Canadian Metalworking June 2012

June 2012 • www.canadianmetalworking.com

HOT JOBS

Canadian shops defy the recession

PM 40069240

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E

18 COVER STORY GETTING BETTER ALL THE TIME. .......................................... 18 Job shops report brighter skies

JOB SHOPS ACROSS CANADA BRINGING THEIR “A”-GAME................................................ 23 A-Line Precision Tool builds for critical aero applications PLASMA, TOWERS AND SUBMARINES ................................ 28 Arjay Industries builds big in Surrey

T1

HIGH TECH IN QUEBEC.....................................................65 Teknion Concept cuts with cutting-edge technology SPECIAL REPORT: MOLDMAKING 2012. .......................... T1-T32 FLYING HIGH..................................................................... 70 Camcor Industries machines the “space” in “aerospace” DR. VERSATILE..................................................................... 75 Implant Mechanix does some very small, very unusual work

28

DAMN THE RECESSION, LET’S WELD!..................................84 Fero Metalcraft thrives in Thunder Bay

ONS

STRENGTH IN NUMBERS....................................................88 Job shops working together for profitability

84 Joint.

2”

DEPARTMENTS View from the Floor........................................................... 6 News.............................................................................. 8 Floor Space.................................................................... 16 Welding News............................................................... 80 Tool Talk......................................................................... 92

CONTENTS...

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Vol. 107 | No. 5 | JUNE 2012 | www.canadianmetalworking.com

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By The Numbers............................................................. 96 www.canadianmetalworking.com | JUNE 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 Dutch Disease?

Absolutely, but it’s just one factor of many As I write this, there’s a lively debate about the cause of the disparity between the economies of Central Canada and the West. Much has been said about the “Dutch Disease”, where a resourcerich economy sees their currency appreciate to levels that make their industrial exports uncompetitive. There are many in Alberta that refuse this theory, and point to lagging productivity in Ontario and Quebec. In Central Canada, pundits, as well as leader of the opposition, NDP leader Thomas Mulcair, draw a direct correlation between demand for oil and the appreciation of the Loonie, resulting in lots of finger-pointing and plenty of media-driven public acrimony.

While it’s tempting to look for simple solutions to complex problems, the sad reality is that both sides are right. The Canadian dollar is regarded as a “petro currency” by global traders; it’s natural to see a linkage between oil demand and the relative value of the Loonie. “Relative”, however, is the real issue. Most of our major trading partners, notably the U.S. have seen their currencies plunge in value. Over the last decade, the U.S. has lost a third of their manufacturing jobs and are currently mired in a recession so stubborn and deep that many experts, like the Nobel prize-winning economist Paul Krugman, have branded it a new Depression. Europe teeters on the brink of fiscal chaos, with inevitable consequences for the Euro.

We’re an island of stability in an insane world and ironically, we’re paying the price with a steadily worsening export position….except for oil, which is of course traded in US dollars. Strangely, we sell this oil at a significant discount to the world price, but that’s a bit of Canadian irrationality that I’ll save for a future “rant”…in the here-and-now Canadian manufacturing is facing a perfect storm of weak export demand from our major trading partners, a major Asian competitor whose currency is held artificially weak by government decree and a reputation as a last chance piggy bank for global “hot” money that has few safe places left to go. This would be OK if that capital was used to invest in advanced manufacturing, but here in Toronto, it’s flowing into condo construction, fueling what looks like the mother of all real estate bubbles.

We no longer have the luxury of allowing market forces to determine the future of manufacturing in this country. If we do, we will end up as hewers of wood and drawers of water, with a declining standard of living.

We need a national manufacturing strategy that goes beyond computer software, starting with technical training and engineering education. I could go on, but as Canadian manufacturers and suppliers to manufacturers, you already know: we’re adrift, with no rudder.

JIM ANDERTON, EDITOR

Canadian publications Mail Sales Product Agreement 40069240 ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.

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

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6 | JUNE 2012 | www.canadianmetalworking.com

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News MMTS 2012 a success with more exhibitors, attendees

T

he Montreal Manufacturing Technology Show ran May 14th-16th 2012 with renewed energy and a larger footprint compared to the 2010 version. Nick Samain, Group Show Manager for SME Canada declared, “when we were planning for the show we were marketing to the exhibitors more than two years ago. Many commit in advance long before the show starts. Back in 2010 it was a different time for the economy in Quebec as well as for the global economy, with manufacturing being one of the most hit sectors. In 2010 we didn’t have the type of representation from major distributors we have in 2012. Companies like Mazak, Mori Seki, Okuma, and Doosan just to name a few have come back.

When we added up the roster for heavy equipment at this show we had 40 percent more units of heavy equipment on the show floor. It

made a fantastic experience for the attendees that came in.”

Semain notes that floor space was up 15 percent over the 2010 edition.

“The technology on the show floor, which is the real value to the Quebec manufacturing professional comparing equipment side by side, has been beyond our expectations”, added Semain. Show attendees were noted from the aerospace, transportation, mining, energy, agrifood and “high-tech” sectors. States Semain: “It ran through the supply chain and really drove the message that this is Quebec’s major manufacturing event. It’s been a big partnership not only with us as show organizers, but with heavyweights in Quebec who are global leaders. It should make every Quebecer very proud.”

8 | JUNE 2012 | www.canadianmetalworking.com

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News GM to close Oshawa plant, 2000 jobs lost

The 28th annual edition of BIMU, the Italian trade show for the metalworking industry, runs from October 5th to 9th, 2012 in historic Milan, Italy.

Hosted by fieramilano, BIMU presents machine tools, robots, automation systems, an extensive overview of technical subcontracting, the latest in components and structural manufacturing, as well as the latest solutions for welding, assembly, dies and moulds plus finishing.

Over 1,200 companies will participate, occupying over 90,000 square meters. BIMU is truly international, with 44% of the exhibiting companies come from outside Italy.

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General Motors has announced the closure of the firm’s consolidate line in Oshawa effective June 2013. Approximalety 2000 jobs will be lost. CAW President Ken Lewenza is calling the decision by General Motors to close the consolidated line in Oshawa short-sighted.

“General Motors should instead be focusing on utilizing its Canadian facilities as it seeks to further rebuild the company,” said Lewenza.

“The decision to close this very productive line and put 2,000 more workers out of a job is ill thought-out and could damage the company in the long run. It is also a betrayal of the tremendous work and sacrifices by our members that went into keeping General Motors afloat in 2008-2009, when the company was on the verge of bankruptcy,” he said.

“It appears today that General Motors has a very short memory,” said Lewenza.

A recent study by the Michigan-based Center for Automotive Research found that General Motors may have to boost capacity in the coming years to keep pace with demand for vehicles.

Lewenza said this latest closure announcement flies in the face of what may actually be the best course of action for the company – using existing capacity well into the future. The workers at the GM in Oshawa are represented by CAW Local 222.

Former Alcan unit to supply advanced aluminum alloys to Airbus

C

onstellium, formally Alcan Engineered Products, has announced that it has signed a multi-year agreement with Airbus estimated at approximately US$2 billion of value to support all leading aircraft programs from Airbus and its parent company, the European Aeronautic Defence and Space Company (EADS). Under the new agreement, Constellium will supply Airbus with a broad range of aluminium rolled products for airframes including wing skin panels and stringers, aero-sheets for fuselage panels, as well as rectangular and pre-machined plates for structural components. In addition Constellium aluminium will be used across all key Airbus and EADS programs, and in particular will accompany the evolution of the A320 Family with advanced solutions for upper and lower wing skin panels. Constellium also collaborates on the longest 34-meter wing panels and largest structural components seen to date in the aviation industry.

This contract builds on the 10-year partnership agreement signed with Airbus in 2010 that marked the introduction of the AIRWARE™ technology on the A350 XWB. Between Airbus

10 | JUNE 2012 | www.canadianmetalworking.com

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News and Constellium there is a common drive to adopt the latest technologies for ever higher performance aircraft.

“This agreement is a significant accomplishment for Constellium. Through our partnership, we have a unique opportunity to work even more closely with Airbus to further develop innovative aluminium processes and designs,” said Christophe Villemin, President of Constellium’s Global Aerospace Division. “We are also eager to see our collaboration explore the full potential of aluminium technologies in future aircraft programs.”

The specific terms of the contract were not disclosed. www.constellium.com

Renishaw to officially open new facility Renishaw, the global engineering technologies company is to hold a Grand Opening of its newly acquired and fully renovated Mississauga facility on Thursday the 12th of July.

Commenting on the new facility, Director & General Manager, Dafydd Williams said, “The event is open to all, so please join us for the celebration by registering at the following site www.renishaw.com/grandopening. This investment marks

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a further chapter in Renishaw’s ongoing commitment to the Canadian market, where we have been successfully trading for more than 9 years. With a strong local manufacturing base for automotive and aerospace, there are many opportunities for Renishaw to assist companies that are striving to raise quality and productivity levels.”

The new office situated within the heart of Canadian industry is to be officially opened by Renishaw plc’s Chief Executive, Ben Taylor and will allow for the expansion of operations that supports Renishaw’s full range of innovative metrology products, including CMM probe systems, touch probes and laser tool setters for CNC machine tools, linear and rotary encoders for position feedback, calibration systems for machine performance analysis and Additive Manufacturing equipment.

Canadian firm develops breakthrough magnesium production process

W

innipeg-based Gossan Resources Limited has conducted an independent Green House Gas (“GHG”) Emission Study of the Gossan-Zuliani Process for primary magnesium production. A dramatic reduction in carbon emissions is achieved by the high raw material utilization efficiency of the production process and the use of hydro-electricity, natural gas and high-purity dolomite.

The study concludes that midsize car emissions could be reduced by almost 7% over the car’s life expectancy (200,000 km) by lightweighting using magnesium produced by the Zuliani Process and that this technology is a new breakthrough magnesium production process. The Zuliani Process is a cost saving magnesium extraction technology being developed by Gossan which has been successfully demonstrated by thermodynamic modeling and bench scale testing. Subject to confirmation of the process on a commercial scale, the direct cost of magnesium ingot produced with the Zuliani Process is expected to be about 25-30% less than the direct cost of Chinese magnesium ingot landed in western markets.

The environmental Life Cycle Analysis (LCA) for Zuliani Process magnesium, shows that the cradle to grave break-even for greenhouse gases saved from the reduced vehicle weight is just over 69,500 km which would make magnesium the most environmentally attractive weight-saving material. At a vehicle life expectancy of 200,000 km, greenhouse gases from vehicles could be reduced by almost 7% and fuel efficiency would improve by an even greater amount.

A copy of PRO’s report entitled “Lowering of CO2 Emission for Magnesium Production by Gossan-Zuliani Process” may be found at: www.gossan.ca/projects/pdf/MgGHGReport.pdf

Canada’s automotive research community receives direct injection of $22 million in project funding

P

rotecting vehicle passengers in side crashes with trucks, helping Canadian seniors drive safely and advancing electric vehicle technologies are just a few of the projects that will benefit from a $22 million investment by Canada’s

12 | JUNE 2012 | www.canadianmetalworking.com

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News HARDINGE KNOWS

custom workholding

Hardinge has a talented group of workholding engineers with over 300 years of combined engineering experience. They have the knowledge to solve gripping problems, improve accuracies, reduce setup times, add flexibility to a machine, and develop new workholding concepts around your application.

automotive research program, the AUTO21 Network of Centres of Excellence. The funding will support 40 automotive R&D projects at Canadian universities in partnership with more than 100 public and private sector companies.

The funding was announced at the AUTO21 conference in Montreal, Quebec. The $22 million will support the projects for two years and includes $10 million from the Government of Canada through the federal Networks of Centres of Excellence program. The remaining $12 million consists of contributions from Canada’s automotive sector, including numerous automakers, parts manufacturers and material suppliers.

Nearly 200 academic researchers will contribute to the 40 projects, which will also provide training opportunities to about 400 graduate students. Topics include advanced material research, biofuels and clean diesel, children’s vehicle safety in Aboriginal communities, and improvements to manufacturing processes.

“These projects focus on automotive knowledge and technology that are close to commercialization for the industry partners,” said Dr. Peter Frise, AUTO21 CEO and scientific director. “AUTO21 is helping to ensure Canadian companies remain competitive in the global automotive sector while helping to develop technologies that will help keep Canadians safer on the roads.”

AUTO21 supports research projects in six key areas: health, safety and injury prevention; societal issues; materials and manufacturing; design processes; powertrains, fuels and emissions; and intelligent systems and sensors.

A recent independent economic impact study of AUTO21 projects estimates that Network research is generating more than $1.1 billion in economic and social benefits to Canada.

AUTO21 is supported by the Government of Canada through a Networks of Centres of Excellence program, and its administrative centre is hosted by the University of Windsor.

A full list and summaries of projects is available at www.auto21.ca.

Bombardier to supply 300 subways to NYC Transit

www.hardinge.com/CustomVideo

Bombardier Transportation has signed a contract to manufacture 300 subway cars with the Metropolitan Transportation Authority (MTA) to be delivered to New York City Transit (NYCT). The order is worth about US$599 million (CDN$623 million).

The cars, known as the R179 series, will be built at Bombardier’s plant in Plattsburgh, New York. The R179 cars will incorporate state-of-the-art technology, said Bombardier, and will be powered by BOMBARDIER MITRAC propulsion equipment with new, energy-efficient inverters. The cars’ on-board systems will be integrated by Bombardier’s industryleading MITRAC train control and management system with internet protocol technology. The propulsion and control equipment will be supplied by Bombardier’s propulsion and controls business unit in Pittsburgh.

Delivery of 10 pilot cars is scheduled for the third quarter of 2014, followed by delivery of the remaining production series cars between mid-2015 and early 2017.

With files from Purchasingb2b staff

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News Wescast announces acquisition agree­ment Wescast Industries Inc. has announced that, in connection with its previouslyannounced strategic alternatives review, Wescast has entered into an arrangement agreement with Sichuan Bohong Industry Co., Ltd. of China, through its wholly-owned subsidiary, Taixing International Investment Limited, would acquire 100% of the issued and outstanding capital of Wescast. The acquisition values the total transaction to Bohong at approximately $195 million. In connection with the execution of the Agreement, Bohong provided Wescast with a $2 million deposit, that is only refundable to Bohong in certain situations.

Bohong requires debt financing from the China Development Bank in order to complete the Transaction.

The Transaction is subject to a number of closing conditions, including the approval of Wescast’s shareholders and the Ontario Superior Court of Justice.

TransCanada wins big pipeline contract TransCanada Corp. has been selected

by Shell Canada Ltd. to build a $4-billion natural gas pipeline in northern British Columbia. The deal would see the Calgary-based company—best known for its controversial Keystone XL pipeline proposal—design, build, own and operate the Coastal GasLink project, which would intersect the west coast province.

The pipeline would run some 700 kilometres from the gas-producing Montney region near Dawson Creek, B.C., to the recently-announced LNG Canada liquified natural gas export

facility in Kitimat, B.C., southeast of Prince Rupert.

TransCanada said the build would take two to three years and create 2,000 to 2,500 jobs.

Upon completion the pipeline would have an initial capacity of more than 1.7-billion cubic feet of gas per day.

The company estimates the Coastal GasLink project will be in service toward the end of the decade, subject to corporate and regulatory approvals.

The final route of the pipeline, according to TransCanada, will be decided on with the consideration of Aboriginal and stakeholder input, as well as the environment, land use compatibility, safety and archaeological and cultural values.

TransCanada currently has about 24,000-kilometres of pipelines in Western Canada, with its B.C. operations dating back more than 50 years.

With files from Canadian Manufacturing

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Floor Space

coffee and see what’s going on. In this business, you have to mind the store very closely, so to say.”

Is your shop open on Sunday?

If not, do you still work on Sunday yourself?

“Our facility is closed and I do not work on Sundays. I believe it is important that all staff members, myself included, take the time to regroup, recharge, spend time with their families and be fresh and ready to go on Monday morning.”

– Rob Muru, president, A-Line Precision Tool, Toronto

“We are always open! [On a recent Sunday] we only had a couple of guys, but there is usually a job we want to get out of the way for Monday. I usually try to go in and buy the guys a

6-2012_CM_Speed_Layout 1 5/7/12 3:03 PM Page 1

– Joseph Manzoli, president, Colourfast, Concord, Ontario

“We are not open on Sunday. I have my equipment running on Sunday but no one is here working. I check up on them from time to time on Sunday but am not here full-time. As soon as we can add more machines to our system it is our goal to power down both Saturday and Sunday of every weekend.”

– Larry Stuyt, president, Ontario Laser Cutting, Tillsonburg, Ontario

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“Our shop is run on a four days a week, 10 hours a day shift.

Therefore Friday to Sunday, the shop is otherwise closed unless overtime is required. I personally do end up in the shop on the weekend, mostly to change over and load parts that we are running in our EDM machines or running lights out cycles on the milling centers.”

– Chad Plath, shop manager, D-M Precision Products, Dunnville, Ontario

“Our shop is not open on Sunday, unless we have a very urgent job that needs to go out.”

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

“Our shop is closed on Sundays.

Overtime is generally accomplished on Friday afternoons/nights and Saturday mornings/afternoons. We preserve the Day of Rest for our time away and our business has felt little ill effects due to this. I believe that God honours this decision and has blessed us with an abundance of work and steady growth over the years. I myself do not work on Sunday either.”

– Gerry Vandersanden, president, Sciens Industries, Peterborough, Ontario

“Although our company is not open on Sunday, I find it much more efficient to come into the office and work on tool quoting, IT and paperwork. Sunday is a time where I can complete my tedious tasks without the constant distractions and fire drills of the typical work week.”

– Adriano Oppio, vice-president, Classic Tool and Die, Oldcastle, Ontario

16 | JUNE 2012 | www.canadianmetalworking.com

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07/06/12 10:36 AM

Canadian Job Shops:

Getting Better All the Time

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

J

ob shop owners have largely good tidings to report, as the economy improves and business outlook becomes sunnier.

According to Statistics Canada, overall manufacturing sales in Canada came to $571 billion in 2011, up from $529 billion the year before. While this is still below 2007 sales of nearly $597 billion, it’s a considerable improvement over 2009 when manufacturing revenues slid to $486 billion amidst recessionary pressures.

Monthly indicators weren’t quite as positive, with manufacturing sales slipping 1.3 percent to $49.264 billion in January 2012 then dropping again to $49.121 billion in February 2012.

This was still better than February 2011, however, when manufacturing sales were $46.201 billion. Sales picked up again in March 2012, rising to $49.7 billion — the largest increase in nine months.

Some alarm bells have been sounded about proposed changes to the Scientific Research and Experimental Development (SR&ED) tax credit program in the 2012/2013 federal budget. Under proposed changes, the SR&ED investment tax credit rate would be reduced from 20 to 15 percent. Other

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changes might see capital expenditures removed from eligible expenses. As a result of these moves, manufacturers might scale back on R&D investment, warns the Canadian Manufacturing Coalition, a new group formed to oppose the proposed cut.

For the moment, however, job shop owners are optimistic about the state of the economy, with several reporting they hired new staff this year.

Leslie Payne, executive director of the Cambridge, Ontariobased Canadian Tooling and Machining Association (CTMA) says the recession had a double impact on the job shop sector.

“A lot of shops have gone out of business ... the shops that have weathered the storm are busy at the moment,” notes Payne, who estimates that three-quarters of the 170 member companies in the CTMA’s ranks are job shops.

Payne, who ran his own job shop until 2005, urges job shop owners to scrupulously manage their cash-flow and keep up-todate on technology.

And, it goes without saying, keep an eye on developments in the manufacturing sector as a whole.

Here’s a look at some job shops across Canada:

MARTEC PRECISION INC. BRAMPTON, ONTARIO 2006

artec Precision is owned and run by husband and wife team, Dawson and Marlene Marks.

Among other services, the shop offers precision metal machining and fabricating, prototyping, dot-peen engraving, sandblasting, saw-cutting, deburring and assembly.

Industries served include aerospace, moulds and mining.

Dawson and Marlene work closely together, as evidenced by the fact they chose to write joint replies to a list of interview questions.

“We are a job shop but our machines are set up with bar feeders for production work also,” they write.

Dawson likes “the regular challenges” that a job shop presents, note the Marks. In a previous Canadian Metalworking article, Marlene referred to her husband as “the MacGyver of machining” — a reference to the 1980s television character who fought crime with clever, improvised devices and equipment.

“Job shops tend to see the most difficult work that other shops don’t want,” write Dawson and Marlene.

The shop currently boasts four CNC lathes and two CNC mills.

“We have been known for our turning but have added the mills so we can provide complete parts to our customers.

Reception area at Martec Precision Inc. Inset: Dawson and Marlene Marks, husband and wife owners of Martec Precision Inc.

Just this year we bought a new CNC mill and are continuously purchasing new machine tools and quality inspection gauges,” state the Marks.

Martec currently employs 12 people who work in two shifts. Since last year at this time, they’ve added two new staff members. “[Our] biggest challenge over the past year has been dealing with decreasing profit margins. We are all feeling the impact of rising costs for metal, tooling, utilities, fuel, to name a few yet we have been faced with adversity when implementing a shop rate increase,” note the Marks.

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The interior of Martec Precision Inc.

The strong Canadian dollar, meanwhile, resulted in a loss of American customers. Still, overall business is good.

“Since opening in 2006, our revenues have increased each year to date. As for 2012, we are confident that we will reach our goal and surpass 2011,” write the Marks.

While hesitant to provide a dollar amount, other statistics underline the shop’s success.

Martec was originally based in cramped 2,300 square foot locale in a Brampton industrial park. As the firm grew, quarters

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became so tight workers had to turn sideways to get between machines. Martec moved into a larger, 4,600 square foot space in the same industrial park in September 2010 and was up and running in a matter of days.

“We have settled in nicely to our new facility with room for the addition of new machines for future growth. We can also extend our capabilities by adding on an additional shift,” write the Marks.

Martec Youtube video: http://tinyurl.com/75pe7ry

MECON INDUSTRIES LIMITED SCARBOROUGH, ONTARIO 1962

“We still consider ourselves a job shop, but a more accurate description would be a design and build shop … we design and build industrial equipment. We build coil handling equipment.

We build press brake tooling. On both products we have a line of standard designs that we work from but we also do custom,” says Mecon president David Foscarini.

Mecon was founded by Foscarini’s father, Tony, back in the Diefenbaker era. The shop does custom design and build projects for a range of industries, including marine, aerospace and automotive, in Canada and the United States.

At present, Mecon boasts 18 employees — “up a couple from last year’s average,” notes Foscarini, but significantly down from a decade ago.

Back in 2000, the company peaked at 56 employees. This number shrank as the economy became more turbulent.

Mecon has 100+ pieces of equipment — everything from head cranes, machine tools and welders to major hand tools.

“We have a lot of equipment because we used to employ

more people. We have six lathes, eight mills, seven boring mills, six grinders, six planers, assorted drills and hand tools, five welders, a shear, a press brake, flame-cutting equipment ... the newest piece is a CNC mill from about 2005,” says Foscarini.

“Our revenues were up last year compared to the year before. We are looking to match or slightly exceed last year for year end, February 2013,” he adds, without providing the actual numbers.

“The strong Canadian dollar has affected our clients more directly than ourselves. They are getting less work so are buying less new equipment or replacing equipment much less often.

The strong dollar has also reduced the number of companies in the stamping business. Again, less of our equipment is being sold,” says Foscarini.

“The biggest challenge for us is marketing. Getting our name and abilities out to as many people in as many industries as possible. I suspect the problem is common among shops in the small to medium-size range,” he adds. www.mecon.com www.canadianmetalworking.com | JUNE 2012 | 19

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NAME: LOCALE: FOUNDED:

D-M PRECISION PRODUCTS

NAME: LOCALE: FOUNDED:

PRECISION COMPONENTS

D

DUNNVILLE, ONTARIO 1952

-M Precision Products has been run by the Plath family for over half-a-century. The family business patriarch, Reinhold Plath founded the business six decades ago. Reinhold went into partnership with his son, Ben Plath in the late 1970s. Today, D-M is managed

by Chad Plath, grandson of the original owner.

Just as the company’s name implies, D-M focuses on precision machining work on all types of exotic materials. D-M makes parts for medical, telecommunications, science research, energy, mobile Exterior of D-M Precision Products devices, defence imaging and data Inset: D-M Precision Products is run by Chad Plath, grandson of the company’s collection sectors and boasts 14 founder. employees — two of whom were hired this year, says Chad Plath. a learning environment that makes employees interested in Based in a 10,000 square foot facility, the shop has four what they are doing. [You can go from] machining a cell phone Hardinge super one day to machining precision lathes, three devices to help people Matsuura milling in the medical industry centers (four axis), six the next day. It’s a very Haas milling centers gratifying industry (four and five axis), knowing what you one Nakamura-Tome are doing is helping SC-200MY mill/turning improve the day-to-day center, one Agie lives of people around Charmille Form 20 die the world,” he states. sinking EDM and Agie Asked to name the Charmille Cut 20 wire biggest challenge facing EDM. Canadian job shops and D-M is “currently Plath is quick to reply. installing the Nakamura SC-200MY,” adds “I hear and have been asked this quesPlath. tion numerous times and responses like Revenues came to “$1-3 million last year unskilled labour, overseas competition, lack … a little better than 2010. We are looking of government funding are all very common at surpassing last year’s revenues, but not issues. I do believe that over the last 30 years, Examples of machined parts made by D-M breaking any records,” he continues. manufacturing has gotten a ‘dirty’ name and Precision Products Plath says he is content to remain a job is unattractive to the younger generation,” shop. he says.

“I think the change of day to day activities/jobs creates http://www.dmprecision.ca/

“T

HAMILTON, ONTARIO 1959

he main service we offer is multi-spindle and Hydromat form tooling as well as custom holder configurations for any of the generic sintered positive or negative inserts commonly used in metal cutting,” says Precision Components vice-president, Shawn Doucette.

The shop also does secondary wire EDM operations in stainless steel and titanium for the medical industry.

“While Precision Components is proud of a strong production platform we are most definitely a job shop and plan to remain that way. Job shops require workers who are multi-talented which allows them to instinctively apply greater attention to detail, providing more value in every job that comes in and out of our shop. It also allows for a little bit of excitement, to keep the entrepreneurial fire stoked by birthing new designs,

techniques and processes to make today’s complex high precision parts competitive,” he adds.

Precision has a total of 13 employees — up two from last year at this time — and 25 machines.

“Over the past 10 years we have transitioned about 40 percent of our production to lights out machining and we have the capability to monitor our machines from home when we are extremely busy,” notes Doucette.

He complains that technology has removed the human touch from machining. New workers have difficulty “envisioning the structural changes that occur” in parts during the metalworking process, changes that “can’t be seen or felt inside a CNC machine ... so unless you have a great programmer and a turning center with live tooling, it is getting harder and harder to be competitive,” says Doucette. http://www.precision-components.ca/

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NAME: LOCALE: FOUNDED:

GAGNON ORNAMENTAL WORKS GRAND FALLS, NEW BRUNSWICK 1968

Marco Gagnon, owner of Gagnon Ornamental Works

G

agnon Ornamental Works (GOW) was founded by the father of the current owner, Marco Gagnon, back in the late 1960s.

“We are a job shop. We do have some products for the potato-growing industry that is more standard fabrication … but 90 percent of our business is job shop work,” says Marco Gagnon.

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Interior of Gagnon Ornamental Works with just some of the many products produced.

The shop currently has 20 employees and occupies 26,000 square feet of space. In terms of gear, GOW boasts four lathes, four mills, one surface grinder, three saws, three bending machines (one CNC), one shear, two iron workers, one plate roller, two pipe benders, 10+ welding stations and a 16’ x 60’ paint booth.

“We installed a new CNC cutting table and CNC bending machine last year, but we have no capital projects planned for this year,” reports Gagnon.

The shop makes parts using aluminum, carbon steel, stainless steel and other steel alloys and also has a painting department.

“Revenues were up roughly 10 percent in 2011 versus 2010. This year we plan on having comparable numbers to 2011 — no decrease and no major increase,” reports Gagnon.

Asked about the main challenge facing Canadian job shops and he says, “For the smaller shops [getting] financing for projects is a big challenge. We all want to grow, but must find our spot within the supply chain.” http://www.gow.ca/en/contact.html 22 | JUNE 2012 | www.canadianmetalworking.com

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W

TECHTRONICS MACHINE WORKS LTD. MUSQUODOBOIT HARBOUR, NOVA SCOTIA 1999

hen Techtronics first started, owner/founder Ron Marks (a distant cousin of Dawson Marks at Martec) ran the company from the bay of a rented garage. Today, the shop occupies 6,000 square feet in an industrial park.

With 26 full-time employees (up eight from last year at this time, notes Marks proudly), the shop offers three main services: prototyping, production and individual jobs.

“We manufacture precision machined components for aerospace and defence, marine, oil and gas, aquatic and emerging technologies,” says Marks.

The shop is ISO 9001:2008 certified with a total of 25 machines — 12 manual lathes, six manual mills and seven CNC machining centers (three lathes and four mills). Techtronics is a full service machine shop using Computer Aided Manufacturing (CAM) and conventional machines for niche markets.

Techntronic’s last purchase was a hybrid CNC lathe with Y axis and live tooling.

“We plan to make additional purchases this summer of more CNC equipment,” says Marks.

Aerial photograph of exterior of Techtronics Machine Works Inset: Ron Marks, owner and founder of Techtronics Machine Works

Asked about larger trends within the sector, Marks offers the following: “Job shops are driven by customers and customers are competing in a global market place; Canadian job shops need to ensure quality, competitive pricing and the ability to meet short lead times as well as boosting the value added services you can provide your customers. I think the biggest challenge is staying competitive so that production stays in Canada,” he notes. http://www.tmwltd.ca CM

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Bringing their “A” Game A-Line Precision Tool builds for critical aero systems

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

Rob Muru, A-Line Precision Tool.

R

ob Muru is a competitive sailor, the son of European refugees, and something of a stoic, accepting business ebbs and flows with philosophical resolve. He’s also the president of A-Line Precision Tool, a Toronto-based job shop that bills itself as “a proud supplier of critical components for the world’s most advanced fighters and weapons systems”.

Among other services, A-Line offers CNC machining (turning, wire EDM, die sink EDM, EDM drilling), inspection, waterjet, precision grinding, welding, micro-engraving and microscopic deburring.

The company also makes parts: “mostly military and aero­space, such as F-18 engine components, Apache attack helicopter gearbox parts, welded frames for submarine search equipment that goes on helicopter based anti-submarine warfare platforms like the MH-60 helicopter. We also do non-military items like nuclear and satellite components,” says Muru.

Despite a few recent missteps (an engine contract A-Line was working on for the Joint Strike Fighter program — a multi-billion

effort to build state-of-the-art F-35 fighter planes — was abruptly cancelled last year) revenue is on the rise.

Sales for 2011 came to $3.8 million, “down a little from 2010.

For 2012, sales are up 62 percent halfway through our fiscal year over last year,” says Muru, who predicts total 2012 revenues will come close to $5 million.

In addition to being a success, A-Line has a unique history, which begins with Muru’s father, Ilmar. Ilmar Muru fled his native Estonia in 1944 during World War Two, to avoid the advancing Russian army. He escaped on a small boat to Finland, where he served in the military. Along the way, Ilmar was also variously employed as a merchant seaman, house builder and a lumberjack in Sault Ste. Marie, Ontario. He eventually settled in Toronto, married a fellow Estonian refugee and opened a machine shop in 1964.

A gifted machinist, Muru Senior called his firm A-Line Toolworks and Manufacturing. The shop was small and “totally old school” with only manual machines, reports Muru Junior, who began toiling in the family firm at an early age.

“I worked my way through the shop on a pair of XLO mills,

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a Boyar Schultz surface grinder, and a TOS manual lathe. We didn’t even have digital readouts on the milling machines until the mid-80s,” notes Muru.

After high school, Muru took the Tool and Die apprentice program at George Brown College in Toronto and earned a BA in Finance at the University of Western Ontario in London, ON.

KEEPING IT IN THE FAMILY

His life wasn’t all toil and study, however.

“My dad, like lots of Estonians, was big into sailing, so he got me started and I spent a lot of time on the National Sailing Team when I was in school. I spent a few years doing an America’s Cup sailing campaign [representing] Canada,” he recalls.

Eventually, he gave up sailing and entered the workforce. In spite of his degree, Muru didn’t take a job with a big corporation, but returned to the family business.

“I hated wearing suits (and still do) and I liked working on machines and being around the shop, so machining seemed a natural for me,” states Muru, who became company president, succeeding his father, in 1987.

Muru says sailing has taught him several valuable life lessons.

“First, you never give up. A sailing race can look really, really bad, but you stick to it. Second, sailing is about [putting in] lots and lots of sailing time. You sail in good weather, bad weather, rain, snow, anything. So when I started the shop, I was there early, I was there late, Saturdays, Sundays, Sunday after dinner, you name it ... if you want to succeed in this business, you have to put some pretty gruelling hours in,” says Muru.

Such extreme focus was necessary for the company’s

survival; by the time Muru took the helm, A-Line’s “old-school” approach was dragging the business down.

“We needed major upgrades in every facet of the shop and business to catch up to the 20th century,” he recalls.

Muru changed the name of the firm to A-Line Precision Tool, as a way of acknowledging the company’s past while also announcing that a new boss was in charge. At the time, A-Line was based out of a cramped 2,000 square foot space in an old building that Muru’s parents purchased in the early 1980’s.

Despite the cramped quarters, Muru moved quickly to bring the business up-to-date.

“I think I got a fax machine first for about 250 bucks, then a small IBM computer to do the accounting. With machines, I got

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A-Line has won contracts in the controversial F-35 project.

started with a used Japax wire EDM. It was slow and there was no wire re-threader, so I had to sleep beside the thing all night if we had any kind of delivery to keep. It cut about two square inches per hour when it was working,” recalls Muru.

“Then I bought a used Leadwell CNC lathe followed by a used CNC Leadwell mill. The lathe cut about .010 taper per inch but we ran that thing 24 hours a day seven days a week. The CNC mill almost killed me — the controls were so crappy — but we moved ahead ... the next two decades were pretty much work, work, work as we got away from tooling and started making actual parts,” he continues.

A-LINE HAS COME A LONG WAY

The company currently boasts “14 CNC mills, 11 CNC lathes, a dozen EDMs (EDM wire, EDM sinkers, and EDM superdrills) and a couple of waterjets ... we are upgrading some of our CNC turning equipment with the new ST series Haas CNC lathes.

It’s a great lathe and also has the same controls as our milling machines so we can standardize that aspect for our operator/ programmers,” says Muru.

To accommodate all these machines, the business has had to expand, literally.

“I have taken over all the units [in the original building the company was based in] and also bought the building next door.

We are at 20,000 square feet now and packed to the rafters with CNC machines! I guess we need a bigger place but it seems to be working so I hate to move,” says Muru.

In terms of labour force, “we have 30 guys now, about the same as last year. In 2008, we had about 40 guys, but it’s better with 30 and our sales are actually higher with the 30 we have now. It’s about teamwork, not how many guys you have.

There is a saying I like: ‘Profit is sanity, volume is vanity’,” he continues.

Muru proudly notes that A-Line recently received Nadcap (National Aerospace and Defense Contractors Accreditation Program) certification for EDM and welding.

BE PREPARED

A seasoned veteran, Muru urges new shop owners to be prepared for bumps along the road: A-Line, for example, was heavily involved in the JSF program. The program is now dogged with controversy in Canada, over the rising cost of purchasing a fleet of these new, cutting-edge fighters. For shops that do aerospace business, however, JSF has proven to be a profitable, if risky, venture.

A-Line won a contract to work on a General Electric/Rolls Royce F136 engine, which 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 were all set up for production to make the main engine struts (17 per engine) for one of the engines ... this took a few years and a lot of cash to set up,” he recalls.

In 2011, the U.S. government pulled the plug on the engine project he was working on — “Just as production was about to ramp up ... I got a stop work order in my email and that was it. It was over,” Muru recalls.

“So, in answer to your question, ‘Am I concerned about the F-35 program?’ ... I would say I am more ‘pissed’ than ‘concerned’,” he adds.

While Muru frets about future defence cuts in the United States, he doesn’t dwell on such setbacks.

After all, things are going so well at A-Line — in spite of the JSF engine fiasco — Muru has taken to sailing again in his spare time.

Muru isn’t blind to the challenges facing his shop, however. When asked, Muru cites a few “problem scenarios” he’s dealing with.

“One, every couple of years, one of my big customers gets ready to go into receivership or runs out cash. Two, I have lost a few big machining contracts now to China. Not a hell of a lot I can do about it, but it’s a problem. Three, one of my big customers moved to the States ... all kinds of issues, but it’s a job shop and that’s how it works. If you don’t want problems go work at the post office,” says Muru. www.a-linetool.com CM

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Of plasma, towers and submarines Surrey’s Arjay Industries Ltd is a thriving fabricator with a great view

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

O

ne of the catalysts of the entrepreneurial spirit is having a job, looking around and saying to oneself — “I can do this. I can do this better. I don’t need to work for someone else — I can do this myself”.

Something like that happened on British Columbia’s lower mainland about 35 years ago. “The business started June 1980 when the then 3 partners all worked for the same local fabrication company and saw the opportunity to start their own business specializing in welding,” said Ray Jenkins, one of the original partners who started Arjay Industries Ltd. in Burnaby, British Columbia. Jenkins is a professional welder by trade.

“I served a 6 year welding apprenticeship in England before immigrating to Canada in 1970.”

His day-to-day responsibilities are quality control, sales and estimating. The other equal partner at Arjay is Lorne Anderson, who hails from Vancouver Island and whose position is looking after engineering and estimating.

Arjay is a custom stainless steel and alloy metal fabricator.

Their main products are process vessels, ASME pressure vessels, shell and tube heat exchangers and a myriad of other custom engineered products. A significant element of this fabricator’s business has been building proprietary equipment for the pulp and paper and chemical industries.

In 1980 they were located in a small industrial shop in Burnaby, a suburb of Vancouver. The company’s startup was aided by favourable financing from the Royal Bank. “They

28 | JUNE 2012 | www.canadianmetalworking.com

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initially matched our investment with a small equipment loan and revolving credit line,” said Jenkins. “They then helped when we wanted to expand in 1987.” They stayed there for four years until the company bought a larger shop in Surrey, another suburb of Vancouver. “The building is 12,000 square feet on just under 3 acres of land,” said Jenkins. There are presently 11 workers on site. “Outside of the 2 partners that run the company, we have a professional engineer and 2 other office staff,” said Jenkins. “The balance are unionized trades people who have served apprenticeships.”

Although you can see the majestic mountains from their location, Jenkins says that the view is generally obscured by all the construction that is going on around them. Their new shop occupies a strategic location alongside the Fraser-Surrey deep-sea port on the Fraser River. There are ship and barge loading facilities, two railway spur lines, major highway access close by and this gives Arjay the ability to ship their products to a wide variety of clients in any location. The ease of access to a variety of transportation also allows them to work on large equipment which needs to be delivered in one piece.

The longest one-piece item manufactured and shipped at Arjay Industries, measured 130 feet high by 10 feet in diameter, while the widest measured in at 21 feet wide by 15 feet high.

Jenkins does not recall the beginnings of the company as being overly difficult.

“In the early 1980’s there was a lot of sub contract work being done from other fabrication companies in the Vancouver area, so it was predominantly miscellaneous work with stainless steel, nickel and titanium alloys being the focus,” he said.

“It took us two-to-three years to really gain our own identity as a specialized fabrication company.”

Two 2205 Duplex batch digesters being manufactured.

LOCATION, LOCATION, LOCATION

Their location and specialization has given Arjay a good reputation. “Our main customers are global OEM engineering companies who we have been working with for over 25 years. We hired a professional sales person at that time to source the type of business that we wanted to do and get the contacts,” said Jenkins. “Consequently we are a high exporting company around the world. We also have had a good relationship with some of Canada’s

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The Ultracut 300 plasma makes short work out of the metal.

leading metallurgical engineers, which has lead to us getting a reputation for successfully welding duplex stainless steels.”

Arjay specializes in building of 2205 Duplex Stainless Steel Batch Digesters, 2205 Liquor Heaters and 2205 Oxygen Delignification Towers.

Just because they chose to specialize in one field does not limit them to taking on other specific tasks. This fabricator has also built 8 submarines that are used to take tourists deep under water in the blue water tropics of the Caribbean. “Back in

1984, through our sales person, we got to quote on some tanks which turned out to be ballast tanks for the world’s first tourist submarine being designed in Vancouver, which eventually led to us building the main submarine hull in 1985,” said Jenkins.

“We eventually built 8 hulls for Atlantis between 1985 and 1997 and a one man submarine for another company in Vancouver.

The submarines are made from carbon steel, with some Monel components. The very high tolerances and inspections required was the attraction for us, as we don’t normally fabricate in

Plasma and Arjay Industries Arjay Industries bought their first Thermal Dynamics Pak45 plasma in 1981. “I believe it was the first in Canada,” said Ray Jenkins, one of the owners of Arjay. “The attraction was it could use Nitrogen and water instead of CO2 as the secondary gas. Being a stainless steel manufacturer, this feature gave us an annealed cut edge which was a benefit for machining stainless because of the soft edge, not the harder edge that you got with a normal plasma cutting system using gas. It also had a capacity of 3” stainless steel.”

In 2007 Arjay started looking for a new plasma system due to the high cost of stainless steel and in an effort to cut fabrication costs. They wanted a system “that would give us a narrower width of cut to enable us to nest closer and save material,” said Jenkins.

“In 1981, when we bought our first plasma the machines were rated on what they would cut in stainless. The newer machines appear to be rated on what they can cut in steel, so being a stainless steel fabricator we had to be sure of what we purchased.

After a thorough evaluation they chose the Thermal Dynamics Ultracut 300 plasma system because it was the only plasma on the market that could use filtered tap water as the secondary and it appeared to meet their other criteria according to Jenkins. “Since

we have purchased it we have found that the gas console enabled us to switch gases quickly, the cartridge/consumables are easy to change, the range of consumables enable us to cut thicker material at a higher speed rate,” he said. “When we bought the machine some of the 300 amp consumables were still in the process of being made, but the Ultracut 300 has exceeded the specified maximum thickness for carbon steel and stainless steel cutting. We have cut 21⁄2-inch mild steel, 21⁄2-inch stainless steel with gas mix, and 2-inch stainless steel with N2/H20. We have also been able to cut our weld bevels on stainless steel and mild steel plates.” This performance enabled them to do away with our oxy-acetylene machine torch according to Jenkins. It has also eliminated some machining operations.

Of the original plasma system that was in the company from the beginning, “our original 1981 Pak 45 that worked six hours a day for 26 years died two weeks before we took delivery of the new Ultracut 300 so we bought another Pak 45 to give us the same thickness capacity over 2-inch and for bevelling plates in stainless.” www. arjayindustries.com www.atlantissubmarines.com

30 | JUNE 2012 | www.canadianmetalworking.com

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A 130 foot oxygen tower being readied for shipment.

One of the Atlantis submarines built by Arjay Industries.

carbon steel.” He said that these are real submarines and not just a simple Disney World ride. Jenkins says that they occasionally have to send a welder down to visit the submarines at one of their exotic sites to fix something. Arjay was limited to only building the submarines that were used in the Caribbean. The ones that are used in the Hawaiian islands needed to be built in the United States, since they fall under the Jones Act. This is a United States federal statute that requires everything carried between U.S. ports, be carried in ships displaying the U.S. flag; be constructed in the United States; be owned by U.S. citizens, crewed by U.S. citizens and U.S. permanent residents.

The manufacturing industry ebbs and flows with the economy. This goes double for one whose main customer is in the forestry business. “This is our third or fourth recession and it’s been a struggle,” said Jenkins. “The combination of a high Canadian dollar and the cost of living in the Vancouver area leads to higher wages, which hurts an exporting company like ours. The same combination also makes it cheaper to import equipment into Canada from the U.S. and Asia, which otherwise could have been built domestically. We are getting through this recession by having shop time available with a skilled workforce for fast turnaround items.”

Jenkins says that a resource based Canadian dollar hurts export manufacturing and also makes it cheaper to import what typically would be made domestically. He said the prospects for Arjay’s future is wrapped around the dollar, but there are other opportunities on the horizon. “I believe it depends on the Canadian dollar. Although our association with the some of the local shipyards and Marine Workers Union Local 1, which will be involved in the Federal ship building contract, we could get some of the subcontract work involved.” CM

32 | JUNE 2012 | www.canadianmetalworking.com

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June 2012

Canadian

MOLD,TOOL &die making

CNC MACHINERY FOR MOLD, TOOL & DIE MAKING: Bigger, faster, better

CUTTING TOOLS FOR MOLDS: Higher feeds & speeds

MOLD MATERIALS: A primer

MARKET outlook What’s hot, what’s not

MOLDMAKING COMPONENTS: New product round-up A supplement to and

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E

contents A supplement for a post-recession world

M

old shops are ordering machine tools at a rate not seen in a decade. Despite the mass media declaration of manufacturing as a dead issue in Canada, on the mold side an increasing number of customers are reshoring mold production.

Why? As the sizes and costs of multicavity and specialty molds increase, the risks go up as well, which, combined with impossible deadlines and back-to-the-ironmine lot traceability demanded by modern quality assurance systems, leaves the tool buyer with a real need to maintain control over the mold making process.

Up-front cost is still a factor, but over the life of the tool, Canadian shops are more competitive than ever and are investing in highly automated machining cells and coordinate measuring equipment to keep costs under control. Enough customers have now been burned by lowprice, low-quality offshore products to reestablish the proper price/performance equation. Lack of skilled tradespeople is still an issue going forward, but for complex, high-volume tools, the survival of the good shops seems more certain than in a long while.

Some of these issues, and a lot more, are examined inside.

It’s a big supplement, designed for what’s shaping up to be a big economic turnaround in the mold, tool and die sector. We hope you find it worthwhile reading.

Market outlook: Clear skies ahead?

The Great Recession is over, and you’re still here. That’s the good news. The bad news is, nobody really knows what lies ahead for Canada’s mold, tool and die sector. That said, here’s a look at some of the forces that might shape your business going forward.

4 Cutting tools for molds Higher feeds and speeds with more durability.

9 Mold materials: A primer Mold steel is misunderstood by many in the industry. Here’s a quick intro — call it ‘Mold Steel 101’.

14 CNC machinery for mold, tool & die making Milling machines for moldmaking get bigger, faster, and better.

20 Moldmaking components A look at some of the latest mold technology equipment on offer.

26

Mark Stephen, editor Canadian Plastics Jim Anderton, editor Canadian Metalworking

Industry statistics Some key Canadian numbers at a glance.

29 A supplement to Canadian Metalworking and Canadian Plastics

Canadian Plastics

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market outlook

Clear skies ahead?

Okay, the Great Recession is over, and you’re still here. That’s the good news.

The bad news is, nobody really knows what lies ahead for Canada’s mold, tool and die sector. But this much is certain: the old days, and the old ways, are deader than disco. Here’s a look at some of the forces that might shape your business going forward.

For the past few years, being a Canadian moldmaker probably felt a little too much like travelling third-class steerage on the Titanic: it was unpleasant enough beforehand, and then came the disaster.

But that was then: the automotive sector in trouble followed by one helluva recession. Cut to today, and everything heard about what a good year 2011 was for mold manufacturers — especially those that service the recovering automakers — seems to be doubly true. “The industry in Canada is definitely healthier than two years ago,” said David Palmer, president and CEO of the Windsor, Ont.-based Canadian Association of Mold Makers (CAMM). “Our industry is driven predominantly by the automotive OEMs, and in 2008-2009 they were starting to re-evaluate how they were going to market and what kinds of platforms they were going to use. We’ve seen rejuvenation, and although the economy hasn’t given us the mandate that it’s all good, we’re seeing good growth again that relates to new OEM platforms and vehicles.”

Down south, meanwhile, almost 85 per cent of respondents to an American Mold Builders Association (AMBA) survey reported business conditions as being either good or excellent, with not a single shop — zero — describing business as poor or bad (See sidebar on pgs. 6-7).

ALL ABOUT AUTOMOTIVE It’s hard to overstate the importance of the automotive sector for Canada’s moldmakers — particularly in Ontario, which is home to 90 per cent of the country’s mold, tool and die shops. According to Ontario’s Ministry of

4

By Mark Stephen

Economic Development and Innovation, the auto sector currently accounts for about 60 per cent of sales within the mold, tool and die industry. Simply put, it’s definitely the straw that stirs the drink.

And for the first time in a long time, that particular drink glass seems more than just half full. Indeed, Canadians and Americans are flocking to dealerships across North America at levels not seen since the global economic meltdown gutted the industry in 2008. With Chrysler Canada Inc. emerging as the unexpected backto-back sales leader in the first two months of the year, Canadian auto sales are up an impressive 13 per cent so far in 2012. Overall sales for February — the latest period for which we have figures — were 106,712, which is up 11.2 per cent over January. It marks the sixth straight month where monthly vehicle sales have been higher than the five-year average sales for a month, a figure that bodes well for vehicle sales in Canada to actually go north of the 1.61 million sales forecast for 2012. The sales gains in Canada have been echoed south of the border — where sales hit an annualized rate of 15 million units in February, their highest point in almost four years — as increasing numbers of consumers replaced their vehicles with revamped or fuel-efficient cars and trucks.

Small wonder, then, that a lot of Canadian mold shops have been busy lately — sometimes to the point of being swamped. “Earlier in the year, some of the bigger shops in the Windsor area were so busy they had teams of people on the road looking for other moldmakers to whom they could subcontract work,” said Tom Meisels, president of Toronto-based FGL Precision Works Ltd. “The workload has dried up somewhat since then and become more manageable, but the shops are still busy.”

Automotive manufacturing renaissance or not, some long-standing problems still linger. “Payment terms from the Big Three automakers have not drastically improved; it can still take one to two years before we see our money,” said David Palmer. “The OEMs have stringent requirements for their production part approval processes, and they continue to use them to their own advantages.”

FAILURE TO LAUNCH? But it wasn’t that long ago that a lot of shops in the industry were looking to transition away from auto parts work.

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market outlook CAMM, for one, encouraged its members to seek out new toolmaking opportunities in sectors like aerospace and wind turbines. So how’s that working out? “The opportunities are still there, and they’ve been realized in some cases,” said David Palmer. “There are three or four tool shops in the Windsor area that are heavily invested in wind turbines, but the volumes are much lower than the amount of tooling demanded by the auto sector, and that’s not likely to change.”

One Toronto-area shop travelling down the aerospace road is FGL Precision Works. “For us, it seemed like a good way to utilize machine downtime,” Tom Meisels said. “Currently we’re in an in-between stage: there’s a lot of development and prototyping going on, but the work is sporadic. It hasn’t quite been the revolution we were hoping for.”

In short, as David Palmer put it, “The reality is that neither the aerospace nor the wind turbine sectors, or anything else, is going to replace the volumes we get out of the automotive industry.”

CONTINENTAL DRIFT A major business challenge for Canada’s moldmakers that pre-dated the financial troubles of the Big Three was the threat of foreign competition. For years now, the buzz among moldmakers has included the persistent complaint that competition from China and other Asian nations is eroding business conditions. But as long as Chi-

nese suppliers were unable to meet international quality standards or to satisfy delivery schedules for North American-based customers, Canadian mold, tool and die shops enjoyed a measure of protection. Then came the recession and an increased concern for the bottom line that convinced many customers to move their tooling contracts overseas, even those in high-end markets that required complex, precision tooling.

While it’s no secret that a number of Canadian shops have closed their doors during the past decade as a result, the dark cloud has had a proverbial silver lining for the survivors, forcing them to adopt new technologies and process improvements to maintain profitability.

Now, as business picks up, there may be signs of work coming back to North America. “I think the bloom is starting to come off the offshore rose — costs overseas have risen, the time zone differences are problematic, and there are cultural differences as well,” said Mike Hicks, North American sales manager with DMS Components. “There’s a reshoring effort currently underway because the Canadian moldshops that had to reinvent themselves as lean, low-cost players to compete are now very attractive to customers.” And a surprising side effect is also becoming apparent. “European mold shops are now outsourcing work to us; it’s a great foot in the door for us, and we can get further in as these companies set up satellite shops in Mexico or the southern U.S.,” Hicks said.

THE YO

Anothe no sign and fas lem isn opting on ente are sud as olde sudden moldm becaus Tom M people now lef press a trades a lem, an are loo sad, sho The “We ne packag “We w have w anyone The there —

BORN IN THE U.S.A.: The view from south of the border* HOW ARE CURRENT BUSINESS CONDITIONS?

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COMPARE YOUR COMPANY’S CURRENT LEVEL OF BUSINESS WITH THAT OF 3 MONTHS AGO

70

Good 54%

up same down

60 50 40 30

Fair 10% Excellent 36%

20

Bad 0% Poor 0%

10 0

33% 51% 16%

34% 55% 11%

41% 34% 25%

Quoting

Shipments

Backlog

25% 63% 12% 29% 63%

Profits

8%

Employment

* All information from the American Mold Builders Association’s Spring 2012 survey, which reflects a 34% response rate from members.

6

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%

Anz DLC_komp 86x254 CDN 4c_Anz Z201 102re 09.05.12 08:59 Seite 1

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THE YOUTH PROBLEM Another commonly-cited business problem, however, shows no signs of abating — if anything, it seems to be getting worse, and fast: the shortage of skilled personnel. The root of the problem isn’t hard to identify: fewer qualified young Canadians are opting to become skilled craftspeople as the emphasis placed on entering college or university increases. And as shops that are suddenly busy again scramble to find qualified workers, and as older moldmakers retire from the workforce, the issue has suddenly become acute. “Once, there were four jobs for every moldmaker — there were labour shortages sometimes, but not because enough people weren’t coming into the trade,” said Tom Meisels. “Now, because of cutbacks and closures, a lot of people were put out of work and couldn’t wait it out — they’ve now left the industry for a new career. Add to that the negative press about manufacturing; parents aren’t recommending the trades as a career option for their kids anymore. It’s a big problem, and it’s a problem right now. Shops like ours that are busy are looking for people and the applications we get are pretty sad, showing no experience at all with the trades.”

The picture doesn’t look much brighter down south, either.

“We need to find qualified help for taking on larger tooling packages,” said a U.S. respondent to the recent AMBA survey.

“We went through two apprentices in the last year that didn’t have what it took, but we had to try as there doesn’t seem to be anyone else interested in moldmaking.”

There are still college-level apprenticeship programs out there — Conestoga College, in Kitchener, Ont., offers a two-

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market outlook year tool and die maker apprenticeship course, for example — but they’re not producing enough graduates to plug the manpower drain.

What else can the industry do to recruit fresh faces? “One of our CAMM board members is a director at St. Clair College; he’s pushing for newer programs and talking about boosting our presence in high schools,” said David Palmer.

“We want to be able to make students aware of opportunities. The problem is, companies are very aware now of their labour costs, and when things slow down they’re not afraid to lay workers off. This lack of job security is playing a big role in scaring people away from our industry, and countering it is probably our biggest ongoing challenge right now.”

THE ROAD AHEAD “The good times can keep going for the next 10 years!!!” one respondent wrote when answering the AMBA survey mentioned above.

But will they?

The consensus seems to be that the mold, tool and die industry will indeed enjoy a period of good business — maybe not for the next 10 years, but at least for the short term. “I don’t think we’ll have the volumes of previous decades, but enough work has built up to ensure at least two or three good years ahead,” said David Palmer.

“Hopefully, this will see us through until the economy is healthy again.”

But don’t be fooled — the odds are heavy that it will never again be your father’s mold, tool and die industry. “The difference between then and now is that lead times are much shorter today, and I expect that to be a permanent part of the business landscape going forward,” said Tom Meisels. “In the past, when business momentum was broken it was only for a very short time, because there was always work that came along to pick up the slack; today, if we get swamped with work for a few weeks, we know we’ll have to face the problem of finding more after that. I cringe when I hear shop owners say they’re going to ride out the storm until things return to normal. This is the new normal, and there’s no going back.”

MT&D

905-564-7227 • 1-800-803-8871 8

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cutting tools Tools for moldmaking Higher feeds and speeds with more durability.

By Nestor Gula, Canadian Metalworking Cutting tools for moldmaking, die making, tool or prototyping come in many forms and designs. The commonality is their high tolerances designed for precision, speed, and surface finish. You might have a high-end CNC mill in your shop but you wouldn’t want to use cut-rate tools and expect a superior finish. In fact, high-end tools can breathe new life into veteran machines.

ISCAR Tools Inc. ISCAR started off in 1984 as a “niche” market supplier with the revolutionary SELF-GRIP PARTING off line of tools and indexable inserts. Now a major presence in the Canadian market, ISCAR operates from state-of-the-ar t facilities serving the Canadian cutThe Minicut family from ISCAR Tools. ting tool market, providing the metalworking industry with innovative and unique technologies and products enabling. Following the very successful introduction of the MINCUT face-grooving family, ISCAR is expanding its application range with inserts for internal grooving, undercutting, and threading; and in addition with solid carbide boring bars.

The MIUR 8 are internal 45° full radius undercutting inserts available in 1 to 2 millimeter grooving widths.

The MITR 8-MT are internal partial profile ISO metric threading inserts that are available for 0.75 to 2 millimeter pitch sizes, for 10 millimeter minimum thread diameter. The MIGR 8 are internal shallow grooving inserts that are available in 0.5 to 2 millimeter grooving widths, straight, and full radius configurations. The three additional insert types make the MINCUT into a multi-

functional, attractive tool family, providing more advantages to the end user.

The company’s new SHANK-MASTER system is comprised of solid carbide shanks and interchangeable cutting heads, carrying indexable inserts. The new Multi-master family from ISCAR design allows for full Tools. carbide shanks without any brazed parts. This makes the new connection very rigid, and ensures stable cutting even at long overhang applications. The SHANK-MASTER’s milling heads and shanks are connected by the MULTI-MASTER thread; unlike the current MULTI-MASTER system, however, the SHANK-MASTER milling heads feature an internal thread and the shanks are equipped with an external thread. Available sizes are: T08, T10 and T12.

The standard shanks are cylindrical, and they differ in their neck and overall lengths from the current carbide shanks. This new modular system consists of a variety of interchangeable heads, including the following advanced ISCAR milling families: SUMOMILL, TANGPLUNGE, HELIDO UPFEED, DROPMILL, BALLPLUS and HELIPLUS. The diameter range of the heads is 12 to 20 millimeters. All SHANK-MASTER milling heads and shanks have coolant holes. www.iscar.com

Sandvik Coromont With representation in 130 countries and 25 state-of-the art productivity centres located around the world, Sandvik Coromant is a world-leading supplier of cutting tools and tooling systems for the metalworking industry.

The newly-launched CoroDrill 860 is touted as the fastest solid carbide drill on the market for steel drilling. This drill is a top performer for conventional drilling, chamfered holes, inclined surfaces, cross holes, stack drilling, and convex/concave surfaces. The drill comes in lengths 3-8xD as standard, and has excellent chip evacuation control when using high cutting data in long and short chipping materials. The drill provides consistent, problem-free drilling at high penetration rates. The

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cutting tools

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unique geometry combined with the new flute shape provides a cutting edge shape for effective clearance of the chip, even at increased penetration rates. Low cutting forces give fewer problems with weak fixturing, thinwalled components, and loads on the cutting edge.

A completely new type of exchangeable tip drill, the CoroDrill 870 was also introduced by Sandvik Coromant. It can be tailored to optimize applications through diameter range, steps, and length possibilities. Holes can be made more efficiently and closer to the specifications required, leaving them better suited to subsequent operations. A highly secure interface between drill body and tip ensures reliability and precision, while the quick and easy tip change procedure helps to maximize active machining time.

The CoroMill 300 is a positive round insert concept for a broad range of operations, including face milling, pocketing, and profiling. Light cutting action allows for smooth entries and exits and for vibration-free use of extended tool set-ups.

Sandvik Coromant also recently launched an extension to its range of Silent Tools milling adaptors. Available in lengths 4-5xD, these new dampened adap- The CoroMill 300 from Sandvik tors can provide more Coromant has light cutting action, allowing for smooth entries and than 50 per cent pro- exits and for vibration-free use. ductivity increases over undampened assemblies. The full benefits of the patented dampening mechanism can be seen when applied to a wide variety of milling operations. The adaptors will enhance surface finishing significantly, even with increased cutting data, allowing longer engagement milling cycles through increased temperature limitation and the possibility to channel coolant through the arbor, increasing tool life.

removal rates.

The JHF 141 is a solid carbide copy milling tool designed specifically for semi-finishing and finishing operations in materials 48 Rockwell and The R217.21 High Feed 2 cutter from harder. It is best Seco features a very strong, robust utilized in high insert and a thick body core for speed applications increased stability and performance in long gauge lengths. for the mold and die industry because of its versatility and quality. Its geometry and edge preparation give it the reliability and performance that make it the ideal choice in copy milling operations in hardened steel.

The R217.21 High Feed 2 cutter is a new indexable cutter also available from Seco. Available from 5/8 to 1-inch diameters, the design features a very strong, robust insert and a thick body core for increased stability and performance in long gauge lengths. With a comprehensive range of grades available, it is a very versatile high feed mill to fit any customer’s needs.

The R220.21 high feed series from Seco is available in sizes from 5/8 to 4 inches in fixed pocketed versions, and 3 to 8 inches in cassette versions. This high feed tool is versatile, The R220.21 high feed series from making it effective Seco is a high feed tool effective in facing, plunging, interpolation, and in facing, plunging, ramping operations. interpolation, and ramping operations. With a comprehensive range of edges and grades, this cutter is applicable in all materials.

www.sandvik.com

www.secotools.com

Seco Tools

Tungaloy

Seco Tools offers a comprehensive range of cutting tools with quality and innovation as a central tenant of their operation.

The JHF 180 is a solid carbide high feed mill designed specifically for machining hardened steels that are higher than 48 Rockwell. This tool is ideal for the mold, tool and die industry, and is available in sizes from 2 to 16 millimetres. It is effective in roughing deep cavities for mold and die components by maintaining high metal

Tungaloy introduces new products for the moldmaking industry. The new DoFeed is the next generation of super high feed milling with diameters from 0.625 to 3 inches.

The high positive chip breaker geometry reduces cutting forces, allowing this tool to be used on even low horsepower machines. The insert offers double-sided geometry, making the insert economical since it offers four cutting edges. The new chip breaker design and the new AH725 Premium Tec coating technology allows for previously un-

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cutting tools attainable speeds and feeds, reducing customer’s costs.

Tungaloy has also introduced its new Tungmeister line of solid carbide indexable end mills. Diameters range from 0.250 to 0.750 inch square and ball-nose.

Slotting, chamfering, and counter boring heads compliment the line. Shanks come in steel, carbide, and tungsten to cover all applications. Downtime due to tool change has been reduced to less than 60 seconds as compared to over 10 minutes for conventional end mills, since the Tungmiester head can be indexed right on the machine. Tungmiester’s repeatability reduces set-up times since the dimensions are predictable. The Tungmiester also reduces the need for inventory since multiple heads fit the same shank. Tungmeister also utilizes the new AH725 coating technology to run at higher speeds and feeds. www.tungaloyamerica.com

Walter USA, LLC With more than 80 years of developing cutting tools and inserts Walter USA, LLC offers an extensive line of cutting

tools for milling, drilling, turning, boring, and specialized tooling for unique applications through its compeFeaturing soft cutting action, tence brands Walter Walter’s Protomax ST has optimum Valenite, Walter Titex, chip transport thanks to a large and Walter Prototyp; helix angle, and can be used for as well as multi-level dry and wet machining. service programs through its Walter Multiply brand.

Their Walter Tigertec Silver ISO P Generation maximizes productivity due to its unique coating, called Tigertec Silver, with up to 75 per cent increase in output.

It will reduce the number of different inserts used in your production process and increase machining reliability due to mechanical post-treatment, enabling you to devote more time to new tasks in your production process. With the Walter Prototyp Protomax ST, increases of machining volume of up to 50 per cent more can be realized in comparison to the usual 3- and 4-edge tools on the market. It features soft cutting action and opti-

MOLD STEEL FOR OPTIMUM PERFORMANCE

SF-2000 PREHARDENED MOLD STEEL IS RECOGNIZED WORLDWIDE FOR ITS UNIFORM HARDNESS AND STABLE MICROSTRUCTURE. TO SATISFY THE NEEDS OF THE MARKET, WE OFFER OUR SF-2000 IN RECTANGULAR BARS IN A VARIETY OF SIZES TO MEET THE REQUIREMENTS OF DESIGNERS, ENGINEERS AND END-USERS.

SOREL FORGE, A FULLY INTEGRATED OPEN DIE FORGE OPERATING IN CANADA

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cutting tools mum chip transport thanks to a large helix angle, and can be used for dry and wet machining. With the latest TAZ coating, it has increased tool life, and features a high level of process stability thanks to stable core and optimised microgeometry. The Walter Titex Xtreme Inox reduces cutting forces due to a new type of geometry and significant increase in productivity over universal drilling and boring tools. Low burr formation on entry and exit, excellent surface quality on components, and stable main cutting edges that guarantee maximum process reliability are other features of this tool.

The new Walter Prototyp Protomax Ultra ball-nose end mill is specially engineered for efficient machining of hard materials. It has enhanced machining performance and tool life, even when machining hard ISO-H materials. The new end mills come in the standard versions from 3 to 12 millimetres; and the mini versions, for small to extremely small contours, range from 0.1 to 2.5 millimetres. For the smaller diameter range, the Protomax Ultra’s reduced neck and its reach of up to 10xD are beneficial for the machining of deep cavities.

It is also coated with the new heat-resistant, TAS-based coating, which leads to longer tool life when machining hard materials. www.walter-tools.com

Emuge Corp.

CBN (Cubic Boron Nitrate) is the hardest known substance next to diamond, and provides the cutting edge for long-lasting end mills. The CBN End Mills are capable of highly efficient machin- Emuge Micro End Mills are used for fine work. ing of hard steels and cast iron, and also provide unmatched tool life and surface finish when machining copper electrodes for use in EDM operations. Emuge Micro End Mills are specially designed to meet the unique and demanding requirements for a wide range of micro-machining applications. They are ideal for milling injection molds, extrusion dies, and electrodes for EDM. They are also well-suited for highprecision surface structuring of macroscopic components as well as micro-mechanical parts production. This series of Emuge Micro End Mills encompasses ball-nose, torus, and flat-end designs that are available in cutting diameters from 0.2 millimetres (0.008 inches) to 2 millimetres (0.080 inches), with effective length-to-cutting diameter ratios up to 10:1. www.emuge.com

MT&D

Why I

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mold materials

Mold Steel 101 Steel is the most basic mold material...and yet little understood by many industry professionals.

By Jim Anderton Materials for plastics processing are many, from composites and exotic light alloys to ferrous metals with decades of experience molding hot resin. Steel was the original mold and die material, and is still the most widely used metal in resin processing. It’s been around as a primary injection mold material for over 70 years, yet a surprising number of plastics and mold, tool and die professionals know little about this basic building block of the industry.

The basics are easy to understand.

Some machining processes introduce residual stresses into the part, which must be removed with a stressrelieving anneal.

WHAT IS MOLD STEEL? All steels are mixtures of iron with different elements; common steels used in construction and consumer goods are alloys of iron and carbon, and are commonly called “carbon steels”.

Commercial steels also contain other alloying elements like manganese, silicon, phosphorus, and others, but carbon is the primary component that makes steel the useful material in everything from skyscrapers to injection molds.

Why carbon? From a practical standpoint, carbon was widely available as an alloying element from the charcoal fires used to smelt and heat primitive handwrought steels. Ancient Damascus and the more familiar Samurai swords are examples of the blacksmith’s art, but until the late 19th century no one knew why or how iron was converted to the tougher, stronger steel.

Carbon is useful because of the way it physically fits into the mass of iron atoms and the way it forms new

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compounds with iron. The chemistry is complex, but the key point is that differing amounts of carbon in the molten iron cool into different forms of iron/carbon mixture. The differing forms have names like austenite, pearlite, bainite, and martensite, among others, but the real significance behind the science is that the different forms of iron and carbon have different physical properties depending on the amount of carbon present and, more critically, on temperature. “High car-

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Corroplast FM is the new stainless steel mold base material available exclusively from SCHMOLZ+BICKENBACH. The team of metallurgical engineers from Deutsche Edelstahlwerke GmbH specifically developed this grade for the plastics tooling industry.

Corroplast FM offers the benefits of an improved microstructure, superior machinability and excellent corrosion resistance compared to other free machining stainless grades.

Corroplast FM is ideally suited for mold bases, manifold plates, hot halves and other plastics tooling associated with processing corrosive resins (PVC) or used in corrosive manufacturing environments.

For more information about Corroplast FM, please visit our website or contact us at (800) 323-1233 ext. 2295.

USA www.schmolz-bickenbach.us (800) 323-1233 — Canada www.schmolz-bickenbach.ca (800) 268-4977

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mold materials bon” steels are a good example. Heated and then cooled slowly (called “annealing”) and the metal is soft, ductile, and easily worked. Reheated and quenched quickly, in oil or air, and the material becomes much harder and more wear-resistant, as well as more difficult to cut or shape. Quenched too quickly and it’s possible to create a very hard steel with excellent wear resistance…and glass-like brittleness. “Tempering” is a carefully controlled reheating to restore some of the ductility lost in the rapid quenching.

“Carbon is the primary component that makes steel the useful material in everything from skyscrapers to injection molds.”

STARTING WITH THE RIGHT STEEL Creating a steel with the right combination of hardness, wear resistance, and ductility depends on the correct “recipe” of alloying elements in the steel with minimal impurities, combined with carefully controlled heattreating. Consistency and purity in the base steel is essential for predictable results in heat-treating. Reputable mold steel suppliers have staff metallurgists and quality control processes to maintain the steel’s composition within limits, and have lot traceability programs to make sure that each sample can be tracked back to a known, qualified batch. This paper trail is important, as mold steels are ordered in shapes and weights that are typically cut to order from larger blocks. Color-coding and tagging are useful, but when mold issues generate the inevitable finger-pointing, it’s important to be able to certify that the starting metals were “in-spec.” Mold steels are raw materials that don’t reward cost cutting or excessive “shopping around” among unknown suppliers.

Some special steels are remelted in vacuum furnaces to remove impurities, which costs more up front but removes uncertainty at the heat-treating stage. Reputable mold shops have long-standing relationships with major suppliers, and retain the paper trail needed to assure quality as well as access their suppliers’ engineering support to specify the correct steel…or catch a marginal or

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suspect metal specification on the printed page, rather than after the mold is in service.

TIME AND TEMPERATURE The reason for heat-treating mold steels is simple: it changes softer, machineable steel into a hard, wear-resistant tool after the machining processes. Why not just start with a hard, wear-resistant alloy in the first place?

For many applications prehardened steels are practical, but for molds handling abrasive, highly filled resins, corrosive gases, or requiring special finishes, prehardened would then require expensive, difficult-to-control machining processes and specialty tools, as well as introducing potential internal stresses into the mold which would need to be relieved with a heat soak process anyway. Heat treatment lets the moldmaker fine-tune the materials’ physical properties, relieve stress, and lower cost both in raw materials and in machining.

Heat treatment isn’t just a finishing touch to the mold building process…it’s vitally important that the tool be treated correctly to maintain durability, surface finish, and dimensional stability. There are multiple processes available, from simple pre-heating to molten salt baths and supercold cryogenic cooling, but the treatment is specific to the material and part. For mold specifiers and end users, the key issue with heat treatment isn’t how it tailors microstructure or grain size, it’s that starting and ending temperatures aren’t

“Heat treatment lets the moldmaker fine-tune the materials’ physical properties, relieve stress, and lower cost both in raw materials and in machining.” the parameters that are most difficult to control. Cooling rate is crucial, and the speed with which the part cools is controlled by multiple variables, including the material, the temperature difference between the hot part and the quenching medium, and, importantly, the shape of the part. If “through hardness” is needed, the centre of the part has to cool fast enough relative to the

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mold materials “A good working relationship with reputable suppliers and service providers, combined with good recordkeeping, will deliver reliable molds and dies without nasty surprises.”

paper trail is important. Extensive heat treatment logs are essential when tracking down a metal-related mold issue… in the age-old “design versus construction” debate that often follows a mold problem, a competent moldmaker will hedge their (and their customer’s) bets with full documentaModern machining techniques can handle steels that used to be too hard to cut tion, speeding the resolution to efficiently. the problem.

With lot traceability plus build and heat-treating surface; if the mold section is thick, the part’s outer surface will cool significantly faster than the core, re- logs, there is a significant and growing “book” on evsulting in different properties across the section. This ery mold, and it’s a good idea to keep a copy of the can be addressed with careful temperature control, records in a secure format away from the shop floor. but in some cases a large part must be redesigned into Some shops prefer to keep logs near the tool, but magsmaller sections to achieve the necessary properties. netic media and USB storage are fragile in most shop Again, an experienced moldmaker with a good work- environments. Building the book on a mold while it’s ing relationship with their heat treater can anticipate under construction can also give the mold designer a problems well in advance. Steel suppliers with in-house running check that mold materials and heat treatment heat-treating services can also suggest alternative al- are as specified on the drawing, potentially catching loys for tough problems. As with the mold steel, the costly errors. Similarly, if the moldmaker recommends

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mold materials

53,000 lbs.

a change in material or heat treatment, a running log lets the mold designer update and issue drawing revisions during construction, useful both for engineering issues and when making payments at contractual build milestones.

MAKING THE RIGHT CHOICES This example uses simple steel materials, but simply specifying “P20” leaves performance on the table, even with commodity resins. There are hundreds of compositions to chose from, many optimized for specific applications. Molding optically-flat safety eyewear lenses? There are alloys that support the superfine polish

you’ll need. Extruding an abrasive and corrosive PVC compound? There are steels for that, too. Choosing the best material for a mold involves research, ideally in conjunction with the steel supplier, heat treater, and moldmaker. Steel suppliers with in-house heat-treating capability are advantageous, as are mold shops with design capability.

No one article can begin to describe the multitude of mold materials used for modern resin processing, but in every case, a good working relationship with reputable suppliers and service providers, combined with good recordkeeping, will deliver reliable molds and dies without nasty surprises.

MT&D

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CNC machining Milling machines for moldmaking Bigger, faster, better.

By Nestor Gula, Canadian Metalworking A good parable for moldmaking is “garbage in/garbage out”. In other words, you’ll never get a good part out of a bad mold. A precisely crafted mold is essential to the well-being, profitability, and reputation to the businesses that use them. Milling machines and EDMs can produce precisely honed molds faster and with finer tolerances than ever before. Matched with the right tools and a skilled operator, the new machines will make precision parts faster while reducing costs on the bottom line.

Hurco Hurco manufactures sophisticated and shop floorfriendly machine tools designed for virtually any application and budget.

The flagship VMX series is a production-oriented line of mills designed for speed. The Hurco 5-axis Hurco’s VMX42SR uses a rotary table and V M X42SR swivel head that allows the tool to tilt and has multiple rotate. benefits for mold shops, especially shops that manufacture deep cavity molds or tall core molds. The VMX42SR uses a rotary table and swivel head that allows the tool to tilt and rotate, which promotes the use of shorter tools instead of long, skinny tools that a typical 3-axis machine requires. When using long tools, the machinist has to decrease the feed rates to prevent tool breakage and minimize chatter. With stouter, shorter tools used on the 5-axis VMX42SR, the machinist can push fast-

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er with increased feed rates and take heavier cuts. The ability to use shorter tooling with the VMX42SR also reduces the deflection of the tool, increases surface finish quality, significantly reduces the need to polish the mold, and eliminates the need for EDM operations in many cases.

The VMX42SR’s table (C-axis) has unlimited and continuous angular movement, which is especially important when machining down a steep wall and going around the part. If the C-axis only has +360°/-360° of motion, the process is significantly slowed down because the table will literally need to unwind at regular intervals to machine the part. The VMX42SR features premium components, such as oversized linear rails, high accuracy encoders, and an integral spindle, and it’s powered by integrated Hurco control with WinMax. Other Hurco products are the popular VM series of mills that combine small footprints with huge work cubes and best-in-class features. The U series and SR series feature application machines with 5-axis technology. Each machining centre from Hurco includes the integrated Hurco control with WinMax that has multiple programming methods, and is the most efficient way for machine shops to increase productivity. www.hurco.com

GF AgieCharmilles The FORM 400 die-sinker EDM system from Swissbased GF AgieCharmilles meets the highest requirements for the mold, tool and die industry. This CNC die-sink was designed for superior quality in large work pieces. The FORM 400 and the smaller sibling FORM 200 combine productivity and flexibility in a compact The FORM 400 die-sinker EDM system from Swiss-based GF Agie­ Charmilles is well-suited for the mold, tool and die industry.

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CNC machining package. With flexible data entry that’s adaptable to the working environment, the FORM 400 virtually guarantees reliable results.

GF AgieCharmilles is also one of the world’s leading supplier of machines, automation solutions, and services to the tool and moldmaking industry, as well as to manufacturers of precision parts and components. The company has supplemented its existing technology portfolio of die-sinking EDM, wire-cutting EDM, high speed and high performance milling machines with its new LASER products.

Laser ablation adds to and extends the technologies offered by GF AgieCharmilles. The company’s laser technology enables moldmakers to produce texturizing, engraving, micro-structuring, marking, and labelling of 2D geometries right through to complex 3D geometries. Laser ablation also enables individualization of products and, compared to conventional surface treatment using etching processes, offers economic, ecological, and design advantages. Four LASER machines offer solutions, ranging Laser ablation, as through this LAfrom the 3-axis SER 1000, extends the technologies entry-level LASER offered by GF AgieCharmilles.

500, to the high end LASER 1200 for 5-axis machining with a travel path of 1200 mm by 900 mm by 1200 mm (X, Y, Z), and a maximum part weight of 1,700 kg. The maximum volume size of the part is 700 mm by 700 mm by 700 mm.

turing complex components as Fanuc’s iD Wire EDM series. The new iE EDM machines have 7-axis simultaneous machining as an option.

The units are also capable of better finishes, increased geo- The Fanuc RoboCut iE Wire EDM metric accu- machine is capable of superior finishes racy to less than and increased geometric accuracy.

0.0001-inches, and virtually no recast. The iE Wire EDMs are ideal for machining a wide range of materials, including cobalt-chrome, high-nickel alloys, and titanium often found in challenging applications such as aerospace, medical, and military parts. The new iE series machines have an upgraded “Ai Pulse Control II” that provides high speed and highly accurate cutting for stepped work pieces, by enabling optimum control based on the accurately detected number of discharge pulses. The Ai pulse control also ensures a minimized witness line at both the wire approach and step point, in addition to improved oval shape and small round hole accuracy.

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

www.elliottmachinery.com

Sodick machines are used for the production of dies, molds, and other various applications that can’t be produced by standard machining methods. Their most popular models are the AG series and VZ series for Wire EDMs, and the AG series for Sinker EDMs; the company’s HS650L, meanwhile, is a popular high speed mill.

The AG series is where speed meets accuracy.

The new AG600LH Wire EDM includes Sodick’s linear motor technology. With new user-friendly

Fanuc/Methods Machine Tools Inc. The new Fanuc RoboCut iE Wire EDM series, distributed by Methods Machine Tools, Inc., features a new power supply for highly accurate and efficient cutting performance in challenging materials. Additional features include a redesigned lower arm and controls for improvements in efficiency, cutting speeds, and energy savings. It now has the same capability for manufac-

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NT4200 DCG

A higher level of productivity requires technology and expertise.

Thanks to an unrivaled investment in R&D, Mori Seiki has the most sophisticated, efficient technology in the industry; thanks to unsurpassed service, application support and training, you have the resources to make the most of it. We call it 360° Support. You’ll call it your competitive edge.

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CNC machining Z (options), provides EDM technology, this technology further a positioning accuenhances productivity and EDM precision. racy of +/-0.00016 The machine’s linear motor axes drives are inches/full length and coupled with 0.4 millionths Heidenhain a repeatability of +/absolute glass scale feedback on the X, Y, 0.00008 inches, with U, and V axes, which ensures precision a spindle speed of 6 cutting and positioning accuracy. Sodick’s to 4,000 rpm and a X, Y, U, and V linear motor drives have no rapid feed rate X/Y/Z backlash, and are backed by Sodick’s 10of 708.7ipm, W of year positioning accuracy guarantee. With 236.2ipm and B of 2 the Heidenhain ultra-precision absolute rpm. The BTH-110. linear glass scales, the true machine posiR18 (H3) has been tion is always known. This reduces set-up Toshiba’s BTH-110.R18 (H3) table-type horizontal boring and milling machine is suited for developed to provide time, since the operator no longer has to all industries. horizontal boring ophome the machine after it has been powered down. Other machines in the AG series are the erational ability with machining centre productivity AG360L Wire EDM, the AG400L Wire EDM, and and flexibility.

The MPF-ES series from Toshiba is a portal-type the AG600L Wire EDM. Sodick’s AG line of Sinker EDM features the AG40L, the AG60L, the AG80L machining centre with high speed and highly efficient Sinker EDM, and the AG100L Sinker EDM. The VZ machining capabilities. This series is designed in conseries is an affordable line of Wire EDMs from So- sideration of energy conservation and environmental dick. The VZ500L is a medium-sized platform, and friendliness. The machines accomplish this by signifiis specially designed for versatile machining. A more cantly reducing power and air consumption, completely preventing any mist lubricating oil to be leaked into compact VZ300L is also available.

The HS650L is designed and built for high speed the atmosphere, and by eliminating a counter-balancprecision milling. Sodick’s linear motor technology ing device for the Z-axis with the use of the twin ballprovides instantaneous servo time, which maximizes screw drive.

Extremely high productivity is achieved by high cutting efficiency. The HS series vertical machining centre range features energy-saving designs and tech- speed and by the machine’s rigid structure. It has a nologies, and superior positioning and cutting accu- rapid traverse rate of 30 m/min (X and Y axis), with racy. This machine tool can handle the most complex, a spindle speed of 40-10,000 min-1, a cartridge-type spindle designed for easy maintenance capabilities, and three-dimensional contours. www.sodick.com long spindle nose compatible in accessibility and heavyduty cutting. The MPF-ES has a highly advanced CNC system with Tosnuc 999 controls. It’s mechaniToshiba cally and electrically integrated with the Tosnuc The Toshiba Machine 999 CNC system, enhancing machine perforBTH-110.R18 (H3) mance with its standard high speed, high pretable-type horizoncision, and high quality machining capabilities. tal boring and milling www.toshibamachine.ca machine has options for all industry needs, especially for general DMG/MORI SEIKI USA machining, mold and DMG and Mori Seiki are two worldwide leaddie, and IT-related ing machine tool manufacturers that are now businesses. closely collaborating. This strategic partnership The H3 offers accuincludes production, purchasing, and research racy, with linear scale and development, as well as sales and service feedbacks for X, Y and The MPF-ES series machining centre. in select markets. Setting a new benchmark in

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high sp the ser smaller a 28,0 flange creases cess, an as roug on the 42,000 only fo die and produc The li the ax min ra of the with 12 5-axis

DMG’s H designe benchm

A close-

CNC machining high speed cutting, DMG’s new HSC 55 linear expands mo-symmetric bridge-type design ensures maximum the series of vertical high speed cutting machines for stability and long-lasting precision.

MT&D smaller sizes. The basic configuration already includes www.dmgmoriseikiusa.com a 28,000-rpm HSC spindle. The larger flange diameter of the HSK A63 taper increases the stability of the machining process, and allows high speed cutting as well as roughing with high chip volume. Based on the available spindles with 18,000 and 42,000 rpm, the machine is qualified not only for HSC machining in the high-end die and mold industry, but also for serial production and machining of electrodes.

The linear drive technology accelerates the axes with more than 2g up to 80-m/ min rapid traverse. The swivel-rotary table of the 5-axis version swivels and rotates with 120 rpm, thus enabling high dynamic PRoToTyPINg, PRodUCT dEvEloPMENT, INSPECTIoN, 5-axis simultaneous machining. The therREvERSE ENgINEERINg & ARChIvINg

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moldmaking components New Product Round-Up A look at some of the latest mold technology equipment on offer.

Four-cavity mold system saves time, money New product development can be time-consuming and costly. Roehr Tool Corporation’s ProtoBridge tool was designed to assist OEMs with reducing costs and development time.

ProtoBridge is a pre-engineered, four-cavity mold system that uses Roehr’s dovetail collapsible cores to develop caps and closures with internal undercuts.

ProtoBridge can be converted from one part design to another while still in the press, saving valuable time; it can be also be reused, meaning there’s no need to construct dedicated mold bases for every new product.

Its compact design is available in two sizes, covering cap or closure part diameters from 5/8-inches to twoinches.

Makino announces its new Inertia Active Control (IAC) horizontal machining centre technology, designed to improve productivity through direct-drive rotary table optimization. By effectively reducing non-cut times resulting from table rotation, IAC technology gives manufacturers improved efficiency and profitability.

The foundation for IAC technology lies in Makino’s direct-drive rotary table design that provides inertia feedback from the B-axis motor to the machining centre’s control system. While acceleration and deceleration rates for standard rotary tables are typically set for maximum inertia and weight to ensure accuracy, IAC uses data from the direct-drive rotary table to quickly evaluate and adjust acceleration and deceleration settings to optimal levels for the specific pallet condition.

IAC technology is currently available on Makino’s nx line of horizontal machining centres, the a51nx and a61nx. These 40-taper machining centres extend the capabilities of the highly successful a-series with a host of technologies for next-generation productivity, accuracy, and reliability.

Makino/Single Source Technologies (Mississauga, Ont.); www.makino.com; 905-565-6886

Lab-tested alignment locks

Hasco is using a new type of coating called DLC (diamond-like coating) on its ejector pins and other components that slide in the mold. This new coating enables the components to operate without any grease, a big advantage when running food and medical applications which don’t allow for the use of any lubricant in the mold.

The DLC coating is applied via plasma-assisted vapour deposition in a process that can reach very high temperatures. The result is a coating that’s extremely hard and that significantly reduces friction. This means less wear and less mold maintenance, as well as no grease.

The DLC-coated mold components are available from Hasco off-the-shelf. They are standardized, but can be interchanged with other non-coated components.

When delivering a newly-built mold, mold builders strive to have that mold run to peak performance levels, with no breakdowns due to worn or substandard components. The new Z-series of alignment locks from Progressive Components has been engineered to help meet that goal by outperforming other styles.

Superior performance has been confirmed with field evaluations and independent lab testing. This is achieved through a combination of geometry for when the mold halves first engage, to materials and treatments, particulate capturing, and lubrication distribution.

Benefits include longevity, confirmed by extensive independent lab testing as well as monitoring performance in harsh, real-world conditions; and exclusive features that maintain clean and consistent lubrication.

Hasco Canada Inc. (Toronto, Ont.); www.hasco.com; 800-387-9609

Progressive Components (Wauconda, Ill.); www.procomps.com; 800-462-6653

Roehr Tool Corporation (Hudson, Mass.); www.roehrtool.com; 978-562-4488

DLC-coated components allow molds to run grease-free

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Machining centre with direct-drive rotary table

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LEADing thE WAy SincE 1905 | www.canadianmetalworking.com

8 issues n 4 show Guides n 1 directory n 80 e-NewsLetters n e-directs n website n Lead GeNerators n

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direct maiL

Get on the

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Steve Devonport | Publisher 416-543-1641 SDevonport@canadianmetalworking.com

2012 June Mold Supplement.indd 27

Rob Swan | Account Manager 416-510-5225, cell 416-725-0145 RSwan@canadianmetalworking.com

Jim Anderton | Editor 416-510-5148 JAnderton@canadianmetalworking.com

31/05/12 11:44 AM

moldmaking components Mold oven gets the job done No. 928 is an electrically-heated, 500°F universal style oven from Grieve Corporation, currently used for mold heating at the customer’s facility. Workspace dimensions measure 36 inches wide by 48 inches deep by 36 inches high. 18kW installed in nichrome wire elements heat the unit, while a 1,000 CFM, 3/4hp recirculating blower provides universal front-to-rear airflow to the workload.

This Grieve oven features four-inch insulated walls throughout, plus an aluminized steel interior and exterior.

Also, a motor-operated vertical lift door is onboard, along with an integral leg stand for convenient work height off the factory floor.

Grieve Corporation (Round Lake, Ill.); www.grievecorp.com; 847-546-8225

New stainless mold base steel Corroplast FM is a new specialty mold steel from Deutsche Edelstahlwerke GmbH and Schmolz + Bickenbach, designed to support plastics processing cost optimization, especially for manufacturers of PET bottles.

With a well-balanced ratio of hardness, corrosion resistance, and machinability, Corroplast FM remains corrosion-resistant even in an environment marked by heat, condensation, and coolant. It also provides stability for filigree components and molds with minimal cavity spacing. In addition to PET bottle manufacturers, other users

ADVERTISER

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who require complex, corrosion-resistant, and easy-tomachine base and build-up plates, mold frames or plastic molds can benefit from the material.

Corroplast FM mold steel can be purchased as rolled or forged plate 1,000 mm wide and from 50 mm to 400 mm thick. Upon request, Schmoltz + Bickenbach will provide six-side machining and chamfering.

Schmolz + Bickenbach Canada Inc. (Mississauga, Ont.); www.schmolz-bickenbach.com; 416-675-5941

CVe monitor system unlocks a mold’s history When tooling engineers visit their suppliers, access to mold drawings and performance data can be cumbersome — and it can be nearly impossible to ob­tain when they’re not there. For this reason, AST Technology GmbH has introduced the CVe monitor system, which, by connecting to the CVe OnDemand software, provides comprehensive reports of a mold’s performance and activity from anywhere in the world.

Besides adding a 2 GB flash drive for storing mold performance reports, drawings, setup sheets, and other critical documentation, the CVe monitor allows moldmakers to set initial and subsequent maintenance actions to ensure the mold is being properly cared for.

AST Technology GmbH/DME of Canada Ltd. (Mississauga, Ont.); www.dme.net; 800-387-6600

Advertiser’s Index E-MAIL

WEBSITE

AceTRONIC Industrial Controls Inc..................MM8............. 800-803-8871.................. sales@acetronic.com...................................www.acetronic.com Bohler-Uddenholm Limited.............................MM5............. 800-665-8335.....................................................................................www.bucanada.ca Canadian Measurement-Metrology Inc...........MM25........... 800-606-9266.....................................................................................www.cmmxyz.com Canadian Metalworking.................................MM27........... 416-543-1641......................................................................................www.canadianmetalworking.com Canadian Plastics..........................................MM30........... 416-510-5116................... info@canplastics.com..................................www.canplastics.com Clinton Aluminum Canada, ULC.....................MM19........... 800-826-3370.................. info@clintalum.com.....................................www.ClintonAluminum.ca DMS..............................................................MMIFC.......... 800-265-4885.................. mh@dmscan.com........................................www.dmscomponents.com FARO Technologies Inc...................................MM13........... 800-736-0234.....................................................................................www.faro.com Hasco Canada Inc.........................................MM7............. 800-387-9609.................. info.canada@hasco.com..............................www.hasco.com Ingersoll Cutting Tools...................................MM17........... 815-387-6600.....................................................................................www.ingersoll-imc.com Mori Seiki......................................................MM23........... 877-765-1331......................................................................................www.etmoriseiki.com PCS Company...............................................MMOBC........ 800-521-0546.................. sales@pcs-company.com.............................www.pcs-company.com Progressive Components...............................MMIBC.......... 847-487-1000................... sales@procomps.com..................................www.procomps.com Sandvik.........................................................MM11........... 905-826-8900.....................................................................................www.sandvik.com Schmolz & Bickenbach...................................MM15........... 800-268-4977.................. ted.callighen@schmolz-bickenbach.ca.........www.schmolz-bickenbach.ca Sorel Forge Co...............................................MM12........... 800-268-3077.................. sales@sorelforge.com..................................www.sorelforge.com Tsugami........................................................MM21........... 905-565-3570.....................................................................................www.tsugamiusa.com

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MT&D June 2012

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industry statistics JUST THE FACTS...

Some key Canadian industry figures at a glance • According to the latest figures from Industry Canada, the highest hourly average wages for mold, tool and die workers nationwide are earned in Halifax, N.S., at $27.70 per hour; the lowest average wages are earned in Winnipeg, Man., at $20.20 per hour.

• According to census data, in 2011 about 78% of mold, tool and die makers worked in the manufacturing sector, mainly in metal product fabrication (26%), machinery (17%), electrical and electronic products and transportation equipment (16%).

• According to Service Canada, a typical full-time annual salary for this occupation is between $42,000 to $52,000.

EMPLOYMENT DISTRIBUTION BY GENDER

EMPLOYMENT DISTRIBUTION BY STATUS

100

Part-time

Males

80

80

Females

60

60 40

20

90%

10%

Mold, Tool & Die

52.7%

47.3%

All occupations

Source: Service Canada

Source: Service Canada

40

0

20

94.5% 0

EMPLOYMENT DISTRIBUTION BY AGE

High school

60

Post-secondary

25-44 years

50

Bachelors

45-64 years

40

14.1% 45.1% 38.8% 2%

Mold, Tool & Die

All occupations

Source: Service Canada

Source: Service Canada

8.1% 49.6% 40.7% 1.6%

All occupations

70

65 years and over 10

20.8%

Less than high school

15-24 years

20

Mold, Tool & Die

79.2%

80 40 30

5.5%

EMPLOYMENT DISTRIBUTION BY HIGHEST LEVEL OF SCHOOLING

50

0

Full-time

100

30 20 10 0

11.7% 17.9% 68.2% 2.2%

14.1% 21.9% 43.1% 20.9%

Mold, Tool & Die

All occupations

June 2012 MT&D

2012 June Mold Supplement.indd 29

29

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industry statistics Source: Circulation of Canadian Plastics magazine, Dec. 2011

EMPLOYMENT DISTRIBUTION BY SELF-EMPLOYMENT 12 10 8

Source: Service Canada

6 4 2

9.3%

11.2%

Mold, Tool & Die

All occupations

0

CANADIAN MOLD, TOOL & DIE MAKERS

BY PROVINCE

Ontario 218 Quebec 61 B.C. 13 Alberta 7

Manitoba 3 Total: 302

n YOUR ONLINE n n INFORMATION n RESOURCE FOR PLASTICS AND MOLDMAKING

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30

MT&D June 2012

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upgrade your specs... in a flash.

unlock mould history When Tooling Engineers visit their suppliers, accessing mould drawings and performance data is difficult - and it can be nearly impossible to obtain when they are not nearby. Progressive’s new CVe Monitor provides: • Cycle time monitoring to verify consistent part quality and cost • Maintenance activity tracking to reduce unscheduled mould stoppages • Reports accessible to Tooling Engineers wherever the mould is run Along with performance history, drawings and setup sheets are stored on the unit’s 2GB flash drive. And, with all of this capability fitting into the same pocket as the world’s most popular cycle counter, your mould specs are ready for an upgrade.

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Hi-Tech in Quebec Teknion Concept’s Levis plant uses advanced cutting technology for quantity and quality production

By Irwin Rappoport ...............................................................................................................................................

T

eknion Concept’s factory in Levis, Quebec (one of five in the Quebec City region) produces over 4,000 metal parts for the company’s high-end office systems and furniture and metal components which are sold across North America and worldwide to commercial and institutional customers.

The Levis operation is the principal centre for metalwork in Quebec for the Toronto-based multi-national Teknion Corp. (founded in 1983 — 3,500 employees), whose Quebec subsidiary is TEKNION ROY & BRETON (founded in 1956 — 850 employees). The subsidiary was purchased in 1999.

Among the top selling products produced by the Quebec operation are its Expansion Desking, Expansion Casegoods, Expansion Training, Modular Cabinets, W/R/S (Wall Rail System) and various storage components, including storage for the popular District furniture system, as well as various parts for Teknion facilities across Canada.

The Levis factory, established in 2001 (250-300 employees), received a major update in 2010 when a conveyer chain system (based on placing encoded parts on hooks) was installed to improve efficiency and ensure that the company remains competitive in a tight market.

The plant essentially focuses on two types of production: 1) Postleg parts based on profiles, extrusions and tubing, and 2) parts based on sheet metal for processing via a Salvagnini Flexible Manufacturing System (S4+P4 FMS – introduced in 2006 by former plant manager Yves Lamontagne) — an integrated system that can operate as one or two units with independent production and automated loading and exiting systems.

includes products with differing assemblies. Furthermore, instead of welding or screwing components together, the system automatically snaps them together.

On a monthly basis, the plant uses $300,000 of sheet metal (about $3.5 million annually) and its essential that waste be reduced to a minimum. This optimization is secured by the use of powerful nesting software to create parts (large and extremely small) in an effective and smart way. This is important because sheet metal products cover close to 70 percent of the factory’s yearly production, with the remainder being tubing for table legs that are manufactured via punching and welding.

When the system was installed, the cuts were so precise that it eliminated the need to sand parts prior to painting, which is done via a powder-painting process. The initial savings led to a 25-percent reduction in the use of primary material, which at the time was deemed to be nearly half the cost of production per-item

FULLY AUTOMATED AND PROGRAMMABLE LINES

The S4-P4 line is fully automated and programmable, with the sheet metal funneled into the system via a tower. The S4, used for punching and shearing, has a multipress punch head with more than 60 life punch stations and an integrated shearing system that permits one tooling set-up, while the P4, which bends metal, creates complex panels and a variety of panels that can be formed in succession or as part of a batch that

A Teknion employee is taking a newly produced panel and placing it on the conveyer rail system to be painted. This ensures that pieces are painted in the order of production sequence, which helps the company process orders more rapidly and efficiently. This eliminates the need for pallets and carriers.

This photo provides a panoramic view of the conveyer system, which provides an extremely accurate snapshot of the production process at any given moment and allows for quick inspections of new manufactured and painted parts. Having this indicator has allowed management to determine where production has slowed down and where production can be ramped up. www.canadianmetalworking.com | JUNE 2012 | 65

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custom orders and customized parts and large standard production runs.

“Over time, we’ve we pushed the limit of the machine by adding new products that were not supposed to be produced on this type of equipment,” says Vézina, which includes new types of bends. “One-hundred percent of the parts being produced by the S4-P4 line are made without any set up on any of the S4 and the P4 machines. The Salvagnini machines also choose the right material for the part, which enhances optimization.”

Welding on postleg parts is done by a Panasonic robot welding machine and a Panasonic Welding source.

REDUCED ENERGY CONSUMPTION

Here the panel, just painted, is ready to be packed and shipped.

“The S4-S4 line was a godsend because it has the capability and flexibility to handle dynamic nesting and order-by-order production,” says Vézina. “For many of the smaller parts (filler parts), we allow the software to choose parts that are not made for specific orders. A Kanban style stock review is done every one to two days to determine what we are low on. It is designed to produced panels with a minimum dimension of 200mm X 400mm, and with the P4, we can cut and produce small parts that are only a few inches in length 10 times faster compared to a standard process.”

The software for the S4-P4 line allows Teknion to produce

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Reducing energy consumption is also critical to the bottom line. This is achieved by automated systems that maximizes the production process and minimizes the handling of parts from the raw material stage. Parts are only touched by employees when placed on hooks assembly for the paint line and from the paint line into packaging.

“We have one operator doing what previously required four or five people,” says Vézina. “Once funneled into the tower, the sheet metal is punched and sheared and should it be necessary, parts can be rapidly removed for bending and additional cuts and immediately be put back into the production sequence. The production sequence is maintained at all times.”

The conveyer chain system, stresses Vézina, is the most important innovation to be adopted since the Salvagnini system was brought in, due to its overall impact on production – four to six hours from manufacturing to painting. Parts produced by each machine are placed on hooks adjacent to the exit of each machine and then sent to the paint line.

“This allows us to begin the assembling process, such as putting on levelers or plastic film,” he says. “Everything we produce is done in order and is hung where it should be and if the chain is full, we can stop production. With automation, we developed a variety of strategies to maximize efficiency. The rail system gives us an excellent snapshot of production at any given moment to catch problems early on should they arise and to rapidly inspect parts.”

Space is tight on the factory floor and eliminating the need to place parts on pallets and carriers has sped production and saves time by streamlining the manufacturing process.

“There is no need to match parts and place them on a specific carrier,” he explains, “nor do we have to search for parts or have them piling up for additional work or painting.

The parts are scanned and electronic tags are placed on them, which eliminated the need to place paper sheets on each part.

Scanning devices throughout the plant let us know where each part is at all times.”

The paint line, based on a flow-through system, occupies a sizeable portion of the floor space and operates continuously.

Solid employees and team work are also key to the plant’s success.

FOCUS AND VERSATILITY

“We are very focused on having versatile employees who can operate several machines – if our equipment needs to be flexible, so do our workers,” says Vézina. “We have many people who know how to operate the Salvagnini machines, including three who can program them. We need everyone to pitch in and when a bottleneck or breakdown occurs along the line, the problem has to be resolved quickly and because of our people, solutions are quickly found.”

Scheduled maintenance is usually done at night, although

66 | JUNE 2012 | www.canadianmetalworking.com

IMTS-124AD cmw june 2012 JS 3 Techni QC pg 65-69.indd 66

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When I hand my son the keys to this shop, I want him prepared to succeed.

Building a shop is hard work, long hours, solutions under pressure.

Building a legacy is guidance, experience, preparation. Which is why I’ll be getting him off the shop floor and onto the floor of the biggest manufacturing classroom in the Western Hemisphere.

Industry trends. New technology.

Suppliers. Purchasing.

Competitor demos and exhibits.

He’ll be exposed to it all, face to face, in one place.

Because someday, all too soon, this will be his place.

Dominate the competition.

Attend IMTS 2012. Register at IMTS.com

be there.

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4/26/12 10:22 AM

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S4+P4 Integrated Panel production system

T

eknion Concept utilizes the Salvagnini America Inc. (www. salvagnini.com) S4+P4 Integrated Panel production system at its Levis, Quebec plant.

“The system punches, shears and bends metal parts from standard blanks with no intermediate handling of the partly machined work pieces,” states a company press release. “Sheets are fed automatically and finished panels are collected at the end of the line. Automatic set-up in masked time ensures not only the highest quality end products, but also sets the industry benchmark for reduced work in process, just in time, lean production.”

Both machines can also operate independently.

The S4 integrated punching and shearing center is distinguished by its patented multi-press head containing 36-96 independent

when opportunities present themselves, such as when there is a backlog in painting, teams are brought in to inspect the machinery and effect repairs.

“It avoids unwanted work stoppages and unscheduled downtimes,” says Vézina, “and our knowledge of the S4-P4 machinery has allowed us to reduce the number of design tools and allow for standardization to produce 100-percent of our production without any tool changes or set up. That is one reason why we are processing on a small gauge.”

Save for rush orders, the plant operates on two shifts – day and evening. Vézina stresses that production is based solely on orders.

“We produce exactly what we need, when we need it and

punching stations for punching, tapping and embossing. “That means no time consuming stops to fetch and carry punching tools to the point of contact,” states a press release. “Cycle time efficiency is further increased through the deployment of the S4’s unique, built-in shear, which completely eliminates unloading, and cutting in a separate operation, thus saving time and capital investment.”

All models of the P4 “are completely automatic with masked time setup for maximum lean production,” states a press release.

“Punched blanks are automatically checked for material type and thickness and introduced onto the worktable where they are precisely positioned and then formed into a final product – all without operator intervention.”

what we can handle in terms of painting and packaging – balance is the key,” he says, noting that the Levis plant received an $8.1 million investment in 2010 which added 70,000-squarefeet of space to create a logistic and customer service centre, including a warehouse. This is where all the various parts and finished products from all five plants are sent to for final preparation and shipping. “[By] focusing on smarter inventory management and shortening all our times, we are improving the just-in-time concept that is so important to all our customers,” says Jacques Alain, President and general manager of TEKNION ROY & BRETON. CM

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68 | JUNE 2012 | www.canadianmetalworking.com

Equator adve cmw june 2012 JS 3 Techni QC pg 65-69.indd 68

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Introducing a unique new

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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

Highly repeatable master and measure technique Thermal stability through simple re-mastering

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Equator advert 2.indd 1 cmw june 2012 JS 3 Techni QC pg 65-69.indd 69

17/03/2011 09:06:53 07/06/12 2:14 PM

Flying High At Camcor Industries, aerospace machining is taken literally with aircraft and space satellite technology

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

(l-r) Orlando Campagna, vice president, Roberto Campagna, president, and Bruce Legere, sales manager, Camcor Industries Ltd.

W

hen Roberto and Orlando Campagna launched Campagna Engineering near Ottawa in 1966, the first generation immigrants from Italy could scarcely have imagined their business in 2012. As Camcor Industries in Carp, Ontario, just west of Ottawa, the firm is one of the few “aerospace” machining job shops in Canada to actually build spacecraft hardware.

“We began aerospace work with Boeing in ’67, says Camcor president Roberto Campagna proudly, adding, “we were the first shop in the Ottawa region with CNC capability and had the first privately-owned CMM”.

Camcor is by no means restricted to aerospace work, but the display of aircraft models in the reception area leaves no doubt about the firm’s enthusiasm for machines that fly. Noting an Avro Arrow among the models, Roberto comments on the cancellation of that world-leading program over 60 years ago: “that never should have happened”, he states with a frown.

Camcor’s interest in aerospace includes parts as diverse as temperature control components for satellite electronics to sensor assemblies for the current (and controversial)

F-35 project. Camcor is currently ISO 9001-2008 certified and uses in-house procedures, including personnel background checks for sensitive tech according to their Tier One customer requirements.

HIGH-TECH MARKETS

The aerospace market is decidedly high-tech, but different.

A major factor is the need for complex, expensive and time consuming certifications to supply airframe and engine makers. Camcor approaches the market as a Tier Two supplier, machining components for integrators who in turn create the final assembly. “For example, Curtiss Wright might buy a precision component from us and sell it to General Dynamics or Lockheed-Martin to be integrated into an assembly” says Camcor sales manager Bruce Legere. The strategy makes sense for several reasons. “Pass through” certifications are less onerous for a Tier Two and more importantly, Camcor can break out the high value machining and assembly portion of the part, avoiding issues such as software testing and integration into engines or whole airplanes. Put simply, Camcor’s strategy

70 | JUNE 2012 | www.canadianmetalworking.com

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cmw june 2012 JS 4 Camcor pg 70-74.indd 71

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C S

to Camcor recently purchased five new Feeler machining centres through Ottawabased Legere Industrial Supplies Ltd. The VB, HV and VMP series centres feature Fanuc controls and very fast tool changeover as well as a very open machining envelope, making loading/unloading and robotic assist easy to integrate.

plays into the firm’s strengths and minimizes the need for subcontractors and outside expertise.

Five-axis is the standard for machining at Camcor, with machines from multiple manufacturers. Camcor also uses a large number of machines from Methods Machine Tools, Inc. (Sudbury, MA), distributed in Canada by LEGERE Industrial Supplies (Ottawa) including a total of 6 FEELER High Performance Vertical Machining Centers and 2 FEELER Turning Centers, as well as 2 FANUC RoboDrill Machining Centers.

Camcor credits the equipment for the company’s profitability in complex, low-to-medium volume parts. Bruce Legere comments, “The FEELER machines deliver the same performance and accuracy as some other higher priced brands, and so allow us to receive more return on our investment.”

We bought 5 new FEELERs and 2 new RoboDrills as part of our expansion”, states Orlando, adding “with the new machines, the footprints are smaller, so instead of expanding we replaced older machines with the RoboDrills and FEELERS. They’re much more efficient.”

Roberto Campagna takes the machinist’s view of the new RoboDrills: “Tool changing is very fast – two or three seconds and it’s twice the speed of our other machining centres. And it’s very precise, plus or minus 2 tenths. It’s very stable.”

CMM and optical comparators are prominent in the Camcor QA department.

The Campagna brothers were early adopters of CMM technology

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Machining centres are well lit with clear, unobstructed access for fast loading and unloading.

That stability is important for aerospace work, especially where difficult specs are combined with little room for tolerance stack. Campagna demonstrates with a sample precision microwave wave guide component designed for a satellite application, declaring it is “plus or minus 2 tenths everywhere, non cumulative. It’s about the machines. The new RoboDrills…I wish I could afford seven of them. They are faster, more precise, and no backlash.”

The parts Camcor machines are exotic, but the challenges are familiar to every job shop in the country. A major issue is labour. Vice president Orlando Campagna explains: “it’s tough to find skilled people. The Ontario government should build training programs.”

Camcor works with local Algonquin College, but finds that additional training is required to bring new hires up to speed.

Camcor trains apprentices in house, but Orlando notes “we invest a lot of time and money in an apprentice, then a competitor offers another two dollars an hour and we lose them. We have to train ten guys to keep three or four.” One technique Camcor uses to enhance retention is a benefits package that includes dental and vision, an expensive option for a smaller firm.

As a specialty shop with unique capabilities, Camcor isn’t a big-volume production shop. “It’s tough to make money on one’s and two’s”, says Roberto, adding “at those volumes it has to be based on time and materials. Pricing can be outrageous when you’re building one part. Your competitor can make a mistake on the price and win a contract. Customers you work with for years do know to leave enough on the table so the business can survive, but they’re few and far between.” Bruce Legere agrees: “Today everything is so price driven; they don’t necessarily know what they’re buying. If three shops quote $200.00 for a part and one quotes $50.00, they’ll award it to the $50.00 shop

72 | JUNE 2012 | www.canadianmetalworking.com

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cmw june 2012 JS 4 Camcor pg 70-74.indd 73

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Satellite electronics require sophisticated passive radiators to dissipate heat. This complex part is machined to two tenths tolerances.

Camcor’s 14,000 square feet are clean and ordered

This complex, fist-sized F-35 component is machined from 306 stainless steel

Camcor tackles unusual, high precision jobs like this gear

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UNIQUE DESIGN CHALLENGES

Building for aviation and space presents some unique challenges at the design stage for Camcor.

“Aviation is easy to work with” says Roberto. “They know exactly what they want.” Orlando agrees, noting that the nature of the customer sometimes means bidding on a part that’s not designed for manufacturability: “Space is more difficult…. they’re often not engineers, they’re scientists. It can take a day to quote a simple part.”

One benefit of five-axis expertise is the ability to machine low volume parts that would in the past require expensive casting. “For low volume work it’s often more cost effective to machine complex parts out of a solid piece” declares Legere, adding “it’s also faster for low volume work.” Legere holds up a fist-size F-35 stainless component for emphasis. “To cast this would add 18 months”.

Camcor’s most unique customer? “Nanometrics”, says Roberto Campagna. “It’s a unit for seismology. Their units are so sensitive, they picked up the tsunami in the Phillipines from a location near Ottawa. It can detect half an inch of movement between here and New York.”

With contracts for high profile space satellite and F-35 work, Camcor does a lot in their typical one-foot cubic machining envelope. Roberto and Orlando Campagna have always been progressive about new equipment, says Legere. “If we don’t keep moving with the technology, we’re out of business. It’s a simple philosophy: if you don’t go there, lock the doors.” www.camcorindustries.com www.methodsmachine.com www.legereindustrial.com CM

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Doctor Versatile

At Implant Mechanix Inc., Marcus Carius will machine parts for nuclear fusion reactors, particle accelerators and a Montreal shop specializing in BDSM culture. He’s also a fully qualified dentist. Is this the most interesting job shop in Canada?

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

Implant Mechanix uses this Haas MiniMill for multi-axis work

O

n Richards Street in downtown Vancouver, there’s a non-descript industrial building and storage facility.

There’s no signage leading to Implant Mechanix Inc., not even a number on the door. There are no directions and nothing to contrast the business from any of the hundreds of doors opening into a maze of hallways. To find president Marcus Carius you simply have to know how to find him, rather like a “speakeasy” in Prohibition-era Chicago. Inside however, is a compact shop containing some of the most intricate and sophisticated jobs anywhere. Marcus owns one of the most versatile and unusual job shops in the country … paralleling his own very unusual background.

MACHINING TO MEDICINE

“I originally started out as a pattern maker, making mahogany casting patterns in a shop in North Vancouver. It turned out that I’m allergic to mahogany. There was a little tool shop down the street from the pattern shop. I walked in and said ‘I want to work for you’. Two weeks later I was sawing blocks and was eventually building things without a formal

apprenticeship. Dentistry happened when I didn’t want to wear the blue coat anymore ... I was working on contract, building tooling job to job. Off I went back to UBC where I studied drawing, painting and sculpture originally. I thought vaguely of engineering, but then I thought about architecture.

Drawing, painting and sculpture sounded good, so I did that.

Then I left to start my apprenticeship and ended up tool making; I did that for a number of years.

I went back to school in 1980, aiming at medical school. My grades were good, so I went to the faculty advisor for the medical school. It was hugely difficult to get in. He laughed at me and told me to get another degree, first class or better. I did a physiology degree and met many of the professors, who needed equipment.

I had access to a tool room ... and many of them were on the admission committee, so I had some access, plus I managed a first class average. They took a chance on me. I went from there to dentistry. One of the examination requirements was the Dental Aptitude Exam ... they give you a small drawing, a piece of chalk and an X-Acto knife. I did well.”

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blue coat. He established the current Vancouver location as a “hobby” but the shop soon became the primary focus. “I’d come in there and play three days a week while I worked three days a week in my dental practice. The business developed with the intention of serving the dental implant industry. My specialty was managing implant disaster cases; for example, when an implant company went out of business, you’d have an implant you couldn’t put teeth on. I was the ‘go-to’ guy who made the parts you couldn’t buy anymore. I had the luxury of being able to develop specialized techniques and tools to make it relatively routine for me, so I developed a huge referral base of disaster cases. For example, they would refer me if they broke a screw off in an implant. They couldn’t get it out. I developed tools to do it intraorally, guide tubes, stabilizing mechanisms and surgical screwdrivers ... like the way a broken screw would be extracted in a die. One day I just walked away from dentistry and started this full time, in 1998.

It was a big, big step.”

Implant Mechanix uses a modest CNC machining centre, a dedicated EDM room, a manual knee mill and tool room lathe for one-off work, but the exotic item is a laser capable of mold repair and micro fabrication of parts so small they are viewed though a microscope. “A lot of the stuff I do is really small” declares the doctor, holding a rectangular block machined to 3 “tenths” that’s so small, dropping it onto the floor means losing it forever. “It’s a typical job that’s difficult because it’s so small.”

NO “TYPICAL” JOBS The laser is ideal for small part repair requiring built-up sections or added metal

“Typical” is difficult to find among the jobs handled by Implant Mechanix. As the “go to” guy for the really exotic smaller parts, Marcus has done work for a local firm building a nuclear fusion reactor, as well as very precise, very tiny parts for a particle accelerator application that’s sufficiently secret that he can’t say what it is, or who’s using it. “I’d have to kill you”, he smiles.

The dental market is key, but it’s clear after a few minutes that the “juice” for Marcus Carius is in the intricacy and difficulty of the many jobs he tackles. Not every dentist makes parts for nuclear fusion reactors, but at Implant Mechanix, there’s a more exotic customer: a Montreal shop specializing in fetish culture. That

Find the job shop. Implant Mechanix is almost hidden in their downtown Vancouver location

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Implant Mechanix has added this CHMER wire EDM unit to their previous Sodick machine. EDM work is a growth market for the firm.

MEdiCAl MANufACturiNg iNNovAtioNS

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For one-off work, you can’t beat a vertical knee mill and Carius uses his extensively

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MMi is the MEdiCAl ANd dENtAl MANufACturiNg industry event of 2012 www.canadianmetalworking.com | JUNE 2012 | 77

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Carius also does conventional mold work and can perform precision repairs with the laser welder

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business came about through a contact who mentioned that a jeweler working in the body piercing culture was looking for someone with the capability to create some truly exotic hardware. “Chris Myers. Nice guy; you’d never guess what he makes”, says Marcus. “He’s a great customer that fell into my lap out of the clear blue sky. It’s a subset of the BDSM culture they call ‘body modification’” explains Marcus, adding, “some of the stuff is pretty extreme. It’s a culture I can’t identify with, but Chris has fed his family and paid his mortgage with it…. some of the chastity cages go for several thousand dollars.

He’ll put as many hours into polishing as I do into the machining. It’s all 3D milling. It requires programming.”

Marcus has the capability to go from “art to part” using popular software including SolidWorks, Mastercam and FeatureMILL. Implant Mechanix can handle a 10-by-20 inch 300 pound mold, but Marcus won’t do general machining and with the exception of the machining centre, pays for his equipment out of revenues. “It’s been organic growth”, he says, adding “It meant that I haven’t had a lot of payments to make, so the pressure to perform is self-driven.”

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Incredibly, the only form of marketing Marcus uses is his excellent website, although he admits that it’s not search engine optimized. The real “hook” that keeps Implant Mechanix busy is the reputation for tackling very specialized jobs, combined with the doctor’s easy going demeanor and enthusiasm for the task. “This is my first love”, he states simply. “I love making stuff. It’s six days a week, nine ‘till seven, but it’s a game I enjoy. I love this profession. It’s as much fun as you can have and still be legal.”

CM www.implant-mechanix.com

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Welding News ESAB ARISTO TECH 5-13 WELDING HELMET

The new Multimatic 200 welding system from Miller provides welders with ultimate multiprocess and multi-voltage input capabilities in a portable, reliable and easy to use package.

MIG, STICK AND TIG PROCESSES IN THE NEW MULTIMATIC 200

The new Multimatic 200 from Miller Electric Mfg. Co. is an all-in-one portable multiprocess welding power source capable of performing MIG, Stick and TIG welding processes in one compact design. The Auto-Set Elite feature allows operators to quickly and easily set weld parameters based on material type and thickness, as well as fine-tune those parameters to match each specific application. The Multimatic 200 system weighs only 29 pounds and connects to common 120- and 230-volt power receptacles with the Miller-exclusive MVP multi-voltage plug. Changing voltage plugs now takes seconds, and Auto-Line technology automatically adjusts the machine to operate at optimal levels based on incoming power Similar to the Millermatic Passport Plus, this machine offers positive arc starts and a stable arc with minimal spatter when MIG welding – with mixed gases and straight CO2. Stick and TIG welding performance matches that of Miller’s Maxstar 150 series of inverter power sources. To provide greater application versatility the system is compatible with a number of accessories, including the TIG Contractor Kit and the Spoolmate 100 Series spool gun for MIG welding aluminium.

The new Auto-Set Elite function takes the basic details of the weld and automatically sets the machine to the optimum parameters for that joint. Auto-Set Elite asks the welder to select the following criteria to accurately determine weld parameters: welding process, wire/rod/tungsten diameter and material thickness. Additionally, it gives the operator the ability to fine-tune the selected weld parameters to further match the arc to the application. An advanced LCD interface prompts the operator to select the proper polarity and gas mix for the process, and uses basic language descriptions to display alerts on the machine.

Ideal for use in light fabrication, maintenance and repair, HVAC, construction and farm/ranch applications, the Multimatic 200 system has a durable, impact-resistant polycarbonate case that protects the machine from harsh environments and the rigors of daily use. The machine comes with a setup and operation DVD, as well as an information/settings chart and quick setup guide. Built and designed in Appleton, Wisconsin, the Multimatic 200 welding system is CSA certified and covered by the Miller True Blue 3-year warranty. www.millerwelds.com

The Aristo Tech 5-13 Welding Helmet is designed for the professional welder, and incorporates the protection and performance ESAB is known for. This helmet features AutoDarkening Filter Lens Technology (ADF), and has a variable 5-13 digital control for adjustment of shade level, sensitivity, and delay. The helmet’s Quick Set feature allows for easy change of shade with a simple up-anddown flick of the switch.

The helmet’s grind mode is activated at the lowest sensitivity.

The lens is pre-molded into a convex curve with an optical class 1, which eliminates the threat of duplicate ghost arcs visible The ESAB Aristo Tech 5-13 Welding Helmet through the cartridge. The has many advanced features but only weighs one pound helmet’s lightweight shell, weighs only one pound, and ergonomically designed headgear offers maximum comfort, even when worn for long periods of time. The operator has the ability to move the helmet closer or further away from the face, making it comfortable and easy-to-wear. Available in 3 high-gloss colours, yellow, black, and white each helmet is backed by a two-year product warranty. www.esab.ca

NEW PUROX AND OXWELD GAS WELDING PRODUCTS

ESAB announces the introduction of a new and improved line of Purox and Oxweld gas apparatus products.

Originally introduced in 1912, Purox and Oxweld are synonymous with high-quality torches and regulators. The brands’ oxygen regulators were the first to include patented technology to contain oxygen regulator fires.

The new Purox Elite Series and Oxweld Elite Series product lines feature the top-of-the-line quality, performance, and durability ESAB customers have come to expect, while adding updated safety and design features.

The Purox Elite Series and Oxweld Elite Series product lines include welding handles, cutting attachments, hand cutting torches, regulators, and complete outfits. The products will be launched initially in North America, England, and South Africa, followed by release to all global markets.

All Purox Elite Series products sold in North America are backed by ESAB’s 100% Satisfaction Guarantee. ESAB guarantees complete satisfaction with the product for the first 100 days of ownership. ESAB’s Lifetime Warranty covers manufacturer defects in materials and workmanship for the life of the product.

ESAB Canada, www.esabna.com/gasapparatus

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The Business of Welding

Reading the pulse of the Canadian Welding Shop floor N

ot that long ago it seemed like welding, as well as many other skilled trades, was on life support, left for dead as a thing of the past. I’m sure you all remember the doom and gloom, with the media reporting multiple back-to-back recessions tied to an overall poor economy, linked to a record high Canadian dollar. The resulting climate seemed ripe for the gutting of our domestic manufacturing sector and with it a lot of welding related jobs. The logic was that if you could build something somewhere else that was the“right” thing to do head out for foreign shores, engage foreign workers and reap the benefits. This had a trickle down effect on education. I’m sure the thinking was along the lines of “why teach trade skills if they are no longer in demand?” This resulted in several generations of student (me included) who went through a school system that seemed to all but ignore the idea that a career in the trades was a valid option. The message was that there’s no future in, or for, the “trades” – or so the powers that be and the media would have you believe.

Surprisingly, it’s not as bad as it was made to look. Yes there have been job losses, but that’s only part of the story.

If you worked in an industry where your product could be built in parts, put in a container and shipped from anywhere in the world then there was a good chance you would be looking for work.

On the upside, welding, when preformed by a skilled welder, is a highly transportable thing, an aspect of this career missed by those who are not part of the industry. Even better, rather than no jobs we seem to have the reverse. Currently within Canada there is lots of work for skilled welders making things that are not so easily offshored, or have a mandated requirement for Canadian content. Think Oil & Gas and Shipbuilding respectively. These are not short terms jobs, these are real, long term opportunities spread neatly across Canada – all we need is people to fill them.

In my day job I head up the Marketing and New Product development for the Canadian Welding Bureau, the Canadian Welding Association and a number of other groups under the CWB Group banner. As a result, I see my share of reports and stats. I can tell you that the need for homegrown, highly skilled (and “CWB Certified” I might add) welders currently outstrips the available domestic workforce. Remember the comment

Ian Campbell, Director of Marketing and New Product Development, CWB

earlier about offshoring and its impact on our education system? Well, we are now paying the price. With the average Canadian welder now in his or her 50’s, we are about to have a large work force hole to fill, and very little young domestic welders to fill it with.

That said, the powers that be have recognized their error and are working hard to catch up. I saw this first hand when I spent a day doing booth duty at the Ontario Skills Canada provincial competition. The place was awash in busloads of high school students who were actively pursuing or looking at a future career in the trades, with a surprisingly large portion having an interest in welding. This event is not unique to Ontario; there are one or more of these in most provinces feeding students to a National Event to rival a mini Olympics, with the winners of the National heading off to the “Worlds” to compete for Canada. It would appear that building stuff with your hands is the “new cool” — and that’s very good news. Check out the future of skilled trades in Canada at www.skillscanada.com.

All this brings me back to where I stated — the need to separate fact from fiction. Through the CWB Group we know there’s a huge demand for welders, it’s even qualifiable in numbers, but we still need your input to create a truly detailed picture: What you work on, where you work, who you work for, the tools you use, etc. With this information we can help the educators, colleges and our government make the right decisions to help create the next generation of skilled Canadian welders. If you only do one thing to help the next generation of welders then please take a few minutes to fill in our CWA “Your Voice” survey at www.cwa-acs.org/yourvoice.html. Contribute to the future, get heard, and make a difference for the future of welding in this country.

“The need for homegrown, highly skilled (and “CWB Certified” I might add) welders currently outstrips the available domestic workforce.”

Canadian Welding Bureau/Canadian Welding Association

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Damn the recession, let’s weld!

Fero Metalcraft bucks the odds in Northern Ontario

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

Fero Metalcraft brings advanced fabrication technology to picturesque Kenora, Ontario.

W

e’ve all been hearing that manufacturing is a dead industry. The cries started at the turn of the millennium and have been amplified during this past

recession.

Offshore competition was supposed to kill all manufacturing companies and jobs in North America. The high loonie was said to be the death knell of the manufacturing sector in Canada. And yet here we are — perhaps sporting a few battle scars.

With all the negative news on the manufacturing front inundating the citizenry of this land in the past decade or so, why would anybody want to start a welding shop? Perhaps there are a few local businesses that need your service? But why-oh-why would anybody start one far from suppliers and customers?

Meet James Fedirchuk. He is the sole owner of Fero Metalcraft Inc. in Kenora, Ontario. Anybody who has been

in Kenora, or passed through it knows it is a lovely town of just over 15,000 people. Situated about 200 kilometers east of Winnipeg, it is located on Lake of the Woods in the Canadian Shield. Fedirchuk started the business about a year ago, in April 2011 after ruminating about this move for a few years.

“We started because we had the entrepreneurial bug,” says Fedirchuk. “There are two of us in the company now and we both are involved in metalworking and we both enjoy the industry. But we thought we could do it from Kenora and enjoy what we do, plus make a living as well.”

Fedirchuk was born 32 years ago in Île-des-Chênes, a small community just outside Winnipeg. He is a licensed professional engineer in Manitoba and Ontario with a specialization in welding engineering and manufacturing engineering. He obtained his degree at the University of Manitoba and worked

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Intricate metalwork from Fero Metalcraft Inc.

for Lincoln Electric as a Technical Rep out of Winnipeg for several years. Three years ago, he ditched the big city life of Winnipeg and moved to Kenora. “I had been living in Kenora for three years before starting the business,” he said. “I was travelling to Winnipeg and had an apartment in Winnipeg where I stayed during the week.” He is married with a baby on the way.

The other half of Fero Metalcraft is Jason Romas who is originally from Dryden, a small town east of Kenora. A graduate of Conestoga Welding Engineering Technology, he was a welding inspector and supervisor in Winnipeg when he met Fedirchuk while sharing an office.

RELAXED COMMUNITY AND LIFESTYLE

“We really like the community and the lifestyle out here. It has a totally different pace to it, than a big city,” said Fedirchuk.

“That brings its own challenges, but for us the quality of life in a small town is what we are looking for. We love the lakes and all that kind of stuff, so we wanted to try to make an industry that wasn’t previously here and make something out of it. Live where we want to live and do what we want to do at the same time.”

Fedirchuk is as passionate about welding as he is about living in Kenora. “Why did we think it was going to go? We both, Jason and myself, have unique skills using technology. I think that is our key,” he said. “We use the latest welding equipment.

We have pulse and double pulse. We have the latest technology in welding and in CNC plasma cutting. You don’t see that in a small town. We have to, to compete. We use technology to our advantage to keep the labour costs down and to keep the prices within reason. We have to use our brains as much as our brawn to make things more efficient.”

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to secure one for this year,” Fedirchuk knew that Fedirchuk explains. “We are opening up a welding shop in currently in talks with the Kenora was not going to be a CFL to get licensing for all picnic. He spent a lot of time of the teams.” Expanding to planning the venture. “We other teams and sports is in built a lot of the machinery the plans. “The Jets. That’s and equipment, like the a million dollar question. We plasma table and so forth, have been in contact with the in my garage before getting Winnipeg Jets, but have not this building,” he explained. finalized anything.”

“When we moved to Kenora However, they don’t plan I didn’t even have a garage. on making ornamental metalI had to build that first.

Custom fire pits were the first product from Fero. work for the cottage owners There wasn’t anything easy their only source of income. about that. I left my position “What we did in the past in September 2010, and in and what we are getting into now and what is going to carry us the first six months, I had to build the garage in which to build forward, is getting back to robotic welding,” he explains. “So we the equipment to get started. We were basically getting things build the fixtures and do the programming for robotic welding organized before we actually had any customers or business cells. This is more along the lines of what I used to do in the coming through. Out of the garage, it was just set-up time and welding industry. Jason as well worked at Guelph Tool and Die getting everything organized and preparing a proper business and has experience with robotic welding. plan.” He notes that it took him some time to find a suitable When a customer buys a new cell, we will fixture it and space to set up shop in Kenora. program it for them, he explains. “They will ship the robotic The shop they eventually found is located on the East side of welding cell to us and we will work on it and ship it out to them, town, a 3,500 square foot space, off Highway 17. “It is pretty much so it is a turnkey operation. When they get their brand new all manufacturing area with a small office. It is pretty standard. cell, it has the tooling and the fixturing and it has the program Part of a large industrial building in which we rent about half of it. for their parts in it, so they just have to push ‘go’ and it runs.

The whole building is approximately 8,000 square feet, standing off We design it, then we do the manufacturing of the cell. We the side of the highway in the industrial zone,” he said. In the year then install and the programme on site for the customers,” he or so he has been operating, he is starting to feel squeezed for said. Customers are located throughout the Prairies, mostly in space. “We started this in my garage and now we are finding that Manitoba and Saskatchewan. The majority of the manufacturing 3,500 square feet is kind of tight,” he said. “We prefer to keep our is agriculture based. “We’ve known most of our customers for steel indoors if possible. It makes all of our cutting and welding years working in the industry.” operations easier to do without all that rust. It does take up more space. We could always have more space. We have to move stuff DIVERSITY AND FLEXIBILITY outdoors and have to shuffle things around.”

Diversity and flexibility is key to their survival according to STARTING LOCAL Fedirchuk. “Since we are in such a small town, it is tough to Finding that first customer and making that first sale is survive with just one product. We are not able to just make always a daunting challenge for any start-up business. “We one single item and have a business out of it,” he said. “So we needed something that the local area was looking for, so we had to be flexible and try to diversify and try to expand. The started making a custom fire pit. That was our first product. It only way that we could figure out how to make it work is to showcased our skills and ability. It showed people what some of try and bring the business in from other provinces, bring it the equipment can do,” said Fedirchuk. “I think there are over back to Kenora and work on it in-house here.” Their business 30,000 cabins in the area and I would say that almost all of them plan works well because it has the flexibility built in. This is have a fire pit. So we just thought that it would be a good way especially true with the robotic process. “They can ship the to get the business going.” The fire pits, some emblazoned with part to us here and we can design, manufacture and program the Winnipeg Blue Bomber logo, are a hit. “We sold them as far out here and then only be onsite for a few days or a week,” he off as Calgary, Kingston and all over Canada, but mostly for the explains. “So the majority of the work can be done in Kenora local Kenorans in the area.” He said that the Lake of the Woods but it comes from Saskatchewan, it comes from Winnipeg. So location is a popular cottage area for residents of Winnipeg, we are bringing it in from there, from here. It is a service that as it is about a two-hour drive to Kenora. “The fire pits were a they need. It works out for all parties.” good way to start the business. We make the fire pits and also Being in a small town is not without problems for a small we do ornamental railing for the interior and exterior,” he said. manufacturer. “There aren’t any bar steel suppliers here, Coming up with a design was natural according to Fedirchuk. they are all out of Winnipeg. Welding supplies are all out “We started out from scratch and we designed them in a way of Winnipeg, all the bolts and fasteners as well,” Fedirchuk that we would want them for our yard. Obviously, we both have explains. “You get a bit of shipping, it’s not too bad. You have to them in our yards now. We made them so that we are happy do a bit more coordinating than you would if you were in a big with them. We are both quite picky, so if we are happy with centre. But we can make it work. It doesn’t hold up production, them then other people will be happy as well. It has been true but it does complicate production because our sandblasting so far.” Marketing was originally through word of mouth. “In and powder coating is in Winnipeg. Our steel supplier is in a small town that is big. We also do some local shows.” They Winnipeg. So if we need something we have to go off hours or pulled of a coup by getting the Blue Bombers CFL team to agree early in the morning. We try not to let it affect our deliveries to lease their logo. “We had a licensing agreement with the but it definitely takes a lot more out of us.”

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wonder that his shop is a Lincoln shop. Their main machine is the Power Wave C300 Advanced Process Welder. It fits in well with their shop as it is ideal for welding a variety of materials, including aluminum and stainless. It is a multi process welder that will perform well with MIG, Pulsed MIG, Flux-Cored, Stick, DC TIG and Pulsed DC TIG. It has an integrated TIG Torch and Spool Gun Solenoid that allows fast changeovers to TIG welding or spool gun operation. This welder features Lincoln’s CheckPoint and Production Monitoring 2.2 systems that allow the user to view and analyze your welding data on almost any device such as a desktop, laptop, iPhone or iPad, Blackberry and others.

They also have a Lincoln 255XT MIG welder that is as close to standard for MIG and flux-cored welding as you will get.

To keep the shop clean they use a Mobi Flex 400-MS Mobile Welding Fume Extractor also from Lincoln Electric. This unit is ideal for smaller manufacturing facilities, has 735 CFM of airflow, and is quiet at 69 dBA.

One of the many signs made by Fero Metalcraft Inc.

what we do. That is kind of why we set it up the way we did.

We chose to cooperate with a lot of the local shops, so if they have some different skills that we don’t have we will share. I will outsource to them and vice versa. They have come to trust us, now that they know that we are not going after their contracts. They now bring us stuff for cutting and rolling using equipment that they don’t have. In turn we have become better partners with the local weld shops, but again we are not building boxes or going after the forestry industry, there are companies located here already that do that. We are starting something basically from the ground up. We are building something totally new. It works because we have gotten some good partnerships with other shops that have helped us and we have helped them.” CM

GROWTH WITH ROBOTICS

Fedirchuk sees their company expanding more into the robotic welding side of things. “That’s going to be one of our main focuses going forward. Improving on the design and manufacturing of robotic fixtures for industry will be where we concentrate.” He is careful not to step on anybody’s toes in his adopted hometown. “Forestry is pretty slow. And there are other guys in town that have been doing that for years and we are doing something different as well,” he said. “We are not directly competing with the other existing job shops. We are going down a slightly different road. Mining will be the big one as the industry is picking up here, so there might be more fabrication down the road. There is no one in the area doing

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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 | JUNE 2012 | 87

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Strength in Numbers Independent Job Shops Taking a Group Approach

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

J

ob shops are traditionally seen as bastions of rugged individualism—small, independent firms offering custom or one-off work in a world of mass production. Some job shops, however, have decided there are benefits to a collective approach and have started banding together in loose networks.

By offering a slew of services, job shops in these networks hope to draw new customers and bigger gigs.

Marco Gagnon, for example, runs a 20-person job shop called Gagnon Ornamental Works (GOW) in Grand Falls, New Brunswick. Founded by Marco’s father, Gerald Gagnon, in 1968, GOW boasts a wide variety of lathes, mills, grinders, saws, bending machines and other assorted equipment in 26,000 square feet of space.

Since 2009, GOW has belonged to something called the

with a fully integrated manufacturing solution to their needs. We can take a project from design to installation to commissioning,” reads the AMMG website.

According to Gagnon, GOW has reaped the benefits of a collective approach.

“We did get new customers and prospects out of this, plus we built our network of shops that can help each other. Now we can look at big projects that previously we would have passed on,” says Gagnon.

While Gagnon admits there’s a bit of a herding cats element to getting job shops to work cooperatively, the AMMG appears to have its act together. The Group is run by a board, has a president who performs administrative duties and a managing director who “handles all business development,” says Gagnon.

“AMMG was formed to have strength in numbers. We now can talk to prospective customers and offer them over 100,000 square feet of available shop space instead of [26,000 square feet]. We now walk into meetings with prospective customers and know that we have five other companies behind us to help deliver on projects,” says Gagnon.

Gagnon hesitates to offer financial specifics, though he does say “revenues [at GOW] were up roughly 10 percent in 2011, versus 2010.”

RAISING REVENUE

Marco Gagnon, owner of Gagnon Ornamental Works (GOW).

Charles Ruecker is more forthcoming when it comes to giving precise figures.

Ruecker is founder and CEO of Core Powered, a Mississauga, Ontario based group similar to the AMMG. Core represents the interests of four job shops, three of which are based in Ontario.

The latter trio consists of Precision Components of Hamilton,

Associated Manufacturing Marketing Group (AMMG). The AMMG consists of six New Brunswick based job shops that have joined forces to “develop new business on a cooperative basis” as the organization’s website puts it. In addition to GOW, the Group features All-Tech Hydraulic and Mechanical, Beaulieu Plumbing and Mechanical, Titan Steel, Rogers Electric Motor Service and Sunny Corner Enterprises.

AMMG represents “a collective company with the size to tackle major projects. On small, local jobs we might all bid against the other, yet on bigger projects we work together,” says Gagnon.

WORKING TOGETHER

All the job shops in the AMMG “have a certain expertise ... for us, it was our design and detailing team, plus having expertise in material handling,” he continues.

Other services available from AMMG affiliated shops include CNC machining, custom fabrication, contract manufacturing, equipment refurbishment and repair, on-site installations and maintenance services, etc.

“Associated Manufacturing looks to provide its customers

Charles Ruecker, founder and CEO of Core Powered

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Exterior of Precision Components

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Steve Koziski, president of Precision Components

Shawn Doucette, vice-president of Precision Components

Micrometric of Scarborough and Schuller Machine & Tool also in Scarborough. The fourth member of the quartet is a British firm called Holmes UK. Core is set up to be a single-source manufacturing hub and industrial consulting firm. Among other services, Core companies design and manufacture work and toolholding systems, design and repair spindles and do complete process design. Parts made by shops in the Core network include collets and clamp jaws. Ruecker has also created complete turnkey programs for companies. Sectors covered include agriculture, automotive, aerospace, plumbing and medical parts.

Asked how shops benefit from being part of Core Powered, Ruecker says, “We give them a lot of work ... last year we did

$1.4 million. The year before we did $1.2 million. The year before that, I think, was $800,000 ... right now, the sales we’re at [for this year], we didn’t hit those sales numbers until August last year.

We’re in the process of doubling our sales and revenue ... in four years, we want to be at $5 million in revenue.”

Interestingly enough, 95 percent of Core’s revenues come from outside Canada. Some 20 percent of business is from the UK, the rest primarily comes from the United States.

NO BRICKS AND MORTAR

There is no bricks and mortar headquarters for Core Powered.

Ruecker operates from a home office in Mississauga. Member companies operate from their own facilities.

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“The most significant piece about our model is that we don’t centrally warehouse anything. We flow our work like a job cart through a shop. [Work] moves from point to point to point. As it moves, it’s going to different companies,” explains Ruecker.

Ruecker hails from a tool and die background. He spent decades working for various companies but eventually became “really restless ... I had a conversation with a friend of mine, who is the owner of Micrometric, and I said there has to be another way to do business,” he recalls.

In 2004, as a result of these discussions, Ruecker founded the company known today as Core Powered (the firm went through some name-changes along the way). He was motivated in part by a desire to create a new manufacturing model that would help job shops compete with offshore manufacturers. Ruecker also believes working together simply makes good business sense for job shops. As boss of Core, Ruecker looks for work opportunities, sets the company’s vision and handles day-to-day management.

Ruecker’s had to adapt to accommodate the independent spirit of his member companies. This is apparent in Core’s operating structure: when member companies proved unenthusiastic about working under formal contracts, Ruecker decided to do away with such arrangements. While Core companies still sign confidentiality and licensing agreements, actual business is often conducted on the basis of verbal agreements.

Ruecker insists that relying on the goodwill of member companies isn’t a risky move, “because of the volume of work we give them.”

INCREASED PROFIT, MORE TRUST

Job shops under the Core Powered banner know that by consolidating their services, they can pick up projects that might have otherwise been unavailable to them as individual companies, he explains.

If increased profit is the goal, trust is the glue that holds job shop networks together.

“You need to have companies that are open to working together and that have a level of trust ... you need to have confidence amongst the group that if you bring a customer to the table for a project, your partners in the group will not come out of that meeting and try to sell direct because [they understand] that together much more can happen than by flying solo,” says Gagnon.

Shawn Doucette, vice-president of Precision Components, is pleased with his company’s dealings with Core. Precision specializes in tooling for automotive, aerospace, medical, military, etc.

“Our relationship works with Core Powered because the work that gets channelled in our direction fits into our skill and equipment capabilities ... we have been working with Core Powered for seven years ... the relationship with Core Powered has been beneficial. It has become a constant revenue stream for us with the type of work we are good at,” says Doucette.

While Precision Components is clearly won over, Ruecker concedes that working collectively goes against the grain for most job shops.

“Unless you understand how to work with other human beings, I don’t think you can make this model work. Every tool and die maker thinks they are the best tool and die maker in the world ... they don’t play well with others,” he says.

Core Powered – http://corepoweredinc.com/index.html Associated Manufacturing Marketing Group – http://www.custom-industrial-services.com/ CM www.canadianmetalworking.com | JUNE 2012 | 91

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Tool Talk

PORTABLE CMM HAS ON-BOARD OPERATING SYSTEM

The FARO Edge is a portable measurement arm that allows manufacturers to easily verify their product quality by performing inspections, tool certifications, CAD-to-part analysis and reverse engineering.

The Edge features a built-in touch screen, on-board operating system for laptop-free measurement, improved ergonomics, wireless connectivity and much more. For rapid prototyping or reverse engineering applications, the Edge incorporates quickly with FARO’s lightweight Laser Line Probe to form the complete Edge ScanArm solution.

FARO Technologies www.faro.com

new Mitutoyo ID-S Solar ABS Digimatic Indicator’s solar power source can function effectively at light levels as low as 40 lux illumination - significantly below values typically found in even low-light work conditions. In addition the ID-S Solar ABS Digimatic Indicator incorporates a super capacitor to maintain a power reserve of approximately 3.5 hours for instances when even lower light levels are encountered.

The ID-S Solar ABS Digimatic Indicator features Mitutoyo’s proprietary ABS (Absolute) measuring system. When the indicator is turned on, ABS automatically restores the most recent origin position. This eliminates the need to re-set the origin at power-on, which can be especially helpful in multipoint measurement - saving time and improving repeatability.

Data-hold and data-output functions are included in the new ID-S Solar ABS Digimatic Indicators enhancing the operator’s ability to manage measurement results. Data functions include a lock to prevent mis-operation. The indicator’s measuring range is .5” (12.7mm) while its resolution is selectable at .0005”/0.01mm or .00005”/0.001mm.

Additionally, the Mitutoyo ID-S Solar ABS Digimatic Indicator supports output to measurement data applications such as MeasurLink, Mitutoyo’s proprietary statistical-processing and process-control program which performs statistical analysis and provides real-time display of measurement results for SPC applications. The program can also be linked to a higher-level network environment for enterprise-wide functionality.

Mitutoyo Canada Inc. www.mitutoyo.ca

NEW HIGH PERFORMANCE MICRO DRILL

NEW SOLAR POWERED DIGITAL INDICATOR

The new ID-S Solar ABS Digimatic Indicator now available from Mitutoyo Canada combines, for the first time in an indicator, the convenience of ABS origin memory with “always ready” solar power to provide highest levels of convenience. The

The new Sandvik Coromant solid carbide micro drills offer outstanding performance for holes from 0.073 inches to 0.116 inches in diameter. The CoroDrill 862 has a thin TiAlN coating that helps retain cutting edge geometry and provides a smooth surface for chip evacuation. This helps prolong tool life in workpiece materials that include steel, stainless steel, cast iron and aluminum.

The innovative post treatment on the CoroDrill 862, combined with specially designed point geometry, reduces the thrust forces and promotes fast and efficient chip removal. This is aided further by Advanced Chip Management (ACM) flute geometry, which helps evacuate the chips. This is vital in microdrilling as even the smallest accumulation can lead to problems such as drill breakage, loss of precision, downtime and scrap.

The CoroDrill 862 also provides good hole entry and exit, and achievable hole tolerance of IT8-IT9. Internal coolant holes deliver coolant directly to the tip of the drill, even at deep

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Tool Talk drilling depths, to further assist precision and chip removal.

Available in drill lengths of 8-12 x D, the drills are only for use with HydroGrip high precision chucks from Sandvik Coromant. www.sandvik.coromant.com/ca

wedge shape pocket design that ensures the optimal fit for the insert. Working with a dovetail system, the insert and toolholder work in synergy to deliver remarkable rigidity and accuracy for high performance boring operations. This highly rigid clamping structure further improves insert tool life and productivity.

Tungaloy America Inc. www.tungaloyamerica.com

BORING BARS WITH NEWLY DEVELOPED INSERTS

For small diameter boring and internal turning operations, the Tungaloy Corporation has now developed its DoMiniBore range of toolholders and inserts. Capable of machining bore diameters as small as 12 mm, the new DoMiniBore is a cost effective solution for the machining of steels, stainless steels and cast irons.

The newly developed WXGU and DXGU inserts incorporate a unique new edge shape and large inclination that reduces the cutting forces considerably and prevents chattering to deliver performance levels beyond that of positive type inserts. With double sided inserts, the new DoMiniBore offers twice the number of corners of conventional positive type inserts from competitors. This significantly reduces tooling costs while the insert design enables one insert type to fit shank diameters from 10 to 20 mm to further reduce costs and tooling inventory.

The inserts are available in left hand designations with G-Class accuracy to guarantee impeccable surface finishes and quality levels. The large edge inclination minimises cutting forces and chatter while the unique chipbreaker design offers excellent chip control over a wide range of material types. The wide chip pocket enhances chip control and also minimizes the potential for re-cutting the chips, which can be a cause for poor surface finishes.

This chip pocket works in synergy with the peripheral insert shape that delivers the clamping rigidity required for high performance boring and internal turning.

The steel or carbide toolholders are available with shank diameters from 10 to 20 mm for minimum bore diameter machining from 12 to 22 mm and upwards.

The toolholders have an innovative new www.canadianmetalworking.com | JUNE 2012 | 93

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Tool Talk The specially designed tool carrier provides for fluid movement when processing trapeze and profile sheets. In addition, cutting direction can be adjusted 360 degrees for maximum flexibility. The quick & easy tool change feature permits the tool to be replaced in seconds.

Trumpf Inc. www.us.trumpf.com

INCREASED FLEXIBILITY IN PROFILE NIBBLING

Trumpf’s TruTool PN130 nibbler is the ideal tool for profile, corrugated and flat sheet metal cutting, offering a new standard feature: The HighSpeed punch which achieves quality cuts at a working speed of 10.5 ft/min. When the highest quality cut is needed, the specially developed HighQuality punch supplies an extremely fine cut edge, produced at the slightly slower rate of 9 ft/min.

The ergonomic design of the electric TruTool PN130, combined with a slim, lightweight and vibration resistant structure, allows users to cut sheets up to 0.05 inches thick with a high degree of comfort and flexibility. The extremely maneuverable tool is capable of cutting radii as small as 1 inch in even the most difficult to reach places.

www.schunk.com/tendo-e-compact/en

CHANGE! Torque of up to 900 Nm (Ø 20 mm) Roughing, Drilling, Reaming, Finishing Run-out and repeat accuracy < 0.003 mm Increase tool life up to 40% www.schunk.com Tel. 905-712-2200

EXCEPTIONAL PRECISION FROM THE COMPETENCE LEADER FOR CLAMPING TECHNOLOGY AND GRIPPING SYSTEMS.

SOFTWARE REPORTS FACTORY HEART RATE AND HEALTH

The Freedom eWARE software suite from MAG is the first all-encompassing manufacturing data reporting platform to provide availability performance, and quality feedback from any industrial asset on the plant floor. eWARE is a modular and scalable software package for data acquisition, condition monitoring, energy monitoring, and cell control, capable of generating reports and analytics for maintenance, process optimization and OEE. The software, which is MTConnect compliant, can interact with smart phones, tablet PCs and similar mobile devices, displaying machinery status, productivity data and machinery analytics for various systems on a plant network. eWARE is “target independent,” capable of collecting data from any plant floor asset – without modification to ladder logic or part programming – and transforming that data into actionable information. With installations that include Department of Defense facilities and contractors, eWARE makes manufacturing activity and system conditions transparent, enabling rapid implementation of operational and maintenance excellence, proven with payback as short as one year. eWARE consists of five modules for logging, analyzing and reporting information, plus a control-resident eCONNECT interface for each machine that uses a PC front-end control. For non-PCbased CNC’s, PLC’s and manual machines, eCONNECT runs on a hardware appliance with discrete I/O connections to specific machine electrics. eCONNECT acts as a data collection hub and access point for equipment on the plant floor, and supplies information to the five software modules: eLOG, eSCOPE, eMONITOR, eENERGY and eCELL. In addition to its software platform, MAG can support users with Lean training, turnkey system integration, simultaneous engineering, producibility/productivity analyses, remote diagnostics and a host of other services to help sustain and maximize improvements.

MAG IAS Canada Inc. www.mag-ias.com

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ADVERTISERS INDEX ADVERTISER . . . . . . . . . . . . . . PAGE

ADVERTISER . . . . . . . . . . . . . . PAGE

AMT Machine Tools Ltd. . . . . . . . . . . . . . . . 25

Machitech Automation . . . . . . . . . . . . . . . . 23

Bohler-Uddeholm Limited . . . . . . . . . . . . . . . T5

Mack Brooks Exhibitions Ltd. . . . . . . . . . . . . 91

Brubaker Tool . . . . . . . . . . . . . . . . . . . . . . . 27

Mascoutech Inc. . . . . . . . . . . . . . . . . . . . . . 10

Canadian Measurement-Metrology Inc. . . . T25

Mate Precision Tooling . . . . . . . . . . . . . . . . 22

Cecor Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 66

Mazak Corporation . . . . . . . . . . . . . . . . . . 31

COLE-TUVE, Inc. . . . . . . . . . . . . . . . . . . . . .12

Megatel Inc. . . . . . . . . . . . . . . . . . . . . . . . 26

CWB Group . . . . . . . . . . . . . . . . . . . . . . . 89

Mori Seiki . . . . . . . . . . . . . . . . . . . . . . . . T23

Data Flute . . . . . . . . . . . . . . . . . . . . . . . . . 27

Nederman Canada Ltd. . . . . . . . . . . . . . . . 78

Dipaolo CNC Retrofit Ltd. . . . . . . . . . . . . . 73

PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Eclipse Tools North America . . . . . . . . . . . . 68

Renishaw Canada Ltd. . . . . . . . . . . . . . . . . 69

Elliott Matsuura Canada Inc. . . . . . . . . . . . . 4

Retention Knob Supply and Mfg. Co. Inc. . . . 95

Emec Machine Tools Inc. . . . . . . . . . . . . . . . 71

Sandvik . . . . . . . . . . . . . . . . . . front flap & T11

8CMM20186

01/07/2008

08:19 AM

IN STOCK

Schmolz + Bickenbach USA Inc. . . . . . . . . . 32

Fagor Automation Canada . . . . . . . . . . . . 11

Schunk Intec Corp. . . . . . . . . . . . . . . . . . . . 94

FARO Technologies Inc. . . . . . . . . . . . . . . T13

Scientific Cutting Tools . . . . . . . . . . . . . . . . 90

Fastcut Tool . . . . . . . . . . . . . . . . . . . . . . . . 27

SGS Tool Company . . . . . . . . . . . . . . . . . . 29

Gibbs & Associates . . . . . . . . . . . . . . . . . . 16

SME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

FOR FAST DELIVERY:

Hardinge Inc., Workholding Division . . . . . . 14

Sowa Tool & Machine Co. Ltd. . . . . . . . . . . 15

HORN USA, Inc. . . . . . . . . . . . . . . . . . . . . . 7

Sumitomo Electric Carbide . . . . . . . . . . . . . . 9

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

Hurco USA . . . . . . . . . . . . . . . . . . . . . . . IFC

Technifor . . . . . . . . . . . . . . . . . . . . . . . . . . 93

IMTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Toshiba Machine Company of Canada Ltd. . 17

Ingersoll Cutting Tools . . . . . . . . . . . . . . . . T17

Trumpf Inc. . . . . . . . . . . . . . . . . . . . . . . . . . IBC

Iscar Tools Inc. . . . . . . . . . . . . . . . . . . . . . OBC

Tsugami . . . . . . . . . . . . . . . . . . . . . . . . . . T21

Jesse Engineering . . . . . . . . . . . . . . . . . . . . 76

Tungaloy America Inc. . . . . . . . . . . . . . . . . . 3

Jet Edge, Inc. . . . . . . . . . . . . . . . . . . . . . . . 74

Walter USA, LLC . . . . . . . . . . . . . . . . . . . . 21

Lincoln Electric Company of Canada . . . . . 81

Walter Surface Technologies . . . . . . . . . . . 87

LVD Strippit, Inc. . . . . . . . . . . . . . . . . . . . . . 13

Weldon . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Page 1

American Standards and specials.

Japanese Standards inch or metric.

ESAB Canada . . . . . . . . . . . . . . . . . . . . . . 79

2012

Welding Canada

ExpandEd WElding CovEragE

Canadian Metalworking gives your advertising the best editorial environment available.

Every issue includes Welding News, CWB Column and a Welding Feature story.

Feature Stories February ......................

March..........................

April.............................

May .............................

June.............................

September ...................

October .......................

Power Supplies Fabtech product preview Welding Safety Positioning & Fixturing Job Shops Cutting & Welding Preparation Special Supplement What’s New In Welding

November .................. AWS Las Vegas Preview

Welding eNewsletter Schedule Jan 31, March 27, April 24, May 29, June 26, July 31, September 25, October 30

Expanded Welding Circulation Added Welding distributors across Canada.

What’s New In Welding Special Supplement in October gives advertisers equal advertorial space.

Introducing…

Nestor Gula, former editor of Metalcraft Magazine as Welding feature writer!

Steve Devonport, Publisher 416-543-1641• Email: SDevonport@canadianmetalworking.com

Welding Canada

www.canadianmetalworking.com www.canadianmetalworking.com | JUNE 2012 | 95

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By The NUMBERS Has China Plateaued?

HSBC’s Flash China Manufacturing Purchasing Managers’ Index survey shows flat to negative growth for March and April.

According to Hongbin Qu, Chief Economist, China (and co-head of Asian economic research at HSBC), “as the April flash PMI ticked higher, this suggests that the earlier easing measures have started to work and hence should ease concerns of a sharp growth slowdown. That said, the pace of both output and demand growth remains at a low level in a historical context and the job market is under pressure. This calls for additional easing measures in the coming months. We expect monetary and fiscal easing to speed up in Q2”.

What does this mean? In essence, the Chinese government will throw money at the growth problem, much as Europe has planned to address stalled growth on that continent. Can the U.S. resist a third round of quantitative easing when her major trading partners are pumping liquidity into the global banking system?

China Flash PMI Summary

Index

Change

Output

Contraction, slower rate

New Orders

Contraction, slower rate

New Export Orders

Contraction, slower rate

Employment

Contraction, slower rate

Backlog of work

Expansion, slower rate

Output Prices

Decline, slower rate

Input prices

Inflation, slower rate

The HSBC Flash China Manufaturing PMI is compiled by market with HSBC. Underlying data is available for market subscribers.

Contact: economics@markit.com HSBC on the Internet is located at: www.hsbc.com.cn

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