PRECISION MACHINING A look at machining for medical applications — p46
TO TAP OR THREAD? For medical parts, that is the question — p54
WELDING AUTOMATION Stick welding remains a relevant process — p80
TRUE TRACEABILITY Laser marking allows parts to be easily tracked — p84
WMTS RETURNS MAY 2015 PM 40069240
Pg. 34
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High-security groove milling CoroMill® QD meets many of the demands of deep groove operations. It combines internal coolant, damped Silent Tools™ adaptors and optimized insert geometries to offer a secure, low-vibration, economical process that extends tool life. When milling narrow and deep grooves, chips often get stuck in the groove, causing low production efficiency, poor component quality or tool breakage. Common remedies are up-milling with critically reduced tool life and the time-consuming and risky task of removing the chips by hand. A better solution is CoroMill® QD, the first cutter of its kind that features internal coolant. The chips are deformed by the insert geometry to a more narrow shape and then flushed out by the coolant, saving valuable tools and production time.
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15-05-01 12:14 PM
MAY 2015 ß VOL. 110 ß NO. 04
www.canadianmetalworking.com
A LOOK INSIDE SPECIAL ISSUE: MEDICAL DEVICE MANUFACTURING & WMTS PREVIEW FEATURES LOOKING BACK: TAPPING AND THREADING — 25 110 years of Canadian Metalworking
WMTS PREVIEW — 34 The show returns to Edmonton on June 15-17
BUILDING A STRONG FOUNDATION — 42
COVER STORY — 28
Additive manufacturing experiencing healthy growth
POSITIVE PROGNOSIS
PRECISION MACHINING — 46
Medical device manufacturing gets clean bill of health
A look at machining for medical part applications
TO TAP OR THREAD — 54 When it comes to medical parts, that is the question
FOCUSED ON EFFICIENCY — 62 Russel Metals, Winnipeg, MB
25 46
34 54
42 54
www.canadianmetalworking.com
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MAY 2015 | 7
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MAY 2015 ß VOL. 110 ß NO. 04
www.canadianmetalworking.com
A LOOK INSIDE SPECIAL ISSUE: MEDICAL DEVICE MANUFACTURING & WMTS PREVIEW
84
FEATURES (CONT.) OPTIMIZING A BENDER— 72 Get the most out of the press brake
PIPE WELDING GETS AUTOMATED — 80
72 80 90
Yet, stick welding still remains relevant
AUTOMATION IN THE FIELD — 82 Welding automation in the oil and gas sector
TRUE TRACEABILITY — 84 Direct laser marking allows for part tracking
THREAD CONNECTION — 90 Tools for thread measurement
DEPARTMENTS VIEW FROM THE FLOOR — 10 NEWS — 12 KEN HURWITZ ON FINANCE — 21 BUSINESS MANAGEMENT — 23 CNC SOLUTIONS — 52 FAB AND WELDING NEWS — 66 TOOL TECH — 96
UPCOMING IN METALWORKING Coming up in our June issue of Canadian Metalworking, we will be focusing on automotive manufacturing. This issue will feature topics like mass production machining, workholding, large part fabricating, stamping, TIG welding, and much more. Also, on www.canadianmetalworking.com right now, visit our “Product News” section on the homepage to get a glimpse of the products and exhibits that will be showcased at this year’s Western Manufacturing Technology Show in Edmonton, on June 15-17, 2015. And don’t forget to follow along and engage with us on social media – look for us on Twitter, Google+, and Facebook!
TOOL TALK — 98 BY THE NUMBERS — 106
8 | MAY 2015
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www.canadianmetalworking.com
15-05-01 11:45 AM
Expand Your Range. “With the FOM2 RI, we have secured new business while meeting the ever-changing demands of our current customers.” — Calvin Schmidt, President Schmidt Laserworks
Quickly Change From Flatbed Laser Cutting to Tube in Minutes. No Handling. No Jigs. No Problem. Located in Edmonton, Alberta, Schmidt Laserworks has earned a reputation as a single source provider of laser processing and precision metal fabrication. That reputation was challenged as a growing number of existing customers were sending parts to machine shops to process holes and cutouts in tubes. To retain current customers while adding capabilities to attract new business, Schmidt Laserworks turned to the technology leader. Amada provided the FOM2 RI laser with an integrated Rotary Index. Calvin Schmidt, President of Schmidt Laserworks, reflects on that investment. “Purchasing a hybrid machine ensures us maximum flexibility. We can go from processing tube, change to cutting flat, and back to tube, with only minutes of setup between jobs. We can also supplement the production of our other flatbed lasers when needed.”
Amada’s FOM2 RI laser with Rotary Index provides: • Process Range Expansion (The FOM2 RI can process round, square, rectangle, C-channel, and angle iron, making it the most versatile Rotary Index laser available). • Reduced Scrap (The ability to nest parts in 20 ft. lengths has minimized or eliminated scrap — resolving a costly problem associated with processing parts on a bandsaw). • Maximum Productivity (Previously, holes were drilled or parts were fixed into jigs on a flatbed laser. One side was processed at a time and parts were turned manually which required running multiple programs.
Reflecting on the decision to choose Amada, Schmidt states, “We’re always looking for a competitive advantage. Purchasing the FOM2 RI has once again raised the bar, placing Schmidt Laserworks at the forefront of laser cutting solutions and positioning us as a premier, one-stop metal fabrication service provider.”
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Amada Canada, Ltd. 885 Avenue Georges Cros, Granby, Quebec, Canada J2J 1E8
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800-561-4578 www.amada.ca
15-05-01 12:14 PM
VIEW FROM THE FLOOR
GOOD NEWS BUDGET & EXPORT DEMAND
A
Do you think its a great time to explore exporting your services? I look forward to hearing what you have to say.
lthough it was delayed because of the sudden shock placed on the country’s economy due to plunging oil prices, the Federal Government was finally able to table its budget for 2015 last month. As expected, Finance Minister Joe Oliver delivered a package that was favourable to manufacturing and supported infrastructure growth across the country. The Automotive Parts Manufacturers’ Association was happy to see a 10-year extension of the accelerated capital cost allowance that was due to expire this year, and more specifically on the auto front, there was a reallocation of the Automotive Innovation Fund, with the end result leading to $100 million over five years being dedicated to support automotive supplier innovation. And $2.8 billion was announced to prop up infrastructure improvements, and $119 million over two years is heading to the National Research Council’s industry-partnered research and development activities. And on top of the good news budget, the Bank of Canada also continues doing its part to help, keeping interest rates at all-time lows and keeping our Loonie low enough to provide exporters a positive exchange when selling to our neighbours to the South. And according Export Development Canada (EDC) there is a “huge opportunity” right now for
PUBLISHER STEVE DEVONPORT 416.442.5125 ß sdevonport@canadianmetalworking.com
Canadian companies to meet U.S. demand for production capacity. EDC’s recent global export forecast predicts industrial capacity constraints in the U.S. will be a key driver of global economic growth over the next two years. “If ever there was a time for businesses, whether small, medium or large, to start exporting to the U.S., it’s now,” notes EDC chief economist Peter Hall. The agency suggests that U.S. consumers are confident, employment and wages are rising, and Americans are spending. “As a result we’re seeing facilities in the U.S. being pushed to capacity as they scramble to keep up with increasing demand,” says Hall. The agency forecasts Canada’s export growth to be one per cent this year and seven per cent in 2016. As we move towards summer, just remember that it’s not always sunny. And while this recent economic news all sounds good, keep in mind that this was a pre-election budget. So it may be wise to take advantage of the allowances while you can. Do your due diligence, invest in productivity-enhancing tools where possble, and if you have the expertise start investigating your exporting potential.
DOUG PICKLYK, EDITOR dpicklyk@canadianmetalworking.com
ASSOCIATE PUBLISHER ROB SWAN 416.510.5225, cell 416.725.0145 ß rswan@canadianmetalworking.com
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ART DIRECTOR STEWART THOMAS 416-442-5600 x3212 ß sthomas@bizinfogroup.ca CIRCULATION MANAGER SELINA RAHAMAN 416.442.5600 x3528 ß srahaman@bizinfogroup.ca MARKET PRODUCTION MANAGER BARB VOWLES 416.510.5103 ß bvowles@annexnewcom.ca PRINT PRODUCTION MANAGER PHYLLIS WRIGHT 416.442.6786 ß pwright@bizinfogroup.ca PRESIDENT OF ANNEX BUSINESS MEDIA MIKE FREDERICKS VICE-PRESIDENT OF ANNEX BUSINESS MEDIA TIM DIMOPOULOS
10 | MAY 2015
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Content copyright © 2015 by Annex Publishing & Printing Inc, may not be reprinted without permission.
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: vmoore@annexnewcom.ca Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9 Canadian Publications Mail Agreement: 40069240. ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.
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.
www.canadianmetalworking.com
15-05-01 3:22 PM
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IN THE NEWS
MMP EXPO LEAVES ITS MARK IN WINNIPEG The Winnipeg MMP Expo was a great success. The keynote address by Don Boitson of Magellan Aerospace was so popular, the room was filled to the brim with attendees interested in hearing about aerospace manufacturing in the region and Canada-wide. After Boitson’s presentation, guests filed into the exhibition hall where booth exhibitors were happy to greet them. With just under 100 booths available, visitors were treated to a wide variety of metalworking and manufacturing companies, showcasing their capabilities. The show lasted from 10 am to 4 pm, with streams of people all day long. There was a buzz in the air as visitors inquired about products, services, and general interest questions.
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“Coming into any new market with our table top expo, we never really know what to expect. But it was clear in Winnipeg, even before the doors opened, that the event was going to be a success. The keynote presentation was standing room only, and we had 150 attendees on the floor when the doors opened at 10am,” says Rob Swan, associate publisher of Canadian Metalworking magazine. “Right away there was a buzz and we had some very happy exhibitors. The MM&P Expo drew not only a good overall number, but the quality of attendee was very impressive. We knew before the day was over that we would be coming back to Winnipeg in 2016. The exhibitor
There was standing room only as keynote speaker Don Boitson discussed the importance of manufacturing in Winnipeg, focusing on the aerospace industry.
response was overwhelmingly positive,” Swan continues. Exhibitors were very happy with the turnout and the show was well received, especially for a first time event. “It was overdue that Winnipeg has its own metal processing expo,” says Stefan Fickenscher, the newly appointed managing director of TRUMPF Canada. “Much like what we saw the first time in Vancouver, the Winnipeg audience was starving for a show, and the opportunity to meet suppliers to learn about technology,” says Frank Bolieiro, vice president, sales and marketing for Elliott Matsuura Canada. “It was a good show, a busy show!” Canadian Metalworking, along with its sister publication, Design Engineering, were very happy to host this premier event. “The strategy of our MM&P Expo is working, and we have found another market that has embraced our event,” says Swan. “Manufacturing in Winnipeg is growing, and the people are hungry for technology. This was made clear to all of us on April 7th.” www.canadianmetalworking.com
15-05-04 11:01 AM
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IN THE NEWS PHOTO COURTESY OF TOYOTA
TOYOTA TO END COROLLA PRODUCTION IN CANADA Toyota will stop producing the Corolla in Canada within a few years but says it will continue to invest in its plants in Ontario as part of a shift in its global manufacturing operations. Production of the Corolla is moving to Central Mexico where Toyota will invest approximately US$1 billion to construct its newest North American manufacturing facility. This plant will feature the latest production engineering innovations, employ approximately 2,000 team members and have the capacity to produce 200,000 units annually. Once Corolla production begins in Mexico in 2019, Toyota Motor Manufacturing Canada Inc. (TMMC) will transform its Cambridge, Ontario North Plant to switch from producing Corollas to mid-sized, higher-value vehicles. This marks Toyota’s first major
14 | MAY 2015
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reinvestment in the plant since it opened in 1997. Toyota will also make significant new investments over several years in assembly plants in Cambridge and Woodstock, Ontario. “We are thrilled to invest further in North America so we can better meet the needs of our customers for decades to come,” said Jim Lentz, chief executive officer of Toyota North America. “Our next-generation production facility in Mexico will be a model for the future of global manufacturing and set a new standard for innovation and excellence,” adds Lentz. “Transforming our Canadian vehicle assembly plants is an equally important part of our strategic plan to position the North America region for sustainable long-term growth.” Toyota will realign production at its Cambridge and Woodstock, Ontario assembly plants; all three plants
will then produce mid-sized vehicles of higher value. The adjustments at these plants will require major modifications to the facilities and significant new investments will take place over the next several years. The Woodstock plant will continue to manufacture the RAV4. The Cambridge South Plant will continue to build the Lexus RX 350 and 450h. “This commitment to Toyota manufacturing in Canada is a huge vote of confidence in our team members,” said Brian Krinock, president of TMMC. “With a new platform, new products and new technology, Toyota’s continued investments in Canada will take us to the forefront of advanced manufacturing, further drive our competitiveness and position.” By 2019, the Cambridge, Ontario plants will all be producing higher-value mid-sized vehicles.
www.canadianmetalworking.com
15-05-01 11:59 AM
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IN THE NEWS PHOTO COURTESY OF GENERAL MOTORS
UNIFOR RELEASES STUDY ON POTENTIAL IMPACT OF GM OSHAWA PLANT CLOSURES the auto sector. The 24-page study, Economic Impact of GM Operations in Oshawa, examines the operation’s overall economic benefits and is authored by Robin Somerville, director of The Centre for Spatial Economics, an independent economic modeling firm. The report confirms the massive economic benefits from the GM operations in Oshawa, ON. If the plant were to close, the report alleges, “a direct loss of 4,100 jobs, currently producing 325,000 passenger vehicles and generating about $1.1 billion of GDP. The modeling system provides estimates of the secondary implications of the closure for GDP, The best press alternative on the market employment, for unitized tools and small die sets. and governMULTICYL INC ment revenue in 640 Hardwick Road, Unit 1, Bolton, ON, Canada L7E 5R1 Ontario and the Tel.: 905-951-0670 - U.S. Toll Free 1-800-388-6359 - Fax : 905- 951-0672 nation.” www.multicyl.com - punch@multicyl.com “Canada is a
If General Motors closed its Oshawa manufacturing complex entirely, Canada’s GDP would shrink by more than $5 billion per year within two years, according to a new report released by Unifor, a union representing more than 305,000 workers, including close to 40,000 in
16 | MAY 2015
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great place for GM to do business, and we all benefit greatly from them being here,” said Jerry Dias, Unifor’s National President at a Toronto press conference. “The benefits to all Canadians are evident in this report. This underlines why Canada needs a focused strategy to win new auto investment, just like other countries have,” Dias said. The study examines the overall economic impact of GM’s Oshawa complex, including its 3,600 hourly production workers and an estimated 500 salaried staff whose jobs are tied to manufacturing. The analysis considers the direct GDP produced in the facility, the indirect impact on auto parts and other supply industries and the economic activity stemming from the spending and re-spending of workers’ wages. It finds that if the Oshawa complex closed entirely, Canada’s GDP would shrink by more than $5 billion per year within two years. Within two years, approximately 33,000 jobs will be lost in Ontario. Eventually employment will partially rebound, but at the expense of a permanent decline in average wages, even for workers who do not work in the industry. The report finds that the closure of the Oshawa facility would constitute an important negative shock to the Canadian economy felt most acutely, of course, in Ontario. www.canadianmetalworking.com
15-05-01 12:00 PM
FIBER OR We’ll help you decide. When it comes to laser technology, both fiber and CO2 are good for business, from fiber’s low cost of operation to the powerhouse performance and versatility of CO2. So whether you’re looking to upgrade, expand or rethink your technology, make sure you talk to the one source with endless expertise.
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15-05-01 12:24 PM
IN THE NEWS
BOMBARDIER FLIES IN A NEW DIRECTION
Bombardier’s new chief executive, Alain Bellemare, is making some drastic changes to the company. Bellemare announced that he is bringing in new talent to reinforce the company’s management team. This announcement comes with a number of other changes to senior management as well as the corporate structure of the aerospace and rail
divisions. Since early 2014, Bombardier has undergone an organizational restructuring, laid off more than 3,500 employees and seen the departure of several officials including aerospace CEO Guy Hachey. The company is working to find several replacements. One of the newest hires is Fred Cromer, who replaced long-time Bombardier executive Mike Arcamone. Cromer was most recently president of International Lease Finance Corp., a major buyer of commercial aircraft and held positions
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at several U.S. airlines. “His strong leadership skills, international network and deep understanding of the aviation industry are a perfect match for Bombardier Commercial Aircraft, as we are preparing to realize the true market potential of our new C Series aircraft while refocusing on our Q400 and CRJ programs,” Bombardier chief executive Alain Bellemare said. Bombardier hopes that these changes will infuse a fresh perspective at the company and move Bombardier in different and new directions. Bellemare also announced that Bombardier will be getting strategic advice from a company headed by former ILFC chief executive Henri Courpron, a former president and CEO of Airbus, North America. His team’s mandate consists of conducting an extensive review of Bombardier Commercial Aircraft’s operations, with the objective of improving its overall performance. “Having Fred and Henri on board gives us a strategic edge like we’ve never had before,” Bellemare said. “We are really paving the way to strengthen our existing commercial programs and to make the C Series aircraft a phenomenal success.” Another major change rumoured to be in the works is the possible sale of the company’s rail division. A sale, merger, or spinoff could yield upwards of $5 billion for Bombardier. However, after speaking with Pierre Beaudoin, Chairman of the Board of Directors of Bombardier, Jacques Daoust, Minister of Economy, Innovation and Exports, confirmed that Bombardier Transportation is not for sale. He did, however, add that there is currently a worldwide consolidation movement in the transportation industry, and Bombardier is considering whether to participate. Bellemare is clearly not afraid to make big changes, so it is best not to rule out any scenario at this point. www.canadianmetalworking.com
15-05-01 12:00 PM
IN THE NEWS
FEDS AIM FOR GROWTH IN MANUFACTURING The Government of Canada has eliminated all remaining tariffs on machinery, equipment and inputs such as screws, electric motors and pipe fittings for industrial manufacturing. It’s all about making Canada a more attractive place to do business. Eliminating these remaining tariffs will lower the cost of imports used to produce manufactured goods for Canadian businesses. “The elimination of all tariffs on imported goods and equipment, along with other tax measures, is providing Canadian manufacturers with a significant competitive advantage,” says Jayson Myers, president and CEO, Canadian Manufacturers & Exporters. “Manufacturers across the country are using these tax savings to invest in innovation, growth and jobs.” The tariff elimination measure was first announced in Budget 2010, with the Government estimating that it could create 12,000 jobs across Canada. Since 2009, more than 1,800 tariffs have been eliminated in the industrial manufacturing sector. This announcement will specifically benefit small and medium-sized businesses that rely on global supply chains and are looking to diversify their export markets. These changes will provide $450
million in annual tax relief for Canadian manufacturers. Canada is the first G20 nation to eliminate all tariffs on machinery, equipment and inputs used in the industrial manufacturing sector. Having access to global trade
opportunities is an important source of competitive strength for Canadian businesses. Eliminating tariffs reduces import costs, allowing businesses to enhance their stock of equipment and improve their access to domestic and foreign markets.
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MAY 2015 | 19
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15-05-01 12:24 PM
FINANCE
STEPS TO ACHIEVING MACHINE FINANCING APPROVAL BY KEN HURWITZ
T
he cycle of machine tool purchasing pretty much repeats itself on a yearly basis. Now that we have survived the winter and are into spring many shop owners have a good idea of what their equipment needs will be for the rest of the year. It’s a time when inquires turn into quotes, and the next step is finalizing pricing, terms and then the issuing of purchase orders. With that in mind I thought it would be a good idea to give some insight into what a finance company looks at when reviewing and approving applications for the financing of machinery and equipment. • Asset Quality and Seller – The first thing any lender will look at is what is actually being financed. When it comes to machine tools anyone with industry knowledge knows a good brand will have an excellent re-sale value. Remember, a lender’s first concern is exit strategy. In the event a deal goes badly, they want a comfort level knowing the asset can be re-sold with relative ease and with a significant portion of the loan recovered. There will also be a review of the vendor (seller) to ensure it is reputable and can provide required service and support. • Amount Required – A question I get all the time is, “Ken, how big a transaction can you handle?” The reality for most lenders is that the transaction size is limited only by the size of the company making the inquiry. The amount of funds a typical finance company has available is for the most part limitless, it is the equity box of the company (or the company plus the credit strength www.canadianmetalworking.com
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of its owners) that determines how much financing will be available. Essentially there will be a review of the company’s working capital and cash flow, meaning can the entity pay for its current loans and/ or expenses before adding anything new. Another factor looked at is Debt to Equity ratio, which indicates what proportion of equity and debt the company is using to finance its assets. A higher debt to equity ratio indicates more financing (bank loans) is used than investor financing (owner/shareholder). Lastly, retained earnings (the profits retained by the company which are reinvested in its core business and are not paid out as dividends) as well as tangible net worth (the sum of all the tangible assets—cash, equipment, property, etc.—less any liabilities) will be looked into. • Financial Statements – Depending on the size the request, the financial statements of the applicant will detail all the above information. I always recommend using a registered accountant (member of CPA) from quality accounting firm as opposed to less expensive tax services. The difference in the quality of the report is significant, and a well prepared report will provide much more comfort to the potential lender. There are three types of financial statements, Notice to Reader, Review Engagement, and Audited. The larger the request the more detailed the financial statements will need to be. Internally prepared statements, called interims, for the current fiscal year may also be required. Most of my clients use QuickBooks or Simply Accounting to generate interim statements, these are fairly easy to use and intuitive applications which keep track of the current year’s performance. • Commercial and Personal Reports – All lenders will also use some sort of commercial reporting, the
most common being Equifax or Dun & Bradstreet (D&B) as well as Paynet. Personal Reports will also be reviewed when the application includes a guarantee of the owner(s) or majority shareholder(s). These reports provide information on the individual including how much credit they have been extended by either credit card companies or their bank, and most importantly their repayment history as well as any legal or collection issues. It is important for any applicant to know the information on their credit report so there are no surprises and an explanation is provided with the original submission. Once all of this information has been collected a write-up will be prepared including a justification for why the equipment is required and what the potential benefits to the company’s bottom line will be. This report along with the financial and commercial information will be evaluated to determine if the application is approved, declined, or structured. A structured approval is an approval for less than 100 per cent of the total request, it just means the deal is approved but requires a deposit and/ or additional collateral (existing equipment owned free and clear) to lower the transaction size and mitigate the risk. I have converted a lot of material this month but in order to have success in finding a lender, or as I often tell my clients a new business partner, it is important to understand the process of evaluating a new application. Till next month… Ken Hurwitz is the Senior Account Manager with Blue Chip Leasing Corp. in Toronto. With years of experience in the machine tool industry, Ken now helps all kinds of manufacturers with their capital needs. Contact Ken at (416) 614-5878 or ken@bluechipleasing.com. MAY 2015 | 21
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BUSINESS MANAGEMENT
RESTRUCTURING: EVOLUTION ISN’T MANDATORY BY ANDREW WOOD & ALMA JOHNS
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estructuring. The word conjures up a negative impression right from the start. We equate restructuring with downsizing, right sizing and several other phrases all associated with contraction and failure. But restructuring doesn’t have to be perceived as a negative process. I prefer to view restructuring as a positive event, recalibrating the existing business structure to embrace and support a ground-breaking strategic goal. Last month, we discussed how management can establish organizational goals by forward modelling last year’s financial statements. Along with the targeting of those goals comes the development of strategies. These strategies will likewise require the evolution of the company’s structure to support and facilitate their execution. Breaking down the process in the following order can provide clarity and seamless execution. • Goals • Strategies • Process Restructuring • Organization Plan • Execution Plan
RESTRUCTURE IN SUPPORT OF A STRATEGY As a Strategic Consultant I often utter the phrase: “never structure before strategy.” Too often I witness companies that limit their potential forward strategic plan to opportunities that are facilitated by existing structures that they would never put in place if they were a newly-formed organization. Existing businesses often view their infrastructure as “fixed” and try to design new initiawww.canadianmetalworking.com
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tives that can be rolled out by archaic structures. If the goal and strategy are more ambitious, they are best served by “bespoke” structures to maximize effectiveness. Step 1 – Create a Competitive Advantage What is the one thing that will make the company have a clear competitive advantage in its marketplace? Some quality or service capability that competitors cannot easily adopt and that clients acknowledge makes the company different. Determine what end result provides a competitive advantage against other companies in the field. Determining this attribute is the single most difficult aspect of a corporate restructuring. Step 2 - Define Strategies Simply put, what needs to occur to result in the company achieving that Competitive Advantage? Define the end product and the required perception by the marketplace. Which internal processes and departments will need a new master goal? What is the new standard of their deliverables? Personally I like to use Mind Maps to quickly outline the interrelatedness of multiple departments and their roles in outputting and achieving their competitive advantage. What do each department’s goals look like when they’re done? The strategies can be as simple as identifying where the business is and where it needs to be, to gain a competitive advantage. Step 3- Map out a System and Processes Flow Chart Since the best way to design restructure is to first map out the service process that will deliver the best output to clients, the next step is to “process flow” all Sales, Customer Service, Manufacturing or Service Provision and Accounting internal processes. This will ensure they are aligned and each
department can quickly deliver the required goals. Scrutinize carefully as this is where all the “sacred cow” processes are hiding. Long-term employees will continue to perform all light-the-candles-at-dusk tasks during this process unless they are specifically carved out and discontinued. Step 4 - Organization Chart Now that the building blocks of processes that support the desired departmental goals are established, the management can layer in positions. Do not think in terms of the staff the company has, but rather the tasks and positions required. Build an organization chart and align departments that support the flow. It is only after the above steps are completed that management can review the labour pool for appropriate candidates for each position. Some will be self-evident, some will require investment in training, and some simply no longer fit the company’s new model. Step 5 - Execution Plan Task each department to establish clear, concise, aligned and quantifiable Action Plans with timelines to evolve into the new desired structure and process deliverables. Taking this approach to restructuring will ensure a stronger market strategy and more efficient execution that will rejuvenate the company and positively impact the bottom-line. Andrew Wood has held senior executive positions in manufacturing, supply chain and logistics, healthcare and other industries and sits on TEC Canada’s Trusted Advisors Council. andrewjmwood@changeagent.ca Alma Johns is President of Bench Capital Advisory Inc., an independent corporate finance and debt advisory firm based in Toronto. alma.johns@benchcapital.ca. MAY 2015 | 23
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LOOKING BACK:
TAPPING & THREADING A
s we continue celebrating the 110th anniversary of Canadian Metalworking magazine, in this issue we take a look at the state of metalworking technology 110 years ago with a focus on tapping and threading. In 1905, several companies introduced new products and machinery developments, as well as advertised the latest and greatest innovations. Here is a look at just a few of the latest technologies of 1905.
Fig. 1
BOLT AND NUT MACHINE Boynton & Plummer of Worcester, Massachusetts, introduced its Bolt and Nut Machine. “The accompanying image (fig. 1) illustrates an extremely useful machine…for threading bolts and tapping nuts.” According to the article, this machine can be built in several sizes, either for hand or power but can be configured for both a hand and power combination. “It is claimed that with these machines larger-sized bolts can be threaded with greater ease and facility than with any other similar make, while small sizes can be cut as rapidly as with a small machine. A very desirable feature of these machines is that they are constructed to accomplish the work intended with the least number of parts to get out of repair, of any tool of its kind. With these machines they furnish taps and dies for rough iron sizes, that is, 1-32 large and V thread. Either solid or adjustable dies are furnished as desired.” In 1905, Boynton & Plummer also manufactured a complete line of machines for blacksmiths, carriage-makers, repair and machine shops, such as drills, forges, tire benders, tire shrinkers, bolt heading machines and shaping machines.
“They are receiving constantly testimonials from users of their machines all over this country and foreign lands, of which volumes could be made, as to the reliability and general satisfaction of the output of their work.” Boynton & Plummer was incorporated in Maine in 1909 with William J. H. Nourse as president. However, in 1918, the company was then incorporated in Vermont under the leadership of John A. McGuire. Boynton & Plummer struggled through the Depression and eventually dissolved in the 1940s. Boynton & Plummer produced metal working machinery including drilling machines, shapers, and bolt threaders in addition to wood working machinery, including planers, jointers, shapers, and saw tables.
TAP AND DIE GRINDER Greenfield Machine Company of Greenfield, Massachusetts, also developed its latest machine, the Tap and Die Grinder. “A recent product…is a tap and die grinder
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Fig. 2
embodying new features (fig. 2). The tap-sharpening attachment consists of two centerheads mounted on a swinging arm, which carries the tap across the face of the cup emery wheel.” A description of the Tap and Die Grinder is as follows: “The arm swings at an angle with the face of the wheel, permitting the tap to be ground at any angle. The tap is indexed by means of a rigid tooth rest and held in place on centres, one of which is attached to a spring lever, allowing the tap to be removed quickly. Means are provided for holding a tap, which has the end broken off, or one without centre holes as shown in the image. The work is brought towards the wheel by means of a hand wheel at the front of the machine. Chucking reamers can also be ground on this fixture. Will hold from 3/8inch hand taps to 1 ¼-inch machine taps.”
Here is an ad from 1905 for a unique solution for tapping operations, adjustable collapsing taps.
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For a look at more tapping and threading products, check out our our cutting tool feature on page 54.
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The Greenfield Machine Company’s Tap and Die Grinder was featured in 1905; however, the company focused not only on their product but also able quality assurance standards when it comes to threads, explaining that “Small Instruments of Measurement” work best for measuring threads.
Fig. 3
Never before have engineers and mechanics possessed such a wealth of measuring instruments as they have at their command today…The problem met with in very fine measuring instruments are far from being new, but their applications to engineers’ tools is mainly a development of the present generation. The place of gauged measurement is that of fixed and unalterable dimensions often repeated.”
When the coolant becomes a liquid tool. becomes a liquid tool. When the coolant
THREAD MEASUREMENT When it comes to measuring threads on screws today, there are many different products available for various features. In 1905, one of the popular products was a special micrometer caliper. “This image (fig. 3) shows a special form of the micrometer caliper used for screw gauging. It is more delicate than the ring gauges used for a similar purpose, because it does attempt the almost impossible task of perfect contact all round the circle and at all sections of the thread. The points and roots of threads do not affect the result, since measurement is taken down the sides and one-half the depth of the thread.” For a look at different tools for internal and external thread measurement, check out our quality feature on page 90.
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1905 TAPPING ADVERTISING On the previous page is advertisement from The Geometric Tool Co. of New Haven, Connecticut from 1905. This company was promoting its adjustable collapsing taps for tapping of metal, either pipe or straight threads of 1-1/4-inch or larger diameters. www.canadianmetalworking.com
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POSITIVE PROGNOSIS
Canada’s medical device manufacturing sector remains healthy and strong BY NATE HENDLEY
T
he Advanced Machine Shop at Toronto’s Sunnybrook Research Institute (part of Sunnybrook hospital) straddles the worlds of medicine and manufacturing. The Advanced Machine Shop is solely devoted to making medical devices. This narrow focus puts the shop in a prime spot within Canada’s thriving medical device manufacturing sector. Established 11 years ago, the Advanced Machine Shop is part of an effort to “develop prototype technologies that are used for research and eventually in the hospitals. Scientists and engineers design and pro-
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duce complex medical devices under highly controlled conditions. Devices are tested for proof of principle and, if successful, they are tested clinically, in collaboration with other researchers and clinicians. Ultimately, the aim is to commercialize the devices we invent, so we can move them into the medical marketplace to benefit patients,” explains shop manager Michael Pozzobon, from SRI physical sciences, design and machining services. Medical devices can be defined as, “health or medical instruments used in the treatment, mitigation, diagnosis or prevention of disease or abnormal physical condition… www.canadianmetalworking.com
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for smaller-sized work,” he adds. some examples include pacemakers, artiAsked where Shop staff generate ideas for ficial heart valves, hip implants, synthetic new medical devices, Pozzobon says, “Most skin, medical laboratory diagnostic instruof the ideas come from the scientists workments, test kits for diagnosis and contraceping at SRI or from industry collaborators. tive devices,” states Health Canada, the govA main focus is image-guided therapeutics. ernment body that regulates such devices. Some ideas arrive with complete drawFrom 2007 to 2012, annual Canadian ings requiring only manufacturing, others medical device exports increased from $1.7 require a bit of redesigning to manufacture, billion to $1.8 billion, according to Industry while other ideas are given requirements Canada. In 2012, Canada’s medical device with parameters outlined and the staff here sector boasted sales of $6.2 billion in total, design the prototype.” accounting for two per cent of the global market. Top-selling items included diagnostic apparatus (25.8 per cent of 2012 Canadian medical device sales), consumables (15.3 per cent), patient aids (12.3 per cent), orthopaedic and prosthetic (11.9 per cent), dental products (6.9 per cent) and other items, including wheelchairs, blood pressure monitors, endoscopy apparatus, etc. “Canada’s medical device sector is a highly diversified and export-oriented industry that manufacturers equipment and supplies. Purchasers include Canadian and international hospitals, physician’s offices, laboratories, clinics as well as patients (through direct purchase)…the industry is primarily based in the three largest provinces—Ontario, Quebec and British Columbia—with over 80 per cent of the medical device industry located in the provinces of Ontario and Quebec,” adds Industry Canada. Demand for medical devices is being driven by the baby boom generation as it enters its senior years as well as technological advances. At Sunnybrook, the Advanced Machine Shop covers 2,000 square feet and employs four technicians, all from machine shop backgrounds. The current equipment lineup includes “Viper SLA and Fortus 400 Rapid Prototypers, five-axis Flow Let our measurement experts help you adjust your fixture to meet spec. water jet cutter, DMU 50T CNC mill, CTX 310 Guildemeister CNC lathe, three manual lathes, three manual vertical milling machines, one vertical/horizontal milling machine, hydraulic shear, bender and roller,” says Pozzobon. When it comes to cutting tools, the 2433 Meadowvale Blvd., Mississauga, Ontario L5N 5S2 Shop favours “Sandvik inserts for Ph:905-819-7878 • Fax: 905-819-6886 • Toll Free: 1-800-606-9266 turning and milling with Horn tools
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One of the most successful medical devices to come out of SRI research was called the MRI Breast Bed. This was a coil-and-bed system designed to make it easier for scientists to detect breast cancer and more comfortable for women to undergo detection. The work was spun off from Sunnybrook into a company called Sentinelle Medical which was in turn purchased by a firm called Hologic Inc. for $85 million in 2010. In spite of such success stories, a common complaint is that the commercialization process for medical parts in Canada is cumbersome and lengthy. It takes too long, say critics, for new devices to go from drawing board to market. “There are many initiatives underway across the country to help ensure that start-up medical device companies are successful. The MDCC [Medical Devices Commercialization Centre] will be an important contributor to those initiatives that are helping to bring new, innovative Canadiandeveloped medical technologies to market,” says Gerry Frenette, executive director of MEDEC, a Toronto-based trade association representing medical technology companies. The MDCC is a new, non-profit organization currently based at the University of Ottawa Heart Institute that brings together “a national collaborative network of stake-
HEALTH CANADA’S MEDICAL DEVICE REGULATIONS Manufacturers must abide by various regulations as laid down by Health Canada. Following are some of the key requirements: A manufacturer shall ensure that the medical device meets the safety and effectiveness requirements. A manufacturer shall keep objective evidence to establish that the medical device meets those requirements. A medical device shall be designed and manufactured to be safe, and to this end the manufacturer shall, in particu-
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lar, take reasonable measures to (a) identify the risks inherent in the device; (b) if the risks can be eliminated, eliminate them; (c) if the risks cannot be eliminated, (i) reduce the risks to the extent possible, (ii) provide for protection appropriate to those risks, including the provision of alarms, and (iii) provide, with the device, information relative to the risks that remain; and (d) minimize the hazard from potential failures during the projected useful life of the device.
holders established to assist medical device technology owners in advancing their technologies to the global market,” says Dr. Tofy Mussivand, president and CEO of the Centre. Dr. Mussivand is also a professor of surgery and engineering at the University of Ottawa and Carleton University and director of the Medical Devices Innovation Institute. He says the MDCC will offer financial support and other assistance to advance the commercialization of viable medical devices. “A team of experts will identify, assess and select medical device technology for commercialization. Following a stage-gate selection process—based on an assessment of technology, clinical needs, market opportunities, finances and regulatory requirements—promising innovators will be advanced to commercialization,” explains the Centre’s website. This intervention is designed to address what Dr. Mussivand considers the biggest challenge facing the Canadian medical part makers: achieving international success. According to Industry Canada, the global medical device manufacturing sector is made up of over 27,000 firms with one million employees and 2012 revenues of US$327.7 billion. The federal government clearly supports MDCC’s mission. On August 25, 2014, Ottawa announced an investment of $14.9 million in the Centre. And this from a government accused of not supporting scientific research. The Canadian government also helps the medical devices sector through the Scientific Research and Experimental Development (SR&ED) Program. The latter initiative offers tax breaks for companies that do research leading to new, improved medical products and processes. “The SR&ED Program still exists and is highly beneficial to many of our SMEs. There can be issues with the implementation of the program but the issues typically exist in regional pockets across the country. The Program is something that we engage with the federal government on a regular basis to ensure that it’s working to its highest capabilities for our members,” says Frenette. MEDEC is also heavily involved with provincial efforts on behalf of medical devices. MEDEC took part in a Medical Technology Working Group launched by the Ontario government in spring 2013, for example. The group was established to “provide policy advice to government and develop/ propose strategic directions and initiatives www.canadianmetalworking.com
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attractive place to manufacture medical technologies given our country’s excellent research and development capacity. One of Canada’s biggest challenges is increasing the adoption of medical technologies into the Canadian healthcare system, including those that are developed here. Removing barriers to adoption will contribute to grow Canada’s medical technology manufacturing sector,” says Frenette. Chad Plath, shop floor manager of D-M Precision Products, a CNC machine shop in Dunnville, Ontario, has a first-hand perspective about offshoring. “I don’t think this is an issue for the type of low-volume medical products we proVarious manual duce…D-M makes an array of parts for the relating to the medical technology (medtech) lathes and milling machines at the medical field, anything from phantoms to industry,” explains Frenette. Advanced Machine ultrasound devices and their components. In the fall of 2013, the Ontario governShop, Sunnybrook We also service some R&D work with compament also established an Ontario Health Research Institute nies or hospitals testing new devices,” says Innovation Council to recommend ways to Plath, who estimates 30 per cent of D-M’s support the adoption of new technologies in work last year was medical-related. the province’s health care system. Phantoms are objects built to be scanned by Pundits are confident that Canada’s medisuch medical devices as X-ray machines, CT, cal device manufacturing sector isn’t about MRI, Ultrasound, PET scanners, etc. to set up shop in low-cost offshore locales. Plath says his firm has “a creative outlook to “Certainly medical technologies are manufactured all over the world. However, Canada is an machining” which puts them in good stead to pick up new medical device manufacturing gigs in the future. That future will likely involve 3D printing technology. Also known as additive manufacturing, 3D printing has been used to make experimental medical implants but is far from a mainstream process at present. “We haven’t used this technology personally but have worked alongside it on past projects…we have discussed Carbide dead centers by [investing in 3D printing] in the past Booth #3909 but haven’t found a need from our cur30 millionths roundness standard. rent customer base at the present time 10 millionths by request. to pursue it,” notes Plath. ß Full or partial carbide tip ß Female carbide tips That might change however, if the ß Bullnose ß Draw-off nut concept of “bioprinting” catches on. ß Extended length ß Morse taper sizes 2-5 The latter is an extreme form of 3D ß Half centres ß Customs available printing “using living cells to print replacement tissues and organs,” states a paper published February, 2015 in Manufacturing Engineering magazine. It’s unclear how shops currently making medical parts from more traditional materials might benefit from this fledgling trend. Still, 3D Exclusive USA supplier printing in general is a niche worth P: 800-349-1044 paying close attention to as demand Morse Taper 3 & 4 centers in stock F: 860-349-1815 for medical devices grows along with Canada’s senior population.
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June 15-17, 2015 Edmonton EXPO Centre Halls F, G & H
Western Canada’s Largest Manufacturing Technology Event! To reserve your booth or register visit wmts.ca
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WMTS 2015 SET TO KICK OFF
IN EDMONTON W
SHOW INFO Schedule: Monday, June 15, 2015: 11 am – 7 pm Tuesday, June 16, 2015: 10 am – 6 pm Wednesday, June 17, 2015: 10 am – 4 pm Location: Edmonton EXPO Centre, Northlands Halls F, G, H 7515-118 Avenue Edmonton, AB T5B 4X4
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estern Canada is a hub both for economic expansion as well as manufacturing technology, and the Western Manufacturing Technology Show (WMTS) expects to bring the industry together. Scheduled for June 15-17, 2015, at the Edmonton EXPO Centre, the event will showcase a variety of world class machine tools, tooling and accessories, fabrication, design, automation, process control, and plant maintenance equipment all under one roof. Ever-evolving technology, unique economic challenges, and the heavy influence of the oil and gas industry present a diverse mix of circumstances in which WMTS hopes to address in a variety of different ways, included a keynote address, expert speakers on a number of different topics, panel discussions, educational sessions, and a job shop appreciation reception. Alberta’s manufacturing sector is the third largest in Canada, accounting for nearly 13 per cent of Canada’s total manufacturing shipments. WMTS is designed to zero in on where those industries are today and what’s ahead in the coming years, says Janine Saperson, Event Manager of SME, organizer of WMTS. WMTS aims to challenge the manufacturing industry to think outside the box by sharing his own insights and experiences. In addition to exhibits of the latest advances in metalworking technology, the event will feature an extensive educational component designed to help manufacturers grow, expand and compete on a global scale. Topics to be presented include: • The competitiveness and productivity in Alberta’s manufacturing sector – a special panel discussion
An Overview of the Build in Canada Innovation Program – Darlene Chuka, Public Works & Government Services Canada • Total Quality Management (TQM) Frameworks: Implementation and Sustainability – Brian (Baher) Amouzgar, Plantek Productivity Consulting Inc. • Productivity Through Welding Automation – Nick Drake, Gullco • Improving Quality and Productivity of Pressure Equipment Fabrication – Iulian Radu, PCL Industrial Constructors •
Opening day Monday June 15th will feature seminars throughout the day and a panel discussion beginning at 4:00PM. The day wraps with a 5:30PM Meet and Greet reception for everyone. The Tuesday schedule is just as informative, and begins with a keynote address by a representative from the Government of Alberta. WMTS has set aside the evening of Tuesday, June 16, 2015 for a night designed to give Job Shop owners and employees a chance interact outside of business hours. This reception will give guests the opportunity to source solutions for their manufacturing operations and network with peers over complimentary light hors d’oeuvres and beverages. The final day of WMTS includes several discussion groups and seminars to wrap up the show. WMTS, presented by the Society of Manufacturing Engineers, is at the Edmonton EXPO Centre (7515-118 Ave) from June 15 to 17, 2015. To learn more about WMTS, visit www.wmts.ca. www.canadianmetalworking.com
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All Fabrication Machinery J.V. — Booth 1215
Cosen Saws — Booth 231
All Fabrication Machinery will be featuring several different product lines including Marvel Manufacturing Company. The MSIW126D/DX Heavy-Duty, Dual Cylinder, Completely Integrated Ironworker offers 126 Ton Capacity, 15 H.P., 14” (D) 24-1/2” (DX) Throat Depth, 5 Work Stations and Simultaneous Dual Operation. www.allfabmachinery.com
The C-325NC fully programmable dual column bandsaw has a 12.8” round capacity. It can store quan-of up to 100 jobs including quan tity and length of cut. The saw is equipped with an inverter driven, 1¼” blade, a 5HP drive motor, and a user friendly SNC-100 programmable control for ease of operation. The machine features automatic Kerf compensation for parts longer than a single index. The hydraulic full stroke vises and double retracting vises allow full capacity movement for both machine and index vises with just the touch of a button. This is an ideal saw for production cutting. www.cosen.com
Elliott Matsuura Canada Inc. — Booth 205 Elliott will feature several machines, including the new MX-850, developed to meet maximum workpiece size of D850 x H450 mm, 500 kg. The MX-850 is compactly built yet ensures high rigidity and a sufficient machining area and workability. Three table types are available: standard: D500 mm, option: D700 mm or D500 mm + flat table. In addition to standard spindle of 12,000 min-1, optionally spindle of 20,000 min-1 for high speed machining or that of 15,000 min-1 (350 Nm) for heavy duty machining are available to cope with the wide range of customers’ requirements. The distance from the machine front to the table center is reduced to 500 mm to improve accessibility and ensure good operability for setup.
Expertech Distribution and Technologies Inc. — Booth 131 & 129 The Rhinobar is an exceptionally stable, heavy-duty, hydrodynamic bar feeder that supports and feeds bar stock through a lathe spindle for production machining operations. It is ideal for use with CNC lathes manufacturing automotive components, hydraulic cylinders, medical devices, firearm parts, motor shafts and a host of similar parts.
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Elliott will also be exhibiting several other machines including Nakamura-Tome NTRX 300, a heavy-duty machine with full twin spindles and a robust tool spindle. Featuring the new Smart X control from Nakamura using Windows 8 software. There are 2 models, 8 in chucks with 2.5 in bar capacity or a 10 in chuck with 3.15 bar capacity. This machine comes with a robust 25 HP tool spindle with 12,000 RPM and full 5-axis capabilities. 40 tool ATC is standard with 80 or 120 as options, Fanuc 31i-A5 5-axis control, unique built-in load/ unload device with built-in automation system. This machine boasts a very compact foot print. www.elliottmachinery.com
Exsys Tool Inc. — Booth 702 EPPINGER’s new line compact, high-transmission gearboxes are suited for a wide range of applications including machinery, automation and robotics. Planetary gearboxes offer modular design and combination of hardened and ground gears with high precision gear box components guaranteeing efficient performance, smooth running and high uptime. www.exsys-tool.com
Fabricating Machinery Solutions Inc. — Booth 113 Fabricating Machinery will highlight its line of Gerima Pneumatic Portable Beveling Tools. All Electric and Pneumatic portable beveling tools mill steel, stainless steel, aluminum or plastic and come with free starter insert cutters. Fabricating Machinery has opted to display samples and host managers from their main builders. They will be available to answer any technical questions. www.fmscanada.ca www.canadianmetalworking.com
15-05-01 1:49 PM
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Fein Canadian Power Tool Co. Ltd. — Booth 1321
Gullco International Ltd. — Booth 1115
FEIN’s new die grinders are suitable for all significant applications in the steel and stainless steel field. Thanks to their optimal shape and outstanding reach, grinding and polishing work can easily be carried out, even on difficult-to-reach spots. They feature impressive product benefits such as high power motors, metal dust protection for armature and electronics, easily accessible variable speed control, and FEIN ErgoGrip handle design for reduced fatigue. Extralong neck bearing provides a long reach into tight areas, and innovative collets protect from work piece damage. Made in Germany, the new product line consists of a range of 10 high performance models. www.fein.ca
The portable design of this heavy duty remote control oscillator makes it easy to handle and setup. This compact unit increases productivity and improves weld quality by providing precise automation of welding applications. Mounted on a KAT automation carriage, the oscillator imparts pendulum, tangential or step motion to the welding gun with adjustable stroke widths, speeds and dwell times. Also a wide range of weld patterns can be produced. This advanced oscillation package is designed to increase production and improve the quality of the weld produced in automatic mechanized welding operations by minimizing weld defects such as poor penetration, incomplete fusion, overlap and undercut. By combining welding gun oscillation movement with the precision controlled travel speed of the KAT carriage, up to 10 weld programs can be produced and stored. www.gullco.com
Horn USA Inc. — Booth 936
Machine Toolworks Inc. — Booth 705
HORN’s patented tangential milling system 406, with four-edged rhombic indexable milling inserts, are an extension of the 409 tangential milling system. The new 406 milling system is a smaller version of the existing 409 range and is designed for milling cutters with smaller cutting diameters. The milling shanks with DIN 1835-B holders offer cutting diameters of 16, 20, 25, 32 and 40 mm, from 2 to 6 effective cutting teeth. The precision-ground rhombic indexable inserts achieve a high level of precision and produce excellent surface finishes. The indexable inserts in carbide grade AS4B, a tough basic substrate, are coated with HORN’s wear resistant TiAlN. www.hornusa.com
The Mazak QTN 450-II M provides high-performance and value via its single setup turning and milling operations that allow for improved throughput. A key element of this machine is its 18” chuck mounted on a 50-hp, 2,000-rpm integrated spindle motor main turning spindle for heavy-duty metal removal. The spindle also serves as a C-axis that indexes at 0.0001-degree increments to accurately position parts for square facing and slotting cuts and precisely drilled holes. Additionally, the C-axis spindle is a full-function CNC controlled axis for milling. The machine utilizes a 12-position drum turret, and 10-hp, 4,000-rpm rotary tool spindle for milling, drilling, and tapping operations. www.machinetoolworks.com
Hougen Canada Inc. — Booth 112
OMAX Corp. — Booth 1121
The HMD905 magnetic drill is packed with power and features. The new model offers a major performance improvement to the mid-range line of Hougen magnetic drills. New features include: magnetic drill pilot light for low light or no light operation, Hougen two speed motor, improved arbor system, hex wrench holder, two stage magnet, and the Hougen operator safety system. The HMD905 has a hole capacity up to 41mm (1-5/8”) in diameter and 50m (2”) deep. Weighs only 15.9 kgs (35 lbs). www.hougen.com
OMAX will feature the precise cutting performance of the 60120 JetMachining Center. Visitors will see demonstrations of the machine paired with a 50 hp EnduroMAX Pump, A-Jet cutting head and Rotary Axis. Ideal for a wide range of production runs across various industry segments, such as oil and gas, aerospace, agriculture, and transportation, the bridge-style 60120 JetMachining Center can cut complex parts from a variety of materials, including advanced composcompos ites, exotic alloys, and traditional metals. www.omax.com
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15-05-01 3:28 PM
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OSG Canada LTD. — Booth 402
SCHUNK Intec Corp. — Booth 431
OSG Canada will feature the new EXOTAP A-Tap, an all-purpose tap series designed to simplify tool management and to excel in a wide variety of materials and applications. Achieving trouble-free chip evacuation with a spiral tap in blind holes is particularly challenging and is a main cause of headaches for many manufacturers. To resolve this problem and to improve the ejection of chips, OSG’s new A-Tap SFT has adopted a variable helix flute design, which encourages stable chip evacuation and reduces cutting forces. The helix angle changes from the chamfer, where chips are formed, to the flutes, where chips are evacuated. This unique geometry enables greater chip control that can help produce tightly compacted chips for easy ejection from the hole. www.osgtool.com
SCHUNK TENDO AVIATION combines the advantages of the SCHUNK TENDO hydraulic expansion technology and of a Weldon chuck. An integrated anti pull-out locking mechanism avoids slipping out of the tool and damages at the workpiece. Moreover, the cutting data can be partly increased. This toolholder is available for the interfaces HSK-A63 (ø 8mm, 10 mm, 12 mm, and 16mm; and HSK-A100 (ø 16 mm, 20 mm, and 25 mm). The clamping diameter can be reduced by using intermediate sleeves. In contrast to the ER collet chucks, or the heat shrinking mountings, TENDO AVIATION is resistant against dirt, and requires low-maintenance. In order to increase the service live of precision mountings, and to maintain maximum process stability during sensible processes, the precision mounting can be inspected, and if necessary optimised during a performance check of the SCHUNK Service. www.schunk.com
Thomas Skinner & Son Ltd. — Booth 505 Thomas Skinner will be exhibiting Okuma’s GENOS M560-V. The GENOS M560-V vertical machining center is rigid and versatile and has the ability to quickly and accurately cut everything from aluminum to titanium. Ideal for a variety of industries it’s standardly equipped with Okuma’s exclusive Thermo-Friendly Concept. Additionally the motor design coupled with Machining Navi technology produces less chatter yielding excellent surface finish and impressive metal removal rates. For work requiring a superior finish, the optional Super-NURBS functionality allows for high speed, high quality machining, and ultra-high feed rates resulting in a faster and smoother tool path. Optional Collision Avoidance and Machining Navi Intelligent Technologies are also available.
Haas Factory Outlet a division of Thomas Skinner & Son will feature an exciting line-up of Haas CNC machines and demonstrations. The UMC-750 high-speed universal machining centre: flexible, 5-axis machining offering reduced set-up times and increased accuracy for multi-sided and complex parts. The ST-45 big-bore lathe: versatile turning center offering more power, a larger chuck, and greater bar capacity – without having to step up to the next larger machine and a the VF-6 vertical machining centre. Both Mitutoyo and Sandvik Coromant will be part of the Thomas Skinner booth. A new face at the Thomas Skinner booth will be Tsugami/Rem Sales showcasing the BO-385 lathe: heavyweight 5-axis Swiss style machine. www.thomasskinner.com
Weingartner Maschinenbau GMBH — Booth 738
Yaskawa Motoman Canada Ltd. — Booth 1233
Weingärtner Maschinenbau will feature its Vario machines. These machines cover the milling and peeling of single and multi lobe components for the drilling and pump industry. They combine sidemilling and peeling operations to machine the so-called Rotors and Stator-cores for the mud-motors which are rotating the drilling bit. www.weingartner.com
The MH24 six-axis robot excels in assembly, dispensing, material handling, machine tending and packaging applications. It features a new curved upper arm that enhances its reach and allows a wider range of applications. This patented double yoke design also offers additional strength if the robot crashes due to a programming error. www.motoman.com
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DMG MORI — Booth 927 The NLX series is a line of high-rigidity, high-precision CNC lathes consisting of 9 models with 30 specification variations. Having a lineup from a two-axis lathe up to a lathe capable of 6-sided machining with the Spindle 2 and Y-axis, the NLX series provides the ideal solution for every customer’s machining requirements. The NLX machines are equipped with the BMT (Built-in Motor Turret) to minimize heat generation and vibration. www.dmgmori.com www.canadianmetalworking.com
15-05-01 1:52 PM
Find us at Booth #505
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Additive manufacturing experiences healthy growth in the medical device market. BY DOUG PICKLYK
I
A highly stable, yet porous titanium cranial implant. PHOTO COURTESY EOS
n mid-March of this year a formal gathering was held at the Orthopaedic Innovation Centre (OIC) located on the campus of Concordia Hospital in Winnipeg. The ceremony was staged to reveal the Federal Government’s $5 million in funding towards the development of a new Advanced Digital Manufacturing Hub (ADMH) being developed at the site. The $20 million initiative is being led by the not-for-profit OIC to bring together research and development with strategic partners over the next five years to develop and commercialize new applications using additive manufacturing technologies, not only in the medical device market but also opening up opportunities for other local industries including aerospace and more.
As indicated by the OIC, the medical and aerospace sectors represent markets with the highest potential to adopt and profit from additive manufacturing, since both industries require significant investments into R&D, rigorous quality controls, liability issues, specific materials, and the components require a long service life. “Additive manufacturing allows engineers and surgeons at OIC to design medical devices that will also allow for patient-specific solutions in ways that were not possible with conventional manufacturing methods,” said Martin Petrak, president and CEO of the OIC at the event.
The lattice structure of the implant supports the attachment and in-growth of bone tissue (osteointegration). PHOTO COURTESY NOVAX DMA
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www.canadianmetalworking.com
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2014 the OIC established its Precision Labs division, a climate-controlled metrology-focused laboratory using a Zeiss automated coordinate measuring machine (CMM) among other sophisticated material and mechanical testing technologies (Elliott Matsuura is a partner with this division). Establishing the Precision Labs was a precursor to launching its new Precision ADM division which will focus on additive and automated subtractive manufacturing for medical and aerospace. The division already has experience with a Stratasys 3D printer using production-grade thermoplastics, but in late April the Centre received delivery of two EOS M 290 machines for metal additive, and according to Snow following an installation it typically takes about two months of training and experience before the users will be making parts. While he admits it is somewhat unique to see this type of operation RENISHAW REVEALS EVO PROJECT on a hospital campus, the adoption In late November last year Renishaw unveiled a new of additive technology in the North additive manufacturing machine developed specifAmerican medical device market is ically for production manufacturing. Provisionally growing. “I would say probably one named EVO Project, it is the first additive system of our most active industry vertidesigned and engineered completely in-house by the cals is the medical space. We have company and incorporates Renishaw designed and engineered optics with a 500 W laser for enhanced precision and surface finish. The new machine is planned to be available in the second-half of 2015, and is designed to complement the company’s AM250 system, a product the company continues to develop. Renishaw recently relocated its Additive Manufacturing Products Division (AMPD) to a new 90,000 sq. ft. facility in Stone, Staffordshire, UK. “The generous new site also accommodates state of the art training facilities and lecture rooms, as well as a large research and development area to help us keep ahead of industry demands. We want the new site to be a hub for innovative ideas and exciting projects, around additive manufacturing,” noted Robin Weston, marketing manager of Renishaw’s Additive Manufacturing Products Division in the UK.
“The Advanced Digital Manufacturing Hub is a unique opportunity for OIC and its strategic partners to create a factory of the future.“ On hand at the event was Andrew Snow, senior vice president, EOS of North America, Inc., manufacturer of additive manufacturing systems for both metal and polymer materials and one of the OIC’s strategic partners. “We’ve been involved with the OIC close to five years, discussing the development of the innovation center and EOS supporting the centre with additive metal technology for qualification of implants,” says Snow. The OIC itself was established in 2010 at the Concordia Hip & Knee Institute to focus on collaborating with universities and industry to evaluate and develop medical devices that could be brought to market. In January
www.renishaw.com/evoproject
www.canadianmetalworking.com
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Left: Precision ADM, a division of the Orthopaedic Innovation Centre in Winnipeg, has taken delivery of two EOS M 290 metal laser sintering systems. Right: Dental dentures are another customized application where additive is a great fit. PHOTOS COURTESY EOS
a lot of activity surrounding it, with everything from tier one suppliers down to tier two suppliers who have adopted the technology and are creating 510k filings with the FDA [the certification required for medical devices in the U.S.]. So we’ve seen a lot of activity in this space.” One challenge to wider implementation of 3D printing in the medial field is in the approval process. “As certifications are achieved I think we’ll see much higher adoption of additive being produced for medical devices,” suggests Zach Simkin, president of Senvol, a U.S.-based additive manufacturing focused consulting firm.
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Free searchable database available to industry. If you’re looking into additive manufacturing and don’t know where to start, Senvol, a consulting firm focused on analyzing and quantifying the 3D printing business case for Fortune 500 companies, has made its comprehensive database of technologies available for free. “We initially developed the database for internal use, but as clients continued asking basic questions about the technology and consumables it became quickly apparent that this tool would be of great value to the whole industry,” says Zach Simkin, who together with business partner Annie Wang launched Senvol in late 2012 and made the database available this past January. The Senvol database lists over 350 machines, 500 materials and is searchable by 30 fields including machine build size, material type, material tensile strength and price range. “Whether you’re new to the industry and simply want to see what machines are on the market, or an advanced design engineer who wants to search for materials by specific mechanical properties, the Senvol Database provides the information that you need, all at your fingertips,” says Simkin. Senvol database of additive machines www.senvol.com and materials
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Renishaw, another supplier of metal additive technology, has years of experience in the UK with its own medical products division, including 3D printing in the dental market. According to Mark Kirby, Renishaw’s business manager for additive products in Canada, getting involved in additive manufacturing is about much more than just the machine. “It’s the processes and procedures around it,” says Kirby. “And what excites me here in Canada is our ability to provide that roadmap to people who are interested in doing it.” As far as metals available for additive processes are concerned, Snow insists there are plenty of bio-compatible materials to choose from that meet the needs of the medical space, listing off a series of metals for implants including titanium and cobalt chrome as wells as stainless steels for customized instrumentation. According to Snow, going back at least four years EOS customers in North America have been making implants, and to date he estimates there have been hundreds of thousands of implants placed into humans in North America. “Right now the most common part is an acetabular hip cup,” says Snow. It’s a part of a hip implant that adheres to the pelvis, providing a solid receptor for the ball of a joint replacement. Constructed out of titanium, by using the additive process it allows the ability to apply randomized porosity to the surface of the cup serving to promote osseointegration (a structural linkage where the human bone and the surface of the titanium-based implant meet). Other common products include cranial implants, toe implants, bone plates and spinal cages. Dental is also a strong market for additive metal. “The real beauty behind the utilization of the technology is you can customize use to the specification of the patient. I think we’re starting to see more adoption in the medical industry where people don’t just have a choice of say seven sizes for a knee implant, now the knee implant can be made specifically for that individual’s anatomy.” www.canadianmetalworking.com
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BY NATE HENDLEY
M
icro Precision Parts Manufacturing (MPPM) is a small but busy machine shop on bucolic Vancouver Island. The majority of the parts the company makes are medical related. “Last year and this year so far, we’re probably about 65–70 per cent [medical parts],” says owner/president Steve Cotton. MPPM has made an array of surgical and dental items, including brain biopsy tools and an aneurysm clamp. Much of their work centers on medical device prototypes. “We’re [currently] doing a very small tool used for surgical processes on children. It’s still in development stages…a lot of the projects we get are what I call finicky and really delicate parts,” says Cotton. Cotton has a background in the excruciatingly minute and complex world of making and repairing watches and clocks, which puts him in good form for doing tiny medical parts. 46 | MAY 2015
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“When you’re handling small parts, if you’re not used to them, the average machinist would probably struggle picking up a part that’s 60 thou, whereas with clock and watch parts you are picking up part sizes like that all day,” notes Cotton. In addition to minute size, tough medical part materials present an additional challenge. “We do lots of titanium. We’re machining titanium all the time, all the different grades…and stainless steel. The last three medical components were all done in stainless steel…medical grade stainless,” says Cotton. The company has also worked extensively with ceramic material. Cotton has considered buying new machine tools for medical parts, but is waiting to see how the training process works out for three potential new machinists. “We’ve discussed it…I probably wouldn’t be doing any expansion until I see how my [trainees] do…I’m not going to jump into an expansion or a new tool until I can see I have it running 80 per cent of the time,” he states. Fortunately for Cotton, if he does decide to purchase a new machine tool for the finicky, delicate world of medical parts, he has a wide selection to choose from. Of course, any machine tool he purchases will almost certainly be customized to suit the special needs of the medical market. His company currently relies on two well-seasoned OM-2A Office Mills and one OL-1 Office Lathe from Haas Automation of Oxnard, California for much of its work. MPPM also has a small benchtop prototyping four-axis mill and small CNC lathe from Sherline of Vista, California.
“WE DO LOTS OF TITANIUM. WE’RE MACHINING TITANIUM ALL THE TIME, ALL THE DIFFERENT GRADES…AND STAINLESS STEEL. THE LAST THREE MEDICAL COMPONENTS WERE ALL DONE IN STAINLESS STEEL…MEDICAL GRADE STAINLESS.” MPPM’s Haas mills are equipped with spindles capable of 30,000 rpm and 20-tool changer carousels. Both mills have sub-spindles that can hit 200,000 rpm for high speed machining and automatic laser tool setting systems from Renishaw for accuracy and repeatability. The OM-2A Office Mills offer x, y and z axis travels of 12, 10 and 12 inches, respectively, and a table 20 inches long by 10 inches wide. www.canadianmetalworking.com
15-05-01 12:02 PM
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The OL-1 lathe has x axis of 12 inches, z axis of eight inches, 6,000 rpm spindle and maximum cutting diameter of 4.95 inches (varies with turret). MPPM has added an axial sub-spindle to the C-axis equipped lathe capable of 60,000 rpm and a radial sub-spindle that can do 40,000 rpm. Cotton’s son, Matthew, does most of the programming for MPPM, utilizing a Mastercam CAM system from CNC Software of Tolland, Connecticut, for this purpose. The company likes to use carbide cutting tools when doing medical parts, primarily from two firms, Drill Bit City of Prospect Heights, IL and Harvey Tool of Rowley, MA. Should Cotton seek out a new machine tool, he might want to look at the Integrex i-150 multi-tasking machine from Mazak. “We developed the Integrex i-150 specifically for the medical industry,” says Ray Buxton, general manager of Mazak Canada in Cambridge, ON. “The Integrex machine is geared towards doing items like hip joints and knee replacement components. One of the criteria for the [medical parts] industry is to be able to put as many machine tools in as small a space as possible, because for the companies that do this type of work, part cycle times can be long. So, the more machines a shop can have running parts, the more it can increase producproduc tion. And several Integrex i-150s will take up very little space.” The Integrex i-150 has full fiveaxis machining capability, 5,000 rpm spindle speed, 36 tool capacity (72 tool optional) and offers a maximum machining diameter of 15.75 inches (400 mm), maximum work bar capacity of 2.6 inches (65 mm) and maximum 48 | MAY 2015
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machining length of 15.160 inches (385 mm). The Integrex i-150 can be ordered with SmoothX CNC, which should result in “a very significant improvement to the productivity of that particular machine in the medical industry,” says Buxton. Introduced at IMTS 2014 in Chicago, “the SmoothX control is geared pretty much for every aspect of the machine. SmoothX, in different forms when we roll it out, eventually will replace all of our controls, primarily on our high-end five-axis machines, because the major benefit is in five-axis contouring and ease of use in complex machining…we’ve seen increases in productivity anywhere from 10 to 15 per cent all the way up to a couple hundred per cent,” he explains. Mitcham Machine Tools of Toronto is distributing an updated Traub TNL18 sliding/ fixed headstock automatic lathe with seven linear axes. Made by Germany’s Index Group, this lathe is now available with an extra axis on the upper turret which expands its ability to handle the kind of challenging machining typical of the medical parts field. The TNL18-7 can be equipped with a B-axis tool carrier which is able to pivot 100 degrees. Complex parts and complicated contour elements that require additional operations such as milling, drilling, lateral drilling or threading can be machined at any angular position. The same company also produces a TNL32 lathe. “The Traub TNL18 and TNL32 lathes were designed with productivity and flexibility in mind. They are convertible from fixed headstock to sliding headstock, so parts that require Swiss-style machining can be processed. This makes possible a wide variety of applications, medical or otherwise,” says Randy Carlisle, proposal engineer at Index. www.canadianmetalworking.com
15-05-01 1:54 PM
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“We have these machines making bone screws, dental implants and anchors for steel and stabititanium bone stabi lizing rods.” While neither are new, the N2 and horN2-5XA CNC hor izontal machining centers from Makino speare “designed spe cifically for small medical components, including knee, hip, spine, dental and other implants,” says Mark Rentschler, marketing manager at Makino’s North headquarAmerican headquar ters in Mason, Ohio. “The four-axis N2 provides a cylindrical work envelope measuring 400 mm high by 400 mm in
DMG Mori ULTRASONIC 30 linear A 5-axis machine tool for preciprecision machining, its stable gantry design and compact footprint of 49.5 sq. ft. aims for component precision in the < 5 µm range and surface qualities of Ra < 0.1 µm. The drives, guides and spindle as well as the machine bed, control cabinet and all media are temperature-controlled. www.dmgmori.com
Okuma LT3000 EX A highly flexible twin spindle turning center in the 8-inch chuck class, the LT3000 EX is available in either two or three turret versions, with or withwith out Y axis. This multi-function horizontal twin-spindle machine integrates lathe and mill/drill functions on all turrets. Thirty two tool stations are available for either mill or lathe function for the twin-turret machine and 48 for the three-turret machine. www.okuma.com 50 | MAY 2015
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diameter. The five-axis N2-5XA accommodates 300 mm diameter workpieces that are up to 270 mm high. These work zone measurements are appropriately sized for the vast majority of components produced within the medical market, preventing medical manufacturers from over-investing in unnecessary work zone space and eliminating excess rapid movements that lead to in-cycle, non-cut time. Additionally, floor space is often at a premium in medical manufacturing facilities, so the N2 and N2-5XA’s appropriately sized work zone enables a highly productive solution that consumes less than 26 square feet of floor space,” he explains.
“THE REDUCTION OF MACHINE TOOL FOOTPRINTS IS IMPORTANT TO A NUMBER OF INDUSTRIES, BUT THIS IS ESPECIALLY TRUE FOR MEDICAL MANUFACTURERS.” The two machining centers have rigid base casting and “C-frame structure and three point leveling system. Together, these design elements provide exceptional rigidity for long hours of continuous machining in hard and exotic materials,” says Rentschler. Industry experts ponder the future of machine tools that make medical parts. “The reduction of machine tool footprints is important to a number of industries, but this is especially true for medical manufacturers. We expect that machine tools for the medical market will continue to become increasingly compact, while simultaneously packing in more advanced technologies for improved rigidity, power and speed. In the near-term, medical manufacturers are likely to begin introducing more automation into their manufacturing processes,” says Rentschler. “I think we will soon start to see more specialized machining processes such as 3D printers become more common for prototyping,” adds Carlisle. This is an area where Cotton agrees. “The 3D printing is interesting…the machines are getting better and better,” he states. More than anything, Cotton expects 3D printing to have an impact in terms of making models or prototypes of medical parts. “I think [3D printing] has its place, for sure. When you’re talking models, if they can put in a program and 3D print something…they can touch, feel and look at the size of it,” says Cotton. www.canadianmetalworking.com
15-05-01 1:55 PM
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7 VMC FEATURES FOR IMPROVING PRODUCTIVITY BY WILLIAM HOWARD
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here are tens of thousands of machine shops located across North America, and each year, on average, these companies purchase upwards of 6,500 vertical machining centers (VMCs) from more than 260 different machine builders. With this volume of purchasing and variety of machine options, it’s critical for machine shops to understand and carefully assess machine features that possess the greatest impact
1
on productivity and profitability. Highlighted below are seven recommended features to evaluate in a production vertical machining center:
1. METAL-CUTTING CAPABILITY The core competencies of any machine tool include its ability to cut metal, meet customer expectations and produce revenue. Therefore, one of the most important features to evaluate on any vertical machining center is the spindle. A productive VMC should have a robust spindle design with wide-ranging characteristics, including exceptional horsepower, superior torque and wide-ranging spindle speed. This level of spindle capability can enable companies to cut a wide variety of materials, reduce cycle times, lower production expense, shrink delivery times and increase profitability through lower part costs.
2. TOOLING SUPPORT AND CAPACITY A typical job-shop VMC is required to produce a variety of parts, perform quick part change-overs and check tool quality frequently. Unfortunately, not all VMCs are
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designed with these considerations in mind, resulting in short but frequent periods of machine downtime that can quickly add up to higher part costs, extended delivery times and significant losses in profitability. Manufacturers looking to avoid these issues should seek a VMC that offers generous tooling capacity, easy access to the tool magazine— while keeping the spindle cutting— and a design built to accommodate a wide variety of tool sizes and weight.
3. CHIP AND COOLANT MANAGEMENT With enhanced productivity also comes greater demand for chip and coolant removal. Additional production time generated from enhanced cutting capabilities can be diminished if the machine needs to be stopped frequently to clear chips from the work zone in order to continue production. Oftentimes, these issues stem from insufficient chip and coolant tank size, lack of coolant flow and inadequate coolant system delivery technologies (e.g., flood, part wash, through spindle). As such, manufacturers should seek features that help improve chip and coolant
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removal, such as wide machine casting openings, robust coolant systems with appropriate volume and pressure, chip conveyors to remove materials from the work zone and external lift-up chip conveyors to evacuate materials from the machine.
4. CONTROL SOFTWARE The control software of a VMC has the ability to facilitate or limit the flexibility of the machine in terms of data storage, coordinate systems, probing and networking. An effective machine control should offer the capabilities to fully support production and enhance ease of use for the operator. Ideal features and capabilities include ample part program storage, diverse program registry, numerous tool offset pairing, extensive work coordinate systems, tool length measurement and spindle probe capability as well as Ethernet, DNC, PCMCIA, USB drive and RS-232C features.
5. FIXTURING AND 4TH-AXIS POTENTIAL The ability to apply unique fixturing and multi-axis tables to a VMC can have a critical impact on setups and workflow. With flexible table space and work-holding opportunities, companies can run multiple setups on the same base plate, providing quick and direct transfer of parts. Similarly, the addition of a 4th-axis table can enable greater machining surface area and access to five-part faces, minimizing fixturing and handling for the highest level of machine utilization and overall productivity.
decoupling setup procedures from the machining process through automation. Decoupling requires a machine that is built to accommodate automated technologies and unattended processing as outlined by the other features mentioned above. In most machine shops, setup is the leading contributor to spindle non-cutting time. By introducing automation, such as pallet changers or robotic part-handling systems, companies can decouple setup time, build a work queue in front of the spindle, and dramatically increase spindle utilization, providing more productive hours and reduced costs.
operator is experiencing fatigue or discomfort in working with the machine, overall productivity is limited. An ideal vertical machining center provides operators comfortable ergonomics, including easy access to the machine worktable, exterior tool magazine and overhead crane access. Automation can also improve operator ergonomics through additional time and space to set up workpieces. William Howard is the vertical product line manager with Makino Inc.
7. OPERATOR-FRIENDLY ERGONOMICS The final key component to VMC productivity is the machine operator and how he or she interacts with the machine. No matter how extensive the capabilities of a machine, if the
6. AUTOMATION INTEGRATION The most efficient means for boosting the productivity of a VMC is www.canadianmetalworking.com
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TAP OR THREAD? TO
When it comes to medical parts, that is the question. BY NATE HENDLEY
“M
edical components span a wide range of applications from replacement hips to custom medical instruments and also a range of work materials, including stainless steels, 6Al4V titanium, and cobalt chromium,” notes Mark Ford, global product manager at Kennametal, in Latrobe, Pennsylvania. While they cover a wide range, medical components share certain characteristics: the materials used to make them are tough, the parts involved are often tiny and the specifications exacting. Then there’s the fact an improperly made medical component might cause infection or worse in a person. With that in mind, is it better to tap or thread mill medical parts? Cutting tool experts have some rather strong opinions on this matter. Nathan Preiss, product manager, threading/reaming at Ingersoll Cutting Tools in Rockford Illinois, for one, is eager to tout the advantages of thread milling. 54 | MAY 2015
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According to Preiss, “tapping exotic materials such as titanium can be difficult, especially when a tap is broken. There are two options when this occurs…wire EDM [Electrical discharge machining] or scrap the workpiece. Over a period of time, the cost of scrapping workpieces can add up quickly. There is no EDM’ing when the end user is thread milling and your scrap rate is reduced tremendously…thread milling is very versatile. As long as the solid carbide TM or indexable TM has the correct clearances to arc in and out of the workpiece, one tool can be used for a wide range of diameters. If end users are tapping…they will need a specific tap for each diameter they are producing…sometimes up to two or three different taps.” There are two more reasons why Preiss prefers thread milling, “horsepower. It takes one third less HP to thread mill than it does to tap…and surface finish. Thread milling generates a pristine thread finish whereas tapping tends to gall or tear the thread resulting in poor surface finishes.” www.canadianmetalworking.com
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For its part, tapping has certain strengths; it’s a faster process than thread milling and taps are generally cheaper than thread mills. What is more, “To learn programming for thread milling is a very steep learning curve. There isn’t a lot of wiggle room when you’re programming thread mills…if you happen to get a decimal at the wrong spot in your programming and you really wanted to program it at point five thou per tooth, and you end up at five thou per tooth, you really don’t even have time to reach for the emergency stop button. That tool is gone as soon as it hits the part if you haven’t got the numbers correct,” states Chris McDonald, round tool specialist for Sandvik Coromant’s Canadian operations, based in Mississauga, ON. For thread milling, “small [part] size is definitely a challenge, particularly when it’s coupled with difficult-to-machine materials. Many medical components require full threads close to the bottom of the hole… the tool design has to withstand significant cutting forces associated with a short chamfer length to be able cut full threads as close to the bottom of the hole as possible,” adds Ford.
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So, in summary is tapping or thread milling the better process for doing medical parts? “Hands down…thread milling. Thread milling requires less horsepower than a tap and will produce a high surface finish quickly and effectively,” says Preiss. “Thread milling, because you have more control over the process. You get better quality thread and more options for sizing the thread. If you break the thread mill, you clean out the hole and [use a new tool] to finish cutting the thread. With a tap, you must cut the tap out or burn it out. That’s very time consuming and requires that the part be removed and set up in another piece of equipment,” says Mike Trimble, product manager, Vargus USA, in Janesville, Wisconsin. “Thread milling by nature is the best option for medical components as it makes very small, manageable chips, can machine difficult alloys easily, can be adjusted for tolerance and wear and can be easily changed if the tool is broken. However, for deep threads, tapping is a better choice. There are many companies having good success with tapping medical components,” states Cullen Morrison, business development manager, threading at KOMET of America, Inc., in Schaumburg, Illinois.
“THREAD MILLING BY NATURE IS THE BEST OPTION FOR MEDICAL COMPONENTS AS IT MAKES VERY SMALL, MANAGEABLE CHIPS, CAN MACHINE DIFFICULT ALLOYS EASILY, CAN BE ADJUSTED FOR TOLERANCE AND WEAR AND CAN BE EASILY CHANGED IF THE TOOL IS BROKEN.” “When you get into very small threads for bone screws and medical implants, typically you are working with very, very difficult materials—nickel alloys, things of that nature. The machinability rating as compared to carbon steel might only be 10 per cent meaning it’s 10 times harder to machine. Consequently, sometimes thread milling is the only option. [The parts] might be a very small size and you need the strength of carbide to work in that material,” says McDonald. Having said all that, McDonald is not entirely committed to thread milling. “There are some definitive advantages to thread milling. Properly applied, I think it has a definite place in the machining pantheon. But I’m a linear guy. I like taps. From a process standpoint…properly applied, a tap with a straight-in and out process like a www.canadianmetalworking.com
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drill, will always be faster than a thread mill,” he concludes. As a rule of thumb, if you’re primarily concerned with flexibility and have a range of hole diameters, go with thread milling. If your primary concern is speed and your holes require few variations in size, tapping is the best bet. Cutting tool representatives were also asked what machine tools they recommend matching with their wares. “Any multi axis lathe or Swiss style machine with a ‘Y’ axis and live tooling can manufacture medical threads with thread mills. Also mills with simultaneous interpolation (X ,Y, Z all moving simultaneously),” says Trimble. “There are lots of good machines out there but something with a very accurate and stable spindle for rigid tapping using a Synchro chuck with through coolant. Also critical is the positioning capability of the machine. With a tap, it is critical that the drill and the tap line-up on exactly the same axis. If the tap lines up a few microns off of where the drilled hole is, that puts more load on one side of the tap than another and will lead to poor hole quality or tap failure,” says Morrison. In terms of workpiece materials, titanium “is both strong and lightweight, making it a very appealing metal for medical, as well as a broad range of other applications,” notes Mark Hatch product director at Emuge, based in West Boylston, Massachusetts. That said, titanium has a high elastic memory, which can make it a demanding material to work with. When tapping titanium, the material sometimes closes up around the tap, which leads to cutting edge wear. “Tapping titanium alloys such as Titanium 6AL4V is more difficult than tapping most alloyed materials, but certainly doable with appropriate taps
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“Emuge has two new designs of taps for cutting threads in titanium alloys. Through-hole applications use the Rekord C-Ti series tap. This tap has an 8-10° left hand spiral flute, designed for right hand cutting in through holes. This is combined with a 4-5 thread chamfer, in addition to face rake and relief characteristics for The Rekord C-Ti Tap (left) and Rekord D-Ti cutting the tough Tap (right) from Emuge alloy material. Blind-hole applications use the Rekord D-Ti. This tap has a 10-15° right hand spiral flute, designed for right hand threads. This is combined with a 2-3 thread chamfer, in addition to face rake and relief characteristics designed for cutting the tough alloy material,” says Mark Hatch, product director, at Emuge, Heritage Cutter based in West Boylston, Massachusetts. recently Sandvik Coromant, a Swedish firm with a U.S. division in introduced Fair Lawn, New Jersey, has expanded the diameter range Brubaker Tool’s Platinum series of its line of CoroMill Plura thread mills. of high“We brought out some very, very small diameters, down performance to 3 mm, 2.5 mm, 2 mm, and things of that nature, primartaps ily for those medical industries where they require very tiny
www.canadianmetalworking.com
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Cutting tool coatings take on a special and techniques. Best performance results consideration when it comes to medical will be realized with good taps and the use of modern tap holders and related equipment parts. Among other factors, the impact of the coating on the inside of a human body has to combined with a positive speed and feed be considered. control of the machine used for tapping,” Selecting a coating for Vargus thread explains Hatch. mills that do medical parts, “depends on the Mike McGee, technical sales engineer for materials being cut, coolants, and equipment taps and threading at Heritage Cutter in being used. TiAlN/TiCN, is usually our stanNoblesville, Indiana, agrees titanium can dard go-to grade,” says Trimble. be tricky to work with. “That’s why our taps Selecting coatings for KOMET taps, meanhave a lot of relief and a special flute conwhile, “depends greatly on the material and figuration. That does two things, the heat generated during the cutting process is reduced keeping the cutting edge cool and the special flute configuration helps with the chip formation,” he states. For Preiss, the simplest solution is to simply not use a tap in the first place. “I would utilize thread milling any time I need to generate an ID TECHNOLOGY thread form in titanium. Excellent Z-TAPS repeatability and it will not ‘grab’ TECHNOLOGY TECHNOLOGY TECHNOLOGY TECHNOLOGY due to the tool being smaller than the entering ID,” he says.
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threads,” says Chris McDonald, round tool specialist for Sandvik Coromant’s Canadian operations, based in Mississauga, ON. Likewise, Heritage Cutter of Noblesville, Indiana, recently introduced Brubaker Tool’s Platinum series of high-performance taps “for medical parts,” says Mike McGee, Heritage Cutter technical sales engineer. The Platinum series taps are made from a specially alloyed, premium, powder metal substrate and come in a variety of coatings and treatments.
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its hardness. Typically we see a type of titanium or a cobalt chrome material, both of which machine similarly from the view point of a threading tool…we typically use a geometry specific to high strength materials and good coating for high heat applications like a TiAlN or AlCrN based tool coating, but it is not uncommon to make something else for a specific request,” echoes Morrison. That being said, “In some instances, some materials tend to work best with no coating. Titanium and some of the super alloys would really prefer bare carbide. In a medical situation, we don’t want any transfer of that coating to the part that could lead to infec-
tion later on,” says McDonald. If they disagree on methods, cutting tool company representatives unanimously reiterate that tapping and thread milling medical parts can be a tricky process. Medical parts “tend to be produced in the most difficult of materials and have very, very small features which means to produce the same features you need a tool even smaller than the feature. So consequently, programming and tool selection and… tool path creation is very, very critical in any medical or dental implants. [Medical] produces its own host of difficulties,” says McDonald.
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Threadmaster Mini from Seco is a thread milling tool for small dimensions in hard materials from 45 to 60 HRc. The tools are available in thread dimensions from M1 x 0.25 to M2.5 x 0.45. Seco’s Threadmaster line-up includes a wide variety of thread mills and taps. The Threadmaster series is ideal for steel, stainless steel, cast iron and high temperature alloys. The line-up offers a large diameter shank for rigidity and 2x reach diameter. www.secotools.com
Walter USA Komet The KOMET JEL MGF XH Micro thread mill is designed for small diameter threads to be milled into hardened components. These thread mills serve double-duty with 90-degree countersinking taking place in the same operation. They are designed without internal coolant for increased stability, and feature TiAlN coating, making thread milling possible up to 1.5xD in the M1-M2.5 range. www.komet.com
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Walter has introduced a pair of high performance taps: the Walter Prototyp TC115, designed for blind-hole threads, and the TC216 for through-hole threads. The taps can handle a range of materials from steel to aluminium. The TC115 blind-hole tap has a 45-degree helix angle for thread depth of 3xD, and a C form chamfer. The TC216 through-hole tap features a spiral point for forward chip evacuation and thread depth of 3.5xD. Both have HSS-E bodies and are available with either TiN or vaporized coating. www.walter-tools.com
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MATERIALIZING VISIONS 15-05-01 12:43 PM
BUSINESS PROFILE: FABRICATING
FOCUSED ON EFFICIENCY Russel Metals, Winnipeg, MB BY DOUG PICKLYK
T
he success of any large organization relies on the efficient performance of every division. Russel Metals is among the largest metal distribution and processing companies in North America with 139 locations. And while the company is able to take advantage of its scale to provide value to customers, it’s the added touches that each of its localized service centres demonstrate that leads to its continuing growth. Headquartered in Mississauga, Ontario, Russel Metals has a long history in Canada tracing its roots back to Montreal in 1784. The company passed through many generations, and in the 1940s expanded beyond Montreal with its first locations in Winnipeg, Vancouver, Saint John, Windsor and Toronto. Growing through acquisition over the years, in 1984 Russel became part of the multi-disciplined conglomerate Federal Industries. A decade later, after deciding to focus exclusively on the metals business, the parent company took on the Russel Metals name. In 2014 the organization reported sales of $3.87 billion, up 21 per cent from 2013, marking five consecutive years of sales growth. Despite its size and scale, Russel Metals manages its businesses in a decentralized fashion, with local managers accountable for day-to-day operations, profitability and growth of their business. The service centers across the organization distribute primarily carbon steel products, along with stainless steel, aluminum and other spe-
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cialty products, offering plate, bars, sheet, pipe, tubing and structural steels offering various processing services as well. In Winnipeg the company operates three facilities, a main distribution hub which offers cut-to-length, distribution and some processing capabilities, a specialty metals branch and a more dedicated processing facility where the recent installation of a new combination cutting and drilling machine is adding another level of service to its local clients. “In recent years Russel service centers have continued to garner market share by adding this sophisticated processing equipment allowing us to add value for our www.canadianmetalworking.com
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customers, a strategy adopted and implemented several years ago at our Winnipeg facility,” notes Greg Ozog, branch manager of the Russel Metals Winnipeg processing facility. Within its 78,000 sq. ft. industrial space the shop has a line-up of flat and tube laser cutters, various press brakes and some welding capabilities. “We assist our customers in primary processing that is one step beyond raw material,” explains Ozog. But while the branch is largely focused on simple processing of metal parts, they’re also what he calls a contract processing center or a “build to print” organization. “We do a lot of program work, where we’ve worked with customers to develop certain projects and continue to do those year over year.” Russel has worked with clients from prototyping right through to production. Aside from operators on the shop floor, the team includes an engineering support group and CAD designers/programmers. For his part, Ozog, as branch manager, works with around 85 people, running a 24/7 operation. A mechanical engineer and MBA graduating from the University of Manitoba, prior to joining Russel he spent over 20 years working in the local aerospace industry where he was exposed to lean manufacturing concepts. It’s a philosophy that he’s brought with him, with the plant going through a lean transformation over the past six years. It’s an ongoing continuous improvement process that extends from the office and onto the shop floor. “We’ve worked with CME for a lot of the training,” says Ozog. Russel also part of a Lean Consortium, with some 12 companies, which he describes as a great way for sharing lean culture experiences and best practices. “It’s allowed us to become a lot more flexible, nimble and able to react. Our focus is always to make our customers successful through ease of transaction. The concepts of lean manufacturing and continuous improvement through technological advancement are not novel to any industry. The talented group of people that I am fortunate to work with every day implemented the concepts in extraordinary fashion and continue to search for improvement daily. Our team’s unrivaled commitment, which is driven by a desire to partner with our customers by adding value, creates a energetic culture that is refreshing and challenging to work in every day,” he says.
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Greg Ozog, branch manager of the Russel Metal’s Winnipeg facility, stands in front of the company’s new machine, a Kinetic K5000xmc multi-functional cutting and drilling machine.
By improving Russel’s own internal processes, it’s enabled the branch to maximize its lean practices to the benefit of its customers. During the process Russel has evolved and continues to improve to a more organized and streamlined operation leading to better inventory management and just-in-time delivery practices. He points to the lack of congestion on the shop floor as an example. Where the shop used to keep two weeks of work in progress on the floor, now only two days WIP is common. “It looks like we don’t have as much work, but actually we’re busier than we’ve been in the past.” Russle has also recently created room on the floor for a new Kinetic K5000 multi-functional cutter and drilling machine. The new machine will introduce plasma cutting and light machining to the operation. Russel had access to a plasma cutter at the other Winnipeg distribution facility, but it was an older machine that had come to the
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end of its life where it was beyond economical to repair. “We knew we had to replace it, and when we considered customer demands it led to us expanding what we could offer,” explains Ozog. The K5000 arrived in January and was commissioned in March under the supervision of the operations manager, Mark Somogyi and his maintenance team, and the shop is still in the early stages of the learning curve. “This machine allows Russel to do processes that were done on multiple machines before, so now we will reduce our material handling, improve our delivery lead times, and ultimately improve our cost competitiveness, because there’s constant pressure for cost reductions.” The new services include including bevel cuts, drilling holes, tapping holes, countersinking and more. “It’s exciting for us to see what it can do,” he says, noting that it’s already opened up the envelope of work opportunities the shop can now offer to clients. “We’ve quoted some interesting projects and should be executing them in the third quarter. These are thick parts with some heavy bevelling on them, so it will be interesting to figure out how we can best do those.” He’s also been impressed with how clean the machine operates, its chip removal and compact operating design, which is a good fit in the branch’s clean and lean culture. The remaining challenge is getting the operators experience with the new technology in order to overcome the learning curve. “It will take time to go through all of the different materials, thicknesses, different drill bits and cutting speeds, but that’s part of the process,” says Ozog, noting that it’s all in the manual, but a much more complex operation than traditional burning. We have great operators on our team and are investing in further training by sending them to machining courses in order to gain a broader context on those 64 | MAY 2015
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aspects of the technology. At the same time, the Russel team is introducing the new technology to its customers collectively evaluating the new possibilities and potential efficiencies in an effort to add value to the supply chain. Russel is excited about the opportunity to grow the business. “Winnipeg is a manufacturing hotbed,” says Ozog, noting that there is a lot of laser cutting capacity in the province and this further diversifies the RMI offering”. Despite the cyclical nature of the service center industry, Russel’s processing business remains steady, supporting numerous local industries including plenty of agricultural, transportation including transit buses and coaches, tractors, industrial materials serving the oil and gas industries among others. One thing you can’t prepare for are broad industry declines like the oil industry has experienced lately, and the residual industries it’s affected. Ozog credits Russel’s continuous improvement culture for keeping the processing component of the business focused and on track. “Our whole lean journey has enabled Russel to be more flexible and nimble throughout the various economic cycles focusing on further efficiencies and improved response times. We are more versatile allowing us to adapt and continuously improve in order to partner with our customers providing them a competitive advantage to grow their businesses.”
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FABRICATING & WELDING NEWS
CWA WELCOMES ONTARIO’S INVESTMENT IN APPRENTICESHIP PROGRAMS The Canadian Welding Association (CWA), part of the CWB Group (CWB), welcomes the announcement by the Government of Ontario of an additional $55 million in funding for three programs that support apprentices in the province. Welding is a high demand trade. The welding industry contributes over $5 billion to the Canadian economy and employs over 300,000 individuals, a large portion of which are part of the CWA, or involved with the CWB Group in some capacity. However, even with the CWB Group’s support, Canada faces a shortage
of highly trained welders, with the average age for the most skilled positions approaching 60. “Given the skills shortage in the welding industry, we welcome today’s announcement to provide additional support for students looking to enter the skilled trades,” said CWB Group president Doug Luciani. “We thank Minister Moridi for recognizing the importance of skilled trades to Ontario’s continued success and economic growth.” “A highly trained and skilled workforce will ensure that Ontario is able to meet its infrastructure
and manufacturing demands in the future,” added Dan Tadic, executive director of the Canadian Welding Association. Included in the funding announcement was $13 million in additional funding for The Pre-Apprenticeship Training Program, which targets groups that are underrepresented in the trades.
ESAB WELDING & CUTTING PRODUCTS RESTRUCTURES N.A. OPERATIONS
The restructuring plan will integrate ESAB and Victor regional operations and facilities, and will roll out in phases throughout this year and into 2016. “This consolidation will enable us to significantly improve the customer experience while leveraging our resources through the application of best practices,” said Clay Kiefaber, ESAB President and CEO. “While we regret the loss of associate positions, consolidating our operations will help improve our overall customer responsiveness, and deliver even better performance and future growth.” The following actions are planned: • ESAB’s Florence, South Carolina, manufacturing operations will be consolidated into the company’s Denton, Texas, and Hermosillo, Mexico, facilities. The Denton and 66 | MAY 2015
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Hermosillo facilities offer stateof-the-art manufacturing with precision CNC machining, automation, and made-to-order assembly, delivering an exceptional level of product quality. • As part of the reorganization, ESAB’s Denton, TX, facility will undergo a significant renovation and expansion that will support future growth and accommodate a number of ESAB’s North American functions. Upon completion, ESAB will consolidate the distribution operations from the Florence facility and from its Roanoke, Texas distribution facility into the Denton site. • Plasma cutting design engineering and R&D functions will be transitioned to ESAB’s West Lebanon, New Hampshire facility. The West Lebanon facility is a state-of-theart R&D center for ESAB’s plasma cutting technology business. • ESAB will maintain a limited commercial presence in Florence, SC (sales, marketing, marketing
communications, and capital goods sales) as well as personnel from order engineering (SIP), IT, and human resources. These functions will eventually be relocated to a new facility in Florence in early 2016. • The Florence facility is scheduled to be closed by March 31, 2016. • All associates at ESAB’s Roanoke, TX facility, located approximately 16 miles from the Denton plant, will transfer to the Denton facility. The Roanoke facility will close by February 29, 2016. No other ESAB locations will be affected. The restructuring plan builds upon the successful integration of the Victor and ESAB businesses. Victor was bought by ESAB in 2014. The combination of ESAB and Victor offers a comprehensive product portfolio that brings a broad array of solutions to the global welding and cutting industry. Today, the company employs more than 8,700 associates working in facilities across four continents. www.esab.ca www.canadianmetalworking.com
15-05-01 11:47 AM
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FABRICATING & WELDING NEWS
SAMCO MACHINERY APP PUTS COMPANY INFO AT FINGERTIPS More and more, customers are searching for information in new ways and Samco Machinery has developed a free Smartphone app to help customers find the information they need. The new application will allow access to company information, pictures, videos as well as detailed technical information. Once the Samco App is downloaded, it can be accessed at any time, without the need for online access. “We believe strongly in analytics,” says Steve Kagan, marketing specialist at Samco Machinery. “We have found that a significant percentage of our website traffic is coming from mobile devices. That number has grown and will likely continue to grow. Offering an app to this audience takes advantage of that growing opportunity.”
The Samco Machinery App, currently available for free in the Apple Store, contains five sections to provide any data the potential customer may need. “About Samco Machinery” contains company information, a product gallery and the corporate video. “Markets” contains spec sheets and machine videos relating to the various industries served by Samco. “RFQ” allows customers to submit a request for information. “Support” features a link to the company website as well as the names, titles and email addresses of support staff. “News” hosts the latest company news, media coverage, as well as providing up to date trade show information. To download the Samco Machinery App, visit www.itunes.apple.com.
TUBE BENDING MACHINE MANUFACTURER ESTABLISHES U.S. SUBSIDIARY
Schwarze-Robitec is expanding its capabilities into North America. The company has opened its own subsidiary in Michigan. Since 1
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April 2015, SchwarzeRobitec America has been implementing the entire sales and service for the high-quality Tube Cold Bending Machines Made in Germany. Regular customers and new customers from the USA, Canada and Mexico benefit from the customer-specific on-site advice, shorter delivery times for spare
parts and attractive conditions. General Manager (CTO) is Chris Dorgan, who brings along decades of experience in service for Schwarze-Robitec machines. He’s looking forward to his new duties. Schwarze-Robitec America Inc. sells Tube Cold Bending Machines ranging from 1/8” to 16” as well as bending tools and application-specific machine equipment. In addition to this, the team of experts implements spare parts procurement, machine maintenance as well as inspections and advises users with regard to modifications, major overhauls of existing machines and optimization of bending processes www.schwarze-robitec.com
www.canadianmetalworking.com
15-05-01 11:47 AM
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FABRICATING & WELDING NEWS
CWA AWARDS TWELVE DESERVING STUDENTS profession. Mr. Doria has been an The Joseph G. Doria Exemplary Twelve welding students from the active participant in the welding Student Award is a national award Western Quebec Career Centre industry for over 42 years and was established in 2013 to honour the were presented with awards by the President and CEO of Lincoln leadership of Mr. Doria as Chairman the Canadian Welding Association Foundation on March 24, 2015 valued of the CWB Group Board of Directors Electric Company of Canada. “This means so much to me,” said from 2009-2013 for the purposes at $2,500 each, and one student, Matthew Smith, recipient of the of promoting and encouraging the Matthew Smith, 17, was awarded the Joseph G. Doria Exemplary Student pursuit of a career in the welding Joseph G. Doria Exemplary Student Award. “I’m lost for Award valued at $3,000. words to be honest. I’m “It was a pleasure to very thankful to receive be part of the awards this award and I want presentation and meet to thank everyone who all of the hardworking helped me realize my full students,” said Joseph potential. I look forward Doria, retired President to a rewarding career in and CEO of Lincoln the welding profession.” Electric Company of Deborah Mates, Canada. “I’m honoured to Executive Director of the have an award presented CWA Foundation, said by the CWA Foundation both the secondary and that is named in my post-secondary awards honour. It was a humprograms are being well bling experience to be on Joseph Doria, retired President and CEO of Lincoln Electric Company of Canada, presents Matthew Smith with the Joseph G. Doria Exemplary received by students and hand during the award’s Student Award. Also pictured, Deborah Mates, Executive Director of the educators alike all across presentation to such a CWA Foundation and Shaun Thorson, CEO of Skills Canada. Canada. worthy student.”
Flexibility to process a wide variety of material types LVD STRIPPIT expands its fiber laser cutting systems product line with the introduction of the Lynx FL, a cost efficient fiber laser cutting system. Lynx offers users the ability to enter the world of fiber laser cutting with the flexibility to process a wide variety of material types and thicknesses all within a modest and cost effective budget. Powered by a high efficiency IPG (2 kW) fiber laser source, Lynx provides dynamic, accurate thin sheet processing of traditional sheet metal materials such as mild steel, stainless steel and aluminium with the added versatility to efficiently process metals such as copper and brass. www.lvdgroup.com
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Improved productivity in harder, more elastic materials Hougen Manufacturing has added a new electro-hydraulic hole puncher to their lineup of hole punching machines. The new HougenOgura model 75006PR features a lightweight single body concon struction allowing the operator to punch holes in steel in as little as 4 seconds. The new “Power Retractable” Punch system provides the user the option to power reverse the punch back out of hole if needed. This improves productivity in harder, more elastic materials which tend to grip the punch (not allowing it to auto return to the home position) after the hole is produced. www.hougen.com
Bend wire with very complex shapes BLM GROUP USA introduced the E-Flex, a highly versatile CNC bending machine for wire fabrication. The E-Flex is equipped with two clockwise and counter clockwise bending turrets ideal for three dimensional bending during one part operation, within the same machining cycle. Coil-fed wire is straightened in both a vertical and horizontal orientation to allow for various size and types of wire as well as automatic operation. The E-Flex is best suited to bend wire with very complex shapes and its flexibility allows for short runs as well as high-volume production. www.blmgroup.com www.canadianmetalworking.com
15-05-01 2:02 PM
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15-05-01 12:47 PM
Getting the most out of a humble press brake BY NESTOR GULA
M
any of the press brakes that were installed 30 to 40 years ago are still in operation. Besides regular maintenance and replacing the tooling, there is not much that can go wrong with a good press brake. For long part runs the introduction of a robotic arm to load and unload a machine is the modern solution to speed up production. “Press brake automation has evolved from just integrating a robot to a press brake,” says Scott Ottens, bending product manager for Amada. In the earliest forms of automation, operators had to manually move a robot through each step of the bending operation, record each move and ultimately build a program by teach mode. “As you can imagine, there are a lot of movements in the bending program so it could take hours to do a setup,” says Ottens. Recently many press brake manufacturers have introduced much more flexible automated robotic bending cells, where they have been able to program off-line and the integrated system takes care of not only loading
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and unloading workpieces, but it can also change the bending tools and the robotic grippers automatically to move from job to job without human interference. “The robot in front of a machine has been tried for 20 years and it can only go so far,” says Casey Schlachter national sales manager at MC Machinery Systems (Mitsubishi Corp.). “You can have a five- or six-axis robot which can mimic the movement of your hand from the elbow to the wrist, but it is costly and generally setup time takes a long time— up to three hours.” And traditionally, unless a company is processing several thousand identical parts, it would be difficult to justify upgrading an older press brake. “There are integrators that will do that, but the problem is that you are putting an automated system with a machine that was never intended to be used for bending with a robot,” says Ottens. “A lot of press brakes that are in automated bending cells have a larger stroke and open height. They make a wider bending envelope, because a robot, even though it might have six- or seven-axis www.canadianmetalworking.com
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“We wanted the loading and unloading to be as ergonomic as possible. With the Shear Genius, there is no more shaking out parts, no more loading the sheets by hand. We’ve also eliminated skeletons by taking advantage of common line cutting. We have very rectangular parts, so the right-angle shear was a perfect solution for us. We were able to nest more parts and to achieve better sheet utilization. With our older turret punch press, we were running about 7-8 minutes per sheet compared to the 3-1/2 - 4 minutes with the Prima Power SGe. That’s a 2-to-1 increase in productivity.”
Prima Power offers the industry’s widest selection of punch/shear and Shear Genius laser/punch combination machines. Prima Power has more than 20 years experience in right angle shear technology combined with proven field performance in nearly 2,000 applications throughout the world. The benefits of Shear Genius technology include:
Flexible automated fabrication Raw material savings Higher productivity/manufacturing efficiency Reduced manufacturing costs Faster return on investment Reduction/elimination of none value-added tasks
The Prima Power laser/punch combination provides punching, forming, tapping, marking, and laser cutting in an integrated machine tool for optimum quality and production speed.
Shear Brilliance
Laser Punch Jacob VandeHei Manufacturing Engineer Unison Comfort Technologies® Minneapolis, MN
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Prima Power Canada Ltd. Tel. 800 344 7143 • www.primapower.com
15-05-01 12:48 PM
An Amada EG6013 AR automated robotic bending cell in action. PHOTO COURTESY OF AMADA INC.
Robots are useful when manipulating very large and heavy parts in a bender sequence. PHOTO COURTESY OF AMADA INC.
of freedom, it is still difficult to get into places like a human can or to turn a part and remove it from the bending area, especially after the last form. You need a bender with a large envelope so that the robot can get parts in and out of the machine easier.” Instead of spending a great deal of money integrating a robot to an older press brake, a wiser investment might be to acquire a modern turnkey solution consisting of a robot and press brake that are meant to work together. “It is a more seamless integration for the end user,” says Tom Bailey, product manager for TRUMPF Inc. “That combined with offline programming software improvements have really got the setup into a manageable timeframe. “If you take a standard robot and a standard press brake and integrate them through a third-party integrator, it works all right if you have a very long run production requirements with piece counts that run into the thousands. We don’t see that too often in manufacturing in North America anymore.
We see 50 parts or less. You really need a system that you can set up and run in an hour or less to justify the short runs.” There is more to press brake automation than just a robot arm in front of a press brake. “A typical automated press brake consists of the following other components,” explains Paul LeTang, product manager of press brake/tooling at Bystronic Inc.: Buffer/storage–typically flat blanks are produced at a different rate than the press brake can consume them. In many cases, the problem is compounded by nesting different-shaped blanks in a single sheet to improve material utilization. Input station–blanks coming to the press brake need to be queued, located and oriented so the robot picks up the correct blank, the correct way and at the correct time.
“MANUFACTURERS SHOULD LOOK FOR PRECISION TOOLS THAT WILL ALLOW FOR INTERCHANGEABILITY OF TOOLS, ALLOWING DIFFERENT TOOLS PURCHASED AT DIFFERENT TIMES TO MATCH UP.” Gripper changing station–it’s not likely that one gripper will fit all the bend part shapes. This is mainly due to the fact that the part shape changes during processing. Referencing station–location of the blank in the gripper (end effector) must be verified to ensure consistency. Turnover station–when there are up and down bends in a single part, the gripper location usually needs to be relocated from one side of the blank to the other. Suction tables or even rotation suction tables are often used to aid in this task. Output station–bent part shapes exiting a system need to be either dropped in a basket, placed on a conveyor, nested in a single stack, or nested in multiple stacks depending on the application. Usually some sort of receiver is designed according to the parts addressed.
THE IMPORTANCE OF TOOLING While the press brake itself provides the force to bend the sheet metal, it is the precision tools that will determine the quality of the finished part. “Initial tooling investment on these types of systems is quite expensive, especially if you are going into the tool changing system where there are special tools that have other operations 74 | MAY 2015
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www.canadianmetalworking.com
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“Quality tools are heat treated on the needed for the automated tool changer to working surfaces. The heat treatment allows work,” says Ottens. the tools to perform like new for longer High quality press brake tools start with than non-heat-treated tools. Manufacturers high quality steel. “Manufacturers should should look for precision tools that will look for tools that are made from a CrMo allow for interchangeability of tools, allowsteel with a core hardness near 30 HRC,” ing different tools purchased at different suggests Robin Morgan of Wilson Tools. “If times to match up.” tools are made with lesser grades of steel, To cope with higher tolerances required or with lower core hardness, the tools will from parts, the tools themselves must deform over time. If tools have too high of a be made to extremely fine tolerances. core hardness, they could pose a safety issue “Generally what we are looking at is measurwhen they break if they are overloaded. SumpAd_CanMetal_6_14_Layout 1 5/5/14 4:51 PM Page 1
The V-Series Black press brake dies incorporate replaceable inserts to decrease friction and enable better performance on certain tough-tobend applications. PHOTO COURTESY OF WILSON TOOL INTERNATIONAL
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Quality tooling is manufactured from premium tool steel with the business end heat treated for extra durability PHOTO COURTESY OF MATE PRECISION TOOLING
ing tooling tolerances in 10,000’s of an inch, a pretty common tolerance would be plus or minus 4/10,000 of an inch or 2/10,000,” says Baily. No matter how hard the tool is, it will eventually wear out. “Yes, the tools do wear,” says Morgan. “The life of the tool depends on the manufacturer’s applications. Difficultto-bend materials, such as Domex will wear
“IN ORDER TO DETERMINE THE CONDITION OF THE TOOLING, MOST OFTEN, USERS WILL NEED TO VISUALLY INSPECT THE TOOLS, LOOKING FOR WEAR ON THE WORKING SURFACES.”
Precision-ground and deep-hardened for long tool life. PHOTO COURTESY OF BYSTRONICS
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tools much faster than mild steel.” He suggests that a great way to extend the life of tools is to keep the tools clean. “If material builds up on the surface of the tooling, it can damage the tool. This is very common when working with galvanized steel and aluminum.” Material build up also causes cross contamination when switching materials, notes Morgan, such as bending mild steel and then switching to stainless steel. “Nitrex coating solution is a great way to reduce the rate of material build up on dies. Wilson Tool cleanrecommends clean ing the tools with a Scotch-Bright scouring pad and oil.” Depending on how the tool is used, uneven
wear can also affect part quality. “If the tool is being used on a particular part repetitively, the area where the bend is made will get worn and the area where the tool is not being used will not get worn,” notes Frank Baeumler, vice president at Mate Precision Tooling. “So the tool itself might have a portion in the middle which is highly used and portions on the extreme ends which are rarely used, and therefore you get a change in the tool. In those cases, when you have a worn tool it will show up in the bent parts and the quality of the parts will go down.” Visual inspection of tools can pick up any problems with the tooling. “In order to determine the condition of the tooling, most often, users will need to visually inspect the tools, looking for wear on the working surfaces. If the tools do not line up in the brake, it might be a sign that the tool is worn out or has been over loaded,” says Morgan. Where a worn tool will show up immediately will be in the bent part. “In reality it is the parts produced by the press brake that will determine whether the tooling is working or not,” says Baeumler. “If the bend is not achieving the 90-degree bend that I am hoping for, for example, you have to examine why the tool is not allowing the material to bend to 90 degrees. It will be a tool issue and you will have to replace the tool.” Press brake operators have various methods of checking the health of their tools. “You could inspect the tools off-line and discover something about their current status,” says LeTang. “Calculating this back to part tolerance will be a challenge. The best way to verify tooling condition is to make a full-length bend, rotate just the punch end-to-end then make another bend. Repeat this process with just the die. If all parts are identical your tools are likely good to go.” www.canadianmetalworking.com
15-05-01 11:40 AM
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Amada
Bystronic
Amada’s HG 1003 press brake is equipped with an Automatic Tool Changer (ATC) allowallowing for faster cycle times and more parts per hour. The capacity of the ATC allows for 18 magazines for dies and 15 for punches. Each magazine can accommodate tool lengths up to 31.5 inches. The HG series features a Dual Servo Power drive system tengineered to increase approach, bend and return speeds (approach: 8.7 inches per second, bend: .79 inches per second, return: .98 inches per second). www.amada.com
An enhanced version of Bystronic’s Xpert press brake incorporates a high speed ram positioning system and the company’s new Fast Bend+ safety system for reduced bending cycle times. The high-speed ram positioning system is capable of reducing bend cycle times by 15 to 35 per cent, in reaching approach speeds of up to 600 inches per minute and bending speeds up to 47 inches per minute. Bystronic has also introduced its new XPT and RF-A Series tooling. XPT tooling is compatible with existing Wila NSCL ll type hydraulic clamping and tooling systems. The Bystronic RF-A tooling maintains high quality features with the added self-seatbenefit of increased open height. Features include self-seat ing and segmented front-loading tooling technology, precision ground and hardened surfaces and the RF-A hydrauupper and lower hydrau lic clamping systems. Bystronic offers RF-A as an option on all new Bystronic press brakes. www.bystronic.com
LVD The ToolCell 135/30 from LVD, featured at FABTECH in Atlanta last fall, is designed to maximize bending productivity with an integrated storage of tooling housed within the machine. While an operator is preparing parts for the next job, the machine automatically unloads the previous tool setup and loads the next setup. ToolCell features LVD’s Easy-Form Laser in-process angle monitoring and correction technology which uses measurement at the front and back of the die to deterdeter mine the exact value of the angle of the workpiece. The sensing devices transmit information to the CNC control unit, which recalculates the correct depth adjustment in process to obtain the correct angle. www.lvdgroup.com
Prima Power The PXseries is built in three sizes based on a modular product structure. The solid PXarchitecture is based on a FEM optimized welded main frame based on the patented Hexa-C structural concept. The working principle of PX brakes is based on electronic synchronized hydraulic drives that allow propro grammable bending speed as well as off-center and conic bending. Short set-up times for correct angles and ease of use are advantages. The PX concept guarantees high accuracy with a high degree of reliability. www.primapower.com 78 | MAY 2015
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TRUMPF The new TruBend Series 3000 from TRUMPF feature a closed-frame design for improved rigidity. The backgauges can move across the entire length of the machine Third-party tools can be used without an adapter and users can select from different clamping options: manual clamping comes standard, with the upper and lower tools secured with Allen screws; the quick clamp option secures the upper tools with a lever, and the automatic hydraulic clamping is the fastest choice. Each option automatically centers the tools, which are inserted vertically. www.us.trumpf.com
Salvagnini The B3 press-brake series features an innovative operating principle, direct drive transmission, KERS energy recovery, AMS angle measurement, Salvagnini SiX numerical control, and PressStudio programprogram ming console. These features allow for higher productivity, improved precision and safety standards, limiting consumption. www.salvagnini.com
www.canadianmetalworking.com
15-05-01 3:27 PM
BECOME A BETTER WELDER THE CWB INSTITUTE For over 65 years the Canadian Welding Bureau has been training and qualifying Canadian welders. The CWB Institute provides range of newly developed online courses to help welders, inspectors and supervisors at all levels get the education they need, where and when it’s required. Scan here for more information on CWBi Training cwbgroup.org | 1.800.844.6790
HELP OUR WELDING REPOSITORY
IT’S UP TO US!
The CWA Foundation is facilitating an online donation repository designed to aid the needs of both industry and welding programs in secondary schools across Canada. A repository has been created where industry can donate welding equipment and materials. Donated items will be placed on the CWA Foundation donation site where educators have the opportunity to make selections that improve the quality and delivery of secondary school welding programs. Charitable Registration Number: 83634 0539 RR0001
Scan here to see the repository cwa-foundation.org | 1.800.844.6790
CERTIFICATION QUALITY THE CWB QUALITY MARK If you are looking for a partner with integrity, knowledge and the trust of the industry then look no further than the CWB Group. The CWB Quality Mark is now available for FREE to existing CWB Clients. Scan here to sign up for the quality mark program cwbquality.org | 1.800.844.6790
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15-05-01 1:13 PM
WELDING ALL IMAGES COURTESY OF LINCOLN ELECTRIC
AUTOMATION
TAKES
HOLD
In pipeline work, stick welding still remains relevant BY NESTOR GULA
W
ith automation creeping into most industries, it is no wonder that automated processes will be present in pipe welding. Unlike most welding automation cells, automation for pipeline welding does not take the shape of a robotic arm moving automaaround a pipe. Pipe welding automa tion consists of a frame with tracks constructed around or adjacent to the joint and a “bug” that moves along the track housing the nozzle that creates the weld. Setting up the frame and track might seem like a long and laborious process, but it can be quick. “Three times autoquicker using flux cored auto mated welding with a manual root pass,” says Gordon Eadie, global pipeline segment manager for ESAB. “The setup is generally done off-line and the welders only come when it is time to weld. Another team, called the spacers, will set up the joint prior to the welders arriving. All the welders do is weld—nothing else,” he says, explaining how they move from one joint to another and weld, they don’t wire brush or 80 | MAY 2015
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grind. Automated pipe welding uses wire feed welding and avoids the starts and stops that are inevitable with stick welding when the welder must place a fresh stick in the holder. “A bug automated system will outperform a rig owner with a stick welder. They are almost incomparable,” says Joe Ryan, marketing segment manager for Miller Electric Mfg. Co. “On a small diameter pipe, the stick will be faster moving from joint to joint because you do not have to turn down all the automated bug system and then reset it on the next joint,” adds Tyler Edwards, pipeline technical sales specialist at Miller Electric Mfg. Co. “You can still achieve the same less than one per cent repair rate with either system. Between the two there is not a whole lot of quality difference.” In an automatic system, there are just two starts and stops for each joint of the pipe, because there are two welding bugs going up each side of the pipe. “A welding bug can easily achieve 60-inches of welding without stopping whereas a stick welder can have a start and stop every six inches. Any start stop in a welding process has a potential for a defect,” says Eadie. Using automated welding for pipes pays off when the size of the pipe being welded, or the length of pipe to be welded, justifies the expense of an automated system. “With manual welding you require an internal line up clamp, and then rigs and welders for the www.canadianmetalworking.com
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first pass (root bead) and more welding rigs for the second pass (hot pass) and the final fill and cap passes,” says Bruce Clark, director of marketing and export sales with Lincoln Electric Company of Canada. “The number of rigs varies with the diameter of the pipe and how quick you want the line finished. With automatic welders (bugs) you first require a shelter (dog house) to protect the MIG welding arcs from wind that could blow their shielding gas away from the puddle. Next there is a very sophisticated internal line up clamp that also guides two or more internal welding heads laying a root bead on the inside of a machined joint, or alternatively from the outside on to a backing bar that is part of the internal line up clamp. The pipe requires a precision machined surface for this kind of welding. “Once the root bead is done it is a simple matter of filling and capping the joint with as many external heads as needed for the diameter and thickness of the pipe. Automatic systems are usually leased for the job along with a crew of specially trained technicians that keep everything running smoothly.” Although stick welding is seen as a basic welding process, in order to weld pipe to code great skill is needed. “Stick welding pipe is still considered the highest skill set,” says Clark. “The variables the welder has to face are numerous, pipe joints that are out of round, changes in the gap between the two pipes, varying land thicknesses, high low, weather, terrain, the list goes on.” Stick welding might require more skills but the automatic process is not foolproof. “The way these welding bugs are designed is that a welding engineer will design the welding profile and that will be stored in the bug,” says Eadie. “All the welders will do is position the torch in the start position and press start and in effect just feed it with any changes that have to be made. There is a different skill set involved with setting up the bug.” The skill set is different but not unequal. An operator of an automated bug system needs to know the welding process to spot any errors. “You still have to understand how to set up the bug, how to place the bug, and how to run the controller,” says Ryan. www.canadianmetalworking.com
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“Whereas in the stick you need to know the torch angle, electrode angle, there is a lot of eye-hand coordination involved in that but there is a lot less equipment set up. You just set the heat and go. If you are lucky you have a helper that can adjust your heat as you are welding around the pipe.” There is a lot more equipment involved with automatic pipeline welding and you will need to supply the wire welders with gas and qualified welders are still needed on site. “You still need to have a welder controlling the automated welding systems,” said Edwards. “The welder, or whoever is operating the bug, still needs to know exactly what they are looking for.” The great thing about stick welding is that it is the most basic form of welding. It requires the least amount of equipment and this is a great advantage when welding in remote locations. “Stick welding requires the minimum amount of complex equipment. There is a welding power source—whether it is an engine driven one or an electrical one. The automated bug is mechanically and electrically complex and it requires additional equipment as well as the welding equipment,” says Eadie. The type of weldweld ing done will also determine if stick or an automated system is the right process. “When the length of pipe being laid continuously is too short to warrant all of the equipment needed to do the job, or when the diameter is too small companies turn to rig welders,” says Clark. While a lot of the major pipeline contractors are shifting to autoauto matic welding for their main-line welding, “they will use rig owners to do repair work, tie-ins or bridge crossings and things of that nature,” says Ryan. “You will never get away from stick welding anytime you are welding outdoors because of location. Whenever there is a repair that needs to be ground out and rewelded, that would be primarily done by a rig owner with a stick.” MAY 2015 | 81
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AUTOMATING IN THE
FIELD BY NICK DRAKE
K
eystone XL, Line 9 Reversal and West to East Pipeline are three major pipeline projects Canada will continue to pursue over the next few years as the glut of oil production in the Mideast and U.S. force Canadian oil exports away from their tradition markets. With oil production landlocked in Alberta, the necessity for transport through pipelines or rail car has become a priority for the energy sector as well as Ottawa, as lower oil prices mean less tax revenue. 82 | MAY 2015
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With the rush to get these proposals approved and start laying the foundation comes a huge focus on how these pipelines will actually be fabricated. Canada will continue to experience a decline in its skilled labor force over the next decade, and as such improved productivity and quality of work will be key in completing these projects on-time. With pipelines there is a huge amount of pre-fabrication being done to minimize the amount of work required in the field. Large column and boom systems designed to produce high-quality submerged arc welds (welds completed using flux were the arc is hidden from view) at a very high speed have made the pipe section fabrication very efficient. The pipe bevels can also be made in the shop and help to improve fit up during the final stages of the fabricafabrica tion process when the field welding must be completed. Until recently, this is where the automation of the fabrication process would take a back seat. The automated welding industry has been focused on developing a solution capable of withstanding the rigorous schedule the final phases of pipeline manufacturing put on the welder. Manual welding of a standard 24-inch diameter pipe with ½-inch wall thickness can take over 3-1/2 hours to complete, and this same process has a generally expected weld failure rate of upwards of 20 per cent. With advancements in automated welding technology, such as the Pipe KAT automate pipe welding carriage manufacmanufac tured by Gullco, this time can be cut down to under 1-1/2 hours per joint. Further time and money is saved by reducing rework as a result of the consistent weld quality propro duced by this type of welding carriage. An operator is able to preset the welding parameters, and from there the main focus is steering the arc and compensating for any irregular fit up in the pipe which is inherent in the production process. By using an automated welding carriage the welder is able to maximize his own efficiency completing more welds in a shorter period of time, as well as eliminate stops and starts (the source of most weld failures) and reduce the fatigue which is a natural part of the process. Pipeline welding can be very strenuous and often requires welders to be on their back or contorted to finish the final portion of the weld on the underside of the pipe. For pipeline manufacturers and companies bidding on these projects automation www.canadianmetalworking.com
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means competitive pricing. By improving the efficiency of the welders, increasing productivity and quality, a manufacturer is able to compensate for unforeseen instances which compromise deadlines that are normally set with very aggressive timelines. An overlooked benefit of welding automation is improved consumable consumption. With manual processes such as stick welding, the welding may use 3/4 of the welding electrode before it is exchanged for a new one, and the process itself leads to over welding. If even a Âź-inch of extra welding is produced per pass, when multiplied by the entire length of the pipeline this can result in hundreds of feet of extra electrode. With automation the operator is able to precisely control the weld width and speed to hundredths of an inch, and as a result the consistency of each weld and the deposition is compara-
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ble from each pass and each joint. The future of the oil and gas storage industry in Canada will depend on the success or failure of these projects, and while environmental concerns have their part to play the overall success will depend on the contractors ability to maintain budget and timeline efficiencies to see the completion of the pipeline in time to keep Canadian oil relevant on a global scale. Welding automation, while not a new technology, has only recently seen a huge surge in the oil regulaand gas sector as regula tions have long kept these technologies from being a viable option. As we move forward with our thinking more projects will see automation incorporated into the budgetary and implementation phases. Nick Drake is marketing manager with Gullco International.
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Amada Miyachi America Inc. “The CO2 is still a very popular marker, it’s good for marking on plastics. It doesn’t do as much with metals, though, primarily because that wavelength is very reflective for metals.” Marking on metal is achieved through different processes. It is done through engraving, which removes material; annealing, which basically uses heat to change the colour, allowing blue, red, yellow and black marks; then there is ablation, which takes a layer of material off like with anodized aluminum, it takes off the anodized layer to reveal a different layer underneath. A laser marking specialist can help determine the correct parameters for each industry application. Although some processes, like engraving, are generally used in all industries, “it really depends on what the part is being used for,” says Thomas Burdel, TruMark national sales manager for TRUMPF. “If it is just a tag or nameplate, you use speed engraving and go very quickly. If it’s an automotive part, they would most of the time use annealing, like when they do gears, also for parts like bearings.” One thing is certain, industry is demanding more and more part traceability. “Direct part marking has been up and coming for a while. Marking goes into almost every industry. Companies want to mark parts, either with a company logo, a product serial number, or whatever they want on there,” explains Boyle. One of the challenges, however, is dealing with stringent requirements from various industries. In the medical industry, parts must have a damage-free mark. Laser markers have a fairly broad range of capabilities to accommodate this requirement. You can use the same marker to make marks with varying degrees of depth. “For example, when manufacturing a medical device, you want your mark to have virtually no depth, because there is concern bacteria could get into and grow in the mark,” explains Michelle Avila, public relations manager for Hypertherm. “On the extreme flip side, if you are a manufacturer of high wear automotive parts, you’d likely want to create a pretty deep mark.” When it comes to medical device manufacturing, those parts require corrosion-free marks as well, explains Wesley Reeves, regional sales manager, marking and micro, for ROFIN-BAASEL Canada, Ltd. “[Rofin markers] can mark a stainless steel part with known parameter settings such that it won’t corrode later on in its lifespan.” www.canadianmetalworking.com
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The medical industry is an extremely important proponent of direct part marking. Burdel explains that the medical industry is probably one of TRUMPF’s largest customer segments for laser marking systems. “Most of the time it’s for traceability. They use data matrix to trace the part. The FDA has certain requirements, each part, even in the assembly, has to be identifiable since the new regulations came out,” he explains. The same is true for Canada. New Unique Device Identifier (UDI) requirements are forcing many industries, specifically the medical industry, to adapt to part identification through laser marking. When it comes to part marking in the aerospace industry, there are strict requirements just like machining tight tolerances. Reeves explains that when it comes to marking on aircraft components, they want very little damage, very little recast in the part because that could cause microfractures and part failure. Direct part marking via laser marking, “is useful for inventory control and to ensure the customer receives the correct part,” adds Avila. It allows lifetime traceability.
LASER TECHNOLOGY OVERCOMES MEDICAL DEVICE MARKING CHALLENGES In June 2014, Health Canada announced its plans to implement a national Unique Device Identification (UDI) system based on the International Medical Device Regulators Forum (IMDRF) guidelines. The regulator plans to develop a Canadian UDI system within the Laser marked next two years. Once a UDI regulaarterial clamp with 2D code. tion is published, medical devices PHOTO: FOBA LASER. licensed for sale in Canada will need to comply. Innovative laser technology has become the preferred solution for marking medical devices as it enables medical device manufacturers to overcome marking challenges. Lasers are used in different ways for processing medical devices. Laser marking machines with integrated vision systems emerged as an effective means of identifying medical components, e.g. for marking UDI compliant codes. Particularly zero-defect laser marking plays an increasingly important role in manufacturing medical devices. FOBA Laser offers a unique laser marking solution. The key to meeting Laser marked the identification requirements while bone screw. PHOTO: FOBA LASER reducing production costs, minimizing waste and improving product quality is a laser marking system combined with the software concept HELP (Holistic Enhanced Laser Process). Apart from the marking of the medical product itself, HELP offers pre-mark verification prior to marking and post-mark validation right after marking. Particularly important for medical device manufacturers: During the unique post-mark verification process, the content of 1D and 2D codes (e.g. Datamatrix [ECC200] GS1 compliant and graded) can be directly read which is indispensable for compliance with the new Unique Device Identifier. www.fobalaser.com
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Rofin The picosecond laser PowerLine Pico is available as a laser source as well as a laser marker. The laser is dedicated to laser marking and engraving as well as thin film ablation and structuring. The PowerLine Pico can be easily integrated in customer specific systems due to all-in-one design. Via TCP/IP, USB as well as RSS 422 interfaces the laser can be quickly and easily operated. ROFIN offers the PowerLine Pico in wavelengths of 1064 nm, 532 nm and 355 nm. Short pulsed lasers by ROFIN feature a pulse length of some 100 picoseconds to a few nanoseconds. They offer much higher pulse peak power at a given average power. This results in better ablation quality, less surface roughness and enhanced precision of selective layer ablation. Furthermore, shorter pulses significantly reduce thermal penetration depth of delicate ablation processes, like marking of semiconductors or certain metals. The exceptionally high pulse frequency provides high throughput and allows for maximum pulse overlap, e.g. structuring of thin films in solar cell manufacturing. www.rofin.com
Amada Miyachi Amada Miyachi’s LMWS Laser Marking Workstation is specifically designed for benchtop operation. The LMWS features a fresh, industrial design, with improved functionality, narrow width for lean manufacturing, and CDRH Class 1 safety. The versatile and easily configurable LMWS is ideal for marking metals, ceramics, and many plastics, and also has cutting, drilling, and welding capabilities. Requiring only minimal workspace, the updated unit is perfect for low volume production and research and development environments in the automotive, medical, aerospace, electronic components, and battery industries. Standard LMWS models are powered by Miyachi’s industrially proven 10-50 watt fiber laser markers. Using the same graphic user interface and lasers as the fiber marker series provides the same platform from prototype testing to high-volume manufacturing. The manual door opens vertically for easy 180 degree access to parts and tooling, and the large viewing window allows for visual process monitoring. Inside the enclosure, the base model has a motorized Z that can be jogged to location by a rotary knob on the front panel. The Z axis can be adjusted to keep the focus on the part height. A rotary axis can also be added for easy marking around cylindrical parts. The LMWS is equipped with F 100, 160 and 254 lenses for marking various parts and sizes. The fume extraction port with flexible tubing makes adjustment to different parts easy and fast. www.amadamiyachi.com
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No matter what the industry or material, laser marking specialists are able to provide state-of-the-art laser marking systems designed with the customer in mind. The systems can either be integrated into the production line or as stand-alone models with class 1 enclosures. “We can take on whatever the requirements are from the customer and integrate that [into the laser marking system],” says Reeves. New features, technical enhancements, and unique accessories can make laser marking easy and highly efficient. Safety is a number one priority, and when it comes to laser marking, there are several additional features that can help. Boyle says that generally, customers want to include a fume extractor. In many cases marking will remove the surface and creates microscopic dust, whether it be stainless steel or likewise, and if you are working with a variety of materials there can be a lot of fumes coming off. “It is good to have it extracted in a safe environment and filtered out before putting it into the general environment,” he says. Another feature that customers are often inquiring about is design overlay. Manufacturers have found different ways to incorporate this into their systems. Rofin uses a vision system to present an image on the design screen, so the customer can see this in real time and can overlay the mark on objects where he wants on the part. TRUMPF uses a pilot laser to produce a simulated image of the marking in visible, safe red light. This makes it easy to position the workpiece in the marking area. Either way, the customer is able to see in real-time just how the mark is going to look on the part. Quality is another concern. Adding a barcode reader, either handheld or integrated into a system, enables operators to verify their part mark. Boyle explains, “A 2D barcode reader is a standard accessory that [Amada Miyachi] offers. More infrequently, but still available as an accessory, is a barcode verifier, a barcode reader will verify that it’s there, a barcode verifier will tell you how good that mark is based on a couple of different standards like ISO and AIM.” When it comes to efficiency, laser markers have come a long way. Most companies offer the ability to include multiple scan heads or dualhead systems. One of the challenges in large production settings is streamlining the process and to avoid bottlenecking. “Sometimes parts are coming down two at a time side-by-side, Continues on page 88 www.canadianmetalworking.com
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[Rofin’s laser markers] can separate the beam in time or energy share so it can mark parallel lines of production that way,” explains Reeves. Part identification and tracking can be challenging using other methods like pad printing or sticker barcodes, which are only temporary. If a part identifier is removed, no one knows what it is or where it came from. This is why direct part marking is so important. “If you do direct marking, you can easily do it with a laser marker, it’s permanent, no one can remove it and it lasts a long time. This has been the strength for the laser marker. It’s readable, permanent, and for example, from a traceability standpoint, it ensures no one else is able to copy the part.”
Laser marking is the way of the future. Every part, right down to the tiniest of bone screws to a large engine block will require some sort of identification. Laser marking technology is becoming more and more mature, explains Boyle, adding, “Autofocus on parts, fixed distance lens and more advanced software are all making marking systems easier to use and more intuitive. They’re already fairly intuitive and now customers can just put in a couple of key strokes and they’re ready to mark.” Laser marking systems can offer standard marking or can be extremely complex with lots of bells and whistles. Regardless of the system, it is important to find a laser marker that suits your everyday needs so that all parts can be easily tracked and traced.
Hypertherm
SIC Marking
ArcWriter plasma marking system by Hypertherm is designed to create temporary or permanent marks on metal surfaces such as mild steel, stainless steel, or aluminum.The dual gas system comes with a 100 per cent duty cycle capable of speeds up to 7.5 meters (300 inches) a minute, while a variable power output makes it possible to control the width and depth of any mark, score, or dimple.In addition, the ArcWriter is designed to maximize consumable life, which in turn reduces the overall operating cost. www.hypertherm.com
The i103L-G laser marker was engineered for seamless integration into industrial production lines. Thanks to its superior quality marking and high work pace level, the i103L-G enhances traceability and identification processes with very low operating and maintenance costs. The i103L-G is a fiber laser capable of marking on a range of materials including steel, titanium alloys, and most plastics. It will mark alphanumerics, 1D bar codes, 2D Data matric codes, graphics, and complex logos, all with a high level of precision and contrast. The compact dimensions of the marking head simplify integration. Control of the laser head can be achieved through the Fiber Unit Controller, or with a PLC interface. The i103L-G system is equipped with a galvanometer assembly allowing fast marking with high accuracy. The i103L-G can mark 2D Data Matrix with high precision and contrast. www.sic-marking.com
Technifor The TD412 Laser offers a diode-pumped Nd:YVO4 Laser for thin marking lines. The very high peak power allows for a high contrast marking result. The TD412 has a very short pulse duration, with a small heat affected zone to avoid deformation of thin and fragile materials. The versatility of the TD412 laser allows for durface, deep, contrasting, shaded marks, each specific effect is possible on most materials. The TD412 is particularly efficient on highly reflective materimateri als (brass, gold, silver, polished stainless steel). www.technifor.com 88 | MAY 2015
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TRUMPF The TruMark 5010 Mobile Marker is an innovative portable laser marking unit. This laser marking concept features a compact and handheld marking head. The operator simply moves the laser marking unit to the work piece, eliminating the need to move the part, and intelligent sensors help guarantee the entire process is conducted safely and accurately. The TruMark laser provides a fast and flexible solution for laser marking large or heavy components. Markings are extremely durable, of consistent quality and there is no need for pre- or post-processing. The laser marking process is achieved without special tooling or consumables. As a tool, the laser is extremely flexible and is capable of marking identifying characters and images including barcodes, variable text, and data matrix codes. The TruMark 5010 Mobile Marker can also handle simple cleaning tasks and can prepare small areas for processing. www.us.trumpf.com www.canadianmetalworking.com
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THREAD
CONNECTION A look at tools for thread measurement BY LINDSAY LUMINOSO
W
hen it comes to measuring threads, there is no “one fits all” solution. There are so many different features of a thread that can affect its effectiveness. Threads themselves come in two different forms, either internal or external. In terms of traditional screws, which you would see in bolt/ nut applications, general fastening, or some automotive applications, there are many elements that make this piece work. The most important question to start off with is: what are you looking for when it comes to thread gauging? What do you really need to inspect? Here is a sample of some common gauging solutions for thread inspection applications:
NON-VARIABLE GAUGES A common gauge for dealing with both internal and external threads is the go/no-go gauge. This comes in the form of thread plugs for internal threads and ring gauges for external threads. It is all about assuring proper assembly, not performance. “When it comes to typical threads, what they want to know is if it’s okay or not okay, go or no-go,” says David Chang, business manager (measurement and automation products) for Renishaw Canada. A go gauge ensures the pitch diameter falls below the maximum requirement, whereas the no-go gauge would verify that the pitch is above the minimum requirement. A thread can have damages to it like nicks and dents but as long as it does not affect the part from fitting, there is no cause for rejection. Non-variable gauges are a quick and easy way to determine pass/fail attributes of the thread. They are also a relatively inexpensive tool. However, there are some challenges when it comes to working with this type of gauge. 90 | MAY 2015
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“The negative is that you need a go/no-go for every size of thread that you are measuring, and you have to maintain those,” says Peter Detmers, vice president of sales for Mitutoyo Canada. “Yes it is the lowest cost, but you need a one to one relationship.” So as much as these are a lower cost option, if you have a large family of screw threads, you will need to purchase a large number of gauges. “If you have a family of parts where there are 50 different pieces with small variances between a few of them, that’s enough to require new gauges,” explains Sean Taylor, applications engineer at Hexagon Metrology, Inc. “That’s just one situation where a flexible gauging solution can help.” The other element that is often checked with a non-variable gauge is whether or not there are enough internal threads in a hole. An operator will put a thread gauge in and see how far down it goes. “Typically there is a line on the thread gauge the will show the tolerance, as long as you can go beyond the line, it’s good,” says Chang. This is a great system if you are able to scrap the failed product, but if internal or external threads are constantly failing, go/ no-go gauges can provide little information as to why the problem occurs. For this information, there are gauging systems that can be used to determine various features that could cause a fail result.
VARIABLE GAUGES When more information than just go or no-go is needed, there are several different tools available. First, it is important to determine what measurements and features need to be known in order to choose the right tool. Does only one feature, like thread pitch, need to be www.canadianmetalworking.com
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fit within the thread forms on the pitch line if measured? If the answer is yes, contacting you are doing a direct measurement without a metrology or gauging manufacturer is the the need for calculations. first step in finding the right option. The main difference between the two tends A thread pitch gauge, or screw pitch gauge, to involve speed over precision accuracy. is just one easy tool for determining the num“The thread micrometer is faster for getting ber of threads per inch on both internal and a measurement, the three-wire method, some external threads. In metric connections, the would say tends to be a bit more accurate. thread pitch gauge is used to determine the distance between threads (the distance on the It’s a standard methodology and has been for several years,” says Detmers. crest of one thread to the crest of another). Another challenge comes when measuring These easy to use tools come in a kit featurthe internal thread. These two systems are ing a wide range of leaves for different pitch measurements. The leaf is placed on the threads until the fit is snug. The leaf will feature a number or code that corresponds to a measurement on a chart, which is matched to determine the measurement. Another method is the three-wire thread measuring system, which is a Changing the world of inspection...with a single click! highly accurate way for determining the pitch of the thread. This method uses two wires on one side and one wire on the opposing side of the bolt or threaded area. You then measure the distance across the wires, usually with a micrometer, and then there is a calculation that is completed in order to give the determined variable. “Normally the three-wire method can be used to inspect the master plug, for setting the ring gauge, it is used to measure male thread,” explains Detmers. This system can be used for a variety of different applications making it a flexible option on the shop floor. However, another option that is equally qualified is the thread micrometer. This hand tool requires Call to book your personal demonstration zero manual calculations and offers speedy results. Thread micrometers Quick Image Features: use a similar approach to a thread • The ultimate in simple operation with one-click instant wire, except you are using v-anvils measurement and pointed spindles. These systems • Telecentric optical system with large focal depth and field of view allow for a variety of screw thread Mitutoyo Canada Inc. • Quick GO/NG judgment for efficient quality control types to be measured; using a 55 Toronto (905) 821-1261 inspection degree V-anvil as opposed to the Montréal (514) 337-5994 • Available in sizes (X,Y): 100x100, 200x100, 200x170, traditional 60 degree v-anvil, widens www.mitutoyo.ca 300x170, 400x200mm, with view field of 32x24mm Precision is our profession the applications this device can be or 12.8 x 9.6mm used for. The v-anvils are designed to www.canadianmetalworking.com
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PHOTO COURTESY OF MITUTOYO
used primarily for external threads. The measurement of internal threads requires several extra processes in order to get an accurate measurement. Obviously the part geometry causes a problem when trying to access internal features. However, if a custom solution is not an option, another way to measure an internal feature on a thread would be to take a mold, similar to a dental cast, to create an external replica that can be measured by the aforementioned gauging systems.
FLEXIBLE GAUGING SOLUTIONS When primarily measuring one element or feature, a dedicated gauge or device is a great way to go. Measuring the pitch diameter might yield a favorable result; however, there is more to an internal and external thread than just this measurement. If you are looking for multiple features, a flexible
Dual Video & Optical Measuring System
SWIFT-DUO
Two measurement systems in one! • High accuracy measurement system • 2-axis dual optical & video measuring system • 3-axis variant with Z-axis for height measurement • Ideal for measuring 2D small, intricate parts • Seamlessly switch between video & microscope measurement
For more information visit: myhoskin.com/vision
www.hoskin.ca 92 | MAY 2015
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Vancouver | Burlington | Montreal
gauging system might be the way to go. When you want to explore the form of an external thread, using an optical comparator can work to highlight variables like the major or minor diameter, pitch diameter, thread or helix angle and depth of thread. Imperfections are also easily seen on an optical comparator, which magnifies the part. Optical comparators are noncontact solutions, which can be a significant advantage when dealing with delicate or very small parts that are hard to manually handle. “A traditional way of doing it would be to take the [external] thread and put it on a profile comparator/optical comparator, and actually optically look and measure the angle of the thread,” Detmers explains. When it comes to specific industry applications, tolerance can differ. “What I see, which is majorly automotive and some aerospace, an external thread generally has a more direct function than just holding something together. It will generally have a tighter tolerance,” says Taylor. This would require more than just a non-variable gauge to pass/fail the part. Using flexible gauging solutions will yield a variety of measurements and allow for changes to be made to part processing if a correction is needed. Another option for a wide variety of variables is a contour system or tracer. This type of device allows for more comprehensive measuring of threads. The purpose of a contour tracer is to use a stylus that follows the profile of the thread itself. That information is transferred into a computer as digital data. Once it’s in the computer, software analyzes angles, radius and other features, and performs nominal/actual comparisons. With this type of thread measuring system, you can really access a wide range of measurements on both internal and external threads. “The tip radius [on the stylus] can be very small,” explains Detmers. “It can get into finer thread pitch and can get a much greater pitch density, so you can get a lot higher number of points, with a higher degree of accuracy, scanning in two axes.” It’s all about checking the form of the thread, making sure there are no minor defects that can affect the overall performance. One of the biggest questions you need to ask yourself when it comes to measuring threads is, “what do I need to know?” In today’s day and age, quality control is significant in the manufacturing process. Adding any number of gauging tools to the shop floor can always enhance overall quality concerns. www.canadianmetalworking.com
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COUNTDOWN T H E I N T E R N AT I O N A L CENTRE
SEPTEMBER 28 – OCTOBER 1, 2015
MISSISSAUG A
THE FUTURE OF
ADDITIVE MANUFACTURING The new RAPID Canada pavilion and speaker line-up to reveal the latest in 3D printing advancements.
REGISTRATION NOW OPEN
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ME has announced new conference content focused on the future of additive manufacturing at this year’s CMTS event, taking place in Mississauga at the International Centre, September 28 to October 1. Registration is now open for attendees and exhibitors for CMTS, which will have a RAPID Canada Pavilion featuring the latest advancements in additive manufacturing and 3D printing technologies. CMTS will offer expert keynotes, educational sessions and panels, as well an exhibit floor featuring new manufacturing technologies, hands-on experiences and experts from leading additive manufacturing authorities such as Anubis 3D, The US Navy, Linear Mold & Engineering, The National Research Centre and Renishaw, not to mention prominent academia from universities in Canada and the United States. “The CMTS team along with the RAPID Canada Conference Advisory Board have worked diligently to build content that will provide great value to attendees and empower us all to ‘manufacture the future’,“ says Julie Pike, event manager at SME. “Within our industry, RAPID has been viewed as the leading conference on all things 3D printing and additive manufacturing for more than two decades.” Educational sessions in the conference
program, focused on additive manufacturing, will enable attendees to discover industry opportunities and challenges such as Additive Manufacturing Innovations for the Medical Industry, the Application of 3D Printing in Space, How to use Additive Manufacturing to Enhance Productivity and the Application of 3D Engineering and Additive Manufacturing for National Defence. With public interest in 3D printing technologies at an all-time high, there’s no better time to share innovative research, case studies or applications with an audience focused on additive manufacturing. CMTS is Canada’s largest national manufacturing event. More than 8,000 manufacturing professionals attend CMTS biennially to discover the latest advancements in machine tool, tooling, metal forming and fabricating, advanced manufacturing, automation, design engineering and plant management from over 700 potential suppliers. Regular updates in this ‘Countdown’ to CMTS” space will continue to appear in each issue, watch out for more announcements and highlights to come for this fall’s show. For the latest event news, or to find information on exhibiting, attending or sponsoring at CMTS, visit www.cmts.ca or contact Julie Pike, event manager at 888-322-7333, ext. 4471 or jpike@sme.org www.canadianmetalworking.com
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TOOL TECH
BIG IDEAS FOR SMALL CUTTING TOOLS BY YAIR SELEK
T
he increasing demand for the production of even smaller and more accurate parts, often manufactured from difficult-to-machine materials, has tested the ingenuity of the world’s cutting tool manufacturers. Many smaller machining applications can be satisfied by the expansion of a manufacturers’ current cutting tool range and the introduction of scaled-down versions of existing products. Although, reducing the size of a cutting tool can diminish its efficiency and render it less robust, often, a more creative and tailored solution is needed. In areas where the re-design of existing cutting tools would not produce optimum machining solutions, inventive R&D departments have developed a range of unique, small-scale cutting tools. By using
the most suitable base materials and advanced coatings, introducing ingenious tool geometries and the application of secure clamping systems, companies have created a range of innovative cutting tool solutions dedicated to a wide range of small cutting applications.
GROOVING AND TURNING WITH A SIDE CLAMPING MECHANISM Usually when turning small parts, light cutting parameters are applied and therefore there is no advantage in using larger inserts. A new tool family for Swiss-type and screw machines from Iscar (fig. 1), for example, have a short head design providing higher rigidity and machining stability, allowing higher cutting conditions and resulting in enhanced surface finish characteristics. Most holders need to be removed from the tool gang for insert indexing on small Swiss-type machines. These new tools enable insert indexing without removing the tool. A variant with a high-pressure coolant capability is also available.
INCREASE EFFICIENCY, REDUCE INVENTORY Traditionally different tools and inserts are used for back and front clamping orientations. New inserts designed with an oval-shaped hole enable two major improvements (fig. 2): the same tool and insert can be used in both clamping directions; and the clamping design uses a special screw that can be accessed and operated from both sides of the tool, enabling inserts to be indexed without the need to fully remove the screw.
ACCURACY, RIGIDITY AND FLEXIBILITY Demand for high accuracy and increased flexibility in clamping orientation has inspired a new range of holders. Most existing tools provide a single clamping orientation. New solutions, like Iscar’s PICCOACE for example, enable operators to install and remove an insert from any orientation. This series features a patented clamping system with two main components—a body and an eccentric cap. When the cap is turned with the supplied wrench, the accenter moves a locking shim that exerts pressure on the insert and
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Fig. 4
Fig. 5
Fig. 6
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TOOL TECH
locks it into position. The clamping system saves time when replacing an insert and ensures rapid indexing while also providing high clamping repeatability of 0.005 mm (fig. 3).
FACE GROOVING WITH COOLANT DELIVERY The addition of high-pressure coolant to face grooving tools provides the advantages of increased tool life and improved surface finish characteristics. A new range of face grooving tools intended mainly for external/internal and grooving along a shaft feature solid carbide bars with two holes that enable precise coolant delivery to the cutting edge and the frontal flank (fig. 4). When high-pressure coolant (up to 100 bar) is induced through the coolant holes, the resulting chips are small and easily pushed out of the groove.
‘TURNING’ - EFFICIENCY INTO PROFITABILITY To accommodate small boring diameters, we are seeing expanded internal turning application ranges with the introduction of positive and negative boring tools with steel and solid carbide shank options and new small size inserts. These new tools feature coolant channels directed precisely to the insert’s cutting edges (see fig. 6).
are available in 8–25.7 mm diameters, in 0.5 mm increments (fig. 7). This advancement in drilling heads provides a substantial cost reduction by cutting machining cycle times and reducing the number of tools required for drilling operations. Another innovation is the addition of flat face drilling heads designed
for drilling steel components (ISO P material group). Drilling with these inserts provides a nearly flat bottom in the drilled hole, a feature required across a variety of applications. Yair Selek, product manager, face grooving systems and miniature industry, Iscar.
Cost
Savings The Series 33 uses the latest in engineering design and grinding capabilities to handle
aggressive ramping, pocketing and slotting of difficult materials such as Stainless Steel, Titanium, and Inconel*
DRILLING FOR PROFIT Major innovations in drilling head options include new head geometry, featuring concave cutting edges that enhance the self-centring ability of the drill. Some new drilling heads, using up to 12xD long drills, negate the need for a pilot-hole operation and Fig. 7
* SGS helped a machining
company GAIN twice the material removal rate, while REDUCING the total job cost by over
50%
www.sgstool.com 330-686-5700
Manufactured in the USA
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JOINT OPEN HOUSE CELEBRATES 10TH ANNIVERSARY
(L-R) EMEC’s Tejal Mehta, VP of Operations, Bill Mara, President, and Trevor Smethurst, VP of Engineering, cut the cake celebrating the company’s 20th anniversary.
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From April 21-23, six of Ontario’s leading machining distributors opened their doors, hosting the 10th annual joint open house to showcase equipment from 21 world class machining builders. This extended open house featured over 60 machines available from distributors Elliott Matsuura Canada Inc., DMG MORI Canada, Ferro Technique, Single Source Technologies, EMEC Machine Tools Inc., and TRUMPF. The idea of a joint open house was sparked by Elliott Matsuura’s former president 10 years ago to demonstrate the machines the involved companies represent, explained Frank Bolieiro, vice-president of sales and marketing at Elliott Matsuura Canada. Mr. Katsu Matsuura, President of Matsuura
Machinery Corporation was on hand to welcomed guests as the Joint Open House kicked off. Many of the companies that participate in this event have been a part of the Joint Open House since its inception. However, this year is the first time that
DMG MORI opened the doors of its new facility, presenting a wide range of its machines.
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TOOL TALK
Stefan Fickenscher, the new Managing Director of TRUMPF Canada, spoke with guests about TRUMPF’s new products.
Ferro Technique had a large display of machines tools.
SST showed off a selection of Makino machines.
TRUMPF Canada joined the event. It was also a time for celebration. Elliott Matsuura was highlighting its 65th anniversary. Meanwhile EMEC Machines Tools brought out the cake to celebrate the company’s 20th anniversary while thanking their customers. The Joint Open House featured a wide range of machine tools, cutting tools, software, and time to interact with customers and network with colleagues. Guests were offered a limo service to take them from location to location, which was spread out throughout Oakville and Mississauga. Guests were also treated to live demonstrations, snacks and lunch, as well as dedicated sales staff to provide any information needed.
Mr. Katsu Matsuura, president of Matsuura Machinery Co., was on hand to speak with visitors.
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MAZAK HOSTS LUNCH AND LEARN ON MACHINING TITANIUM Machine shops from the Greater Toronto Area and Southwestern Ontario travelled to Mazak Canada’s Technology Centre in Cambridge, Ontario on Friday, March 27 to expand their knowledge in the art of machining titanium at a lunch and learn event. Welcomed by Ray Buxton, general manager of Mazak Canada, over 80 people registered for the learning session. After a brief introduction the crowd was ushered to the floor of the demonstration centre where three machines were set up with assistance from presentation partners, Iscar, Kennametal and Sandvik Coromant. With a focus on techniques for maximizing milling performance in titanium, Kennametal’s Matthieu
Guillon led the first demo on a Mazak VCU 500C. Guillon stressed the importance of optimizing processes in order to accelerate productivity. He demonstrated trochoidal milling with Kennametal’s HARVI III solid carbide end mills. Other applications included drilling and plunge milling using a selection of Kennametal tools. Brian MacNeil from Sandvik Coromant led a demonstration on a Mazak Variaxis i-600, addressing pre-programming challenges to consider. He also spoke about considering the “right depths of cut.” “Showing off the strength of the Variaxis,” noted MacNeil. One audience member commented, “It’s like cutting through aluminum.” The final demonstration was led by
Iscar, represented by David Vetrecin and Thomas Hagen. Machining on a Mazak Vortex 630V/65, for Iscar the
Sandvik Coromant’s Brian MacNeil (left) shares insights with attendees at Mazak Canada’s Advancements in Titanium Machining lunch and learn event.
focus was on using chip thinning to their advantage, using a high feed rate and low depth of cut. Following the demonstrations attendees had time to mix and mingle with the experts and take a deeper look into the machines, tools and processes best suited to their own applications. www.mazak.com
The Most Complete Tapholder & Tap Collet Offering S-191 The ultimate machining solution… for small precise parts.
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Tap Collets in ANSI, JIS & DIN Sizes
ERI AMERICA ERICA ERI
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TOOLHOLDING SOLUTIONS
www.eri-america • info@eri-america.com • 877-374-8005 100 | MAY 2015
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TOOL TALK
THOMAS SKINNER ADDS TSUGAMI TO LINEUP
A UNIQUE PARTNERSHIP In the fall of 2013 Castelar Tool of Mississauga, Ontario became the first Canadian member of the KOMET SERVICE partner network, and now Castelar and KOMET Canada have further enhanced that relationship by moving into a shared location. To celebrate, on April 15th the companies held a joint grand opening event to show off their new space.
Machinery will be the exclusive distributor in Michigan. “We’re pleased to welcome Network Machinery and Thomas Skinner as new Tsugami distributors and we’re confident these changes will enable us to enhance support to our grow-
ing customer base,” Rem Sales Vice President Michael Mugno said. George Media, the Tsugami/Rem Sales Regional Manager, will continue to support Michigan customers as well as serve the Eastern Canada market. www.thomasskinner.com
NEW INNOVATIONS in Steel Turning
CA5 Series G r a d e s
P Series C h i p b r e a k e r s Wear Resistance
Thomas Skinner & Son has been named the exclusive Tsugami distributor in Western Canada. Tsugami/Rem Sales, the exclusive North American importer of Precision Tsugami machine tools, announced the addition of two new Tsugami distributors, effectively immediately. While Thomas Skinner & Sons will be responsible for distribution in Western Canada, Network
CA510 P05
CA515 CA525 P15
CA530 P25
Conventional Coated Carbide
P35 Stability
Together Castelar and Komet Canada now share a fresh 24,000-sq. ft. facility minutes from Toronto’s Pearson airport with a production area, warehousing and office space with meeting and training rooms. “The fact that KOMET Canada and us now share the same roof really accentuates our commitment to working together and to develop this marketplace in a more concise way, and a way that we can benefit from each other’s expertise,” said Renato Evola, owner and president of Castelar Tool, whose father started the cutting tool manufacturing and grinding company 43 years ago. www.canadianmetalworking.com
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In comparison tests, KYOCERA’S new CA5-Series steel turning inserts combined with the PP, PQ, and PG smart chipbreaker lineup have consistently outperformed the competition. Don’t take our word for it…try it for yourself! Contact your local KYOCERA Sales Engineer or visit KyoceraPrecisionTools.com/CA5 to request a FREE SAMPLE.
NEW
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BUY 20 INSERTS, GET 10 FREE More Information at KyoceraPrecisionTools.com/promo-pack
800.823.7284 cuttingtools@kyocera.com www.kyoceraprecisiontools.com
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KAISER AND BIG DAISHOWA STRENTHEN PARTNERSHIP KAISER Precision Tooling has strengthened its relationship with long-term partner, BIG Daishowa of Japan. As of April 15, 2015, KAISER became a company of the BIG Daishowa group. The two companies have had a close technology and distribution partnership since 1980. “During the past 10 years, our partnership has steadily increased through the creation of two joint ventures in the U.S. and Germany and an exclusive distribution arrangement for BIG products in Europe”, says KAISER CEO Peter Elmer. “Today the distribution channels are practically
JOE POULIN JOINS ELLIOTT MATSUURA CANADA Mr. Kitaguchi, Chairman of BIG Daishowa Seiki Co. Ltd. and Mr. Chris Kaiser, Chairman of KAISER Precision Tooling Ltd.
grown together.” Executive management will remain in place following the transaction, with Peter Elmer as CEO leading European operations, and CEO Chris Kaiser overseeing North American operations. “Our family has been working for some time on a succession plan to ensure the continued growth and success of this company,” says Chris Kaiser. www.kaisertooling.com
Automotive Workholding.
If it’s hard to hold... the answer’s not hard to find. www.forkardt.us
camshafts, ABS units, compressors and transmissions to name just a few. Our technical knowledge and expertise in automotive workholding can provide you with a solution that fits your process. From power chucks and collet chucks, to special fixtures and cylinders, we offer a complete line of assemblies and accessories. Give us a call. 2155 Traversefield Drive • Traverse City, MI 49686 800-544-3823 • sales@forkardt.us
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GF MACHINING’S NEWEST APPOINTMENT Scott Fosdick has been appointed as GF Machining Solutions’ new Head of Market Region Americas. Fosdick takes over for former region president
We’ve developed workholding technologies for rotors,
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Joe Poulin has joined ElliottMatsuura Canada as a new regional sales manager. Prior to this move, Poulin was the sales manager for Canada for Hurco Companies. He has 15 years of experience in the machine tool industry and is a welcome addition to the ElliottMatsuura team. www.elliottmachinery.com
Glynn Fletcher. “After nearly 24 years in Asia, I’m excited to be back in the United States with GF Machining Solutions and heading a key division within the industry’s leading supplier of EDM, milling, laser texturing and automation technologies,” said Fosdick. “I look forward to contributing to the company’s ongoing success and continued growth in an ever-changing manufacturing landscape.” www.gfms.com/us
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PRODUCTS & SERVICES
Introducing an opportunity for small-space and classified advertising in Canadian Metalworking
For a quote on any size ad, contact: STEVE DEVONPORT, Publisher 416-543-1641 sdevonport@canadianmetalworking.com
Metalworking Marketplace will be available in all nine issues of Canadian Metalworking, and provides the opportunity to run small space advertising and classified ads at low cost. There are two main parts to Marketplace, Listings for Products and Services, and Classified for Machine Tool and Fabricating Equipment. ROB SWAN, Associate Publisher 416-510-5225 cell 416-725-0145 rswan@canadianmetalworking.com
ADDITIVE MANUFACTURING RENISHAW (CANADA) LIMITED. Renishaw laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD. From tooling inserts featuring conformal cooling, to lightweight structures for aerospace & high technology applications, laser melting gives designers more freedom. Find out more at www.renishaw.com/additive. T: 1 905 828 5519 E: Canada@renishaw.com www.renishaw.com
ASSOCIATIONS CANADIAN MACHINE TOOL DISTRIBUTORS’ ASSOCIATION (CMTDA) The CMTDA is a trade association dedicated to the marketing of machine tools and services in Canada through distributors. For more information about CMTDA or our members products and services, contact us at: T: 519 599 2803 E: info@cmtda.com www.cmtda.com
CUTTING TOOLS HORN USA, INC. HORN is the technology leader of indexable cutting tools with experience in over 100,000 custom application solutions and engineering expertise applied to more than 17,000 standardized turning and milling tools. T: 888 818 4676 E: info@hornusa.com www.hornusa.com ISCAR TOOLS INC. ISCAR provides industries machine tools, carbide cutting tools, engineering and manufacturing solutions for a wide range of metal cutting applications, including innovative products, designed specifically for customer increased productivity requirements globally. T: 905-829-9000 www.iscar.ca SANDVIK COROMANT (Cutting tools for turning, milling and drilling, modular tooling systems for lathes and machining centres. Direct sales personnel and specialists in more than 60 countries plus authorised distributors and 20 Productivity Centres worldwide providing training in tooling solutions for increased productivity) T: 905 826 8900/800 268 0703 E: coromant.ca@sandvik.com www.sandvik.coromant.com SGS TOOL COMPANY. SGS is a privately-held, ISO-certified leader of round solid carbide cutting tool technology providing value at the spindle for the aerospace, medical, power generation, and automotive industries. T: 330-688-6667 E: sales@sgstool.com www.sgstool.com TUNGALOY. Tungaloy has supplied carbide cutting tools for over 70 years. Supported by our sophisticated materials technology and state-of-theart processing technology, Tungaloy is committed to quality. For more information on our extensive range of products contact us at: T: 888 886 4256 www.tungaloy.co.jp.ca WALTER TOOLS. The five competence brands of Walter, Walter Titex, Walter Prototyp, Walter Valenite and Walter Multiply, are united under one umbrella. With a product range of around 49,000 catalogue tools for milling, drilling, turning and threading. Walter is a complete service provider for the metalworking industry. T: 800 945-5554 E: service.ca@walter-tools.com www.walter-tools.com/us
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NICHOLAS HEALEY, Account Manager 416-442-5600 x3642 nhealey@canadianmetalworking.com
EMPLOYMENT OPPORTUNITIES
Campbell Morden specializes in recruiting full-time staff for a broad range of industries, such as aerospace, automotive, CNC Machine Builders, and system integrators. Positions include: technical sales, CNC machining, applications engineers, manufacturing management, and field service technicians – among others.
Email: bp@campbellmorden.com Call Brian Pho at 905-482-0636
EXCITING SALES CAREER OPPORTUNITY As a result of a recent promotion, we are seeking an individual to fill an inside sales position selling new Metal Forming Machinery. This is a developmental position that will lead to an exciting career in outside sales with excellent earning potential. Requirements for this position include previous sales experience, strong mechanical aptitude, technical trade school/college diploma or apprenticeship and above all, enthusiasm. For more details about this Inside Sales Professional role, please visit the careers section of our website: http://westwaymachinery.com/inside-sales-professional. Send Resume to: careers@westwaymachinery.com
EVENTS – TRADE SHOWS FABTECH CANADA. March 22-24, 2016 Toronto Congress Centre, FABTECH Canada is Canada’s largest one-stop, all-encompassing venue for the latest technologies and trends in fabricating, welding, metal forming, stamping, coating and finishing. With an unmatched reputation in the industry, FABTECH is the largest event in this sector in North America. For more information contact us at: T: 1 888 322 7333 E: jsaperson@sme.org www.fabtechcanada.com WESTERN MANUFACTURING TECHNOLOGY SHOW (WMTS). June 1517 2015, Edmonton EXPO Centre. Evaluate and compare cutting-edge manufacturing equipment, advanced technologies, new products & applications, and services at Western Canada’s largest manufacturing technology event. For more information contact us at: T: 1 888 322 7333 E: jsaperson@SME.org www.wmts.ca
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CANADIAN MANUFACTURING TECHNOLOGY SHOW (CMTS). Sept 28 – Oct 1 2015, The International Centre, Mississauga. Canada’s largest display of manufacturing equipment and technology attended by over 8,000 professionals. Connect with over 700 suppliers under one roof demonstrating live, working equipment. For more information contact us at: T: 1 888 322 7333 E: jpike@sme.org www.cmts.ca
FABRICATING MACHINERY AMADA CANADA, LTD. Since 1987, Amada has provided the Canadian industry with innovative sheet metal fabrication equipment including: CNC turret punch presses, lasers, punch/laser combination machines, press brakes, automated systems, tooling and software. Peter Burell T: 905 858 4496 pburell@amada.ca www.amada.ca TRUMPF INC. TRUMPF Inc. is the largest manufacturer of sheet metal fabrication equipment and industrial lasers in North America. Our Farmington, CT facility produces precision laser cutting machines, punching machines and CO2 and solid-state lasers. T: 860 255 6000 E: info@us.trumpf.com www.us.trumpf.com
LASERS
METALS
ROFIN-BAASEL, CANADA LTD. A Canadian division of the laser industry leader ROFIN-SINAR, provides applications, sales and a sophisticated service/technical support network for our vast line of lasers for marking, welding, cutting, and surface treatment. For more information contact us at: T: 905 607-0400 E: Info-canada@rofin-inc.com www.rofin.com
MACHINE TOOLS AMT MACHINE TOOLS LTD. AMT specializes in Sales & Service of: Star CNC Swiss Style Automatic Lathes and Hydromat Transfer Machines. We also have a complete line of filtration products including Filtermist Oil-Mist collectors. T 416-675-7760 E: sales@amtmachine.com www.amtmachine.com DIPAOLO MACHINE TOOLS. DiPaolo Machine Tools is the one stop shop for all of your machine tool needs. We’ll source the equipment, rebuild it, retrofit it, calibrate and service it. For more information contact us at: T: 905 676-9265 E: sales@dipaolocnc.com www.dipaolocnc.com HAAS AUTOMATION, INC. Haas Automation, Inc. – America’s leading machine tool builder – manufactures a full line of CNC vertical machining centers, CNC horizontal machining centers, CNC lathes, 5-axis machining centers, and rotary products. T: 805 278 1800/Toll Free: 800-331-6746 E: haascnc@haascnc.com www.HaasCNC.com HURCO COMPANIES, INC. Hurco invents CNC technology that makes our customers more profitable. We design and manufacture more than 60 models of CNC machines with the most versatile control in the industry— equally powerful for NC and conversational programming. T: 1-800-634-2416 E: info@hurco.com www.hurco.com
Alro Steel
Metals Industrial Supplies Plastics
Your One Stop Shop for cut-to-size Metals & Plastics with daily deliveries to Ontario, Canada Since 1948
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888-888-ALRO 2 5 7 6
alro.com
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PRODUCTS & SERVICES
MAKINO, INC. Makino is a world leader in advanced CNC machining centers for today’s most complex metalworking applications. With a wide range of high-precision metal-cutting and EDM machinery, we help our customers make what matters. T: 513-573-7200 E: webmaster@makino.com www.makino.com MAZAK CORPORATION. Mazak is a leader in the design, manufacture and support of advanced technology solutions, including Multi-Tasking, 5-axis, milling, turning, CNC controls and automation, for all metal working industry segments. T: 859 342 1700 E: triddell@mazakcorp.com www.mazakusa.com MITCHAM MACHINE TOOLS INC. Mitcham Machine Tools Inc. are Canadian distributors of CNC and manual Machine Tools. With our extensive product line from manufactures around the world, we will work with you to find you the right machine for your needs, both on time, and within budget. T: 416-458-7994. E: sales@mitchammachinetools.com www.mitchammachinetools.com TOS TRADE CANADA Inc. is a subsidiary of TOS Varnsdorf, the established manufacturer of a broad range of quality horizontal boring mills. Over 1000 boring mills installed within past 25 years. T: 905-878-0888 E: info@tostrade.com www.tostrade.com
MACHINERY ELLIOTT MATSUURA CANADA INC. Elliott Matsuura Canada Inc. is an industry-leading supplier of quality machine tools coast to coast in Canada. Since 1950, Elliott has provided complex metal cutting solutions to meet the challenges of aerospace, automotive, medical, energy, and other industries. T: 905-829-2211 E: info@elliottmachinery.com www.elliottmachinery.com
MARKING GRAVOTECH, INC. Gravotech are global leaders in the design, manufacturing, sales, and support of innovative solutions for engraving, marking and artistic modeling. As a global leader in durable marking technologies such as engraving, laser, micro-percussion and scribing, we utilize our expertise to develop and market equipment, software and consumables for every application. T 800-843-7637 E: sales@us..gravotech.com www.gravotech.us
MATERIAL HANDLING PRAB. A global manufacturer of material handling equipment for scrap metal and coolant recycling. A broad line of conveyors, wringers, crushers, briquetters, and fluid filtration and recycling equipment will automate scrap processing while maximizing production and improving safety and environmental compliance. Robert Webb Authorized PRAB Sales Representative T: 905-296-2039 E: robert@rgwsalescanada.com
METALS BÖHLER-UDDEHOLM CANADA is a leading manufacturer of high quality tool steel, high speed steel, powder metallurgical steels, stainless steels, and specialty alloys. Products and conveniently located facilities are supported by a highly trained technical sales force and by a local and international metallurgical support staff. For more information contact: 1-800-665-8335 or www.bucanada.ca/contact_us.htm
QUALITY CONTROL RENISHAW (CANADA) LIMITED. Introducing a unique versatile gauging system. Equator, an alternative to custom gauging, offers inspection of an unprecedented variety of manufactured parts. Proven and Developed on the shop floor with industry leading gauging users in a variety of industries and applications. For more contact us at www.renishaw.com/gauging. T: 1 905 828 0104 E: Canada@renishaw.com www.renishaw.com
RETENTION KNOBS
IN STOCK American Standards and specials. Japanese Standards - inch or metric. FOR FAST DELIVERY: Contact your local tooling dealer or order direct.
TEL 937-686-6405 FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O.Box 61 Bellefontaine, OH43311
WELDING SUPPLIES LINCOLN ELECTRIC COMPANY OF CANADA. Lincoln Electric is the world leader in the design, development and manufacture of arc welding products, robotic arc welding systems, plasma and oxyfuel cutting equipment and brazing and soldering alloys. For more information contact us at: T 905 565 5600 www.lincolnelectric.ca
WORKHOLDING SAMCHULLY WORKHOLDING, INC. Samchully Workholding leverages a broad range of complementary products to provide full turn-key custom solutions. The ability to single source the solutions ensures customers optimal compatibility and unsurpassed quality control. T 949-727-3001/1-877-750-4747 E info@samchullyworkholding.com www.samchully.com
METAL FINISHING PFERD. The PFERD brand name is synonymous with outstanding premium-quality tools and abrasives. Today, we manufacture more than 7,500 PFERD brand grinding, cutting and surface finishing tools. And a complete range of ADVANCE BRUSH power and maintenance brushes. T: 905-501-1555 E: sales@pferdcanada.ca www.pferdcanada.ca WALTER SURFACE TECHNOLOGIES. Walter Surface Technologies has been a leader in surface treatment technologies for more than 60 years, and has been providing high productivity abrasives, power tools, tooling, chemical solutions and environmental solutions for the metal working industry. T: 1-888-592-5837 E: csr@walter.com www.walter.com
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ISCAR's High Productivity Machining Solutions for the Aerospace Industry
Indexable cutters specially designed for high speed milling of fuselage components
Special ultra high pressure tools for the aerospace industry
Indexable drilling heads for machining CFRP and honeycomb plastic parts
Whisker ceramic inserts for machining exotic materials
Machining Intelligently
ISCAR HIGH GH Q LINES
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