Canadian Metalworking

June 2011 • www.canadianmetalworking.com

Job Shops

ROAD TRIP Cross-country look at the backbone of the manufacturing industry

31 Machine tools

Smart investment for Ontario mould shop

45 Cutting Tools

R oundtable discussion on grooving

61 Fabricating

Flexible manufacturing in Edmonton

70 Welding

Advantages of modular fixturing

Inside this issue...

Volume 106 | Number 4 | June 2011 | www.canadianmetalworking.com

INDUSTRY REPORT

FABRICATING

JOB SHOPS

PLASMA cutting

road trip........................................21

BATTLE OF THE GASES.......................55

A cross-country look at manufacturing’s backbone.

Can plasma replace its older sibling oxyfuel or is there room for both?

BENDING/case study

BUSINESS REPORT

WORLD-CLASS FABRICATING.............61

SKILLS TRAINING

THE YOUTH GAP..............................28 Manufacturing industry faces a challenge attracting the next generation.

Leading edge technology gives Alberta fabricator a competitive leg up.

WELDING POSITIONING & FIXTURING

MACHINE TOOLS

31

A FIX ON FIXTURING.........................70

EDMs/CASE STUDY

SMART INVESTMENT.........................31 Redoe Mold builds detailed ROI calculations to find the true value of its investments.

CUTTING TOOLS

Modular fixturing can add flexibility and process improvement to your welding operations.

OVERSPRAY POWDER FINISHING

TECH TIPS FOR BETTER TE................... 74

TURNING

NEW TURN FOR SPINNING..............39 What if you could take the “spinning” of a typical milling tool and combine it with the advantages of a fixed turning tool?

Improve transfer efficiency to optimize your powder finishing process and cut costs.

GROOVING TALKS........................... 45 A discussion with industry experts on key factors that can impact grooving tool performance.

39

MASKING

A PLACE TO HIDE......... 77

GROOVING

52

Examining the latest developments in masking techniques.

DEPARTMENTS

QUALITY CERTIFICATION

GETTING CERTIFIED...........................52

No formal degree program exists in Canada, but there are options to become a certified quality engineer.

Upfront................................................... 6 News..................................................... 8 Floor Space.......................................... 18 Calendar.............................................. 18 Metal…Works....................................... 80

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6 | june 2011 | www.canadianmetalworking.com

Upfront Is Green Just a Dream?

It’s difficult to argue against the green energy movement. Who doesn’t want to improve the environment and create a cleaner, healthier tomorrow for future generations?

The green energy movement promises cleaner technologies that don’t generate toxic waste or consume finite natural resources. And for the manufacturing sector, particularly in Ontario with its local content requirement rule for green energy investments, it represents a new emerging manufacturing market. It holds the promise of more jobs and growth opportunities for companies looking to diversify away from automotive and aerospace.

Canada is not the only country jumping on the green bandwagon. The US, the European Union and China are examples of other global regions that have made commitments to renewable energy.

In his State of the Union Address in January this year, US President Barack Obama called for 80 per cent of US energy to come from clean sources—wind, solar, nuclear, clean coal and natural gas—by 2035. In September 2010, Germany adopted an energy policy that set out targets and measures for sustainable energy supply through to 2050. By 2010, at least 18 per cent of that country’s total energy consumption should be covered by renewable energy sources. By 2030, that percentage goes up to 30 per cent and then 60 per cent by 2050. In January 2011, French President Nicolas Sarkozy confirmed his country’s plans to invest $13.5 billion in 600 turbines off the country’s Atlantic coast. Britain and countries in Scandinavia have also earmarked billions of dollars for new offshore wind projects. China is the big player here. In a study by the Pew Charitable Trusts released on March 29, 2011, it noted China invested a record US $54.4 billion in wind, solar and other green projects in 2010, a 39 per cent increase from a year earlier.

The question for manufacturers though is, what comes next? What happens when these emerging markets reach a saturation point, if they’re allowed to? Will powerful lobby groups for traditional energy sources thwart attempts to move to greener energy sources thereby limiting opportunities for manufacturers wanting to diversify into new markets?

For the record, I think there is opportunity for manufacturers in this emerging green energy sector. The important question manufacturers need to ask themselves is: are they being short-sighted by focusing attention on markets with relatively short saturation points? Wind turbines and solar panels for example, aren’t like cars or appliances that break down after five to seven years or are replaced for newer, modern designs; they typically last 20 to 25 years.

There may be opportunity in the maintenance and parts supply area, but that won’t be able to sustain a healthy manufacturing base.

The green movement is essential to the long-term health of any economy, but such a movement needs to move beyond the energy markets and apply to all areas of life. When green designs become standard in everything we build, perhaps then we can more securely put our manufacturing future into greener hands.

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

News Machine tool “store”

On May 4 and 5, hundreds of manufacturers from across Ontario and other parts of the country, attended the largest open house of its kind, the 6th annual Joint Open House.

The multi-distributor open house brought together more than 500 manufacturers who had the opportunity to visit the facilities of machine tool participants in the event—DMG Canada, Mississauga, ON; Elliott Matsuura, Oakville, ON; EMEC Machine Tools, Mississauga, ON; Ferro Technique, Mississauga, ON; and SST-Canada, Mississauga, ON. In total, there were more than 55 machines under power representing all the major technologies, from CNC lathes and mills, to a variety of machining centres.

The most significant difference between last year’s event and this year is the optimism among both machine tool suppliers and manufacturers.

Gary Hollinger just started his company, Fine Line Control in Mississauga, ON, six months ago. The company plans to supply tooling for the fine black industry. Canadian Metalworking spoke with him at Elliott Matsuura’s facility. Unlike many walking through the facility, he had purchased his AgieCharmille Cut20 wire EDM a

couple of weeks ago and had dropped by to pay for the machine.

“I had a 15-year-old AgieCharmilles EDM that I got from Elliott previsously and it’s been trying to get it going, but I found that Elliott was great in servicing it and now with my new business I needed another EDM so I just purchased the Cut20 from Elliott.”

Hollinger is one of many new customers for Elliott Matsuura.

Indeed, Frank Haydar, president of Canada’s largest machine tool distributor, says “the first quarter of this year was our second best first quarter ever, and that’s saying a lot because we had some really good years in the late 90s and early 2000. I think a lot of it has to do with the improving economy. Many of our customers are getting contracts and are in need of machines.”

At SST-Canada, Canadian Metalworking caught up with a busy Juergen Moeglich, president of the Makino machine tool distribution company in Canada. Moeglich came up with the idea of a joint distributor open house six years ago while working for another machine tool distributor. Over the years, the event has grown to include today’s five participants. Asked if he 8 | June 2011 | www.canadianmetalworking.com

thinks it will get bigger, he says “the problem with getting bigger is that you can’t just have it in two days. You can cover four or five open houses in a reasonable amount of time in one or one and a half days, but if you get to six or seven participants, then you get people coming in just for five minutes and then going to other places because they want to see all the machines.”

Instead, with the current supplier participants, customers are able to take their time looking at machines and if they’re interested in one, they can speak to product managers and get details.

“So far attendance for us has been steady and I like it that way because we can dedicate time to customers. We sold a Murata machine today, but it’s not a customer that just saw it and bought it today. People don’t typically come to open houses to buy the first time they see a machine. The whole purpose of open houses is to give customers an overview of the supplier they’re thinking of purchasing a machine tool from. They can do research on the machine—that’s where we compete on a technical level—and find out what type of parts inventory, service and maintenance is available from each company.”

Mike Phung, who oversees plant operations for B&R Machine, Mississauga, ON, asked two of his machinists to join him for the joint distributor open house. Canadian Metalworking spoke with Phung at DMG Canada’s facilites.

“We’re looking to purchase this machine, the Ecoline CTX 510 turning machine. The machine fits our envelope in terms

News of size, horsepower and performance. And of course the price caught my attention tool. It’s always good though to get a second opinion and who better to get that from than the people who are going to run the machines? That’s why I brought two of our machinists with me today.”

Like many job shops that survived the recession, B&R diversified its customer base, says Phung. Aerospace was its primary business focus, but after the recession the company found new markets.

“Now aerospace is a smaller portion of our business. We build and assemble automated machines, such as battery making machines. We have a lot of different machines in our shops, such as Hardinge, Hurco, Haas, DMGs and Mazaks. We actually purchased a DMG machine at an auction. It was an older model, but it was in excellent condition and we saved ourselves a ton of money. The good thing is that DMG services the refurbished machines tool.”

There was a steady flow of customers at Ferro Techniques’ facility too. Indeed, the customers there during Canadian Metalworking’s visit were busy discussing machine tools with representatives.

Brent Patton was happy to see customers. Patton, who works with AirCell, Mississauga, ON, sells weatherproof compressed air systems for manufacturers. His company was one of several ancillary suppliers with tabletop exhibits at Ferro’s facility. He was eager to discuss his product, which essentially frees up floor space for manufacturers by placing all compressed air equipment outside in a temperature-controlled room.

AT EMEC Machine Tool’s open house, customers were still streaming in to view the machines under power. Among EMEC’s line of Okuma machine tools, there was a video demonstration of a simultaneous five axis machine manufactured by German machine tool maker Grob and sold in Canada by EMEC. Robert J. Ruelle, account director of standard machines for the company, which has a manufacturing operation in Bluffton, OH, came up from the US to talk to customers interested in simultaneous five axis machining.

“Other manufacturers have simultaneous five axis, but Grob’s machine is a high precision machine and we’ve taken into account a lot of details in design with regards to ergonomics for the machine tool operator.”

Martin Craven, area manager for EMEC, echoes the optimism voiced by Elliott Matsuura’s Frank Haydar. He says business has been very good and several of his customers that attended the joint open house are also optimistic about business and are looking at new machinery.

Manufacturers “discover” Mazak

More than 300 manufacturers, some from as far away as Alberta, came out to Mazak Corp. Canada’s Cambridge, ON, facility for the company’s Discover Mazak-Canada event.

The intent of the event (similar events have been held in several of Mazak’s US locations) was to showcase the latest machining technologies Mazak thinks can help manufacturers become more competitive.

“The event was set up in two phases,” explains Ray Buxton, general manager for Mazak’s Canadian operation. “The previous evening we had a special preview for some of our customers. We had 60 people who came for dinner and to see the machines in 10 | June 2011 | www.canadianmetalworking.com

our facility. It was a wonderful event because it was a relaxed environment for our established customers who had the chance to see some of our newest technologies. The May 4 event was open to the general public, for existing customers and potential customers, and the intent is to simply expand the Mazak brand and show people what we’re doing with our machines.”

Werner Harder flew in from Edmonton, AB, to see Mazak’s latest machines, including one his company is likely to buy, the Quick Turn Smart 250 CNC turning centre.

One customer who liked what he saw was Werner Harder, a machinist with Domino Machine Inc., a 67-year-old machine shop based in Edmonton, AB. The company specializes in custom machining for the oilfield industry and has a machining capacity up to 7 tons. Domino’s shop has more than 40 Mazak CNC machines, including horizontal machining centres, multi-tasking machines, lathes and a variety of manual equipment. Its biggest customers are OEMs, primarily based in Houston, TX, with some customers in Western Canada and overseas.

Harder liked the Quick Turn Smart 250 CNC turning centre.

“We’re looking at this machine to make a specific family of small parts. We usually work with larger parts, so we need a machine to handle these smaller parts. One of the things I like about the Mazak machines in our shop is the ergonomics and human machine interface, which seems to work better than in other machines. We do have other types of machines and when it comes to programming and tool set ups, the Mazaks seems to be more user friendly.”

For Bill Bryne and Bruce Kay, who work at Cascade Canada’s Guelph, ON, facility, the best thing about the Mazak machines is the Mazatrol controller. The company recently purchased a Variaxis series 510 three axis vertical mill to manufacture some of the material handling products it makes for lift trucks.

Says Bryne, “the learning curve on it is a lot better than other programs we’ve worked with on other mills in our shop. There’s a lot I like about the machine, including the drives. Other pluses are that this machine is built in Kentucky, not overseas and our shop is just 10 minutes away from here, so from a service

News standpoint, we like that.”

Indeed, service is a big component of Mazak’s success, says Buxton, adding that Mazak has increased staff by 25 per cent in recent months, adding a new service manager, Steve Mackay, and a new applications manager, Sean Harrison.

“We’re also increasing our staff in those areas who will report to Steve and Sean.”

Part of the reason for the increased staff is to accommodate the growing customer base in Canada, a base Buxton says is likely to grow stronger based on the activities he’s seeing in the manufacturing sector.

“Oil patch, aerospace and automotive are all becoming very busy and nuclear power is another area where we’re seeing more activity among our customers involved in this sector. It’s in the quotation stages now, but many of our customers are on the cusp of huge amounts of work and within the next six months we’re going to see a lot of machines being purchased for machining highly complex components required for machinery in nuclear plants.”

Jim Okada, president of Mori Seiki Americas, and Graham Hooper, president of Ellison Technologies, attended the event— “Productivity in Motion”—to welcome Canadian customers to the new facility.

Asked what sets Ellison Technologies apart from other distributors in Canada and Robert Dunbar, vice president and general manager for Ellison in Canada, doesn’t hesitate: “Ellison is not just a distributor of machine tools. The company has been successful because it takes a different approach to selling.”

For one thing, the company has more engineers than it does sales representatives, roughly a 60/40 split, estimates Dunbar.

The new kid on the machine tool block

Canada’s newest machine tool builder and distributor made its debut in April. Ellison Technologies and Mori Seiki held the grand opening of their Canadian Technical Centre in Mississauga, ON. Close to 300 people attended the event. Key executives from Mori Seiki and Ellison Technologies in the US, including

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INFO: VDW – Generalkommissariat EMO Hannover 2011 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstrasse 4, 60325 Frankfurt am Main, GERMANY Tel. +49 69 756081-0, Fax +49 69 756081-74 emo@vdw.de · www.emo-hannover.de

12 | June 2011 | www.canadianmetalworking.com

1977

1978

1979

1985

1989

1996

Invention of the panel bender – P4

Invention of the combo punch-shear machine with multipress punching head – S4

First integrated FMS fabrication system – S4+P4

First lights-out sheet metal fabrication factory is installed in North America

First automatic 3D design to finished product software

First integrated stores-MRP software

FIBER L ASER CUT TING

Invented by Salvagnini.

Perfected by Salvagnini.

Three years ago, competitors told customers that fiber laser cutters were limited, dangerous and unproven.

Now… everyone wants in. Too bad.

Those competitors are way, way behind the curve.

L3 and L5 laser cutters.

In 2010, Salvagnini introduced the 2nd generation of fiber laser cutters while competitors were rushing to bring out a first. With over 100 fiber laser cutters already in the field, Salvagnini has the technology, the experience and the track record of success. No mirrors, no beam alignments, no laser gasses, no maintenance, no limits.

And of course, like all products from Salvagnini, the L3 and L5 fiber laser cutters can be equipped with the industry’s most innovative automation technology.

Salvagnini fiber laser cutters. Cutting edge technology. Lowest operating costs. Production-proven automation.

Salvagnini laser cutters. The first.

And the best.

www.salvagnini.com

1997

1998

2000

2002

2008

2010

2011

First “no teach” robots for parts handling with panel benders

First panel bender with zero set-up

Creation of the Automated Job Shop

First automated, robotic bending cell with off-line programming

First fiber laser cutter, the L1Xe

First punch-laser to use fiber optic technology – SL4

First lasers designed exclusively for fiber optic technology – the L3 & L5

News As well, Ellison has two other businesses, Ellison Technologies Automation and Advanced Manufacturing Group.

“Combined, these businesses offer a value-added approach to the selling process. Because of this, Ellison has become Mori Seiki’s largest distributor in the world. Approximately 30 per cent of all production of Mori Seiki comes to Ellison Technologies. And we will bring this success to Canada. We plan to become the best engineered solutions manufacturing company in the country.”

For Eugene Kokbas, the event was an opportunity to see the machine tool his company plans to purchase. Kokbas is the section manager, engineered materials machining section of BCI Instrument Precision Machining. The company is expanding and moving to a new larger facility in Orillia, ON, later this summer.

The shop already has seven CNC machining centres, mostly Mori Seiki and DMG machines. During the open house, Kokbas had the opportunity to see the Mori Seiki NMV5000DCG (Driven at the Centre of Gravity) five axis vertical machining centre in action and liked what he saw.

“We like this machine because it has a rotating table. It’s a 1200 rpm machine and we will be purchasing it with a pallet system. We need automation to improve our processes because we compete with Asia and it’s the only way we can become more competitive,” says Kokbas.

Go West for manufacturing technology

As Canada’s economy continues to rebound from the recent turmoil, manufacturers are seeking opportunities for growth. It’s not surprising that many are focusing more on Western Canada, where diverse industries such as oil and gas, mining, alternate energy and agricultural implements are booming.

It’s one reason why the Western Manufacturing Technology Show (WMTS), running June 14-16 at the Edmonton Expo Centre in Edmonton, AB, is expected to be a bigger event this year, according to the Society of Manufacturing Engineers, event organizer. More than 2000 attendees are expected at this biennial event.

“This is the event for manufacturers to grow their business and showcase the latest in technology development,” says Janine Saperson, event manager. “For attendees, WMTS provides opportunities to learn, evaluate and compare technologies and solutions on a one-on-one basis. All under one roof, over three days.”

Saperson says Alberta’s manufacturing sector is booming. She sites a few examples: 170 aerospace and aviation companies in Alberta employ more than 6000 people in skilled areas such as robotics and unmanned vehicle systems, defense electronics, space science and geomatics. The province has $15 billion per year of existing metal manufacturing and is third only to Ontario and Quebec. Alberta will require more than $200 billion in new construction and maintenance spending over the next 25 years, much of it in fabricated metal products.

In addition to the trade show, which will feature close to 100 suppliers to the manufacturing industry, WMTS will include an industry keynote and interactive town hall.

For registration information and event details, visit www.wmts.ca.

16 | June 2011 | www.canadianmetalworking.com

News Floor Space Do you typically work through holidays such as Easter or Christmas or do you take some time off to enjoy the occasion?

“Traditionally, we always respected holidays such as Christmas and Easter weekends by closing and this tradition still holds true. There have been situations, however, that have caused us to bend those rules the last two or three years, mainly because of economic and market changes.”

-Joseph Manzoli, president, Colourfast, Concord, ON

“In all our 40+ years we have always been closed on Easter and Christmas.

On Canada or Labour Day, we have also observed these holidays. On rare occasions we have worked to complete a project or have worked and taken the holiday to extend a weekend. At Christmas, we always plan our workload to have some time off to enjoy a break and come back fresh at work.”

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

“I typically work through the holidays.

My employees have the days off but I

keep the machinery running. Because our machines are automated, we have the ability to keep running production even though no employees are working. It’s not something that I enjoy doing but it’s the only time we can catch up on overdue orders.

-Larry Stuyt, president, Ontario Laser Cutting, Tillsonburg, ON

“Well, I would say I used to. We worked all the time. As the shop grows and you get a little more organized we seem to be doing less of that. And that’s good.”

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

“We always take holidays off. The type of work we perform—tight tolerance, miniature parts—takes a lot of concentration. The time off allows for regeneration of staff.”

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

People Sean K. Harrison has joined Mazak Corp. Canada, Cambridge, ON, as applications manager. He is a fluid power and robotics engineering technologist and has 25 years of experience in the machine tool industry working with machine tool builders, distributors and job shops in Canada. Harrison is one of several recent additions to Mazak in Canada. (see Mazak Corp. Canada news story in this issue).

18 | June 2011 | www.canadianmetalworking.com

“We usually shut down for the whole of Christmas and come back in the New Year. We also close for Easter.”

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

“We typically will take advantage of the holidays. Life is very short already.”

-Gerry Vandersanden, president, Sciens Industries, Peterborough, ON

“We have worked through a few holidays in our time but as a rule, we take the time off. I think it’s good to get away from work once in a while and spend extra time with friends and family.”

-David Foscarini, president, Mecon Industries Ltd., Scarborough, ON

Calendar June 8-9 Automotive Parts Manufacturers’ Association 2011 Annual Conference & Exhibition in Windsor, ON. ww.apma.ca June 14-16 Western Manufacturing Technology Show in Edmonton, AB. www.wmts.ca June 21-23 CAMM Moldmaking Trade Show in Toronto. www.cmm.ca June 21-23 Green Manufacturing Expo in Toronto. www.canontradeshows.com

Job Shops: Canada’s Manufacturing Backbone

BRITISH COLUMBIA

INDUSTRY REPORT

West Coast Success Proactive sales approach helps BC shop expand business

By David Kosub..........................................................................

Anyone in business during the recession of 1989/90 will remember the effects: investment and plant construction down, unemployment and interest rates up, business bankruptcies soaring. What they may not remember is that not every business shrank, that some actually expanded.

That’s just what Mahler Industries of Coquitlam, BC did—a manual machine shop that shifted from manufacturing small brass ornaments for the home into a cutting edge CNC machining operation that services the aerospace, mining, marine and forestry industries.

Canadian Metalworking takes a cross-country road trip and talks to job shops about what they’re doing to succeed in today’s tough market Economists use many indicators to gauge the state of manufacturing in Canada, but one they don’t often look at is the health of job shops.

The backbone of the manufacturing industry, when trouble arises among OEMs, job shops are often the first to feel the effects of any downturn. Such was the case with the recent recession, and such has been the case throughout industry’s history. But job shop owners and operators are a resilient group of people who have learned by experience how to survive— and in many cases grow—through tough times.

Our initial plan was to profile job shops in each of Canada’s provinces. The fact that we did not succeed in doing so is actually good news.

Many of the job shops we approached simply were too busy to take the time to speak with Canadian Metalworking.

Some, however, did find the time to speak with us and their inspirational stories are featured in this issue, pages 21-27.

Mahler Industries’ owner Pedro Fernandes purchased the company at the outset of the 2009 recesssion and then did something even more unexpected: he hired a sales manager.

Scroll forward twenty years to a Canadian economy again buffeted by tighter credit, rising interest rates and smaller markets and Mahler is still in business. More remarkable still is that Mahler’s new owner Pedro Fernandes took over at the very outset of the 2009 recession, when things looked their bleakest. A big appeal for Fernandes was Mahler’s loyal customer base, loyalty he chose to reward by, among other things, meeting his customers’ shortened delivery times.

“When the recession hit, people didn’t have as much money to spend so they didn’t buy for long term; they had to buy when they needed it. So we had to be able to adapt quickly: when they needed something in a week we had to get it done in a week.”

To meet the crunch Fernandes added a graveyard shift to his normal twoshift work day. But he did something even more unexpected. With sales still dropping (down 30 per cent in 2009) he hired Phil Archer. Prior to Archer’s arrival Mahler relied almost exclusively on word of mouth to generate business; hiring Archer as sales manager, says Fernandes, “right off the bat helped us to keep up with and expand our existing customer base.” Within a short period, Mahler Industries had two new clients on Vancouver Island, one in the US and its sights firmly fixed on its next target: Alberta.

“Up until the last two years Alberta has been uncharted territory for www.canadianmetalworking.com | june 2011 | 21

INDUSTRY REPORT

BRITISH COLUMBIA

Mahler Industries,” says Archer. “And I’ve always been a big believer, and Pedro is the same, that the broader customer base you have the better off you are. It enables you ride out these recessions a lot better.”

Today, Mahler sales stand at about 10 per cent below pre-recession levels, a recovery Fernandes also attributes to the machinery on Mahler’s 20,000 sq ft floor. Fernandes is a huge fan of Mazak Canada machines.

In fact, all but one machine is designed and manufactured by the Cambridge, ON, builder (which manufacturers many of its machines in Florence, KY). No single workhorse drives business at peak times here, though; instead Mahler depends upon a small team of CNC machines, among them a seven axis live tooling CNC with full subspindle, two horizontal machining centres and two small lathes.

Mazak machines were distinguished early on, says Fernandes, by the software, which is “very user-friendly. The programming at the machine was very simple, very point-and click.” Another key feature was accuracy.

The Mazak horizontal machining centre, for example, not only allows the operator to work on all sides (e.g. the front, right and left faces of a manifold block) it provides .001° indexing, something Fernandes says is critical: “if I need to do angling around the outside I can do that as well.”

Another plus for Mazak machines: their rigidity.

“If we’re working on parts that have a five micron tolerance on dimensions we have to be able to hit that consistently without having to measure each part and readjust the tool. Using Mazak machines we can hold five to ten micron tolerances for hours.”

Two turning centres figure prominently at Mahler Industries: the Mazak QT8 and QT10. Both 10 HP lathes have .5 mm to .38 mm through spindle capability, can chuck 6-8 in. comfortably and are designed for long production runs. The smaller lathe, Fernandes points out, has a distinct advantage over the larger turning centre, however: “On our larger lathes you have to load the parts manually. Attached to our smaller lathes are bar stackers. The collet system on that one enables us to bar load so that the part continuously feeds out, relatively unmanned.”

For all its success opening up markets Mahler Industries is treading carefully where future equipment purchases are concerned. Pedro Fernandes has only had the company for two years, after all, and the economy is still soft. He and Archer believe they can still compete by stressing key aspects of business including quality, on-time delivery and relationship building with customers. Still, that doesn’t stop Fernandes from pouring through machine catalogues.

“Personally I’d like to expand with a new lathe with live tooling and a new five axis mill. A lathe with live tooling would maybe speed up some of our processes. A larger mill would expand my capacity, as would the five axis mill.”

Fernandes is quick to point out that Mahler Industries is not just about machines, but about people. “95 per cent of the guys on the machines can program them as well; they’re not just operators.” The ability to turn a drawing into an exceptionally well-made part is due to inhouse training, but also to a floor-wide commitment to quality, he says. Each operator knows there are always competitors willing to cut corners and supply parts cheaper, but at the end of the day Mahler’s ability to stay in business and expand depends upon maintaining its reputation.

Mahler’s physical location doesn’t hurt either. Coquitlam is at the centre of Canada and BC’s Pacific transportation gateway, and a massive $8 billion federal-provincial investment in transportation infrastructure aimed at supplying emerging economies along the Pacific Rim. New markets there mean more potential business for companies like Mahler.

But the Pacific Rim, says Phil Archer, also presents “a double edged sword”, i.e. more business, but more competition, too, especially from places like China that can produce larger volumes of parts at lower cost.

That means for now, most of the opportunities for growth at Mahler Industries remain here on this side of the Pacific where “busier shops” and a Canadian economy, says Archer, are “starting to take off.” CM 22 | june 2011 | www.canadianmetalworking.com

alberta

Surviving the Recession Carving a reputation in a tough marketplace

By Brynna Leslie ..........................................

In an industrial park in the Calgary, AB, foothills, close to suppliers and amidst like shops, Clear Cut Metal Works Inc. is housed in a 2800 sq ft stand-alone building. There’s nothing striking about the exterior; it’s basically a drive-in bay door, with an adjacent entrance to a small office. What makes the firm stand out is its diverse offerings, everything from interior and exterior home decor ornaments designed and cut inhouse, to intricate metal parts custom fabricated for the nearby oil and gas industry. All have been made with an OMAX waterjet machine, selected by owners Steve and Richelle Skrilec for its laser-like precision.

Clear Cut Metal Works fabricates all of its metal parts with an OMAX waterjet cutting system.

“My background was in laser cutting,” says Steve. “But start-up with a laser is much higher. The waterjet is similar but it cuts with water instead of a laser, so it doesn’t burn. I thought it would help me get my foot in the door.”

In October 2007, after 15 years working as a machinist for a number of companies in Calgary, Steve decided it was time to branch out on his own.

At the time, the economy was booming—buoyed by high prices in the oil and gas industry and a hot housing market—and Skrilec felt the time was right to take a risk.

“It was a tough decision,” recalls Skrilec. “It was based a lot on family and friends more than anything. It was something that I had wanted to do for a long time, but I didn’t know how to go about it.”

SASKATCHEWAN Skrilec partnered with his wife, room to diversify.

Richelle, who has a background in “We tried to pick up work wherever business management and had been we could, we lowered our rates so we running her own bookkeeping shop could get work,” explains Richelle. “But for several years. “I knew about sitting in the meantime we had to find other down and making a business plan and avenues. That’s when Steve got busy searching out the best financing for the with some of the interior designers and equipment,” says Richelle. doctors’ offices.”

The couple created a five-year plan Clear Cut started to become known that forecast modest growth. By 2012 they for stainless steel kick plates for kitchen hoped to purchase a second renovations, ornamental wall Waterjet machine and decorations over fireplaces and quadruple their staff to four gates for the backyard. to operate a double shift. A Although they had to lay stellar first year saw Steve off one of their two employees, working 16-hour days and which “was a tough thing to do, taking on extra help long especially in a small shop,” the before the business plan capacity of the waterjet allowed had predicted. Oil and gas the couple to keep going. clients were banging down “We decided we could wait out Steve Skrilec owns Clear the door, putting in orders the recession,” says Richelle. “We Cut Metal Works Inc. with for customized fittings, have always been conservative wife Richelle. designed by industry draftswith our expenses, and we found men. Everything was made-to-order and out that it pays to be a little bit thrifty, the small family shop could barely keep even when things are going well.” up. But the economy had other plans.

The next 24 months were sporadic. It’s “In January, 2009, it was like someonly since March that Clear Cut has seen a body flipped a switch,” says Steve. “It surge of business from its more traditional was like somebody just turned off the client base. Everything’s finally starting water.” to pick up full force again,” says Steve.

All around them, shops began to close “We have consistent work, we’re running doors. Business from Clear Cut’s main 16 hours a day at least and we’re keeping clients all but dried up. The company was everyone happy and organized.” just over a year old and the Skrilecs found The post-recession economy is not themselves in survival mode. perfect, with clients getting cold feet “For us, from a financial point of view, on projects when they see a dip in the it would have bankrupted us if we’d shut dollar or the oil price. the doors and said, ‘sorry, we can’t pay “But the biggest fear after the recesour lease,’” says Richelle. “There was sion is inflation,” says Richelle. “This no other option but to keep going. We affects how much we buy our material knew the potential because of the first for and parts for the maintenance and year of business, and we knew it was our rent.” tremendous.”

Prices have gone up, which means What the Skrilecs hadn’t counted customers are paying more for final on was the machine’s capacity to cut products. plastic, granite, marble, titanium, “Steel has gone up by about 20 per plexiglass, lexan, tile and rubber. This cent,” says Steve. “And it’s been really would eventually make the waterjet fluctuating. For about three months their financial lifeline. there, you had to get a quote every “Laser cutting is a lot faster,” says couple of days because the price was Steve. “But you don’t have as much changing that fast.” variety in the material. The waterjet can Even during the recession, however, cut anything.” the Skrilecs were careful to look after The waterjet works like a laser, but it customers, providing discounted doesn’t burn. It’s designed to cut through pricing, or even advising clients against materials ranging from 1/16 of an inch to using the Waterjet if it wasn’t their best 10 in. (0.6 to 254 mm) with accuracy of .005 option. of an inch (0.127 mm). Clear Cut had been “I’ve worked in places where they’ll working mostly with mild steel, stainless take advantage of the little guys,” says steel and aluminum, producing customSteve. “That doesn’t sit well with me. If ized fittings for clients at nearby welding you’re fair with the customer, you’ll get shops and machine shops, contracted by repeat business. And most of our work the oil industry, so they knew there was is coming through word of mouth.” CM

Responding to Change A flexible approach to customer demands and investment in new machinery spurs growth

By Brynna Leslie .............................

“It’s during an economic downturn when all your problems shake loose,” says Lina Foster, the human resources manager at IMM Industrial Machine and Manufacturing Inc. in Saskatoon. “You see waste very clearly and you really start to manage the small stuff more carefully.

It’s the things that you don’t really think about that can make the difference between the next day or not.”

IMM is an anomaly in Canadian machining and manufacturing. Not only has the firm “seen the next day,” since the economy took a nosedive in 2008, but the company is reputed for its growth in the wake of three recessions since the Foster family first took over the firm in 1976. The first expansion happened in the mid-eighties under the leadership of Lina’s father, Perry Foster. In 1997, the company initiated and completed a succession to Lina’s brothers Tom and Craig Foster.

“Since Tom became president, IMM has become a different company,” says Lina. “Our capacity has grown twelvefold.”

IMM’s client base has also diversified dramatically in its 55-year history.

It’s best known for the manufacture of industrial centrifuges used in the milling or refining operations of mines. The firm is situated in the north industrial area of Saskatoon, the heart of Canada’s potash industry. In the last 14 years, IMM has made a name for itself domestically and globally as a custom shop that machines, fabricates and exports some of the largest custom industrial equipment in the world for mining, oil and gas, agriculture and power generation.

“Our market is very different from what you would see in Ontario or other urban centres,” explains Lina. “A lot www.canadianmetalworking.com | june 2011 | 23

INDUSTRY REPORT

SASKATCHEWAN

of companies can specialize and focus on specific industries.

Because of our size and our location, if we want to keep people working, we must be able to service a large number of industries. And we’re landlocked, so if we’re not producing for local industries, we’re shipping our product out.”

Tom Foster with one of the large decanter centrifuges his shop builds. Below, the track frame of a miner in the process of being built.

Alongside large metal fabrication projects–which include miners (a machine that removes potash from mine walls) and agricultural equipment–IMM is equipped to mass produce machined parts out of steel blocks, some that are “as small as a loonie.” A 17,500 sq ft facility houses the company’s office and machine shop. The capacity is enviable: two CNC horizontal boring mills, a conventional horizontal boring mill with a 22,000 lb capacity, a vertical boring mill with a 84 in. x 96 in. (2133 mm x 2438 mm) table, and a maximum turning capacity of 104 in.

(2641 mm), ten CNC lathes with up to 39 in. (990 mm) swing and a 236 in. (5994 mm) length, six CNC vertical and horizontal multiaxis machining centres, and a four-axis multitask turn/mill, along with a number of conventional lathes, grinders, ejector drills and boring drills. The company recently purchased four brand new Haas CNC machining centres—two ST-30 turning centres, two vertical machining centres, the VF-4 and the VF-6. And that’s just the machine shop.

“If we think we can build it, if we think we can do a project, we’ll put in a bid,” says Lina.

IMM is undergoing another considerable expansion, doubling the floor space of its welding and mechanical department to 12,000 sq ft. It’s a fraction of the more than 33,000 sq ft on site. The manufacturing facility is designed for diversity, with collapsible welding booths that can be removed when greater space is required for large assemblies. Excess stock is housed in an adjacent 5,600 sq ft covered storage facility.

IMM has recently partnered with four other firms to take on mammoth projects, including the manufacture of miners the size of “two city transit buses,” each of which takes more than 76 weeks to complete.

“The market is completely different than it was twenty years ago,” says Lina. “Doing long term project work is vastly different.

We responded to that by changing how we build customers and 24 | june 2011 | www.canadianmetalworking.com

being flexible in how we respond. Right now, with the mines and the expansion within the industry, there are different capacity demands. In order to service that you have to make sure you have the equipment that can do what the customer needs. And you need space.”

Within such a competitive environment, keeping staff engaged, particularly during a downturn, is essential.

Conversations around the family dinner table allowed Tom and Lina Foster to get insight into their father’s experience during the eighties, when he successfully oversaw IMM’s first expansion following a harsh recession in the province.

“I remember the eighties,” says Lina. “In 1989, 45 people a day were leaving Saskatchewan to find work. So it’s great to have the ability to reach back and have dad’s advice feed into Tom’s strategic plan, even though we are running a completely different company and in a completely different market today,” says Lina.

“One of the things we all understand is that the economy ebbs and flows, and you always know that it will get better, and our company has a history of coming out stronger.”

An integrative management approach has helped IMM emerge successful whenever the economy has taken a dip.

The company opted, for example, to acquire four new controllers to provide consistency for staff moving from machine to machine. IMM purchased almost-new equipment from competitor firms selling off stock to survive the recession. Every employee, meanwhile, was encouraged to reduce waste, identifying excess material that could be sold for recycling.

“You have to manage resources, facilities, people and equipment very carefully to make sure you don’t have too much, but that you still have enough to remain competitive,” says Foster. “It’s like Goldilocks, you have to be ‘just right’ all the way through the downturn.”

The firm’s human resources strategy, for example, is long term, with a focus on cross-training and the accumulation of experience. New machinists are given time to build their confidence and skill on machines by undertaking projects where parts are mass-produced. Custom jobs are reserved for the dozens of staff that have been with the firm for more than 20 years. There is also a lot of value placed on the single purchasing agent who sources materials from across the globe.

“We live and breathe by someone putting out a request for a quote,” says Lina. “Only when we are successful in getting the quote are we authorized to get the material. We may know months in advance that there is likely a large amount of money coming our way, but we have to wait for the purchase order to go through and we need our purchasing agent to be on top of this at all times.”

Also integral recession management is to “never be idle,” says Lina.

IMM was able to retain its staff at full capacity in 2008 by encouraging those who intended to go for trade apprenticeships to “go now.”

“For the managers, if there’s not work for people to be quoting on, then there’s time to be planning,” says Lina. “We always have a plan in place for ensuring we have a modern facility. The recession allowed us time to be even more strategic about going forward.” CM

ONTARIO

Reinventing the Job Shop

From job shop to specialty manufacturer: Ontario job shop changes to meet market needs

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

New-Form Tools of Stratford, ON, has 30 employees, roughly “Hydroforming was rather new in the late 1990s. After the 70 CNC machines and big plans on the part of owner and tube is formed, they need to re-cut the end of the tube because founder Jim Jantzi. Opened in 1983, the company has endured it’s been deformed through the hydroforming process. So, we by keeping an eye to the future and trying new ventures. In produce these knives—like giant chisels—that cut the end of doing so, New-Form demonstrates how job shops can reinvent the tube off,” says Jantzi. themselves to suit changing markets.

Customers include tier one and two automotive clients.

The history of New-Form Tools Newer in-house specialties include cryois complex and involves rapid genics and building customized, automatic/ expansion, rapid downsizing, and robotic work cells. Cryogenics involves challenges with offshore competistrengthening steel parts by immersing tion and a bouncing Canadian them in liquid nitrogen, which reduces their currency. temperature to nearly minus 200C. When it first launched, however, “We’ve built a little computerized unit New-Form was a one-man operation, that dumps liquid nitrogen to keep it at a with “lathes, a mill and a few other certain temperature … it looks like a glorilittle items,” recalls Jantzi. fied deep-freeze unit,” says Jantzi.

The shop did standard tool New-Form also came up with patentand die work—“all the stuff that’s pending tweaking stations for CNC tube left and gone to China, Korea or bending centres and a new quick change someplace,” he laments. tool system. The latter fits existing tubeIn its earliest incarnation, Newshear cutting machines and reduces tool Form was a “100 per cent” job shop, package changes from nearly an hour to a Jantzi continues. minute. The tweaking stations, meanwhile, After a decade in the business, allow users to straighten or bend steel however, Jantzi began to sense a tubing to consistent tolerances. sea change in the market he operFor the past five years, the company has ated in. Starting in the early 1990s been designing and installing automatic/ then gaining momentum in the early robotic work cells for select clients. In 2000s, the shop began transitioning putting these cells together, New-Form has a towards being a specialty manudefinite preference for Fanuc robots. facturer. Employees were added or Jantzi has to be a bit cagey when discussdropped during ebbs and flows in ing work cells—customers who buy them New-Form owner Jim Jantzi, left, is taking his job shop in a the company`s fortunes. new direction to adapt to changing market needs. aren’t eager to give away manufacturing “We began to see the deteriorasecrets by showcasing their internal set-up. tion of the manufacturing world here in North America … we felt He does allow that most of the clients buying work-cells are we had to keep moving in [a new] direction, because all the old working in the automotive sector. work we historically had done was being sent offshore,” Jantzi Jantzi explains the basic procedure: a customer who “has recalls. a particular product they want to produce” gets in touch with That new direction involved specialization. New-Form became New-Form. New-Form comes up with a design then puts the renowned for its blade and knife work. The company started work-cell together. Once constructed, New-Form is also willing manufacturing tube shear blades, slitter knives, roll form blades, to install the work-cell at the client’s plant, and integrate it shear blades and machine knives, among other implements. with existing machinery. The emphasis is on creating “a fully “A large part of our business is doing tube shearing knives. automated cell without personnel,” explains Jantzi.

We’ve pretty much become [one of the best known tube Designing and manufacturing customized work cells shearing knife manufacturers] in the world … what’s given represents one of New-Form’s last ties to its job-shop past, he us prominence is simply that we have all the heat treatment notes. processes in-house and all the coating centres are in-house. All “NFT has transitioned into a product and service provider the procedures are done within our facility,” says Jantzi. for the steel tube and pipe manufacturing industry. Our Roughly a decade ago, New-Form got into manufacturing designs assist companies in becoming more cost-effective hydroform blades for the automotive industry. in their manufacturing processes in order to compete www.canadianmetalworking.com | june 2011 | 25

ONTARIO

internationally,” says Jantzi.

The current shop is small (14,000 sq ft) and admittedly crowded, but well organized. NewForm manages to cram 70 CNC machines into the space, arranged for efficient product through-flow.

Most of the CNC machines are from Haas or Sodick.

“From one side of the building, the primary product comes in the door. Then it flows out the other side of the building at an exit door,” explains Jantzi.

Jantzi wants to keep his workspace tight and personnel low to avoid heavy property and payroll taxes. He complains about “government getting their claws into you” and doesn’t see the situation changing much even with a Conservative majority government.

Jantzi would rather not reveal his revenues, though he does say the company is economically stable—“I can sleep at night,” is how he puts it.

Faced with increased offshore competition and a strong Canadian dollar (which makes Canadian manufactured products less appealing to American clients), machine shops that want to survive and thrive need to follow some basic steps, says Jantzi. Automate as much as possible, keep your workforce small, specialize in a product or service, do value-added work (such as installing work-cells) and above all, be creative.

The company is firmly set for the future: New-Form has recently embraced “green technology” and anticipates a growing market for electric vehicle plug-in stations.

While some of the firm’s website copy on electric plug-ins reads like science fiction, Jantzi says his interest in this area reflects New-Form’s progressive outlook and creative spirit.

“I believe that any of us that are creative and have new ideas are going to succeed, while those that are just trying to do things the same old way will not make it,” he states. CM 26 | june 2011 | www.canadianmetalworking.com

QUEBEC

At Your Service Quebec job shop success based on customer service

By Danny Kurcharsky .......................................................................................

Metaltek Laser may have some of the most Whenever we have a chance to leave advanced metalworking technology in the plant, it’s to meet customers. That’s Quebec, but good old fashioned customer something they really appreciate.” The service is what really sets the company brothers attend machinery trade shows aparts, its owners insist. three or four times a year.

The 10-employee shop, which will celebrate its fourth birthday in July, is co-owned by brothers Sylvain and François Vouligny. Sylvain is responsible for bids and purchasing and François handles production.

Metaltek Laser is located in Bécancour, near Trois-Rivières and about 100 miles from Montreal. It specializes in laser cutting and sheet metal bending, primarily for clients in agriculture, forestry and mining, and has two 4,000 W Mitsubishi machines for CNC laser cutting.

According to Sylvain Vouligny, the fact the company has a new generation Mitsubishi model (ML3015 LVPlus II) Sylvanin Vouligny, left, with his brother Francois. The brothers as well as robotic capabilities is unique have big plans for their company’s future. They’re looking at purchasing new equipment for oxyfuel metal cutting and multito Quebec. “I don’t understand why tooling capabilities, like beveling. we’re the only ones in Quebec who have it. It’s a really good machine.” He calls the machine the most efficient on the A benefit of trade shows is that potenmarket, because it provides high speed and tial clients can be sent to existing clients unmatched laser cutting accuracy. “One of a few feet away who can give Metaltek the reasons we chose Mitsubishi is that the Laser positive reviews. “When we meet company manufactures 100 per cent of the a potential customer, we can tell him ‘go machine’s parts. They know their machines. see him, him and him.’ There’s no better That’s important.” marketing than a client who can say ‘You Adds François Vouligny: “If you’re not can trust those guys.’” looking for trouble, buy the Mitsubishi.”

Metaltek Laser got its start in the He cites its reliability and requirement for summer of 2007. The brothers had worked much less maintenance than other models. together at a John Deere dealership, with Some companies “need an inventory Sylvain as a sales manager and François of $50,000 in spare parts,” to keep their as parts clerk, but had long dreamed of machines running, he says. running their own business. After gaining Still, service trumps machinery, their chops at other metalworking shops, Sylvain Vouligny says. Customer service they set out to do so. at Metaltek Laser includes such old-time They found a 4,000 sq ft building with features as having a human being answer the 20 ft ceilings they were looking for, the phone— there’s no voice mail—and and bought it. By July 2007, they were in working long hours. One of the brothers business doing work for a snow removal is in the shop by 6:30 every weekday equipment firm. “We were able to start off morning, and somebody is usually around with money in our pockets,” Sylvain says. until 7 or 8 pm. “We’re from the farming First-year sales hit $900,000. world, so it’s part of our lives,” Sylvain says Big changes came in 2009, when the of the long hours. growing company bought the Mitsubishi “One of our strengths is that we care machine, which Sylvain had seen at trade about our clients. We know their names. shows, and more than tripled its facility in

QUEBEC

size to 14,000 sq ft, at a total cost of $1.25 million.

They did so with financial assistance of $633,150 from the Quebec government, in the form of a $201,900 loan from the Ministry of Economic Development, Innovation and Export, and a loan guarantee of $431,250 from Investissement Quebec’s small and medium sized business financing program.

The production line is now completely automated, meaning the company can now run on nights or on weekends without employees on site. The robot has easily saved the company 10 jobs, Sylvain says.

“We have very few employees for the number of tons of material we generate— that’s where we win. “ The machine’s reliability, translates into being able to offer lower rates than the competition, François adds.

That reliability includes exceptional service in the form of technical support from Mitsubishi, Wood Dale, IL, when it is (only occasionally) needed. “They really listen to their customers,” Sylvain says. “It’s easier for me to get service from Chicago then from someone in Trois-Rivières, 30 minutes away.”

What really differentiates the company is fast service, François says. “We can do everything within two days,” compared to competitors who, he says, take a week or longer to deliver the goods.

INDUSTRY REPORT

In the zero inventory and just-in-time environment that prevails today, it’s important that clients receive their orders as quickly as possible, Sylvain adds.

Aside from attending trade shows, the company gets lots of business from word of mouth and its website. “We put a lot of money into the Web. It’s the new way of doing business, so we’re taking advantage of it,” Sylvain says.

Sales should hit about $3.5 million this year, almost double 2010 sales. About 80 per cent of business comes from Quebec, and the rest from Ontario and the Maritimes. The company now has about 350 clients.

Metaltek Laser has big plans for the future. “We’re looking at bringing in new equipment that will revolutionize our market,” Sylvain says.

The new equipment will provide oxyfuel metal cutting and multi-tooling capabilities, including beveling. There’s very little beveling offered in Quebec, says Sylvain.

Obtaining the new machinery will give Metaltek Laser the opportunity to provide more services and chase markets that can’t currently be serviced, such as the nearby Marmen wind energy facility in Trois-Rivières. It will also require another plant expansion and the hiring of a few more employees. That should all happen next year, Sylvain says.

www.canadianmetalworking.com | june 2011 | 27

Business Report

SKILLS TRAINING

Manufacturing industry faces a challenge attracting next generation

By Tim Wilson Canada has emerged from the recession with a lean manufacturing sector forced to compete under a robust currency. And we are doing this while staring down a demographic crisis. Sadly, we aren’t so good at getting our youth excited about the skilled trades.

“We still have a couple of hurdles to get over,” says Robert Chittim, chair of the School of Skilled Trades at St. Clair College in Windsor, ON. “Over the past five years there has been a lot of negative news on the front of the newspaper about manufacturing, and that put a lot of people off.”

From Chittim’s perspective, the challenge is with parents and guidance councillors in secondary schools. There is still a stigma attached to the trades, and that is affecting enrolment in programs. But the fact is, trades require higher and higher levels of education, and the industry demand is out there.

“We are getting two to three calls a week from manufacturers saying they need people right now,” says Chittim, “but the pipeline has been shut off for the past five years. And if you look at the trades, there are not a lot of high schools producing technical graduates. We have a new program here in WindsorEssex County, but those are the exceptions.”

Even with youth unemployment persistently high, at over 14 per cent, Canada’s younger generation isn’t showing great enthusiasm. This is despite the fact that the most recent data from statistics Canada indicated employment has actually declined among youth.

“Canada is faced with demographic challenges,” says Shaun Thorson, CEO of Skills Canada, a not-for-profit organization that works to promote skilled trades and technology careers among Canadian youth. “We have an aging workforce that was well represented in skills for trade and technology, and challenges exist in finding younger skilled workers.”

Thorson agrees a key area of focus should be high schools, which could be better equipped to guide students toward a career in the skilled trades.

28 | june 2011 | www.canadianmetalworking.com

“They need to understand what is involved in those careers,” says Thorson. “That’s a great part of our program here at Skills Canada. We give young people the hands on, sensory experience, so that they can get a sense of what the job is like.”

Skills Canada is giving young people the opportunity to experience what it would actually feel like to work in the trades.

However, Canada still has a gaping hole in our training infrastructure as long as the secondary schools themselves do such a poor job of highlighting the trades.

“It is true that the funding for high school programs has been very inadequate over the past number of years,” says Dan Tadic, director of the Canadian Welding Association (CWA), which is part of the CWB Group. “We have tried to promote welding, and have raised some funds for thirty schools, specifically in the Hamilton region. The school board also provides money, and the principals divvy it up to support programs, but in many cases the technology programs get less funding, even though they cost more money.”

The CWB Group itself helps out by offering a range of courses, from those for experienced industry professionals, people new to the industry, and individuals who want refreshers.

“Our delivery methods are as varied as our students,” says Tadic. “Self study, classroom, online and private courses and training are all available depending on the student’s need. Our self study module program consists of 39 specific areas of study.”

Where the growth is

Training in Canada has to suit two integrated trends: regional economic growth, and sector-based activity. Therefore, it must support the boost in oil and gas out west and down east, as well as hot industries in central Canada such as the environmental and alternative energy sector.

“When we look at the skills needed for manufacturing and maintaining wind turbines, a lot of them are directly connected to our current training,” says Thorson. “The turbines and blades are

SKILLS TRAINING

held up by structural steel—these are all areas certified by us.”

But these aren’t the sorts of jobs you can sign up after high school, and if an employer wants to take advantage of an apprenticeship program, they have to understand that they will be responsible for the majority of the training. Fortunately, in communities like Windsor, which was hard hit by the recession and the downturn in the automotive sector, there is a renewed focus on apprenticeships.

“We used to have 100 people in our apprenticeship program for general machinists,” says Chittim from St. Clair College. “In 2009 that dropped to 16 apprenticeships, but it has since come back to 35.”

Chittim says the demand in Windsor isn’t coming from the big three automakers, but instead from local, smaller tool shops and medium-size manufacturers.

“A lot of the people who have survived have diversified into aerospace,” he says. “But that industry has long lead times; there are a lot of materials requirements,

Business Report

it is far too passive.

“Since the 1980s the big companies, the Fortune 500s, they’ve had budgets for training,” says Dave Smith, president of Canada Training Group, an international management and training consulting firm based in Turtleford, SK. “But many smaller companies still feel they can’t afford it.”

Smith says workers and supervisors know the value of training, but managers have to argue for more training dollars with an eye to return on investment.

“The big ones are doing what they can, and budgeting to take care of what they must do, such as mandated training,” says Smith. “But discretionary spending is a tougher argument and not an option for smaller companies that are just fighting to stay alive.”

“ In communities like Windsor, ON, there is a renewed focus on apprenticeships.”

and about 75 per cent of the labour is paper work. It can take five years from initial contact until you get the job.”

Work in alternative energy and aerospace is very different from an automotive assembly line, where a skilled worker would essentially perform the same task every day. These individuals can be hard to re-train. The future, therefore, is with our youth, and the situation is urgent, because we are sitting on a demographic time-bomb, says Chittim.

“All the boomers are coming to retirement age. About 50 per cent will soon be eligible for retirement, and in some steel plants essentially all the skilled workers could retire and walk out tomorrow.”

Industry’s role is crucial

With the exception of high schools, Canada is working hard to develop programs to train its workforce for the demands of a more sophisticated, high-value manufacturing 4548 CStrip 178x38 had (L) AW.pdf 17:39:43 sector. Industry has always a role to3/3/08 play, but sometimes

Though technical training is easier to evaluate than human resources or managerial “soft skill” training, a lot of companies don’t have effective evaluation systems.

“Training is a waste of time and money unless skills transfer to the worksite and create a measurable economic benefit,” says Smith, who uses both the International Board of Standards for Training Performance and Instruction (IBSTIPI) and the Kirkpatrick evaluation model.

Perhaps it’s time for industry to lead with a nation-wide, youth training initiative focused on our high schools. As it stands, Canada has community colleges, technical schools, government programs, and industry apprenticeships. Sadly, many of our best and brightest are being lost from the get-go due to a lack of focus on skilled trades in secondary schools. CM Tim Wilson is a freelance writer based in Peterborough, ON, and a regular contributor.

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machine tools

Smart

Investment

Redoe Mold builds detailed ROI calculations to find the true value of its investments

By Tony Facione.......................................................................

Justifying large investments in machining equipment is a difficult but necessary task that all manufacturers encounter in their mission to remain competitive. While several factors should influence these investment decisions, none is quite as significant as return on investment (ROI). For Redoe Mold of Windsor, ON, smart purchasing decisions are key to its long-standing success and financial stability.

“Determining an accurate return on investment extends farther than just the machine’s performance specifications,” says Eric Leene, Redoe Mold shop foreman. “You have to also consider the financial impact a machine has on other aspects of your shop floor and ultimately the service you provide to your customer.”

To ensure the most accurate ROI calculations, Redoe Mold has refined its investment process by assembling a lean manufacturing team comprised of leadership from various positions across the shop floor.

Together, they discuss how the performance of a potential machine investment could influence secondary machining operations, handwork, spotting and other post-processing labour.

“If you’re investing in capabilities that just simply get the job done, you may have dollars slipping through the cracks in other areas of your shop floor,” says Leene. “Our investments in high performance machining centers from Makino have taught us that the speed, accuracy and flexibility of a machine can offer dramatic savings even outside of the work zone. So when you’re cutting out anywhere from 30 to 50 per cent in manual labour on some jobs like we are, there’s a dramatic change in the profitability and return on investment the machine can offer.”

The Makino EDNC157, seen here above and below (close up view) was purchased as a replacement to the company’s previous large work zone EDM to perform high speed roughing and rib-head machining.

Making a Dollar Go Farther

Redoe Mold was established in 1969 under the namesake of founders and friends, Ed Regan and Pat Endo. In the early days, the two men commonly found themselves serving several different roles for 20 hours a day, seven days a week, to keep the business running smoothly. They frequently faced difficult financial challenges due to limited savings, but quickly learned the value of smart investments.

“Financial considerations have always been critical to this company’s success,” says Leene. “We do all that we can to make sound investments that add or improve capability to the shop floor while ensuring profitability. By being wise and responsible with our finances, we’ve always been able to keep reinvesting in the business.”

With over 40 years of experience, Redoe Mold has now become a well-known and respected name across North America for its dedication to best in class on time delivery, quality and service. The company’s www.canadianmetalworking.com | june 2011 | 31

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knowledge and skills have provided it with the expertise for design and production of high end injection moulds and prototype moulds. Redoe Mold specializes in surface-critical, multi-material and multi-colour moulds for plastic components, including automotive headlamps, tail lamps and reflectors.

High speed ROI

“When you’re working with optic lens moulds, accuracy and finish are imperative,” says Leene. “Even the slightest inconsistency can be detected by light refraction tests. For this reason, we needed to invest in new capabilities that could

provide the best finishes possible, straight out of the machine.”

Starting in 2002, Redoe Mold began investing in new high speed machining capabilities to enhance the quality of its moulds. The first purchases included a Makino V77 vertical machining centre, a MCC2013 horizontal machining centre and SP64 wire EDM. “Because these machines were adding new capabilities and eliminating several outsourcing procedures, it was easy to justify the investment,” says Leene. “What we didn’t anticipate was the long standing, dynamic impact these investments would have on our overall shop efficiency. In several jobs, we were able to eliminate secondary machining operations and handwork altogether.

“These machines provided a huge benefit with our optic lens moulds, where

The a61’s automatic pallet changer with tombstone fixturing allows Redoe to produce several jobs in a single setup with fewer operations.

we were previously receiving results that varied between 0.004 and 0.010 in. (0.102 and 0.254 mm), and required extended hours of manual labour to meet required accuracies and finishes. Even after nearly 10 years of service, these machines are still providing bench-free surfaces and tolerances under 0.002 in. (0.050 mm).”

Developing a Lean Cost Justification

After witnessing the results produced by its machine tool investments, Redoe Mold began to take a closer look at how it calculates its return on investment.

“For each investment moving forward, we decided to assemble a manufacturing team who could discuss current bottlenecks, share specifications and determine projected performance across the entire part process,” says Leene. “Upon gathering this information, we can accurately quantify how much the process is costing us with current equipment and the cost savings that could be realized with proposed equipment.”

The first investment opportunity to use the new lean cost justification process came in 2007 with the replacement of 32 | june 2011 | www.canadianmetalworking.com

EDMs/CASE STUDY

Redoe has integrated a Makino E33 graphite machining centre and EDNC85S sinker EDM into a robotic cell to extend its unattended machining capabilities.

machine tools

Makino’s EDNC85S with HQSF [high quality surface finish] and rib-head technologies was the only machine surveyed capable of meeting our requirements fully unattended,” explains Leene.

In 2010, Redoe Mold was on the market again to replace its large work zone sinker EDM. With 70 to 80 per cent of its large mould applications featuring deep ribs, the investment team quickly reflected on its experience with the EDNC85S and Makino’s high speed rib-head technology.

Designed to eliminate the traditional compromise of speed versus accuracy in sinker EDM machining, Makino’s high speed rib-head technology uses a linear motor powered W axis located within the Z axis to achieve jump cycles up to 1,600 ipm, which is eight times faster than a stand alone Z axis. This high speed motion, in turn, reduces the length of roughing processes, cuts down on out-of-cut time and flushes the workpiece more effectively, especially in smaller details, thin ribs and deep cavities.

“After our previous EDM broke down, we were forced to outsource several large EDM applications, so it was imperative that we made an investment decision quickly,” says Leene.

“And while we typically conduct thorough evaluations for each machining investment, we knew from our experience with the EDNC85S that Makino’s rib-head technology could reduce our rib roughing times by 80 per cent or more. This led us to invest in an EDNC157, one of Makino’s largest sinker EDM machines.

With performance like that, no other machine could compare.”

three vertical machining centres used in the production of small mould components.

“The manufacturing team determined two significant issues with our current process that needed to be resolved,” says Leene. “It was no longer feasible to have an operator stationed at each machine throughout the day, and inconsistent part quality was resulting in long hours of hand finishing and Investment Demonstrates Commitment spotting. As a result, we knew we needed a Redoe’s part designs are now more complex Automotive part designs are machine that could provide high productivity with longer, deeper three-dimensional continuously growing in complexity and exceptional accuracy and finish with little shapes and fewer draft angles. with longer, deeper three dimensional operator attention required.” shapes and fewer draft angles, making After conducting thorough market research it increasingly difficult to meet time and gathering data from friends in the sensitive orders with three axis industry, Redoe Mold decided to invest in a machines. To meet these demands, Makino a61 horizontal machining centre.

Redoe Mold also needed to “Operating nearly 24 hours per day, invest in multi-axis machining seven days a week, the a61 has delivered capabilities. more than what our three previous “When it came to our more machines ever offered,” says Leene. “Its complex multi-axis jobs, we were automatic pallet changer combined with sacrificing time and money by outtombstone fixturing allows us to produce sourcing three and five axis work several jobs in a single setup with fewer and using less efficient methods, operations. The accuracy and surface such as picker head machining, that required us to perform finishes it produces have reduced EDM and hand finishing by up several setups on multiple machines,” says Leene. “Neither of to 50 per cent and fitting and spotting times by over 70 per cent. these solutions delivered on the quality, lead times or competitive Overall, the a61 has saved us nearly $300,000 per year.” pricing our customers have come to expect from us. To maintain Go Big or Go Home our reputation as industry leaders and reinforce our commitment The success of Redoe Mold’s lean cost justification continued in to quality and service, we assembled our manufacturing team to 2008 with an investment in a robot cell featuring a Makino E33 research a machine that could truly set us apart.” graphite machining centre and EDNC85S sinker EDM. Redoe Mold’s manufacturing team spoke with several “The E33 was intended to be a stand-alone investment to machine tool manufacturers and visited many other shops to replace our outdated graphite mill,” says Leene. “However, the determine the features and technologies they wanted from machine’s accuracy and repeatability provided us with the their investment. To produce the highest quality possible, they ability to completely eliminate benching and CMM verification knew they needed a single, large multi-axis machine that could from our electrode production. We took the opportunity to go complete even their largest jobs as a one-piece fixture assembly. bigger and better by adding subsequent investments to build a During the search, Redoe Mold heard Makino was working robotic cell that could directly feed fresh electrodes to an EDM. with a large car manufacturer to develop a new technology for “The EDNC85S investment was a simple decision. A test machining complex, limited draft deep section tooling, similar piece made from P20 featuring a 0.027-in. rib with 0.5° draft to their lighting moulds and fascias. In reaching out to its and a depth of 1.6 in. was sent out to six different EDM supplilocal Single Source Technologies representative, Redoe Mold ers. The size of the rib did not permit manual finishing, so we found out about the Makino MCC2013-VG six axis horizontal needed a machine that could achieve a 12 RMS finish throughout. machining centre. www.canadianmetalworking.com | june 2011 | 33

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“The MCC2013-VG was very similar to our current MCC2013 but included several unique features and technologies that we hadn’t seen anywhere else,” says Leene. “While many of our competitors have invested in five axis machines, no one in North America had the six axis capabilities of the Makino VG technology, with respect to accuracy and rigidity. We knew that a machine like this would not only meet current market standards, but create a new market advantage that would exceed our competitors’ current capabilities.

“To determine the impact the MCC2013-VG would have on our shop floor, our manufacturing team worked closely with Makino to test several of our most complex 3D applications. The results were nothing short of astounding. By investing in this machine, we’re expecting to reduce semi-finishing and finishing times of cores and cavities by 50 per cent, while eliminating almost 100 per cent of our previous secondary machining operations and associated setups.”

Leene adds that the new capabilities can cut outsourcing “substantially” as well as cutting out all related handwork and spotting.

“As with all our high speed CNC machines, we anticipate it will run close to 24 hours a day, seven days a week, for a total cost reduction of 35 per cent with full return on investment in approximately three and half years.”

A Guarantee for Success

For Redoe Mold, investing in capital equipment is more than just meeting expectations. It’s a sure fire way to secure the

The MCC2013’s high quality finishing capabilities enable Redoe Mold to reduce secondary operations in its optic lens moulds.

future of the business. Its ability to calculate the true value of a machining center enables the company to continuously improve its efficiency, profitability and competitive stance in the global marketplace.

“Even if you go to a bank, you have to show some type of justification and return for your investment; a machine shop shouldn’t operate any differently,” says Leene. “And while we always conduct thorough evaluations for each machine purchase, it’s no coincidence that Makino has frequently come out on top.

The products and services they provide reflect the same quality and service we aim to provide for our own customers.” CM Tony Facione is a sales and process engineer with Single Source Technologies. www.redoegroup.com www.makino.com

How can the right support make your business better?

Visit www.etmoriseiki.com or call 877-765-1331 to find your local Ellison representative.

EDMs/CASE STUDY

machine tools

PRODUCT REPORT AgieCharmilles

GF AgieCharmilles’s new Cut 300 Wire EDM provides faster spark-to-spark wire threading, increases energy efficiency and boosts productivity when cutting parts of variable heights, claims the company. As a successor to the FI 440 wire EDM, the Cut 300 also offers higher flexibility through its ability to hold tolerances measured in microns in both light and heavy parts.

GF AgieCharmilles’ Power Expert smart module continuously calculates part thickness, checking injection pressure and adjusting machine power accordingly. This prevents wire breakage when changing the part thickness being machined. As a result, the EDM improves accuracy and cutting speed in parts of variable heights, such as plastic injection moulds, aluminum extrusion dies and components for the aerospace and medical industries. The machine’s optional touch probe allows the user to inspect a finished part in the machine before it is removed from the worktable, eliminating the need for part inspection with a CMM. The machine accommodates wire

diameters ranging from 0.07 mm to 0.33 mm and can handle part tapers of up to 45°, regardless of part thickness. The machine’s digital CC generator enables surface finishes as fine as Ra 0.1 µm and an optional power module can boost cutting speed to 37.2 in2/hr with an adapted wire.

prior to production. It also automatically turns off the machine when a job is completed or a machining process is interrupted.

To minimize machine footprint, the Cut 300 implements a drop door to provide access to the work area. The machine measures just 102 in. x 111 in. x 88 in.

(2590 mm x 2819 mm x 2235 mm). www.gfac.com/us

Makino

Users can achieve energy savings via the Econowatt 2 smart module. This standard feature can be programmed to automatically switch off the machine at the end of unattended operation or awaken the machine and complete thermostabilization

Makino’s next-generation wire EDMs, the DUO series, provide enhanced performance, accuracy, speed, ease of operation and maintenance with features such as dual wire guide options, a dual spark generator, dual anchored ball screws, and dual high pressure flush pumps.

“This is really the next step in Makino’s wire EDM design,” says Jeff Kiszonas, Makino EDM product manager. “With recent technologies such as Heat, SurfaceWizard and Pico guides, our machines have revolutionized EDM. The DUO series takes these advancements a

360º SUPPORT IS A PARTNERSHIP THAT WORKS FOR YOU. North America’s most trusted machine technology partners bring superior service, application support and product selection to Canada Ellison Technologies and Mori Seiki: A powerhouse combination of superior product selection and machining expertise.

A proven model in the United States, Canadian customers can now reap the benefits of one of the most dependable, accessible and knowledgeable service and application support networks in the industry. It’s just one aspect of Mori Seiki’s 360° Support—total customer care from a global leader in advanced machine tool technology.

THE MACHINE TOOL COMPANY

ELLISON Ellison Technologies • 6497 Edwards Blvd. Mississauga, ON L5T 2V2

T E C H N O L O G I E S

machine tools

EDMs/CASE STUDY

PRODUCT REPORT step further, and will enhance our ability to serve more customer’s needs and provide the most technologically advanced, yet simple to operate, wire EDMs available.”

The series features two models, the Duo 43 and Duo 64. Both models feature a 20 per cent reduction in footprint size compared to their Makino SP-series counterparts. The sizes for the 43 and 64 are 74.8 in. x 102.3 in. (1899 mm x 2598 mm) and 82.7 in. (2100 mm) x 122 in. (3098 mm) with X, Y, and Z axis travels of 17.7 in. (449 mm), 12.0 in. (304 mm), 12.6 in. (320 mm) and 25.6 in. (650 mm), 15.7 in. (398 mm), 16.5 in. (419 mm) respectively. The 43

will accommodate a maximum workpiece size of 27.9 in. (708 mm) x 22.0 in.

(558 mm) x 11.8 (299 mm) with a payload of 1764 lb (800 kg), while the 64 holds sizes up to 35.8 in. (909 mm) x 26.0 in.

(664 mm) x 15.7 in. (398 mm) with a maximum payload of 2200 lb (997 kg).

This series was designed to provide a smaller footprint and ease of installation, without sacrificing work area.

The series feature dual wire guide options, allowing the user to choose either V-guide or Pico Precision (round) wire guides. Whether the application is small hole threading, threading small holes in close proximity, maintaining land accuracy in contoured stamping dies, cutting tapers up to 45 degrees, or general wire EDM job shop work, Makino is the only wire EDM builder that provides a guide solution to every wire EDM application. Duo Spark Generator technology is featured, which utilizes unique spark waveforms with multiple ON and OFF times, almost like using two E-codes at one time. This assures delivery of consistent spark energy that provides superior performance in

speed, finish, and accuracy, while improving energizer life and performance.

The series’ dual high pressure flush pumps provide independent control of upper and lower head flushing jets. The pumps can provide pressure up to 290 PSI to improve roughing speeds and aid in producing superior surface finishes. By circulating through

two pumps, one for each machine head, the machine is able to improve efficiency over wire EDMs containing only a single pump, reduce mechanical failures, and achieve finer finishes. The pumps are independently controlled and monitored through the controller, allowing faster adaptation to changes

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ABB’s easy to use VirtualArc and RobotStudio software lets you program perfect welds in the design phase, before ever touching a piece of metal. These powerful tools let you optimize production cell layout, minimize cycle time and guarantee weld quality by simulating robots, power sources, wire feeders, wire, shield gases and torches.

And the best part is that what you see on your PC will be what you get on the shop floor – repeatable, reliable welds without surprises. This software puts control of the widest most advanced range of welding robots & positioners at your fingertips, all supported by ABB’s in depth application expertise and global service network.

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EDMs/CASE STUDY

during machining operations and providing higher quality parts in shorter cycle times.

This design provides its greatest advantages during detached nozzle applications (poor flush), and further improves the performance of Makino’s HEAT technology.

With dual anchored ball screws, the DUO series provides a rigid construction for long-term sustained accuracy and precision.

Backed up by a 10 year/20,000 hour ball screw guarantee, the Duo series is built for long term repeatability and reliability. www.makino.com

Methods

Methods Machine Tools has introduced a new Fanuc RoboCut iE wire EDM series, featuring a new power supply for accurate and efficient cutting performance in challenging materials. Additional new features include a re-designed lower arm and controls for improvements in efficiency, cutting speeds and energy savings. Offering the same capability for manufacturing complex components as the Fanuc iD wire EDM Series, the new iE

EDM machines offer seven axis simultaneous machining as an option.

“The Fanuc iE wire EDMs are capable of better finishes, increased geometric accuracy to less than .0001 in. (.002 mm) and virtually no recast,” says Steve Bond, national sales manager for Fanuc RoboDrill, RoboCut & EDM products at Methods. “For example, recast is virtually undetectable at 1000:1 magnification in high nickel alloys like Inconel and Waspaloy. As a result, we have significantly broadened the range of EDM applications.”

The new machines feature an upgraded Ai Pulse Control II, providing high speed and accurate cutting for stepped work pieces by enabling optimum control based on the accurately detected number of discharge pulses.

A re-designed lower arm incorporates a unique system that isolates the lower arm power feed contact during final cuts.

This design improves finishes during skim cutting with less passes, straighter parts and improved cutting speeds.

A new energy-saving function displays

ur o y k r Ma r o f r a d calen 1 r 8, 201 e b m e re Nov s Cent s e r g n nto Co

Toro

machine tools

power consumption in real time along with cumulative electric power. The energy saving setting reduces surplus electric power during idle time, reducing overall electrical consumption by up to 20 per cent.

To significantly reduce operating costs and heat output, the iE Series uses high efficiency inverter style chillers.

In addition, the Fanuc Auto Wire Feed System (AWF) has been enhanced to thread while submerged through the start hole of a workpiece with a maximum thickness of up to 8.0 in. (200 mm). In the event of a wire

Conference streams

The Future of Metal Cutting Conference is a one-day conference organized

by Canadian Metalworking. One conference stream will educate you on where metal cutting technology is going. The other conference stream will help you address issues surrounding key management issues. You can mix and match the presentations you hear based on your needs.

Exhibits

As part of the conference leading machinery, equipment and services suppliers will be available during breaks and at lunch to discuss problem solving.

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canadianmetalworking.com www.canadianmetalworking.com | june 2011 | 37

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PRODUCT REPORT break, the iE Series Ai auto wire repair system can now thread through the kerf while submerged to a depth of up to 6.0 in. (150 mm) without returning to the start point.

The iE series also offers software enhancements. The high speed graphic drawing capability provides a drawing time that is three times faster than before.

Software checks the real-time machining status, sends and receives NC programs, and changes cutting conditions. Options include a feature which allows for easy generation of NC programs including tapers with upper and lower irregular figures or tapers with angle commands. www.methodsmachine.com

of very large moulds. The company says it is considered the largest machine tool of its type in the world. The TX10 offers travels of 118 in. (2997 mm) in the X axis, 59 in.

(1498 mm) in the Y axis, and 40 in. (1016 mm) in the Z axis, and accepts workpiece loads as massive as 45,000 lb (20,000 kg).

Sodick

Mitsubishi

Mitsubishi’s latest developments in wire EDM and sinker EDM include the FA10S Advance wire EDM with the M700 Series Mitsubishi control. This Windows-based system with 15-in. LCD touch screen display provides a simple menu configuration for easy navigation. The EA12V sinker has a space-saving footprint and multiposition work tank that allows the operator to set up while circulating the dielectric fluid. The E.S.P.E.R. II software can create programs for measuring, power settings for burning, and orbital paths for finishing.

Mitsubishi’s ED2000M small hole EDM drill’s low energy consumption combines high speed with low wear. The patented power supply generates no bullet nosing on the electrode, creating cleaner holes and quicker breakthroughs. www.mcmachinery.com

ONA

The Model TX10 die-sinking EDM machine from ONA EDM is well suited for the automated and high precision production 38 | june 2011 | www.canadianmetalworking.com

with micro-fine circuitry for achieving high quality surface finishes. The TX10 also comes standard with a 1 micron ecological long life filtration system without consumable cartridges, to ensure long unattended machining. www.onaedmusa.com

With two heads that are commanded by independent CNC’s, the machine allows for the possibility of eroding two cavities in a large workpiece independently and simultaneously. In addition, equipped with open-design S-64-type CNC’s, the machine is easy to integrate into the user’s production management and control system. The latest generation of this control guarantees effective movement and eroding in simultaneous six axis operation (C, A, and B axes in addition to X, Y and Z axes).

Its A-Space function enables any programmable CNC erosion function to be carried out in any spatial direction. The ONA-S64 CNC also includes an extensive set of automatic measurement cycles that simplify the tasks of completing the workpiece and electrode in the machine.

The TX10 belongs to the modularly designed ONA NX family of EDM machines.

The hallmark of these machines is their versatility. Because customers can choose among 40 different standard elements, each user can flexibly configure a machine to suit its precise needs.

For example, one purchaser of a TX10 EDM has a system that is effectively two machines in one. It can be used with a divided work tank, thus operating as separate machines each with its own CNC. Alternatively, when the divider is removed, this TX10 functions as a single machine with a capacious 158 x 79 x 40 in. (4000 x 2006 x 1016 mm) tank.

All models in NX Modular family are equipped with powerful generators of 100 amps and optional 200 or 400 amps. These machines also come standard

Sodick’s new AD30L is a linear motor driven sinker EDM featuring a small footprint and linear motor drives on three axes.

The machine features the SVC Circuit.

Voltage is controlled by the SVC Circuit; therefore the surface finish can be uniformly and efficiently controlled to provide a hig -grade texture or mirror surfaces in a very short period of time. The machine also achieves Zero Electrode Wear. This technology allows the machining of steel materials with virtually zero electrode wear when using graphite or copper electrodes.

Less electrode wear results in fewer electrodes required for machining, saving on production costs and errors associated with multi-electrode preparation. The EDM has an X, Y, Z travel of 12.59 in. (320 mm) x 7.87 in, (200 mm) x 9.84 in. (250 mm) and can accommodate workpieces up to 1,212 lb (550 kg).

The new machine can reduce EDM machining time by up to 50 per cent over conventional EDMs, claims Sodick. Since it is linear motor driven, there are no ball screws or couplings and backlash is completely eliminated. Glass scales on the X, Y and Z axes ensure complete accuracy.

The machine comes standard with a ten-year positioning guarantee to provide the user with peace of mind knowing that positioning accuracy will not be lost. www.sodick.com

TURNING

Cutting tools

A New Turn for Spinning What if you could take the “spinning” of a typical milling tool and combine it with the advantages of a fixed turning tool?

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

Spinning is an established, well-known form of metalworking.

It typically involves a mandrel rotating at high speeds, which is pressed into a metal blank. Simply put, it is the process of turning a single, flat piece of metal on a lathe around a pattern, which then allows the metal to form into a desired, three dimensional shape. A good example of a Canadian company in this area is M.W. Metal Spinning Ltd. in Downsview, ON. “We design table bases,” says Annette Goldstein, the owner of M.W. Metal Spinning. “And we also do a lot of industrial parts—we have CNC, PNC, as well as hydraulic and manual.”

Most in the industry are familiar with CNC, but perhaps less so with PNC, which stands for “Playback Numerical Control.”

Despite the use of these technologies, spinning has not changed very much over the years, and still requires experienced workers who are good with their hands and understand the importance of playing back to perfect the form.

“With spinning you can’t just program it and stick in a disc,” says Goldstein. “There are too many steps. Sometimes you have to literally spin by hand and then play it back.”

Goldstein has spun aluminum, stainless steel, brass, copper, even titanium. There are challenges with each grade; for example, stainless steel will often work harden, risking a crack in the middle of the part. Nonetheless, the advantage of spinning technology—it produces hardened metal—results in significant savings potential of material and weight. And, as we shall see later in this article, the simple act of spinning can be a natural heat dissipater, though with power spinning, lubricants are usually necessary to control the heat build-up on the mandrel.

But spinning is a non-cutting manufacturing process. What if you could take the “spinning” of a typical milling tool and combine it with the advantages of a fixed turning tool?

Spinning, milling, and turning–in one

A few years ago Greg Hyatt was working at Kennametal, where he wanted to conceive of a way to leverage the abilities of a multi-tasking machine to combine the advantages of a mill and a lathe. When he moved to Mori Seiki, (he is vice president of engineering and chief technical officer of the company now known as DMG/Mori Seiki USA) he was in a good position to get the two companies together to realize his vision. The result has been a spinning turning tool jointly developed by Mori Seiki and Kennametal.

“When I was an employee at Kennametal I was director of their disruptive technology group,” says Hyatt. “We had a tool that no machine could support, so it made sense that, when I joined Mori Seiki I gave Kennametal a call.”

What he came up with was a turning spinning tool designed to distribute heat and wear more effectively than a single-point lathe cutter.

“In some ways the idea is not as revolutionary as it appears,” says Hyatt. “The first patent for a rotating lathe tool came out in the 1920s, and it was reinvented many times over the years. But the problem with the original concept is that they were self-propelled–-the cutting force itself propelled the rotation of the tool.”

A test part. Image: DP Technology.

This solved one set of problems, only to create another. It was impossible to precisely control the speed of rotation, which also made it impossible to control the thermodynamic cycle, and without control over the heating/cooling cycle, thermal cracking then became the dominant issue.

“Our innovation was to realize that we could use the milling spindle,” says Hyatt. “We conducted research to understand the thermodynamics of the tool in order to manage the heat cycle.

We can now eliminate fatigue while also attacking the classic thermal modes of failure.”

Specifically, the technology developed by Hyatt uses a turning insert similar to a full radius insert. Typically, this would be mounted on a turning holder. The specialized insert, however, is mounted at the bottom of a cylindrical tool shank and held in a rotary spindle that spins at high speeds. Though a completely different form of metalworking from the non-cutting process mentioned above, the “spinning” in this context also serves to dissipate heat.

The results have been impressive. By using the tool’s rotation to distribute heat and wear around the tool’s entire www.canadianmetalworking.com | june 2011 | 39

Cutting tools

TURNING

diameter, Mori Seiki has found that the spinning tool can increase productivity by up to 500 per cent and tool life by up to 2,000 per cent.

“We see these improvements because conventional tooling can’t do 3,000 sfm,” says Ruy Frota, manager product engineering, tooling systems, at Kennametal. “These are extremely high speeds that would normally generate too much heat.”

When the spinning turning technology first came out, CAM developer DP Technology performed a test cut on a steel workpiece mounted on a Mori Seiki NT4200. The test was run without coolant and included roughing and finishing operations. Because the tool has no single point of contact, the test found that it was excellent for heat dissipation and wear. As well, because it directed most of the cutting forces axially into the spindle, vibration and chatter were reduced. The test also found that the tool was good at back-and-forth-cutting, as well as taper and arc moves.

“By being able to cut on the YZ plane you don’t have the heat and wear limitations presented by single point inserts,” says Dave Bartholomew, technical marketing specialist for DP Technology. “Mori Seiki’s research also found that a 20° angle is the best angle to cut at.”

The images illustrate how spinning turning works.

The team behind the technology is now working on a second generation of this unique tooling concept.

The next generation

Hyatt and his team are now working on a second generation of the tool.

“We are targeting the most difficult and challenging applications such as large work pieces, where you often can’t get through a single cut without tool failure,” he says. “Tool replacement interrupts the process, is labour intensive, and creates opportunity for operator error.”

This second generation of the tool is part of an on-going learning process.

One of the new challenges relates to chip formation.

“What we know from conventional turning does not necessarily apply,” says

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TURNING

Scott Etling, manager, global threading, grooving & cut-off at Kennametal. “The way you orient the tool to the workpiece is critical; this is one of the variables that we don’t have in conventional turning—it changes chip formation. It is easy with this technology to produce very long chips, which are hard to break.”

Because of the orientation of the tool, conventional chip breakers don’t work. The plan is to optimize the parameters

Cutting tools

and geometries based on the spinning tool, with chip breakers around the inserts. The second generation will also be coolantcapable, with the fluid coming through the holder and delivering coolant to the cutting edge radially.

“It uses a hollow insert with coolant passages,” says Hyatt.

“It delivers coolant directly to the cutting edge, with no external nozzles required.”

In some ways, the development of the next generation is made more complex by the very capabilities a spinning turning tool can deliver, such as the fact that the cutting conditions are no longer limited by heat generation, but by the power available in the machine.

“As a general rule, the tool can handle more power than the machines can deliver,” says Hyatt. “To fully utilize it, we will have to start making more powerful machines. The low hanging fruit was in structural and stainless steels–which can still be challenging–but the greatest benefit will come with Inconel, titanium, and other high-temperature alloys.”

The advantages of higher removal rates and improved productivity (of essentially doing more with less) likely won’t be overlooked in the market.

“Our customers are looking at the technology and saying ‘This is cool’,” says Etling from Kennametal. “With coolant delivery and the chip breaker, it feels like the sky is the limit in terms of what we can do with this.” CM

The turning spinning cut process shown in DP Technology’s ESPRIT software program.

Tim Wilson is a regular contributor and freelance writer based in Peterborough, ON.

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Grooving

Cutting tools

Grooving Talks A discussion with industry experts about optimizing grooving tool performance

Canadian Metalworking invited several cutting tool suppliers to a virtual roundtable to discuss key issues around grooving techniques.

How important is it to understand the differences between groove types and what impact can using an incorrect type have on your machining process?

Steve Geisel: Grooving is one of the most technical (if not the most technical) type of machining operation that is performed on a turning machine. Therefore, it is extremely important to know and understand the type of groove being created as this will determine the best tool and insert that should be applied. Selecting an incorrect tool or insert will not only have a disastrous affect on the tooling, but you also risk damaging or even scrapping the work piece.

Dave Andrews: It is important that the correct insert and tool are used to achieve the best results, face grooving requires tools specific to the diameter of the groove, and ID grooving requires great stability in the tool holder as well as optimum chip control inside the component. Tight tolerance grooving requires tight tolerance ground inserts and rough grooving requires insert capable of heavy feed rates and long tool life. Each application in grooving is very specific and care should be taken to select the correct tool and insert for the application to get the desired results.

attempt to (for example) groove and face with an insert that is designed for grooving only. In this example an insert that can machine a groove and face is the one to use. Grooving has many different cutting tips for specific shapes and making a groove to a required print is to know the proper tip shape and size to meet the requirements of your drawing.

Grooving tools come in a multitude of widths. How do you manage to keep inventories for such a vast number of widths?

Steve Geisel, senior product manager, Iscar Tools, Oakville, ON

Glen Ueberschlag: For every machining application there has to be an understanding of what the expected results would be, therefore selecting the proper grooving tool is no different than any other tool used to make parts. If the incorrect tool is selected you can expect to see a less than optimum use of the tool there by effecting the cycle times, tool life and even increase cost per job. If for example you know you are going to use a grooving holder and the application requires grooving and facing you need to understand that inserts used in these holders can compliment different applications but the wrong one used will cause premature wear, possible vibration and even breaking of the insert and damaging of the part if you

Steve Geisel: Iscar has the longest history in providing solutions for grooving applications, and as such we literally have hundreds of grooving inserts varying not only by widths but also profiles, edge preparations, chip formers and grades. We manage our extensive inventory for our North American customers from our central warehouse located in Texas. This warehouse is one of the most sophisticated warehouses anywhere in the world.

Iscar offers customers next day delivery on 98 per cent of standard products.

Dave Andrews: At Sandvik Coromant we try to stock a large assortment of standard widths in both metric and inch to suite customer requirements, this is a big commitment but our customers rely on our quick delivery so its necessary for us to carry this inventory. We also offer a tailor made program of semi standard inserts we will manufacture to a customer’s specific width in a four to six week time frame John Mitchell: When running low volume production it is generally best to have a grooving tool smaller than the actual finished groove. The grooving tool would groove the part twice, thereby controlling the width of the groove. The turn-groove feature would allow this tool to chamfer the groove. In this way the CNC will control the width of the groove. As the tool wears, the machine operator can use offsets to maintain a highly accurate groove width. In high volume production where cycle time is www.canadianmetalworking.com | june 2011 | 45

Cutting tools

Grooving

critical a special grooving insert would be used that would allow for the groove and chamfer to be performed in one plunging motion. The obvious advantage to this is the reduction of cycle time, however as the tool wears there is no recourse other than to change to tool. So it is not necessary to stock a multitude of widths. Standard widths available off the shelf will allow a user to plunge the groove twice and in the case of high volume grooving, specials would be produced to dramatically reduce cycle time.

Inventories can grow out of control if a user

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is to stock multiple widths and in multiple grades.

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Glen Ueberschlag: There are a number of widths you can purchase to do grooving, some may be the exact sizes and others will either be a special if you choose for a specific job width or you will be required to do a step over. The best way to keep the number of John Mitchell, general manager, widths to a minimum is to look at all the different Canada, Tungaloy America, widths and determine which ones you can use on Brantford, ON more than one part width. For example, if you have groove widths on four parts having four different sizes .098 in., .104 in., .109 in. and .115 in. and the only sizes available for these tools are .088 in., .095 in. and .125 in., you would pick the largest one which is under the smallest size you need to machine a groove in, in this case ( .095 in. ). This will require a step over to be make any groove larger than the tool size selected. In doing so, you will reduce your inventory sizes and dollar value you need to have and the number of different tool sizes for grooving.

How important is proper toolholder set up for grooving? Does this change when comparing OD, ID and Face Grooving?

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Steve Geisel: Proper set up is the most important aspect when grooving. In fact, let’s say it is paramount. Whether OD, ID or face grooving, the basic principal of set up is the same. Since grooving style inserts are designed for multi-directional machining, the toolholders should be indicated 100 per cent to ensure that the tool is parallel/perpendicular to the work piece. Over 80 per cent of all performance related issues when grooving are related to improper set up of the tool. If the tool set up is incorrect the following problems will occur. When grooving, achieving a “flat bottom” will not be possible. When side turning, risk of chatter/vibration is high due to incorrect clearance angles.

When ID grooving centre height is extremely important especially when machining small diameters.

Dave Andrews: Sandvik Coromant offers short, medium and long reach grooving holders in most insert widths. This allows the customer to choose the shortest possible overhang to make their component, giving them the best possible stability for the operation. In face grooving, the toolholder must have a curved blade to match the diameter of the groove, this means holders are specific to a diameter range and it is important to choose the

Cutting tools

Grooving

correct holder for the range to avoid rubbing the blade on the work piece.

Glen Ueberschlag: The tool set up for grooving doesn’t really vary between OD and face grooving but it does vary slightly with ID grooving and this is mainly because you are facing the end of the part to machine verses the long side of the part. OD grooving starts with a moving tool to Dave Andrews, turning product specialist, Sandvik Coromant, point of contact of the part and then Mississauga, ON the depth of travel before retracting.

Face grooving starts with a moving tool to point of contact of the part and then the depth of travel before moving laterally along the part.

The major difference will be the maximum depth of groove still allowing the tool to move laterally achieving the face machining, the finish etc. ID grooving is the same as OD. Grinding with exception of the tool position on the machine is held at 90Ëš to the part compared to the position of the OD tool.

Also, unlike OD grooving, you are restricted by the minimum head size that will fit the ID bore.

John Mitchell: Obviously face grooving requires additional clearance. The tool must sit square to the part. Squareness of the tool to the part is much more important in grooving than it is in turning.

| june 2011 | www.canadianmetalworking.com 1 48SGS_609_GIE_R2.indd

Today’s turning machines have undergone significant changes in recent years. There is a growing use of multi-tasking, multi-spindle type machining centres. How do these types of machines impact grooving techniques?

Steve Geisel: These new machine types have a huge impact on performance, offering improved coolant supply thereby allowing higher feed rates, spindle speeds and depth of cuts to be achieved. These machines have the option to enable multiple tools to be used at the same time. All of these combinations result in higher production rates and reduced costs for the end user.

Dave Andrews: Particularly with multi-task machines, the tooling requirements become more complex. They offer great flexibility in terms of machining operations but tool reach and clearance can sometimes be challenging due to the nature of the large spindle unit being used for both tuning and milling.

One of the ways we have helped overcome these issues is by expanding our SL (serration Lock) system. This system gives customers a wide range of adapters set at different angles as well as a large assortment of OD, ID and face grooving blades.

This allows the customer modularity and they can build up the tool assembly for their specific application with proper reach and clearance to suit the machine tool.

Glen Ueberschlag: The single spindle type machines have been and still will be used for a long time to come. The main

9/23/10 5:23:11 PM

Grooving

difference or impact with multi-tasking and multi-spindle type machines today is the speed at which a task can be completed and the complexity of the jobs and tools that can be loaded and run with just a software change reducing down time and job cost. The cycle times become a very important part of these types of machines allowing the operator/owners the ability to do more parts, more complex parts and completing them faster.

John Mitchell: Multi-tasking machines generally implement the use of live tooling. Live tooling allows the machine to utilize traditional milling type tools on lathes. This allows the user to machine grooves with an end-mill. Grooving with an end mill creates small chips, which eases chip evacuation and provides easier access for coolant to reach the cutting edge.

In deep grooving/part off applications, chip evacuation can be a problem. How do you address this?

Cutting tools

control. 2. We can play with the insert grade making the insert either more wear resistant or increase the toughness. This will affect how much heat the insert is able to handle, and ultimately provide us with the best possible tool life. 3. We can turn off the coolant. Grades can be provided that are able to run dry, although we recommend that this be the last resort.

Dave Andrews: Coolant is critical to achieve good tool life in grooving. We have recently introduced a line of grooving tools for deep grooving called SL70. This system is based on our existing serration lock (SL) system but with a larger, oval shaped 70 mm connection between the grooving blade and the Cormorant Captor adapter. This system also offers multiple high pressure coolant jets directed at the insert tip, and helps to get a high velocity, concentrated stream of coolant directly to the cutting zone, keeping the insert cool and extending tool life. It also helps to improve chip control in some materials.

Steve Geisel: The material type and condition ultimately decides what chip former should be used for optimal chip control and evacuation.

Sometimes, however, further control is needed.

At Iscar, this is accomplished by fine tuning the chip former being used, and also by being able to provide tooling like our Jet-HP line that allows through tool, and even through insert coolant.

Glen Ueberschlag: Because chip blocking causes a part to create a lot of heat due to the coolant not reaching the part at the point of contact of the cutting tool, I suggest using a Vortex Air supply positioned just ahead of the cutting area as much as 90° to the part. The Vortex design for air projection is a cooling application more than a pressure application and cooling the part prior to the cutting area generating the heat has, in my experience, been very helpful. The temperatures from Glen Ueberschlag, outside sales/support representative, the Vortex Design are staggering reaching for example Dave Andrews: We have developed a host of Sowa Tool & Machine Co., chip breakers across our grooving platform to -40°coming out of the end of the Vortex Tool. This is not Kitchener, ON try and have an offering for all applications. We always the best possible answer because there is no currently offer ten different chip formers for parting off alone lubrication to the cutting tool edge and the cutting tool life may depending on material and feed range. The most important be compromised but it may be worth it in the long run if you thing in deep grooving is reducing the chip width with the chip don’t have to scrap the part that has value add costs because of breaker. This allows the chip to exit the groove without binding. thermal cracking.

Glen Ueberschlag: The best way to control chip evacuation concerns for deep grooving or parting off is to always flood the area. Depending on material type, you may need to back off or peck once or twice to allow chips to fall away. Also, just as important is considering the best chipbreaker for the material being machined. It is important to have the chips break and fall away from the cutting area so as not to be re-cut verses continuous chip, which in most cases entangles the tool.

John Mitchell: Chip breaker selection is the determining factor in chip evacuation. The chip breaker should curl the chip’s width making it smaller than the groove being produced. The chip should then be coiled along its length giving a “watch spring” type appearance.

In grooving applications, there’s a tendency for the chip to block the coolant from reaching the cutting edge. This can be problematic since intermittent coolant can cause thermal cracking and poor tool life. What do you do to prevent this from occurring?

Steve Geisel: This can be remedied with a few different solutions: 1. The best solution is to provide toolholders, like our new Jet-HP line, that supply coolant to the insert two ways. One nozzle directs coolant to the top cutting edge while a second nozzle supplies coolant from underneath the cutting edge. This helps reduce the heat being generated in the cut and improves chip evacuation, resulting in the best possible tool life and chip

John Mitchell: The chip can act as an umbrella, preventing the coolant from reaching the cutting edge. One way to reduce this from occurring is to direct the coolant just slightly beneath the actual cutting edge, directing the coolant upward. Another way to help prevent thermal cracking is to select a grade of carbide that has a strong resistance to thermal cracking.

Many manufacturers are moving more to unmanned operations.

This requires predictable tool life. How do you reach an acceptable, predictable tool life?

Steve Geisel: This is accomplished by complete, thorough and qualified performance testing and results documentation for the customer. Once the best insert grade and chip former combination is found we can establish the proper cutting parameters to be used that will provide the customer the best tool life and cycle time. Let’s say that we have established tool life to be 450 parts per corner for an unmanned environment. We can set in the machines parameters to index the insert every 400 parts.

This will ensure that we do not run the insert to the point of risking breakage.

Dave Andrews: In unmanned operations it is important to choose not only the correct tool but also the correct cutting speed, high cutting data obviously offers productivity but sometimes also creates unpredictable tool wear as well. We recommend customers that plan to run unmanned to choose www.canadianmetalworking.com | june 2011 | 49

Cutting tools

Grooving

cutting data suitable to achieve the best tool life and maximize machine up time. Also in unmanned operations, chip control is critical as it could interfere with part load and unload and possibly lead to tool breakage. In some cases, we might consider using a side turning operation to open a groove rather than a plunge. Side turning, in many cases, may not be as fast a solution but it can offer more predictable chip control, improving the predictability of the process and insert life, and improving overall machine up time.

Glen Ueberschlag: We all know that there are now more machine operators than there are machinists in our shops and the operators are typically running more than one machine.

This is because of predictable tool life determined by testing the actual run times of the tools being used. Example: if you run a grooving tool in a material and the tool always machines no less than 500 parts and may run up to 550 parts. You then can assume with an almost certainty to always reach a minimum of 10 per cent less than the lowest amount of parts before any of the tools need replacing. The machinist, CNC programmer or machine operators can then program the machine to shut down at the number of parts determined by the previous testing and percentage used, which may vary depending on consistency of material, toolholder or inserts used.

John Mitchell: Insert grade selection and experimentation are critical for unmanned operations. After experimenting with a grade of grooving insert, the maximum consistent tool life

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What challenges do manufacturers face when grooving exotic or composite materials?

Steve Geisel: The challenges tooling manufactures face is that industries like aerospace, automotive and mould and die (just to name a few) continue to develop new materials that need to be machined and it is our job to be able to provide the end user with tooling that is not only able to cut such materials, but also provide him with the best, most reliable and cost effective tool possible. That is why Iscar invests tens of millions of dollars annually in to research and development of new substrates, grades and chip formers.

Dave Andrews: We have an assortment of grooving tools to handle these materials. Whether it be composite products requiring PCD (poly-crystalline diamond) or exotic materials like inconel requiring grooving tools manufactured from whisker reenforced ceramic, we typically have an offering for the customer.

We have also recently expanded our CBN (cubic boron nitride) line of grooving inserts, adding a full radius grooving insert with a CBN tip for the finish machining of cobalt chrome alloys used in the medical industry.

! w! ed Ne rov p Im

NEW & IMPROVED

should be recorded. The number of parts before a tool index should be 10 per cent less than the maximum tool life. This figure should be programmed into the CNC. If there is space on the turret, redundant tools should be set up. Once the machine reaches the predetermined number of parts, the machine should index to the redundant tool.

Glen Ueberschlag: The exotic and composite materials available today present many challenges because of the material toughness (machinability), hardness, and abrasiveness, including the heat that is generated differently between multiple material types. Due to any one of these, tool life can be even harder to predict.

There are many new grades and chipbreakers being designed for these exotic type materials to achieve a common or acceptable tool life.

John Mitchell: Composite materials have very different concerns. Composites can be reinforced plastics, metal matrix or ceramic matrix. Composites have a tendency to delaminate, have fibre buckling, debonding and fibre bending.

The properties of the material are critical.

Fibre orientation or direction of the fibre is an important aspect to machining this material. The rake angle is one of the most critical aspects to grooving composites. The nose radius should be as small as practically possible. Unlike exotic materials, composites require a fast RPM and a very slow feed rate. CM

Quality

CERTIFICATION

So you want to be a

Certified Quality Engineer?

No formal degree program exists in Canada, but there are options to become certified

By Andrew Milivojevich.........................................................................................................................................

Take a close look at all the leading companies in the world today and you will quickly notice their success is intimately tied to the quality of their products and services. A case in point is the birth of Six Sigma at Motorola. This genesis came about because of an analysis of warranty claims in the 1980. The company discovered reworked product had a higher likelihood of failing before the expiration of the warranty period. This was in stark contrast to those products that were manufactured right the first time. They continued to perform beyond the warranty period. This stunning revelation fueled the drive to produce zero defects and the desire to achieve what became known as Six Sigma quality. The result was a renewed focus on quality and the need to engineer zero defects into their products and services. The result for Motorola was an enormous increase in public popularity, which translated into increased sales and profitability. Recently, Toyota automobiles experienced recalls driven by poor quality engineering. It had a major impact on safety, their reputation and profitability globally.

The quality engineer is an individual who understands how to evaluate and control product and service quality. This includes the development and operation of quality control systems, designing and implementing testing and inspection procedures, using metrology and statistical methods to systematically investigate and correct improper quality, an understanding of motivation and human factors, the know-how to implement cost of quality techniques, the quality information systems, and audit quality systems for deficiencies and correction.

In Canada, quality engineering is a discipline gained through on-the-job experience or various continuing education programs offered through local colleges. These programs use a body of knowledge developed by the American Society for Quality as the basis for their curriculum. To the best of my knowledge, no formal degree program exists in Canada.

My own personal journey took me to the Rochester Institute of Technology in Rochester NY. There I obtained my graduate degree from the College of Engineering in Quality and Applied 52 | May 2011 | www.canadianmetalworking.com

Statistics. This had an enormous impact on my career. I had the experience and requisite knowledge to pioneer six sigma tools and methods in corporate Canada and shortly thereafter became the first ASQ certified Six Sigma black belt in Canada.

My journey started as a certified quality engineer and provided a platform upon which I gained my graduate degree, opened a door to six sigma and shortly thereafter resulted in recognition from ASQ as a fellow of the society.

The ASQ defines certification as, “… formal recognition by ASQ that an individual has proficiency within, and a comprehension of, a specified body of knowledge. It is peer recognition, not registration or licensure.”

ASQ was founded by pioneers in the field of quality engineering including Walter A. Shewhart, Mason E. Wescott, Ellis R. Ott, and John W. Tukey. It has a long and prosperous tradition in quality engineering.

ASQ’s Certified Quality Engineering (CQE) program provides individuals the opportunity to achieve peer recognition from the largest global society promoting quality. Not only does the society have more than 85,000 members globally, it is endorsed by many of the leading corporations around the world. ASQ’s latest salary survey shows a full time quality engineer in Canada earns, on average, $64,633, whereas a certified quality engineer earns $69,241, an increase of $4,607.

To become a certified quality engineer, the applicant must meet a number of requirements. First, the applicant must have a total of eight years on the job experience, with a minimum of three years in a decision-making position. If you graduated with a college diploma, bachelors or Masters Degree, two, four, or five years may be waivered. In my case, I had four years of on-the-job quality experience as an engineer, supervisor and manager. I graduated with a bachelor’s degree in engineering, thus four years were waived. I wrote the CQE exam in the early 1990’s and was subsequently certified by ASQ. The CQE exam consists of multiple choice questions that test an applicant’s comprehension of the body of knowledge. The exam consists of 180 questions and the applicant has five hours to complete the exam. The exam is only offered in English.

CERTIFICATION

Quality

AQS Certified Quality Engineer Body of Knowledge Subject

anagement M and Leadership (15 Questions)

he Quality T System (15 Questions)

roduct and P Process Design (25 Questions)

roduct and P Process Control (32 Questions)

ontinuous C Improvement (30 Questions)

uantitative Q Methods and Tools (43 Questions)

Topics Quality Philosophies and Foundations The Quality Management System ASQ Code of Ethics for Professional Conduct Leadership Principles and Techniques Facilitation Principles and Techniques Communication Skills Customer Relations Supplier Management Barriers to Quality Improvement Elements of the Quality System Documentation of the Quality System Quality Standards and Other Guidelines Quality Audits Cost of Quality Quality Training Classification of Quality Characteristics Design Inputs and Review Technical Drawings and Specifications Design Verification Reliability and Maintainability Tools Material Control Acceptance Sampling Measurement and Test Metrology Measurement System Analysis Quality Control Tools Quality Management and Planning Tools Continuous Improvement Techniques Corrective Action Preventive Action

Collecting and Summarizing Data Quantitative Concepts Probability Distributions Statistical Decision-Making Relationships Between Variables Statistical Process Control (SPC) Process and Performance Capability Design and Analysis of Experiments

Examinations are conducted twice a year, in June and December, by local ASQ sections across Canada. The use of reference materials and calculators is allowed, however not in previous study exams.

The body of knowledge spans the following subject areas and topics shown in Table 1. Four out of the six subject areas are technically focused and cover about 80 per cent of the questions on the exam with a particular emphasis on product and process design, product and process control, continuous improvement, and quantitative methods. The complete CQE Body of Knowledge can be obtained from ASQ. It goes into greater details versus levels of cognition, based on Bloom’s Taxonomy, for each of the topics described in Table 1.

If you believe you meet or exceed the experience requirements and want to become a certified quality engineer, go to ASQ.org and download an application. The cost to apply and write the exam varies, depending on whether you are an ASQ member. Once you submit your application, you will need to choose your exam date, so make sure you have given yourself suitable time to prepare for the exam.

You are allowed one opportunity to reschedule your initial exam and have up to one year after your original date. In the event you wish to cancel your exam, you must notify ASQ no later than six business days prior to your exam. In each of the previous cases, you will receive a refund minus an administrative charge. In the event you miss your exam, you will forfeit all fees and will need to re-apply.

Many resources are available to assist you. Your local ASQ section will be able to guide you. Some applicants will choose a course of self-study. If you choose this route, the Quality Council of Indiana offers self-study material that will be of assistance. However, this course of study requires focus and discipline. Alternatively, refresher courses are available through your local ASQ section or through online training from ASQ. Writing the exam can be a daunting task. I have met many applicants that had the required knowledge but failed to obtain certification because of the enormous pressure they placed upon themselves. My conversations with many of these applicants revealed that they would benefit from the opportunity to take a practice exam. I have created a free web-based CQE e-learning Practice Exams site for applicants who want to get a “feel” for what they might expect on the CQE exam. You can test your knowledge, grade your efforts and see which subject area requires additional study. It can give you an enhanced level of confidence.

To register for the CQE e-learning Exam Site, click on the Sign-Up button located under the User Login section located at www.tkmg.org. Once you become a registered user, go to the User Login section of of the site, located at www.tkmg.org and click on the Login button Enter your User Name and Password that was emailed to you when you registered. Once logged in, you will gain access to our Member Site where you can take advantage of our CQE e-Learning Exams. CM Andrew Milivojevich is president of The Knowledge Management Group Inc. www.tkmg.org www.canadianmetalworking.com | june 2011 | 53

PLASMA CUTTING

Fabricating

Battle of the Gases Can plasma replace its older sibling oxyfuel or is there room for both?

By Nate Hendley

For years, plasma cutting was seen as the upstart younger sibling of oxyfuel, a considerably older, more established cutting process. Sure plasma was faster, but it came burdened with a host of operational issues that made end users wary.

Recent technological advances, however, have made plasma consideringly more appealing. Still, even its most ardent supporters don’t think plasma will completely displace oxyfuel any time soon.

Plasma is an ionized gas that conducts electricity. Developed in the 1950s, plasma cutting can be used on any electrically conductive metal with a minimum of pre-heating. It can, however, only cut about two inches deep on average. The plasma process is used in many industries, including metal fabrication, construction, agriculture, and automotive repair.

“The biggest benefit [of plasma] is the speed in which it cuts,” says Timothy Joslin, cutting machine product manager, Koike-Aronson, Arcade, NY. Indeed, plasma can cut up to six times faster than its oxyfuel counterpart.

Oxyfuel typically uses one of five fuel gases—acetylene, propane, methylacetylene-propadiene (MAPP), propylene and natural gas—in combination with oxygen. An old-school cutting method, oxyfuel can pierce mild steel up to 24 in. (609 mm) thick. It won’t, however, cut aluminum or stainless steel and requires pre-heating. The oxyfuel process is popular in agriculture, fabrication, construction, maintenance repair, mining, automotive and among hobbyists.

“The main advantages of the oxyfuel cutting process are its simplicity, low cost and ability to cut thicker materials.

However, its disadvantages are its slow cutting speed and the higher heat input into the plate,” says Steve Zlotnicki, regional product line manager, cutting, North America for ESAB Welding and Cutting Products.

Experts urge shop owners to ask themselves what materials they cut most often and the thickness of their cuts before

Hypertherm’s HPR400XD plasma cutting system making a hole using the company’s True Hole Technology process.

purchasing one process or the other.

“The thing to remember about these two popular processes is that they each have their place. It makes no sense to favour one over the other because each has unique capabilities that lend themselves better towards some applications,” says Zlotnicki.

Nonetheless, a few hard-fast rules do exist: if you’re cutting aluminum or stainless steel, then obviously plasma is the way to go. Plasma is a wise choice for thin materials in general.

“For anything half-inch or less, plasma cutting really does shine,” says Steve Hidden, product manager, plasma group for Miller Electric, an arc welding and cutting equipment manufacturer from Appleton, Wisconsin.

On the other hand, if you’re cutting nothing but thick metal and aren’t using aluminum or stainless steel, then oxyfuel is your best bet.

Besides cutting thicker material, old-fashioned oxyfuel has www.canadianmetalworking.com | june 2011 | 55

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two big advantages over plasma: cost and portability.

Plasma needs a primary power source, and is thus not hugely portable. By contrast, an oxyfuel cutting setup consists of a fuel tank, an oxygen tank and a torch. An oxyfuel system doesn’t require a primary power source (that is, electricity) to run, which means it can be easily toted around. This feature makes oxyfuel a good choice for repairing farm equipment in the field, for example.

Plasma’s power requirement limits how deep it can cut.

Theoretically, plasma could cut well beyond two to three inches (50.8 to 76.2 mm), but this would require an enormous, power generation source—not something shop owners interested in maximizing floor space would welcome.

“The limitation [with plasma] is how much power you have to bring,” says Hidden.

If they’re more portable, oxyfuel systems are also cheaper than their plasma counterparts—up front, at least.

“Capital equipment costs for oxyfuel are dramatically lower,” states Jim Colt, strategic account manager of Hypertherm, Hanover, NH. Colt points to his company’s HPR400 plasma system, released four years ago, for a cost analysis.

“The HPR400 has the ability to cut up to two inches thick on carbon steel, but it’s $60,000 for one plasma system, which would be bolted onto a CNC cutting machine … a one-torch oxyfuel system would probably be about $6 – 7,000,” says Colt.

The big difference is that “that HPR400 will cut six times faster … if you’re looking at long term operator costs, plasma is a far better deal over time,” he adds.

The HPR800 is a more recent Hypertherm offering. It promises

56 | june 2011 | www.canadianmetalworking.com

Hypertherm’s HPR400 plasma system cutting thick stainless steel.

PLASMA CUTTING

dross-free cutting to 38 mm, and is capable of piercing 75 mm (three in.) of stainless steel and aluminum.

While plasma is faster than oxyfuel, it used to have a reputation for being complicated, finicky and tough to use. Fabricating equipment suppliers have made enormous strides, however, in improving the technology behind the plasma process.

“We’re not done developing greater capability with plasma.

Plasma’s not going to get any cheaper, but it is getting more productive, with higher accuracy over time … oxyfuel has been pretty stagnant for about 30 to 40 years,” says Colt.

“Modern plasma equipment is far easier to set up than it used to be. Almost all plasma systems these days are available with an “automatic gas control” which simplifies setting up many of the plasma parameters. ESAB’s plasma systems are fully integrated with the CNC, so that they can be completely automated. In a fully automated system, the part program calls the plasma parameter file so that the operator doesn’t have to adjust anything. His only responsibility is to load the table with the correct plate and make sure the right consumables are in the torch,” adds Zlotnicki.

As Zlotnicki notes, a windows-based CNC control has enormously simplified the plasma cutting process.

In a recent magazine article, Colt stated that “virtually anyone can operate even the most complex, large, multi-torch CNC plasma machine manufactured today … the CNC controls every function that an expert operator was required to do in the past, thus eliminating errors and dramatically improving process consistency.”

Fabricating

“Other features of modern plasma systems also make operation easier and more reliable, such as pre-assembled consumable sets and on-screen process information. For example, ESAB’s PT36 plasma torch features a SpeedLoader system that allows the operator to pre-assemble a nozzle, diffuser, shield and retainer. Then when it comes time to switch from one nozzle size to another, switch out is a breeze,” adds Zlotnicki.

ESAB has also created a Vision T5 CNC that includes a database of plasma torch parts, depicting pictures and part numbers on a screen. The operator can use the system to look up detailed information or get close-up views.

The latest technological breakthrough for plasma centres around “bolt-ready” holes.

“Our goal was to make plasma cut holes more round. Plasma cut holes typically have a ding or a divet where the object entered into the cut-path of the hole,” says Colt.

Hypertherm’s patent-pending “True Hole Technology” eliminates the hole taper that usually comes with plasma cut holes, reduces ding and makes it easier to remove dross. The end-result is a “bolt-ready” hole.

True Hole is the “way to get extremely good holes… in some cases, better than laser cut holes,” says Colt.

Other companies have similar systems: ESAB’s process, for example, is called “Precision Hole Technology.”

This technology “allows users to dramatically improve their plasma hole cutting results on mild steel up to one inch thick,” says Zlotnicki.

Koike-Aronson, meanwhile, distributes a plasma cutter called

www.canadianmetalworking.com | june 2011 | 57

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the Kaliburn Spirit 400A which offers a 400 amp output and an automatic gas console. The latter automatically sets process parameters for maximum ease-of-use. The system also apparently makes a pretty decent hole.

Hypertherm’s HPR800 plasma system cutitng extra thick stainless steel.

For all of plasma’s advances, experts doubt it will become the dominant process in the future.

“It would be improper to say one process is superior overall.

Rather, either could be superior for a specific application. And since so many fabrication shops and manufacturers deal with a wide array of cutting applications, the majority of cutting machines sold today are still equipped with both plasma and oxyfuel cutting tools. This allows the end user to choose the tool that is superior for the application. The important thing for the user to know is where that distinction lies for the equipment they have,” says Zlotnicki.

“Anybody that’s working with metal, especially in any type of repair situation, you’re always going to find a place to use that oxyfuel and you’re always going to find a place to use the plasma. It’s a matter of understanding which tool works the best in the application you’re working on,” agrees Hidden. CM Nate Hendley is a regular contributor and freelance writer based in Toronto. www.esab.com www.hypertherm.com www.koike.com/index www.millerwelds.com

58 | june 2011 | www.canadianmetalworking.com

PRODUCT REPORT ESAB

ESAB Welding & Cutting Products has added a new capability to its CNC plasma cutting machines—Precision Hole Technology, an integrated set of systems that improve hole cutting cylindricity as well as delivering the highest possible edge quality. This new system takes advantage of the advanced gas control capabilities already available in ESAB’s m3 Plasma systems by capturing the best hole cutting techniques in ESAB’s new Columbus.

Net programming software. Precision Hole Technology also utilizes the company’s encoderbased height control, as well as the Vision 5x series of CNCs. The technology is available on new ESAB cutting machines and can also be retrofitted on many existing ESAB machines in the field.

The Precision Hole Technology represents a significant engineering development encapsulated in a new process control database. This database is used by ESAB’s Columbus.Net programming and nesting software to automatically produce the highest quality plasma cut holes on mild steel up to 1” thick, for hole sizes down to 1:1 ratio without manual intervention.

The database is also used in ESAB’s new Vision T5 CNC, where it automatically processes any part program created through the EasyShape library with optimum small hole quality. This includes DXF and DWG files imported right at the Vision T5 CNC, as well as nests. Building this technology into both the off-line programming software as well as the new CNC gives ESAB customers the flexibility to quickly and easily produce the highest quality plasma cut holes.

The Vision T5 features an ergonomic, wide screen layout and an advanced touch screen interface that offers twice the display area of other CNC controls, as well as unique process control features designed to simplify operation and boost productivity.

ESAB integrates all process controls for every cutting or marking tool, making operation quicker and easier for every machine. The Built-In Process Database simplifies cutting tool setup by automatically setting parameters such as cutting speed, kerf offset, and timers based

on material thickness, material type and cut quality desired. The operator sees a picture and part number for the torch parts that are needed for both plasma and oxy-fuel torches. All cutting and marking process tools are controlled directly on the touch-screen. Operation is easier and faster when the controls you need are always at your fingertips. This makes the Vision T5 the ideal CNC system for controlling complex cutting tools and processes, such as triple torch oxy-fuel beveling, plasma beveling, inkjet marking, laser cutting and beveling, grinding, milling and drilling. Operators can handle special applications, including grate cutting, wind tower section cutting, or panel cutting with material thickness transitions.

Vision T5 controls from 1 to 12 stations without additional panels and controls numerous axes for variable beveling and rotating tools.

Automatic machine referencing makes machine startup quick and easy. Program parking allows cutting of rush jobs without losing your place in a nest. Remote diagnostics using a live connection between ESAB service and your control speeds up trouble-shooting or training.

An important part of Precision Hole Technology is the automatic height control system that sets and maintains the optimum torch height during hole cutting. ESAB’s m3 Plasma system features an automatic gas control that has always had the capability to mix and switch shield gases as required. The Process Database built in to the Vision T5 CNC is now expanded with the additional data required for small hole cutting. www.esabcutting.com

Fastcut CNC

The new Icon Elite Series from FastCut CNC has quickly become our best seller.

Dollar for dollar it out performs all competitors, claims the company.

With dual linear guideways on the gantry, solid welded cutting substructure and a standard Cable Carrier, the Icon Elite has what it takes to produce non-stop profits in an

PLASMA CUTTING

industrial application.

The complete drive system has what the company says is the best guarantee in the industry–two years. This includes the HD 570 oz/in motors, the Helical Rack and Pinion Linear Drives and even the Automatic Torch Height Control with its Sealed Ball Screw.

will help JMH buy another plasma system for the shop.

The Duramax retrofit torches also offer convenience. They are designed with the same Easy Torch Removal (ETR) connection as the standard Powermax1000 and Powermax1250 torches, enabling switching from the older torch to the new in just seconds.

These retrofit torches use the same consumables as Hypertherm’s Powermax65 and Powermax85, allowing customers with a mix of systems to simplify their consumables stock. In addition, Spring Start technology, a new patent pending design, eliminates moving parts within the torch for greater reliability.

This CNC system ships easily in a small wood crate and includes the start-up instructions and operating manual. FastCut CNC customer support is part of the service. The new system raises the bar in the affordable CNC plasma cutting category and includes quality, user friendly software. www.fastcutcnc.com

Hypertherm

Powermax1000 and Powermax1250 owners interested in upgrading to the latest Hypertherm torch technology can now enjoy the benefits of Hypertherm’s Duramax torch series, including more durability and longer consumable life, while using their existing Powermax systems.

Similar to the new Duramax torches introduced last fall with Hypertherm’s new Powermax65 and Powermax85 systems, the torches were designed with durability in mind. They can withstand impacts five times greater than the previous generation of torches and are more heat resistant so they can easily conquer the most demanding job.

The Duramax torches use a new Conical Flow nozzle and spring electrode for longer consumable life. Hypertherm testing shows an increase of up to 55 per cent in the life of the Duramax consumables, which translates into a 30 per cent savings on consumable costs.

“We were using five sets of tips per week. Now with the new retrofit torch, we use the system more and are using only one set per week,” says Travis Bering, a manufacturing foreman at JMH Trailers in Pennsylvania. Bering estimates the money his company is saving on consumables

The Duramax retrofit torches are available in an ergonomic, 75° hand torch (HRT) or a 15-in. full length machine torch (MRT).

Similar to the standard Duramax machine torches, customers have the ability to convert the MRT into a 6-in., short-barreled machine torch perfect for robotic and pipe-cutting applications. www.hypertherm.com

Miller

Miller has introduced the Spectrum 875 Auto-Line plasma cutter, which replaces the company’s Spectrum 2050 plasma cutter. Weighing 56 lb (24 kg) and able to cut metal up to 1-1/4-in. thick (7/8-in. at a rated quality of 10 ipm), (31.75 mm/22 mm/254 mm per minute) the new plasma cutter is ideal for fabricators, contractors and businesses that require job site versatility, portability and exceptional cutting performance.

The cutter recognizes and adjusts to any input voltage from 208 to 575 volts, single or three phase power and 50 or 60 Hz without the need for physical linking mechanisms. The Auto-Line technology enables the unit to operate on generator power without being affected by power fluctuations during the use of other power tools.

Fabricating

“The Spectrum 2050 provided users with features, benefits and durability that defined its product category. Building on that legacy, the Spectrum 875 Auto-Line offers everything that users loved about the Spectrum 2050 in a smaller package and with a lower price tag,” says Steve Hidden, product manager with Miller.

The new plasma cutter offers increased cutting power and several upgraded features, yet with a lower price tag and in a package that weighs 30 lb (13 kg) less than the 2050. Among these upgrades, the Spectrum 875 Auto-Line provides automatic air regulation, eliminating the need to manually adjust the air pressure to match the cutting application, an additional 5 amps of output power and Miller’s patented Ultra-Quick Connect torch and work cable for the fastest torch and cable connection and removal in the industry.

The Auto-Refire technology automatically keeps the pilot arc lit while cutting expanded metal or multiple pieces of metal, eliminating the need for manual re-triggering and reducing operator hand fatigue.

For fabricators who want to take plasma cutting precision to the next level, the Spectrum 875 Auto-Line is also available with an optional machine torch package for mechanized cutting applications.

The machine torch package includes a barrel-style torch for attachment to an automated cutting system, and a cable kit allowing easy access to remote on/off, ok to move and voltage sensing.

In mechanized applications that require very precise output consistency, the Auto-Line technology provides a smooth, reliable cut in the event of brownouts or other primary power fluctuations.

The Spectrum 875 Auto-Line will not replace the standard Spectrum 875, which operates solely using the most common input power in fabrication environments: 230-volt single-phase. www.millerwelds.com www.canadianmetalworking.com | june 2011 | 59

BENDING/CASE STUDY

Fabricating

World-class

Fabricating

Leading edge technology gives Alberta fabricator competitive leg up

By Patty Jessome..............................................................................

Ingenuity, opportunity and the ability to see beyond manufacturing restrictions has made Ray Turner and his Edmonton, AB, company, Lenmak Exterior Innovations Inc., a success story.

Turner is a humble visionary who used his knowledge of equipment and his keen sense of research to turn his small shop into a world-class facility. In fact, he invested in a flexible manufacturing system (FMS) made by Prima Power (formerly Prima Finn-Power) and applied it to making exterior building components.

“I don’t think anyone else anywhere is doing what I’m doing,” says Turner. “I’m using precision equipment and using it in a non-precision environment.”

The installation of Prima Power’s Punch, Shear and Bend Flexible Manufacturing Cell has given the company a competitive edge with the potential to double earnings over the last three years.

Of course; getting to this point didn’t happen overnight.

Thirteen years ago, Turner was a salesman for a residential exterior wholesale distributor, when he recognized an opportunity that turned into a full-fledged business. “We were selling maintenance-free vinyl windows but there was no way to dress up or add character to the windows without adding maintenance to them,” he says.

“I gave it some thought and came up with a prefinished aluminum window batten that added colour and character without compromising its The Shear Genius (SG) integrated punch shear combination transforms a full-sized sheet into punched parts.

Prima Power’s flexible manufacturing system (FMS) has given Lenmak a strong competitive edge. The system includes an automated bender (Express Bender EBe5), seen here.

maintenance-free quality.”

He opened a small shop and started to produce decorative accessories for residential exteriors including linear channels, aluminum shutters and octagon louvers. He had already built a good client base from his former competitors in the residential exterior building business and had a successful start.

Soon after he started his business he attended a metalworking show in Atlanta and began to research equipment. When he returned, he went to his wife Lori (the other part of this successful venture), and asked her if they could remortgage the house to buy a 10 ft folder and a 10 ft shear. She agreed.

“Everything took off after that,” he says. “We added more equipment and the business expanded to other markets. I was bending pre-finished steel trims for flat roofers, agriculture and standing seam buildings.”

In 2004, Lenmak progressed to vertical integration and moved to master coils giving the small but evolving company a lot more flexibility. It also implemented Lean Manufacturing which led to greater company structure. “We learned the power of reducing non-value added activity and how to pull production rather than push.”

Prima Power

The company continued to grow. It was producing a very good and substantial product line but Turner had an idea that kept floating around in his mind. “I always wanted to take the FMS concept and see if I could adapt it to manufacture multiple side exterior panels.”

Over the years, he had contact with Prima Power’s sales rep who shared information about their products to Turner. He also continued his research; www.canadianmetalworking.com | june 2011 | 61

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talked to people in the business, and travelled to metalworking shows around the world. When the opportunity came his way, he visited other manufacturing facilities where the equipment was being used. “I talked to people from all over the world who were using the Prima Power equipment and even hung around Prima Power’s booth for days at one conference. I did whatever I could to educate myself about the equipment.”

Then, in January 2009, just when the recession hit, the opportunity presented itself. Even though the company’s sales dropped by 35 per cent and the Canadian dollar started to creep up, Turner kept his eyes on the prize. “Sales for machines world wide were declining because of the recession. There was an opportunity there and I took it,” says Turner.

He went to Lori for guidance. She agreed to buy the equipment but with one stipulation. “She wanted to stay in the same location and I knew that would be difficult considering the space restrictions we had.”

Prima Power had a solution to his space problem. They told him about a 90˚ line they created for a company in Italy for making pizza ovens that might work in his facility. It did.

Today the company is using Prima Power’s Punch, Shear and Bend Flexible Manufacturing Cell, which includes the Shear Genius (SG) punch/shear combination (model SG6: 3,074 mm x 1,565 mm (120 in. x 60 in.) and the EBe automated bender.

Shear Genius flexibility

The SG integrated punch shear combination machine transforms a full-sized sheet into punched parts. These parts can be moved

Ray and Lori Turner are big believers in investing in leading edge technologies: “invest in as much automation as you can. You will compete and win,” says Ray.

to secondary operations using sorting and stacking automation and then on to bending operations without being touched by human hands.

Mike Stock, vice president and bending products manager for Prima Power North America Inc., says the combination delivers finished parts with a dramatic reduction in scrap and manual labour along with increased profitability.

The SG also eliminates wasteful skeletons and costly secondary operations such as deburring. It allows the automated process to begin with a full-sized sheet of material and

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BENDING/CASE STUDY

The Prima Power flexible manufacturing system includes the Express Bender (EBe5) automated bender, seen in top image, and the Shear Genius (SG) punch/shear combination machine, seen below in the background, with transfer table in forefront.

end with a punched part after automated loading, punching, forming, shearing, stacking and unloading — all in one operation.

“This allows true single-piece flow to be synchronized with a customer’s takt time,” says Stock.

The Sorting and Stacking Robot automatically unloads the parts from the SG and loads the parts to the Express Bender (model EBe5) automated bender. “The EBe is designed specifically for each fabricator’s production requirements to achieve maximum productivity, quality, and repeatability,” says Stock.

The bending operation is fully automated, from the loading of flat punched parts to unloading of the finished product.

It has a maximum bending length of 2550 mm (100.39 in.) and a maximum opening height of 200 mm (8 in.). The new construction features actuations of the bending blade movements (vertical and horizontal)

by NC servo axes instead of hydraulic cylinders. The upper tool movements are also made by another NC servo axis.

Fabricating

without losing on his investment. “We cut all of our sheet, which the new system required.”

Lenmak is making a distinct product with the Prima Power manufacturing cell: decorative exterior panels (up to 42 x 96 in./1066 x 2438 mm). “I created my own market for the panels just by looking at my existing equipment and seeing if it could make something I hadn’t thought it could.”

The line has certainly changed the manufacturing process. “We do it from start to finish; from cutting the sheets to bending the final pieces,” he says. “A job that used to take 20 minutes, now

With Hypertherm’s True Hole™ technology, now you can.

The patent-pending True Hole process delivers bolt-quality holes on mild steel without operator intervention, giving you consistent results from operator-to-operator, shift-to-shift, and site-to-site.

To learn how True Hole works, visit www.truehole.com or scan the tag below to watch a short video that explains the process.

A manufacturing marriage

The automated system married well with Lenmak’s previous business and Turner was able to continue working with master coils

MaNUal PlasMa I MECHANIZED PLASMA I aUTOMaTION I laser I CONsUMaBles

www.canadianmetalworking.com | june 2011 | 63

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takes a fraction of the time.”

But the benefits don’t stop there. He says part quality, along with increased production and flexibility is due to Prima Power SG and EB technology.

There’s been elimination of labour costs due to automation and improved operator safety due to the structural integrity of the line, which removes the operator from the process area.

There is also a tremendous value

or awkward that are made in a facility of where a building is being built, bring in more LEED credits. We should be looking at this as a marketable edge.”

Competing with China

Turner believes if Canadian manufacturers tool up and offer worldclass in manufacturing capabilities and equipment, they can compete, and they can look after their own needs. “We can potentially make better products and move them to other parts of the world.”

He believes efficiency equals pricing and manufacturers should buy good equipment and be efficient and let the

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The sorting and stacking robot, seen here, automatically unloads parts from the Shear Genius (SG) and loads them to the Express Bender (model EBe5) automated bender.

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to the customer with delivery times drastically cut. “What used to take six to eight weeks to deliver now takes one to two,” Turner says.

price look after itself. “Prima Power is an excellent example of the quality equipment I’m referring to.”

LEEDing the way

Turner sees a bright future for Lenmak.

“I will survive. I’m out in front and will always buy top-of-the-line. I see a new custom building in our future with more capacity and we will gain more LEED credits as we more foreword.”

Turner’s advice to Canadian manufacturers is simply this. “All you have to do to compete is buy quality equipment and believe in yourself,” he says. “Labour will become less of an issue when more automation is used. To keep just-in-time delivery, invest in as much automation as you can and you will compete and win.” CM

Turner also saw the advantages of Lenmak earning Leadership in Energy and Environmental Design (LEED) credits from his new line. Something Turner sees as a marketable advantage. (LEED sets new parameters to develop sustainable and environment friendly buildings.)

“This is becoming a significant issue in the building materials business,” Turner says. “Buildings provide 48 per cent of the carbon worldwide and the construction industry is under pressure to produce sustainable buildings.”

The challenge is to produce structures with the least amount of carbon footprint during and after construction. “The more commodity items or items that are bulky

Future friendly

Patty Jessome is a freelance writer based in Edmonton, AB.

BENDING/CASE STUDY

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PRODUCT REPORT Amada

With models varying in capacity from 55-600 tons, Amada’s new HD NT press brake series can handle a full range of applications in bend lengths from 79 to 276 in. (2000 to 7010 mm). This series features a Hybrid Drive system engineered for low energy consumption and requires less hydraulic fluid than conventional machines.

In addition to being eco-friendly, the Hybrid Drive system maintains a high rate of repeatability (± .00004 in./0.001 mm).

Available on most models, Amada’s patented variable slit crowning feature ensures consistent angle accuracy. Larger models are equipped with an auto-crowning feature that provides precise results based on calculations created by the AMNC-PC control. Additional features of the new HD series include: •High speed, high precision bending sensor that eliminates test bends.

•Increased distance between tooling and greater stroke length provides for a larger processing area.

•Expanded processing area enables deep box bending.

•Increased distance between punch and die allows for safe and easy processing of heavy materials.

To maintain bending accuracy while processing materials that vary in type, thickness and grain direction, the HD series is equipped with BI (Bend Indicator) sensors that utilize probe and laser technology. BI-S (probe type) or BI-L (laser type) result in trial-free bending. Bend angles are measured and adjusted on the fly to provide the correct angle on the first bend and to monitor and adjust angles throughout the run. BI technology boosts bending repeatability and reduces QA inspection and rework.

Fabricators processing thin sheets will benefit from the HD’s consistent accuracy and ease of use. The combination of an ecofriendly, Hybrid drive system and BI sensor technology ensures precision bending even if the operator lacks experience. Fabricators

processing medium and thick sheets will profit from consistent angle accuracy, fewer trial bends, reduced material handling and the ability to perform deep box bending.

Additionally, fabricators processing thick and large sheets will welcome safe and easy processing of heavy materials, easy to adjust angles plus simplified tool changes.

A wide variety of part geometries can be accurately processed thanks to a high precision (± .0004 in./0.010 mm) tapered backgauge. For precise bending control, the backgauge provides continuously updated feedback to the AMNC/PC NT-based control where exact positioning can be viewed at any time.

To provide maximum productivity, the HD’s intelligent control digitizes the bending process and delivers offline programming.

Enhanced network functions within the AMNC control allow operators to call up complete sets of bending data from the server. In addition, the AMNC control can create 3D images from DXF, DWG and IGES files. Programming bending data using 3D images makes programming a more intuitive process. More importantly, 3D simulation enables the identification of problems before they can occur. www.amada.ca

Bystronic

Bystronic’s enhanced version of the Xpert press brake incorporates a high speed ram positioning system and the new Fast Bend+ safety system for reduced bending cycle times. The high speed ram positioning system is capable of reducing bend cycle times by 15 to 35 per cent, approach speeds of up to 600 ipm and bending speeds up to 47 ipm without sacrificing accuracy. The company claims it is the only press brake on the market that introduces no angle errors itself with a ram positioning accuracy of .00015 in./0.0038 mm.

The Fast Bend + safety system allows the machine to draw extremely near the sheet at high speed, so that slow movement is only necessary during the actual bending process. This cuts the time required by

Fabricating

BENDING/CASE STUDY

PRODUCT REPORT approximately 20 per cent. Furthermore, the new safety system adapts itself automatically after each tool change and moves the machine to the correct tool height without any additional intervention. If a tool is not recognized by the system, the machine stops, making it nearly impossible to use an incorrect tool, which increases the safety even more.

Low energy consumption, less machine noise, and less heat characterize the Energy Saver. As soon as the upper beam has reached the top dead centre position after a bend, the main motor of the Xpert switches off automatically until the next bend process is started. This does not change the operational flow and the process speed remains as high as usual. However, it saves up to one third of the energy, produces less noise, and does not produce any excess heat.

The Bystronic Xpert adjusts ram position and crowning during the bending process in response to material properties. With the touch of a single button, the bending sequence and the positioning of the backstops are determined, the tool plan is created, and the process data is generated, all automatically. www.bystronicusa.com

Cincinnati

The MaxForm hydraulic press brake from Cincinnati Inc. combines state-of-theart forming speeds and part processing productivity with “smart” controls that speed and simplify programming, setup and part handling. An industrial PC-based touchscreen control and Windows software eliminate two thirds of the programming steps with conventional CNC controls, while advanced hydraulics and control technologies deliver cycle-eating ram speeds—up to 700 ipm—for more strokes per hour and parts per shift.

The high speed precision forming machine is available in 90 to 350 ton models and lengths to 14 ft (4.3 m). Exceptional ±0.0002 in. (3 Sigma) repeatability delivers consistency for bending of complex parts without deviation, drift or error stacking. Cincinnati backs the MaxForm with industry-best five-year parts and one-year labour warranties.

Simulation software enables easy offline part programming, while advanced “see and do” 3D graphics and automatic processing intelligence compensate for varied operator 66 | june 2011 | www.canadianmetalworking.com

experience levels. A Bend Simulation Module, standard on the machine, allows programs to be created quickly offline or at the machine and proved out step-by-step in realistic 3D views to avoid trial bending.

Smart controls automatically calculate and apply adjustments for ram reversal position, bottom bending tonnage, gage allowances, and material springback.

The machine comes standard with bolt-on Cincinnati Quick Clamp ram nose designed for hardened, sectionalized American tooling.

It maximizes ram protection by doubling load capacity from 15 to 30 tons psi.

The versatile press brake offers as options Wilson’s Power Express hydraulic clamping and a Euro-style Ram Nose for European punch holders. www.e-ci.com

Haco

seamless fusion of hardware and software that results in fast and accurate production. www.hacocanada.com

LVD

PPS Series of cost effective press brakes offer the precision and reliability of LVD bending technology in a value-minded package. Available in six models from 55 to 220 tons and bend lengths from 78 in.

(2000 mm) to 157 in. (4000 mm), the PPS press brake is offered in CNC configurations and is equipped with an easy-to-use touch screen control.

The touch screen control employs the same reliable infrared screen technology used on several LVD products. The 10 in. screen features large buttons that can be seen from a distance and which can be operated using work gloves.

The Euromaster CNC press brake line comes standard with an easy-to-use colour graphical 2D Fastbend control (also available with touchscreen). The Syncromaster line has recently been upgraded with a new Linuxbased controller line. Both controls can work with the same offline software (available with network connection).

The Syncro system of both lines of machinery works with the highest accuracy.

The backgauge fingers from both lines have been upgraded and are easier to use.

Each can be equipped with different type of tool holders: North American Wila Tools and European style of tooling. The controls can work with different safety systems as LaserSafe, Akas Fiesler, Light Curtains, and DSP Laser. Machine construction conforms with North American and European safety standards.

The Syncromaster machine can be equipped with three axis capability. The Euromaster machine can be easily equipped with a six axis backgauge system. It can also easily be upgraded with a robot system.

The robot and press brake are controlled by the Graphic 3DFastbend control. It offers a unique approach to robotized bending:

Software developed by LVD allows for fast and simple programming with minimal training thanks to a “spread sheet” program layout in which each row is a bend and each column is a parameter. The user friendly format eliminates the time consuming effort of moving back and forth from page to page when making and reviewing part programs.

The system is ideal for quick programming of all parts and is suitable for all levels of users. It provides a number of user friendly features, including: • Unlimited tool library for use of any tool, any name and any quantity • Automatic angle calculation eliminates the need to manually assess ram reversal position • Automatic bend allowance calculation eliminates manual assessment of bend allowance or back gauge setback www.lvdgroup.com

Prima Power

Prima Power has introduced the EBe servoelectric bending machine designed for each customer’s production requirements to achieve maximum productivity and product quality.

It offers complete automation of the bending process. The bending operation cycle is fully

Fabricating

BENDING/CASE STUDY

PRODUCT REPORT automated; from the loading of the flat parts to unloading of the components.

This EBe bending cell has a maximum bending length of 84.65 in. (2150 mm) and maximum opening height of 8 in. (200 mm).

The system is operated by CNC control and exchanges information and synchronization with the PLC through digital communication.

All machine main functions and all axes involved in the bending process are numerically controlled.

The new construction features actuation of the bending blade movements (vertical and horizontal) by servo NC axes instead of hydraulic cylinders. The upper tool movements are also made by another NC servo axis.

Prima Power EBe provides the high bending quality required in demanding applications such as component production for design products. This is achieved through precise control of bending axes, fast and smooth bending, open programmability, and CONFERENCE the construction that is immune to variation in thermal conditions.

New Bending Principle: A fundamental characteristic of the EBe bending technology is the

TURE OF

ating Cutting

movement of the blades. For optimum product quality, a new bending principle has been applied for the EBe. With this new principle, when the “rolling mode” is used, there is a wider contact surface between the blade and the sheet but no relative friction. Part marking and tooling wear is minimized.

New Industrial Design: Prima Power EBe has also been designed for the modern manufacturing facility to meet the high ergonomic standards through integrated safety covers.

The EBe featuring Prima Power’s E-technology offers: • Reduced labour cost • Reduced set-up time • Increased speed/productivity • Reduced tooling cost • High component quality

• Off-line programming • Programmable bending blade crowning • Energy savings (-50 per cent compared to all hydraulic solutions) • Low maintenance cost • Reduced noise level • Reduced vibrations • No influence by thermal conditions www.primapower.com

Safan

The E-Brake from Safan produces the pressing force with synchronized electric motors and transfers via belts and pulleys to the beam. This unique drive principle brings many advantages: No problems with hydraulic oil, low energy consumption as well as higher productivity.

Westway Machinery Ltd. is the exclusive Canadian distributor for Safan equipment.

When a product requires several bends it is common practice to operate the machine at its fastest beam speed. Between the bends, the component is turned and inserted as required for each fold. Most time is lost between the bends by handling, the change over time

Mark your calendar for Conference streams

The Future of Fabricating Cutting Conference is a one-day conference organized by Canadian Metalworking. One conference stream will educate you on where fabricating cutting technology is going. The other conference stream will help you address issues surrounding key management issues. You can mix and match the presentations you hear based on your needs.

Exhibits

As part of the conference, leading machinery, equipment and services suppliers will be available during breaks and at lunch to discuss problem solving.

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BENDING/CASE STUDY

between fast and slow points of the beam and the back gauge positioning speed. With safety on the one hand and the well-known inertia of Hydraulic systems on the other hand being the major limiting factors. Safan’s solution is the E-Brake Mechatronic press brake.

The control of the electric motors in the machine are the basis of this innovative system. The principle of the system is a pulley-block, which pulls the Top beam of the press against the effect of laterally arranged return springs into the die and applies the pressing force evenly along the length of the machine. In 98 per cent of cases no crowning table is required.

When rolling the belt up the driving motor pulls the beam downward into the die. The return springs strained during the bending procedure return the beam to its initial position.

The E-Brake is available from 35 to 300 ton pressing force and lengths from 1250 to 4100 mm. The drive is provided by Lenze electric motors. The 4 m machine with 200 ton pressing force requires a total output of 22 kw.

The force is distributed evenly over 36 roles attached to the upper beam.

in the telecommunications and aerospace industries. Bending such parts with large, heavy press brakes is typically inefficient because of the space and energy requirements involved.

A feature of the TruBend Series 7000 includes the ability to increase its bending speed simply by making adjustments to the machine parts relevant to the bending process: the back gauge and the beam.

The back gauge is made with lightweight carbon fiber, and the surfaces on which the bent part contacts the fingers of the back gauge are made of hardened steel. These design features enable the TruBend Series 7000 to set new standards for achieving accurate results.

In addition, the torque motor, which drives the beam, can deliver power even at low speeds. It ensures rapid axis movements and is low maintenance, since it has no gears and, therefore, needs no gear oil.

The TruBend Series 7000 also features enhanced ergonomics. Optimum working conditions and user friendly operating elements are integrated into the machine design. The

Fabricating

operator can control the machine while sitting down and work without becoming fatigued, which helps ensure the quantity and quality of the fabricated parts. Gas spring supported pedals allow the height and angle of the foot rests to be adjusted. The arm support is also adjustable in height, so that every operator can set up his or her workplace individually.

In addition, the monitor for the TASC 6000 control system of the TruBend Series 7000 can be adjusted electronically and set to the appropriate angle.

Optional TRUMPF LED lighting illuminates the area in front of and behind the beam, ensuring correct lighting conditions precisely at the bend, without heat radiation. A laser diode also projects the bend line onto the surface of the sheet metal, simplifying the accuracy of guiding the workpiece into the back gauge. www.us.trumpf.com

Pipe Saddle and Hole Cutters from Jesse Engineering

Safan’s electronic control system ensures very short response and delay times resulting in bending speeds of up to 20 mm/sec. The high acceleration and other servo motor characteristics mean not only very fast approach speed but also a seamless change over to bending speed.

The absence of hydraulics means no seals, and no pressure valves, resulting in less downtime and lower maintenance costs. As well, the press brake uses less energy than hydraulic machines because the motors operate only when the beam is actually moving. www.westwaymachinery.com

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TRUMPF

TRUMPF’s TruBend Series 7000 precision press brake is a compact machine that offers a high quality, efficient solution for the production of small bent parts up to 40 in. (1,016 mm).

Typical applications include sheet metal parts used in the production of vending machines and electrical equipment as well as

www.JesseEngineering.com | p. 253/922-7433 | f.253/922-2536 Represented exclusively in Canada by MAG Tool | p. 800/661-9983 Jesse Engineering manufactures pipe benders, pipe shop equipment and PipeShop® software, in Tacoma, WA - USA www.canadianmetalworking.com | june 2011 | 69

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Welding

POSITIONING & FIXTURING

Getting a Fix on Fixturing Modular fixturing can add flexibility and process improvement to your welding operations

By Bob Ellig.........................................................................

Where does your company stand when it comes to producing quality weldments? The Wall Street Journal reported in 2006 that the average age of the North American welder was 54 years. When these people retire, they take with them years of experience in welding parts with simple hand tools, along with a wealth of technical knowledge and a great deal of process skill.

And though the faces doing the welding may change, the basic welding process does not. In an age where newer generations are more familiar with USB ports, joy sticks and computeraided design (CAD) than they are with framing squares, chalk and tape measures, producing a quality weldment can still be a challenging task.

For this reason many companies still use “tack” tables (see Figure 1), a steel plate that has been ground flat that rests on its own legs or on saw horses. The locations for the stops are scribed on the surface and then the stops are tack welded.

When the job is finished, the stops are broken free and the

Figure 1: Framing square, chalk, tape measure and a tack table are the only tools available to many companies. When the job is finished, the locators are “chopped off” and the surface is refinished with a hand grinder. Quality and repeatability suffer while productivity lags.

surface is cleaned with a hand grinder. After a period of time, the flat surface resembles the surface of the moon. If you were able to make a good part with this old technology, making an identical part at a later date would be extremely difficult and equally time consuming.

At the other end of the spectrum are dedicated fixtures.

Properly conceived and constructed, repeatable quality is all but assured. However, at the prototype stage, dedicated fixtures can be a very expensive exercise. Imagine trying to make a fixture for a part whose design has not yet been finalized.

Along with that comes the challenge of guessing where and how far the part will move during the welding process. Any change to the part design usually requires a similar modification to the dedicated fixture, which can be expensive and time consuming. Furthermore, imagine investing in a dedicated fixture for a product that never gets beyond the prototype stage before the project is canceled!

As an alternative, consider modular fixturing for welding.

A modular system includes all of the free-form flexibility of a “tack” table with all of the precision and repeatability of a dedicated fixture. The only difference is that when the job is done, Figure 2: CAD models can be used to design fixtures and to document the setups for the welder.

Shown here is a complex outrigger box for a construction machine that was welded in Bluco’s Validation Center. The process was proven before a system was purchased.

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POSITIONING & FIXTURING

Figure 2A: CAD models can be used to design fixtures and to document the setups for the welder. Shown here is the mid-section of a bus showing the floor with a cutout for a handicap ramp and the support frame for the roof.

all of the components can be disassembled and reused for the next job. Being modular makes it possible to use CAD to create (see Figure 2) and document the fixture. Out on the shop floor, the welder constructs the fixture according to the instructions prepared by engineering.

A typical system features a five-sided table with a regular pattern of bores located across the top and around the sides.

Table sizes range from 1000 mm x 1000 mm (40 in x 40 in) to 2000 mm x 4000 mm (61/2 ft x 13 ft). These tables are hardened so that spatter will not stick to them. A wide variety of components assemble to the table to create a precise fixture. Where the part envelope exceeds the table surface, angles can be mounted

F U E L

welding

Figure 3: Before the welder strikes his first arc, he will know if the guy on the saw got it right. Modular fixturing can be used as an in-process gauge, checking the quality of the loose pieces before the weldment is started.

to the sides to act as outriggers that extend the capacity.

This modular fixture (see Figure 3) serves as the first in-process quality check for all of the loose pieces. Before the first arc is struck, you will know whether the guy on the saw cut it correctly. Occasionally, when engineering oversights are uncovered, corrections can be made before things get out of hand. During welding, any changes in the fixture that are needed to compensate for weld pull can be made easily. When the part geometry is correct, data can be extracted from the modular fixture and given to a tool designer to have a dedicated fixture

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Welding

POSITIONING & FIXTURING

Figure 4 at right: A rail system with precision bores join the various system elements together to fixture larger parts. In addition to easier welder access, part lengths of 30 meters (100 ft ) or more are possible.

Figure 3A above: This engine exhaust system was produced by a small Canadian company. In addition to establishing the location for all of the loose pieces, the fixture also acts as an in-process checking gauge. Parts that do not fit the fixture must be reworked before a quality part can be made.

Figure 5: The setup operator builds a modular fixture and then teaches the robot the welding sequence.

This makes it practical for short runs and frequent changeovers on a robot.

made with the exact same clamping locating points that made the good part.

For large parts, there are efficient and precise elements of the modular system that are more appropriate. For example, rails with the same pattern of bores as the tables are lagged to the floor, precisely spaced and leveled. A combination of tables with special spacer frames and narrower bridges with the same pattern of bores as the tables can be used to hold and locate the large parts (see Figure 4).

The relationship of bores from one end to the other is assured by the precise bore locations in the rail surface. The same positioning and clamping bolts that hold together and locate the modular element of the system are also used to fasten the bridges and frames to the rails.

This eliminates past worries about tape measure sag when measuring for a setup.

By using two positioning and clamping bolts in the system bores, one universal stop and a spacer set incremented down to 0.5 mm (0.040 in) locators can be set precisely and repeatedly.

The term robot and the phrase “short run� are rarely used in the same sentence. Since robotic welding requires 72 | june 2011 | www.canadianmetalworking.com

POSITIONING & FIXTURING

welding

rent-to-own or short-term rental program.

Before you make your commitment, make certain that the supplier has sufficient hardware in stock to support your project. And, because using modular fixturing for welding is a different way of doing business, be sure to include the right people in your plans to implement a system. Once you get started, you will wonder how you ever got along without a system. CM Robert Ellig is the president of Bluco Corporation, Aurora, IL. www.bluco.com Figure 6: A modular beam mounted between a headstock and a tailstock provides the “backbone” for all fixtures on this twin station gantry robot. The result is minimum fixture weight and maximum weld access to the part.

more precision and repeatability in fixturing than manual welding, fixtures are an absolute necessity. However, dedicated fixtures can often cost more than the robot itself. In applications where the parts are simple but the lot sizes are low, it is possible to physically build a fixture and then teach the robot how to weld that part.

When the welding program is approved by the setup technician, the remaining 99 pieces of a 100-piece lot can be run by the robot operator. The setup technician moves to the second station and repeats the same process sequence. All day long they trade places setting and welding.

Modular fixturing makes all of this possible (see Figure 5). Where larger parts are being considered for robotic welding, gantry robots (see Figure 6) are one solution. The fixturing used in this case consists of a square spacer block with a full pattern of system bores on three sides and the two ends. Mounted between a headstock and a tailstock, the robot is able to access all sides of the part.

Fixturing elements are mounted to the sides of the spacer block using the outrigger approach discussed earlier. The mounting of the spacer block incorporates an adapter that allows the center of gravity to be adjusted to handle a number of part sizes and configurations.

Modular fixturing brings the accuracy, repeatable quality and the speed of the robot to a whole new range of part configurations. If any of these examples have encouraged you to look further, contact a modular fixturing supplier and challenge them to tackle your problems. Let them design a fixture for you to help you prepare your justification. If you want to see your part mounted and welded in a modular fixture before purchasing a system, challenge your supplier to do it for you in their validation center. If your budget is short but your need is urgent, ask if they have a

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Tech Tips for Better TE Improving transfer efficiency is one of the best ways to optimize your powder finishing process and cut material consumption costs

By Pierre Bachand..................................................................................................................................................

Maximizing the efficiency of your powder finishing system will result in a more cost effective operation. The first thing you need to do is understand transfer efficiency (TE) in powder finishing operations. TE is defined as a ratio: POWDER ON THE PART X 100 = % T.E POWDER SPRAYED This doesn’t mean necessarily using the best coating. Instead, it’s about using the powder coating that most effectively gets onto a part.

I had the opportunity to work for more than 15 years in the pretreatment area (chemical and mechanical) before spending the next 15 years selling, designing, installing, and sometimes repairing powder and liquid paint equipment. A good part of my time was dedicated to problem solving, which allowed me to learn different techniques for improving TE in powder finishing applications.

Tip 1: The three “C's” of powder painting

Cleanliness, cleanliness, cleanliness. This is the most basic, but also the most important factor to consider to improve the efficiency of your powder finishing system.

Tip 2: Improve line density

This is important for optimizing both manual and automatic systems. Optimizing line density ensures that powder is best directed at the part, that distances are such that coverage of the sides of parts is maximized and that overspray is reduced to a mininum.

Tip 3 : The mirror effect

This is a favourite tip of mine. You use a sheet of plastic to bounce back the powder to improve coating transfer to the back, the bottom or the sides of parts. It is not universally applicable but where it can be, you can achieve significant savings, particularly in spray-to-waste powder booths.

Tip 4 : Follow the needle

Quite a few painters use this technique to improve coating in recesses.

The painter uses the pointed tip as a lightning rod that attracts the electrostatic line forces and the paint inside the cavity. This seems to be most usefull for recoats. It is often used when hooks are coated with paint.

Tip 5: The ion collector

Improving powder transfer efficiency will cut material costs and improve your finishing operation. Image: Nordson

74 | June 2011 | www.canadianmetalworking.com

This is also marketed as the Super-Corona by one equipment manufacturer (ITW Gema, which was acquired by Graco recently). It improves penetration, reduces orange peel and optimizes paint thickness. Anything that reduces initiation of kV rejection improves TE. It also makes recoats easier.

POWDER FINISHING

Tip 6: The special kit for metallics

This is a simple solution to many application problems you may encounter working with metallics, even bonded metallics. Paint will often accumulate inside the flat jet or on the inside face of the round jet. Then it spits on the part.

To solve this problem, glue, two round deflectors, face to face before installing them on the electrode holder. The ion wind is maintained in front of the cloud and there is added turbulence that makes the coating or accumulation of paint on the unit virtually impossible.

solvent (ex : butyl carbitol). Use a product like Recoat Magic, Ransprep or similar products mixed into water with the recommended solvents. I have mixed this type of product with Windex or Winshield Washer fluid. This type of product leaves a molecular film of hydrated salts on the surface of the painted part.

Tip 10: Write down the formula

When you are testing equipment to optimize TE, take note of the best settings then have everyone work with them. A few years ago, a multinational lighting company asked me to improve the

Tip 7: Sandtext , veined and textured finishes

Many painters remove all types of deflectors when they want to optimize the special effect. A few months ago I was given samples of an aggressive santext finish (called an anti-slip). One sample was done with a flat jet and the other sample was applied without a nozzle. The difference was impressive.

(One suggestion that has nothing to do with TE but improves the finish is to make sure the oven is hot when you introduce the parts. If the temperature rise is very slow there is a good chance that the powder will level off and kill the desired textured effects.)

Tip 8: The right ID hose for the right flow

The objective is to reduce powder paint velocity as it exits the front of the applicator. The right speed equals improved TE. Many operators do not realize there are usually a couple of powder hoses with different IDs available from their supplier.

To improve very low flows, use a small ID hose. The smaller ID reduces or eliminates the need for supplementary air to keep the powder in suspension.

When shooting a large volume of powder, using a large ID reduces the linear speed of the powder as it exits the powder gun. As an added benefit, there is less impact fusion if you are using PVC.

Tip 9: Better recoats

To improve TE in both in batch and conveyor applications, there are a few rules of thumb: • use the right settings • do not stay in one spot: move, move, move, but not too fast • clean hooks • warm or hot parts coat better For batch application there are a few tricks you can use. Wipe or wash the parts with a mixture of a fast solvent and a small quantity (less than 10 per cent) of a slow www.canadianmetalworking.com | June 2011 | 75

POWDER FINISHING

Tip 12: The right deflector for the right job

A lot of people think there are only two types of deflectors: the standard flat jet typically used and a round jet stored in the spare parts box. All the major powder coating equipment manufacturers offer a wide choice of nozzles for their applicator to maximize efficiency.

“ Wide flat jets allow for the gun to

be closer to the target to improve the target finish point, while keeping the same stroke on a gun mover.”

X nozzles are usually very good for difficult geometry parts.

I once used one for deep lighting reflectors on a chain-on-edge system and achieved excellent results. Wide flat jets offer a wider pattern, which allows the gun to be closer to the target while keeping the same width as a standard flat jet nozzle. This improves target finish point while keeping the same stroke on a gun mover. One manufacturer uses a sleeve that can be slid over a round jet. This is useful for difficult to reach areas, particularly where one piece of metal lets the air pass. With a standard nozzle you remove the powder on the opposite side.

There are other nozzle shapes available, such as star, oblong and even blank ones that enable the operator to experiment.

Tip 13: Mix and match Gun extensions can help improve TE when finishers are coating large or deep parts and often have to apply the powder from more than 12 in. away.

touchup of some parts. The company was having varying results depending on the operator. The company filmed the operators and the settings on the control panels. Then it selected the best operator and his settings. This gave the company a good idea of the number of passes, how he adressed the part and the speed of his movement.

Tip 11: Slow down the powder when possible

As mentioned in past articles, it is important for the powder to move as slow as possible when the part geometry permits it.

One element of today’s control panels is the concept of total air and percentage of powder.

Here’s a scenario: You have two guns painting the same parts with everything the same: hose length, line speed and paint. Gun number one is working at six cubic meter/hr with 25 per cent powder flow. Gun Number two is working at three cubic meter/hr at 50 per cent powder flow.

The actual volume of powder per minute of each gun is the same. If the powder delivery is regular with no “sputtering”or coughing of the guns, this means that the velocity of gun number two is much lower than gun number one.

Why? Gun number one: 75 per cent of the total air is supplementary air = speed and suspension air (75 per cent of six cubic meters is 4.5). Gun number two: 50 per cent of 3.0 cubic meters is 1.5 or three times less.

It is always good to keep the hoses as short and straight as possible.

76 | June 2011 | www.canadianmetalworking.com

In an automated line it is important to use simultaneously or alternatively fixed and moving guns to maximize TE.

Tip 14: Get close (enough) to the part Use of extensions on the gun when the targets are so large or deep that the operator must shoot powder from over 12 inches away, are a good way to improve TE. Remember: A tired painter is not an efficient painter.

No 15: Invest in technology

In automatic powder paint systems, invest in in/out positionners, triggering packages, robots and other options that will improve transfer efficiency by optimizing application parameters.

Tip 16: Get assistance from your paint supplier

Coatings manufacturers can often improve charging qualities of powders when required. The improvement can be attained by changing the resin type, ratios of filler to resin, particle size or by adding charge enhancers. A note of warning though: this is not appropriate for finishers who don’t ground parts properly.

I recommend you run a test before usage when finishing parts with complex geometries.

Information provided in part by Paul Boucher, ECE Canada and Brian Coutts, Erie Powder Coatings. CM Pierre Bachand is president of Chromatech Inc., a finishing training and consulting firm based in Quebec. pbachand@chromatech.ca

MASKING

A Place to Hide Examining the latest developments in masking techniques

By Fred Mueller Masking is a mature finishing process, but there are some twists you can use to improve on masking techniques and reduce costs.

Masking tapes have new pressure sensitive adhesives that release easily for better edge protection and ease of removal.

The backbone of a successful masking tape is not just the paper but the adhesive. The newer pressure sensitive adhesives allow the tape to be removed without leaving a residue or harming the surface being finished. The industrial tapes are rated on a 1–100 scale based on the strength of the adhesive; one rate at about works for most industrial masking applications.

Paper masking tapes have some very real drawbacks when it comes to use in harsh application environments. To cope such conditions, tape suppliers change the base and the adhesive to match the usage. By mixing and matching the adhesives with the material bases, masking tapes can be used for any masking purpose, not just for painting.

Polyester, metal foils and vinyl based tapes will standup to the chemistries found in the plating industry. Powder coating masking tapes include glass cloth-based and polyester-based types. Polyimide film-based tapes have good heat resistance and are used in electronics applications including hand and wave soldering.

The thousands of industrial adhesives fall into three main categories: rubber, acrylic and silicone. Rubber adhesives have the lowest temperature resistance but can be formulated to provide the highest adhesion. There are now new smooth minicrepe paper masking tapes designed for automotive applications where aggressive room temperature and high temperature curing maybe required (163º C for 30 minutes).

Masking product images left and right from Brampton, ON, masking products supplier Caps ‘n Plugs.

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Wagner Systems, Inc. Phone: 630-503-2400 Fax: 630-503-2377 www.wagnersystemsinc.com

www.canadianmetalworking.com | June 2011 | 77

MASKING

Acrylic adhesives offer a wider temperature range from below freezing to about 150º C. The new acrylic materials have an advantage as they don’t age in the same way as rubber-based adhesives. They don’t discolour significantly and don’t soak into the surface like rubber based adhesives.

Silicone adhesives provide the highest temperature resistance, with some tapes (polyimide films and glass cloth tapes) allowing for intermittent (check the data sheets to match the tape with cure) use around 260°C.

paper dispensers with shelves. Stationary models are wallmounted units. Remember though, you get what you pay for and the less expensive models are not always the best value.

So how can masking increase the productivity and improve the quality of the product you are finishing? Walk the shop: do you see workers removing excess masking with razor blades? Workers removing excess masking with a razor blade could be doing it faster, safer and better with a die-cut tape or a molded mask.

Masking Machines

Die-cut masks

Masking machines help to control the dispensing of the tape and paper tape combinations. They come in all sizes and shapes and start with portable carts with several different sized tape/

When do die-cut tapes work out better than hand masking?

“Peel and stick” die-cut masks usually become more economical than individual workers taping and cutting at fairly low

Shercon Ultrabake UMFP multi-flanged plugs.

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MASKING

production rates. The tipping point between hand and die-cut masking for most finishers needs a fairly complicated masking project that takes about 20 minutes using hand masking techniques. Just the same ten to twenty parts a day offers a good economic argument for die-cut masks.

If your customer is unhappy about your dimensional masking consistency, then you have another reason to look at die-cut masking. Die-cut masking is dimensionally stable when you choose the correct base and adhesive to within 0.127 mm. Widths as narrow as 0.77 mm are possible. Die-cut masking can help to minimize alignment difficulties by using guide holes or tabs, which allows for quick precise alignment of the mask onto the part surface. If you’re masking a serial number, new refinements such as transfer liners allow for quicky, easy and precise alignment of several separate masking elements like.

We’ve discussed applying the mask, but what about removing it? It’s easy to overlook the fact that time saved removing the mask is just as good as time saved applying the mask. Other factors in removing the mask should be taken into consideration. To eliminate finish marring, avoid using tools. Die-cut masks can be made to include tabs that speed up the mask removing process.

Custom Moulded Masks

Custom moulded masks represent a major step up from the die-cut tape masks. These masks can be placed quickly with better protection and are reusable. The more complex masking requirements, the more custom moulded masks make sense. An example of a great

application would be wheel assemblies.

You can mask the stud holes and the hub or bearing surfaces all at the same time, saving time with installation and removal.

You need masking speed to take full advantage of today’s high speed coating lines and robotic coating equipment.

“ Nothing is faster than

custom moulded masks; you can create grips in the mould to apply and remove masking.”

Nothing is faster than custom moulded masks because you can mould ergonomic hand grips into the mould to rapidly apply and remove masking.

The materials that the moulds are made from can be varied to meet your line’s chemical and abrasive environments as well as your temperature requirements. But they are not indestructible. You may see up to 50 uses depending on conditions.

Competitive Pressures

Looking at your masking in a new light can be difficult without some new eyes.

Invite a masking engineer from your supplier to have a look around. He may see a bottleneck you are missing. Or he may see concerns for worker safety that can easily be fixed. The bottom line is yours to fix, and improved masking is a good place to start looking. CM Fred Mueller is a finishing expert and corporate quality and safety manager with General Magnaplate Corp. Linden, NJ.

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IN STOCK American Standards and specials.

Japanese Standards inch or metric.

FOR FAST DELIVERY:

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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 | June 2011 | 79

Page

Metal...Works Mum’s the Word How to protect your company’s confidential information

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

According to Ralph Kroman, a partner at the law firm WeirFoulds LLP, security measures will reduce the likelihood of hacking and other electronic intrusions; however, competitors often acquire confidential information such as customer lists through former employees of a business. If an employee leaves a business and discloses confidential information to a new employer who is a competitor, it can be difficult to prove in court that confidential information was in fact disclosed. When dealing with confidential information, the age-old adage applies: “an ounce of prevention is worth a pound of cure”.

Kroman believes “many companies have confidentiality agreements in their files which are signed by employees but often they overlook the importance of employee entrance and exit interviews. During an entrance interview, each new employee should be reminded of his or her obligations regarding the company’s confidential information. The information that the company considers confidential must be clearly identified to the employee. A company policy regarding confidential information should be reviewed with the employee and a receipt obtained from the employee.”

A wise employer also tells the employee during the initial interview that the employee must not disclose confidential information of former employers. The confidentiality agreement, signed by the employee, should contain a representation and warranty to this effect. Legal cases have shown that if an employer turns a blind eye to the disclosure by an employee of confidential information of a former employer, the directors and officers of the employer may be held personally liable.

Ralph Kroman advises “if an employee signs a confidentiality agreement after employment has commenced, it must be structured properly or else the agreement will be unenforceable.

The courts like to see that the employee gave consideration for the agreement and the lack of consideration may make the agreement unenforceable”.

It is imperative that employees who depart employment are given proper exit interviews where their legal obligations regarding confidential information are explained. Employees will likely be more reluctant to disclose confidential information to a new employer if they know that the former employer is serious about protecting its interests. It should be confirmed by the employee that no copies of confidential information remains in the hands of the employee.

80 | June 2011 | www.canadianmetalworking.com

If, after an employee departs, the employee will be employed with a competitor under suspicious circumstances, an appropriate letter should be sent to the new employer. This letter does not need to be adversarial, but is intended to put the new employer “on notice” that the new employer must not use confidential information disclosed to it.

One of the best ways to protect confidential information is with a “confidential stamp” which is placed on each electronic or hard copy of a document. It is preferable that this stamp appears on each page. Many companies simply stamp “confidential” but the stamp is more effective if it includes the name of the owner of the confidential information, states that copying is not permitted without the express consent of the owner, and confirms that the document and all copies of the document are the sole property of the owner.

It is common practice today for businesses to exchange confidential information to further the negotiation of a business deal. It is a typical practice that “standard form” non-disclosure or confidentiality agreements are signed.

However, the fine print should be reviewed. Some agreements require that confidential information, which is disclosed orally, must be confirmed in writing within a certain number of days.

If it is not feasible to comply with this obligation, the agreement should be amended.

Kroman advises that “when a company discloses confidential information to a third party, the company should maintain a file which contains proof of the delivery of the confidential information including an exact copy of all information disclosed, the date of the delivery, and the identity of the recipient.

The cover letter should list the enclosures and highlight the confidential nature of the information”.

On the whole, it is important for a company to recognize that protecting confidential information is not simply a matter of adopting a “cookie cutter” approach. A protection plan should be customized to reflect the type of information and the commercial realities of the business. Unfortunately, many companies do not focus on a plan until it is too late. CM Mark Borkowski is president of Mercantile Mergers & Acquisitions Co. mark@mercantilema.com Ralph Kroman is a lawyer with WeirFoulds, LLP. rkroman@weirfoulds.com

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