Canadian Metalworking February 2012

February 2012 • www.canadianmetalworking.com

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Contents...

Vol. 107 | No. 1 | February 2012 | www.canadianmetalworking.com

FOCUS ON AEROSPACE HIGHER, FASTER, FARTHER.....................18

A Government review, huge orders and a controversai fighter plane make for interesting times in aerospace

SKY-HIGH IN PEI..................................23

18

3 Points Machining and Aerospace has set up a new operation in picturesque Charlottetown, PEI ... and reaps multiple rewards.

38

CAD/CAM TRIPLE PLAY..........................................28 Match machine, control and software

CUTTING TOOLS THE NEED FOR SPEED . ....................... 30 Higher speeds and feeds with lighter cuts

QUALITY

FABRICATING

LET THE GOOD TIMES ROLL................. 45

AUTOMATION AND THE PRESS BRAKE.. 57

Kawasaki uses advanced CMM tech for consistent quality

Evolution towards “hands off” production

WELDING

FINISHING

NEW!

ATTENTION TO DETAIL.........................61

WELDING NEWS............................... 36 EFFICIENT POWER............................... 38 New power sources bring production gains and energy efficiency to the plant

GRINDING TOP GEAR.......................................... 50 Ontario Drive and Gear is a Canadian success story

Optimize the elements of your spray painting system to achieve better efficiency and lower costs

50

DEPARTMENTS View from the Floor................................... 6 News...................................................... 8 Floor Space........................................... 16

By The Numbers..................................... 64

61 www.canadianmetalworking.com | FEBRUARY 2012 | 5

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PUBLISHER Steve Devonport 416-442-5125 | SDevonport@canadianmetalworking.com ACCOUNT MANAGER Rob Swan 416-510-5225, cell 416-725-0145 | RSwan@canadianmetalworking.com EDITOR Jim Anderton 416-510-5148 | janderton@canadianmetalworking.com EDITORIAL DIRECTOR Lisa Wichmann 416-442-5600 x 5101 | LWichmann@canadianmanufacturing.com ART DIRECTOR Sheila Wilson 416-442-5600 x 3593 | shwilson@bizinfogroup.ca CIRCULATION MANAGER Selina Rahaman 416-442-5600 x 3528 | SRahaman@bizinfogroup.ca MARKET PRODUCTION MANAGER Barb Vowles 416-510-5103 | vowlesb@bizinfogroup.ca PRINT PRODUCTION MANAGER Phyllis Wright 416-442-6786 | Pwright@bizinfogroup.ca BIG MAGAZINES LP.........................................................

PRESIDENT OF BUSINESS INFORMATION GROUP | Bruce Creighton VICE-PRESIDENT OF CANADIAN PUBLISHING | Alex Papanou EXECUTIVE PUBLISHER, MANUFACTURING | Tim Dimopoulos HOW TO REACH US..........................................................

Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, North York, ON M3B 2S9 Phone: 416-442-5600. Fax: 416-510-5140 CM, established: 1905 is published 7 times per year by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. SUBSCRIPTION RATES Canada $55.00 per year, Outside Canada $90.00 US per year, Single Copy Canada $8.00.

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View From the Floor There is no labour shortage That’s right, you read it here first….there is no shortage of skilled labour in Canada. Need a machinist or toolmaker? CNC programmer? They’re there for the picking…at a price. Willing to pay 40-45 bucks an hour plus benefits? You’ll have all the good hands you need. I know, that’s ridiculous…no one can afford wages like that, which is the real issue the industry faces regarding skilled workers. Here’s how it evolved: Offshoring wiped out the marginal and undercapitalized players in the Canadian industry, which, combined with recession, spiked unemployment in the skilled trades. Young people noticed. Then the surviving metalworking businesses got off the mat and fought back with higher efficiency, quality and speed despite slimmer margins driven by the offshore competition.

Smart operations not only bounced back, but used the new flexibility and productivity to chase new markets and look again at growth….until they hit the skilled worker gap. And that gap will continue for one simple reason: Kids are smart. In fact, despite what many in the industry claim about the “new generation” they’re smarter, stronger and faster than we ever were…. and right now they see little future on the shop floor. There are several reasons why. One is the way capitalism has evolved over the last 30 years.

The common perception is that winners are wealthy speculators, bankers and lawyers who trade millions at the push of a button. And looking at executive compensation these days, they’re not wrong. How do you move up to the front office if you’re ambitious and smart? How many toolmakers are running Bombardier or SNC Lavalin?

The only way off the bench is to go the Frank Stronach route, except that the current level of automation, plus ISO and other certifications makes the cost of entry very high for budding entrepreneurs in the industry….and we know what it’s like trying to raise capital in Canada if you’re a small business. A young MBA with a lousy business plan has a better chance than an expert machinist with a sharp mind and good entrepreneurial instincts.

Kids see this and stay away, unless they’re incapable of handling business or law, which is the other problem: we’re still perceived as little more than “grease monkeys”. High school guidance councilors still drive illiterate, innumerate students into the trades, somehow thinking that a useless office worker makes a great machinist or moldmaker. Why? How many guidance councilors are trades people? I know of community colleges here in Toronto that run remedial English and math classes to try to get apprentices up to speed. How much do you want to pay a new hire that can’t read a drawing? And so it goes: in the Twitter age, perception is reality and the perception is that the industry is dirty, demeaning, poorly paid and offers no future for the young.

This can be fixed. To start, we need to look at apprenticeship systems like the Germans use. Add continuous education, and provide a route into engineering for bright, ambitious machinists and toolmakers. This would also provide a pool of engineering talent that really understands metalworking.

The SME is looking at this right now. Stop throwing financing, taxation and regulation roadblocks in front of young entrepreneurs who want to set up a business and build new markets. Stop the irrational paper trail drowning existing employers who want to hire. And get some sense in income distribution in this country before we completely wipe out the middle class… and condition our youth to admire scheming, speculation and inside dealing while rejecting the real wealth generators in society as idiots. The scary thing is, it would take little to fix this mess and the tools are in Steven Harper’s box. But I’m not holding my breath.

JIM ANDERTON, EDITOR

Do you agree? Let me know, and feel free to drop me a line at the e-mail address below, or buttonhole me at a show or event. I’d love to hear from you! janderton@canadianmetalworking.com 6 | FEBRUARY 2012 | www.canadianmetalworking.com

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News FABTECH Canada adds social media, mobile apps On-line excitement builds for FABTECH Canada, the first exclusive fabricating, metal forming and welding event, to be held in Canada in March Show floor exhibits aren’t the only leading edge tools and technologies expected to create a stir at FABTECH Canada, the country’s first exclusive fabricating, metal forming and welding event making its debut at the Toronto Congress Centre March 20-22, 2012. Emerging social media trends and innovative mobile applications will also be in the spotlight as show organizers embrace the latest in communications tools to deliver a state-of-the-art, interactive attendee experience. “Our studies indicate that the more we can immerse show visitors into the overall experience, the more industry knowledge they will take away from FABTECH Canada,” said Janine Saperson, Event Manager with the Society of Manufacturing Engineers (SME), which is hosting the inaugural event together with Fabricators & Manufacturers Association, Intl. (FMA) and American Welding Society (AWS). “By incorporating the hottest trends in mobile devices and social media, we’re making it easier than ever for attendees to contribute ideas, provide feedback, receive up-todate industry education and get the most out of their show floor visit, with the added benefit of keeping our finger on the pulse of our industry at the same time,” she said.

FABTECH Canada’s regular on-line Twitter discussions are moderated sessions are intended to engage audiences on key topics in the metal forming, fabricating and welding industries; to access the forum, users sign onto Twitter and enter “#fabtechcanada.” Additional social media outlets used

by FABTECH Canada to engage industry members include Facebook, LinkedIn and YouTube.

Another innovative technology promising to take FABTECH

Canada Revenue Agency gets failing grades from small business: CFIB Survey

Some say they’re intimidated. Some feel treated as if they’ve done something wrong. Those sentiments reflect the overall consensus from small business owners and their experiences with the Canada Revenue Agency (CRA), according to a report by the Canadian Federation of Independent Business (CFIB) The survey of 10,600 small business owners and tax practitioners were asked to grade the CRA’s overall service to small business. The majority of respondents gave the agency a “C” or lower. Nearly 40 per cent gave them a “D” or “F.” For most, there has been little improvement in service in the last three years.

“While CRA has taken steps to improve the way it treats small business owners, those efforts are being drowned out by poor customer service, including audits that some of our members

Canada to new heights is the ability for audiences to take advantage of an optimized mobile application which can run on any mobile device, including cell phones and tablet PCs, and provides attendees with easy on-line access to the exhibit guide, conference agenda, and more. This application will allow visitors to personalize their trade show experience, receive alerts about conference start times, take notes during sessions and be notified about last minute show changes. A real-time audience response system also enables immediate feedback and can be used to facilitate on-line polls and surveys.

“As Canadian manufacturers continue to gain visibility as a critical engine for innovation, technology and economic growth, it makes good sense to foster that growth using the latest in communi­ cations technology,” said Ed Youdell, FMA President and CEO. “Social media, in particular, is a great way to build a sense of community within our industry,” added Ray Shook, AWS Executive Director. “The more we can get people talking about issues of importance, the more innovation we are likely to see.”

Featuring the most comprehensive showcase of the latest industry technologies, tools and trends geared towards the needs of this country’s estimated 1.5 million manufacturing employees, FABTECH Canada is building on the success of the recent FABTECH event, held in Chicago in November, which exceeded expectations with an attendance of more than 35,000. Canada’s premiere industry event will feature an extensive exhibition floor, side-by-side machine evaluations, expert-led educational sessions, Canada’s Best Welder Competition and many other networking opportunities.

For more information on FABTECH Canada 2012, visit www.fabtechcanada.com. Show updates are also available on Twitter and LinkedIn.

described as witch hunts,” said Laura Jones, CFIB’s senior vicepresident of research and economics.

The survey suggests 28 per cent of Canada’s small businesses were audited in the last three years, 34 per cent of which were in the manufacturing sector. It also found that the more people a company employs increased the likelihood of an audit. Only 20 per cent of companies with one to four employees were audited, while 56 per cent of those with 100 to 499 employees were audited. CFIB outlines a number of recommendations in its report, which include publicly monitoring and reporting the customer service performance of CRA agents.

The report also suggests implementing impartial third-party reviews to level the playing field.

The full report is available at: http://www.cfib-fcei.ca/ cfib-documents/rr3256.pdf

“The majority of

respondents gave the agency a “C” or lower”

With files from canadianmanufacturing.com

8 | FEBRUARY 2012 | www.canadianmetalworking.com

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The new WFX four-cornered WaveMill has a state-of-the-art insert and highprecision body design, offering a tool that machines a superior finish and exceptional squareness. Available in coarse, fine, and super fine pitch.

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News $18.9 million in Southern Ontario funding assistance available through SMART program

Manufacturers that are exporting, planning to export, or selling into an export supply chain and planning productivity assessments or improvements can apply for the funding provided by the Federal Economic Development Agency for Southern Ontario (FedDev) through CME’s SMART Prosperity Now program.

“Two of the largest challenges that companies will face in 2012 are finding new customers and enhancing productivity performance,” said Ian Howcroft, vice-president of CME Ontario.

He said funding will help companies commercialize new technologies, enter new domestic and foreign markets, invest in sustainable and green technology, purchase new or upgraded equipment and technology, and implement efficiency improvements.

Assessments are eligible for funding of up to half the eligible costs to a maximum of $5,000. Productivity enhancement projects are eligible for up to 33.3% of eligible costs to a maximum of $75,000.

Eligible projects under FedDev Ontario’s Prosperity Initiative must: • accelerate the adoption of new technologies, processes and skills;

•d iversify the regional economy by increasing the number of new industries or opportunities that will have a long-term impact on regional economic diversity; and • build a competitive advantage by creating or expanding economic clusters and enhance their global competitiveness.

CME said it will be hosting a series of workshops throughout the region in the coming months to help businesses navigate this initiative.

For more information go to http://www.cme-smart.ca .

With files from PLANT

The indu pro for Aer US October manufacturing tech orders up 80.5% from 2010

LES SUMAB NO CON ING COSTS NN U R O N

■ ■ ■ ■ ■ ■

October U.S. manufacturing technology orders totaled $463.32 million according to AMT-The Association for Manufacturing Technology and AMTDA, the American Machine Tool Distributors’ Association. This total, as reported by companies participating in the USMTO program, was down 22.4% from September but up 20.3% when compared with the total of $385.21 million reported for October 2010. With a year-todate total of $4,529.11 million, 2011 is up 80.5% compared with 2010.

These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTO program.

“Manufacturing technology orders through October had already surpassed the total value accumulated in 2007,” said AMT President Douglas Woods. “The beginning of 2012 will be a little slow as tax incentives pulled some orders back into 2011, which will likely make 2012 growth softer.”

The United States Manufacturing Technology Orders (USMTO) report, jointly compiled by the two trade associations representing the production and distribution of manufacturing technology, provides regional and national U.S. orders data of domestic and imported machine tools and related equipment.

Analysis of manufacturing technology orders provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.

10 | FEBRUARY 2012 | www.canadianmetalworking.com

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News U.S. manufacturing technology orders are also reported on a regional basis for five geographic breakdowns of the United States.

Business missing key internal competencies that enhance productivity: global study

ESI International, a global project management training company, has released the findings of a new global study conducted to examine the state of business analysis (BA), a core discipline for translating project objectives into actionable project requirements and deliverables. The study was conducted among both public and private organizations worldwide in September.

“The disconnect between those who ultimately sponsor projects and those who execute them was frankly a bit shocking” said Mark Bashrum, Vice President for Corporate Marketing and Strategic Intelligence at ESI. “We were surprised to see how seldom business analysts linked key project success criteria to broader organizational goals.”

When business analysts were asked what they thought were the organization’s key project success criteria only 22 percent listed “Organizational Profit Impact” in the top three most important and only 8 percent listed it as the most important criteria in determining project success. The top three responses, were “customer satisfaction”, “on-time completion” and “on-

budget completion” (of the project), clearly indicating a focus on project execution over business impact.

“It’s understandable that business analysts are focused on the tactical execution of their projects, however, it’s a bit disappointing that they fail to take the next step and link their project outcomes to obvious organizational goals such as revenue growth or cost reduction,” said Bashrum.

These findings strongly indicate that people are missing the big picture in terms of what their overall BA objectives should be, and as a result, organizations are not realizing BA’s full potential in terms of improving efficiencies that increase productivity and profitability, especially important in the current challenging economy.

Additionally, key findings show that immaturity in BA organizations may represent an unrecognized deficiency in many of the surveyed organizations. The study, which tracked project outcomes against core BA activities, years of professional experience, BA certifications and a variety of other factors revealed that nearly half of BA practitioners had five or fewer years of experience in the field and that very few respondents possessed any type of BA certification.

“Business analysis is obviously recognized as a driver of project success, but organizations and business analysts themselves need to raise the bar in terms of their expectations in order to get the most out of the discipline,” said Glenn R. Brûlé, CBAP, Executive Director of Global Client Solutions, ESI. “This

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News study indicates a relatively high level of satisfaction with BA performance and results, but business analysts have barely scratched the surface providing the enterprise level activities of which they’re capable, and from which organizations will benefit most.”

The survey was anonymous unless respondents wanted to receive the results, in which case they had to complete their details.The full study, “Why Good Isn’t Good Enough: The Global State of Business Analysis”, is avaialble at: www.esi-intl.com/BAsurvey

continue to expand our staff to provide sales, service and engineering support for our customers both in the English and French languages. The new facility is located at 6710 Maritz Drive ,Mississauga, Ontario, Unit 4, ands can be reached at (905) 670-8600

KUKA Robotics Canada Ltd, with its parent company, KUKA Roboter GmbH, Augsburg, (a member of the KUKA Aktiengesellschaft) develops, produces and sells industrial robots, controllers and software. www.kukarobotics.com

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Hardinge workholding precision, accuracy and reliability.

KUKA Robotics Canada opens new facility

KUKA Robotics Canada, a subsidiary of KUKA Roboter GmbH, has announced the opening of their facility in Mississauga, Ontario, Canada.

The facility is home to KUKA Robotics Canada’s sales, applications, service and engineering staff to support customers in reviewing applications and applying robotics technologies to improve produc­tivity and quality while reducing costs and ergonomic related injuries. The fully equipped facility includes spare parts, training, and a demonstration area to provide customers with an opportunity for “hands on” experiences with the latest technologies and products. The location is in the heart of one of the largest corporate and industrial sectors in Canada, also home to many major international com­panies.

Five major highways within 10 km and Toronto’s Pearson International Airport within minutes ensure KUKA Robotics can provide quick access to its customers and major markets throughout Canada.

KUKA Robotics Canada’s President Chris Claringbold stated, “The location is well suited to KUKA’s needs, allowing our Canadian Team to offer greater support of products and services to KUKA’s growing customer base. We

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Precision and Special Accuracy Collets and step chucks

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www.canadianmetalworking.com | FEBRUARY 2012 | 13

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News New president for the CMTDA

December 1st saw the 69th annual general meeting of the Canadian Machine Tool Distributors’ Association. Held at the Board of Trade Golf and Country Club in Woodbridge, Ontario just north of Toronto, John Manley, outgoing president CMTDA introduced the new president, Frank Haydar. Haydar, (Elliott Matsuura Canada Inc.) reported dramatic increases in orders for both machining and fabricating equipment but also warned about the impact of a rising Canadian dollar: “a low Canadian currency during the past two decades has allowed Canadian manufacturers to make gains internationally without investing in more efficient technology. Now that our dollar hovers around parity with Incoming CMTDA the US dollar, Canadian manufacturing president Frank Haydar companies are struggling to balance the productivity gap between Canada and the US by investing in new machinery-and this is ultimately good for all of us.”

Membership in the CMTDA is up from 78 to 82 members over 2010. New member companies are: HUB Sinclair Cockburn, Kennametal Inc., Mitcham Machine tools, Garant

Best selling author Tom Deans makes the case for planning your business exit strategy

Machinery and Zecom Media. Following the membership report from Steven Fitz, a plaque was presented to new members company representatives Robert Dunbar (Ellison Technologies) and Dean Drager (National Leasing). John Manley introduced keynote speaker Tom Deans, author of the bestseller “Every Family’s Business”, who delivered a presentation about protecting wealth within a family business.

For more on Canadian machine tool sales expansion, see “By the Numbers” on page 64 www.cmtda.com

14 | FEBRUARY 2012 | www.canadianmetalworking.com

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Floor Space What’s the biggest mistake a new shop owner can make in their first year of business?

“The worst decision that a new business owner can make is to overextend themselves financially [so they can’t] compensate for any downturns in the future. I have found that many businesses have failed due to owners purchasing top-of-theline equipment, brand new and financed over long terms.

Any minor dry spell—which is bound to happen—will result in disaster [with the shop owner] not being able to make payments on equipment.”

-Adriano Oppio, Vice-President, Classic Tool & Die Inc., Oldcastle, Ontario

“I think the biggest mistake is under estimating the amount of time you need to devote getting the business off the ground.

Expect to work long hours for a fraction of what you were getting working for someone else.”

-Peter Alden, co-owner, Wessex Precision Machining Limited, Ayr, Ontario

“There are not as many new start-ups of late in our immediate marketplace, in big part because of the economy and the recent pressures on manufacturing in general. However, there

have been a couple and the common mistake they tend to make is in their pricing. The natural tendency is to undercut their competitor’s right out of the gate, in some cases by significant amounts. They are “buying” new business. From my experience, this is short-sighted and cannot last. Newcomers are trying to compete with companies who have been in the field for 20 – 30 years and have a precise understanding of their costs … [under pricing themselves] is a mistake. Unless they can do so and still generate a profit, it is a useless exercise and will inevitably result in financial losses in their near future. Being competitive is one thing, being silly is altogether another.”

-Joseph Manzoli, president, Colourfast Custom Coatings, Concord, Ontario

“Underestimating the needs of running the business and putting too much faith in one customer. Too many people forget that the cost of opening the doors in the morning plus overhead along with a top heavy organization can kill a company. Startups [sometimes rely] on a relationship with a past customer who feeds them work until an adjustment happens—new overhead costs come in, the customer leaves and the new company is stuck without an anchor customer for its survival.”

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

“Not having enough credit or cash.”

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

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Higher, Faster, Far t her A Government review, huge orders and a controversial fighter plane make for interesting times in aerospace

By Nate Hendley Canada’s aerospace sector will soon be put under intense government scrutiny and industry leaders couldn’t be happier. The scrutiny comes in the form of a comprehensive policy review, as Ottawa looks for ways to enhance the industry’s competitiveness. Proposed in March 2011 as part of the federal budget, the aerospace policy review is expected to start soon and last a year at least.

The proposed review, plus a sunny market outlook courtesy of aviation giant Boeing, has left industry leaders feeling giddy, even in the face of so-so revenues.

“We’re pretty optimistic,” says Jim Quick, president and CEO of the Ottawa-based Aerospace Industries Association of Canada (AIAC).

Canadian aerospace revenues amounted to $22 billion in 2010 (the last year figures are available), with employment standing around 80,000. Revenues are down slightly from 2009, when they stood at $22.2 billion, with employment at 78,965.

Roughly 80 percent of aerospace products in Canada are ex­ported. About 83 percent of the industry’s profits come from civil (commercial) aircraft while 17 percent is from the military sector.

AIAC is eagerly awaiting an announcement marking the official launch of the aerospace review. Among other things, the government will examine programs and policies that benefit aerospace. These include SADI (Strategic Aerospace and Defence Initiative), a program launched in 2007 to fund research via repayable government loans to aerospace companies.

According to Quick,

Ottawa will continue to fund SADI during the course of the policy review.

The proposed review was one of the main topics of discussion at the First Canadian Aerospace Summit, an industry event hosted by AIAC in Ottawa last November. The summit attracted hundreds of people including federal Industry Minister Christian Paradis, who gave a keynote luncheon address. The summit was intended to covey a simple message, namely the importance of aerospace to Canada’s economy. “The reality of our industry is that we generate high-quality, high-paying jobs,” notes Quick.

To a large extent, these high-paying jobs are dependent on the actions of major aerospace OEMs such as Boeing and Airbus. Chicago-based Boeing reported 778 net orders for new planes through December 20 last year.

This is up from 530 net orders in 2010 and a vast improvement over 2009 when only 142 net orders were recorded.

Airbus (which is headquartered in France and controlled by parent company European Aeronautic Defence and Space

18 | FEBRUARY 2012 | www.canadianmetalworking.com

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Co.) reported 1,378 net orders for 2011, as of November 30.

This is a large gain from 2010 when 574 net orders were made and 2009 when only 271 were recorded.

Each year, Boeing issues a report, called Current Market Outlook, which offers an overview of industry conditions and a peak into the future. The most recent report, called Current Market Outlook 2011 - 2030, predicts heady times ahead.

“Passenger air travel rose eight percent in 2010, after declining about two percent in 2009. The persistent resilience of air travel is expected to sustain six percent growth in 2011 and keep the growth rate at or above the historical trend through the middle of the decade,” states the report.

Current Market Outlook 2011 - 2030 is equally bullish on new plane orders: “The long-range forecast for 2011 anticipates delivery of 33,500 new airplanes over the next 20 years, valued at more than $4.0 trillion ... single aisle airplanes account for the majority of deliveries over the next 20 years-70 percent of the airplanes and 48 percent of the value. Rapidly expanding air service within China and other emerging economies and the spread of low-cost business models

throughout the world, drive this market segment.”

The report breaks down demand by region. It predicts Asia will require 11,450 planes, at a value of $1.51 trillion over the next two decades. Demand in Europe will stand at 7,550 planes (worth $880 billion) while North American demand will come to 7,530 planes (worth $760 billion) in the same time period.

“Worldwide economic activity is the most powerful driver of growth in commercial air transport and the resulting demand for airplanes.

The global gross domestic product (GDP) is projected to grow at an average of 3.3 percent per year for the next 20 years. Reflecting this economic growth, worldwide passenger traffic will average 5.1 percent growth and cargo traffic will average 5.6 percent growth over the forecast period,” states the Boeing report.

Rival firm Airbus also has its own report, Global Market Forecast 2011 - 2030, which differs slightly from the Boeing document but still predicts massive growth ahead. Airbus pegs global demand for aircraft over the next two decades at 26,921 aircraft with a value of $3.2 trillion.

Closer to home, major Canadian aerospace players report healthy revenues.

Montreal-based CAE, which makes flight training simulators, announced a slew of contracts last year. In the second half of 2011 alone, the company recorded roughly C$400 million worth of new business with military and civilian sources.

The aerospace segment of Longueuil, Quebec-based Heroux-Devtek received a seven year contract from Bombardier Aerospace (third largest civil aircraft manufacturer in the world) in February 2011. Heroux-Devtek will make over 300 different structural components, including wing spars, wing ribs, fuselage frames and other parts for Bombardier, which is headquartered in Montreal. The deal is worth around $175 million.

For its part, Bombardier continues to work on the CSeries family of passenger jets. Launched in July 2008, the CSeries consists of 110 and 130-seat commercial aircraft scheduled to enter service next year. At present, some 2,100 Bombardier Aerospace workers are labouring on the planes, in Canada, Northern Ireland and China.

The CSeries, which features heavy use of composites and advanced aluminum alloy, is being billed as eco-friendly.

Bombardier promises that the CSeries “will be the greenest single-aisle aircraft in its class” when it finally enters service.

The company claims the plane will emit 20 percent less carbon

“Canada’s aerospace sector

will soon be put under intense government scrutiny and industry leaders couldn’t be happier.” dioxide and 50 percent less mono-nitrogen oxide, fly four times quieter and burn 20 percent less fuel than other similarly sized jets.

While the true environmental value of the CSeries has yet to be determined, the plane does represent a huge opportunity for Canadian firms. Final assembly will take place at Bombardier facilities in the Montreal area, which will mean a bonanza for domestic aerospace suppliers.

The Joint Strike Fighter (JSF) program meanwhile, continues to attract suppliers and generate controversy. The JSF initiative is a multi-billion dollar, multi-decade, American-led program to build F-35 state-of-the-art fighter planes. Canada signed onto JSF in 1997. In July 2010, the Canadian government announced it would acquire 65 F-35 Lightning II Joint Strike Fighter planes for C$9 billion, with maintenance and support costs of C$250 - 300 million.

The JSF initiative has come in for some tough criticism, however. In March 2011, the office of the Parliamentary Budget Officer released a damning report, blasting the JSF project for massive cost overruns and production delays.

The AIAC are still strongly supportive of the initiative, www.canadianmetalworking.com | FEBRUARY 2012 | 19

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Airbus enjoyed record orders in 2011. The new A350XWB nears production as the static test airframe is prepared and the final assembly line in Toulouse, France nears completion.

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Case Study

Boeing’s ongoing FA-18E/F Super Hornet programme includes landing gear assemblies manufactured by Messier-Dowty Inc. in a contract valued at nearly US$200 million. The contract also includes gear assemblies for EA-18G Growler aircraft. Messier-Dowty will manufacture the assemblies at its production facility in Ajax, Ontario near Toronto.

however. According to Quick, about 60 Canadian firms have gotten JSF contracts to date, at a cumulative value of over $800 million.

One of those firms was A-Line Precision Tool, a Toronto shop that counts on aerospace for about threequarters of its business, according to President Rob Muru. A-Line’s experience underscores the profits and pitfalls of working in the aerospace sector.

A-Line picked up a JSF contract to work on a General Electric/Rolls Royce F136 engine. The latter was intended to be an alternate engine for the F-35 if for some reason the original engine, which is being manufactured by Pratt & Whitney, didn’t work out.

“We made the main titanium engine struts in the front of the engine.

Seventeen per engine. These would be the first line of defence when hitting Canada geese or incurring FOD (foreign object damage). We also did speciality EDM work as well as five-axis machining.

One casting that we machined had 2,500 plus machining features ... that’s a lot of features and a lot of G-code,” says Muru.

For a variety of reasons, however, the F136 initiative lost the vital support of the U.S. government. In early December 2011, GE and Rolls Royce cancelled the F136 project, which meant no more work for suppliers.

“We did all the development and were basically set up for production when the plug was pulled. So we took a bath on that one ... that’s the nature of these super programs ... you suck it up, have a beer, a little cry, tell your wife and kids your summer vacation will involve domestic car travel and you move on,” says Muru, philosophically.

Indeed, despite the F136 fiasco, Muru remains buoyantly optimistic.

“The past few years have been up and down. The last six months have been great! I am expecting [business] to ramp up in the next few years,” he states. CM www.canadianmetalworking.com | FEBRUARY 2012 | 21

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Sky-high in PEI 3 Points Machining and Aerospace has set up a new operation in picturesque Charlottetown, PEI...and reaps multiple rewards

By Jim Anderton, Editor .........................................................................................................................................

Seven and a half years ago, Tom Considine and John Druken had no intention to start an aviation machine shop. In fact 3 Points Aviation began at the exact opposite end of the aviation parts life cycle: dismantling old aircraft. “Our focus was in the regional aircraft parts business, declares Tom Considine. “We buy aircraft, dismantle them and then have those components rebuilt and recertified before selling them to airlines worldwide.

We focus on Bombardier products; we have dealt in Fokker and ATR, but our real core aircraft is the DeHavilland Dash 8. We also buy inventories of airlines who find the Dash 8 no longer fits their fleet. If they’re not leased we try to buy the airplanes.

We want ‘run out’ aircraft, as well as low time aircraft. They’re expensive; we go after the components, expendables, engines and landing gear.”

3 Points still operates a substantial Toronto-based parts trading operation, but chose to expand into part machining and fabrication by launching 3 Points Machining and Aerospace, Inc. That considerable change in the business model was driven by

the repair/overhaul operations the firm was subcontracting to outside machining operations.

“We do a lot of component exchange”, says Considine, adding, “they give us back a core. But they don’t want to stock inventory. We were charging them a fee, taking their core and sending it out to a shop for overhaul. We billed it back, but figured that there was a lot of money that we could capture if we had our own shop. That’s what drew us into the business. The manufacturing side of it supports the repairs, but our end users ask for remanufacturing plus reverse engineering. Some parts we can manufacture a good deal cheaper than the repair would cost. It’s another opportunity. And of course, some parts aren’t repairable.”

Machining and fabricating for overhaul is a different paradigm from the extensive support needed to actually manufacture replacement parts. Many would simply buy an existing business, but 3 Points’ machining operation is a clean sheet startup. “We were looking for existing shops but found so many www.canadianmetalworking.com | FEBRUARY 2012 | 23

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issues in fixing them, we thought it would be better to start from scratch”, states Considine, adding “it’s all integrated, built all at once. We’ve worked very closely with Elliott Matsuura Canada.”

One of the benefits of building a custom shop from the ground up is the ability to choose the best location....and 3 Points chose one that seems improbable: Charlottetown, Prince Edward Island. Co-owner John Druken was the driving force behind the decision to set up in PEI, says Considine: “John is from Newfoundland; he explored all over Canada and the US and he knows people in PEI from the aviation business who set up in Charlottetown. The government here focuses on the aerospace sector. They want to grow that sector on the island and have various incentive programs. We were also looking for a skilled workforce. Charlottetown was the ‘right place’”.

The Government of Canada, through the Atlantic Canada Opportunities Agency, invested $500,000 towards equipment purchase and the Government of Prince Edward Island supported the project through their Department of Innovation and Advanced Learning with a $1.9 million secured, repayable loan.

Although 3 Points isn’t immune to the skilled labour shortage, there is an aero base on the island, with majors like Honeywell well established. And the natural benefits of PEI are there: affordable housing, natural beauty and the island lifestyle.

Considine has not had difficulty with employee relocation: “We’ve had people relocate from Ontario and Alberta as well as some that wanted to come back East.”

3 Points Machining and Aerospace operates both a repair/ overhaul service and aerospace manufacturing. Unlike most

Part complexity, extensive certification/approval processes and serious quality assurance are a given in th

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y assurance are a given in the aerospace sector.

metalworking segments, finished and remanufactured parts require extensive lot traceability and inspection by certified personnel. On site Transport Canada approved engineering staff brings the entire process under one roof. Certifications are key in this industry, and 3 Points carries ISO 9001-2008, AS9120 and has recently earned EASA Part-145 Approval. Certification is an ongoing process with updates and new approvals always in process. The business has developed a specialty in what Considine describes as ‘legacy product”, especially the deHavilland (now Bombardier) Dash 8. The Dash 8 is in many ways the ideal product for 3 Points’ business model: used globally, with a large fleet of aging aircraft (the aircraft was introduced in 1984), operating costs efficient enough to keep the small turboprop economically viable for many operators and perhaps most importantly, an OE manufacturer interested in avoiding the high cost of supporting the Dash 8 fleet. And the cost for an aerospace heavyweight like Bombardier is significant, with the need to inventory potentially slow turning parts which must be approved and shipped globally, often to small operators. That’s where the ability to cut metal gives 3 Points an advantage: “We can turn things quickly”, Considine states. “For new product, there are often long lead times. Look at the Joint Strike Fighter; they keep pushing it back year after year...you have equipment sitting there. With legacy support the customer needs it now. In fact, they need it yesterday. It’s ‘can you do this for us?’ ” What the legacy Dash 8 operators want 3 Points to do is supply a wide variety of parts from seat frames to engine parts. The Dash 8 is a common aircraft for smaller regional and

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ints facility. All inent in the 3 Po ikron unit is prom processes are multi-axis M GF s ile rm This AgieCha d machining ment is new an production equip

non-scheduled operators, meaning single aircraft and small fleets which mean customers who won’t inventory parts and need as little as a single repair component, fast. 3 Points uses modern equipment to fill the gap. It’s about smaller quantities. We’re using today’s technology to build yesterday’s parts”. 3 Points also supports airframes from ATR, Fokker and the Canadair Regional BCP_QT_PAGE_AD_FINAL_RESIZED.pdf 1 10/17/11 12:30 PM Jet. And Considine won’t rule out new part production in the

future. “There are a number of major airframe manufacturers we’re talking to as well...Boeing, Airbus, Agusta Westland, Bell, Pratt and Whitney. They’re interested. Boeing has looked at our operation. Others are coming to look. Our goal is to work closely with the OEM’s.”

With aerospace machining, there isn’t much carbon steel on the shop floor. There are traditional aero aluminum alloys like 7075 and 6061 in heat treatments from T3 to T6. Adding processing heat to a heat treated alloy destroys the mechanical properties of the material, so cutting processes are an important consideration. Water jet cutting is one solution but in many cases the part must be post machining heat treated to the proper state before approval. 3 Points also works with titanium, Inconel, some stainless and difficult to machine tungsten.

Regardless of the material, speed is crucial to a low inventory business model and customers who can’t afford aircraft downtime. 3 Points can scan and create CAD files to generate tool paths that flow directly to the shop floor with very little interruption or tool setup. Jobs are not palletized, although equipment like the Nakamura-Tome Super NTX Max does auto feed. The ability to approve and certify to Transport Canada and FAA standards in house closes the loop and gives 3 Points a definite advantage where speed matters...and in the airline industry, it usually does.

“We can do ‘one off’s’ to thousands”, says Considine. “That’s where to auto feed comes in. It’s by demand. Some parts we make and consign to end users...as they use them we replenish their stock. For spares on site they might order two a year...if it’s a retrofit to address a corrosion issue and a fleet might be 85 aircraft, with 14-15 rails per aircraft, it’s a production run.

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This Jet Edge waterjet machine allows clean, efficient cuts, important when the raw material can cost several thousand dollars per billet

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The airlines more and more order parts that they need today... everything is critical. They don’t want to stock inventory, so if you have one ready to go, you get the sale.”

3 Points has a solid business model and lots of experience with the Dash 8, but the firm isn’t stopping there. Other aircraft types, from small feeder liners to 737’s are aging and there is new work surfacing in pilotless UAV’s from manufacturers like Grumman, BAE and General Atomics. Combined with contract non-destructive testing and growing East Coast markets like the offshore oil industry, 3 Points’ operation is poised for growth.

Nothing is off the table for the firm, including new part design and manufacturing. “It’s something we’re exploring”, says Considine, a pilot himself. “How do you eat an elephant? One bite at a time.” CM

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26 | FEBRUARY 2012 | www.canadianmetalworking.com

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Triple Play Match machine, control and CAM software for hyper-productive high speed machining

By Jim Anderton, Editor .........................................................................................................................................

Modern CNC machine tools are capable of cutting fees and speeds that were considered impossible only a decade ago… yet many shops fail to take advantage of the full performance available to them. There are several reasons, from physical limitations in the machine tool to the code created to control tool motion. Mark Sully, Account Manager – Central Ontario for Delcam International presented a comprehensive overview of the productivity problem at Canadian Metalworking’s 2011 Future of Metalcutting Fabricating Conference and has several tips to win back that lost time and money. Sully describes the problem as three-sided: “The trend is toward a ‘triple paradigm’:

According to Sully, to manufacture in ‘high cost’ regions and make a profit, businesses must: • Get the maximum output from machine tools • Minimise unskilled labour content • Minimise quality costs How? Sully states: “by implementing the latest manufacturing methods to achieve fast, robust, automated, and productive machining processes.” The future is clearly in high speed machining, involving very fast tool feeds and speeds. The key is to ensure that the machine, machine control and software are all state-of-the-art; saving money on any link in the chain

THE TRENDS – “THE TRIPLE PARADIGM” Part Side Increased Complexity Smaller Lot Sizes Shorter Lead Times

Engineering Side More Capable Machines 3D vs 2D Design • Paperless Manufacturing • Solid Modeling

Personnel Side Skill levels are harder to find

“The future is clearly in high speed machining, involving very fast tool feeds and speeds. The key is to ensure that the machine, machine control and software are all state-of-the-art; saving money on any link in the chain compromises the strength of the system.”

28 | FEBRUARY 2012 | www.canadianmetalworking.com

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compromises the strength of the system. From a machine standpoint, Sully advises these basic parameters:

‰ Spindle speed range up to 80,000 rpm ‰ Spindle power better than 22 kW ‰ Programmed feed rate up to 60 m/min ‰ Rapid traverse up to 90 m/min ‰ Axis deceleration/acceleration of at least 2.5g (faster w. linear motors) ‰ High thermal stability ‰ Air blast/cutting fluid through spindle ‰ High frame rigidity and mechanical precision

And for the control:

‰ Fast block processing speed (0.5 – 2 milliseconds) ‰ Fast data flow via Ethernet/data server ‰ Handle extremely small, increments point-to-point. ‰ Different error compensations –temperature, quadrant, ball screw ‰ Advanced smoothing/look ahead (HSM functions) ‰ Support probing and tool setting cycles

processing to minimize down time. ‰ HSM Strategies e.g. raceline, spiral, arc fitting ‰ Powerful editing to optimise toolpaths. ‰ Gouge prevention and holder collision checking. ‰ Advanced entry/exit moves – reduce wear and dwell marks. ‰ Machine tool simulation and collision verification ‰ Customizable with macros, Visual Basic**.

There is much more to process optimization in high speed machining than can be covered in any one article….watch Canadian Metalworking for more coverage of this high-productivity, high profit process. CM

To maximise machine tool productivity, NC programs must be produced using a “state-of-the-art” CAD-CAM software. Sully advises the following features:

‰ Support for 64 Bit Windows ‰ Multi-threaded algorithms to make use of multiple CPUs. ‰ Fast Toolpath calculation and background

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A Need for Speed Still faster feeds and speeds with lighter cuts

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

When it comes to ongoing milling trends, experts point to the need for speed.

“I think that the trend will continue towards faster milling as customers seek to reduce cycle time. The machines and tools will be the only limiting factors. We will have to make tools that can work at higher speeds and the machines will need to be able to perform as well,” says Todd White, national sales manager, Scientific Cutting Tools, Simi Valley, California.

“Higher milling speeds and feeds with a lighter depth of cut will continue to grow as more and more customers upgrade their milling machines,” agrees Duane Drape, national sales manager for Horn USA, based in Franklin, Tennessee. “People want to run faster and faster and faster.”

Thomas Hagan, milling product manager at Iscar Canada, based in Oakville, Ontario, sees plunge milling to machine deep cavities as another growing trend.

“Plunge milling is very effective and productive in machining deep cavities and walls,” he states, pointing to Iscar’s Helitang – FTP line of cutters.

“This family of cutters is capable of straight plunge side plunging, boring and face machining with ramping at high feed rates at shallow depth of cuts. The inserts are double-sided with four cutting edges that are tangentially clamped,” continues Hagan.

Drape suggests CVD (Chemical Vapour Deposition) diamond tipped tools, used to cut hard, non-ferrous materials, will become increasingly popular.

“A CVD diamond tip is where we see the future ... the cost for the tool is 30–50 percent more than a polycrystalline (PCD) diamond for the overall manufacturing process ... but the hardness of the CVD diamond is equal to natural diamond, so it’s 30–40 percent harder than polycrystalline diamond,” says Drape.

Here’s a look at what’s new and/or noteworthy in cutting tools:

ISCAR – EFP LINE

Israeli tool giant Iscar offers a new family of EFP Solid Carbide Endmills.

The EFP line blends features from Iscar’s Feedmill, Chip Splitter and Chatterfree endmills. EFP Endmills can be used for slotting, pocketing, helical interpolation and contouring.

“The Feedmill bottom utilizes a large radius cutting edge configuration that allows for greater increase of feed rates—up to 0.5 mm/tooth at 0.3 to 1.0 mm depth of cut. The results are higher productivity in the application of pocketing into the mould. The Chip Splitter edge is able to break up the chips and reduce the cutting forces. The Chatterfree helix has variable pitch which is excellent in dampening the vibration, especially in long overhangs,” states Thomas Hagan, milling product manager at Iscar Canada, based in Oakville, Ontario.

EFP Endmills come with either four or five flutes and can machine hardened steel, cast iron, stainless steel, titanium and high temperature alloys. The series is also designed to reduce cycle time and boost productivity. http://www.iscar.com

KENNAMETAL GOES BEYOND

Kennametal presents the BEYOND KCPM20 indexable milling grade.

“KCPM20 is a micro-engineered milling grade featuring a CVD coating process with special surface treatments. KCPM20 is targeted as a best in class grade for high-speed dry milling capability, under stable conditions, in plain and alloyed steel,” says Scott Etling, a manager of global indexable milling at Kennametal, which is headquartered in Latrobe, Pennsylvania.

In terms of secondary applications, Etling says KCPM20 is “an ideal optimization grade for stainless steel machining applications where coolant is not used and optimal wear resistance required.” www.kennametal.com

NEW SHOULDER MILL FROM SUMITOMO

Sumitomo Electric Carbide, the Illinois-based branch of the Japanese parent company, released their WFX series of shoulder milling cutters just before Christmas.

The high-precision body on the WFX Series includes a cutter containing a 90-degree lead angle, and is optimal for shoulder milling. The WFX offers high accuracy which translates to exceptional part squareness.

30 | FEBRUARY 2012 | www.canadianmetalworking.com

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The high-precision body on the WFX Series includes a cutter containing a 90-degree lead angle, and is optimal for shoulder milling

“The WFX inserts’ convex cutting edge provides extreme toughness and features an integrated wiper that delivers an excellent surface finish. The Series includes coarse, fine and super fine pitch cutter bodies. Coarse and fine pitch versions range from 2 to 8 inch diameters, while super fine pitch bodies are available in 2 to 5 inch diameters,” according to the company.

Cutters in the WFX series feature a newly developed, multilayer Super ZX coating which strengthens fracture and adhesion resistance and lengthens tool life, says Sumitomo. www.sumicarbide.com

WALTER – NEW MILLING CUTTER

German tool giant Walter Tools recently introduced the F4050 Milling Cutter with polycrystalline diamond (PCD) cartridges.

“Key features are adjustability of run-out to improve finish, flexibility of different cartridges for specific applications, large selection of geometries for universal use,” says Thomas Benjamin, a marketing manager for Walter USA, which is based in Waukesha, Wisconsin.

The cutter uses high-tensile steel cartridges with brazed PCD drill points. An adjusting key results in a micro-precise run-out of the cartridges. Settings are effected by clamping screws, which are tightened with defined torques to allow for high limiting speeds. Fine balancing screws ensure a high balance class as

well. Tool bodies are available in diameters ranging from 80 to 200 mm. The F4050 mill is designed for machining non-ferrous materials. www.walter-tools.com

SGS TOOL COMPANY – EXPANDED Z-CARB-AP VARIABLE RAKE ENDMILLS

Late last year, SGS Tool Company of Munroe Falls, Ohio, expanded their line of Z-Carb-AP Variable Rake End Mills to include smaller sizes for a fuller offering.

The company’s flagship endmill product, the Z-Carb-AP features enhanced corner geometry with a tighter tolerance corner radius for more accurate machining, unequal flute spacing, and unequal helix design. The Z-Carb-AP’s geometry is designed with chatter suppression in mind.

This year, SGS will be releasing a multiple flute end mill for finishing applications. Said mill will be “primarily geared towards aerospace and medical materials like titanium, stainless steels, those types of materials,” says SGS product manager, Jason Wells. www.sgstool.com

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32 | FEBRUARY 2012 | www.canadianmetalworking.com

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MMTS_gu

Montréal Manufacturing Technology Show 2012

Official Show Guide

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Canadian Metalworking has been chosen by SME to produce the official 2012 MMTS Showguide.

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cmw MMTS_guidepromo.indd feb 2012 Cutting tools pg 1 30-35.indd 33

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Mate…the Special Applications Experts.

Scientific Cutting Tools of Simi Valley, California released a complete line of Acme and Stub Acme Thread Milling Cutters a little over a year ago. Now a standard item, these mills had been previously manufactured as special tools.

The line offers thread sizes from 1¼ - 5 inches and micro grain carbide uncoated and TiALN (titanium aluminum nitride) coated tools. These thread mills produce small chips which can be controlled with flood coolant. Tools cut both left and right hand threads.

The line is designed to ensure speedy thread cutting and cost-savings, compared to tapping. www.sct-usa.com

HORN USA — SMALL DIAMETER CARBIDE TOOLS

Last year, Horn USA introduced their DC line of Solid Carbide Cutting Tools for machining grooves, threads and chamfers.

“These tools are for diameters smaller than our Mini-Milling replaceable insert product line,” explains Duane Drape, national sales manager of Horn USA. Horn also offers a threadmilling line featuring multiple flute tools.

“We stay with our preferred method of only one level of cutting edges. Most of our competitors have multiple levels of cutting edges and a reduced number of flutes. Our approach results in the customer being able to feed the tools substantially faster and if the thread is not perfect, he can rerun by changing an offset diameter. The multiple level cutters potentially leave a slightly tapered thread,” adds Drape, speaking of the threadmilling line. www.hornusa.com 34 | FEBRUARY 2012 | www.canadianmetalworking.com

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EC-H mills come in two family types: cylindrical and relieved shank endmills.

Endmills in both families offer a 6 – 25 mm diameter range, while all have corner radii. Improved dampening performance will prolong tool life up to 25 percent, says Iscar. These mills reduce the cutting forces and power consumption of the machine and provide improved chip evacuation. CM

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NIAGARA CUTTER INTRODUCES NEW THREAD MILLS

Niagara Cutter of Amherst, New York has introduced a new line of High Performance Carbide Thread Mills, designed to ramp up productivity, quality and performance consistency. Said mills come in a variety of thread sizes and diameters. Options include AlCrN (aluminum chromium nitride-based) coating and extended reach. www.niagaracutter.com

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WALTER USA NEW FOR HARD MACHINING

Another new offering from Walter is the Proto-max Ultra, a ball-nose, solid carbide endmill designed for hard material machining. These new mills come in two different diameter ranges: the standard version offers a 3 – 12 mm diameter while the mini version offers diameter ranges as low as 0.1 – 2.5 mm.

Main applications for the Proto-max Ultra line include hardened materials up to 70 HRC in die and mouldmaking and similar operations in general machining and heavy construction. In addition to semifinishing and fine finishing, the Proto-max Ultra can be used for semi-roughing and roughing.

ISCAR IMPROVED DAMPING PERFORMANCE Iscar also recently introduced a line of new EC-H endmills, with a four flute, variable pitch and different helix flute angles: two 35 degree helix flutes and two 37 degree helix flutes. The

Visit HydroFlow.Eriez.com or Call 888.300.ERIEZ www.canadianmetalworking.com | FEBRUARY 2012 | 35

cmw feb 2012 Cutting tools pg 30-35.indd 35

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Welding News PORTABLE WELDING SOLUTIONS FROM SEMIAUTOMATIC WIRE FEEDER

Designed for use in shipbuilding, offshore, construction or pipe welding operations, the Lincoln Electric’s portable Active8 wire feeder is small enough to fit through ship manways. It’s modular designed is light enough to carry around the site.

The Activ8 is capable of feeding self-shielded FCAW or FCAW-G and GMAW (MIG) gas-shielded wires at 50–800 IPM (1.3–20.3 m/min). The unit will handle GMAW wires .023–.052 in. (0.6–1.3 mm) in diameter and FCAW wires of .035–5/64 in.

(0.9–2.0 mm) in diameter. The portable wire feeder is rated at 330 amps at 60 percent duty cycle and weighs in at only 27 lbs. (12.2 kg).

This modular unit is designed specifically for 8 in. (200 mm) spools, is compatible with any DC CV and/or CC power source, boasts simple controls including front WFS knob and internal booted cold feed and/ gas purges, trigger interlock Lincoln’s Activ8 is a tough durable portable and CV/CC switches. The wire feeder. unit is enclosed in a tough plastic case molded from high-impact, flame-retardant material and features the MAXTRAC Drive System with dual gear-driven drive ensuring positive feeding performance, a patented wire drive with tool-less drive roller and wire guide changes for quick spool replacement. A tachometer-controlled motor powers drive rolls for smooth, steady feeding without wire slippage. www.lincolnelectric.ca

AWS BRINGS AUTOMATED WELDING TO ORLANDO

Orlando, Florida will be the scene of the American Welding Societies’ (AWS) Conference on Automated Welding. Held on March 6 and 7, 2012, the conference will feature talks on a variety of topics, including tandem arc welding, hybrid welding, several hot wire processes, Computer-Controlled Hot Wire Tig Welding and Cladding of Land-Based Gas Turbines, the new SAT process from Sweden, as well as presentations on the latest in networking, laser welding, welding of aluminum, robotic inspection, and friction stir welding. Speakers on U.S. Army challenges, such as GMA welding of titanium and the welding of ballistic steels will also be on the agenda. www.aws.org/conferences/2012automated.html

HOBART BROTHERS OFFERS FILLER METALS FOR DEMAND CRITICAL SEISMIC APPLICATIONS

16 metal-cored and flux-cored (gas- and self-shielded) wires that meet the AWS D1.8/D1.8M, Structural Welding Code-Seismic Supplement for Demand Critical welds in seismic moment frame welded connections are being offered by Hobart Brothers.

These filler metals have all been three-lot tested in accordance with AWS D1.8/D1.8M:2009 testing requirements and meet the requirements specific for their diameter and shielding Hobart Brothers now offers sixteen gas (where applicable). As a flux-cored and metal-cored wires, including its popular Fabshield XLR-8 result, they are considered wire, that meet the D1.8 Seismic pre-qualified for seismic Code requirements for Demand applications and can be used by Critical Seismic applications contractors without additional

filler metal testing. The additional testing also ensures that the deposited weld metal has adequate strength and toughness at the specified heat input envelope for the low and high heat inputs according to individual diameter sizes.

Included in the company’s offering for D1.8 Seismic filler metals are the popular Hobart Fabshield XLR-8 self-shielded flux-cored wire, the Tri-Mark Metalloy Vantage metal-cored wire and the Hobart FabCO Hornet gas-shielded flux-cored wire. www.hobartbrothers.com

LINCOLN EXTENDS MONEY MATTERS REBATE PROGRAM

Lincoln Electric’s successful Money Matters rebate program has been extended until Feb. 29, 2012. The company has expanded the program to include additional products like the Power MIG 180 Dual and the new Power MIG. Rebates on the new additions are $100 for the Power MIG 180 Dual and $200 for the Power MIG 256. Lincoln has also bundled its Tomahawk 625 plasma cutting system with a Torchmate(r) 2x2 CNC plasma cutting table, offered with a $300 rebate. The existing offer are: Power MIG 140C - $75 rebate, Power MIG 180C - $75 rebate, Power MIG 180 Dual - $100 rebate, Power MIG 216 - $125 rebate, Square Wave(tm) TIG 175 - $150 rebate, Outback 145 Engine-driven welder/generator - $150 rebate, and the Ranger 225 Engine-driven welder/generator - $200 rebate. www.lincolnelectric.ca

HYPERTHERM CUTTING INSTITUTE NOW ONLINE

Hypertherm has unveiled an enhanced Hypertherm Cutting Institute, an online training community that offers a number of resources for people who work with or want to learn more about cutting metal. Key features found on the online site are video tutorials providing thorough step-by-step instruction, interactive e-learning courses on everything from consumable care and optimization to gouging and cutting technique, discussion forums and blogs where metal fabricators and hobbyists can talk about their current products, troubleshoot issues and share ideas.

An added bonus: Hypertherm experts like Jim Colt will drop by from time to time to offer advice and answer questions.

The idea section, called My Hypertherm Voice, is designed for visitors who want to offer suggestions for future metal working products and then vote on their favourite ideas. www.hyperthermcuttinginstitute.com

36 | FEBRUARY 2012 | www.canadianmetalworking.com

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cmw feb 2012 Welding news-col pg 36-37.indd 37

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Efficient power New power sources bring production gains and energy efficiency to the plant

By Nestor Gula . ...................................................................................................................................................

We all want to do more with less. This is the human condition. charge ($/kWh), number of shifts, hours per shift, days per In most situations this is an ideal that is doomed to fail — one week, weeks per year, operator factor, number of machines can’t get blood from a stone after all. However, with the new and percent of machines welding at one time. In the example breed of welding power sources you can get more welding above, one machine welding at an operator factor of 30 power while using less energy. percent for one six-hour shift for five days a week and 48 “Today’s inverters are smaller and require less energy to weeks per year gives a savings of $317.67. use,” said Brent Williams, marketing manager for Miller Electric “There is a huge difference particularly when power Mfg. Co. “it’s a matter of refining that welding output and supplies are idling,” said Neil Armstrong, Vice President and providing the welder with as much flexibility and functionality General Manager of ESAB Canada. “A power supply is only as possible, and that’s what new inverters are able to do: More being used maybe 25 to 30 per cent of an eight hour shift power and more control in a smaller but it still is using a lot of energy, especially the footprint.” Inverter power sources fan, when it is idling. Most manufacturhave been around for a while, and are ers now make various versions of fan replacing the older rectifier/transistor on demand or fan as needed.” based power sources due to their effiInverter power sources are much ciency. “In terms of energy savings, one smaller in size and lighter in weight inherent benefit is a reduction in your reducing the footprint on the producenergy bills. A 350-amp conventional tion floor. “Newer power sources are machine draws 128 amps of input designed to take advantage of innovapower under a rated load on 230-volt tive and superior design platforms,” single-phase power while a comparasaid Elaine Slatter, Country Manager/ ble inverter only draws 32 amps,” said Director of Marketing Administration Williams. “More important, however, for Thermadyne Welding Products is the ability to run more equipment Canada Ltd. “For example power off of your existing electrical infrafactor correction (PFC) allows structure. Power efficient inverters maximum performance to be use substantially less power than achieved for a given input. The newer machines of the past, which may allow inverter power sources also can be operations to increase production by as much as 650 times faster than adding more work cells without having conventional Thyristor (SCR) welders to add more power to the building. It and deliver superior arc starting goes to a bigger theme of being able performance.” There are great posto do more in your existing footprint.” sibilities of innovation with inverter You might imagine that the power power sources. “The capabilities of savings are not at all significant, can only some of the newer machines such as be measured in a laboratory environment the new Thermal Arc Inverter and will only show savings to the bottom line 3 in 1 machines allow for three when using multiple machines in processes to be completed in one The Miller Axcess 300 is loaded with welding programs including an intense industrial setting. At machine, MIG, (GMAW/FCAW) Accu-Pulse, Accu-Curve, Accu-Speed, and has multiple data ports for Lincoln Electric’s Web Site they STICK (SMAW) and TIG (GTAW),” data transfer and optional program downloads. have a handy tool that will let she said. Having three processes you estimate, with a fair degree in one machine “enables flexibility of accuracy, the amount of savings you will see by switching on the production floor and cutting down on set up time. The to a new power source. “If you select a Power Wave S350 as newer machines are Analog Inverters with Digital Control the Inverter Machine, a CV-400 as the Conventional Machine, Platform design which enables very fast control response and and an output current of 300A, you can see the resulting optimized welding performance.” differences,” said Joe Daniels, Manager - Machine Technology Smaller footprints, lighter and more energy efficient the R&D for Lincoln Electric. “You can configure the calculation inverter power sources are less expensive to manufacture. for a given production schedule/usage rate and a given energy “An inverter based power supply has a significantly smaller cost.” The tool can be adjusted for output current, energy main transformer,” said ESAB’s Armstrong. “Power supplies 38 | FEBRUARY 2012 | www.canadianmetalworking.com

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Astralloy Saves Big Using New PHD System From ATTC Astralloy Steel Products Inc. is a steel service center Birmingham Alabama.

“We are cutting steel .75 inches and above. To do

John Mattocks Branch Manager Astralloy Steel Products

and the ability to cut thicker plate,” said Mattocks, “we considered purchasing new CNC plasma cutting not an option.”

“The new torches have increased productivity by about 25% due to an increase in speed and longer consumable life.”

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plasma system to a high density cut quality without a big capital investment. and longer consumable life. Now, there is very little grinding time needed to remove slag and dross. Grinding time was reduced by 75%, from eight hours to two,” said Mattocks.

“All in all it was a good investment.” ®

www.BetterPlasmaCuts.com/now * Our Plasma PHD kit turns standard plasma into plasma high density

cmw feb 2012 Power Sup Weld pg 38-43.indd 39

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“Canada represents a very important market for Fladder-Hansen & Hundebol Inc..

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Lincoln Electric power sources come standard with Checkpoint and PowerWave software built in. Here we have a Power Wave S350 welder with a POWER WAVE® STT® ADVANCED PROCESS WELDER MODULE and the Power Feed 25M semiautomatic wire feeder.

can be much smaller and use less copper. You can ultimately make the power supplies at a much reduced production cost that will also result in a lower sales price. As the technology of the inverter power supplies continues to develop you will see them becoming less expensive. On the other side your transformer/rectifier power supplies will become more expensive because of the cost of the raw materials like aluminum and copper.”

COMPUTER CONTROL

It is hard to believe that but 30 years ago computers were only starting to be adapted into the workplace. “Computer control is becoming more prevalent, especially in the higher end of the industrial power supplies,” said Armstrong. “You can record the welding data: heat input, time of arc on, efficiency, control the wave form down to the smallest detail or you can use the factory driven setting so you turn one button and you have automatic welding procedures already in place. ESAB has a patented technology called Qset where you set a plate thickness and the algorithms will set all the currents and amps for you and as you weld, it will measure your welding and automatically adjust the arc to optimize the weld.”

Modern power sources can collect data to streamline and improve productivity on the shop floor. “CheckPoint is our new version of our production monitoring software,” said Lincoln’s Daniels. “Where we are able to collect data from our power sources and you will be able to understand everything that is going on in a production environment.

The ESAB Aristo 1000 AC/DC Power Source can be controlled by a remote function and is designed for used in installations where long welding cables are necessary.

Idle times, welding performance and you can aggregate that data over a period of hours, days, weeks.” Using cloud computing, CheckPoint ��������������������������������������������� allows the operator to obtain performance information on their Lincoln Electric welders and welding operations wherever they are, from any computer and almost any mobile device, without the need to install, purchase or maintain specialized software or IT hardware.

“We have a function, in Checkpoint, that tracks consumable usage so if, for example, you have a 33 pound spool of wire, the machine keeps track of that” said Daniels. “So it knows when you have five pounds or eight pounds left. So with that information you can send an email alert to the person that is responsible for bringing more wire to that workstation. You can do it in a timely manner so that you do not run out of wire. You also have the capability to predict how much work time you have remaining with that consumable supply.” This function works like a new gas gauge in newer automobiles that predict the driving range based on current driving conditions.

It works in both semi automatic or automatic applications.

WAVE CONTROL

Modern inverters give the operator the ability to adjust AC balance and frequency beyond the limits of conventional machines. “Old transformers typically allowed only the electrode negative (EN) portion of the cycle to be dialled up to 70 percent,” said Miller’s Williams. “Today’s inverters allow operators to set it up to 99 percent. This extended balance range (along www.canadianmetalworking.com | FEBRUARY 2012 | 41

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“Power efficient inverters use substantially less power

than machines of the past, which may allow operations to increase production by adding more work cells without having to add more power to the building.

”

with AC frequency, described below) allows for the arc to be fine-tuned according to base metal conditions in each application. It achieves greater penetration, faster travel speeds, narrows the weld bead, extends tungsten life, produces a smaller etched zone and permits the use of a smaller diameter tungsten to more precisely direct the heat into the joint. Also, EN and electrode positive (EP) cycles can be set independently to further fine-tune the arc.

“We have two specific weld forms, one is called Rapid Arc, which is a waveform that has been around for quite a few years and we have Rapid X that we just introduced at the FABTECH show (November 2011),” said Daniels. “We have had the capabilities to modify waveforms for 15 years now. The approach that we have been taking lately is to use our engineers to create these waveforms for our customers so that the customer does not have to be concerned with trying to optimize or create a waveform of their own. We do that work for them because it

can be quite a complex process to create a new waveform.

There is currently a lot of interest in this area because they are job specific. We are able make waveforms that are specific for high travel speeds. We can make waveforms that are specific for out of position work. We have some waveforms that work better for high deposition. So we are able to create waveforms for any number of specific applications.

“Inverter based power sources are the future in North America,” said Elaine Slatter from Thermadyne Canada.

“There have been some big advancements in the last five years in inverter technology. The new power sources are becoming more sophisticated in design and yet simpler to operate and much more portable due to the lighter weight.

The technology will continue to advance to take advantage of designs that deliver lightweight, portable machines that are energy efficient while at the same time delivering outstanding welding characteristics.” CM

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Let the good times roll Kawasaki uses advanced CMM technology for precision small engine production

Kawasaki encourages motorcycle enthusiasts to “let the good times roll,” but good times of another sort are rolling at the company’s Maryville, MO small engine plant, where two 5-axis scanning probe systems are slashing CMM inspection and probe calibration times, and speeding up QC feedback for machining of small engine components. The 5-axis Renishaw REVO systems, installed on Mitutoyo Crysta-Apex 121210 CMMs, replaced two PH10 articulating heads using SP25 scanning probes on traditional 3-axis CMMs. The REVO-equipped CMMs have cut inspection times by half or more on scanning intensive applications, eliminated the need for custom probe configurations, cut probe calibration times from six to seven hours to about 45 minutes, and added new capability to collect large amounts of form measurement data, improving part quality. Of primary importance, the REVO systems have greatly increased inspection throughput, data quality and flexibility of the QC department, enhancing its value as a strategic support asset to both manufacturing and R&D.

THE KAWASAKI PRODUCTION SYSTEM

Kawasaki’s 800,000 square-foot Maryville plant, opened in 1989, produces single and twin-cylinder air-cooled or water-cooled engines, 1000 cc or smaller, for commercial and consumer lawnmower OEMs, as well as for a sister plant that manufactures ATVs and Mule™ utility vehicles. Operations at Maryville include aluminum die-casting, plastic injection molding, extensive amounts of machining, painting and assembly. All engines – approximately 500,000 per year – are run-off before shipping as well.

“We use the Kawasaki Production System (KPS),” said JC Watts, Quality Control Technical Group Supervisor at the Maryville plant. “Our quality and engineering requirements are comparable to the best in the automotive industry, though our manufacturing is focused on lower volumes of many different kinds of products.” The plant has 50 machining lines, typically arranged in a U-cell pattern with start and end machines across from each other. “Primarily, it’s one-piece production with

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ecting ad insp Revo he s small e a FX seri wheel fly engine

machining lines running a part through multiple processes at a high rate,” Watts explained. Kawasaki utilizes automation in many die cast and some machining operations, accomplished through the integration of Kawasaki robots. On one of the crankcase lines, robots load raw materials and unload finished parts that are placed into inventory for assembly to draw upon. Machined parts include aluminum, cast iron and steel.

“We’re running similar tolerances that automotive powertrain uses for high-end products, and there are probably four or five critical processes for our aluminum parts and 15 for the steel parts,” Watts added. It is not uncommon to find tolerances “in single digits in microns” for form, and 0.05 mm true position.

The QC lab is responsible for inspecting 125 different massproduced parts, as well as vendor parts and those produced for engineering development. The environmentally controlled lab is located adjacent to the machining lines, and parts intended for routine inspection are delivered on carts or via train (an electric vehicle towing several trolley carts). Critical components may be hand delivered for priority inspection during a line changeover or if an operator suspects a problem.

5-AXIS SCANNING ADVANTAGE

“When I started here, we had a couple of 3-axis CMMs with PH10 articulating heads and SP25 probes, and another CMM with a fixed probe head,” Watts explained. However, we wanted to do better than what the industry considered the norm, so we looked at several options and the 5-axis REVO system appeared to be the fastest and most flexible available. It was the best fit for our requirements.”

Kawasaki bought a new Mitutoyo Crysta-Apex 121210 in 2009 with the REVO system installed from the factory, and retrofitted an identical machine in 2010, after the first machine was up and running with all the part programs.

The REVO 5-axis scanning probe head can collect up to 6000 data points/sec. It is engineered for high-speed precision measurement of contoured surfaces and complex geometries requiring high volume data collection to validate fit and form with high accuracy. It uses two rotary axes, one in the vertical plane and one in the horizontal, for infinite rotation and positioning. Five-axis software drives the measuring head and synchronizes its motion with the linear axes of the CMM. Lookahead algorithms drive the probe path and CMM in coordinated continuous motion. The head adapts position while measuring on the move, maintaining stylus tip contact with changing contours at scanning speeds of up to 500 mm/sec.

“Though our SP25s were scanning probes, we were doing 95

percent touch probing because scanning was too slow with a 3-axis CMM,” Watts explained. “Our cylinder and crank bores are probably the best examples of where we believed touch probing was inadequate. To accurately collect enough data points to measure the geometry of a bore 80 to 100 mm in diameter and 150 mm in length, the SP25 probe took so long we limited those inspections to machine set up or special requests from our design department. Now on every crank case we measure, the REVO does a spiral scan of bores and the system outputs the values to software. We also send a graph of the data points to our network that can be used by anyone in QC, engineering or production, and it really helps troubleshoot problems. You can visualize the problem. What would take 3-4 minutes with an SP25, we’re measuring in 10 seconds with the REVO.” The REVO scanning heads have all but eliminated the need for touch probing. Now 95 percent of inspections utilize scanning, with no “time penalty” as before, allowing Kawasaki to collect so much data that it challenges the speed of computers doing the analysis. The REVO probe can also do “head touch” probing or be used for traditional machine-touch probing when the situation calls for touches.

“With scanning inspections, our production and engineering people have a lot more confidence that the data is valid,” Watts added. “With touch probing it is easy to get one speck of dirt that causes an out-of-round condition if you’re only sampling seven or eight points. It can throw the location of that circle off.

We have specific documented examples of where there were flatness errors we would not have caught with touch probing, and cylinder bore geometries that would not have been caught with touch probing because of the amount of data sampled with the touch probe. We still caught these problems before they left the plant, but the parts were scrap. The REVO scanning capability allows us to catch form errors much more quickly, without a time penalty on our inspections. It has definitely made us more proactive in catching quality problems early in the game.”

High performance, low price CNC Coordinate Measuring Machine meets global standards Mitutoyo Canada’s new CRYSTA-Apex S Series CNC coordinate measuring system provides high speed scanning with high accuracy in the 1.7µm class and is equipped with a new controller algorithm for performing high speed and accurate scanning. Mitutoyo’s newly developed drive system offers increased speed and low noise. Standard equipment includes built-in temperature compensation, auto-leveling pneumatic vibration isolator and ultra-high accuracy crystallized glass scales on all axes. Mitutoyo’s bridge-type CNC CMM’s with high speed and high accuracy are available in a large variety of measuring range capacities. Mitutoyo has Metrology Centres in Mississauga and Montreal, with a full complement of Canadian service and sales support personnel.

Mitutoyo Canada Inc. www.mitutoyo.ca

www.canadianmetalworking.com | FEBRUARY 2012 | 45

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FEWER PROBE CONFIGURATIONS, MORE FLEXIBILITY

With REVO, the Maryville operation now has two probe configurations that measure all of its mass production parts, reserving custom probes in a changing rack for a few special applications. Special configurations for vendor parts have also been eliminated because the infinite positioning angles of REVO allow measuring of a part without special fixturing or consideration of which probe to use. With so few probes, calibration time has dropped to around 46 minutes. Now QC technicians monitor the calibration instead of calibrating every shift.

“We are now able to measure all our mass production parts with just two probe configurations,” said Watts. “We were able to eliminate the large ball stylus configurations because of the large approach angle the REVO creates between the stylus and the work piece. During scanning the REVO maintains the approach angle which allows a large cylindrical feature such as a cylinder bore to be measured with the same stylus used for measuring a 5mm bore, with no chance of shanking the stylus.”

Flexibility of the REVO system has also proven to be a time-saver for Kawasaki. “We can measure any part on either machine with a limited amount of fixturing and no special calibrations,” said Watts. “We measure all our parts on three types of fixturing. The REVO probe orients itself to the part after it’s initially aligned. The utilization of special fixtures has almost been eliminated, without concerns of measurement error due to part alignment.”

Kawasaki programs all of its inspection routines in-house

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using Mitutoyo’s Mcosmos 3.1 software. The upgrade to REVO instigated a shift to parametric and modular programming of inspection routines through in-house development of coding.

This allows a program to be used for a part family. “We might have 30 different crankshafts, for example, but because everyone has the same features, only in a different size or location, we can use the same inspection program to measure all the parts,” Watts stated. “That’s one of the big advantages we gained.” Infinite angles of the REVO system make it simple to create parametric programs because there is no concern about the stylus interfering with a part feature, due to size or orientation of the feature. The probe automatically aligns normal to the feature being measured, simplifying programming.

FASTER INSPECTION, BETTER DATA FROM QC TO R&D

Watts says the transition from 3-axis to 5-axis programming is not difficult, and a programmer with limited ability can still program REVO inspections as 3-axis. However, when it comes to optimizing speed of inspection, it is critical to use head motion as much as possible. “This allows you to scan parts the quickest, without inducing measurement error,” he added.

“REVO opens up a lot of possibilities, with few limitations, so speed gains are obtainable for both the higher and lower skilled programmers.”

Inspection results may be relayed to the machining lines manually or they can be accessed locally by line operators over a computer network. “Some of our inspection reports supply offsets directly back to the machining centers coordinate system; this allows the CNC operator to read the offset adjustment right off the report, allowing no misinterpretation of what offsets the operator needs to input,” Watts explained.

“We take advantage of some of the ‘best fit’ algorithms and work with our production engineers, especially on parts that require more complex algorithms to get the adjustment right, and to utilize multiple process adjustments simultaneously. We had limited ability to do this before the REVO; the REVO allowed us to utilize parametric programming, which in turn allowed us to expand our capability across the board more easily.”

Five-axis CMM scanning has been a game-changer for QC at the Maryville plant in terms of speed, data quality, and inspection capacity, according to Watts. “We’ve enjoyed big gains from having two machines that are completely redundant, so if one machine breaks or is down for calibration, it’s no problem to measure critical parts on the other machine. That’s a big advantage in the QC lab, because we were the ones who, in a pinch, had to get the large part on the small CMM, or the part requiring the odd angle probe on the machine that didn’t have it. We used to get requests from R&D to measure certain geometries, and it was next to impossible to achieve in the time allotted. Now we can provide the data much quicker and, being scanned data, our people have greater confidence in it. This new flexibility, the reduced fixturing, form measurement, the parametric programming – these are all collateral advantages, in addition to the raw inspection speed.”

The Maryville facility has run more than 50,000 parts through the two REVO equipped CMMs, and Watts indicated there are plans to expand the use of the REVO system to gear inspection and cam lift if it proves feasible. “We’ve developed our own algorithm and sub-routine in our software for cam lift, and, that’s something that would have been more difficult to do without the REVO system due to the angle the probe requires to measure the lift on the lobes.” CM

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

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

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Speed and form measurement with the industry standard SP25 scanning probe Automation and feedback – interface with robots and machine tool controls Plug and play – rapid installation, single phase, no air supply

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Top GEAR Ontario Drive and Gear started as a transmission maker for ARGO off-road vehicles….but they’ve become a premier Canadian success story in gear making

By Jim Anderton, Editor .........................................................................................................................................

“Grinding gears” is not an expression that conjures up a pleasant image….unless you’re New Hamburg, Ontario-based Ontario Drive and Gear. For ODG, grinding gears using new state of the art equipment has changed the “blank-hobbfinish” paradigm and closed the gap between custom job work and mass production runs.

Founded in 1962 in Kitchener, Ontario, ODG launched the iconic ARGO amphibious vehicle in 1967. By 1969, the firm had outgrown their Kitchener facility and moved to their current 10-acre site in nearby New Hamburg, Ontario. In 2001, a new 40,000 square foot climate controlled facility on the site effectively split the operation into a Vehicle Division and a Gear Division, driving a new focus on outside customer gears and power transmission solutions.

“Actually we were a gear shop before we were a vehicle manufacturer”, says ODG general manager Joel Wright adding, “we were originally the subsidiary of a German gear company, using older hobbers and shapers. At the time there were over 40 different all terrain vehicle manufacturers and we became suppliers of parts and gearboxes; when one of the manufacturers went out of business we bought the design rights. That became the ARGO, in 1967. We went from being a gear shop to making ARGOs…..machining was an offshoot of the operation. Somewhere in the mid 80’s we asked ‘where do we go’? Part of the plan was to revive the gear business. We added CNC technology in the early 90’s. It’s almost all CNC today. This facility is built to accommodate these machines. We expanded on 2007…its been interesting going from a nothing, to a $20M dollar operation, looking at $25M next year. It’s been quite a ride.”

That ride has brought ODG’s 110 employees to a level of

sophistication that the company now handles complex OEM power transmission engineering for everything from Mars rovers to hybrid buses, military machines, to automotive drivetrain assemblies, all for major, brand name manufacturers. The reliability of these types of equipment simply does not allow for failure. The majority of the shop floor personnel are licensed machinists. ODG partners with Conestoga College to rotate five apprentices and co-op students through the facility every year. ODG boasts a strong product and process engineering team that allows design from concept to production to validation under on roof. “It’s been rapid growth” says Wright. “We’ve added lots of technology. The focus has been gear grinding and hard finishing. It’s tight tolerance work and grinding has been at the centre of it. Grinding is not a cheap process…we spent about 10 million dollars in the

“ODG handles complex power transmission

engineering for everything from Mars rovers to MRI machines”

1

2

past five years. It’s allowed us to move forward. We look to differentiate ourselves technologically….we’re not a ‘me too’ manufacturer.”

One way ODG avoids the “me too” philosophy is through the firm’s unusually broad capability. The operation is profitable with a mix of high and low volume, simple and complex, as well as fast turnaround and long lead products. What’s the minimum order? The new grinding technology allows a run to be as small as a single unit, or thousands, and ODG easily run 50 to 100 jobs per week at the facility, with over a thousand

3

1. ARGO transmissions on the ODG line 2. The floor at ODG’s New Hamburg, Ontario production facility. Climate controlled, clean and efficient.

3. The iconic Canadian-made ARGO ATV features complete transmission assemblies built and assembled by ODG www.canadianmetalworking.com | FEBRUARY 2012 | 49

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A dressed wheel engaging a blank inside the Kapp KX 300P. Actual work is high-speed, pallet fed and is coolant-flooded

4

ODG’s QA department has extensive checking and CMM equipment….and a gantry hoist to handle heavy jobs.

Operators can control multiple machines…this pager lets QA communicate with the operator to verify parts without excess legwork.

5 5. When used for gear work, this Studer favoritCNC cylindrical grinder (supplied by Machine Tool Systems, Inc.) establishes a reference datum for Kapp grinding centres’ inmachine coordinate measuring probe

4. A typical workstation at a Kapp KX 300P gear grinding centre.

(Supplied by Machine Tool Systems, Inc.) The control replaces most of the paperwork and efficient shop-floor control leaves no clutter.

SKU’s in the ODG design library. What makes ODG’s system so flexible is a paradigm shift in the way gears are made. The traditional method is to hob a blank, then use a second op shaving process for some gears, then heat treat. This process was refined with a post heat-treat skiiving step where a hard, tough and expensive hob removed small amounts of material from the very hard surface, a process that was both hard on the expensive tool but more importantly, required custom tools with order lead times that could be 16 weeks or more.

Simple tool breakage could delay delivery by weeks. The new grinding process changes the flow to hobbing, heat treating hard turning and grinding, using the new Kapp grinders. The abrasive process not only tolerates the hardened surface well, but the ability to diamond dress the wheel has opened up new possibilities in gear production by tailoring the gear profile on a level impossible with conventional hobbing, both in microfinishing and by eliminating a major source of error: heat treating. Declares Wright: “Years ago we had to live with the post-heat treat shift. That’s why transmissions were noisy.

By adding the after heat treat finishing process, we get to the near perfect gear. The transmission error is significantly reduced. Even the forklift driving down the aisle at Home Depot is quiet. With the new hybrid and electric vehicles you can’t hear them driving on the road. The next revolution might be an appealing noise, for safety reasons.”

The new process is clearly better and reduces the lead

times imposed by the skiving process, but it’s also more productive. “We’re probably running at higher speeds, sometimes 30 to 50 percent faster with grinding”, says Wright. “Consumable costs are less. A carbide hob could cost thousands of dollars, then make 200 or 300 pieces before it needed resharpening. For a German hob, it could be a 16 to 20 weeks lead time. If an operator crashed a hob, you were stuck.

Now it’s a reliable process, and grinding is cheaper than a skiving process, at any volume. I can set up the grinder faster than the hobber.

And it gives us total flexibility. We no longer need to wait for a special hob. We can green grind a blank, heat treat and finish grind a prototype in as little as a week. We did a rush job for a major OEM that needed master gears for a dynamometer where downtime cost thousands per hour. We delivered in two weeks.”

At 50, Ontario Drive and Gear has come full circle, from a small job shop making gears to a major manufacturer that can still profitably create short runs with fast lead times hand-inhand with big volume OEM orders.

“There’s not another gear manufacturer in North America with this variety of gear grinding, from manufacturing to design to assembly…we run the gantlet”, says Wright. It’s all from in-house engineering. We are a world leader, right here in New Hamburg”. CM

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Prime Cut

Laser and waterjet options aplenty

By Nestor Gula . ...................................................................................................................................................

TRUMPF

The TruLaser 5030 fiber will significantly reduce the cost of producing parts by achieving very high cutting speeds in thin sheet. In fusion cutting of stainless steel up to 0.16 in. thick (4 mm), the TruLaser 5030 fiber achieves feed rates up to three times faster than the CO2 version. This reduces the table time up to 45 percent, and significantly decreases the cost per part. It cuts mild steel, stainless steel, aluminum and nonferrous metals such as copper and brass. www.trumpf-machines.com

The TruLaser 1030 has the ability to easily add laser cutting to in-house services— opening the door for fabricators to pursue new business opportunities. The TruLaser 1030 with TruCoax 2500 and pallet changer is available with either semi or fully automatic pallet changer, this addition to the machine facilitates loading and unloading parallel to the production process, which helps manufacturers maximize their time to achieve greater efficiency and increased productivity. www.trumpf-machines.com

The TruLaser 3030 combines innovative technology and high laser power with a new design concept and optimized

operation. The machine’s long X axis works with a maintenance free gearless torque motor while Y and Z axes are driven by wear-free and oil-free linear motors, which increase the simultaneous axis speeds from 3346 in/min to 5512 in/ min. The swivel-mounted control panel features a self-explanatory touch screen and a control system that is designed to meet the goal in as few clicks as possible. www.trumpf-machines.com

PRIMA POWER

Prima Power’s Zaphiro is a high range 2D laser machine that is suitable for very high productivity and quality. The patented Perfect Cut system avoids production defects and wastes. Zaphiro detects possible differences from the “perfect cut” and corrects the parameters to bring the quality back to the desired standard. With the standard single lens you can cut all materials and thicknesses. www.primapower.com

The new generation of RAPIDO can be equipped with a fiber or CO2 laser source, according to the type of production. The high brilliance fiber laser with high en­ergy efficiency, eco-compatible use and no maintenance gives the greatest benefits in large series production. The CO2 lasers by PRIMA Group feature top application flexibility, high reliability, low running costs, latest technology (solid state HVPS, magnetic levitation turbine), and are particularly

suitable for frequent changes of production. www.primapower.com

LVD STRIPPIT

The Sirus 3015 Plus is a mid-level laser cutting system for fast, efficient sheet metal processing. With a 1500 x 3000 mm (5’ x 10’) work table area the machine incorporates automatic shuttle tables and a quick change lens (5” and 7.5”).

Capacitive height sensing maintains a constant distance between the head and the material being processed and adjusts to any undulations in the plate. www.lvdgroup.com

An ideal entry level machine for job shops as well as cellular manufacturing and high production environments, the Orion 3015 Plus has a 4000 x 2000 mm (160” x 80”) (X x Y) sheet size capability.

It will cut up to 16 mm (0.63”) Mild Steel, 15 mm (0.59”) Stainless Steel and 10 mm (0.39”)Aluminium processing capability.

The robust hybrid design delivers excellent cutting quality and reliability. www.lvdgroup.com

AMADA

The FOM2 is engineered to meet the high quality and shorter lead time demands of today’s fabricating companies. Features www.canadianmetalworking.com | FEBRUARY 2012 | 53

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include the new Amada tuned oscillator from Fanuc as well as spatter free pierce for higher quality piercing in thicker material, a high-speed shuttle table, and an operatorfriendly windows-based network compatible control. www.amada.ca

Amada produced the LC-F1NT to have the best machine for any manufacturing requirement with ability to produce high-quality product as efficiently as possible. The 3 axis linear motor drive is exceedingly fast and extraordinarily precise and the twin adaptive optics eliminating lens change. Cut process monitoring gives repeatable edge quality with auto-plasma detection. www.amada.ca

pump pairing option, and FlowMaster software, are the very same components found on our elite Mach 3 and Mach 4 waterjet series. www.flowwaterjet.com

The Mach 3 series offers you intelligent process monitoring and an array of unparalleled options. This comes within a convenient compact design preserving your valuable floor space. The Mach 3b comes in five sizes from the small 1313b (1.3m x 1.3m (4ft x 4ft)) to the large 7320b (7.3m x 2m (24ft x 6.5ft)). www.flowwaterjet.com

The FOL-AJ is engineered to produce the highest quality parts at unmatched speed while reducing operating costs and environmental waste. The benefits of fiber laser technology are faster cutting of thin material (2 to 3 times that of a comparable 4000 W CO2 laser) and superior speed and edge quality in material thicknesses up to 7/8˝ compared to other solid-state systems The FOL-AJ has the ability to laser cut copper, brass, titanium and other materials that were previously difficult to process. www.amada.ca

The Mach 4c models modular design allows for unique configurations and customization to meet a variety of individual needs. This waterjet includes exclusive HyperPressure Technology, as well as the advanced Dynamic Water­jet XD technology for faster, more accurate bevel and 3D cutting. This unique design allows the Mach 4c to accommodate up to four cutting heads. www.flowwaterjet.com

FLOW

BYSTRONIC

The Mach 2c waterjet models are the perfect combination of proven performance, robust design, and exceptional price. The core components, including the exclusive PASER 4 abrasive cutting system, Dynamic Waterjet Taper Control Technology, the latest HyPlex Prime

The BySpeed 3015 new features include a faster shuttle table, simultaneous nozzle cleaning and calibration during shuttle times and a conveyor system for small cut drops. Additional options include a new 3.75-inch focal length cartridge that can increase feed rates by as much as 15% for material thicknesses less than

16ga. (.062 inch) and an optional secondary outlet conveyor that can deposit drops directly into a metal drum. www.bystronic.com

The Bystronic BySprint Fiber 3015 is a high-power fiber laser cutting machine based on the BySprint Pro platform and the ByVention Fiber laser machine.

Equipped with a 2-kilowatt Fiber 2000 fiber laser, the BySprint Fiber 3015 is powerful enough to cut steel, stainless steel, aluminum, and non-ferrous metals, such as copper and brass, with high process reliability and precision. www.bystronic.com

HYPERTHERM

The HFL015 is the first fully-integrated fiber laser system designed specifically for cutting applications, including marking and fine-feature cutting. This powerful new system makes it easy to produce a quality cut consistently, across a wide range of materials and thicknesses. Shorter wavelength improves beam absorption in the material, enabling more efficient inert-gas cutting and facilitating cutting of brass and copper. www.hypertherm.com

JET EDGE

The Mid Rail Gantry Waterjet System produces complex parts out of virtually any material. Designed to easily accommodate overhead loading, the Mid Rail Gantry is available in several sizes and comes standard with one abrasive jet cutting head; a second cutting head can be added for increased productivity. It utilizes an industrial PC controller and

54 | FEBRUARY 2012 | www.canadianmetalworking.com

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can be configured so that all three axes are fully programmable. www.jetedge.com

The 100hp X-Stream xP90-100 is capable of producing pressures in excess of 90,000psi.

It supports a 75,000psi continuous operating pressure with a flow rate of 1.45 gpm (5.49 lpm). It achieves much faster cutting speeds and drastically lowers operating costs compared to traditional 60,000psi pumps, enabling users to increase productivity and reduce part costs. www.jetedge.com

laser but also the perfect tool for a wide variety of applications. The laser operates with only a few extremely durable components and does not need conventional gas recirculation, leading to a considerable reduction of maintenance and service. The gas consumption is also minimized: the integrated gas bottle eliminates the need for an external gas supply. In addition, the excellent beam quality of K = 0.95 makes the fastest cuts and deepest weld seams. With its excellent attributes and high efficiency, the ROFIN Slab laser has become a mainstream tool in countless production lines around the world. www.rofin.com

MAXIEM product line is equipped with state-of-the-art drive technology which delivers a reliable performance by harnessing Intelli-TRAX’s superbly accurate motor movement on protected, precision ground drive shafts with stainless steel track rollers. www.maxiemwaterjets.com

OMAX

MAXIEM

The OMAX 80X JetMachining Center series are bridge-style waterjet machines and come with the durable, factoryaligned OMAX MAXJET 5i Nozzle and a Bulk Abrasive Delivery System. It also features Intelli-TRAX, the high-precision, traction drive technology designed for the abrasive waterjet. Multiple table sizes available and the 80X offers two additional extended table sizes with the 80X-1 or 80X-2. www.omax.com

ROFIN

The diffusion-cooled CO2 Slab laser from ROFIN is not only an excellent cutting

The Model 1530 allows you to cut within an X-Y cutting travel area of 10’ 2” x 5’ 2” (3,099 mm x 1,575 mm). The complete

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

Tools are stocked uncoated and ALTiN coated.

Designs for threading, grooving, PCD, and CBN-tipped inserts

Solid carbide grooving, boring and threading tools.

Set includes boring bar, 5 inserts, 5 screws, and a torx plus key

Threadmills

Available in coated AlTiN or uncoated sub micrograin carbide

Port tools

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

Low profile screw keeps chips flowing

SCIENTIFIC CUTTING TOOLS, INC. 110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com www.canadianmetalworking.com | FEBRUARY 2012 | 55

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Four Brands.

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For over half a century, we have been known worldwide for high performance, made-in-USA cutting tools. Our products are supported by the most skilled and experienced applications engineers in the industry.

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s.

e ed

CINCINNATI

MAZAK OPTONICS

The CL-900 laser offers a fiber laser resonator and linear motor drives to maximize productivity and minimize operating and maintenance costs. The Human Machine Interface (HMI) is easily understood and intuitive, enabling operators to produce good parts independently. Using the Windows Operating System it has a touch screen display with easy to understand buttons and a full size keyboard. A web cam is available for easy monitoring of the cutting process. www.e-ci.com

The Optiplex3015 Advanced Laser Machine incorporates 120 m/min rapid traverse rate and the high-power 4kW resonator ensures high-speed cutting of thin to thick mild carbon steel, stainless steel and aluminum worksheets.

Intelligent functions in this machine contribute to a reduced setup time 88% reduction when compared with conventional machines. www.mazaklaser.com

The CL-800 laser offers 5000 watts of power and linear motor drives for the optimum in productivity and versatility.

The controlling Human Machine Interface (HMI) is easy to understand and intuitive. Rather than using cumbersome tech tables, the CL-800 uses Dynamic Power Control (DPC), which computes optimum power and the fastest possible cutting speed for any material on the fly. www.e-ci.com

The Optiplex3015 Fiber is designed for improved high-speed cutting of thin worksheets when compared to conventional laser processing machines. The fiber laser performs high-speed cutting with lower output thanks to the shorter beam wave length (90%) when compared to a CO2 laser. Productivity is increased more than 30%. www.mazaklaser.com

MC MACHINERY (MITSUBISHI)

The eX series is designed to meet the needs of the most demanding users in today’s 24/7 competitive manufacturing environment. This machine features faster movements, more powerful piercing and an ECO mode that provides even more running cost savings. The helical rack and pinion reduces noise, and allows for an increase in acceleration and provides increased accuracy. www.mcmachinery.com

The new DX Series Waterjets from Mitsubishi are now constructed with an independent frame/tank design which separates the machine frame, ways and drive system from the worktank so machining accuracy is not affected by large or heavy workpieces. The 4-Axis Intelligent Taper Control (ITC) provides full 360º taper control by adding a one or two degree mechanical tilt to the cutting head, compensating for the jet getting wider as it exits the focus tube. There are three models, the DX44, DX510 and the DX612 www.mcmachinery.com

n-

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Automation and the Press Brake The press brake is evolving into a “hands off” machine

By Nestor Gula . ...................................................................................................................................................

Doing more with less has forever been the quest of humanity.

New press brakes, and the technology that drives them, answers this quest.

“New Press Brakes have one of the highest production gains in the fabrication industry,” said Paul LeTang, Press Brake Product Sales Manager for LVD Strippit. “300 per cent to 500 per cent gains are typical and depending on applications even 10 times plus is achievable.”

With these kinds of gains it seems that upgrading the old press brakes should be on every manufacturer’s “to do” list for 2012. What is stopping new press brakes from being sold and installed in record-breaking numbers lies in the fundamental essence of what a press brake is. “The force recommended to cold form metal is about 15 tons per linear foot,” said LeTang. “Even when the application is for smaller parts, most fabrication shops like to have 10 foot capacity. To build even a cheap machine with capability to apply 150 tons over a 10-foot length requires a very robust design. The massive components required simply do not wear out. Some people even believe the components “work harden” with use, and like a fine wine, get better with age.” Press Brakes were typically overbuilt and the hydraulic systems have pressure regulators to protect them from abuse by the users. The term “bullet proof” is commonly used to describe press brakes. “Press brakes don’t take breaks, they brake metal, forever,” adds LeTang.

The actual operation of the press break is not much faster but

The PPEC from LVD Strippit is a mid-range bending solution offering a balanced mix of performance and value.It comes in a 4-axis, 5-axis, 6-axis and 7-axis models.

The Amada HD series is equipped with Bend Indicator (BI) sensors that utilize probe and laser technology. The included 3D simulation software makes bending solutions easier to resolve and ensures error-free processing. The HD8025 NT shown has an 88-ton capacity and 101-inch maximum bend length.

where the productivity comes in is in the setup time. “Typically, in the past the operator on the floor would get a new job, then he would have to start a trial and error process to determine which tools would work and you would end up with a lot of false starts.

He would end up with three bends and then realize that he could not go any further and he would have to rethink the process.

That would be a very lengthy set up process,” said Scott Ottens, Bending Product Manager for Amada America Inc. “I think one of the major things with press brakes now is the control where the 3D graphics load and the offline programming software is probably one of the biggest production gains.”

“Set-up time is the biggest factor in production gains as the machines do not require a sheet metal mechanic in order to set tools, crowning, back gauges, etc. Newer press brakes have set-up aids, 3D graphics in conjunction with offline software which allow the programmer to preview bend sequence, tool set-up, and collisions before bending any parts that could have otherwise turned into scrap,” said Shane Simpson, Product Manager, TruBend with Trumpf. “Software now allows you to unfold a part from a 3D, with tooling applied to the part therefore allowing the exact bend allowance based on the tools selected. In the past, the operator had open rein to select tools at the machine that may not have been what the part size was based on.”

Most manufactures are working from a 3D model or even a

58 | FEBRUARY 2012 | www.canadianmetalworking.com

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Prima Power eP 1030 The Bend

Using offline setup programming on modern press brakes, manufacturers that relied on large orders can now supplement their income by running smaller runs and custom jobs. “The speed of set-up and programming possibilities allow for quick change of parts and programs, therefore allowing even the smallest lot sizes to be run efficiently,” said Simpson from Trumpf.

“In the past, prototypes could take days or even weeks and now can be done in hours.” Reduction in set up time has made the press brake even more adaptable to changing orders. “Press Brakes have always been one of the most flexible machines in fabricating metal,” said Michael Stock, of Prima Power, “however TH ON E SP EN EC D IA OF L M UNT AR IL CH !

flat CAD these days. Using offline programming software gives the manufacturer the ability to see the whole brake environment on their computer screen. “They have the machine, the shape of the tooling and everything else,” said Ottens. “They have the 3D shape of the part, which you can start to fold up offline so you can do your bends, you can check for collisions, you can sit there and create your tool set up that you are going to use to bend this part.” All the experimentation and set up work is done offline. “You basically externalize the intellectual part of the set up process, where you figure out which tools and bend sequence to use. All this is removed from the press brake now and it is done on a PC,” he said. The offline programming allows the machine to be bending metal and not sitting idle while a setup is being performed. “When a machine is not running then it is not making parts and it is not making money for you,” he notes.

Many different parts can be stored on the system, as much as your server has memory and can be called up in seconds.

The computer software does a lot of this set up work as well. “Programming systems can automatically select tooling for forming from the library of available tools,” said Michael Stock, Vice President, Sales for Prima Power North America Inc. “With today’s programming systems it is possible to go from a 3D model to a viable bending program quickly and with minimal processing interaction. The specifics related to running a particular part are easily communicated to the brake operator via 3D graphical simulation of the bending process and tool setup.”

With a few well-trained tweaks on the control panel of a modern press brake, the operator can adjust the size of part being bent or change the thickness or type of material being bent.

Most new press brake systems are supplied with the manufacturer’s offline programming system to ensure that no machine time is lost programming on the shop floor. “The press

MAGNETIC CORE DRILLING MACHINE German technology at a lower price than the Chinese competition!

The TruBend5130 from Trumpf has a bending length of 3.23 metresand a press force of 1,300 kN. It features Trumpf’s ACB - Automatically Controlled Bending system.

brake operators just execute the programs,” said Paul LeTang, of LVD Strippit. “This powerful offline system can be used to create “setups” for older press brakes too. Instead of downloading the programs to the new press brake, all the calculated part production information can be printed in instructional form for the operator to manually setup an older press brake.” He said that the newer press brake systems could achieve single minute setup times to speed production and reduce idle time of the machine. The benefit of offline programming is most evident in short run production or custom work. “Batch size has practically no influence on piece cost. This opens the door to all the latest production management techniques like just in time, kit production, one piece flow and lean manufacturing.”

Technical data: • Core drilling capacity: 1-3/8’’ • Twist drilling capacity: 1/2’’ • Speed: 400 RPM • Magnet indicator • Stroke: 6-5/16’’ • Weight: 26,5 lb • Power consumption: 1100 watts • Carry case, cutting oil pump bottle and safety belt are included 100% German made !!

1-800-442-2535 sales@mascoutech.com www.mascoutech.com www.canadianmetalworking.com | FEBRUARY 2012 | 59

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The Amada HD series is equipped with Bend Indicator (BI) sensors that utilize probe and laser technology. The included 3D simulation makes bending solutions easier to resolve and ensures error-free processing. The HD1703 NT shown has an 187-ton capacity and 122 inch maximum bend length.

the CNC controlled multiple axes and advancements in tool technology has made this flexibility more adaptable on the production floor. Most fabricators are positioning newer brakes in a cell close to the blanking equipment. As run quantities continue to become smaller to reduce WIP (Work In Process) these newer brakes provide the solution for efficiently forming a variety of parts, “hot off the press” so to speak which are then pushed on to the next operation.”

From offline computer setups the obvious leap forward is to automate the material handling. “The next step is automation where you put a robotic arm to help you bend parts,” said Amada’s Ottens. Integrating a big robotic arm with your press brake is more geared for work with large panels. Some of these panels would need several people working together to manipulate them properly in the press brake. A properly integrated robotic arm can be programmed, offline of course, to sort, lift and manipulate these panels in the bender making perfect parts each time.

“Automation typically still requires a little higher quantity to be justified,” said Simpson from Trumpf. “But, again, ease of programming through offline software is gradually bringing the quantities down.”

The future is automatic as more and more processes become integrated and automated. “Automated Material Management Systems can deliver parts to the brake for forming, however to automate the forming process it typically involves a robot,” said Michael Stock of Prima Power.

“This integration has seen a lot of advancement in the past few years in both hardware and programming to become a feasible solution for many fabrication cells that wish to automate the process from raw material, through blanking then bending and onto the next operation... welding, painting, assembly etc.”

Paul LeTang at LVD Strippit said that we are near the zenith of press brake technology. “Press brake technology is already there! Starting from a paper napkin sketch, to placing a finished part in your hand, within tolerance, without scrap and including creating the flat blank, in less than 5 minutes, is in my opinion close enough to “there”!” CM

60 | FEBRUARY 2012 | www.canadianmetalworking.com

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Attention to detail Optimize the elements of your spray painting system to achieve better efficiency and lower costs.

Photo courtesy Global Finishing Solutions

By Cindy Macdonald ............................................................................................................................................

In the current economic climate, a new spray booth is not in the cards for most Canadian in-house and independent spray paint operations. But there’s lots you can do to boost the efficiency of the existing spraying system.

A recent article by Timothy Kurcz, director of sales, Jessup Engineering (in Product Finishing magazine), notes that instead of buying a new paint installation, the lowest-cost solution is often to “increase demand on already stressed human/ machine resources. This is risky given the operator-sensitive nature of the finishing business and finicky, well-worn machines. A better choice is targeted investment of carefully engineered upgrades designed to enhance existing plating, anodizing, coating, and other types of finishing systems.”

Some of this you may already know, but just like reading articles on winter driving tips every November, it never hurts to review the details.

TARGET: ENERGY SAVINGS

Variable frequency drives may reduce energy costs on equipment that uses electric motors. In a paint booth, VFDs can be used to control motors on the air makeup intake and the exhaust system.

They provide a smooth motor start, and if your utility rate is calculated on your highest peak usage, then they have the potential to reduce electricity costs in that way too.

If your booth is not already equipped with VFDs, consider a retrofit. An upgrade to the booth control system may also be required.

Other energy saving upgrades are a recirculating system for when the booth is in bake/dry mode, and a heat recovery system that recovers heat from the air exhausted by process equipment and uses it to warm intake air brought into the building.

TARGET: MIXING ACCURACY

Exel North America, in partnership with Air Electric Tool & Equipment, was able to improve the throughput and quality of the metal parts painting operation of a manufacturer of car wash equipment.

Exel worked with Sonny’s Enterprises of Florida to replace its hand mixing process with a system that incorporates Cyclomix™ Micro and four 17A2 Kremlin pumps.

Cyclomix™ Micro is Excel’s smallest electronic mechanical two component system. It comes standard with up to three colour controls and a remote booth mounted control panel.

The benefits for Sonny’s are accurate coating mixing, lower labour costs, and less waste generated.

The system has also improved the quality of finish, thanks to Exel’s Airmix® technology, and proper catalyzing of the material by using Cyclomix™ Micro instead of hand mixing. www.canadianmetalworking.com | FEBRUARY 2012 | 61

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TARGET: DUST

There are two benefits of proper dust collection: quality and safety, according to Marty Powell, industrial territory manager with Global Finishing Solutions. A high quality finish is the direct result of adequate removal of airborne particles that may contaminate finished surfaces, says Powell in an article on spray booth fires in Product Finishing magazine. Contamination causes rejects or rework that results in lost profits.

But, it’s not just surface finish that particle build-up can affect, says Powell. If not cleaned, particles can migrate to areas where operators may not have proper breathing protection, and fire becomes a real hazard. Sufficient airflow is key.

For safety purposes, spray booth manufacturer Col-met offers as a rule of thumb: It’s time to clean the ventilation ducts and duct discharge points when residue accumulates to a thickness of 1/8 inch. At that point, shut down the operation until the cleaning is complete.

TARGET: FIRE SAFETY

While you’re giving thought to your spraying system, spare a thought for fire safety. The Booth Blog on Global Finishing Solutions’ web site points to the NFPA 33 Annex D Fire Record to help booth users understand the reasons behind various fire prevention regulations.

This section lists, as the leading causes of fire in conventional systems (air spray, HVLP, airless): • Use of spark producing equipment such as cutting, welding, and grinding near the spray area.

• Friction, in most cases by overheated bearings on the exhaust fan or by rubbing of exhaust fan blades against the overspray deposits on the wall of the duct.

• Arcing electrical equipment.

• Spontaneous combustion.

• Discharge of static electricity.

TARGET: FILTERS

What makes a paint booth filter cost effective? Long life?

Efficiency rating? Ease of installation? Low purchase price? Low initial resistance? Compliance compatibility? The answer is “all of the above”, according to Mike Snow, filter sales manager for Global Finishing Solutions.

In a Global Finishing blog entry last year, Snow noted that identifying the characteristics of the coating material is the logical starting point for filter selection. “Although, there are several aspects of a coating material that directly affect filter performance, viscosity has a large role. Viscosity dictates how a coating is atomized for application. Atomization consequently, dictates how dense, or open, a filter’s fiber matrix must be to yield maximum performance from the paint arrestor. Too dense, and the efficiency may be acceptable but the service life is unacceptable. Open the fiber matrix to extend the service life, and the diminished efficiency leads to bleed-through that would create excessive fugitive emissions. In turn, that would contaminate the plenum, fan, and stack, possibly leading to the discharge of pollutants into the atmosphere.”

Snow goes on to say that the values from a paint arrestance test may not reflect the efficiency of a filter in actual operation.

Generally, in paint arrestance tests, a high-solids enamel is the default coating. Testing of the actual coating used in your operation is the only accurate way of gauging the true performance of a paint arrestor.

TARGET: MAINTENANCE

A high quality air filter will provide high efficiency, and the

The Wave, optimized for water GFS Wave Aqua paint booth filters are the world’s first to be designed specifically to achieve maximum performance with waterborne paints.

Mike Snow, GFS’ filter sales manager was the driving force behind the development of the Wave Aqua filters.

He says the Wave Aqua is designed for situations where high viscosity, fast drying industrial coatings might face-load conventional polyester, paper/poly, or poly/fiberglass media.

The Wave Aqua is a versatile, non-woven, polyester media comprised of coarse fibers specifically chosen for strength, durability, and performance in overspray collection applications.

The low initial resistance of the Wave Aqua, 0.03”wg at 150 fpm, is a key feature of the product’s performance capability. The proprietary fiber blend, in conjunction with the patented Wave pattern, enables paint laden air to be captured across the surface and within the depth of the media; extending filter service life and reducing operating costs.

According to GFS, Wave Aqua can provide performance advantages that can make even under-powered exhaust systems operate more effectively than can conventional polyester collectors. The new filter has a removal efficiency of 99.73% on overspray.

The patented Wave pattern provides 2.3 times more surface area for every square foot of face area in an existing frame system.

Today’s economy dictates energy conservation as well as high output in production facilities. GFS states that the Wave Aqua has 25% lower initial resistance than the next closest polyester media and 50%, or more, lower resistance than many of today’s conventional standard and high capacity polyester overspray collectors.

Global Finishing Solutions, www.globalfinishing.com

correct diffusion to prevent inconsistent airflow and turbulence, says Snow.

It’s also important to routinely replace the filters, he reminds users. A plugged filter throws off the balance of the booth and allows buildup of overspray on some exhaust fans. Filters should be changed when the final resistance, as specified by the manufacturer of the booth, has been reached.

Col-met, in its blog, suggests monitoring filters constantly so you’ll know when they need to be changed. Consider installing a filter gauge that will automatically shut down the spray gun when the filter fails to allow a minimum amount of air to pass through.

If your booth does not have a pressure gauge, says Snow, establish a strict maintenance schedule based upon the volume of spraying taking place on a day-to-day basis. It is typically recommended that ceiling filters be changed at least twice a year. All other intake filters should be changed once a month or as needed.

Snow explains that clogged or overloaded filters may not allow proper air flow through the booth causing dust or overspray to re-circulate with the booth and affect the finish.

IT’S YOUR RESPONSIBILITY

Spray booths and painting equipment operate at peak efficiency when first installed. It’s up to the shop to keep the system clean and well maintained so it continues to function at optimum levels. CM

62 | FEBRUARY 2012 | www.canadianmetalworking.com

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ADVERTISERS INDEX ADVERTISER

8CMM20186

01/07/2008

08:19 AM

IN STOCK American Standards and specials.

Japanese Standards inch or metric.

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

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

PAGE

American Torch Tip Page 1 AMT Machine Tools Ltd.

ADVERTISER

PAGE

39

Machitech Automation

16

60

Makino Inc.

22

AMT Machine Tools Ltd./Star CNC

17

Mascoutech Inc.

58

Biro Engraving

20

Mate Precision Tooling

34

Brake Cluth Pro

26

Mazak Corporation

27

Brubaker Tool

56

Cecor Inc.

20

MMTS SHOW

33

Chemetall

43

Cincinnati Inc./Elliott

4

Mori Seiki/Ellison

47

Retention Knob Supply Co.

63

Rofin- Bassel

15

CWB Group

42

Data Flute

56

Dipaolo CNC Retrofit Ltd.

51

Eclipse Tools North America Inc.

10

Eriez Magnetics

35

Fagor Automation Canada

11

Fastcut Tool

56

Gibbs & Assoc.

29

Sumitomo

Hardinge Inc.

13

Technifor USA

HORN USA, Inc. Hurco Canada Ingersoll Cutting Tools Iscar Tools Inc.

7

24 & 25

Renishaw Canada Ltd.

Sandvik Coromat

front flap & 31

Schmolz + Bikenbach

14

Schunk Intec Corp

46

Scientific Cutting Tools SME

Trumpf Inc.

5 40 9 21 IBC

IFC

Tungloy

48

Walter USA, LLC

52

Walter Surface Technologies

12

Weldon

56

OBC

Lincoln Electric Company of Canada 37

3

www.canadianmetalworking.com | FEBRUARY 2012 | 63

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By The NUMBERS

Source: Canadian Machine Tool Dealerâ&#x20AC;&#x2122;s Association

Equipment orders are growing: CMTDA

Average percentage of new, used and rebuilt fabricating equipment (all plant sizes) New

Used

Rebuilt

60

2012 Forecast 2011

50 40 30 20 10 0

Source: Fabricators Manufacturers Association International

64 | FEBRUARY 2012 | www.canadianmetalworking.com

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Reduce Cutting Time by 30% and Double Your Tool Life

The new 88째 cutting edge angle face mill family carries inserts with 8 helical cutting edges

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6

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