flyer has since purchased four more TRUMPF laser machines. “Our most recent piece of equipment was purchased in the last 12 months. It’ll process any of our flat sheet material requirements.”

The newest addition to New Flyer’s fabricating operation is the TruLaser 3030 NEW equipped with a 5 kW CO2 with TRUMPF’s LiftMaster Compact. The new laser features a long X axis with maintenance-free gearless torque motor. The Y and Z axes are driven by wear-free and oil-free linear motors, which increase simultaneous axis speeds from 3346 in./min to 5512 in./min.

From the start, the laser cutting technology proved its worth.

It immediately replaced the company’s plasma cutting process.

Simpson says the plasma unit “was older technology, with limited accuracy and flexibility; there was a grinding process that had to take place after the cutting and there was a lot of fumes emitted from it. We’ve removed all of that with the TRUMPF machines, which have low light emissions and a closed cab. It allows us to utilize that technology in terms of integrating it into the design of our products. The plasma technology didn’t have that capability. We can get pretty creative with the designs of our products. They can get complex, because it’s not difficult for the [laser] equipment to achieve that.”

compressed natural gas (CNG) heavy duty transit buses, with options for up to an additional 340 CNG buses.

Not bad for a bus builder that started out in Winnipeg back in 1930 as a little five-person outfit called Western Truck & Auto Body Builders Ltd.

MANUFACTURING INNOVATION

Today, New Flyer’s not just the leading bus manufacturer in North America, it’s the company that developed the first handicapped-accessible low-floor bus, the first energy efficient diesel-electric articulated bus, and, with its most recent energy efficiency innovation, the world’s largest zero emission hydrogen fuel cell fleet (the buses that rolled in Whistler during the 2010 Winter Olympics). Those babies belch out nothing but pure water vapour from their tailpipes, and you just can’t get more environmentally friendly than that.

A COMPETITIVE MARKETPLACE

Stacked up against four other transit bus building competitors in North America, Winnipeg-based New Flyer Industries Inc. boasts a hefty 37 per cent of the US and Canada’s transit bus market, with annual revenues of $1.1 billion in 2009.

The company rolls out more than three dozen shiny, stateof-the-art, environmentally oriented, spanking-new buses a week, with approximately 75 per cent of those vehicles destined for the US market. Clients include major cities like New York, which in 2010 ordered $216 million worth of public transportation in the form of up to 475 buses—135 40-ft

Scott Simpson shows some of the bus parts produced on the TRUMPF laser cutting machines.

Hybrid buses, zero emission electric trolleys, alternative fuel CNG and LNG buses, electric trolley buses, clean diesel buses: this company takes environmental issues very seriously.

It’s no wonder New Flyer picked up a 2009 First Place spot in the American Public Transportation Association’s (APTA) Annual AdWheel Awards competition for its Earth Day Awareness campaign. www.canadianmetalworking.com | FEBRUARY 2011 | 63

fabricating

LASER CUTTING

Taking a Flyer: The genealogy of a bus making giant

Perhaps 1930, the beginning of the Depression, was a less-than-auspicious time to be starting up a new company, but that didn’t stop Western Auto and Truck Body Ltd. from giving it a go—and the fledgling manufacturer not only survived, but grew through the same sort of innovation it shows today as New Flyer.

In 1941, the “Western Flyer,” the first coach with the engine inside the coach body (enabling extra seating inside the bus), was built.

In 1948, the company was renamed Western Flyer Coach after its popular new product, introduced the “Canuck” highway coach five years later, and then, with city transit buses a fastgrowing market, opened a new plant in southern Winnipeg in 1964. By 1971 the company had another name change to Flyer Industries Ltd. and a line of heavy-duty diesel transit buses and electric trolley buses. In 1986, Holland’s biggest bus manufacturer, Den Oudsten, B.V., bought Flyer, gave it another name—New Flyer Industries Ltd.—and developed the “low-floor” bus for the North American market.

Innovation continued to be a hallmark of the company, with development of articulated low-floor buses, hydrogen fuel cell powered buses, and features like programmable logic controlled electrical systems.

The company’s growth in the US, combined with new “Buy America legislation” sparked the founding of New Flyer of America in 1987, with a final assembly plant in California that was moved to Grand Forks, NK, in 1990, then closed in favour of a new, updated final assembly facility in Crookston, MN. A third assembly plant opened in St. Cloud, MN, in 1999, built to both manufacture complete buses and to handle final assembly operations of bus parts produced in Winnipeg.

But times were tough in the bus-making world and despite its sterling record of innovation and productivity, in 2002, a financially-struggling New Flyer was recapitalized and restructured under the KPS Special Situations Fund, a company that specializes in turnarounds, restructurings, bankruptcies, employee buyouts and other challenging financial situations.

Later that year, the company got a plum order for North America’s first fleet of 218 articulated hybrid buses, for King County Metro in Seattle, WA, pushing the bus maker to the front of the hybrid bus production pack. Over the next couple of years, New Flyer partnered with San Bernardino County in California to build the first gasoline-electric hybrid buses.

In 2004, the same year New Flyer delivered the world’s first hydrogen hybrid bus to California’s Sun Line Transit and Canada’s first hybrid bus to BC Transit in Kelowna, BC, and launched its electric trolley line with an order for buses for the Greater Vancouver Transportation Authority, New York-based equity firm Harvest Partners Inc. bought New Flyer Industries Ltd., and went public on the Toronto Stock Exchange.

Innovation and new developments just kept coming, with the world’s first fleet of hydrogen fuel cell buses showcased at the 2010 Winter Olympics in Whistler, BC, and New Flyer’s latest stunner, introduced in 2008—Xcelsior, a “best-in-class” vehicle with a 10 per cent weight reduction, upgraded styling, single-reduction axle, all-wheel disc brakes, better access to components, wider door and entry area, lower front step and improved ramp angle, better ride quality and visibility, and interior LED lighting. Brampton, ON, was the first to buy these buses,with 25 of them in the city’s new BRT service, branded “ZUM”, and orders for up to 389 Xcelsiors have been placed by New Haven, CT, Waterbury, CT, and Atlanta, GA. Xcelsior buses in 35-ft and 60-ft configurations are under development.

In 2010, New Flyer bought Elkhart, Indiana-based TCB Industries LLC, a designer and manufacturer of interior LED lighting systems, grab rails and seamless stanchions, drivers’ barriers and other bus parts.

Its capacity will be needed in future years, as this Canadian success story just keeps on rolling.

64 | february 2011 | www.canadianmetalworking.com

And, with its emphasis on new product development and manufacturing innovation and efficiency, and its commitment to industry leading practices like competitive compensation, training opportunities, employee involvement, and solid benefit and retirement programs, it’s also little wonder New Flyer, now an international organization with some 2,300 employees in its Winnipeg, MB, and Crookston and St. Cloud, MN, manufacturing and assembly facilities—all of them ISO 9001, ISO 14001 and OHSAS 18001 certified— was named one of Canada’s top 100 companies for the last six consecutive years. It was also named one of Canada’s Greenest Employers in 2008, 2009, and 2010, one of the Financial Post’s Ten Best Companies to Work For in 2008 and 2009, one of Canada’s Top Employers for Canadians Over 40 in 2010, and received the Winnipeg Chamber of Commerce 2010 Spirit of Winnipeg Award as well as the 2010 APTA AdWheel Award Grand Prize in the Electronic Media category, for its new intranet, iBus, an in-house communications tool for employees.

But while awards and corporate kudos are lovely to have and delightful to display, it’s in the marketplace and out on the public roads where a busbuilding company must prove its ground-level mettle, and New Flyer shines there as well. The company is the manufacturer of choice for 248 transit authorities around North America, among them 21 out of the 25 biggest transit authorities including New York, Chicago, and Philadelphia, and city fleets as small as Grand Forks, North Dakota and Los Alamos, New Mexico.

New Flyer’s management systems are geared toward continuous improvement in first-time product quality (early adapters need not worry about the useful shelf life of a brand-new prototypical New Flyer bus), on-time delivery, and keeping manufacturing costs trimmed as closely as possible while keeping up product performance and reliability. The company operates parts distribution centres out of Winnipeg, Erlanger, KY, and Fresno, CA.

LASER CUTTING

Winnipeg is the location for the main manufacturing of component parts, producing a significant amount of them for Flyer’s other Minnesota assembly plants in St. Cloud and Crookston to put together. Winnipeg also builds the shells for its Crookston facility to complete.

To be top dog in this industry requires top quality workmanship and efficient manufacturing flow. To help ensure those aspects, New Flyer obtains the best available equipment and technology. And environmental issues also matter here; from encouraging workers to carpool and having “satellite” recycling depots available, to keeping the shop floor clean and air quality high, New Flyer’s manufacturing processes echo their commitment to the development of ecologicallyconscious buses.

“We process carbon steel, stainless steel, and aluminum on our flat-sheet process equipment.

We have three TRUMPF flat sheet lasers, we have five press brakes, four of them Accurpress and one Cincinnati, and we do have a couple of Wiedemann CNC punches that we use to process vinyl-coated aluminum and other parts that have small stamped features,” notes Simpson. “On the tube side, we process that through two TRUMPF tube lasers, and we have some bending equipment.”

fabricating

The TRUMPF cutting machines, one of which is seen here, give New Flyer the ability to nest smaller parts with larger ones, minimizing scrap.

The company does have some CNC machines in its tooling departments, turning out jigs and fixtures in relatively small volumes, for the weld shop.

Other components—heating, cooling, and hydraulics, anything from carbon steel to stainless steel and copper— are processed through a number of saws and more assorted bending equipment.

On turn-around time, the TRUMPF lasers are much faster, he adds. And with the TRUMPF machines, they can nest smaller components in with larger ones and minimize scrap by fitting different shapes more efficiently onto the flat sheet. Without

www.canadianmetalworking.com | february 2011 | 65

fabricating

LASER CUTTING

grinding, repeatability is very good, and “we can reduce the tolerance on our component parts, because the repeatability is there,” Simpson observed. “Everything fits together better, too.”

The two newer TRUMPF flat-sheet lasers, joining the original workhorse bought in 1997, also enable a degree of automation.

“We can load multiple flat sheets,” Simpson noted. “We program that in advance, and the machine will run by itself. We quite often will do that over the weekend (lights-out operation).

When there’s nobody here, we just run a load. It gives us more capacity beyond our regular 40-hour work week, and it reduces the cost of our parts.”

Cost efficiencies have improved with the new lasers as well. “We try and utilize every square inch of the raw material to cut costs,” explains Simpson. With the TRUMPF LiftMaster Compact, the newest machine here and, as relatively new technology in Canada, the first one running in Western Canada, “we can load up all the raw material in the lower section, and a suction system will lift each sheet, and place it on one table, while the other table is in the process of cutting, so it’s virtually a non-stop process. The LiftMaster Compact will also take the finished components off and put them on the upper table, where we just remove the parts.” Much less human labour is required, it’s fast (the cycle time is just 55 seconds) and the equipment takes up a small footprint on the shop floor—the older Liftmaster New Flyer uses, while it offers many of the speed and efficiency advantages of the Compact version, does take up twice the amount of floor space as the new model.

Equipment like this has been “very popular in Europe” for years, Simpson notes.

The tube lasers allow labeling of each part, not just with part numbers, but with the revision level of each component, “so if we ever make any design changes to that component and the revision level changes, we can go back to our stock and identify in a fairly quick fashion what rev it is and whether we need to pull it off the floor.”

The technology in these machines that results in better precision and accuracy in machining parts also contributes to a superior final product, noted Simpson. “New Flyer is very flexible in terms of customer needs. We try and tailor to what the customer requirements are,” he said. “Our products are the leaders out there, and I would say the technology and equipment is an instrumental part of that.”

Manufacturing organization

Even more instrumental though, is how New Flyer runs its factories, and how it manages its employees to create a work environment that emphasizes safety, cleanliness and efficiency as well as constantly improving quality.

Its impressive collection of corporate kudos and awards shows New Flyer doesn’t just build top-notch buses; it’s built a top-drawer, rewarding work environment for employees.

The company operates under an Operational Excellence Program. “We have a 5S--sort products, set them in order, shine, standardize and sustain—it’s a lean principle and a value stream-mapping lean facility,” Simpson explains. “We make sure everything is clean and organized. Visually, if all our machines are clean and something should go wrong, like an oil leak, it’s visible right away. If we have a clean shop environment, issues will be visible and easy to address right away.” An Oracle-driven Materials Requirement System enables sorting and streaming within the manufacturing flow—especially important because of the variety of vehicles and parts this plant turns out.

66 | february 2011 | www.canadianmetalworking.com

Attention to everyday details matters: shadow boards are used for tools that bear colour codes to identify them as belonging to a specific work area; they help cut down on time wasted hunting for that particular wrench.

Communication flow contributes to efficiency as well. About a year ago, New Flyer re-organized its shop floor to split it into mini-business units called manufacturing cells and then created “cell pods”—open-cubicle, half-walled office areas right on the floor, where all of the support personnel designated for that cell are located right in the middle of the action. “The idea was to get all the support departments—manufacturing, engineering, quality, production, planning, all in one location so that communication is very close,” Simpson notes. “It’s really taken off.

People really see the benefit of it.”

The weld shop where bus components are welded togetther for assembly down the line.

The cell pods provide immediate access to the personnel that are there to support the workforce as they transform our product. Issues can be quickly dealt with and ideas to improve the operation can be implemented faster than before. It’s just a way of life for us now,” he added. “We’ve got everybody right in the area where the work happens.”

Ambient noise isn’t a distracting factor; for a componentmaking and assembly facility, it’s actually pretty quiet in many areas of the shop floor, and that’s where these pods are located, he explains.

Simpson adds “our efficiency has improved and our work environment is improved, so those definitely play a factor as well.” But all that doesn’t mean complacency. “We’re constantly looking at ways to improve our manufacturing facility; ways to improve quality and cut costs. Those types of things are looked at between the manufacturing group and the production team. Additional equipment is reviewed as demands require or as we have justification that would say this is the right thing. We’re constantly looking at that. We’ve made several capital investments over the last year and we’re continually reviewing opportunities.”

And with the innovative, environmentally-rigorous, public transportation products this industry leader produces, there will undoubtedly be plenty of opportunities down the road. CM Judy Waytiuk is a freelance writer based in Winnipeg, MB.

LASER CUTTING

fabricating

PRODUCT REPORT Bystronic

Bystronic’s BySprint Fiber 3015 is a high power fiber laser cutting machine based on the BySprint Pro platform and the concept ByVention Fiber laser machine. The BySprint Fiber 3015 marks the company’s first production series model of a laser cutting system that employs fiber laser technology.

Equipped with a 2 kW Fiber 2000 fiber laser, the BySprint Fiber 3015 is powerful enough to cut steel, stainless steel, aluminum, and non-ferrous metals, such as copper and brass, with high process reliability and precision. It offers what the company claims is unparalleled performance with thin metal sheets that range up to .160-in. thickness, and the laser source provides power enough to process sheet materials as thick as .500-in.

The laser beam is transported to the cutting head through a passive fiber, as opposed to the deflection mirror systems employed by carbon dioxide lasers. The result is lower operating and maintenance costs, in addition to significant energy savings as a result of using the Fiber 2000 laser source. The laser cutting system offers fast cutting speeds and a high degree of system flexibility that job shops require.

The cutting head is available in several configurations, with focal lengths of 100 mm and 150 mm. Both the laser source and the chiller are integrated into the equipment control console, eliminating the need for additional floor space. www.bystronicusa.com

Cincinnati Inc.

The Cincinnati CL-850 laser cutting centre makes fast work of thick and thin material with a powerful 5000 W GE Fanuc laser resonator, advanced cutting head, innovative optics and third-generation linear motor drive system. It delivers 1000 ipm cutting on 20 gauge steel, and up to 1.125 in. processing range on mild steel. The CL-850 is available in 5 x 10 in. (1.5 m x 3 m) and 6 x 12 ft. (2 m x 4 m) cutting table models, each featuring dual quick-change pallets.

Pallets move simultaneously, so changes take

just seconds and cutting is virtually continuous. Full guarding and a frame-mounted resonator save shop space over other lasers, claims the company.

The laser cutter’s third generation linear motor drive system makes fast work of large parts or batch processing of smaller parts, while delivering industry-best dynamic positioning accuracy of ±0.001 in. at high cutting speeds.

A next-generation cutting head system gives superior edge quality and comes standard with latest Autofocus head providing 5 in., 7.5 in. and 10 in. (127 mm, 190 mm and 254 mm) focal length lenses. The lenses allow the focus points to be instantly adjusted – especially between piercing and cutting–for optimal processing of various materials. Innovative optical features enhance part quality and improve productivity. An adaptive beam enhancer manipulates the size of the beam to improve piercing and cutting productivity.

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The new Cincinnati Modular Material Handling System (MMHS) boosts productivity of CL-800 series dual-pallet laser cutting systems, reducing cost per part and allowing unattended operation for up to three shifts via automated load/unload of raw materials and finished parts. www.e-ci.com

Hypertherm

Hypertherm has launched its new fiber laser cutting system that includes all components in one complete package.

Unlike products from many other fiber laser manufactures, Hypertherm’s HyIntensity Fiber Laser HFL015 system includes the power source, cutting head, gas supply, operator interface consoles, motion controls, and software.

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Sheet metalworking solutions

perfect solutions Flexible and productive manufacturing environments demand an integrated process solution. At LVD Strippit we have THE solution.

We look at the whole process from laser cutting to punching to bending, ensuring that all our machines work together to form an integrated process solution.

What ever your requirements are, we have the perfect solution for you.

To help your shop on the way to perfection call us at 800-828-1527. Perfect.

LASER CUTTING

FABRICATING

PRODUCT REPORT Hypertherm says this solutions-based approach will make it easier for partners and their customers to use laser cutting for their fine feature cutting requirements.

The system operates on familiar Hypertherm control platforms, with pre-developed cutting processes for simplified table integration and operation, as well as higher levels of efficiency, when compared to other laser cutting solutions. A single-emitter diode based design enables extremely reliable performance.

“Our fiber laser system is unique in that all of the components are engineered and designed to work together.

Cutting application specialists defined and validated all of the cutting parameters so our partners and their customers can easily use laser for a broad range of applications including marking, efficient processing of gauge and fractional materials, and fine feature cutting,” says Doug Shuda, Hypertherm’s fiber laser product manager.

Fiber laser offers several advantages over CO2 laser systems. It requires virtually no maintenance, is more energy efficient, and takes up less space. The power supply is much smaller than CO2, yet fiber delivery enables the beam to travel greater distances allowing for installation on larger tables.

Hypertherm’s introduction of a fiber laser system follows several years of intense research and development.

The company applied more than four decades of metal cutting expertise to develop a powerful system that builds upon Hypertherm’s existing plasma cutting system offerings. www.hypertherm.com

LVD Strippit

LVD Strippit’s Sirius 3015 Plus CO2 laser cutting system is an automation-ready flying optics laser cutting system with efficient processing of parts at optimal speeds and accelerations to suit the part geometry.

It offers reliable cutting performance at an affordable price-performance ratio, according to the company. Sirius is offered in a standard and a Plus model. The Sirius Plus is optimized with additional features and automation capabilities.

Sirius provides quick and precise positioning and consistently accurate laser processing. The combination of a dynamic machine with an excellent laser beam quality allows high speed laser cutting. Quick positioning is achieved with axis speeds up to 120 m/min.

The Sirius machine is designed with a modular construction, permitting the user to select the configuration that works best for the application and budget. As a standard unit, the laser cutting system features 3 m by 1.5 m integrated shuttle tables, which maximize uptime by allowing one table to be loaded while the machine is cutting on the other table. Table change time is 25 seconds.

Sirius Plus is engineered as automationready and can be expanded with the addition of various components to form an automated load/unload system. An optional compact tower system creates a productive, flexible manufacturing cell that can be operated “lights out.” The tower system, working in concert with the material handling unit, provides full capabilities for loading and unloading, and includes a shelving unit for storing raw material and finished parts.

Sirius is equipped with a laser cutting head that accommodates a 5 in. or 7.5 in.

(127 mm or 254 mm) quick-change lens for fast changeover and minimal set-up.The high pressure cutting head produces exceptionally clean cuts. A crash protection system protects the head from damage after collision with

the workpiece. A total power control feature automatically adjusts the laser power in relation to the cutting speed, ensuring an optimal cut at every contour width and minimizing the heat-affected zone. The machine’s edge function feature processes sharp corners cleanly, particularly in thicker materials.

The series employs the reliable Fanuc RF excited fast axial flow CO2 laser. Sirius is available with a powerful 2.5 kW or 4 kW CO2 laser.

The laser, CNC control, drives and motors are fully integrated, providing superior processing speed, high reliability, and low operating and maintenance costs.

The integrated Fanuc PC-based control provides perfect reproduction of programmed contours, producing acute angles at high speed. www.lvdgroup.com

Mazak Optonics

The Mazak STX RTC 2D laser system is designed to help job shops differentiate and diversify the services they provide.

This machine laser cuts thin to thick sheets of flat material, and also has an integrated rotary chuck to cut tubes and pipes, an extended Z height for cubic components, a standard tapping head and even chamfers, all on a single machine.

The rotary table cuts round pipe up to a maximum diameter of 14.76 in., (372 mm) and square tubes up to 6 in. (152 mm).

The large 16.14 in. (410 mm) range of Z travel enables you to laser cut preformed parts and other three dimensional shapes requiring greater cut height.

The STX Mark III RTC is available in 2,500 W (0.75 in. mild steel) or 4,000 W (1 in. mild steel) watt configurations and accepts up to a 5 ft x10 ft sheet of flat material. It can be delivered with a large range of automated material handling systems including Load/Unload Cells and Flexible Manufacturing Systems. www.mazakoptonics.com www.canadianmetalworking.com | FEBRUARY 2011 | 69

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LASER CUTTING

FABRICATING

PRODUCT REPORT MITSUBISHI LASER

The new higher wattage 4.5 kW resonator for 2D lasers from Mitsubishi Laser replaces the former standard 4.0 kW resonator. This power upgrade will increase output, keeping customers productive and profitable.

The Mitsubishi cross-flow resonator technology reduces rise time/fall time of square wave pulse. This enables more consistent beam power during the cutting process and delivers a more brilliant and consistent edge quality. Additionally, the uniform low current discharge provides low-power stability for improved micro-machining and etching.

The company’s patented three axis, crossflow resonator technology is simple, eliminating from its design the expensive quartz glass tubes and turbo blower systems. This simplification not only optimizes cutting power, it requires two to five times less maintenance than other designs, delivering the industry’s lowest cost of operation and ownership. www.misubishi-laser.com.

Prima

Prima North America has introduced the Laserdyne 430 multi-axis laser system.

The Laserdyne 430 is a three axis system designed for precision cutting, welding and drilling two and three dimensional components. The new laser

cutting system is available with a fourth rotary/circular axis option; a fifth tilt axis will be available this year.

The laser cutting system operates at speeds up to 800 in./min in the X, Y, Z axis (0-20 m/min) with bidirectional accuracy of 0.0005 in. (12.7 micrometer). This accuracy is throughout the system’s 600 x 400 x 500 mm work envelope, making it ideal for processing a broad range of components such as precision drilled fuel filters, electronic assemblies, and transition components at the highest rates with precision quality.

The unit features the company’s latest and most powerful system controller, the S94P. The laser cutting system includes the full complement of the company’s hardware/software features where required, with features such as BreakThrough Detection (BTD) and a patented Automatic Focus Control (AFC). www.prima-na.com

Salvagnini

The revolutionary Salvagnini LiXe fiber laser, acheived its first wide-spread reception at Fabtech 2009.

Based on Salvagnini’s proven L1X architecture, the L1Xe is a totally new kind of laser cutter for metal fabrication that reduces cost per part by 50 per cent. With only one mirror, no gas consumables, no turbine, no glass tubes and no moving parts - the L1Xe is a model of simplicity and efficiency. All made possible by the latest in fiber optic technology from IPG Photonics.

The L1Xe system is built for speed and performance: • 60-100 per cent faster than CO2 lasers • 70 per cent less power consumption • Cost per part reduced by 50 per cent • No laser gasses required • Virtually maintenance free • Able to process reflective materials such as brass and copper • Space efficient • Economical to buy and own www.salvagnini.com

TRUMPF

TRUMPF’s new generation of the TruLaser 3030 combines innovative technology and high laser power with a new design concept and optimized operation.

Now available with up to 6 kW of laser power and TRUMPF’s RotoLas tube cutting option, the TruLaser 3030 with the single head cutting strategy sets the standard for the future with features that increase productivity and flexibility when cutting sheet thicknesses up to1 in.

The machine’s long X axis works with a maintenance free gearless torque motor while Y and Z axes are driven by wear-free and oil-free linear motors, which increase the simultaneous axis speeds from 3346 in/ min to 5512 in/min (85 m/min to 140 m/ min). The FastLine process, now a standard feature, generates a flow transition between the piercing and cutting processes, which reduces processing times by an average of 20 per cent in thin sheet.

The result of the innovative technology found in the TruLaser 3030 is that a greater number of parts can now be cut in the same amount of time as before. Another result is that the power usage per part is reduced, making the TruLaser 3030 an excellent example of energy efficient productivity. The laser also contributes to the machine’s energy efficiency. When it is not cutting, the laser turns into an optimized standby mode until it is needed again. This leads to an energy savings of more than 10 kilowatts as soon as the machine is not in cutting mode.

The TruLaser 3030 also offers a high degree of flexibility during set up.

The pallet changer can be configured in the traditional format or in a transverse fashion, making the best use of space available on the shop floor. An advantage of the transverse position is that the operator has a view of the entire process form the control panel. The swivel-mounted control panel features a self-explanatory touch screen and a control system that is designed to meet the goal in as few clicks as possible. Also, all of the machine’s maintenance areas, including the broadened parallel conveyor belt, are made for easy access. www.us.trumpf.com www.canadianmetalworking.com | FEBRUARY 2011 | 71

With our nesting software there isn’t much left to talk about.

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10 TIG Problems

tig

welding

A visual troubleshooting guide to overcome common TIG welding issues

By Brent Williams . ................................................................................................................................................

Gas Tungsten Arc Welding (GTAW), or TIG, is often specified to meet strict aesthetic, structural, or code/standard requirements.

The TIG process is complex, and it is undisputedly the most difficult process to learn. This article contains photos and descriptions of common TIG mistakes and basic tips on how to prevent these errors from happening.

Figure 2A: Aluminum welded in DC with argon

Figure 1 – Poor Gas Coverage Leads to Contamination

The weld here shows contamination caused by lack of shielding gas, which can happen when the shielding gas is not turned on, there is either too little or too much gas shielding, or the gas shielding is blown away.

To troubleshoot gas contamination issues, first check the gas cylinder label to be sure you’re using the right type of gas for TIG welding, generally 100 percent argon (or perhaps an argon/helium blend for thick aluminum). Attempting to weld with an AR/CO2 mix (used for MIG welding) will cause immediate contamination.

Next, set the proper gas flow rate, which should be 15 to 20 cubic feet per hour (cfh). Welders commonly—and incorrectly—assume that a higher gas flow/pressure provides greater protection. In fact, excessive gas flow creates turbulence and swirling currents that pull in unwanted airborne contaminants (and it can cause arc wandering). Generally, err on the lower side of recommended shielding gas rates to ensure proper shielding coverage without turbulence.

Figure 1: Poor gas coverage leads to contamination

Third, check all the fittings and hoses for leaks. Any breach may pull air into the shielding gas stream, which can cause the weld to be contaminated (and you’ll waste money if gas escapes). Rub soapy water over the hose and all fittings.

If bubbles form, you have a leak and need to replace the defective components.

Finally, assuming you have a full cylinder, the right type of gas and no leaks, consider that you may have a tank contaminated with moisture. Shielding gas cylinder contamination does not happen frequently, but it is possible. Check with your gas supplier to resolve this issue.

Figure 2A-2D – Welding Aluminum in the Wrong Polarity/ Adjusting Balance

This TIG weld (Figure 2A) was created with the machine’s polarity set on direct current electrode negative (DCEN). As you can

Figure 2B: Ideal aluminum weld

Figure 2C: AC balance set too high

Figure 2D: Balled tungsten

see, the weld did not break through the aluminum oxide layer.

This created a weld where the filler metal mixed in with the partially melted oxide and created the contaminated bead seen here. To defeat this, always TIG weld aluminum with the polarity set to alternating current (AC).

TIG welding in AC (Figure 2B) allows the electrode positive (EP) portion of the cycle to blast away the aluminum oxide while the electrode negative (EN) portion melts the base metal. A feature called AC balance control allows operators to tailor the EP to EN ratio. If you notice a brownish oxidation and or flakes that look like black pepper in your weld puddle (Figure 2C), increase the cleaning action. However, note that too much EP causes the tungsten to ball excessively (Figure 2D) and provides too much etching. Lastly, when TIG welding aluminum, do not start welding until the puddle has the appearance of a shiny dot. This indicates that the oxide has been removed and it is safe to add filler and move forward. Adding filler to the weld zone before the oxide layer is adequately removed will result in contamination.

Figures 2B and 3 – Weld Graininess

Figure 2B shows the way an aluminum TIG bead should look.

Figure 3 (see page 74) shows a bead with a grainy appearance, which is typically caused by filler metal problems. For instance, a 4043 aluminum filler rod from one manufacturer may have different properties than a 4043 rod from another www.canadianmetalworking.com | february 2011 | 73

welding Figure 3: Grainy aluminum weld

tig Figure 4: Lack of fusion in the root

Prior to welding, always check the filler metal type and remove all grease, oil and moisture from the surface to prevent contamination.

Figure 4 – Lack of Fusion in the Root

manufacturer. The welder (if the application permits) may need to adjust filler brand accordingly. The rod may also be defective (too much of a certain ingredient). The welder may even have the wrong type of filler rod, such as 4043 filler instead of 5356 filler.

Lack of fusion at the root of a T-joint or a fillet weld can be caused by a number of factors: improper fit-up, holding the torch too far away from the joint (increasing arc length) and improperly feeding the filler rod, to name a few. This issue may be seen more often with a transformer-based machine, as the arc tends to wander between the two sides of the joint as it seeks the path of least resistance. In this case, reducing arc length will provide better directional control and help increase penetration. It is also important not to under-fill the joint or weld too quickly.

Note that inverter-based machines (especially those with an advanced output controls such as adjustable frequency and pulsing controls) offer more control over the arc. These controls create a narrower, more focused arc cone that provides better directional control over the weld puddle and deeper penetration (and often at increased travel speeds).

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Figure 5A: Poorly filled weld craters

Figure 5B: Weld crater filled

Figure 5A and 5B – Craters

Craters, such as the one shown in Figure 5A, typically occur at the end of the weld, and they often lead to cracking. Causes include instantly reducing the welding power (which causes the puddle to cool too quickly) and removing the filler rod too quickly at the end of the weld. You can easily fix crater cracking issues by continuing to feed filler rod while slowly reducing current at the end of a weld.

Note that some TIG welders feature a “crater control” function that automatically reduces the current at the end of a weld. The result is a good-looking weld bead, as seen in Figure 5B.

Figure 6A through 6D – Dirty Base and/or Filler Metal

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On day one of welding school, your instructor should have taught you to clean materials prior to welding. Figure 6A (see page 76) shows what happens when you don’t clean the mill scale off of hot-rolled mild steel. All base and filler metals need to be cleaned, whether

74 | february 2011 | www.canadianmetalworking.com American Torch Tip.indd 1

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welding

tig

Figure 6A: Uncleaned steel weld

Figure 6B: Clean steel weld

Figure 6C: Uncleaned chrome-moly

Figure 6D: Cleaned chrome-moly

it’s mill scale, oxide on aluminum, or dirt and grease on filler metals. Grind, brush and wipe away all potential contaminants.

For cleaning aluminum, dedicate a stainless steel brush to the task to prevent contamination from other metals.

Figure 6B shows what happens when a weld on mild steel has been properly cleaned before welding. Figure 6C shows a weld made on chrome-moly tubing that has not been cleaned, hile 6D shows a weld made that has been cleaned prior to welding.

Figure 7A and 7B – Poor Colour on Stainless

Figure 7A: Poor colour on stainless steel

Figure 7B: Good colour on stainless steel

76 | february 2011 | www.canadianmetalworking.com

Figure 7A shows discoloration on a stainless steel weld caused by overheating, which not only affects a material’s colour, but degrades its corrosion resistance and mechanical properties as well. Unfortunately, once this error is made, there is nothing that can be done to fix it except for scrapping the part and starting over. To prevent overheating, reduce amperage, slightly increase travel speed or shorten the arc length. If your welding equipment features pulsing capabilities, learn how to use them. Pulsing reduces heat input, and it offers excellent control of the weld puddle. Figure 7B shows proper coloration of stainless.

tig

Figure 8: Sugaring on stainless steel

welding

Figure 9: Excessive amperage/heat input

Figure 8 – Sugaring on Stainless

Figure 8 shows sugaring on the backside of a stainless steel weld. Sugaring (oxidation) occurs around the weld when it is exposed to oxygen in the air. The best way to prevent this is to back purge the weld with argon shielding gas or reduce welding amperage.

Figure 9 – Too Much Amperage on Aluminum

Figure 9A shows what a weld bead looks like on aluminum with the amperage set too high. This creates a wider profile, an illdefined bead and can potentially lead to burn-through. To solve this problem, reduce amperage and/or increase travel speed.

Reference back to Figure 2B to identify an ideal weld.

Figure 10 – Proper Arc Length Control

The color change in the middle of this aluminum weld bead (Figure 10) resulted from an increase in arc length (arc length, the distance between the electrode and the base metal,

Figure 10: Change in arc length

determines TIG welding voltage). Holding too long of an arc increases overall heat input, increases the potential for distortion, widens the weld bead while decreasing penetration and affects weld bead appearance. Practice holding a consistent arc length to improve heat input control and improve weld bead quality.

Brent Williams is the manager of TIG solutions for Miller Electric Mfg. Co., Appleton, WI. www.millerwelds.com

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Back To Basics Troubleshooting pointers from industry experts on common powder spray gun problems

By Pierrre Bachand ...............................................................................................................................................

The well-known definition of insanity, “doing the same thing over and over again and expecting different results,” (often incorrectly attributed to Albert Einstein; the current concensus is that it came from Rita Mae Brown, in her 1983 book Sudden Death) may be an apt description for what many powder coating specialists think when customers ask for assistance to correct problems in their powder coating line. That’s because the problems—and the source of those problems---are almost always the same.

Overspray approached several experts in the powder coating equipment field to find out what are the top problems they see over and over again and how finishers can overcome such problems. The experts were asked “what do you consider to be the main problems in the powder coating industry?”

The Experts

The industry specialists who participated in our mini survey were: •A ndré Cyr, finishing systems specialist, Nordson Canada •A lain Tousignan, senior field engineer, Finishing Equipment Group, Nordson Canada •B rian Brent, co-owner, Annadale Finishing Systems (Wagner distributor in Ontario) •P ierre Proulx, owner, Gestion Pierre Proulx (Wagner distributor in Quebec) • Greg Taylor, sales manager, Canada, ITW Gema •C laude Baribeau, sales manager ECE Canada (Gema distributor) •V al Barone, owner, Powder Coating Supply (Eurotech distributor) •R .T. Rajan, vice president, Exel Industrial Canada (Sames) • Michel Brissolin, sales manager, Quebec, Exel Industrial Canada

Top problems

According to our experts, the top reoccurring powder spray gun problems they see in powder finishing operations is lack of maintenance (specifically they cite poor grounding because of dirty hooks, poor air quality and poor maintenance of venturi pumps), lack of training and knowledge (again, specifically experts cite not knowing correct fluidization basics, not adjusting for proper flow, poor knowledge about colur change and poor control of powder coating thicknesses). Other key 78 | february 2011 | www.canadianmetalworking.com

problems they identified included using old powder, mechanical failures, and incorrect oven temperatures for curing.

Lack of maintenance

The prime example of lack of maintenance is poor grounding, accounting for 30 per cent of all calls to technicians/sales personnel for assistance.

What happens when you have poor grounding of parts? The smaller the part the more evident is the effect. As the part that is in the ion bombardment field gets charged with powder and air ions seeking ground, the high density areas (corner, edges) get charged to the point where they actually repel the paint.

Powder paint, as we all know, is an insulator or it could not retain the charge. Furthermore, similar charges repel each other.

As the hooks get dirty, orange peel will increase and eventually starring or KV rejection will damage the finish.

“ Poor grounding accounts for 30 per cent of all calls made to technicians and sales personnel for assistance.”

For the larger parts (total surface area) the effect may be initially more difficult to observe due to the ¨static bleed¨ from the part into the air stream, but the lower transfer efficiency is always there.

More difficult geometry parts (inside corners) become virtually impossible to coat. Powder consumption, especially in ¨shoot to waste¨ operations, increases rapidly. When the paint is recycled there is an increase in recycled fines (small sized powder particles) in the cartridge collector system and wasted paint in cyclonic separator units. Increase in fines in the recycled paint make fluidization increasingly difficult.

Certain paints will be affected adversely by the situation: textured, veined, and metallic finishes (specially metallic blends versus bonded powders) will vary from the standard. In certain conditions there may be “pinholing.” Sometimes “spiking” or sanding paper finish can be observed with some metallic finishes. Often “marring” of metallic finishes is caused by this.

Let us not forget the electrical shocks the operator may suffer

MANUAL SPRAY GUNS

PRODUCT REPORT when he gets too close to the part and, in extreme cases, the shutdown of the booth by the UV or UV/IR detectors.

Remember, poor grounding always means higher costs and lower quality.

Other areas where lack of maintenance cause problems include poor quality compressed air. The cause can be poor fluidization of the powder, blocking/ blinding of the cartridge powder filters, or reduced static charge to the powder.

I have seen a couple of situations where the water flooded the control units and was sprayed from the powder pumps into the powder flow. When the powder gets sufficiently wet the gun shorts out and there is no longer any static charge.

The charge tracks from the front of the applicator to the ground on the handle; it’s like putting the electrode directly on a grounded part.

These situations cause a lot of downtime, loss of productiona and costs for repairs: What do you do with wet cartridge filters?

What about lack of maintenance/ supervision of the pretreatment?

Unclean or poorly cleaned parts will create fish eyes, poor or disastrous salt spray results, and poor adhesion, to name a few problems. There is no profit possible when you have to strip parts and recoat them.

Eventually poor maintenance means lower sales of your product, loss of your customer and increase in costs. It always means less money for you and your company.

In one of my training seminars I make note of the “three Cs of success” in powder coating: cleanliness, cleanliness, cleanliness.

LACK OF KNOWLEDGE/TRAINING

A couple of years ago a client asked me to put together a short training seminar for his employees. The company runs a medium size conveyor type manual custom coating business. All the painting is ¨shoot to waste.¨ Before putting the course together I decided to have lunch with the paint/plant manager, who I did not know. I asked him about 50 questions related to powder painting. The questions were all pretty basic, ranging from pretreatment chemicals to oven performance/temperatures, racking, powder types, application and reclaim equipment and maintenance; what you should know to run a paint production

Binks

Binks PitBull Airless Spray Guns are ergonomically designed with a lightweight forged aluminum body shaped to fit an operator’s hand and fingers. A new patent pending tungsten carbide fluid valve eliminates the traditional needle/ spring design, reducing spitting and reducing the gun’s required trigger pull pressure. Operators get more comfort, control and leverage with a lighter touch.

The result? More productive finishing operations, less hand fatigue and less risk of RSI. In addition to its ergonomic design, the “no needle” Binks Pitbull is said to offer better overall performance, require less maintenance and last twice as long as ordinary airless spray guns. Available in four finger and two finger models in 3500 psi and 7500 psi sizes, the Binks Pitbull also features a built-in long-life filter with 20 per cent more surface area. www.binks.com

guns is better than other brands we tried –they fit in the hand well and they’re better balanced. This is less tiresome for painters and leads to a better finish.”

Built to provide proven DeVilbiss quality atomization with all types of solvents and waterborne materials, the Compact Series is offered in Trans-Tech or HVLP technology versions. www.devilbiss.com

Gema

With ITW Gema’s OptiFlex Series, finishers have all they’ll need to power up productivity, right in the palm of their hands, claims the company. From the OptiSelect Gun to the OptiStar Control Unit and OptiFlow Pump, every component of the system is designed for reliability, convenience, and performance.

100,000 volts of FirstPass Power

DeVilbiss

DeVilbiss Compact Manual Performance Series spray guns are designed to be hand sized, yet offer the comfort and versatility of full size spray guns. They are offered in both standard and mini sizes, and with a number of operational and technology options. Ergonomic features include a unique curved handle design with increased finger space, and an operator-friendly trigger shape for improved comfort. A sensitive fan control provides pattern adjustment needed for fine atomization finishing and touch up.

Jack Louie of Esterline Hytek, an aerospace finishing facility in Kent, WA, reports “the weight distribution of these www.canadianmetalworking.com | FEBRUARY 2011 | 79

MANUAL SPRAY GUNS

PRODUCT REPORT line. He scored less than 20 per cent.

Eventually the training was given, and employees were eager to learn and participated actively. The manager also attended the training and applied much of the information learned in the following months.

Before the training, the company operated its finishing shop by trial and error; after training, it used method and reasoning.

This is typically the type of company that puts a heavy burden on its paint and equipment suppliers. It may become a victim of the “it’s a powder problem¨ or “it’s an equipment problem¨ when issues appear. If the problem disappears the company is no better off because of its poor diagnostic knowledge.

Some companies invest in personnel training every year. One such company is a major heating equipment manufacturer I have been dealing with for many years.

Personnel training is part of the company philosophy. The company has learned that knowledge is power. It developed the knowledge base to solve problems and reduce production losses. The manufacturer has increased its power, skill and capacity to better select finishes and equipment.

The benefits of knowledge based personnel are too numerous to list.

One simple example is when an employee is absent or leaves the company, the firm is never vulnerable; someone else is trained for the job. This company spends time on improving and maximizing production instead of reacting with panic.

There is a large source of technical literature and training available to companies. I encourage everyone to read technical articles, attend seminars, take additional training and always pick the brain of the knowledge people who call on you.

A knowledge-based company will always perform better. CM Pierre Bachand is president of Chromatech Inc., a finishing training and consulting firm based in Quebec, and a regular contributor to Overspray.

gives finishers the ability to coat parts right the first time, every time. OptiFlex “smart” technology stores application settings for easy recall in any coating scenario.

Quick, easy-to-learn procedures reduce training needed to turn operators into manual powder coating experts. “On-gun” remote controls adjust coating mode and powder delivery without requiring operators to turn away from their work.

OptiStar Advanced Control Unit provides total control flexibility, giving operators a choice between 20 custom programs and three preprogrammed settings. Patented Digital Valve Control (DVC), automatically and precisely adjusts all air required for powder coating.

Finishers can choose Fluidizer, Box or Stirrer units. www.itwgema.us

Nordson

Nordson Corp. has introduced a cup gun kit for its Encore manual powder spray gun, providing users with the ability to achieve full scale production results in laboratory and field test trials of various powder formulations and colours.

In its cup gun configuration, the Encore manual gun achieves the transfer efficiency, part coverage and cured finish results matching that of a production Encore system spraying from a more typical capacity hopper or vibratory box feeder.

Designed for efficient, small scale testing with results that correlate to production coating operations, the cup gun kit is ideal for evaluating new powder formulation types and colours by powder manufacturers and end users.

80 | FEBRUARY 2011 | www.canadianmetalworking.com

The kit’s “optimum powder test” capacity along with its plug-and-play design complement the gun’s other features and performance benefits, allowing operators to focus solely on the coating task.

Features and benefits: • Patent pending On-Gun controls and display.

• 20 user-programmable electrostatic and pneumatic presets.

• Patented Select Charge technology.

• One-hand powder flow adjustment or preset selection.

• Highest first-pass transfer efficiency.

• Through-the-handle purge cleaning.

The cup gun kit itself also features: • Encore inline pump, a 14-ounce capacity cup.

• Easy clean-up for fast powder changeover.

• Optional cups with lids for powder storage for even faster changeover or subsequent testing. www.nordson.com/en-ca

Wagner

The Wagner Prima-Sprint manual powder coating unit offers users flexibility, performance and ease of operation. The new control unit provides up to 50 recipes with precise settings for voltage, current, curve characteristic and powder delivery.

The curve characteristic allows operators the flexibility to dial in application performance regardless of powder coating material or substrate. The operator will also benefit from the dual trigger that allows toggling back and forth between two different recipes. The user friendly controller allows for easy adjustment of powder delivery. The Wagner Prima-Sprint uses an improved PEM-C4 ERGO manual powder gun. As with all Wagner equipment, the new controller and powder gun are compatible with any previous generation of application equipment. www.wagnersystemsinc.com

STRIPPING

The Naked Truth Can you achieve cost savings with green stripping technologies?

By Fred Mueller ............................................

It doesn’t matter what technique you use, stripping paint is hard and costly work. One of the oldest methods of stripping paint is to use heat. I remember using a blowtorch to literally bubble/soften the paint so that it could be scraped off the surface. Using sharp edged tools and/or sandpaper (mechanical stripping) is not only the most labour intensive technique but it won’t make Pratt Whitney Canada or any other aerospace customer happy.

Enter chemical paint strippers and environmental friendly chemical paint strippers. We’d all be environmentally conscious if it didn’t cost more money.

Right? So, is there an economic upside to the environmental friendly paint strippers?

All chemical paint strippers are formulated with a variety of chemical compounds to strip and clean the base surfaces. They’re formulated to do a combination of things at the same time.

PAINT STRIPPER COMPONENTS

Depending on the type of coating being stripped, different co-solvents are added to boost the solvency of the primary ingredient. These co-solvents differ according to the target paint type Activators increase the penetration rate by disrupting the molecular bonds within the paint film helping to weaken it.

Surfactants help by making the stripper wetter and increasing the stripper’s surface penetrating power. Anionic surfactants are used in acidic stripper formulae and cationic or nonionic are used in alkaline stripper formulas. Paint strippers that contain surfactants make the best brush cleaners.

Thickeners are used to make a gel of the liquid paint stripper. These types of formulae help the mixture adhere to vertical and “ceiling” surfaces and reduce the evaporation rate of the solvents, which dramatically prolongs the time the solvents can work at penetrating the paint.

Corrosion inhibitors protect the

Samples of paint stripping work conducted by Canadian firm Molecular-Tech.

Images: Molecular-Tech Coatings Inc.

www.canadianmetalworking.com | FEBRUARY 2011 | 81

STRIPPING

Environmentally friendly green paint strippers are not only effective but safer for workers involved in the process.

underlying substrate and the “tin can” the paint stripper comes in from by neutralizing acids that form from the decomposition products created as the stripper ages.

Chelating agents are used to suppress/”remove” metal ions present in the stripping solution from the stripper solution/stripping reaction. Loose metal ions could reduce the efficiency of the stripper’s components and could contribute to surface stains.

Colourants are often added to make the paint stripper stand out from the competitors. But this marketing ploy has a practical up-side for the customer as it makes it easier to see where the paint stripper has been applied.

GREEN PAINT STRIPPERS

The new friendly strippers work differently. With the old strippers the molecules of the stripper enter the pores of the coating all the way down to the intersection of the coating with the base. This causes the coating to swell and, together with the chemical weakening of the coating’s adhesion to the substrate, the stripper degrades/breaks down the coating. In other words, the older stripper formulations do more swelling than surface bond weakening and will generate small paint flakes together with more solvent waste.

The newer environmental friendly strippers will aggressively go after the surface bond which generates larger sheets of paint and less hazardous waste.

82 | FEBRUARY 2011 | www.canadianmetalworking.com

With environmentally friendly paint strippers it’s what’s not in the formula that matters. As a rule, solvents in these formulations are not as highly flammable as older generations of solvents like methylene chloride. Many of the environmentally friendly strippers have a mild smell but don’t be fooled into thinking that you can use one without proper ventilation. Using the proper ventilation and personal protective equipment (PPE) is important with any mechanical or chemical stripper.

All successful new and old formulations specific for your paint type and substrate can strip without damaging/interacting with the surface material while leaving the surface in a semi re-paintable condition.

Now that you have time invested in exposing the substrate to be repainted, don’t rush it. Cleaning the substrate is the final step and another area of cost. Depending on the paint formulation, the chemical make-up of the substrate and the paint stripper solution type, with the old strippers you may have to clean the substrate by wiping the surface with a suitable solvent, such as turpentine or mineral spirits. Green strippers require only water to clean up the substrate.

CASE STUDIES

Outside tanks at the Brookhaven National Laboratory’s RHIC (Realativistic Heavy Ion Collider) facility in Upton, NY, needed to be repainted. Research into the costs of conventional paint stripping found it to be economically impractical. One of the

STRIPPING

supervisors for plant engineering had read about a proprietary hydrogen peroxide stripper distributed by PPG and thought it was worth a try.

The process involved spraying on a proprietary hydrogen peroxide mixture, waiting 12-24 hours, then using a broom or squeegee to wipe off the peeling paint layers, and then power washing to remove any lingering paint flakes.

The use of the hydrogen peroxide paint stripper is estimated to have saved BNL in excess of $100,000 and at least 50 per cent of labour and waste disposal costs.

Molecular-Tech Coatings Inc., Maple Ridge, BC, has developed a new general environmentally friendly paint stripper that works without the usual suspects (solvents). The formulation contains no methylene chloride, no formic acid, nor carbonic acid, and no N-MP (N methyl Pyrolidone).

The ingredients used in this formulation comply with the US EPA rules on emissions. It’s non toxic and safe enough to ship with UPS, Fed-X and Canada Post.

Pat Thiphavong, co-owner of Molecular-Tech, says “the product is very economical because you use less of the product to strip more paint.”

And since the paint stripper is not as volatile compared to the old strippers,

less does more stripping.

“The lower toxicity of today’s paints together with the non toxic paint strippers make it (after testing) possible to landfill the waste products, adding that these strippers “are easier on the employee who’s applying the stripper and removing the paint because they need less personal protective equipment.”

Thiphavong says because worker safety is so important, more and more regulatory bodies across North America are banning methylene chloride-containing paint strippers. “When you look at the results from workers in automotive body shops’ blood tests, well it can be pretty scary, even with the proper PPE.” So in answer to the question, “can you achieve cost savings with green stripping technologies, the answer is yes.

The advantages to going green— lower VOCs, less PPE, safer products for shipping, reduced disposal costs—are good reasons for your company and your employees. CM Fred Muller is a finishing expert and corporate quality and safety manager with General Magnaplate Corp., Linden, NJ. Images: Molecular-Tech Coatings Inc.

In addition to being safer to use, you use less of Molecular-Tech’s new product to remove more paint.

ADVERTISERS INDEX ADVERTISER PAGE American Torch Tip 74 Bohler - Uddeholm Corp 30 Canadian Metalworking 17, 44 CMTS Show Ad 22 CWB 76 Elliott Matsuura 4 Emuge Corp 13 ESAB Canada 20 Ferric Machinery 70 Future of Metal Cutting 21 Future of Fabricating 77 Subscriptions 5 Haas Automation 11 Hardinge Group 34 Heinman Machinery Ltd 42 Horn USA Inc 7 HSBC 60 Hurco Machine Tool 2 Ingersoll Cutting Tools 52 Iscar Tools Inc 86 Kennametal 54 68 LVD Strippit Maclean’s 75 Makino 35 Mate Precision Tooling 67 Method Machine Tools 26 Mori Seiki 40 OSG Canada Ltd. 51 PCT Carbide/TNT 56 Reid Tool Supply Company 58 Renishaw Canada Ltd 15 Sandvik Coromant Cover Flap, 46 Schunk Intec Corp 28 Scientific Cutting Tools 49 Scotchman Industries Inc 65 SigmaTek 72 SMD Machinery 14 Sumitomo Electric 9 Toyoda/Elliott Matsuura 38 Trumpf Inc 62 Tungaloy Canada Ltd 3 Walter USA Inc 59 WIDIA Brand Migration 32 8CMM20186 01/07/2008 08:19 AM WMTS Weld Expo 85 YG-1 48

IN STOCK American Standards and specials.

Japanese Standards inch or metric.

FOR FAST DELIVERY: Contact your local tooling dealer or order direct.

TEL 937-686-6405 FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O. Box 61 Bellefontaine, OH 43311 www.canadianmetalworking.com | FEBRUARY 2011 | 83

Page

Metal...Works Managing Cash Flow If your company has cash flow issues, consider factoring or invoice discounting

By Mark Borkowski .........................................................................................................................................................

A familiar but difficult scenario unfolds. You are the owner or CFO of a growing company. Sales are up 20 per cent over last year.

Success is causing stress. You need a source for some quick capital to keep the company on track. Business is booming, but you are experiencing a cash flow crunch. A cheque expected from your largest customer has not arrived and your payroll is due tomorrow.

The phone rings and your call display tells you your key supplier is phoning you for the third time this week. You know what he wants, so you avoid speaking with him. Your banking facility and your charge cards are maxed out. You might also be at the other end of the spectrum. Your business is on the downside. No matter. You are in the same mess. What do you do?

When timing and access to working capital are critical, invoice discounting (also known as factoring) is a practical alternative to traditional methods of financing.

WHAT REALLY IS FACTORING?

Factoring involves purchasing businessto-business (commercial) invoices at a discount. Factors “buy” and the client “sell” invoices. Clients are advanced funds on invoices due from creditworthy customers/account debtors, and advances range from 75 to 90 per cent. There are two types of factoring products available: recourse and non-recourse.

Why use invoice discounting?

We are living in volatile economic times and traditional lenders are reducing their exposures. A slow motion credit crunch is underway. Banks are tightening their credit standards in the face of problem loans and declining credit quality. Small to medium size enterprises (SMEs) are most vulnerable to reductions or withdrawal of operating facilities for working capital under this scenario.

Invoice discounters provide more funds or availability than traditional lenders, and a regular and predictable cash flow, as and when required.

Factors often provide advances by working behind the bank as a source of secondary working capital.

Factors can improve banking relationships, as clients can remain in covenant and in margin.

Invoice discounting facilities are higher because they are linked to sales and not to rigid balance sheet criteria. Decision-makers within factoring companies better understand your business and the variables 84 | FEBRUARY 2011 | www.canadianmetalworking.com

affecting your normal course of business, including seasonality issues. Factors inherently offer a more favourable assessment of risk. There is reliance upon the quality of the product or service rendered and the credit quality and standing of the customer to repay advances, not the strength of the client’s balance sheet.

Quality of accounts receivable (A/R) is the common denominator, not equity base, liquidity, and cash flow. Customer credit limits are established on a pre-screened basis, allowing clients to stay away from potential problem accounts.

“When timing and access to capital

are critical, invoice discounting is an alternative to traditional financing.”

Factors have a proven history of leveraging assets leading to accelerating sales growth and greater profits, which offset invoice discounting costs. This allows you to promote your business with confidence. Opportunities to do more business are not lost to competitors.

Invoice discounting terms and conditions vary, but generally speaking the following practices apply: •Proposals/term sheets can be issued to potential clients in as little as two days upon receipt of the required information.

•Invoice discounting fees vary from 2 to 5 per cent (or more) for each 30 days; calculated on the gross sale value.

•No minimum term (length of time) contract is required; this means that a client can work on a “spot” or “as needed” basis.

•Notification: Customers are aware of the invoice discounter’s involvement; customers agree to send their payments directly to the invoice discounter.

Whatever the source of capital, the banks have been very difficult on all companies. Wise executives need to consider all of their financing options. CM Mark Borkowski is president of Mercantile Mergers & Acquisitions Corp., Toronto. www.mercantilemergersacquisitions.com

Teeth like these need a different kind of dentist One that understands the importance of consistent quality and accuracy in performance.

One that can deliver productivity and cost efficiency, who works closely together with you to optimize tooling solutions.

One that puts focus on good after service with frequent check ups and support with discussions for development.

One that wears a yellow coat.

If gear milling is your business call us today.

Contact 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.

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Get prepared and equip yourself with the tools to succeed; • See the latest new products and technologies • Meet industry experts • Watch live demonstrations of the latest machine tools, automation technologies and production methods • Mingle with your peers It’s your industry. Celebrate it. Make your plans to attend or exhibit today

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