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Inside this issue...

Volume 106 | Number 5 | September 2011 |




1 11 1



30 SPECIAL REPORT CMTS 2011 PREVIEW ...........................


New technology, new opportunities in Toronto.




EFFECTIVE BUSINESS PLANS FOR BANK LOANS ...........................78 Get financing with solid preparation.


A LONG, WINDING ROAD BACK TO PROFITABILITY.....................24 Rail and sea sectors grapple with a cyclical economy.



HPC TAMES TOUGH ALLOYS .............52

Strategies and choices with difficult materials.




DON’T LEAVE WELDERS IN THE DARK ...................................82

THE MANY FACES OF FACE MILLING .......................................60 Keeping the high-value work at home with technology.


LASERS BALANCE CUT WITH COST ....................................68 Gas battles fiber for low-cost supremacy.

Auto-darkening set to dominate.



WATERBORNE ON THE WAY ............92 Acceptance advances for industrial applications.

DEPARTMENTS View from the Floor ................................. 6 News .................................................... 8 Floor Space ........................................ 22 Metal...Works ...................................... 95

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PUBLISHER Steve Devonport 416-442-5125 | ACCOUNT MANAGER Rob Swan 416-510-5225, cell 416-725-0145 | EDITOR Jim Anderton 416-510-5148 | EDITORIAL DIRECTOR Lisa Wichmann 416-442-5600 x 5101 | ART DIRECTOR Jill Nelson 416-442-5600 x 3204 | CIRCULATION MANAGER Selina Rahaman 416-442-5600 x 3528 | JUNIOR WEB PRODUCER Jessica Mirabelli 416-442-5600 x 3227 | MARKET PRODUCTION MANAGER Barb Vowles 416-510-5103 | PRINT PRODUCTION MANAGER Phyllis Wright 416-442-6786 | BIG MAGAZINES LP ........................................................ PRESIDENT OF BUSINESS INFORMATION GROUP | Bruce Creighton VICE-PRESIDENT OF CANADIAN PUBLISHING | Alex Papanou EXECUTIVE PUBLISHER, MANUFACTURING | Tim Dimopoulos HOW TO REACH US......................................................... Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, North York, ON M3B 2S9 Phone: 416-442-5600. Fax: 416-510-5140 CM, established: 1905 is published 7 times per year by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. SUBSCRIPTION RATES Canada $55.00 per year, Outside Canada $90.00 US per year, Single Copy Canada $8.00. RETURN UNDELIVERABLE TO Circulation Department 80 Valleybrook Drive, Toronto, ON M3B 2S9 All rights reserved. Printed in Canada. The contents of the publication may not be reproduction or transmitted in any form, either in part or in full, including photocopying and recording, without the written consent of the copyright owner. Nor may any part of this publication be stored in a retrieval system of any nature without prior written consent. Content copyright ©2011 by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd., may not be reprinted without permission. CM receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. CM, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. CM accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DISCLAIMER This publication is for informational purposes only. The content and “expert” advice presented are not intended as a substitute for informed professional engineering advice. You should not act on information contained in this publication without seeking specific advice from qualified engineering professionals. PRIVACY NOTICE From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 Email: Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9 Canadian publications Mail Sales Product Agreement 40069240 ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.

View From the Floor A New Era at CM Change and be good, bad or something in between, but in the second decade of the 21st century, it’s certainly inevitable. Changes come quickly in technology, economics and even at century-old trade publications like Canadian Metalworking. CM, along with a large portfolio of Rogers Publishing trade magazines, has been bought by Toronto-based Business Information Group making BIG by far the largest and most powerful trade publication company in the country. That’s great for the future of Canadian Metalworking, but it does mean a few changes. I replace Mary Scianna as Editor, and former Sales Manager Steve Devonport takes the helm as Publisher, taking over from Larry Bonikowski. Jill Nelson came over too, ensuring continuity as Art Director and Rob Swan joins as Account Executive to round out the team. Rob and I are new to CM, but Steve has been with Canadian Metalworking for a remarkable quarter-of-a-century, so you’ll definitely see familiar faces. I’m looking forward to meeting many of you at trade shows, in your offices and best of all, on your shop floor because that’s where the action is…..and it’s where I started. Can you remember your first day in the industry? I can. It was thirty years ago and I was a rookie setup man working on a Brown and Boggs 70-ton C-frame press running a simple progressive die. The press was built in the ‘Fifties: full revolution by mechanical dogs engaging what seemed like the biggest flywheel on Planet Earth. My idea was to jog the press by blipping the start switch, tripping the pedal and carefully adjusting down from bottom dead centre. “Why waste all that time?,” I thought, as there were index marks scratched conveniently on the collar and labeled with a Magic Marker. So I wound down the ram, locked it up smartly with a quick spin of the wrench and fired up the motor. It took five minutes to get that big flywheel up to speed and the second it smoothed out at running RPM I hit the pedal and watched the test strip. The die bottomed instantly, breaking off a fistful of .250 round punches and sending them laterally in every direction out of the unguarded shoe. One flew between my legs, ripping the seam of my Levis at the upper thigh and blew a neat bullet hole through a 12-gauge sheet metal partition behind me. An inch higher and I’d end up editor of Ladies Home Journal instead of Canadian Metalworking, but I got lucky. The die set was destroyed and the press was jammed at the bottom of its stroke, the frame “sprung” tightly. It took most of the rest of my shift packed in dry ice before it released with a loud bang. Amazingly, I kept my job. I also learned to check everything at least twice and to keep a meticulous book on each tool and setup. In retrospect, it may have been the most useful lesson I ever learned on a shop floor, along with the Ukrainian swear words I picked up from the toolroom, where they would fix my expensive mistake. Now, thirty years on I’m impressed by how much the industry has changed. I started in dark, oil-soaked and noisy press rooms where pull-backs were considered the ultimate in safety and operators could be expected to squirt oil from a pump can into a tool with every slow stroke. SPC was the operator yelling “It’s doing it again!” over the din and if your hands weren’t cut and bleeding, you just weren’t working. Today it’s a science as well as an industry and despite the impact of China, I predict that our side of the manufacturing industry will grow in sophistication and prosper. JIM ANDERTON, EDITOR

Do you agree? Let me know, and feel free to drop me a line at the e-mail address below, or buttonhole me at a show or event. I’d love to hear from you!

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Sensitivity instead of gross motor skills – this is the motto of the new HORN “System DR” reaming tools. Very narrow cutters, simple handling, and high repeatability when replacing inserts. A large selection of base material, coatings, and cutting geometries make the DR from HORN the perfect tool system for high precision bore machining. HORN – INTELLIGENT TOOL DESIGN AT WORK.

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CTMA suspends new funding requests

The Canadian Tooling & Machining Association has suspended requests for funding support under the CTMA’s Advanced software & Machine Training Fund program. According to CTMA executive director Les payne, “we have received an overwhelming number of requests which indicates the obvious need for this kind of funding to support the Machine, Tool, Die & Mould industry. We were pleasantly surprised to receive over 100 proposals from companies in the industry that have been deemed eligible and will receive funding; however, the total of these applications far exceeds the level of funding that is currently available.” payne notes that the program can be restarted when additional funds are available and that updates will be posted on the association’s website,

Future Outlook Positive at CMTDA Cruise

June 21st was the first day of summer and the date for the annual Canadian Machine Tool Dealers Association annual cruise. 80 members registered for this year’s dinner cruise which took place in foggy conditions aboard the Mariposa belle in the waters around Toronto’s Centre Island, but the mood was decidedly upbeat. Declared CMTDA president John Manley: “Half a dozen board members couldn’t make it because they’re busy. It’s a great sign.” Manley, who is also president of Toronto-based Machine Tool systems, bases his assertion on CMTDA statistics, adding, “we’re seeing a major increase in orders since January...we’re way off per-recession times….we’ve turned the corner, no question.”


Canadian Metalworking’s The Future of Fabricating Cutting Conference runs November 8th, 2011 at the Toronto Congress Centre with a loaded slate of high-value seminars in three streams: the Future of Metal Cutting, Metal Cutting/Fabricating Management and Fabricating/Cutting with a special emphasis on waterjet, plasma and laser technologies. Mix and match the presentations to meet your learning needs and be sure to visit the exhibit space to discuss problems and solutions with leading equipment and service providers. Who should attend: shop managers, plant managers, manufacturing engineers, manufacturing executives and anyone else with an interest in improving manufacturing competitiveness. Register today at:

sowa Tool & Machine Co. Ltd. is pleased to announce the appointment of Mr. Ryan Weber to the position of Western Canadian sales Manager.

Ryan’s 13 years of experience with sowa Tool included his relocation from Head office in Kitchener, Ontario to Edmonton in 2007. Ryan will work with recently appointed sales support Representative John Farkas to continue to support the entire sowa product line throughout Western Canada. KbC Tools & Machinery is pleased to announce the appointment of the company’s first-ever Director of Canadian Operations. Karen Neath, branch Manager at KbC’s Canadian headquarters in Mississauga, Ontario, was selected for the position earlier this month. Neath will continue her role as branch Manager while expanding her mandate to include

overseeing and coordinating activities among KbC’s Oldcastle, Ontario and Delta, b.C. branches. Neath’s many accomplishments during her tenure at KbC include spearheading the effort to achieve IsO:9001 certification for the Mississauga branch, an internationally recognized standard for quality management.

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803-11204 Cast Iron Ad (CMW)


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PROMO Free DNX cutter with the purchase of inserts (see website for details) Our range of inserts, cutters and drills features the advanced, high performance characteristics and longer tool life for roughing and finishing gray and ductile cast iron applications. Call or go to for more information. Go to or scan the QR Code with your phone >>

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News US equipment finance activity grew in 2010 Growth follows two years of declines

Following declines in new business volume in 2008 and 2009, the equipment finance industry began to regain volume in 2010, according to the 2011 survey of Equipment Finance Activity (sEFA) released by the Washington, D.C.based Equipment Leasing and Finance Association. The survey reported an overall 3.9% increase in volume in 2010, compared to a significant 30.3% decline reported in 2009 and a 2.2% decline reported in 2008. The metal and machinery segment outperformed the average with 4.3% growth, matching last year’s figures. The sEFA, which is based on responses from 108 ELFA member companies, covers key statistical, financial and operations information for the Us$521 billion American equipment finance industry. “Through 2010, the equipment finance industry showed gradual but steady growth,” said William G. sutton, ELFA president and CEO. “Although uncertainty about the broader economy continues, more recent data collected in the first two quarters of 2011 suggests the trend toward an improved equipment finance industry is continuing.”

The sEFA is a broad compendium of industry data, comprising a representative cross-section of equipment lease and loan origination by product, structure and origination. It provides a baseline and benchmark for companies operating in the equipment finance space through a voluntary survey of ELFA member companies. pricewaterhouseCoopers LLp managed the 2011 survey.

Auto sales will soften in Q4: Report

Research and Markets has announced the release of business Monitor International’s “Canada Autos Report Q3 2011” report. According to the report, Following a 2% rise in Canada’s total vehicle sales in Q3 led largely by light trucks, a shift in consumer preference prompted by rising gas prices has altered the competitive landscape once again. As average gasoline prices in Canada rose 25% year-on-year (y-o-y) in April 2011, to CAD1.31 per litre, sales of compact and subcompact cars outperformed the overall market during the month.

In contrast, the pick-up segment, which had been carrying total market sales earlier in the year, contracted 5%. This is a similar trend to that reported in the Us, where small car sales have grown in line with rising gas prices. Although total vehicle sales in April were up 7% y-o-y, which is respectable growth in itself, the subcompact and compact segments grew by 17% and 11% respectively, according to data from DesRosiers Automotive Consultants. based on results for the year so far and potential supply issues for the country’s best-selling car, the report has revised downwards slightly its forecasts for sales and production. It is now expected that passenger car sales to end the year down by around 2%, until more is known about car supplies, while a correction in gas prices later in the year could easily result in another shift in consumer sentiment away from cars. This also follows bMI’s view that private consumption will contribute less to economic growth in 2011 than in previous years. Conversely, the forecast for heavy truck sales remains positive and indeed relatively bullish at 11.5%, based on sales growth of 21% in Q1. According to the report, the expected 2010 recovery in vehicle production growth played out. This is sustainable through to the end of 2015 as investment projects come into play and labour agreements ensure that the Detroit Three keep an agreed proportion of North American output in Canada. However, the report has lowered its light vehicle output growth forecast slightly to 8%, although its forecast for heavy truck production stays at 15% in line with sustained strong demand in Q111. production for the Japanese brands, and particularly reduced output of the Civic will continue to pose a downside risk to light vehicle output until all companies are back at full swing. The shift towards smaller passenger cars in April 2011, as well as supply issues for Japanese brands has also impacted the

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Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment.

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US manufacturing technology orders up 103.9% from June 2010

competitive landscape. A shortage of stock resulted in sales of the Honda Civic, the country’s best-selling car, falling 1.5% in April, at a time when it should be cashing in on demand for compact sedans. As a result, Honda Canada’s market share for the first four months of the year dropped slightly to 7.1% compared with 7.9% for the same period of 2010. In contrast, south Korean brands Hyundai Motor and Kia Motors, which have been largely unaffected by the Japanese earthquake thanks to their mostly Korean supplier base, have gained market share from the previous year.

June Us manufacturing technology orders totaled $459.39 million according to AMT – The Association for Manufacturing Technology and AMTDA, the American Machine Tool Distributors’ Association.

Critical security flaws found in Siemens’ PLC series

Network security site,, reports that Dillon beresford, a researcher at security testing company Nss Labs, has demonstrated a number of “critical” security holes in certain siemens pLC models running the company’s simatic step 7 firmware. Among the most serious of the reported flaws is a hardcoded username and password that was embedded or hardcoded in a version of s7-300 pLC model’s firmware. The backdoor, beresford said, would allow an attacker to gain access to the pLC by Telnet or HTTp and execute commands or reprogram the entire unit. Another serious vulnerability, called a “replay attack,” allows a hacker to capture commands transmitted between his own pC and siemens pLC and then replay them to a remote siemens pLC. Using this method, an attacker could shut down the controller or sabotage the processes the pLC controls. potentially affected pLCs in the line include siemens s7-200, s7300, s7-400 and s7-1200 pLC models. siemens officials, who were also present at the conference, said they have issued alerts for the vulnerabilities and are addressing the issue. While not a security fault in itself, beresford said he also found an Easter Egg — a bit of hidden code programmers sometimes include as a sort of private in-joke – in some versions of the step 7 software that, when run, displays a cartoon animation of dancing monkeys.


Canadian Metalworking has a new team following the magazine’s recent move from Rogers Communications to business Information Group in Toronto.

pictured (l-r): Rob swan, accont manager, steve Devonport, publisher and Jim Anderton, editor. steve is in his 26th year with Canadian Metalworking.

This total, as reported by companies participating in the UsMTO (Us Manufacturing Technology Orders) program, was up 15.3% from May and up 91.7% when compared with the total of Us$239.68 million reported for June 2010. With a year-to-date total of Us$2,453.78 million, 2011 is up 103.9% compared with 2010. These numbers and all data in this report are based on the totals of actual data reported by companies participating in the UsMTO program. “At this pace, the industry would post orders equal to all of 2010 by the end of August,” said Douglas K. Woods, president of AMT. “still, industry leaders view the rest of 2011 with cautious optimism given the weakness in parts of the economy illustrated by the Dow’s plunge at the beginning of August. We expect a bump in orders related to customers taking advantage of the current bonus Depreciation rate before it is reduced in 2012.” The United states Manufacturing Technology Orders (UsMTO) report, jointly compiled by the two trade associations representing the production and distribution of manufacturing technology, provides regional and national U.s. orders data of domestic and imported machine tools and related equipment.

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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

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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.

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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

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News Thomas Skinner reports traffic up at WMTS

This year’s Western Manufacturing Technology show was held June 14 to 16, 2011 at Alberta’s Edmonton Expo Centre, where Thomas skinner reports increased floor traffic and intentto-buy with the majority of the attendees looking for innovative production equipment and new technologies. Thomas skinner displayed two booths, with equipment from Hass Automation,

and engineering consultancy. The India show will also have sectoral representation from important sectors of the Indian economy such as defense, science & technology, renewable energy, heavy industry and tourism. 2011 was declared as the ‘Year of India in Canada’ by Indian prime Minister H.E. Dr Manmohan singh and Canadian prime Minister stephen Harper, during the latter’s visit to India in November 2009.

North American robot orders jump 41 percent in first half of 2011

Hyd-Mech, Lenox and Mitutoyo as well as Okuma and Thomas skinner’s Integrated solutions Division. “It was great to hear our customers are busy, financially healthy and investing in their companies to improve productivity” said Ross McDonald, Edmonton branch Manager, Thomas skinner. “We got very positive feedback on our machine demonstrations. We look forward to seeing our customers at the 2013 WMTs.” “It was interesting to note that only half of the people who scanned into our area were from the Edmonton area” said Al Leskow, sales & Applications specialist, Mitutoyo. “The others came from Fort McMurray all the way across Canada to Ontario.”

India Show co-locates with CMTS Toronto

The India show at Toronto has been declared ‘strategic International partner’ by CMTs (Canadian Manufacturing Technology show) event organizers, the society of Manufacturing Engineers (sME). The shows will run in Toronto, October 17-20th, 2011. EEpC India (Engineering Export promotion Council), that nation’s largest trade promotion organization, will take more than 150 Indian engineering companies from large, medium and small scale enterprises to the show. The India show in Toronto is going to be the largest Indian engineering exposition in Canada and is the second India show to be organized by EEpC INDIA. The first was organized in Istanbul, Turkey, in which 168 companies from India participated. India’s participation will largely comprise industrial machinery, machine tools & accessories, motion controls, engineering equipment & components, plant engineering & maintenance, auto parts, hand & cutting tools and accessories, aluminum products and supplies, intermediate goods, metallurgy, energy, packaging, electrical & electronic products, steel & fabrication, raw materials, non-ferrous metals, castings, forgings, moulds, tool & die

Fueled by a second quarter that was its best in six years, the North American robotics industry jumped by a whopping 41 per cent in the first half of 2011. In the statistics released by Robotic Industries Association (RIA), the industry trade group headquartered in Ann Arbor, Michigan, a total of 8,879 robots valued at Us$577.8 million were ordered by North American companies in the first six months of the year. When orders from outside North America are added, the totals are 10,476 robots valued at Us $667.9 million. “This was the best first half for our industry since 2007,” notes Jeff burnstein, president of RIA. The second quarter was particularly strong, posting gains of 50 per cent in units and 55 per cent in dollars over the same period in 2010. According to burnstein, most of the growth comes from an increase in orders from the automotive industry—from both manufacturers and suppliers, who are traditionally the largest robotics customer. “With the revitalization of the auto industry in the Us, robot orders to these customers rose 60 per cent in the first half of the year,” he says. Non-automotive orders increased 23 per cent through June, led by gains up to 70 per cent in metalworking. Not to be outdone, however, burnstein notes that some non-automotive customers who were slow to purchase robots in the first quarter accelerated their buying in the second quarter of the year. says burnestein: “Food and Consumer goods customers placed orders for 60 per cent more robots in the second quarter of 2011 than in the first, hopefully a sign of strong growth going forward in this sector.” Regarding the robotics industry as a whole, burnstein believes it is heading for its best year since 2005 because of new volume orders. The RIA estimates that some 205,000 robots are now used in the U.s., and more than one million industrial robots are used worldwide.

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The unique new Renishaw Equator™ is a versatile alternative to custom gauging, offering inspection of an unprecedented variety of manufactured parts. Developed and proven on the shop-floor with industry-leading gauging users in multiple industries and applications, Equator 300 is the first of a range of gauging systems from Renishaw.

Versatility – operators change parts in seconds; engineers adjust programs for any part design changes

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Equator advert 2.indd 1 News.indd 17

17/03/2011 09:06:53 8/30/11 7:40 AM

News TRUMPF wins Bosch Supplier Award

TRUMpF has been honored with the bosch supplier Award in the Machinery and Equipment category. The award places TRUMpF among the few bosch suppliers that have received the coveted award for the second time in a row. bosch presents the award to recognize companies that have provided outstanding services in the manufacture and delivery of products or services in the past two years, especially with regard to quality, pricing, reliability, technology and continuous improvement. “We are very proud that TRUMpF was able to meet the tough selection criteria for the bosch supplier Award,” said peter Leibinger, vice chairman of the TRUMpF GmbH + Co. KG and president of the Laser Technology and Electronics Division. This is the twelfth year since 1987 that bosch has conferred the supplier award that is advertised worldwide and is issued every two years. TRUMpF received its first award in 2007. Due to the financial and economic crisis, there was no award given in 2009. This year’s award was issued in seven categories to a total of 60 suppliers from 14 countries.

Dr.-Ing E.h. peter Leibinger, Vice Chairman of the TRUMpF GmbH + Co. KG and president of the Laser Technology and Electronics Division and Dr. Kurt Mann, Director of International sales at TRUMpF Laser and systemtechnik GmbH, accepted the award on behalf of TRUMpF. The award was given by Dr. Karl Nowak president Corporate sector purchasing and Logistics and bruno Nieberl Vice president Head of purchasing Machinery and Equipment from bosch. photo credit: Bosch

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News Methods signs SMS Machine Tools to distribute three major product lines

their steadfast commitment to providing superior service, it is an ideal match for Methods.” sMs Machine Tool will provide service, support, application engineering and training for all three product lines as well as equipment installation, CNC control and mechanical repair, preventative maintenance, onsite/offsite training and parts replacement. Methods will also provide full support to sMs customers for RoboDrill, KIWA-Japan and Feeler machines. Dave Collison, president of sMs, remarked, “We are looking forward to working with Methods to represent the well-regarded Robodrill, KIWA-Japan and Feeler lines so that we can serve the Canadian metal working industry with more quality products backed by exceptional service.”

sudbury, Massachusets-based Methods Machine Tools, Inc., has announced the appointment of sMs Machine Tools Limited to represent the FANUC Robodrill, KIWA-Japan and Feeler product lines in Ontario and Quebec. sMs is headquartered in Toronto with a satellite office in saint-Laurent, (Montreal) Quebec.“We’re pleased to have sMs on board to help us meet the growing demand we are seeing in the Canadian region,” commented Mr. Dave Lucius, Vp of sales at Methods Machine Tools. “With their solid history of distribution in this area and

Mitcham Joins CMTDA

Toronto-based Mitcham Machine Tools Inc. has announced that the firm has joined the Canadian Machine Tool Distributors Association. Mitcham Machine Tools is staffed by former 600 Group employees, representing 600 Group pLC from the UK through Clausing Industrial in The UsA. 600 Group employs more than 760 people worldwide. Mitcham Machine Tools represents Nomura CNC boring mills,

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News Kitako CNC 4 spindle turning centers, shoda 5 Axis CNC bridge type high speed machining centers, Colchester CNC and manual Lathes, Harrison Lathes CNC and manual lathes and Clausing CNC and manual machines with additional lines rolling out next month.

Hurco hosts lunch & learn

Hurco Canada hosted a 5-axis learning event on July 6th at the firm’s Mississauga, Ontario headquarters for an invited group of industry professionals. The comprehensive seminar prsented by sales and operations manager Joe poulin and

applications engineer Ian Candolini covered an overview of machine tool configurations, advantages of five-axis machining and programming methods.

Applications engineer Ian Candolini with a Hurco VMX30U 5-axis machine.

sales and operations manager Joe poulin.

Calendar SEPTEMBER 19-24 EMO Hannover Hannover, Germany

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20 | sEpTEMbER 2011 |

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News Miller Launches ‘Nominate a Hero’ Promotion

Miller Electric Mfg. Co. has announced the launch of a new website (www. to support the introduction of its “Nominate a Hero” promotion, where customers can submit information on a coworker or friend for a chance to win prizes from Miller. The promotion recognizes those individuals who make a special contribution to their workplace and the welding industry

easier through product innovation and technical support.” Visitors have the opportunity to fill out a profile on their hero to be entered into the promotion. Ten finalists will be chosen, and members of the general public will have the opportunity to vote for their favorite three next summer. The three grand prize winners will be flown in to the Miller

headquarters in Appleton, Wis., for a closer look at the company, and will be awarded a Miller product of their choosing, in addition to Arc Armor® welding apparel. Miller will also feature at least one hero per month on the site, in addition to information on products, service and support. Visit MillerWelds. com/hero for more information.

through job performance, education, training and other worthy causes. “Our customers use their welding equipment in numerous applications to perform very difficult tasks on a daily basis,” said Vickie Rhiner, brand manager at Miller. “We wanted to take the opportunity to recognize the work of “heroes”; and we’re happy to work alongside them to make their job a little | september 2011 | 21

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News Floor Space Did your company lose any work-hours this summer because of the intense heat (that is, did you ever have to close because it was too hot to work)? “Unfortunately yes. Operating several dry-off and curing ovens in our facility, combined with daytime highs of 40+ degrees would have been unbearable, unfair and would pose a definite health concern to our employees, and would also have negatively impacted our equipment and raw materials use. Based on the nature of our work, and because of the heat that is normally generated by our process, the summer months are always most challenging to our operation. This year, the month of July has been abnormally cruel with high temperatures. Health and safety issues are always a major concern and consideration at our company, so instead of trying to work our way through and combat the elements, we decided as a group to work overnight as an alternative. Normally, our operation runs two shifts, and on several occasions in July, we abbreviated our shifts and worked overnight instead of days to offset the temperatures and still maintain an on-time delivery schedule suitable to our customer’s needs.”

[hydrated]. This year we never had anyone go home early or sick. The one problem that we did have was keeping our equipment running. We just couldn’t keep the machines cool enough and they would shut down from time to time.”

-Larry Stuyt, president, Ontario Laser Cutting, Tillsonburg, Ont.

-Peter Alden, co-owner, Wessex Precision Machining, Ayr, Ont.

“We keep an ample supply of freezies and a Gatorade mix that helped keep our employees

-George Barnes, president, Foldens Machine Works, Tillsonburg, Ont.

“This year we have not lost any work hours due to heat and humidity. We have in the past lost time due to heat … in preparation of heat waves we usually adjust our hours to start earlier in the morning and finish earlier in the afternoon or even close down at noon.”

-Marco Gagnon, co-owner, Gagnon Ornamental Works, Grand Falls, New Brunswick

“We did not lose any hours due to heat, but it was a pain in the ass.”

-Rob Muru, president, A-Line Tool, Toronto, Ont.

“No. We didn’t get a summer yet. It’s been quite cool this year.”

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

-Joseph Manzoli, president, Colourfast Custom Coatings Ltd., Concord, Ont.

“We lost half of a shift during the heat wave.”

shop for our Controlled Goods certification. Our burning and saw operations are subject to the heat stress but we shift the hours of work to avoid the worst heat of the day.”

“No. We have air conditioning. It is a necessity with the parts we make.”

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

“We have only lost minimal time due to heat stress. Three years ago we installed a large air conditioning unit to allow us to maintain a closed

“We did not close but did provide more breaks during the intense heat as well as Popsicles at breaks.”

-Ted Squires, president, TFI Aerospace, Orangeville, Ont.

“No. We switched our hours of work to end early on hot weeks ex: 5am-1pm.”

-Remi Groulx, owner, Groulx Machining, Astorville, Ont.

22 | September 2011 |

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Non-contact Line-Laser Probe for Coordinate Measuring Machines Revolutionize your quality inspection. With a scanning range of 60mm and a scanning rate of 75,000 points per second, you’ll boost your conventional CNC CMM performance to extraordinary new heights. Mitutoyo’s new SurfaceMeasure probe is adaptable to Mitutoyo CNC CMMs and is designed to enhance every stage in the product life cycle from development, to prototyping, to production. Call today to book a personal demonstration.

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Colour map of wall thickness

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economic uncertainty throws a curve at the transportation sector

24 | september 2011 |

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The Long and Winding Road

BACK TO PROFITABILITY bY NAte HeNDLeY There’s no doubt about it: its brutal out there. In late June 2011, Metrolinx, the government agency that manages GO, the transit system serving the Greater Toronto and Hamilton area, decided to award a $120 million contract to a Quebec firm. The contract, to refurbish GO Transit railway coaches, was given to CAD Railway Industries of Lachine, Quebec. This was done despite the fact that another company, Ontario Northland of North Bay was already refurbishing GO coaches under previous contracts. No matter; CAD’s bid was lower so they got the work. Ontario Northland wasn’t the only firm that lost out on the deal. Small shops in the area such as Groulx Machining in Astorville, near North Bay, were also stung. This machine shop had been making components for handrails and automatic doors on GO trains. Under Metrolinx’s new arrangement, Groulx Machining stands to lose a healthy piece of business, says owner Remi Groulx. This story exemplifies the downside of doing business in the

vast transportation sector, which encompasses trains, buses and ships. Like other shops that service this sector, Groulx Machining remains at the mercy of bigger players and macro economic trends. In this way, transportation is similar to automotive and aerospace, two other sectors hugely impacted by national economic cycles that can still be highly lucrative for shops. While the recent economic recession wrecked havoc on Canada’s transportation sector, there are some emerging opportunities. The City of Toronto, for example, is in the midst of a massive expansion of its public transit system. The Federal government, meanwhile, has been pouring money into the once inert shipbuilding sector. Public transit ridership (on trains, buses and streetcars) was up 4.1 percent nationally in 2010, with an estimated 1.9 billion trips taken, according to the Canadian Urban Transit Association (CUTA). In March, 2011, Toronto and the province of Ontario announced $12.4 billion worth of transit projects, the main

photo credit: | september 2011 | 25

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Transportation Sector Report

initiative being a 25 km underground light rail line in the city’s north end. Another big scheme involves a $4 billion expansion of Toronto’s Sheppard Ave. subway line, a pet project of new Mayor Rob Ford. Some of these projects might not come to pass. Mayor Ford, for example, wants to pay for the Sheppard expansion with money raised from the private sector, despite his critics’ contention that this simply isn’t possible. In a similar vein, the Toronto Transit Commission (TTC) might attempt to re-jig a $1.25 billion deal inked with Bombardier Transportation (BT) in 2009 for 204 lowfloor streetcars, aka Light-Rail Vehicles (LRVs). Budgetary pressures could force the TTC to delay or revise this deal. One suggestion is to let Metrolinx buy the LRVs, which would then be leased to the TTC. The streetcars themselves can fit 270 people each (versus 60 for a bus) and were originally scheduled to enter service in 2013. A branch of Montreal-based giant Bombardier, BT is the largest transportation-related firm in Canada, boasting revenues of $9.01 billion for the fiscal year ending January 31, 2011. Bombardier Transportation operates Canadian manufacturing facilities in Thunder Bay, Ont. and La Pocatiere, Quebec, has 6,300 employees in North America and a global workforce of 34,900. The Thunder Bay facility had been slated to build the low-floor streetcars. If the LRV deal seems iffy, another major project between BT and Toronto is on more solid ground. This project involves the construction of 70 new train sets consisting of 420 cars for use in Toronto’s subway system. The so-called “Toronto Rocket” trains are intended to replace older subway cars. “The first Toronto Rocket is now in service. The second is being tested on the line and will go into service in [August] … the third will go into service in September,” says Danny Nicholson, a spokesperson for the TTC. The Toronto Rocket trains are being built at Bombardier’s Thunder Bay facility, which means ancillary jobs for Ontario suppliers. For all of BT’s efforts, rail in general has been having a tough


time of it thanks to the economic doldrums of the recent past. As of December 2010, Industry Canada estimated there were a total of 52 Canadian establishments involved in manufacturing railroad rolling stock (that is, making or rebuilding locomotives and railroad cars). Employment slid from 8,702 in 2000 to 3,601 nine years later while GDP in this subsector decreased from $745 million in 2001 to $213 million in 2010. Of course, making locomotives is only one aspect of working on the railroad. The Ottawa-based Railway Association of Canada (RAC) estimates some 32,000 Canadians are directly employed in the rail industry in a variety of positions, with an additional 60,000 indirect jobs among suppliers. Overall rail operating revenue declined 14.3 percent to $9.6 billion, from 2008 to 2009. In spite of recent troubles, rail remains something of a behemoth; Canada boasts nearly 50,000 kilometres of railway track, which transport some 70 million people each year. Three-quarters of all surface goods moved annually in Canada are transported by trains, thus “relieving road congestion and helping limit harmful emissions,” notes RAC literature. Larry Stuyt, president of a shop called Ontario Laser Cutting has done his share of rail-related work but claims no expertise in the field. “We cut parts for the train industry. I’m not sure what the parts are, but we do know that they are part of a train,” says Stuyt, whose company is based in Tillsonburg, Ont. If rail has had its woes, the shipbuilding industry was on a major decline until recently. Industry Canada counted 665 firms involved in ship and boat building, as of December 2010. Ships are larger vessels that transport people and cargo while boats for the most part are either personal or recreational watercraft. Industry Canada figures indicate some 8,172 people were engaged in ship and boat building in 2009, down from 2000 when 10,336 people were employed. Things might turn around significantly, however, thanks to a series of actions from the federal government. These include two major funding initiatives and a recent decision by Ottawa to

“Rail in general

has been having a tough time.”

Algoma Central Corporation has ordered eight new ships. | september 2011 | 27

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Transportation Sector Report

drop a 25 percent duty on imports of foreign ships. This tax, say industry leaders, pushed shipbuilding operations abroad and discouraged fleet reinvestment. Announced June 2010, the government’s National Shipbuilding Procurement Strategy is budgeted at $35 billion over three decades. This money will be used to beef up Canada’s federal fleet. Ottawa will choose two Canadian shipyards to build new civilian and military vessels. One month later, the government announced a $2.6 billion project to purchase two support ships with an option to acquire a third. The ships will be purchased as part of an initiative called the Joint Support Ship Project. The vessels will be built at one of the shipyards selected in the National Shipbuilding Procurement Strategy. Canada is a country of vast internal waterways as well as ocean-lying coasts. Making ships for the Great Lakes and St. Lawrence Seaway is also a big business—potentially. For a variety of reasons, however, most Canadian cargo ships on the Great Lakes are relatively ancient. According to a press release issued late last year by Marine Delivers (an initiative of the American Great Lakes Ports Association in the U.S. and the Chamber of Marine Commerce in Canada), the average age of “a Canadianflagged ship operating in the Great Lakes” is 38. That all might change however; Algoma Central Corporation, owner of Canada’s largest fleet in the Great Lakes-St. Lawrence Seaway, recently placed orders for eight new vessels. The vessels are scheduled to enter service in two years, with a total price tag of $400 million.

If shipbuilding has been somewhat dormant until now, the bus manufacturing sector has also been fairly quiet. That said, there have been a handful of sizeable deliveries. Nova Bus, a Saint-Eustache, Quebec-based branch of the Volvo Bus Corporation, delivered 300 new buses to BC Transit and TransLink in early 2010. Almost half of the fleet were hybrids. Classic Tool & Die in Oldcastle, Ont., has done bus-related work in the past, though shop vice-president Adriano Oppio hesitates to name any customers, citing confidentiality. “We have manufactured brackets for seating systems in the past,” he states. If he’s cagey about his shop’s clientele, Oppio remains optimistic about picking up new transportation-related work. “I believe that there are many opportunities in the transportation field which are overlooked by our industry,” he says. While conceding that some transportation firms seem to use “the same vendors for decades,” Oppio thinks shops can use this to their advantage: “There is little competition in this sector and this is why I chose to concentrate on prospects [in this field] along with other overlooked industries,” he says. CM Nate Hendley is a regular contributor and freelance writer based in Toronto.

28 | september 2011 |

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Reenergized Manufacturing Sector Meets at CMTS

the Canadian manufacturing technology show showcases the latest equipment and techniques by Nestor Gula ..................................................................................................................................................... Uncertain times aren’t the time to batten down the hatches and ride out the storm — they’re a time to refine your business and reinvest. This statement seems to be born out by a recent national survey conducted by the Society of Manufacturing Engineers (SME). The survey found that nearly 60 per cent of Canadian manufacturing companies are planning to spend more money on manufacturing equipment this year compared to 2010. Another 30 per cent of the companies surveyed will hold their spending at a constant level. Canadian manufacturers are investing in the future according to the survey. To succeed in today’s competitive marketplace a manufacturer has to hone his product and production line to be the best and most efficient. A manufacturer has to remember that their competition is not just down the street but also on the other side of the world. To achieve success in manufacturing field these days it’s crucial to live on the sharp end of technology. The success of any business is how it incorporates the latest technology and equipment. This, combined with efficient business and management practices is a proven road to success. While the SME survey also showed that close to half of the companies surveyed are concerned with “keeping production costs under control” a major concern was “improving workforce productivity.” Nick Samain, SME’s sales manager/event manager said, “that means ongoing investment in new technology and processes is not only happening, but continues to play a key role as manufacturers rebound from the economic downtown of 2008-2009.” About one-third of the respondents noted that plans were afoot to either expand into new markets or updating equipment and processes. The CMTS show occurs every two years and is the largest and most comprehensive show for the manufacturing industry in Canada. “ It is the equivalent of the IMTS (International Manufacturing Technology Show) which is held in Chicago

every two years as well,” said Samain. CMTS is held in alternating years from the IMTS. “Our survey shows that there is optimism for the future and as Canadian companies look for ways to increase efficiencies while keeping costs down, they rely on a venue like CMTS more than ever to help break through the massive clutter of information,” said Samain.

“The CMTS show is the largest and

most comprehensive show for the manufacturing industry in Canada.”

The show has seen a vast transformation from the one held two years ago, according to Samain. “There will be a great breadth of different manufacturers and suppliers exhibiting on the floor,” he said. A lot of companies, which were not able to exhibit two years ago because of the recession, have returned to the show according to Samain. “I can’t think of any builders who will not be present at the show.” The international component will have India taking up a significant amount of floor space to encourage trade between Canadian and Indian companies. (See sidebar page 34.) With technological advances coming at breakneck speed it is imperative to keep up with these changes. Gathering the latest and greatest equipment under one roof, the Canadian Manufacturing Technology Show (CMTS) will allow you to see and experience the leading edge of technology that will allow your business to succeed in today’s marketplace. Organized by the SME, the show will take place on October 17-20 at the Direct Energy Centre in Toronto. Featuring live equipment demonstrations, the trade show will give attendees a great experience with hands on demonstrations and a chance to have meaningful conversations with

30 | september 2011 |

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iew Prev w SHo suppliers from all areas of manufacturing including: automated manufacturing and assembly, automation and controls, CNC programming software, composite manufacturing, cutting tools, energy and environmental efficiency, flexible manufacturing systems, machining centers, mechanized plasma cutting, metal forming and fabricating equipment, micro manufacturing, rapid prototyping, robotics, water-jet cutting, and much more. Over 400 companies have already signed up to the show, which will cover about 250,000 square feet of the Direct Energy Centre, to display their wares and dispense advice on how your company can achieve success in the marketplace. Besides the exhibits and the demonstrations at the trade show, attendees to CMTS will have the privilege of attending fascinating keynote addresses and to participate in interactive panel discussions. On Monday, the conference’s first day, the keynote address will feature Kevin O’Leary. O’Leary has developed a near cult following through his entrepreneurial vision, his blunt assessment of business and assessments and drive to succeed. He is well known from exposure on CBC’s Dragon’s Den, Newsworld’s Lang & O’Leary Exchange and ABC’s Shark Tank. O’Leary co-founded SoftKey Software Products in 1986 and sold it in 1999 to the Mattel Toy Company for $3.7 billion, one of the largest deals in the consumer software industry. “It is one thing to listen to him on television,” said Samain. “It is another thing to experience him face to face and be able to not only listen to what he has to say but to hear his thought and views on the situation on manufacturing as he knows it.” O’Leary’s brazen and opinionated

nature combined with insightful business advice entertain and motivate entrepreneurs whenever and wherever he speaks. He will also be part of a VIP breakfast before his talk on Monday. Later that day seminars will be held on Cost Control and Efficient Manufacturing, Controlling Energy Costs in your Manufacturing Facility and Improving Workforce Productivity in the Manufacturing Environment.





CMTS offers multiple opportunities to get your hands on the latest technology. MY Photo courtesy of SME. CY

Not to be missed on Tuesday, the Automotive Summit, sponsored by the Automotive Parts Manufacturers’ Association (APMA), will be moderated by John McElroy. He was born into an automotive family and actually took his first plant tour when he was only six years old. He found some success in amateur road racing and got his automotive bona fides while working as an hourly UAW employee while attending college. McElroy became an automotive journalist and has probably read every book about cars he could obtain. He has a great understanding of automotive engineering principles and spent five years as the Detroit editor for Road & Track magazine, and has been a regular guest on ABC World News Tonight, CBS News and NBC Nightly News. He is the host of the Emmy Award-winning television program Autoline, and Autoline Daily, the latter is the first webcast of industry news and analysis. It broadcasts five daily radio segments on the CBS affiliate in Detroit. His unique insight is highly valued by manufacturers and suppliers both inside and outside the automotive industry. He will be joined on the panel by a variety of leaders from the automotive manufacturer sector. Also that day seminars will be held covering topics such as: Machining Technology & Trends, Laser Cutting Technology and Manufacturing Innovations in the Transportation Industry. Wednesday will feature seminars on Design Challenges in Medical Device Manufacturing, Use of Additive Manufacturing for Medical Device Manufacturing and Innovations in Medical Manufacturing. Trade shows play a large part in formulating purchasing decisions according to SME’s survey. “Two-thirds of respondents said trade shows play a role in their purchasing strategies and 81 per cent use trade shows to see equipment in action,” CMY



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according to the survey. “Almost 11 per cent of Canadian manufacturers planning to spend more than $1 million on equipment this year, 16 per cent plan to spend between $250,000 and $1 million, 25 per cent between $50,000 to $249,999 and 22 per cent under $50,000.” Samain said they are be using the downtown Toronto location of the CMTS to entice buyers and visitors to the show. “We are offering Stay and Play packages where you will get your accommodation, get a chance to see a show in Toronto, and will include tickets to CTMS, the keynote and the panel,” he said. There are one and two night Stay and Play packages available all include accommodation at the Westin Harbour Castle Downtown Toronto, shuttle service to and

Networking opportunties are everywhere at CMTS.

Photo courtesy of SME.


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from CMTS, automatic upgrade to Elite Package includes trade show registration fee, fast track registration, keynote session or automotive summit, networking reception and executive welcome package plus special evening entertainment discounts courtesy of Tourism Toronto. CM Nestor Gula is a Toronto-based freelance technical writer and editor specializing in metalworking and welding. Nestor was the former editor of Metalcraft Magazine. Nestor can be reached at nestorgula@

India comes to CMTS

The India Show will be held in conjunction with this year’s Canadian Manufacturing Technology Show (CMTS). Organized by EEPC INDIA and the Ministry of Commerce & Industry from the Government of India with the support of the Consulate General of India in Toronto, the show will take more than 150 Indian engineering companies to the Direct Energy Centre in Toronto. The India Show on October 17-20, 2011 is going to be the largest Indian engineering exposition in Canada. EEPC India is the largest trade promotion body in India and caters to the trade and business development needs of India’s engineering sector and The India Show is a flagship event that the Ministry of Direct Energy Centre in Toronto. Commerce & Industry from the Government of India organizes worldwide. 2011 was jointly declared the “Year of India in Canada” by the Indian Prime Minister. Dr Manmohan Singh and Stephen Harper, during the Canadian Prime Minister’s visit to India in November 2009. Currently, bilateral trade between India and Canada is about $5 billion. This is expected to grow to about $15 billion in the next 5 years. While Canada’s economy has coped well in the midst of a financial crisis India’s economy had a growth of 8.6% in 2010-2011 and is projected to grow by another 7.5% to 8% in 2011-2012. This growth is attributed to a strong manufacturing sector, of which engineering is a key element. According to EEPC India, “Canada, with its advanced technological base, can become India’s natural partner in manufacturing, food processing equipment, training, science & technology, innovation, environment, cleaner technology, etc. The objective of The India Show is to establish the credentials of India as a trustworthy source of engineering goods and service and to spread awareness on India’s engineering capabilities in Canada. India’s participation will largely comprise industrial machinery, machine tools & accessories, motion controls, engineering equipment & components, plant engineering & maintenance, auto parts, hand & cutting tools and accessories, aluminum products and supplies, intermediate goods, metallurgy, energy, packaging, electrical & electronic products, steel & fabrications, raw materials, non-ferrous metals, castings, forgings, moulds, tool & die, engineering consultancy, etc. The India Show will also have sectorial representation from important sectors of the Indian economy like Defense, Science & Technology, Renewable Energy, Heavy Industries and Tourism, to name a few.”

34 | september 2011 |

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Featured Technologies at

CMTS 2011

One of the reasons to attend Cmts 2011 is the rollout of new technologies. many companies will be using the show as the launching pad for a host of new equipment and processes for Canadian metalworking industries. Delcam

Delcam will launch the 2012 version of its powermILL CAm system for high-speed and five-axis machining at Cmts. the new release will include a number of new strategies, together with more general enhancements to make programming faster and machining more efficient with the bestpossible surface finish. the most important new option is flowline machining. With flowline machining, the toolpath is divided between a pair of drive curves in a constant number of passes, rather than having a varying number of passes with a constant stepover. Other enhancements include an additional spiral machining strategy, plus more control in 5-axis for angular point distribution. In addition, thread milling options have been added, and workplane editing, and Z-height selection and limiting, have been made easier. Delcam Booth 2732

Hurco Canada

What Our Customers Are Saying...

At Cmts 2011, Hurco Canada will showcase advanced control and emphasize the benefits of 5-sided machining. the Hurco 5-axis VmX30U and VmX42sr machining centres are designed with specific control technology to increase profitability for shops of all sizes. the control features robust NC capabilities required for simultaneous 5-axis, such as full FANUC compatibility, a 40 Gb capacity hard drive, 2 Gb of rAm, Usb port, up to 2,277 bps processing speed, and 600 ipm maximum programmable feed rate. For 5-sided machining, Hurco conversational programming makes converting to a 5-sided process straightforward, with minimal training and no need to buy a CAm system. At the Hurco booth, guests will get one-on-one attention from applications and sales engineers. Hurco Canada Booth 1800

ESAB Welding & Cutting Products


esAb CNC plasma cutting machines are now available with 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

36 | september 2011 |

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Prima Power is a leading supplier of 2D and 3D laser sheet metal processing systems. We provide the option of either CO2 or fiber laser power sources. A single-source provider, Prima Power manufactures the CO2 laser source, machine tool, control, software, and material handling. For more than 40 years, the Prima laser manufacturing division has been producing high-quality industrial CO2 laser resonators, providing DC excited, fast axial flow 3000, 4000, and 5000-watt resonators.  

Compact design saves floor space, facilitating efficient material flow, and requires no special foundation. Efficient resonator design reduces power consumption by as much as 33%... and uses fewer optics, further reducing operating expense and maintenance costs. Cantilever design provides tremendous flexibility in terms of operator access and material handling options.

machine. And it was also one of the only lasers that offered the rotary axis option for tube cutting.” Alfredo Darolfi VP Manufacturing D & R Electronics Co. LTD Bolton, ON

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Prima Power Canada

1040 Martin Grove Road / Unit 11 Toronto, Ontario / M9W 4W4 Tel. 416 242 4431 •

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utilizes esAb’s unique encoder-based height control, as well as the VIsION 5x series of CNCs. this new technology is available on new esAb cutting machines and can also be retrofitted on many existing esAb machines in the field. 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. the required data is embedded automatically, either by the Columbus.Net software or by the easyshape library. Operation is simplified, and no special operator intervention is required to take advantage of this feature. ESAB Welding & Cutting Products Booth 1232


trUmpF Canada will feature the trupunch 3000 at the Cmts. With its 4’ x 8‘ format, the trupunch 3000 offers innovative, skeleton-free punching. the resource-efficient machine’s small footprint, compact automation concept, gentle handling of materials, and skeleton free processing puts the power of choice in customers’ hands. the trupunch 3000 with its electric punching head technology averages electrical consumption of about 5 kW, which makes the machine very energy efficient. With

skeleton free processing, an average of 10% higher material utilization is realized as well as additional process reliability. part sorting or tabbing are available, and the machine also features scratch-free small part sorting for parts from the parts flap or the scrap sorting unit. because the punching head is not in continuous use in the trupunch 3000, another innovative feature has been added to the machine: an electric punching head. It’s quiet, and in contrast to the hydraulic version it uses very little power in standby mode. In punching mode it’s also more efficient, which adds up to power consumption that’s two kilowatts less per hour than the predecessor model. thanks to its

high rotation speed, the electric punching head is very fast when it comes to rotating tools or forming threads. TRUMPF Canada Booth 2000

OMAX Corporation

OmAX Corporation will demonstrate its 80X Jetmachining Center at the Cmts in spark & Co.’s booth where visitors will experience this large format abrasive waterjet system equipped with the revolutionary enduromax pump and tilt-A-Jet cutting nozzle. Ideal for large-scale precision machining of larger or multiple parts, the 80X Jetmachining Center is equipped with Intelli-trAX, an innovative traction drive that ensures higher accuracy. the 80X comes standard with OmAX Intelli-mAX software suite, which runs on the Windows 7 Ultimate operating system. the machine has the ability to cut a wide variety of materials, including ceramics, composites, plastic, glass and stone, as well as metals like aluminum, tool

steel, stainless steel, mild steel and titanium with an accuracy of motion up to +/- 0.003 inches (0.076 mm). the enduromAX pump provides double the operating life of previous pumps, and makes for faster part processing, lower operating costs, and easier maintenance. It maximizes machine uptime with its 1,000-hour operating range between required pump rebuilds when run at 55,000 psi (3,800 bar). the pump can also effortlessly run continuously at 60,000 psi (4,100 bar). the tilt-A-Jet cutting nozzle, allows OmAX Jetmachining Centers to achieve virtually zero taper. by automatically calculating and adjusting the angle of the nozzle through the controller software, the tilt-A-Jet transfers taper from the part being cut to the scrap material. OmAX customers do not have to purchase new equipment to take advantage of these two revolutionary accessories as the company offers retrofit kits for both. Spark & Co. Booth 1910

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Elliott Matsuura

At Cmts 2011, elliott matsuura Canada Inc. will present new and automation technology from four core product lines: From GFAC, new Laser Ablation technology to produce texturizing, engraving, micro structuring, marking and labelling of 2D geometries to complex 3D geometries. Laser ablation at GFAC enables

individualization of products and compared to conventional surface treatment using etching processes, offers economic, ecological and design advantages. From matsuura, the new mAm72-100H 5-axis machine offers a dynamic & robust solution for machining hard-to-cut materials, such as titanium or Inconel, for the aerospace and other industries. From Nakamura-tome, the super NtmX is the world’s first system to offer dual 24-tool AtC magazines, a unique design to simplify complex multitasking machining. Full 5-axis milling capability provides high precision and accuracy for manufacturing complex contoured components, including medical, aerospace and more. Elliott Matsuura Canada Inc. Booths 2300, 2400 and 2216

LVD Strippit

LVD strippit will exhibit the Axel 3015 s Linear laser cutting system with 4 kW laser source at the Cmts. the Axel 3015 s Linear provides advanced laser cutting capabilities and high-speed part processing to maximize machine productivity. the Axel 3015 s Linear offers maximum performance when processing thin sheets and thick materials. A high pressure (clean cut) cutting head is available for 5”, 7.5” or 10” cutting lenses. the high-pressure cutting head produces exceptionally clean cuts and is equipped with a safety system that protects the head from collision with the workpiece. A 10” cutting lens allows the Axel to quickly

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Today’s high speed, high acceleration drives let you work faster…but not necessarily better.

For that you need the advanced engineering and ultra-rigid designs found in Doosan’s new Puma 2100, 2600 and 3100 series turning centers:

• 20% heavier castings to absorb the

stresses of heavy and interrupted cuts, • 25% to 50% wider box ways to hold the tightest tolerances, • Frame rigidity almost 15% greater than before, • Wider surface contacts for main- and sub-spindles, • Y-axis saddles with 30% to 46% greater width and span. Results…superior performance during both heavy-duty and high-speed operations. Learn more. Contact your Doosan distributor for complete information.

Doosan Infracore T EC H N O LOGY



Visit us at CMTS October 17-20 at the Direct Energy Centre - Booth 3014

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and efficiently process thick mild steel 10 mm to 15 mm. the 10” lens permits processing of 1” (25 mm) mild steel with a 4 kW laser source. Using the 10” lens, ¾” (20 mm) mild steel can be processed at 40”/ min., 3/8” (10 mm) mild steel can be cut at speeds of 80”/min. the high beam quality of the 4 kW laser allows processing of thin material at extremely high speed and thick material with high quality surface finishes. the Axel laser system is available with LVD strippit’s exclusive CADmAN-A software. the software simplifies machine use by providing

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mid rail Gantry water jets utilize an industrial pC controller and can be configured so that all three axes are fully programmable (Z optional). the mid rail Gantry is powered by a Jet edge waterjet intensifier pump. Jet edge’s range of waterjet pumps, ranges from 25-280hp, including 36KsI (2500 bar), 60KsI (4100 bar) and 90KsI (6200 bar) models. electric and diesel pumps are available. Elliott-Matsuura Canada Inc . Booth 2216

Scotchman Industries

an explanation of error messages, automatic calculation of stand off distance, and graphic display during the cutting process. the Axel laser system combines high-speed part processing with integrated shuttle tables for continuous, uninterrupted part processing. the shuttle table design allows one table to be loaded while the machine is cutting on the other table, maximizing uptime. the Axel 3015 s Linear features a newly redesigned shuttle table drive system with double driven timing belt for improved machine performance and reliability. table change time is now three times faster and is completed in 15 seconds. LVD Strippit Booth 1926

scotchman Industries will feature the Dual Operator 85-ton Hydraulic Ironworker at Cmts. the DO 8514-20m has five built-in stations, an 85-ton capacity punch and a 14-inch throat depth, which can punch a 1-1/16-inch hole in 1-inch material. the dual operator machine has a hydraulic system designed with two pumps to ensure full hydraulic pressure and speed to both operations, complete with two valves, two stroke controls and two remote foot pedals. the DO 8514-20m’s standard features include: 6-inch x 6-inch x 1/2-inch angle shear and a rectangular notcher that can notch 2-inch x 4-inch through 1/2-inch material. the 20-inch flat bar shear features a low rake angle and has the ability to shear up to 1-inch x 16-inch and


shown is an mLr system using four 20 ton DL series multicyls to power Unipunch tooling. Adjustable Y axis, and quick change set-up accommodates punching various lengths and hole combinations. the DL series is a new introduction to the firm’s mLr package, previously used only with smaller mC and XL series multicyls. MULTICYL INC. Booth 2539

Jet Edge Inc.

Jet edge Inc. will display new water jet cutting technology specially sized for fabricators and machine shops. the mid rail Gantry model mr513, is capable of processing material up to 5’x13’, and cuts complex parts from virtually any material without creating a heat-affected zone (HAZ). Optional mirroring makes it possible to cut large parts twice as fast. Jet edge mid rail Gantry waterjet systems are available in a wide range of work envelopes, from 5’x5’ to 24’x13’.

Come and test the BEST performance annular cutters!! KARNASCH has the biggest range on the market!! • Gold-Line … Special XE-HSS – The Economic! • Blue-Line … Special XE-HSS + Blue-Tech – The First Class! • Hard-Line … Carbide tips + 3-cut geometry! • Power-Max … Carbide tips – The Versatile! All can fit almost any machines with our assortment of shanks. Come and meet with us at the CMTS show, stand #1612.

Mascoutech inc. 1-800-442-2535 | september 2011 | 41

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JUsT The facTs

aBOUT aBRasiVe WaTeRJeTs

MyTh #1 90,000 psi Pumps Cut Parts Faster

facT The facT is that a 60,000 psi direct drive pump provides more actual cutting power than a 90,000 psi hydraulic intensifier with the same size motor. With the same abrasive flow, the direct drive pump cuts faster, at a lower cost. OMAX is committed to truth in technology. But don’t just take our word for it. Ask us for a test cut.

GeT The facTs aT OMaX.cOM/facTs.

Connect and follow OMAX for the latest news in waterjet technology. Facebook


LinkedIn 1.800.838.0343

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please visit us at Cmts bOOth #1910

3/4-inch x 20-inch material. this machine also has the ability to accept optional equipment such as press brakes, rod shear, tube shears, picket tools, as well as special tooling. the scotchman DO 8514-20m is made in America and comes with a 3-Year Warranty. William Brennan Ltd. Booth 1826


Understanding the vertical turning segment of the machine tool market was under serviced, smtCL recently introduced the VtC line of vertical lathes. smtCL Canada will have the new VtC model 2526 on display at their booth no. 2526 at the Cmts show.

software on the 4-axis DX612 features Intelligent tapering Control, which corrects the natural tapering of the cut automatically. mitsubishi Laser will showcase several new performance-enhancing features of the LVpLUsII-45CFr. the machine delivers new brilliantcut technology, which can produce a cutting surface roughness equivalent to the typical machined finish. the new Diamond smart hydraulic press brake is a real innovation for small and medium size sheet metal working companies. the Diamond smart CNC control offers simple operation, quick and easy part programming, easy machine setup, auto calculation of the bend angle and back gauge position, and angle and back gauge correction.the Consumable products Group (CpG) will showcase its extensive line of Oem quality consumables. Mitsubishi/MC Machinery Systems Inc. Booth 1400

everything yOu need. When it COmes tO abrasive Waterjet maChining, OMAX Corporation has everything you need.


mitsubishi will highlight the latest in wire eDm, sinker eDm, waterjet, press brake and laser technologies at Cmts 2011. mitsubishi will showcase its newest, large-capacity wire eDm, the bA24. the machine’s 16.5-inch fully submerged Z axis makes it ideal for the large oil and gas components typical to this region. the eA12D sinker eDm features 64-bit pC-based CNC control with a 10.4 inch LCD screen for faster data processing and servo control. the DX612 mitsubishi Waterjet with 60,000 psI pump will also be on display. mitsubishi Waterjet is designed to complement eDm technology with the precision of mitsubishi controls and servo system.

One COmpany.

these new vertical lathes are built using the latest casting technology in an IsO factory environment, using finite element analysis used in the process of design. the new VtC product line is equipped with components and accessories from the industry’s leading component manufacturers and they feature the new modern product paint scheme and laser-cut and welded body components, first introduced in Chicago last year. the new model 2526 VtC on display at Cmts will be equipped with a FANUC 0i-tD CNC control, 21-inch hydraulic chuck, FANUC Alpha-p main spindle motor and a horizontal-axis 8-position Duplomatic tool turret. SMTCL Booth 2526

OMAX is a single-source provider of the industry’s most innovative abrasive waterjet technology. With the OMAX and MAXIEM lines of waterjet equipment, we offer a complete range of capabilities from industry standard to high performance. When it comes to waterjets, OMAX is the only partner you need.

DMG Canada Inc.

the DmU 65 monobLOCK from DmG offers high-tech at an attractive price while setting a new benchmark in its class with its convincing performance features. the DmU 65 monobLOCK features a spacious machining compartment with axis paths of 650 x 650 x 560 mm (in X, Y and Z) in its 5-axis version. the entire indexing table surface can be traversed allowing the workpieces to be machined in one pass. With its 7.5 m2 footprint it is the most compact machine of its class. even oversize workpieces of up to 840 mm diameter and a weight of up to 1,000 kg can be loaded 1.800.838.0343

WWW. MAXIEMWATERJETS .COM TEL 877-MAXIEM5 (877-629-4365) Made in the USA | september 2011 | 43

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iew Prev w SHo on the swivel-type indexing table. simple and comfortable operation and loading of the 30, 60 or 90 position tool magazine speeds set-up and the fast sword-type tool changer reduces the chip-to-chip time to a

and simplify programming, setup and part-handling. Elliott Matsuura Canada Inc. Booths 2300, 2400, and 2216

Modular, quick change tooling

convincing 4.9 seconds. A wide centrally arranged chip conveyor permits fast and process reliable chip removal towards the rear of the machine. DMG Canada Inc. Booth 2512

Cincinnati Incorporated

mAXFOrm press brakes speed part bending with “smart” controls, 700 ipm ram, and linear-drive backgage. engineered for high-throughput lean manufacturing, the mAXFOrm hydraulic press brake from Cincinnati Incorporated combines state-ofthe-art forming speeds and part processing productivity with “smart” controls that speed

beNZ solidfix for Live tools, Angle Heads and multi-spindle heads reduces setup times up to 90% vs. standard equipped tools. the modular quick-change-system beNZ solidfix can be operated with one hand, without the use of any special tooling. With one simple turn of the clamping screw by 180° the tool adapter - and respectively the tool - is fixed. tool change can be done in as little as 7 seconds. A safety bayonet ensures that when the tension on the adapter is released the tool cannot fall out, but rather will only release after an additional turning motion from the operator, avoiding damage to expensive tools. Furthermore, with its resistance controlled clamping over tightening and the resulting damage to the tool cannot occur…no torque needs to be observed. With the beNZ solidfix quick-change-system’s high-precision design with a large contact surface and high clamping forces, even in high stress milling applications the tool is fixed solid. Benz Inc. Booth 1812

Precision Hole Saws and Arbors

Weldon tool has expanded its product offering of precision hole saws. Weldon now offers diameter sizes of .500 to 2.50 diameter from

stock. Hole saws are made from hardened High speed steel with plenty of chip clearance. tools are design to cut aluminum and mild steel. specials are available upon request. Weldon Tool Booth 1718

Complete line of automatic drilling machines

Nitto Kohki offers a complete line of automatic feed magnetic base drills that use self regulated feed systems to optimize cutting performance with a number of safety features. Used with Jetbroach tungsten carbide tipped annular cutters, it can significantly increase production while reducing labor hours and safety hazards. Nitto Kohki also manufactures several other steel working tools including portable hydraulic punches, bevelers, pneumatic and electric power tools. Fabricating Machinery Solutions Booth 138

New high performance CNC

the CNC 8065 takes the most advanced CNC technology available in the world and makes it simple to use. by combining the operating system aspects of the extremely operator friendly 8055 series CNC with the power and technology of the CNC 8070, the 8065 was born. the industrial hardened pC based Windows 8065 CNC utilizes a simple to program icon key based conversational programming system made popular with the highly successful 8055 CNC system. this method utilizes a variety of “ICON Keys” that are symbols of the operation to be performed. the customer simply chooses the operation via the appropriate ICON key and then fills in the blank directly off the blueprint on a single graphic assist screen. the 8065 CNC also has the capability of traditional IsO G-code programming, thus enhancing the versatility of the CNC to match the Operators experience and skill-level. All 8065’s have the capability of ethernet communication and are equipped

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13.9 Seconds

“The EPIC R/T’s Proven Track Record Leaves The Others Behind.”


e’re in our 33rd year now and one thing that I have always strived for, that I can happily say I’ve achieved, is longevity. No, not me...the company and our products. Hydromat did it with a philosophy of “Committed to Excellence”. We have kept the solid core of the strong Hydromat rotary transfer machine, while tossing off the old technologies as we replaced them with faster, more accurate systems and components. We never sit idle. It’s been a couple of decades since we introduced our first CNC system, now our flagship product line, the full CNC EPIC R/T, is the standard by which all other rotary transfer systems are judged. All of our EPIC machines feature EMC Technology, Embedded Motion Control, it brought new power to the Hydromat machine’s inherent production capabilities and streamlined the CNC system. Each cutting station has its own control system integrated into each toolspindle unit,

a true plug & play control architecture. These advancements substantially lower re-tooling costs and gives the user superior flexibility. Many EPIC users run par t families with up to 30 par t types in one set-up. Changeover times are generally now only counted in minutes, not hours. The EPIC R/T has proven itself as a lasting valuable asset not only for production. Used EPIC R/T machines are being sold at premium prices these days. With new machine sales, service, and par ts available from AMT in the Toronto, Ontario area, we care for our customers as if they are par tners and neighbors. We consider them as being ‘right down the road’, and for all practical purposes, they are. We don’t let our neighbors down. These are long-term personal relationships that are precious to me, and I am the promise keeper that we exceed your expectations. We’re always here for you, in Toronto, ready to help. Just down the road.

18.2 Seconds





12.0 Seconds

It’s all about perfection! The EPIC R/T 25-12: A Part Family Expert


Bruno Schmitter President/CEO • Hydromat Inc.

AMT Machine Tools Ltd.




73 Galaxy Blvd. Units 16 &17 • Rexdale, Ontario M9W 5T4 phone 416.675.7760 • fax 416.675.6988

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as standard with a USB port, thus making the integration of the CNC into the customers network easy, as well as for allowing quick and easy transfer of programs. Additional new features include new high speed processors for maximum performance in high speed applications. Booth 2926 Fagor Automation

New tooling catalog

Sowa Tool & Machine announces the GS Tooling Catalogue featuring GS Premium Balanced Rotary Tooling. GS Premium fetures a DIN Coolant option as standard, an all ground body and 100 per cent forged construction. GS Premium Balanced Rotary Tooling is balanced up to 25,000 rpm. Sowa Tool & Machine also features a complete package of workholding solutions, and an expanded range of vises, lathe chucks and rotary tooling including shrink fit and HSK. Sowa Tool & Machine Booth 3826

New insert grades with exclusive coating

Seco Tools introduces new turning insert grades and chipbreaker inserts within its exclusive Duratomic

coating.Two new insert grades, TK1001 and TK2001 are the latest additions to Seco’s Duratomic family of turning and milling insert grades. Additionally, there will be a large offering of geometries and chipbreakers designed for the ISO K10-K20 range of cast materials, such as grey and ductile irons. The new grades offer better wear resistance, allowing for higher cutting speeds and improved productivity. Seco will also showcase its new M5 and FF2 chipbreaker inserts.

As a result of these inserts, there are now 125 new available items spanning Seco’s Duratomic line to its recently introduced Cermet technology. Seco’s exclusive Duratomic technology is a process that creates a durable coating by uniquely arranging aluminum and oxygen atoms to provide increased toughness

46 | september 2011 |

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and abrasion resistance. In addition to new products, Seco will have its recently launched Minimaster Plus replaceable tip milling system on display at CMTS. This highly productive, precision-focused system makes tool-length re-measurement a thing of the past. It offers a large selection of shanks and inserts for a multitude of applications. Twenty-four versions of the shank are available, along with square shoulder and ball nose inserts that have through tool coolant on all two and three flute designs. The inserts come in two grades for machining all types of materials and E- and M-geometries for a smooth cutting design. Insert diameters range from 0.375” to 0.625”, and corner radii are available from 0.0157” to 0.122” to match a variety of design requirements. Seco Tools Booth 2726

Steel movement without slings, hooks or cables

Eriez Lifting Magnets safely lift and move steel without direct attachment by slings, hooks or cables. Complete line in both permanent and electro designs with various models, sizes and strengths to

applications including slotting, facing, helical and pocket milling. (Diameter Range: 5/8”-5”) The PHC Series is designed for high feed milling applications, maximum metal removal rates with low

radial cutting forces for stable milling performance in a variety of milling applications such as pocket milling, 3D roughing and helical milling. (Diameter Range 1”-4”) The PRC Series (Round Insert) excel in a wide variety of milling

WE’VE BEEN PASSIONATE ABOUT WATERJET FOR YEARS. At Flow, in 1979, Dr. Mohamed Hashish invented the abrasive waterjet...

handle many different lifting jobs. Used singly or in gangs. Eriez’ powerful Lifting Magnets make quick work of difficult, time-consuming steel handling. Eriez Magnetics Booth 1839 he

Indexable carbide tool series

OSG Canada introduces the Phoenix Indexable Carbide Cutting tool series. The PSE 90˚ Series produce a highly accurate 90˚ square shoulder and feature free cutting insert geometries as well as the latest in carbide substrate and coating technologies for excellent surface finishes and optimal tool life in a variety of milling

Our passion for waterjets, years of experience, and dedication to our customers drives us. Waterjet is our life. Driven by passion. Inspired by you. 800.446.3569 | september 2011 | 47

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Heinman Machinery Machinery Ltd. Ltd. Heinman

CNC Vertical Machining Centres Dah Lih MCV-1020A MCV-1020BA 40”x21”x22” XYZ travel 15HP 6000 or 8000rpm Fanuc 21iMB 25 or 24 tool ATC

Dah Lih MCV-1450 57”x29”x29” XYZ travel 25HP 6000rpm Fanuc 21iMB 32 tool ATC

Dah Lih MCV-1700 67”x31”x29” XYZ travel 25HP 6000rpm Fanuc 21iMB 32 tool ATC

Dah Lih MCV-2100 MCV-2600 82”x34”x30” XYZ travel 102”x34”x30” XYZ travel 30HP 6000rpm Fanuc 21iMB 32 tool ATC

CNC Horizontal Machining Centres Dah Lih MCH-500 MCH-800 29”x26”x23” XYZ travel 53”x39”x39” XYZ travel 30HP 6000rpm or 10000rpm Fanuc 21iMB 60 tool ATC Fortworth Horizontal Boring & Milling Machine HB-110-20T 79”x59”x59” XYZ travel 35HP 2500rpm Fanuc 18iMB 60 tool ATC

CNC Vertical Machining Centres First MCV-300 24”x12”x18” XYZ travel 10HP 8000rpm Fanuc Oi-Mate 10 tool ATC

First MCV-1000 40”x20”x20” XYZ travel 15HP 8000rpm Fanuc Oi-MD 24 tool ATC

First MCV-1100 43”x23”x22” XYZ travel 25HP 10000rpm Fanuc 21iMB 24 tool ATC

First V-43MD 43”x23”x20” XYZ travel 25HP 15000rpm Fanuc 18iMB 24 tool ATC

First MCV-1600 MCV-1500 63”x 30”x 27” 59”x30”x27” XYZ travel 25HP 10000rpm Fanuc control 18MC 24 tool ATC

First MCV-2000 Double column 80”x45”x30” XYZ travel 25HP 15000rpm Fanuc 18iMB 30 tool ATC

Kao Ming KMC-3000SV(B) Double column 127”x67”x33” XYZ travel 35HP 5200rpm Fanuc 18iMB 30 tool ATC

Phone 905.564.9479 6105 Kestrel Road, Mississauga, ON 905.564.1052 Phone 905.564.9479 FaxFax 905.564.1052 Email Email CNC Grinders Chevalier Smart H/B818II Smart H/B1224II Smart H/B1640II 8”x18”/12”x24”/16”x40” Conversational control Dress while you grind capable Test grind in simulation mode Chevalier FSG B818CNCII FSG C1224CNCII 8”x18”/12”x24” Fanuc OiM 3-axis control Wheel dresser with auto compensation, Double “V” guideways on Y, THK linear guideways on Z


Chevalier FSG H2440CNC FSG H2460CNC FSG H2480CNC 24”x40”/24”x60”/24”x80” Fanuc OiM 2-axis control Double “V” guideways on Y

Co Co Ste Klo *Se *He

Chevalier FSG B2440CNC FSG B2460CNC 24”x40”/24”x60” Fanuc OiM 3-axis control Double “V” guideways on Y


CNC Lathes


Chevalier FCL-1840/1860/1880 FCL-2140/2160/2180 FCL-2540/2560/2580 FCL-2660/2680/26120/26160 Teach-in type flat bed Rigid tailstock 18”-26” swings 40”/60”/80”/120”/160” between centres


Chevalier FCL-820 FCL-1028 Slant bed Fanuc Oi-Mate or Oi-TC Hydraulic 10-station ATC 8”/10” chuck

w w w . h e i n m a nMacHines m a c h i n e r y . c ounder m Visit our sHowrooM, power

05 Heinman V1.indd 1 CMTS preview.indd 48

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479 ON 052 52 com m m

Phone oil 905.564.9479 We offer manufacturing solutions and training. Since 1977 Heinman has supplied aerospace, medical, farm, construction, and Fax 905.564.1052 energy, machine shop, automotive, fluid power and fitting, research and development industries as well as educational institutions and Heinman Machinery Ltd. Email government agencies with high quality metalworking machinery. Let us help you with manufacturing solutions specific to your needs.

Baxter Bandsaws Verticut 115B

Semi Automatic Horizontal 360SAHD

Chevalier Automatic Surface Grinders

First Milling Machines LC-185VS-B R8, 3HP LC-185VSX-B ISA40, 5HP

Column Type FSG-24x60ADll FSG-20x60ADll FSG-20x40ADll

Table 50”x10” Rapid up & down Z-Axis box way

Kao Ming Radial Drills KMR-700DS KMR-1100S KMR-1250DH KMR-1600DH

LC-20VHS Vertical/Horizontal LC-20VSG Vertical Table 51”x10” ISA40, 5HP Rapid up and down Gear box long table feed

LC-1 1/2VS Table 42”x9” R8, 2HP

Microweily Lathes Complete with: Coolant System & Full Splash Guard Steady Rest, Chuck Guard Klopfer Quick Change Tool Post Set *Self Centering Steel Chuck *Heidenhain 2-Axis Readout System TY-1630S TY-1640S TY-1845S TY-2060 TY-2080

30” centre 16” swing 40” centre 16” swing 45” centre 18” swing 60” centre 20” swing 80” centre 20” swing

Heavy Duty Variable Speed TY-2500 45” centre 18” swing TY-2000 63” centre 18” swing

TY-2680 80” centre 26” swing TY-26120 120” centre 26” swing TY-26160 160” centre 26” swing *excluded


Linear Bearing Ways FSG-16x40ADll FSG-16x32ADll FSG-12x24ADll Slide Ways FSG-3A12x24 FSG-3A10x20 FSG-3A8x18

Chevalier Handfeed Surface Grinders Grinders that will last for years ACCU-618SP Super Precision FSG-618M Includes: 6”x18” Walker Neo Micro magnetic chuck

Mills equipped with: German Collet Set Heidenhain 2-Axis Readout

Chevalier Hydraulic Cylindrical Grinders Fortworth Milling Machine

CGP-816 CGP-1224

CS-G450B Vertical & Horizontal Table 51”x12” ISA40, 5HP & 7.5HP 3-Axis power feed Rapid traverse

Chevalier, Deckel & Michaellin Cutter Grinders Forthworth Bed Type Mills CS-VBM-5VHL Vertical & Horizontal CS-VBM-5VL Vertical Table 86.5”x20” Metric ball screws Pneumatic clamping AC servo motor CS-VBM-4V Vertical Table 74.5”x17.5” Metric ball screws Spindle head feed 2-Axis feed

FCG-610 Universal

SO Single Lip

U2 Single Lip

Portable Drill Bit Sharpening Machines GS-11


w w200 w . h eMacHines i n m a n m a c h i n ein r y . stock c o m oVer

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iew Prev w SHo applications including face milling, pocketing Industry first general purpose, and 3D roughing of large mold components. high performance tap Emuge Corp. will feature (Diameter Range: 1”-4”) MultiTAP at CMTS, The PFB Series (Finish Ball) endmills are the industry’s first high designed for finishing and semi finishing 3D performance tap designed milling applications. PFB endmills feature an to cut a wide range of extremely accurate insert radius as well as materials including carbon excellent insert pocket accuracy for optimal steel, steel alloys, stainless tool life and surface finish. (Diameter Range: steel, aluminum, cast iron, 8mm-30mm)”. 2339 SafeHold 1_2Ad_Layout 1 8/2/11 1:29 PM Page 1 copper, brass, and bronze. OSG Canada Booth 3626

Eriez’ SafeHold® Lift Magnets Eriez’ offers the widest selection of compact permanent lift magnets. SafeHold® is available in four different styles to meet any price or performance requirement with capacities up to 10,000 lbs.

MultiTAP is also uniquely designed to produce threads within both 2B and 3B classes of fit, eliminating the guesswork of calculating H-limits. Emuge has designed MultiTAP to offer job shops and other manufacturers an affordable, high performance tapping solution for a wide variety of common materials and applications. Emuge design engineers chose a select base material, along with a special cutting / flute geometry and a surface treatment that would work in as many common materials and applications as possible. MultiTAP is constructed of a proprietary grade of high speed steel (HSS-E), Nitrided with a Ne2 surface treatment. It is available in both spiral point and spiral flute configurations for through-or blind-hole applications. Tap sizes cover a full range for UNC or UNF threads, from #4-40 to ¾”-16 in inch sizes, to metric sizes from M4 x 0.7 to M16 x 2.0. Emuge is also offering guaranteed performance for MultiTAP: If the tool does not successfully outperform the user’s current taps in most common materials, the tool purchase will be fully refunded. Emuge Corp. Booth 3508


From Zeiss, the new MICURA is a premium class and compact, bridge-type CMM. It features Zeiss active scanning. The MICURA system exhibits high precision (0.9 micron + L/400) with low probing force and is an

NEW SafeHold Selection Guide! excellent solution for measurements of close tolerance parts with delicate structures. Application Specialists will be on hand to answer questions. Elliott Matsuura Canada Inc. Booths 2300, 2400 and 2216

888-300-3743 or visit


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Tooling Innovation | Double Octomill




That is a lot to have at the ready, plus the edge in use is engineered for higher cutting speeds to increase productivity while lowering component costs. Our unique design makes indexing precise, easy and secure as well. The pre-hardened coated cutter body ensures

long usability even in adverse conditions. With choices in cutter size, pitch, insert geometries and multiple grades, featuring Duratomic , Double Octomill provides impressive performance for roughing to finishing in all ISO materials. ®

See us in Booth #2726 at CMTS 2011


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machine tools


Turning the Tough Ones

Hi gh pressu re coo l ant tech boosts th rou gh put The turning of stainless steels, superalloys and other “difficult” materials grows less difficult all the time, as a result of equipment improvements and refinements in High Pressure Coolant (HPC) machining practices. In many such applications with flood or low pressure coolant and advanced tooling, throughput gains of 20% or more are reported, together with a doubling of edge life. In addition, when you turn the pressure up to the 70-300 bar range, you increase potential gains by another big step. In fact, with proper HPC practices and tooling, you can routinely expect order-of magnitude gains in edge life and/or hourly output. First let’s take a brief look at some recent key improvements for turning the exotic superalloys, stainless steels and titanium materials. A drop-in in retooling of a rough turning operation on 316L stainless steel extended tool life from 4 to nearly 10 parts per edge, despite running the part 20% faster. The insert which provided the advantage was coated with the new ISCAR 6015 grade. The job ran with conventional flood coolant. Likewise, turning of hard superalloys has been improved with whisker-reinforced ceramic inserts (such as the new ISCAR IW7) that performs well even in roughing applications. Indeed, these inserts have enabled eight- to ten-fold improvements in roughing and semi-finishing removal rates compared with carbide inserts. The new ceramic insert has withstood cutting speeds high enough to heat and soften hard materials such as Stellite, and performed reliably enough to permit unattended turning of superalloys.

Controlling Heat, Managing Chips

Gains stem mainly from better control of heat and chip formation in these gummy, long-chipping nickel- and cobaltbased alloys, made possible through advanced insert design. Even without HPC, the driving strategy in insert design for these materials is to provide a very sharp edge, slippery, heat resistant coatings and aggressive chipbreakers. That combination quickly breaks up the chip and propels it away from the insert and cutting zone before it can adhere to the cutting edge, overheat the insert or clutter up the toolworkpiece interface with chips that create recutting conditions. Remember, chips can be much harder and more brittle than the base metal, compounding the damage caused by recutting. With HPC in the picture, coolant (boiling point 350C.) remains in the liquid phase, thereby maintaining its lubricity, cooling power and chip-flushing capacity. Moreover, the flow rate under true HPC conditions is high enough to create a “hydraulic wedge” in the cutting zone, significantly reducing friction and all its consequences.


While we have all heard about the promise of high pressure coolant (HPC) machining, we may have shied away from it because of the added equipment cost and uncertainties of an “untried” technology. Let’s take a look at these issues: Untried? The technique is well proven among the aerospace, powergen and turbomachinery industries. On one hand, experienced practitioners report two- and three-fold gains in machining rate with no loss in edge life. Others mainly concerned about

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Try our SolidWorks, Inventor or Siemens 3D file importers. You’ll be a big fan. SigmaNEST is simply the most advanced and efficient nesting software for sheet metal fabrication and profile cutting. Our CAD importers are available for SolidWorks, Inventor, Siemens and many more! Please call 1-513-674-0005 to find out how we support your CAD system. Nest with the BEST!® SolidWorks®, Inventor® and Siemens® are registered trademarks of Dassault Systèmes, Autodesk, Inc and Siemens AG., respectively.

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machine tools


edge life, report up to sevenfold improvements at equal removal rates. These are actual results on ID and OD work on titanium and Inconel turbomachinery parts, titanium airframe parts and a variety of stainless steel components. Added equipment cost and availability? This was true in the early years, but not now. When first introduced in the ‘50s, there were no spindles fast enough or coolant pumps powerful enough to make the process workable on the shop floor. However, today most machine tool providers routinely offer optional high speed spindles and high pressure pumps. High Speed Machining is more the norm than the exception in industries that must contend with stainless steel and superalloys.

hpc-reaDY tooling

Now “HPC-ready” tooling has become more widely available. While providing the geometries and physical properties tailored to particular difficult-to-machine materials, true HPC tooling (such as the ISCAR JETHP line) also features the means to deliver coolant through the tool and discharges it in a tight, laserlike stream, aimed directly into the cutting and secondary shear zones. This is critical. There it cools, lubricates, creates the hydraulic wedge effect and quenches the chips so they break up into compact, manageable curls. On its passage from reservoir to cutting zone, the coolant also lowers the temperature of tool and insert. True HPC tooling is specifically designed for 70-300 bar pressures. HPC tools are indispensable to truly optimal performance; standard through tool coolant systems simply are not adequate. The main differences are twofold: (1) where and how precisely they pinpoint the stream as it leaves the tool and (2) orifice diameter to deliver the correct pressure at the exit point. It is like the difference between true power washing and spraying with a garden hose.

BeneFiting From eXperience

Experienced HPC practitioners have learned enough about the process to provide tips for newcomers. Here are a few to help you get started on the right foot: Use carbide tooling. Ceramic and CBN tools do not deliver the same degree of improvement in the HPC realm. Direct the coolant through the tool. Don’t take a “flood coolant approach” with a HPC coolant stream.You’ll just make a mess, create an employee hazard and miss out on the main benefits of the practice in the first place. If you need more cooling power (i.e. the coolant is vaporizing or chips aren’t flushing well enough), turn up the flow rate, not the pressure. This way is far more cost effective. How to estimate coolant requirements? A good rule of thumb is 0.5 gpm/horsepower. For example, a cut requiring 10 hp will need 5 gpm to achieve the high pressure effect. If you are still having difficulty turning those materials, look around. Better answers, including today’s HPC machining, are more readily available for the asking. Your competitor may have found them already! cm Article courtesy of ISCAR Canada.

stainless steel is a common “hard” steel alloy encountered in machining operations, but there’s a considerable library of technical information to help select grades and techniques. The specialty steel industry of north america website has an excellent designer’s handbook that describes free machining stainless grades that turn cleanly with high productivity.

303, 303se

Types 303 and 303 se stainless steels are the free-machining variations of Type 304 (austenitic — 18cr-8ni) that are particularly well suited for screw machining operations. Their greatest benefit is higher productivity resulting from longer tool life and higher cutting speeds in comparison to Type 304. Type 303 has wide application for shafting, valve bodies, valves, valve trim, fittings, etc. This stainless steel has desirable non-galling properties that make disassembly of parts easy — and help to prevent scratching or galling in moving parts. Type 303 se has applications similar to Type 303 except that it has slightly better corrosion resistance than Type 303 and better formability for applications involving hot or cold working operations.

machining characteristics: Types 303 and 303 se stainless steels

machine easily with a brittle chip. in turning operations they can be used at speeds of 102-130 surface feet per minute. moderate cold working increases the machinability. grinding and polishing operations can be very satisfactorily performed. in comparison to Type 416, their machinability rating average is 75 percent. much higher speeds are possible if carbide tooling is used.


Type 203 is an austenitic free-machining stainless steel containing higher levels of manganese in order to obtain maximum machining speeds. The grade is particularly suited for high production high volume automatic screw machine work. machining speeds are somewhat higher than for Type 303.

machining characteristics: Type 203 stainless steel machines with chip characteristics similar to Type 303 but requires slightly higher machining speeds. Typical turning speeds are 125 to 155 surface feet per minute for high speed tools. Higher speeds are possible with carbide tooling. The machinability rating for this steel is about 85%.


Type 430F stainless steel is suggested for faster cutting and reduced costs when making machined parts from a

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16.00/18.00 percent straight chromium stainless steel. Type heavy duty equipment, speeds of 90-110 surface feet per minute 430F does not harden by heat treatment. it is used for parts and feeds of 0.0008-0.0020 inch are suggested. requiring good corrosion resistance, such as solenoid valves, For more information, go to: 9-11_CM_CenterRock_Layout17/30/1110:51AMPage1 aircraft parts, gears, etc. Type 430F is not usually recommended for vessels containing gases or liquids under high pressure.

machining characteristics: Type 430F machines in turning operations at speeds of 124-155 surface feet per minute or at about the same as ase 1120, 1030, etc.


machining characteristics: Type 416 stainless

steel cuts very freely because of the sulfur content. in automatic screw machines Type 416 machines at about 165 surface feet per minute.


Type 420F stainless steel is easy to machine, grind, and polish, and has certain anti-galling or non-seizing properties in service. it is used for parts made on automatic screw machines, such as valve trim, pump shafts, needle valves, ball check valves, gears, cams, pivots, etc. This freemachining hardenable steel is used mainly for machined parts requiring high hardness and good corrosion resistance.

machining characteristics: For automatic

screw machines, Type 420F stainless steel machines like sae 2315 and 2340. in single point turning operations employing


Type 416 is the most readily machinable of all stainless steels, and it is particularly well suited for good productivity on automatic screw machining operations because of the longer tool life that results. The uses for Type 416 are extensive and include fittings, gears, housings, lead screws, shafts, valve bodies, valve stems, and valve trim. in fact, this type is ideal for parts requiring considerable machining work. its low frictional properties minimize galling in service. Threaded sections work freely without seizing, and disassembly is particularly easy. pump shafts and valve stems work more smoothly in packing, and many metal-to-metal contacts withstand more pressure because of their anti-seizing characteristics.

“We call it Gibbs Can!”

Drills used to rescue Chilean miners were made with CNCs programmed by GibbsCAM. Brandon Fisher, Center Rock founder and CEO (left), with Richard Soppe, down-hole-drill project manager, and their worn 26” Low Profile drill that made the final bore to the Chilean miners, 2,067 feet below the surface.

• Solid Modeling • 2-5 Axis Milling • High Speed Machining • Turning • Mill/Turn • Multi-Task Machining • Swiss • Tombstone Machining • Wire-EDM

Center Rock Inc., of Berlin, PA, combined state-of-the-art technology and expertise to cut in half the time (from five months to two and a half) to rescue 33 Chilean miners. Today, Center Rock programmers and machinists continue to accelerate production of drills and drill bits by using GibbsCAM to drive their machining centers, lathes and MTM machines. GibbsCAM integrates all operations. As a result, when programming mill-turn or MTM, the CNC programmer stays within the same user interface. Turning, milling, drilling and non-cutting processes, such as tool changes and transfers between spindles, are executed without having to exit an active module. This dramatically saves time while providing unmatched ease of use. If you’re searching for CAM software that can provide breakthrough performance... Gibbs Can!

See GibbsCAM at Booth 2934


Powerfully Simple. Simply Powerful.


Bill Gibbs Founder/President

See GibbsCAM at Cimatron Stand #H30 • Hall 25

Gibbs and Associates /GibbsCAM Production CNC Programming

Cimatron Technologies /CimatronE

Integrated CAD/CAM for Mold & Die, Design and Manufacturing

• 1-800-654-9399 | sepTember 2011 | 55

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proDuct report tools for tough materials

iscar’s ic 6015 insert features the aggressive m-style chipformers and a sumO Tec cVD coating that improves flaking and chipping resistance in cutting continuous cuts/finishing cuts/stable conditions. The entire insert is given the innovative sumO Tec post coating treatment, pioneered by iscar, which has proven to improve performance more than 30% over all grades and applications. Following

soon will be an ic6025 grade, with the same features and a geometry suited for m15-25 conditions (roughing/interrupted cuts). HeliTurn and HeliTurn lD inserts bring the high-positive, helical-edge, high-feed, double-sided benefits to turning of stainless steel, nickel based alloys and titanium. The lD versions feature the sharp edge and aggressive Hm and m4mW chipformers that make such a difference in gummy materials. The helical edge creates a more gentle entry and exit and helps reduce breakout at those points in a cut. Throughput and edge life aside, their high rake angle has also proven to reduce power requirements by 10%.

powerful, heavy-duty cnc turning center

Designed for large workpieces, the cybertech Turn has the rigidity and horsepower for heavy-duty cutting with multi-Tasking capabilities for big-part machining. Turn, mill, drill and tap in a single setup. it also does deep boring up

to 40�. The cybertech Turn is ergonomically designed with tools highly visible and is easy to setup and program. an optional pipe re-threading program calculates positions and performs re-threading in a few

simple steps. The cybertech Turn features a 12-tool upper turret with live spindle, an 8-tool lower turret for simultaneous turning, a built-in premium threading function, deep hole boring with automatic changer and a programmable servo tailstock. The cybertech Turn uses mazak’s mazatrol conversational cnc system. cmts Booths 2500, 2600

coated carbide turning insert for cast iron roughing

sumitomo electric carbide, inc. announces the latest addition to its coated

How can the right support make your business better?

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

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carbide grade lineup – insert grade ac420K. isO classified as a K20 grade, the ac420K performs exceptionally in cast iron roughing applications involving medium to heavy interruptions. The ac420K is a new black sumitomo super FF (Fine and Flat) cVD coated

super FF coating provides excellent chip adhesion resistance. along with the ac420K, sumitomo added the egZ chipbreaker to its product lineup. The egZ is a groove style chipbreaker that is ideal for medium- to light-roughing depth of cut (0.070”-0.200”) applications with a feed rate range of 0.004-0.020 ipr. cmts Booth 3708

machine tools

stability, abrasion resistance, oxidation resistance and chemical inertness. The Wg-700 is an extremely strong, wear-resistant, mechanical-shock resistant ceramic grade that is capable of much

sophisticated whisker-reinforced ceramic insert

grade. its ultra-thick coating layers of Ticn for wear and chipping resistance, and al2O3 layers for excellent wear and heat resistance drastically improve conventional cast iron grade tool life. additionally, the flat surface of the

greenleaf introduces a new whiskerreinforced ceramic grade, Wg-700. Wg-700 is a completely new whiskerreinforced ceramic insert and is the most sophisticated ceramic insert developed by greenleaf. Wg-700‘s substrate benefits from an optimized whisker load, which improves its crack- and wear-resistance characteristics while increasing its overall strength. greenleaf’s new, proprietary “platinum” nano layered coating provides low-friction machining in both wet and dry environments, high temperature

higher metal-removal rates than any other whisker-reinforced ceramic insert.

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.


Visit us at

Booth #2800

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

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proDuct report

new iso s insert program boosts turning of heat resistant super alloys and titanium

October 1st sees the launch of more than 300 inserts from sandvik coromant in a new series of optimized isO s turning geometries with easy-to-choose guidelines for every machining requirement. used for turning Hrsa and titanium alloys for roughing to finishing through from continuous to interrupted cuts, these new geometries ensure easy optimization,improved productivity, first rate process security and fulfilled surface quality demands. The six different geometries are designed to handle depths of cuts from 0.2 to 10 mm with great chip control and low tool pressure. Four geometries are introduced for moderate to small depths of cuts in light roughing to finishing applications. Two stronger geometries are introduced for larger depths of cut in roughing or light roughing. cmts Booth 2538

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




Price CAD

¼” 5/16” 3/8” ½” 5/8” ¾” 1”

¾” 13/16” 7/8” 1” 1 ¼” 1 ½” 1 ½”

.008”x45° .008”x45° .012”x45° .012”x45° .015”x45° .015”x45° .020”x45°

2 ½” 2 ½” 2 ½” 3” 3 ½” 4” 4”

$9.99 $14.99 $17.99 $29.99 $52.99 $84.99 $144.99

C.N.C. VARIABLE HELIX: 4 Flutes 10% Co, 0.6µm grain size Phone: 888-398-9449 2011 PCT CarBidE

new coolant through tool holders

genswiss announces the launch of “coolant Thru” line of coolant through tool holders featuring delivery through the shank providing optimal insert lubrication and cooling, longer cutting tool life and improved swiss-type machining. Holders feature interchangeable coolant orifice plates at the insert top level enable exact control over coolant volume, pressure and velocity as low, medium and high flow action for more

efficient chip removal. The holders are available with high pressure to 10,000 psi, stock sizes are 1/2” and 5/8” square shank, other sizes available on request. insert pocket conforms to isO style turning inserts, 80˚, 55˚, and 35˚. The coolant inlet of the tool holders uses standard npT fittings, allowing for faster setup and more accurate coolant delivery position to the insert. in addition, there is no need for custom proprietary gang plate and no coolant manifold installation is required, or other modifications to the coolant feed systems.

new chipbreaking inserts improve iD grooving

iscar has launched a line of improved cuT-grip grooving inserts for iD grooving that features the n-type chipformer that has proven so effective in OD turning of problematic metals. internal groovers with the advanced chipformer are available for diameters down to 22mm. in OD grooving applications, the n-type chipformer has outperformed competitors in numerous automotive parts in steels that consistently prove excellent performance compared to other chipbreakers: 42crmo4, 20mncr5 38mnVs6, 1045 and 4340. several Tier-One suppliers report that it begins to reliably break up chips at feed rates as low as 0.05 mm/rev. The expanded cuT-grip line includes double-ended gini inserts for iD turning and grooving and new sizes of gimn 302 inserts in grade ic907.

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Meet tHe integrex FAMiLY we Are a growing family with 36 members since 1983. We have a unique ability to Multi-Task, and our talents include complex simultaneous 5-axis machining and Ultra-Tasking applications. we Are diverse in our specialties, ideal for parts ranging from those requiring machining above and below centerline and y-axis capabilities to complex geometries, in sizes from small and light to large and heavy. we Love to try new things, including grinding, gear cutting and boring. we Are overachievers, allowing you to increase throughput with fewer machines. we Are a family with a long tradition of productivity. We accommodate a large tooling capacity and offer a second spindle, allowing us to run multiple jobs from a single operator setup. we incorporAte the Mazak MX Hybrid Roller Guide System to deliver unmatched levels of rigidity, durability and reliability that result in long-term accuracy. we Are a smart bunch, with Intelligent Machine functions that boost our accuracy, reliability and productivity. These include INTELLIGENT THERMAL SHIELD and ADVANCED VIBRATION CONTROL, among others.

integrex j-200

integrex i-300 -300

integrex i-630v

integrex e-500H

integrex e-1060v

we Are tHe integrex MuLti-tAsking MAcHines, And You’ve never Met A More powerFuL FAMiLY.

www.MAzAkusA.coM tel: 859-342-1700 Florence, Kentucky Mazak corporation canada Mazak canada technology centre 50 Commerce Court Cambridge, Ontario Canada N3C 4P7 1-800-668-5449

turning.indd 59

tHe LArgest event oF its kind Florence, kentucky october 18-20 & 25-27, 2011 west canada Machine toolworks, inc. 4803 74th Avenue Edmonton, AB T6B 2H5 (800) 426-2052

east canada A.w. Miller technical sales 5590 McAdam Rd. Mississauga, Ontario L4Z 1P1 (905) 890-8686

A.w. Miller equipment technique 2685 Boul. Pitfield St. Laurent, Quebec H4S 1T2 (514) 333-9174

8/29/11 11:43 AM

Cutting tools


The Many Faces of Face Milling Face milling has changed with advances in tooling

by Tim Wilson ..........................................................................................

“The precision, high-value

work is being done in North America and some of the lower grade jobs are done off-shore.

Komet pCD face mill.

Face milling has been around for a long time, and though the basic concept remains the same – a cutter body with a machine taper holding multiple tips or inserts – face milling has changed with advances in tooling. It can be a challenge to wade through the wide range of options. “We have about 45 different styles of face mills,” says Tom Hagan, Iscar Tools Inc. milling product manager in Oakville, ON. “But there are some that really stand out, like our SOF 45 degree face mill.” Hagan says that Iscar’s SOF 45 is unique in that it can take two inserts in the same body, using square or octagonal double-sided inserts with 8/16 cutting edges. “It’s good for smaller shops that don’t want to carry extra stock of cutters,” says Hagan. “When considering cost per edge, it’s the most economical face mill we have out there.” The company’s standard 16 edge 45 degree mill can also provide value because, at about $1.20 an edge, it has the ability to machine a wide range of materials with a hefty depth of cut. And then there is the 90 degree Helido brand, which has 4 cutting edges that can withstand high forces. “All of these face mills come with our latest SUMO TEC grades,” says Hagan. “This is a unique substrate, an advanced coating process that is followed by a special treatment. The result is improved tool life, low surface stress, and an evenly coated top surface.” The even surface of these grades contributes to an uninterrupted chip flow, reducing friction and built-up. This can improve machining conditions for all types of workpiece materials, and deliver on a core metric: cost per edge. “The technology is then more effective, even when the insert costs more money,” says Hagan.

a world of CHoiCe – and CHange

One appealing option is to purchase a face mill kit, which can deliver overall price reductions. Having a standardized kit can also take some of the stress out of the decision-making process.

Delcam powerMill CAM software.

“Kits are appealing to our customers because they are packaged with pricing as an incentive,” says Eric Cram, a manager at Lovejoy Tool Company, Inc., in Springfield, VT. “We put in some extra screws and inserts in a box that can be stored – it has pretty much all you need to get up and running immediately.” The kits, which come with an application guide for reference, can be customized by the purchaser, who can select from a range of standard insert grades. “If one insert works better than another, this gives the customer a chance to run both grades,” says Cram. “They can then determine down the road which one to buy, or both.” Lovejoy, which sells direct and also partners with distributors in Canada, has a standard product line, which makes up

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Four Brands. One Mission... To ensure success in all of your aerospace milling applications. For over half a century, we have been known worldwide for high performance, made-in-USA cutting tools. Our products are supported by the most skilled and experienced applications engineers in the industry. We are second to none in the manufacture of a complete selection of high-speed steel, cobalt, powdered metal and solid carbide end mills for machining aluminum, steel, stainless, titanium, and exotic alloys. We have the right stuff‌.





Please Visit Us at CMTS – Booth 1718 05 Dauphin.indd 1 milling.indd 62

7/28/11 10:37 AM 8/29/11 2:56 PM


about half its sales, as well as a made-to-order business. Cram says he is seeing greater emphasis on smaller diameter tooling. “Machines are moving faster, with wider cuts,” says Cram. “We are seeing less heavy-duty, slower machining.” This seems to reflect a larger trend, wherein the precision, high-value work is being done in North America and some of the lower grade jobs are done off-shore. Manufacturing in areas such as aerospace and automotive is relying on advanced CNC-based applications, many designed to be specific to certain materials, such as composites and aluminium. “In aerospace you used to have one large part for forging, with a lot of metal removed,” says Cram. “Now in the new Boeing 787 we are seeing the fuselage made of composites.”

“Machines that are no longer moving at hundreds of inches a minute – now it is into the thousands.”

Within automotive, Latrobe, PA-headquartered Kennametal Inc. has the KSCM AluMill face-milling system, which is wellsuited to high-volume aluminum milling operations for engine blocks and cylinder heads. Cutters are available between 2.5 in. and 12 in. diameters, with five different cartridge styles. Beside Kennametal, companies that have been strong in other areas, like Komet Group, are also now seeing opportunity with face mills. “We have our PCD face mill, which is good for the automotive industry,” says David Toomey, president of Canada Tooling Solutions at Komet, which has recently opened an office in Newmarket, ON. “Some of our inserts are brazed into a tool, and regrindable, whereas others are indexable.” Derek Divok, a sales engineer at Komet of America, says that brazing is a differentiator for Komet. “We physically braze PCD into the steel base, which is unusual for milling,” says Divok. “We have that in the HSK 63 shank, which is a very high density milling cutter.” HSK is the most popular spindle in Europe – and perhaps in the world. The brazed diamond supports two styles of cutters: erode and ground diameter. “It depends on the finish a customer needs,” says Divok. “You might get away with an erode finish, and then grind it afterward.” The advantage is that the precision is within microns in both diameter and length, with no presetting of the mills. “You can take it out of the box, without having to adjust the program for height or depth, and continue to run,” says Divok. Komet says that there has been a lot of interest in the technology, but that the installed base of old-style milling cutters can make it hard for many to make the leap. “They don’t all want to throw out their inventory and replace it with a $15,000 to $20,000 cutter,” says Divok. “But the advantages are real: we can take out an 8 mm depth of cut, whereas a lot of our competitors are at 2 to 4 mm, maximum.”

Software supports industry trends

The issues surrounding optimal face milling, such as reduced cost per edge, can also be addressed with the assistance of the proper software package. One leader is Delcam, which has CAM software named PowerMill for high-speed and five-axis machining.

Cutting tools

“The PowerMILL face milling application includes an auto angle option which will orientate the tool path to the most efficient machining angle for the block,” says Mary Shaw, marketing manager for Delcam North America, which has an office in Windsor, ON. “A cut direction reversal for the last pass prevents edge burring,” adds Shaw. “The software can also help extend tool insert life by reducing the feed rate on entry and exit.” This is sophisticated software, with “FeatureCAM” strategies that are designed to accelerate part programming, “PartMaker” for Swiss-type lathes and turn-mill equipment, and “ArtCAM” for artistic design and manufacturing. “The latest FeatureCAM includes comprehensive options for the programming of two- through five-axis,” says Shaw. “This includes face milling strategies to create a NC sequence to face down the workpiece for some time.” Software products like those offered by Delcam also support the move to smaller face milling applications. These smaller geometries are being built into inserts on an ongoing basis, with a constant effort to get more edges per insert, and for machines to run faster. Despite these impressive capabilities, there is more to be done to improve face milling, particularly as new materials and composites are being used in increasingly demanding machining environments. “There is still a lot of work ahead to establish the best way to machine,” says Eric Cram from Lovejoy. “With resin bonding, faster rates, and machining in one direction and then another, composites have a tendency to fray and delaminate; for example, they can be twisted and woven – presenting a big challenge to cutting tools.”

Iscar HeliDo845

The advantage, says Cram, is that we are seeing more of the ability to do what you want being built right into the software. “There are options for circular oscillation, and programs that can keep up with machines that are no longer moving at hundreds of inches a minute – now it is into the thousands.” One thing is certain: the face of face milling will continue to change, with tools, machines, and software having to adjust to fluctuating – and demanding – industry trends. CM Tim Wilson is a freelance writer based in Peterborough, ON and a regular contributor. | september 2011 | 63

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news Products available from October 1, 2011


Economical milling as easy as 1, 2, 3 New inserts for the exchangeable head milling system


Re duce cutting time by 50% with our new

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Cutting tools

produCt report

new insert designs for exchangeable head milling system

October 1st sees the launch of 3 new styles of inserts for the CoroMill 316 exchangeable head milling system. The 3 new designs of end mill, each with 2 cutting edges, extend the depth of cut for the CoroMill 316 range to 0.8 x Dc, making them versatile problem solvers with maximum strength and security. The new range features a ballnose for profile milling, aluminum machining and finishing, and has a strong cutting edge for profile roughing. Other features include a corner radius for

industry needs for tighter part tolerances and greater machining accuracies, the HMC series comes standard with linear scale feedback in X, Y and Z axes, providing 8 micron (0.0003 in) positioning accuracy and 5 micron (0.0002 in) repeatability.

Micro Line high speed spindles, including back working and right angle models. spindle speeds up to 90,000 rpM are possible, significantly reducing cycle time and boosting productivity.

5-axis cryogenic machining for mega-size parts

slot milling, shoulder milling, plunge milling, face milling, ramping and pocketing, excellent for chip evacuation problems when slot milling, and finally a chamfer for chamfer milling of different angles and optimised for spot drilling capability. The system of exchangeable end mills are connected to a tool shank by a unique threaded coupling which combines high-strength with guaranteed accuracy. The tool is based on CoroMill plura geometries and is available in the latest pVD grade technology. Cmts Booth 2538

Higher accuracy for smaller applications

IbAG North America has introduced a micro collet system that can achieve higher accuracies for precision milling and ultra small drilling applications becoming increasingly common in the medical industry and other micro manufacturing applications. The new system delivers accuracies of one micron T.I.r at the collet nose and handles up to 1/8” tool diameter, and is equipped for use with 22, 25 and 33 mm IbAG

MAG’s modular HMC 1250/1600 series uses cryogenic tool cooling technology and a new cryogenic-equipped A-axis tilt-spindle for 5-axis horizontal machining on large parts. The HMC1250/1600 series is engineered for high-precision, highproductivity machining of large aerospace, power generation, pump, valve, and off-road equipment parts. It now includes six spindle options to suit special-purpose or general machining requirements. standard on the live spindle, MAG’s exclusive Z-axis thermal compensation software dynamically offsets spindle growth to maintain tight tolerances. powerful and agile, the new HMC offers 56 to 80 kW (75 to 107 hp) spindle

power, 35 kN (7870 lb) Z-axis thrust, and super-rigid, full-contouring hydrostatic rotary table. The 360,000-position contouring table provides a rigid work platform, while a rugged worm gear drive with clamp securely holds axis position. rotary table positioning accuracy is 10 arc seconds, repeatable to 5 arc seconds. positioning accuracy of the tilt-spindle is 4 arc seconds, repeatable to 2 arc seconds. Meeting

drilling and plunge milling with a single tool

KOMeT’s Quatron hi.feed milling cutters boosts roughing operations by enabling machinists to use the four-effective indexable inserts for both drilling and plunge milling. The Quatron indexable inserts also have a radial cutting action, which affords a considerably higher degree of flexibility in plunge and pocket milling by comparison with two- or three-edged inserts and adds rapid removal of high chip volumes. Machinists who need to cut deep grooves or large cavities in their workpieces often opt for plunge milling due to the dimensions

or cutting capacities of the tools or the performance of the spindle inside the machine. rather than boring with the use of multiple boring tools, it is possible to achieve various diameters and complex contours in one roughing operation by milling with an axial and a horizontal feed. The KOMeT Quatron hi.feed can use the very same indexable inserts for drilling as well as milling. The proven bK8425 coating delivers exceptional tool life while enabling universal use of these milling cutters for steel, cast iron and stainless materials. Cmts Booth 3516 | sepTeMber 2011 | 65

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Cutting tools


PRODUCT REPORT New series vertical machining centers

Makino’s PS-Series machines are the new standard in vertical machining centers for production machining, offering a reduction in cycle time, increased productivity, improved quality and minimization of capital investment. The PS-Series features a field-proven design with key technologies from several of Makino’s most reliable production machines. Its rigid construction, thermal stability and versatile spindle are ideal for a variety of applications, including automotive, aerospace, medical and other small-component manufacturing applications. Makino’s PS-Series comes standard with a high power 33.5 HP, high speed 14,000-rpm CAT40 spindle delivering 130 ft-lbs peak torque. The PS-Series is available in two models: the PS65 and PS95. The smaller PS65 features X-, Y- and Z-axis travels of 26”, 20” and 18.1”, respectively; a 36.2”-by-20” table; and a maximum workload of 1,323 lbs. The larger PS95 features X-, Y- and Z-axis travels of 36.2”, 20” and 18.1”, respectively; a 46”-by-20”

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table; and a maximum workload of 1,763 lbs. Both models are equipped with an easy-to-access, highly reliable, 30-toolcapacity automatic tool changer (optional 50-tool capacity available). Large-diameter bearings, air-oil lubrication and jacket-spindle temperature

standard features, chips are efficiently and effectively removed from the cutting zone. Spiral chip augers located in the front and rear of the worktable quickly and efficiently evacuate chips and coolant from the machining zone and into a standard lift-up chip conveyor.

Newly designed horizontal boring and milling machine

control deliver long-term thermal stability and stiff, rigid, chatter-free cutting. Created with the production environment in mind, the PS-Series chip and coolant systems enhance the productivity of the machine. Configured with flood, overhead shower, flush and through-spindle coolant as

The new Nissin HBM BHP130-3.5 Series Horizontal Boring and Milling Machine from SNK America, Inc. is rigidly designed for accurate and tough prolonged cutting.The heavy, high quality cast iron construction of the HBM BHP130-3.5 is complemented by the scale feedback of the worm and wheel. Large worktables, featuring nine T-slots, simplify work fixturing. The HBM BHP130-3.5’s extra-wide solid boxways, precision finished using SNK’s “Mirror Surface Finish” technology, easily accommodates the largest parts.

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models include the b0203/204/205, s205/s206, bH20, be20-V, ss20, and the s207. previous to this announcement those models were equipped with a 12,000 rpm main spindle. Tests have shown the new higher torque spindles provide three times the metal removal capability of previous models in certain

applications. Turning cutting area has been increased from 0.15 mm2 to 0.50 mm2. Drilling and tapping power has also been boosted. Tapping capability has been increased from M8 in swiss configurations and M6 in chucker configurations to M10 in both.


Bo C e U ot M s a h T t # S 35 08

Oversized ballscrews on all linear axes provide consistent precise positioning in the most demanding machining conditions. The combination of a robust design, thermal compensation and scales on axes

Cutting tools

results in high accuracy. The HbM 130 series’ high-powered boring spindle (5.1” diameter) performs at speeds from 5 to 3,500rpm and travels within a 7.08” milling spindle to provide a full 90.5” stroke. A built-in rotary table provides a fifth axis of operation, and positioning control within 0.001 degree. The table size of the bHp -3.5 model is 70.8” x 98.4” with a maximum load capacity of 44,000 lbs. strokes are 138” (X-axis), 98” (Y-axis), 63” (Z-axis) and 27.5” (Waxis). X, Y, Z and b-axis scale feedback is included as standard. The 60-tool ATC features a pneumatic pedal for ease in loading and unloading tools. All sNK Nissin HbM machines are equipped with Fanuc 16iM CNC controls.

1 TAP 10 of MATERIALS 100 of JOBS of THREADS 1000 ’s



new high-torque spindles combine increased power with precision

reM sales, LLC (Windsor, CT), the exclusive North American importer of Tsugami machine tools announces that select 20mm models will now be equipped with a new higher torque main spindle. The new 10,000 rpm higher torque spindles will boost metal removal and productivity without sacrificing precision. Affected



The industry’s first general purpose, high performance tap. Now the leader in tapping technology has designed a tap to cut multiple materials from common steels to stainless, aluminum, cast, copper, and more, producing threads within both 2B and 3B classes of fit. If you could have only one tap in your tool crib,

MultiTAP is the ONE.

Also available in spiral point.

Visit us online: Learn about our guaranTee Tee. Tee ee. See MultiT MultiTaP in action.


s | sepTeMber 2011 | 67

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Bright Lights

Laser cutting balances the need to burn through metal without burning through money By Jim Anderton, editor ......................................................................................................................................... Few technologies have promised so much so quickly as lasers. Only four years after their 1960 invention, in the popular film Goldfinger an “industrial laser” was depicted cutting James Bond in half…and arch villain Auric Goldfinger took the time to explain the technology: “Laser light, being of one colour, never widens, never weakens…it can project a spot on the Moon, or at closer range, cut through solid metal.” The public was ready for laser cutting years before it became a practical industrial process, but that doesn’t mean that the technology is too mature for innovation. The 21st century challenge, however, isn’t just to cut metal, it’s to do it cost effectively with ever increasing speed, accuracy and precision… and at lower cost than competing technologies.

What are the costs?

Day to day operating costs (not counting floor space, financing or machine throughput) typically break down into power, equipment maintenance and consumables, and assist gases. Power is a major cost factor, with CO2 lasers typically delivering 10 percent “wall plug” efficiency. Efficiency can be boosted in CO2 machines by “pumping” the cavity with RF energy instead of DC current through conventional electrodes, a technique which also reduces erosion and optical darkening (plating) problems associated with in-cavity excitation. Fiber laser technology is a real alternative from an energy standpoint. “Fiber laser systems offer the same cut quality as a traditional CO2 laser system yet have a significantly lower total cost of ownership,” says Doug Shuda, product marketing manager at Hypertherm. “Fiber laser requires little to no maintenance and is three to five times more energy efficient. Another advantage, for businesses that cut with plasma, is that fiber laser systems can use the same table, and in many

cases the same gantry, as the existing plasma system and all can be managed by a single CNC controller.” For CO2 cutting, the power required for a clean cut can vary markedly depending on the material….a .125 stainless or mild steel sheet might require a heat input of 500 watts, while a good thermal conductor or highly reflective material like aluminum might need six times this power for the same sheet thickness. Using the same machine for both materials would be overkill for the ferrous sheet parts, but using an underpowered laser can create edge surface roughness issues that might require an expensive and potentially energy intensive second operation. (See sidebar to the right.) On the ideal floor, there would be a variety of machines tailored to each job, but in the real world versatility matters. “Laser cutting systems designed for maximum material versatility and usage have proved to be the heroes with our customers. Machine downtime is the enemy, and high-wattage laser systems that cut a variety of materials keep setup times to a minimum,” said Ed Bosse, Marketing Manager, Cincinnati Incorporated. “When teamed with the right programming and nesting software, these systems help manage inventory and get the most out of every sheet of material. Inventory control and material usage are two areas that greatly influence a shop’s bottom line.”

Gas or no gas?

Machine consumables are another cost factor determined largely by the machine design. Industrial gas lasers in this power class require a supply and circulation of CO2 or gas mixtures, requiring blowers or turbines. Machine builders have addressed this cost in several ways. Trumpf, for example, uses turbo radial blowers for increased efficiency and have added magnetic bearings for lower maintenance costs. Cross flow resonator designs can also

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Fabricating |  Built-in Process exPertise  |  true Hole tecHnology  |  remote HelP |  raPid Part tecHnology  |  consumaBle life oPtimization

save power and downtime. Mitsubishi claims two to five times less maintenance plus lower power consumption using this technology, combined with a pre-mix system for laser gases. Of course, the best way to manage laser gas cost is to switch from gas laser technology. Fiber is a hot technology, and according to Salvagnini America president Bill Bossard, the cost advantages are many. “Although there is no real saving in the purchase cost vis à vis a CO2 laser, there are, in most applications, considerable savings in operating and processing costs, with additional savings when the machine is fitted with full automation. First, let’s consider maintenance. For all practical purposes, the life expectancy of the fiber laser source is that of the machine, meaning no resonator replacement. There are no mirrors to align with fiber optics, and because no laser gasses are required, there are no tanks to place into service. Energy consumption in most applications is reduced by at least

sUrFace roUghness in nUMbers

most laser users have an intuitive sense of cut surface roughness (typically 150-250 micro-inches) in terms of the relationship between power, cutting speed and material thickness, but is there a hard and fast rule? According to research using mild steel and a CO2 laser by miroslav radovanovic and predrag Dasic (reported in the Annals of University “Dunarea de Jos “of Galati Fascicle viii, 2006 (xii)) there is a mathematical relationship linking these parameters:

rz = 12.528 x rz pL s v

Efficiency of movement delivers superior performance for your operators, your company, and your bottom line. Introducing Rapid PartTM – the latest automated benefit of Hypertherm’s Integrated Plasma Cutting Solutions achieve greater productivity by reducing cut-to-cut cycle time.  rapid Part controls and optimizes every step in the plasma cutting  process – without operator intervention – so you can focus on  your business and your customers.

Visit us at the cWa conference in Banff on  september 19th – 20th.

s 0.552 pL x v 0.322

standard roughungss equals laser power in kW equals sheet thickness in mm equals cutting speed in m/min

the primary take away from this simple equation is this: surface roughness is proportional to sheet thickness, but inversely proportional to power and cutting speed. In other words, to achieve a smoother surface for a given sheet thickness, increase the power and/or the cutting speed. If a high-quality as-cut surface finish is a must, consider overrating the power of your equipment, or use a “bigger” machine for your application. From a running cost perspective, there’s one price for the cut and another, higher cost for a smooth cut on a per-hour measurement…..which can be offset with higher available cutting speed at higher power outputs. In this case, extra reserve power over the basic minimum for the job can pay dividends in overall productivity. see the whole paper at: ro/AnnalsFasc8tribology/pdf/2006/13Annals2006-radovanovic.pdf

|   manual Plasma   |   mecHanized Plasma   |   laser |   automation   |   consumaBles   |   softWare | september 2011 | 69

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70%, and overall running costs are only one-third that of a 4000 W CO2 laser with chiller. Capability is expanded because a fiber laser can cut reflective materials such as brass, bronze and copper that previously was impossible to be processed by a laser cutter. There are also savings in shop floor real estate, with a fiber laser occupying a smaller footprint than a CO2 laser owing to a smaller chiller and the elimination of laser gas tanks. Work-In-Process is also reduced, as the fiber laser cuts much faster than a CO2 on most applications – however much of that advantage is lost when cutting the thickest materials. But in general, cost per part produced on a fiber laser cutter is one-half that of the same part produced on a CO2 laser. ”

Cash flow is still king

It’s clear that there are major per-part cost savings to be had using new laser cutting equipment….but this is a recession. Should you invest in new equipment now? James Rogowski, director of Machine & Power Tools for TRUMPF Inc. feels that we’re well placed to take advantage of new laser technology: “The Canadian banking system has performed well this last decade to prevent large scale swings in the economy that could lead to a recession. While Canada certainly is not impervious to a setback, Canada seems stable right now and able to withstand many of the outside influences that are key to its economy.  The most important thing a sheet metal fabricator can do in a challenged environment is to develop flexibility and creativity. Don’t assume the customer base you’ve had for years is going to remain your primary source of revenue. Think to diversify your business by taking on projects that you would not have considered doing in the past.  Fully utilize the flexible machinery you have and consider changes that will differentiate your business from your competitors. During any recession the last thing people want to hear is that they should spend money.  However, you have to keep outsourcing on a short leash, as cash flow is your life-line and you are spending it to have your goods produced. Finally, an important key to operating in a challenging economy is to finance your capital equipment purchases. Don’t tie up cash in your machines; instead, finance the equipment with recent and aggressive plans that suit your business

needs. The justification process is simple and you will no longer wonder if your machines are paying for themselves on a monthly basis.  Speak with an industry leader that provides both the fabrication machinery and financial know how to do this.” There is far more to laser cutting

technology and economics than can be covered in a single article…speak with your suppliers, customers and in-house production personnel to form a concrete plan for laser equipment upgrades. And watch Canadian Metalworking for ongoing coverage of this fast-evolving technology. CM

PRODUCT REPORT New laser cutting system features linear motors, very high productivity

The new ZAPHIRO from Prima Power is designed for high dynamic motion and top cutting quality, with linear motors and a rigid structure featuring a maximum combined speed of 240 m/min (9449 inches/min) and drastically reducing production times and costs. The ZAPHIRO  Perfect Cut System intelligently detects cutting quality and automatically corrects system parameters in case the quality differs from the desired standards.   This provides zero-defect, zero-waste production for intensive, unmanned production.  Perfect Cut works by storing on the system CNC a sample cutting piece for each material and

thickness that is used by the system. These samples serve as references to judge the cut quality during the process. The sensitivity of the system can be set according to the application and to the required result. The ZAPHIRO laser beam delivery head is an evolution of PRIMA 2D heads.  The new F-axis, with a higher dynamic response and longer stroke, allows substantial cycle time reduction and superior cutting quality. The new “cartridge design” lens change system is extremely quick and easy-to-use. With Beam Size Control (BSC), the laser beam diameter is adjusted to the material type and thickness to be cut. ZAPHIRO is equipped with P30L, the latest generation numerical control manufactured within the PRIMA Group. Faster and more powerful, the new numerical control is compatible with all previous control versions and with all PRIMA 2D machines. ZAPHIRO’s CV5000 laser allows cutting up to 25 mm (1.0 inch) material thickness with quality and efficiency. The CV5000 lasers feature

a magnetic support turbine, solid state high voltage power unit, servo-controlled gas mixing that adjusts gas usage as a function of power and the a new “zero-emission” gas discharge device. www. CMTS Booth 2026

Fiber-guided solid state laser cuts costs

TRUMPF’s TruLaser 5030, with its fiber-guided TruDisk solid state laser, will reduce the cost of producing thin sheet parts by up to 20 percent. Because of its high dynamics, the machine is able to make full use of the solid state laser’s advantages and achieve very high cutting speeds in thin sheet when producing parts such as medical products, items for ventilation systems and façade elements. In fusion cutting of stainless steel up to 4 mm thick (0.16 in.), the TruLaser 5030 fiber achieves feed rates up to three times faster than the CO2 version. This reduces the table time up to 45 percent, and significantly decreases the cost per part. The TruLaser 5030 fiber cuts not only construction steel, stainless steel and aluminum cost-effectively, but also non-ferrous metals such as copper and brass. The core of the TruLaser 5030 fiber is a fiber-guided TruDisk solid state laser with an output

rating of 3 kW. With the 2D laser cutting system, users can process sheets measuring 3,000 mm x 1,500 mm (10 feet x 5 ft.). With the TruLaser 5030 fiber’s flexible beam line, the solid state laser can be placed independently of the machine. Also, the machine and the solid state laser come from the same source, which means the two components are optimally adjusted to each other. CMTS Booth 2000

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TruBend Press Brakes Flexible, Precise, Productive Bottlenecks and scrap are a thing of the past with TruBend press brakes. It’s never been easier to set-up and bend using TRUMPF’s latest bending technologies. Regardless of part type; simple or complex, big or small, short or tall – TRUMPF has a press brake to match them all.

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ProDUct rePort automation-ready flying optics laser cutting system

LVD strippit offers sirius, an automationready flying optics laser cutting system. sirius is designed to provide efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price/performance ratio.


ricating Cutting

sirius is offered in a standard and a CONFERENCE plus model. the sirius plus is optimized with additional features and automation capabilities. sirius provides quick and precise positioning and consistently

accurate laser processing. the combination of a dynamic machine with excellent beam quality allows high-speed laser cutting. Quick positioning is achieved with a combined axis speed of 3939 in/ min. sirius is designed with a modular construction, permitting the user to select the configuration that works best for the application and budget. As a standard unit, the laser cutting system features 120” x 60” integrated shuttle tables, which maximize uptime by allowing one table to be loaded while the machine is cutting on the other table. sirius is equipped with a high-pressure cutting head that produces exceptionally clean cuts. Like all LVD strippit laser cutting systems, sirius series employs the highly reliable Fanuc rF excited fast axial flow CO2 laser. sirius is available with a powerful 2.5 kW or 4 kW CO2 laser. the laser, CNC control, drives and motors are fully integrated, providing superior processing speed, high reliability, and low operating and maintenance costs. cMts booth 1926

new 6,000-Watt laser-cutting technology

mazak Optonics Corporation has taken its superturbo-X mark III 2D laser cutting system and has increased its power output to 6,000 Watts. this boost allows the system to meet the unique demands of processing thicker mild steel and stainless materials. the stX mark III system is a flexible, rugged workhorse that offers significant technical

advantages and standard features for a variety of material types and thicknesses. built utilizing mazak’s proven hybrid platform, the new system’s constant-beam length construction provides uniform cutting across the machine table. Additionally, the stX mark III utilizes several advanced features found in mazak’s high-end Hyper series machines, including intelligent setup functions

Mark your calendar for

Conference Registration NOW AVAILABLE ONLINE Visit us online and see the exciting line up of presentations.

p p c

F p w d h a p o



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CM S B T TS – EE US AT.. EC Boo . t H– h Boo No. 1 th N 9 o. 26 11 5 9

per fect punching capabilities From entry-level, price-sensitive punch presses to high end models with fast, high-performance 360 degree all-tool rotation, 3" (75mm) high forming, and 24/7 lights out automation systems – LVD Strippit’s punch press range strikes the balance of price and performance at all levels. To find the right machine for you call us at 800-828-1527. Perfect.

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ProDUct rePort for automated nozzle spatter removal, a three-station nozzle changer as well as focal point measurement and adjustment capability. these functions are part of the mazak Opti-pod, which helps minimize system setup time and extends unattended operation for longer periods of time while still maintaining optimized machining conditions. the stX mark III also incorporates a servo Focus torch and High Accuracy Auto Centering Lens and Nozzle. the servo driven system significantly reduces piercing time, while the lens and nozzle design further reduces setup time and increases pierce, plasma and poor cut sensing to ensure consistent performance over a wide range of materials. together, these technologies yield a considerable increase in productivity. the stX mark III is available in 4’ x 8’, 5’ x 10’ and 6’ x 12’ table configurations and offers three power output levels: 2.5 kW, 4.0 kW and 6.0 kW. It is also available with a large range of automated material handling systems, including load/unload cells and flexible manufacturing systems. cMts booths 2500, 2600

new fiber laser system boosts cutting speed on sheetmetal, reduces operating costs by 40 percent

Cincinnati Incorporated expands its laser cutting product line with introduction of the CL-900 series fiber laser cutting systems. the CL-900 series combines the low operating cost of fiber laser technology with the company’s high-performance 12,000 ipm linear-motor axis drives to create the most productive, economical and easy-to-use

laser cutting system available for sheet metal processing. the CL-900 series cuts mild steel two to three times faster than conventional lasers, while reducing operating costs by up to 40 percent. the solid state fiber laser cuts maintenance costs associated with conventional CO2 lasers by eliminating laser

gas, internal optics, glassware, blowers and vacuum pumps. Also, fiber lasers deliver the beam via a flexible glass fiber, thereby eliminating the external mirrors, bellows and beam purge gas needed with CO2 lasers. Fiber laser systems deliver power efficiency greater than 30 percent, roughly five times higher than CO2 systems. CL-900 series laser cutting systems are available with bed sizes of 5 ft. x 10 ft. and 6 ft. x 12 ft. the pC-based HmI control comes standard with Cincinnati’s programming and Nesting software to optimize machine performance and is available with a web cam for easy monitoring of the cutting process. cMts booths 2216, 2300, 2400

Fiber laser tube cutting system reduces operating costs

Lt FIber, the newest member of the Lasertube family from bLm GrOUp UsA is the first automated laser tube cutting machine to utilize a fiber laser resonator. With its advanced 2 kW IpG fiber laser source, the system can now efficiently process highly


The Future of Metal Cutting... Our November issue will look at all aspects of Metal Cutting including Milling, Turning, Hole Making and Laser, Plasma and Waterjet Cutting. Increase productivity and production through Innovation. For more information contact: Steve Devonport | Publisher 416-543-1641 JIm Anderton | Editor 416-510-5148

Visit us online at 74 | september 2011 |

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PRESS BRAKE Simple – fast – accurate – reliable Capacities: 40 – 1000 tons Bending: 5’ to 20’ ( Tandem , tridem possible) Equipped with: HYDRAULIC SHEARS

• Syncro depth control Y1 – Y2 • Manual Adjustable crowning table • 2D or 3D Graphic control

• Backgauge X-axis ( Z1,Z2,R1,R2) • N.A. Style Top & Bottom Tool clamping • Crowning table





KOMPAKT The APC59-T with a HACO KOMPAKT series plasma burner, represents a most desirable system for demanding, high-precision and high-volume sheet metal productions. From 7’ until 20’ machines available. With Hypertherm units from 130 A and 260A with thru hole technology.





























HACO CANADA INC. Mississauga Office


2550 Dunwin Drive Mississauga, Ontario L5L 1J5

Tel: 905.828.1087 Fax: 905.828.2062 Toll Free: 1.866.605.1087

lasers.indd 75

Vancouver Calgary Edmonton Winnipeg

Tel: 604.214.4455 Tel: 403.281.1600 Tel: 780.426.0008 Tel: 204.942.4877

8/29/11 11:46 AM

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Original content is posted to daily in a variety of content zones such as: home page, news, products, machining, fabricating, quality, automation and events. Or you can research your latest project by using our search bar. Each search gives you the option of articles on the topic or suppliers that match search criteria.

CONTACT: Steve Devonport | Pulblisher 416-543-1641 Rob Swan | Account Manager 416-510-5225, cell 416-725-0145

Stay on top of news Every two weeks, Editor JIm Anderton gathers together the most interesting news, products and events to catch his eye and posts them in our eNewsletter. You can sign up on the website to receive the eNewsletter by email.

Technology eDirects More suppliers are choosing to communicate with manufacturers electronically, but you need to opt in to receive them. You can sign up to receive these 3rd party eDirects on our website. lasers.indd 76

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ProDUct rePort reflective materials such as brass, copper and aluminum. It also exhibits superior cutting characteristics with galvanized steel and has registered considerable productivity increases in the cutting of thin-walled tubes. the fiber laser provides a dramatic improvement in energy efficiency when compared to the more traditional CO2 resonator leading to as much as a 50% reduction in the hourly operating cost. the new Lt FIber laser cutting system accommodates tube up to 6-inches (152 mm) diameter with maximum raw tube lengths of 256 to 335-inches (6500 to 8500 mm), depending on the configuration chosen. the

integration and operation as well as higher levels of efficiency when compared to other laser cutting solutions. A single-emitter diode based design enables extremely reliable performance. Fiber laser offers several advantages over CO2 laser systems. It requires virtually no maintenance, is more energy efficient, and takes up less space. the HyIntensity system cuts a full range

of materials (mild steel, stainless steel, aluminum) with broad thin-to-thick cutting abilities and easy plug-and-play integration with other Hypertherm products. A new auto gas console enables consistent cut quality, compensates for variation of incoming gas pressures, and continually measures and adjusts gas flows.

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Business Report


Show me the money Effective business plans for bank loans

By Tim Wilson ...................................................................................................................................................... When it comes to writing effective business plans for bank loans, experts agree that manufacturers consistently make the same mistakes – and they aren’t always what you might expect. “An advanced plan isn’t just a bunch of numbers,” says Adrian Rudzikas, a business consultant at Business Plans Canada in Gibsons, BC. “We see a lot of mistakes; it doesn’t matter what size the business is, we find it has more to do with the years of experience a person has had running the company – a new entrepreneur may be sitting on a multi-million dollar company and still have a hard time putting a business plan together.”

Rudzikas says that the most common mistake is not to build the financials in such a way that you can easily answer all of the bank’s questions. This can be tricky, because you have to be prepared for the differing criteria of the various banks. “Each bank may analyze a concept in a different way,” says Rudzikas. “For example, on a recent project of mine the bank wanted to see all the company’s financial ratios – working capital ratios, equity ratios – but this won’t always be the case.” Not surprisingly, Rudzikas spends most of his time working with clients to

make certain they cover all the bases. This means a solid financial statement with income and profit – ideally with increasing monthly cash flow – so that you are ready for any line of inquiry. “You have to be prepared for any question,” says Rudzikas. “That’s the most important thing. You also have to put yourself in the position of the banker – they want to see someone who is enthusiastic and confident.”

The importance of planning

Getting it right means taking some time. And though the financials are crucial, a business plan requires emphasis in

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the right places – anything else puts the manufacturer in a poor light, and reduces the likelihood of a successful application. “The biggest single problem I run into is that people tend to go into too much detail in the wrong places,” says Skip Green of Alden Green Financial in Oakville, Ontario. “Banks are trying to find out certain things quickly in order to analyze a particular deal.” Green notes that banking has changed significantly in the past 10 to 15 years, with account managers trying very hard to understand their customers’ businesses. This means looking beyond the numbers.

Business Report

“What your company is, what it does, and why it can expand, no one knows that better than you – don’t undersell.” Rudzikas from Business Plans Canada agrees with Carlson, and makes the additional point that a well researched and thought out business plan can provide ongoing benefits to your business. “It is important to be accurate and show the true story – if you do it quickly you won’t get the attention you deserve,” says Rudzikas. “Yes, the business plan is for the bank so that you can raise the money you want, but the plan is also an asset for the business itself and can function as a base for running operations over the coming years.”

“What your company is, what it does, and why it can expand, no one knows that better than  you – don’t undersell.”

“They need to know how the business is structured,” says Green. “Who owns the business? Who do they contact if they have general questions? They really need a general sense of how the business works and who the customers are.” The social relevance of positioning a business plan to appeal to a banker is not lost on Murray Carlson, a professor of finance at the Sauder School of Business at the University of British Columbia in Vancouver. “You really have to do your homework to educate the banker who is sitting across the table from you,” says Carlson.

Rudzikas says that some manufacturers will go to the bank when they are in the middle of the first draft, before all the financials are in place. But not showing up with all the information can leave a bad impression. And, according to Skip Green from Alden Green, it can cost you in the end. “I will sit down with an account manager and look over the plan,” says Green. “These days the manager no longer approves the deal – it all goes downtown, where it is analyzed and then recommended. I will assess with the account manager, and sometimes

we’ll defer sending in a client’s application in order to ensure a higher likelihood of approval.” There are good reasons for this approach. The relationship with the account manager is protected, because you are respecting his or her time and reputation, and ensuring a higher likelihood of success. As well, if you are shopping around in an undisciplined way you could start knocking points off your credit score.

Under your control

All the focus on financials and correct execution can steal the spotlight off of some of the important social dynamics inherent in putting together a successful business plan. “Don’t forget the people side,” says Carlson from the Sauder School of Business. “Bankers don’t only care about numbers; you are also establishing a relationship.” Carlson notes that a banker will take great satisfaction in finding a business that will do well. “What makes their day is a relationship with a company that results in a small-size organization becoming mid-size, or mid- size to large. That flowering means a lot to someone who is lending money.” Carlson adds that showing a business | september 2011 | 79

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Business Report


character will serve your interests. Looking at competing financing options and acting in the best interests of your company will reflect well on you. “Your character is important,” agrees Martin Povey, a business consultant in Medicine Hat, Alberta. “The bank assesses the trustworthiness of the potential borrower on more than credit history: there is also overall character, business experience, knowledge, and personal business acumen.” But Povey concurs that charisma alone won’t do it: if you have no credit history, and limited experience or education, you won’t stand much of a chance of getting a loan. For Povey, character is just one of the “five Cs” that the banks look at, the other four being capacity, collateral, capital, and conditions. Capacity is simply the business’s ability to pay back the loan, and collateral and capital address an individual’s ability to secure the risk. Borrowers may not have much control over these factors, but they can add unique insight into conditions. “You can play an important role in educating the bank on your business and industry,” says Povey. “Banks will have well-rounded specialists, but for specific industry issues they may have to bring in a consultant, and of course they’ll listen to you, too.” The consultant will look at external conditions such as the customer base, dependence on one or many customers, the state of the competition, and liabilities. These areas provide an opportunity for you to contribute your unique understanding of the market, and to explain why you are well-positioned to benefit from the loan.

Practical tips

Some tips are purely practical. “You can deliver the correct amount of detail with 15 to 17 pages of information,” says Green. “Every business plan needs an executive summary, which many people don’t know how to write and a mission statement, as well as a small marketing section and some detail on the nature of the business, but stick to financials – if you are offering product details they won’t be interested.” Any overly-technical details will be lost on the banker. What they do want to see is fallback, which is essentially what management can rely on if they don’t make their numbers. Some of the pitfalls that Green sees are almost comic – like forgetting to add your contact information. “I see a lot of business plans, and most of them are of extremely poor quality,” he says. “You need to put your name and phone number on the plan – this is silly stuff, but these are the biggest complaints I hear from bankers.” Of course, the sources for this article are all in the business of assisting companies to write business plans to get loans. It is only fair then to suggest that an external consultant could be considered in an advisory role. They have contacts in banking and can smooth the process. Business Plans Canada, for example, has a separate website at that can walk you through the planning process at no charge. And Mr. Povey’s website at offers links to a wide range of free resources. CM Tim Wilson is a freelance writer based in Peterborough, ON and a regular contributor. 80 | september 2011 |

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HELMETS Won’t Leave Welders in the DARK Auto darkening helmets are now the standard. Has your company made the switch? by Nestor Gula ..................................................................................................................................................... Auto-darkening helmets have been on the market for about 15 years and I have to admit that I’m lucky as I learned to weld with auto-darkening and have not used the traditional passive helmet. There has been the odd occasion that I’ve donned an old helmet but I was not happy with the experience. I’m not going to go back to using dial-up Internet instead of my DSL, and I definitely will not be using anything but an auto-darkening helmet when I weld. “The market for the old type of helmets is dying very, very quickly,” said Bruce Clark, National Manager, Marketing & Export for Lincoln Electric. “We will not see it last much longer.” The main benefit of an auto darkening helmet is that the quality of the welding improves remarkably” he said, adding “you are not going to be striking the arc in places other than in the joint where you want to be welding in the first place.” This sentiment is echoed by Carrie Mailloux, Product Marketer - Protective Eyewear and Welding Solutions for 3M Canada, Occupational Health & Environmental Safety. “Auto-darkening filters (ADF) allow the welder to view their work clearly and safety

during set-up, during the weld and after without interruption and without the burden or delay of manually lifting the shield or filter. ADFs allow manual arc welding to be performed more quickly and accurately in comparison to traditional passive welding filter plates,” she said. “Welders looking to increase their productivity have been quick to migrate from a traditional helmet to an auto-darkening helmet. In the past the purchase of an ADF was seen as a luxury, however, in recent years, manufacturing improvements have made auto darkening helmets affordable for all.” “There are many different shapes, sizes, colours and functionality readily available for welders to choose from,” said Kristy Giebe, Category Manager – Welding from Kimberly-Clark Professional. “They are certainly not all created equal and when choosing a welding helmet, the welder must ensure that the welding helmet is ANSIZ87.1 compliant the Viking 3350 from Lincoln electric, here in terrcuda colours by Foose, is a solar-powered helmet that is design augmented with a user-replaceable lithium battery.

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The POWER of Two Machines Built Into One The portable, multi-voltage, power-packed CUTMASTER® 42 from Thermal Dynamics® is the newest addition to the popular CUTMASTER TRUE™ Series. With the ability to switch from 120V to 230V, the CUTMASTER 42 provides the power of two machines – cutting up to 1⁄4” with ease or up to 5⁄8” when extra PUNCH is needed. Vent2Shield™ technology allows the use of considerably smaller compressors (less weight to carry) compared to similar 40 Amp units. And like all Thermal Dynamics TRUE Series plasma systems, it carries an industry leading 4-Year Warranty. The CUTMASTER 42 – MORE POWER when you need it.

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and from a reputable manufacturer. Both passive and Auto-Darkening Filter (ADF) welding helmets provide excellent eye protection. But now research shows that ADF helmets also offer impressive productivity gains, as well as greater user comfort.” Auto-darkening helmets should work well in all environments and have been replacing the traditional passive helmet quickly. According to some in the industry there are some applications where a traditional passive helmet is still the way to go although this is rare. “We’ve gone to great extents to make auto-darkening helmets accessible to as many people in the field as possible, but there are still some applications where a passive helmet provides greater performance, high-amperage, high-heat, extended duration welding situations,” said Eric Sommers, product specialist, Miller Electric Mfg. Co. “We have a customer who works in wind turbine fabrication who regularly experiences continuous arc-on time of 45 minutes. Auto-darkening helmets reach a heat threshold in some applications like

this due to the LCD display (although it is rare). Advances have been made, such as in our Titanium Series of auto-darkening welding helmets, that allow for these helmets to be used in high-amperage, high-heat applications. The silver color scheme helps reflect heat, and an aluminum shield protects the lens itself. Progress is being made to make auto-darkening helmets suitable to all applications, but there are some jobs where a passive helmet will still be required.” Another major advantage of the auto-darkening helmet is that it prevents a sore neck for the welder. “Most welders start with the helmet in the up position on the head, and once they have positioned their torch, they then nod the helmet down to begin welding,” says Guy Shelverton, Global Product Manager, Personal Protective Equipment, ESAB Welding & Cutting Products. “With an ADF you’re always looking through a clear state, which allows you to position your torch, and then once the arc is struck the cartridge reacts.”

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Katie Twist-Rowlinson, Welding and Hard Hats Product Manager for Honeywell Safety Products adds that, “instead of wasting time nodding the helmet down into place before welding and pulling it up after welding, the helmet can stay in the down position the entire time. This not only saves valuable time but saves the welder from a very sore neck at the end of a shift.”

“The welder must ensure that the welding

helmet is ANSIZ87.1 compliant and from a reputable manufacturer.”

Auto-darkening helmets work by sensing when the arc is struck and electronically darkening the shade to the appropriate level. “Three sensors on the front of the auto-darkening filter (ADFs) react independently at the moment the welding arc is struck and cause the filter to darken. The ADF switches back to the light shade after the welding arc has stopped,” said Mailloux from 3M. “Two lithium batteries are used as the power source. Protection from the ultra-violet radiation (UV) and infrared radiation (IR) is continuous, whether the ADF is in the light or the dark state. In the event of battery or electronic failure, the welder remains protected against UV and IR radiation equivalent to the darkest shade setting (shade 13).” The reaction from light to dark is quick according to Elaine Slatter, Country Manager/Director of Marketing Administration for Thermadyne Welding Products Canada Ltd. “It depends on the | september 2011 | 85

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The Miller Titanium 9400 series features an innovative aluminum heat shield whose silver shell reflects heat to keep helmet and user cool.

manufacturer. Anywhere from 1/10,000 of a second, which is slow, to 1/25,000 of a second.” Most auto-darkening helmets have an adjustable shade feature that is a real benefit when the welder has to move between different welding processes. In addition some of the newer helmets have a grinding feature. “There is a grinding mode that you switch on,” said Clark. “You don’t want it to go dark – you can lose a finger if it goes dark while you are grinding. It will still stay light for grinding. You can set the sensitivity so that it senses the difference between welding and grinding.” This feature will save time, energy, equipment and stress on the shop floor and lead to a smoother workflow. Gone too are the days of drab grey shields on the shop floor. Sure, those helmets occasionally sprouted a sticker of the local sports franchise or the union allegiance of the person wearing the helmet but today’s helmets positively sing with colour, style and pizzazz. One can get a plain black one but most spout great graphics and colours that usually come at very little extra cost. Other great features that can be added are built in magnifying lenses for detailed work. Choosing a helmet is not difficult but there are many options

to sort through. Some helmets rely on solar power while others are battery powered. “The solar auto-darkening helmets have a solar cell to charge a lithium battery so you don’t have to constantly change the standard battery powered ones,” said Slatter. “The solar helmets do need to be recharged by the sun. Battery operated helmets mean if you haven’t checked your batteries, the helmet could malfunction in the middle of a job. If you don’t have the correct replacement batteries on hand, then the welder could lose time on the job until he finds some.” Sommers from Miller said, “Lenses with replaceable batteries are going to be a little faster. All auto-darkening helmets have a battery in some way shape or form – even the solar-powered variety. Built-in batteries will eventually fade and not allow the helmet to respond as quickly, whereas a helmet with a replaceable battery will react faster and have a longer life as it is not dependant on a fading battery built in to the helmet.” Another reason for using standard battery power is that, “some ADFs with larger viewing areas and added features have a considerable larger power consumption, and solar panels alone are not enough to recharge, so replaceable batteries are needed,” according to ESAB’s Shelverton.

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Another useful feature built into most auto-darkening helmets is the delay selection. “The delay setting controls the time it take for the ADF to come back to the light state once welding is complete,” says Rowlinson from Honeywell. “It is recommended to use a shorter delay for spot welding and a longer delay with welding applications using high currents.” Having the shade pop to light a millisecond after the arc is cut can still damage unprotected eyes as the molten pool is still white hot. “The delay provides extra protection in applications where the material gets really hot and glows bright even once the arc is extinguished,” said Sommers. “Conversely, shortening the delay helps when tack welding to let you move on to the next tack as quickly as possible. That flexibility is important, but ultimately the most important reason is to fully protect the welder’s eyes for each application.” Welding helmets, like all things in a manufacturing setting, do wear out over time. “Like anything electronic, it ages with time. ADFs will continue working unless there is a component failure or batteries need to be replaced. It’s hard to determine the exact life span of an ADF as it differs for everyone depending on usage. However we have seen some 10 year old 3M Speedglas ADFs still out there being used,” said Mailloux. “The helmet shells have been ANSI tested for impact resistance and flame

the Viking 2450 from Lincoln electric, here in street rod colours, has continuously variable control, for shade and sensitivity and features a grind mode.

resistance,” said Greg Coleman Group Leader, Marketing Communications for The Lincoln Electric Company and they do not offer replacement shells. “However, we do consider many parts of the helmet to be expendable or replaceable. For example, inside and outside cartridge cover lenses and sweatbands are considered expendable and are easily replaced. The headgear assembly is replaceable if damaged in use. The cartridge is available for replacement to extend the life of your helmet. We have standardized on two industry-standard cartridge sizes, so it is also possible to upgrade your cartridge from one model to a more premium model with additional features if desired.” Auto-darkening helmets speed the process of welding, help produce better welds and protect workers better while making the toil of work more manageable. Upgrading to these technical marvels should be a foregone conclusion. Cm Nestor Gula is a Toronto-based freelance technical writer and editor specializing in metalworking and welding. Nestor was the former editor of Metalcraft Magazine. Nestor can be reached at 88 | september 2011 |

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PROdUCt RePORt low spatter flux core wire for heavy jobs

the premier brand of tri-mark tubular wires features self-shielded, gas-shielded and low alloy flux cored wires, along with mild steel and low alloy metal cored wires. stringent quality control standards ensure tri-mark brand wires meet or exceed specifications established by the American Welding society (AWs) and other welding organizations. tri-mark flux cored wires are available in various diameters and packages and feature benefits including: fast-freezing, easily-removable slag and low hydrogen weld deposits. Compared to competitive products in the market today, tri-mark metal cored wires improve weld quality and minimize rework and/or post-weld cleanup. benefits include: low spatter levels, excellent wetting action and high deposition efficiencies. tri-mark brand filler metals are the ideal choice for industries such as shipbuilding, infrastructure construction, offshore oil and heavy equipment.

Aristorod 12.50 is a premium quality, non-copper coated solid welding wire for GmAW welding of unalloyed steels and fine-grained, carbon-manganese steels. the wires are a new generation of mIG wires manufactured using Advanced surface Characteristics technology (AsC). AsC wire technology provides excellent starting characteristics, consistent trouble-free feeding, superior arc stability at high currents, and very low levels of spatter, says the company. AsC technology also provides reduced contact tip wear and creates a barrier on the wire surface that is highly resistant to corrosion. esAb’s new 1,000 lb (454 kg) drums for welding wire replace the standard 800 lb. (363 kg) drums for welding wire diameters 3/16 in. and smaller. the 1,000 lb drums reduce changeovers by up to 20 per cent allowing the fabricator to spend more time welding.

Versatile rod for austenitic/stainless steels

Lincoln electric’s excalibur 308/308L-17 (AWs: e308-17, e308L-17) electrode is designed with low carbon levels to help eliminate carbide precipitation in high temperature service. the versatile 308/308L-17 is designed to weld several types of austenitic “18-8” stainless steels like 304/304L. the flux coating provides smooth arc transfer in the flat and horizontal positions and slag is self-peeling for easy removal. Certifications aer fully available, with the Q2 Lot® - certificate showing actual deposit chemistry and calculated ferrite number (FN) available online.


esAb’s offerings in consumables includes the eco-Coil, the Aristorod non-copper coated solid welding wire and welding wire drums. According to esAb, eco-Coil is ideal for high-production fabrication including wind towers and pipe mills holding 2,200 lbs (1,000 kg) of wire in an ecologically friendly package. the package is shipped around a cardboard core, shrink wrapped and strapped to the pallet for shipping. Once received, the eco-Coil is then removed from the pallet and placed on a “one-way-spider” or “stem” for use. the “oneway-spider” is intended for re-use with future eco-Coils by the fabricator. | september 2011 | 89

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PROdUCt RePORt Hobart Brothers

Hobart brothers has developed a new metal-cored welding wire designed to maximize performance and increase productivity on high volume robotic welding applications, especially those for heavy equipment manufacturing. According to Hobart brothers, the new matrix wire from the company’s tri-mark brand is a first of its kind in the industry—a proprietarily manufactured product formulated specifically to provide uncompromised arc starting and wire feeding consistency. the exacting nature of this proprietary manufacturing process ensures that matrix performs consistenty, regardless of the application. matrix’s reliable arc starting and excellent wire feedability are the result of a Hobart brothers’ exclusive technology. this special technology has also been shown to extend the life of robotic gun liners and to eliminate buildup at the drive rolls. Combined, each of these features reduces downtime for maintenance and post-weld activities, and ensures greater overall welding productivity. testing also shows matrix creates a consistent weld bead shape, offers excellent crack resistance and minimizes silicon island formation. Combined, these attributes make it suitable for heavy equipment and similar manufacturing. Hobart brothers created matrix in response to a growing industry demand for a welding wire that could provide better performance and minimize downtime on robotic welding applications. Field tests have shown the wire offers precise arc starts and smooth wire feeding, along with excellent seam tracking and touch sensing. matrix metal-cored wire is available on 33 lb plastic spools that are precision layer wound to support consistent wire feeding, and each spool ships in a heat-sealed, VCI (Vapor Corrosion Inhibitor) impregnated bag to protect against contaminants. Hobart brothers also offers the matrix wire in its exclusive 750 lb X-pak drum.


plasma arc metal cutting technology supplier Hypertherm has launched two types of consumable kits that will help powermax owners realize the full versatility of their systems. the All-in-one kit is specifically for handheld cutting. Although contents of the kit vary depending on which powermax system you own, end users can find up to four different consumable types: • shielded consumables with drag-cutting technology for following a line or template • unshielded consumables with an unshielded nozzle for hard-to-reach areas and bevel cutting

• gouging consumables for tough metal removal jobs • FineCut consumables for more precise cuts on thin metal. the All-in-one kits provide a significant savings over purchasing the kits separately. A free reference guide that provides tips on different cutting techniques and shows how to properly assemble a torch provides even more value. the FineCut kit is designed for both handheld and mechanized cutting. It includes a guide with cut charts and a visual that shows proper torch assembly. reordering individual kit components for both the All-in-one and FineCut is easy thanks to part numbers and part descriptions found directly above the corresponding consumable in the kit. “powermax systems are the ideal tool for a variety of applications. these All-in-one and FineCut kits demonstrate the added versatility of the systems for cutting in tight places, bevel cutting, gouging, and precision cutting on thin plate,” said Clayton Gould, product marketing manager for Hypertherm’s torch and consumable team.


Adding to its tOUGH LOCK Contact tip system, tregaskiss has upgraded the design of its tOUGH LOCK retaining Heads. the retaining heads now feature tregaskiss’ Dual taper technology—a second rear taper between the gooseneck and the contact tip. this design further improves electrical conductivity and heat dissipation to provide consistent welding performance and extend the life of consumables, claims the company. the new retaining head design complements the company’s contact tips. these tips are machined with tight tolerances and feature a dual-lead thread design that allows the tips to be rotated 180° to create a new wear position and extend tip life. the tips operate at cooler temperatures than many competitive tips, reducing wear and minimizing downtime for changeover. Useable for both semi-automatic and robotic mIG guns, the tOUGH LOCK system also acts as a common consumable platform to help minimize inventory and reduce consumables cost. Customers can identify the new tOUGH LOCK retaining Heads by the black O-rings (the preceding single taper design had red or green), the two score marks above the clip and the part number roll-marked along the bottom edge.

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Waterborne on the Way Waterbased coatings are becoming more accepted for industrial applications By Nate Hendley ................................................................................................... Make way for waterborne! A combination of government legislation, technical advancements and environmental awareness is driving demand for waterbased coatings and while it dominates the architectural paint sector, waterborne is also gaining favour in industrial circles. As the name implies, waterborne coatings contain water as their main solvent. While not completely “green”, waterborne coatings are less toxic and flammable than their solvent-borne counterparts and emit fewer VOCs (Volatile Organic Compounds). On the downside, waterborne has a reputation for taking its time to dry. No matter: industry experts are unanimous that waterborne’s time has come. “Once in place, [government] regulations create a level playing field for the types of products available in the market and the transition to waterborne coatings increases. Once purchased, the consumer finds quality and performance in waterborne products as well as enhanced application and cleanup properties and the cycle towards acceptance continues,” says Gary LeRoux, interim president of the Ottawa-based Canadian Paint and Coatings Association (CPCA). Figures from Phil Phillips, managing director of the Chemark Consulting Group, a coatings industry consultant group based in Southern Pines, NC, chart waterborne’s upward trajectory. Phillips pegs global sales of paint and coatings at $US89.5 billion in 2010, rising to $104.2 billion by 2015. Waterborne paint and coatings accounted for $28.9 billion of global sales in 2010, with a predicted increase to $37.7 billion by 2015. Sales of waterborne coatings and paint in North America (defined as Canada and the U.S.) are expected to jump from $9.5 billion in 2010 to $11.1 billion by 2015.

“Acrylic, waterbased latex is the market leader in architectural paints and is challenging powder coatings, high solids and 2K systems in industrial applications, automotive and agricultural equipment today, based on performance,” says Phillips. Darren Armstrong, Brampton-based regional manager for Sherwin-Williams, the coatings giant headquartered in Cleveland, Ohio ticks off a check-list of waterborne’s virtues: “The benefits of waterborne technologies are three-fold. In the current economic environment, the long-term cost benefits of eliminating or reducing the solvents used for reduction and clean-up can be a significant cost savings, as can the potential for reduced insurance costs. Additionally, waterborne technologies for metal finishing can provide a better work environment for employees with lower VOCs and less exposure to solvents. Finally, waterborne technologies provide another way for finishers to differentiate themselves from the competition and meet customer interest in products that are produced in ways that are more environmentally-preferable,” states Armstrong. “When you look at metal finishing applications, I think the trend is really the expansion of applications where waterborne technologies are being considered and used successfully. The previous myths regarding the limitations of waterborne have been overcome by the performance of today’s product offering,” he adds. In terms of industrial use, waterborne is becoming increasingly popular in the automotive sector. “Many automotive exteriors—bodies and automotive components—are now being coated in waterbased paints ... the automotive industry

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Waterborne coatings

continues to push the technology for better and better [waterborne] coatings,” states Brad Sparkman, president of Innovative Finishing Solutions, an Orangeville, ON company that puts together waterborne and solvent-based robotic and automated paint systems. “Water coatings for [exterior car surfaces] are smoother, more robust, have improved DOI (depth of image) and can withstand impact as good as 2K solvent-borne systems at less cost per gallon,” adds Phillips. Inside each auto “there are over 34 different kinds of plastics that must be painted to accomplish a uniform ‘look’. Most of the paint is waterbased,” he continues. Other industry experts offer similar observations. “In the past, we’ve been primarily been a solvent-based wood coating company ... but in the last 18 months or so, we’ve been working on waterbased coatings for not only wood but metal also ... waterborne direct-to-metal coatings for manufacturers of parts,” says Michael Arndt, a Minnesota-based industrial accounts manager for Gemini Coatings, which is headquartered in El Reno, Oklahoma. Customers using Gemini waterborne coatings include “the heavy truck and trailer component industry ... we’re supplying coatings for manufacturers of the frames and axles primarily,” adds Arndt. Innovative Finishing Solutions has also been keeping a close eye on waterborne’s budding popularity. “In the last year-and-a-half there has been a drastic change in the sales of new paint lines and waterbased coatings are certainly being utilized more so ... automotive OEMs, Tier One automotive, aerospace and industrial are all using a fair amount of waterbased paints,” says Sparkman. While waterbased coatings win kudos for ease of clean-up and low environmental impact, waterborne has also been helped along by government regulations. The recent flurry of antiVOC legislation in Canada and the U.S. has been a boon for waterbased paints and coatings. In July 2009, for example, Ottawa announced new regulations regarding VOC emissions in automotive refinishing. These regulations, which came into effect in 2010, are designed to reduce

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Waterborne coatings

VOC emissions. “The most significant affect on the collision repair industry will be the need to switch to waterborne basecoat in order to meet the new VOC limits,” states VOCcompliance. com, a website for Canadian auto refinish facilities impacted by VOC legislation. Other Canadian businesses have responded in kind to the federal government’s anti-VOC campaign. “In view of regulatory changes and in response to market demand, most industrial paint companies have already increased their offerings in waterborne coatings over the past years. Canadian industrial paint manufacturers are getting prepared for the next round of regulations by planning their product reformulations early,” notes LeRoux. It’s the same story south of the border. Asked if stricter federal and state regulations were driving sales of waterborne coatings in the United States, David Darling—director of environmental affairs for the Washington D.C. based American Coatings Association—says, “Yes, since in general waterbased coatings have lower VOC contents.” While celebrated today, it’s important to remember that waterborne coatings had something of a bad reputation in the past. “Waterborne coatings have long been saddled with concerns about surface preparation tolerance and dry time. While not eliminating the need for surface preparation, today’s waterborne technology is more surface tolerant and allows finishers to be less exacting with their pre-finish preparations. And waterborne products can be a fast dry finish alternative for many metal products manufacturers, depending on their process,” notes Armstrong. Some companies have developed products that address waterborne’s sluggish drying time. Osseo, Wisconsin-based Global Finishing Solutions offer something called the AdvanceCure Accelerated Airflow System.The system is 8CMM20186 01/07/2008 08:19 AM Page 1 designed to accelerate the drying time of both waterborne and

solvent-based coatings in paint booths. “The key to AdvanceCure ... is the convection-type airflow it creates. This type of airflow dramatically improves the heat transfer from the air to the painted panels and provides much more even heat distribution over the entire vehicle,” explains Global product literature. The end-result is a sped-up drying process for waterborne and solvent-based coatings. If AdvanceCure represents a solution to one problem, waterborne enthusiasts still have to contend with other issues. For one thing, “it’s difficult to ship water-based coatings in the wintertime. That is a major struggle,” notes Arndt. Humidity is another challenge: “When the air is saturated with moisture, water-based coatings do not dry well,” he adds. In spite of such challenges, no one expects waterborne’s rise to falter. “Interest in waterborne technologies will continue to grow as there is increasing demand for environmentally-preferable production solutions and more focused attention on how manufacturing impacts our environment. Much of this is driven by government regulations, but consumers in all forms are more interested in these types of solutions and this also supports government actions. As the demand for waterborne coatings grows, so too does the product availability and advances in technology,” says Armstrong. Consumer preference and technical advances aside, it’s a safe bet that waterborne coatings will continue to be the indirect beneficiary of government regulations. “We all know [further regulations on VOCs] will be legislated in. It’s just going to be a matter of time,” notes Karen Winter, Canadian sales manager for Global Finishing Solution’s Canadian operations, based in Barrie, ON. CM

“Industry experts

are unanimous that waterborne’s time has come.”

Nate Hendley is a regular contributor and freelance writer based in Toronto.

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Metal...Works When the Bank says NO Sources of non-traditional financing By Mark Borkowski.......................................................................................................................................................... In the business of investment banking we are exposed to many difficult situations that business owners can face. Sometimes our client’s need for financing is driven by an unexpected business or sector slowdown, other times it is for acquisition or growth purposes. But more often than you might think a need for capital will arise as a result of a breakdown of existing credit facilities through no real fault of the borrower.   I spoke to one of my colleagues in the Financing arena and sought his advice. Barry O’Neill, Managing Partner of Zed Financial Partners. He had this advice, “Some of the most disheartening circumstances we’ve seen have involved management becoming” blindsided by their traditional financial partners. A business owner can have a long-standing relationship (along with shining credit rating and excellent margins) with a traditional lender and still find their loan called, or “no-brainer” requests for further capital declined. Changing market conditions, concerns around exposure to industry sectors and risk management strategies can change a traditional lender’s interest in a client and the effects can be devastating.” But there are steps that business owners can take to go on the “offensive” and secure the liquidity they

need to grow outside of traditional financing sources. Business owners and managers must learn to become as creative and versed in options for financing their businesses as they are in other facets of operations. Sometimes it is a matter of looking for another financial institution that better understands the business. Other times, it requires re-examining the assets of a company from a different perspective. Alternative or non-traditional financing options can help to facilitate and allow for the execution of business plans. Often access to the appropriate financing may solve liquidity problems or even present hidden and creative opportunities for freeing up cash flow. Several unique structures may be employed in order to ensure a successful transaction and to maximize the availability of funds. Knowing where to find the different types of financing is crucial.  Barry O’Neill suggested a few options:


An increasingly viable option for Canadian businesses is U.S. private equity and private debt lenders. In Canada there are a limited number of such sources of capital available, but in the United States, there are hundreds of different institutions that are actively seeking opportunities in Canada. Because of the vast amounts of money available south of the border and a limited number of transactions, many of these financial institutions are looking for opportunities outside the United States. Because of the size and specialization of the U.S. financing market there are numerous funds that specialize in specific industries. Understanding industries allows them to better assess the risks and rewards associated with the financing, resulting in a better financial partner. As a result, there is growing demand for more creative financial structuring to solve liquidity issues. Companies seeking U.S. funding should work with financiers who understand the industry sector and business, so they can work with the company as it changes and grows.


Regardless of whether the source of capital is domestic or foreign, the key to securing capital is presenting value where others don’t and then translating that value into a workable | SEPTEMBER 2011 | 95

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Metal...Works “An increasingly viable option for Canadian businesses are U.S. private equity and private debt lenders.” solution for a lender. There are many ways to put financing together. It’s a matter of being creative and knowing where the money is. Some examples of different vehicles for creative financing that we’ve secured through non-traditional sources include:


A well-suited, strategic financial partner, who understands the business and industry, can provide the appropriate financial structure to take the company forward. These partners typically bring cash injections to relieve immediate problems and supply sufficient liquidity to take the company forward and often times are critical to the future viability of a company. Private equity partners can be important tools in situations where owners want to retire or semi-retire and transition the company to family or a management group but wish to extract some wealth from the business.              

REFINANCING OF SUBORDINATED DEBT Subordinated debt may need to be restructured or refinanced in order to alleviate liquidity concerns. Strategies for accomplishing this objective include: purchasing the debt at a discount; converting debt to equity; exchanging the debt for future royalty payments tied to revenue or cash flow; moving the debt off the balance sheet.


In many cases, there is significant capital being tied up in working capital. Various operational specialists can help to assess cash flow restrictions and assist companies to unlock liquidity by putting in proper controls and systems.


Cash flow streams that are associated with long-term contracts and a high degree of certainty may be sold to a third party.


Land and/or buildings can be sold to certain lenders at market value or greater using long-term sale leaseback agreements. In this case, the financier relies on the company’s business plan and future cash flows to support future payments.


Specific machinery and equipment within a company may have little or no collateral value to traditional lenders. Other lenders, such as appraisal or auction companies, may attach value to these assets that allow other financiers to loan against them regardless of whether they have been fully depreciated.


Many companies find that intangible assets (i.e. patents, trademarks) carry little or no collateral value to traditional lenders. However, some non-traditional lenders will lend against such assets. In fact, there are firms that will attach a value to intangible assets and guarantee that value to lenders.


Off-balance sheet structures may generate additional liquidity. For example, intellectual property may be sold into a separate company, which reverts back to the “parent” company after a period of time. So what was Barry O’Neill’s bottom line? “Accessing capital can be expensive, time consuming and incredibly frustrating.” But it doesn’t have to be, and there are a number of other options outside traditional financing sources. One of the most important advantages in maximizing a company’s access to capital is finding the most beneficial source of capital from the most ideal financial partner.   In many cases for Canadian businesses, banks and traditional sources of funding are the ideal financial partners. The convenience and the efficiency of the commercial branch suit most situations effectively and commercial bankers work hard to service their clients. However, for businesses in periods of transition, whether caused by distress, explosive growth or the potential for a change in ownership, the traditional lenders can be impediments and obstacles. There are numerous other options available to Canadian businesses and with a little research, business owners and managers can unlock a realm of new possibilities that suit their situation and best serve their needs.  There are countless ways to improve business liquidity and it makes sense to review options regularly, before additional liquidity is necessary. With the wide avail of creative alternative options for financing one’s business, sometimes a “no” from your traditional lender might actually do you a great favour resulting in a better financial partner. As a result, there is growing demand for more creative financial structuring to solve liquidity issues. Companies seeking U.S. funding should work with financiers who understand the industry sector and business, so they can work with the company as it changes and grows.  CM Mark Borkowski is president of Mercantile Mergers & Acquisitions Corporation.   Barry O’Neill is Managing Partner of Zed Financial Partners. He can be contacted at  

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Canadian Metalworking  

Canadian Metalworking is one of Canada’s largest industrial magazines and also one of its oldest, publishing continuously since 1905. Canadi...