Cmw2013oct01

October 2013 • www.canadianmetalworking.com

Serving the Canadian Metalworking Industry Since 1905

Mold, Tool & Die Market Outlook OEM's are booming ... can we grow our share of the market?

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A LOOK INSIDE Vol. 108 | No. 7 | October 2013 | www.canadianmetalworking.com

COVER STORY: Mold Tool and Die Market Outlook ... 20 Will OEM strength continue?

FEATURES WATER OR OIL FOR EDM? ............................ 30 Each has benefits, applications

MACHINE TOOLS FOR THE TOOLROOM ...... 36

COPPER COST CLIMBING............................. 62 A new global report suggests future upward pricing pressure

Productivity matters in the toolroom, too

HIGH FIBER DIET ........................................... 66

NEW GRADES, NEW COATINGS ................... 40

Fiber lasers expand their reach

Major changes in turning tool technology

ADDITIVE VALUE ............................................ 76

WELDING AUTOMATION FOR THE PEOPLE ... 58 Robotic welding is not just for the big boys

Renishaw’s Dafydd Williams and Mark Kirby on additive manufacturing

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DEPARTMENTS View From the Floor ......................................................... 6 News ................................................................................ 8 Tool Talk .......................................................................... 46 The Business of Tooling ................................................. 52

Welding News................................................................. 54 Business of Welding ....................................................... 57 The Cutting Edge ........................................................... 80

By The Numbers............................................................. 82 www.canadianmetalworking.com | OCTOBER 2013 | 5

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PUBLISHER Steve Devonport 416-442-5125 | SDevonport@canadianmetalworking.com ASSOCIATE PUBLISHER Rob Swan 416-510-5225, cell 416-725-0145 | RSwan@canadianmetalworking.com EDITOR Jim Anderton 416-510-5148 | janderton@canadianmetalworking.com ASSOCIATE EDITOR Nicholas Healey 416-442-5600 x 3642 | nhealey@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 ............................................................................

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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 8 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 Sell to Succeed

A

s editor of Canadian Metalworking I’m fortunate to have the opportunity to visit mold tool and die shops across the country. It’s a rare opportunity; like many industries metalworking tends to be compartmentalized, like silos, with each subsector understanding its own market but rarely dealing with others in the industry.

I’m lucky, in that I get to visit shops across the spectrum and across the country. As different as they are, successful shops seem to share several common attributes. The obvious ones are cleanliness, organization, modern technology and high employee morale. A much less visible factor, but one which is vital, is the one which is least visible to shopfloor personnel: a dedicated sales team. If you’re a mold, tool or die shop, who markets and sells your services? For many shops, including historically successful ones, it’s the owner or manager that pitches the business and asks for the order. “I know my customers” is something I hear everywhere, and although a close working relationship with your customer base is essential, I can’t help but wonder what we as an industry are leaving on the table.

This came to mind while preparing the mold, tool and die market analysis that’s featured on page 20. Historically, automotive is the major consumer of mold tool and die products and there is a profound shift going on.

Assembly plants are moving south, not to Detroit but to the deep south of the U.S. Tennessee, Alabama and the Carolinas are replacing Michigan as the centres of US auto production, and Canada is not keeping up. Only Toyota and Ford are expanding production and heavyweight Tier Ones are lining up for government handouts to keep production in this country. Tier Ones and Tier Twos that locate within a couple of hours drive from their customers’ assembly plants have a clear advantage, as do their local tooling suppliers. On the surface this would seem to be bad news for the Canadian industry, but it doesn’t have to be that way. We are simply going to have to reach down south of the border and win the business by building new relationships from scratch. There are tools to help the sector deal with the problem, especially from Export Development Canada, who offer a range of services and advice. Many, perhaps most Canadian mold, tool and die shops are not used to exporting. While their products are often shipped out of the country, the deal making is usually based on long-standing working relationships. While this is great for vendor customer communications, it can blind us to the potential for a wider market in the US. To crack a new market that’s 1000 or 2000 kilometres away, shops will have to adopt modern sales and marketing techniques. For most operations it doesn’t make sense for the owner/manager to go on the road, so this translates to dedicated technical sales personnel. Can’t afford to hire a dedicated technical salesman or woman? If you intend to properly serve a Tier One and Tier Two client base that’s 12 hours by truck from your shop, you have to. It’s expensive, yes, but there are other advantages to a dedicated sales force. Perhaps the most important is market intelligence. There are many ways to find out what’s going on in the industry, from Canadian Metalworking magazine to expensive consultants, but nothing beats direct feedback from people speaking directly to the customer base.

A salesperson with “boots on the ground” can help a shop build a profile not just of the size and location of potential customers, but what kind of equipment they use and who supplies their current tooling. Is that press shop intending to switch to larger, higher volume stampings? Their current tooling supplier may not have the capability or capacity to supply them, a natural opportunity. And a dedicated sales force also gives the distant customer a sense that there is local accountability and a familiar representative of your shop to stand behind the product.

Simply put, if you are an owner/manager, you need to be a quarterback ... if you need to make a “Hail Mary” pass, you’ll need a good receiver downfield.

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JIM ANDERTON, EDITOR

Do you agree? Let me know, and feel free to drop me a line at the e-mail address below, or buttonhole me at a show or event. I’d love to hear from you! janderton@canadianmetalworking.com 6 | OCTOBER 2013 | www.canadianmetalworking.com

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IN THE NEWS

Alcoa to curtail smelting capacity; Quebec location affected Aluminum prices hit four-year lows, industry feels the effects

NEW YORK – Alcoa has announced that it will close or curtail 164,000 metric tonnes of smelting capacity in the United States and Brazil as part of a review that was announced in May. One potline representing 40,000 metric tonnes at the Massena East plant in New York state will be permanently closed.

In addition, the company has started to temporarily curtail 124,000 metric tonnes at its smelters in Brazil. The closures and curtailments will be complete by the end of September.

“We committed in May to review our global smelting capacity for possible curtailment to maintain the company’s competitiveness,” said Bob Wilt, president of Alcoa’s Global Primary Products.

“Aluminum prices, including premiums, have fallen to four-year lows and we continue to operate in an uncertain, volatile market.”

Wilt added that the company will work with stakeholders in affected communities to minimize the impact of the closures and curtailments.

To date, Alcoa has announced closures or curtailments representing 269,000 metric tonnes of the 460,000 metric tonnes placed under review in May. This includes the permanent closure of 105,000 metric tonnes of capacity announced earlier at Alcoa’s Baie-Comeau smelter in Canada. In addition, the Company permanently closed its Fusina, Italy smelter representing 44,000 metric tonnes that was not part of the May review.

Once the Massena and Brazil closures and curtailments are complete, Alcoa will have 16 per cent, or 646,800 metric tonnes of smelting capacity idle. CM

8 | OCTOBER 2013 | www.canadianmetalworking.com

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IN THE NEWS

Toyota Corolla dubbed ‘world’s most popular car’ Japanese company claims 40 million Corollas sold since car’s launch in 1966, 1.3 million built in Cambridge, Ontario plant since 1988

T

oyota is touting its longstanding Corolla model as the world’s most popular car as it launches the 2014 edition of the compact car in Canada.

According to the company, it has sold more than 40 million Corollas—including 1.3 million in Canada—since its inception almost 50 years ago, taking the crown as the top selling passenger car globally.

The Corolla has been built in Cambridge, Ont., since 1988, just one of 14 plants worldwide that build the vehicle.

“The key to the Corolla’s success is the faithful passing down of its original development concept from (then chief engineer Tatsuo) Hasegawa: that the Corolla must bring happiness and well-being to people around the world,” Corolla chief engineer Shinichi Yasui said in a statement.

Originally designed to meet the needs of commuters in Japan, production of the Corolla was first launched November

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1966 when the automaker opened a new plant in Takaoka, Aichi Prefecture, Japan, dedicated solely to the car.

Two years later, with an emphasis on providing region-specific vehicles, production began in Australia and Malaysia—the same year exports of the Corolla were launched in the United States and Canada.

The Corolla is still built at Toyota’s plant in southwestern Ontario.

– With files from CanadianManufacturing.com

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Canada’s motor vehicle parts industry growth to stall in 2013: Conference Board Outlook more positive for 2014 OTTAWA – Following a strong year in 2012, production in Canada’s auto parts manufacturing industry will slow down significantly this year, according to The Conference Board of Canada’s Canadian Industrial Profile — Summer 2013.

“The motor vehicle parts industry will produce only marginal growth this year,” said Michael Burt, Director, Industrial Economic Trends. ... continues on page 12

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IN THE NEWS ... continued from page 10

“However, this slowdown should only be temporary. U.S. car sales are expected to reach their pre-recession level next year, which will drive parts production higher in the next couple of years.”

The report also predicts parts production will edge up just 0.1 per cent this year due to weak demand from automakers in late 2012 and early 2013. Although, production is then expected to increase 5.5 per cent next year due to strong gains in U.S. vehicle sales.

It also suggested some concern regarding the ongoing shift in North American vehicle assembly away from the U.S. Midwest and Ontario to the southern states and Mexico — something that could adversely affect the Canadian auto parts sector in the long run.

Industry pre-tax profits will decline by 16.5 per cent to $1.16 billion this year, however this is well above pre-recession levels. CM

Report refutes Dutch disease claims, reveals improvement in Canadian manufacturing CALGARY – A report published by The University of Calgary’s School of Public Policy is refuting the idea of “Dutch disease” affecting the country’s manufacturing sector.

The phrase is often used to describe instances when a flourishing resource sector and high dollar can have an adverse affect on other sectors of the economy.

“The term ‘Dutch disease’ is a misnomer; the Canadian manufacturing sector was arguably healthier in 2008 than it was in 2002,” writes Stephen Gordon, the report’s author.

Gordon examines employment numbers in the Canadian manufacturing sector between the years 2002-2008. He finds that in those years manufacturing employment fell by 328,000 jobs; however, real wages in the sector increased over the period and “the jobs that were lost were generally low paying.”

The author contends that Canadians should not be concerned about the fall in job numbers because the “transition of employ-

ment out of manufacturing was largely achieved by attrition, and job creation in other sectors more than offset those losses”.

Gordon also indicates that Canada is the only G7 country in which manufacturing employment is on par with what it was 40 years ago. Other industrialized countries have seen steady declines for decades.

As further evidence that the manufacturing sector is not facing its demise, Gordon’s analysis reveals an increase in the stock of hi-tech technology in the sector: “The manufacturing sector continued to invest in information and communications technology (ITC) machinery and equipment, the sort of investment that is most closely linked to technical progress.”

Gordon also indicates that R&D activity in manufacturing appears to have held its own after 2002.

The report can be found on the University of Calgary’s School of Public Policy website: www.policyschool.ucalgary.ca

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IN THE NEWS

Canadian-designed human-powered helicopter wins $250,000 Sikorsky Prize Toronto team first to achieve flight in 33-year old challenge

AeroVelo pilot Dr. Todd Reichert pedaled the Atlas human-powered helicopter to the 250,000 US dollar prize. The challenge had been unmet for 33 yerars.

ALEXANDRIA, V.A.—Toronto-based engineering firm AeroVelo, Inc. has won the vaunted Sikorsky Prize by developing a functioning human-powered helicopter.

This is the first time in the 33-year history of the Igor I. Sikorsky Human Powered Helicopter Competition that anyone has actually won it.

A panel of vertical flight technical experts including the AHS International Human Powered Helicopter Competition Committee reviewed the design and flight testing of AeroVelo’s “Atlas” human powered helicopter, as well as data from its June 13, 2013 flight.

Based on that review, the committee has verified that the Atlas flight met all of the requirements to win the competition and its US$250,000 prize. AeroVelo’s Dr. Todd Reichert piloted and pedaled the Atlas on that flight, which was conducted inside The Soccer Centre in Vaughan, Ontario.

The requirements to win the AHS Sikorsky prize were for an aircraft using only human power to fly for at least 60 seconds, reach an altitude of at least 3 metres (9.8 feet) and remain hovering over a 10 by 10 metre (32.8 by 32.8 foot) area.

The full competition regulations, as well as past news updates, videos and other information, are available on the AHS International website. www.vtol.org/hph.

“The AHS Sikorsky Prize challenged the technical community to harness teamwork, technical skills and cutting edge technologies to meet requirements that were on the ragged edge of feasibility,” said AHS International Executive Director Mike Hirschberg.

“It took AeroVelo’s fresh ideas, daring engineering approach and relentless pursuit of innovation—coupled with more than

three decades of advances in structures, composites, computer-aided design and aeromechanical theory—to succeed in achieving what many in vertical flight considered impossible.

We congratulate the Atlas team on its incredible success.”

The American Helicopter Society (AHS), as the Society was then known, established the competition in 1980, and named it for one of its most important founding members, Igor I.Sikorsky.

AHS originally offered a US$10,000 prize, which was soon raised to US$25,000. In 2009, Sikorsky Aircraft Corp. – which Igor I. Sikorsky founded in 1923 – increased the prize to US$250,000 to better spur vertical flight innovation.

The international competition has attracted teams from Canada (including schools in Montreal and Vancouver), Japan, the U.S., and around the world.

AeroVelo’s Atlas is larger than any operational helicopter ever constructed, based on its overall width of 58 metres (190 feet), though it weighs only 52 kilograms (115 pounds). It has four 20.4 metre (67 foot) diameter rotors that are powered by the pilot pedaling a Cervelo carbon-fiber bicycle.

The Atlas project was begun in January 2012 and made its first flight in August 2012.

AeroVelo is one of three teams recently flying as part of the AHS competition. The others are the University of Maryland in College Park with its Gamera II helicopter and California Polytechnic State University in San Luis Obispo, Calif. with its Upturn II aircraft.

The AHS announced the Igor I. Sikorsky Human Powered Helicopter Competition will soon be followed by another grand challenge, the details of which are currently being refined. CM

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IN THE NEWS

Gear-free automotive transmission on the horizon?

Controlled Rotation System a gearless gearbox that maximizes efficiency

By Dan Ilika, Reporter, Canadian Manufacturing

A

s automakers look to comply with global emissions regulations, innovations like eight-speed automatic and continuously variable transmissions are being widely applied as “Band-Aid” solutions to buy time.

But the intricate inner-workings of these mechanical marvels mean potential headaches as they make their way to market in everything from commuter cars to pickup trucks as manufacturers look to reduce emissions and increase fuel economy across their respective vehicle lineups.

Enter the gearless gearbox.

That’s right—a transmission without transmission parts.

Developed and patented by four Dutch inventors, the Controlled Rotation System (CRS) transmission does away with gear wheels and provides a maintenance-free gearbox that Parts Services Holland Ltd.

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doesn’t require lubrication and improves fuel efficiency because it lacks friction between gears.

In place of gears, the CRS uses two discs powered by a belt.

And with the help of a hydraulic oil pump and so-called “slide units,” the diameter of the discs is increased or decreased for acceleration and deceleration, acting as traditional transmission gears in the process.

“It’s easier, more compact and cheaper to assemble than traditional transmissions,” the designers said in a joint statement. “It saves energy, offers more gear possibilities and can be used in all kinds of applications.”

The designers said the CRS is most effective when used in electric cars because the electric engine can run in a constant rpm, and further energy can be saved by linking each wheel to a separate transmission.

Originally developed for bicycles, the first prototype for the automotive industry measures 30 x 22 x 18 centimetres—tiny compared to traditional bulky gearboxes.

According to the designers, the new transmission can be applied in automobiles, motorcycles, ships, windmills or any other machine that relies on gear wheels. CM

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FABTECH Returns: Bigger, Better, More Comprehensive L aunched in 2012 with overwhelming success FABTECH Canada returns, providing a unique platform for hundreds of suppliers and thousands of customers to come together under one roof and learn about new products and solutions, attend education sessions and network with industry peers. SME Canada is proud to once again bring FABTECH Canada back to Toronto to serve the needs of the industry March 18-20, 2014 at the Toronto Congress Centre.

A one-stop, all-encompassing venue for the latest technologies and trends in the fabricating, welding, metal forming, stamping, coating and finishing industries, FABTECH Canada delivers the industry’s most comprehensive showcase of new products, tools and cutting edge technologies through hundreds of dynamic exhibits by the industry’s who’s who, as well as top speakers, multiple networking hubs and interactive educational sessions.

FABTECH Canada is geared towards the needs of Canada’s estimated 1.5 million manufacturing employees in industries ranging from automotive and energy to transportation and construction, as well as businesses that either produce or rely on equipment and machinery in their day-to-day operations.

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FABTECH Canada allows you exclusive access to thousands of industry professionals and decision makers, offering a multitude of promotional opportunities for your company, your products and your services. It’s a unique platform to educate manufacturing professionals about your company face-to-face to grow your sales leads. Major changes for 2014 make FABTECH the most anticipated show of its kind in Canada. New for 2014 is: An Expanded Show Floor More Working Equipment Additional industry partners New Pavilions Job Shop Night

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Mold, Tool & Die Market Outlook 2013

20 | OCTOBER 2013 | www.canadianmetalworking.com

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OEM’s are booming, but retaining our share of the market is a challenge

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

I

n metalworking, there are two kinds of operations: interest rates flat, a modest U.S. recovery will drive businesses that make parts, and those that make the export growth in 2014. tools that make the parts. Among the latter, the mold, OEM’s are healthy and are still in a growth mode, tool and die community has seen radical restructuring as but can Canadian shops benefit? A major question is a result of the recent recession, changes that have made geography — more specifically, the distance between the sector better equipped than ever to face offshore competition, and an uncertain future. But what is that future?

Michael Burt, the Conference Board of Canada’s Director, Econ­ on­ omic Trends and author of “Can­­ SINCE 1975 ada’s Industrial Profile­Summer Summer 2013”, declares, “The motor vehicle parts industry will produce only marginal growth this year, however, this slowdown should DOWNLOAD FROM ✔ INCREASE YIELD DETAILING SOFTWARE only be temporary. U.S. car sales ✔ NEAR SCRAPLESS are expected to reach their pre­­ ✔ SQL DATABASE recession level next year, which will ✔ REDUCED CUTTING TIMES drive parts production higher in the ✔ EASIER PROGRAMMING next couple of years.” ✔ MULTI-LINGUAL SOFTWARE The report states that parts production will increase by a tiny Since 1975 SHOPDATA SYSTEMS has been providing fabrication software tools with one goal...

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Lightweighting will continue to make demands on mold, tool and diemakers. These die cast transmission cases are thin wall and need near net shape processing. Light weight means little extra metal to clean up porosity or adjust straightness in the mating/gasket surface machining step. Porosity, once a common problem in alloy transmission housings, has largely disappeared with better process control, tooling and inspection.

Canadian parts producers and their customer plants.

The migration of auto plants away from Ontario, Québec and the Midwestern U.S. states continues. With “Right to Work”, southern U.S. jurisdictions and Mexico are gaining ground rapidly. While auto plants south of the Mason­Dixon Line are still only a day’s drive from the mold and die hotbed of Southwestern Ontario, the shift means dealing with tooling specifiers, designers and purchasers, at a distance that makes face to face contact more difficult than an afternoon appointment in Detroit. The shift will favour Canadian shops with the critical mass or sales savvy to literally travel the distance in search of the work.

RAW MATERIALS PRICES SIGNAL SOFT INDUSTRIAL DEMAND According to Statistics Canada, the Raw Materials Price Index (RMPI) rose 7.6% during the 12-month period ending in July, after advancing 4.0% in June. It was the largest year-over-year increase in the index since November 2011. The advance of the RMPI was mostly because of higher prices for mineral fuels (+18.6%), specifically crude oil (+19.8%). The RMPI excluding mineral fuels was down 1.1% on a year-over-year basis. Compared with July 2012, the increase of the RMPI was moderated slightly by non-ferrous metals (-6.6%). Raw materials pricing is an important indicator of expected future industrial activity. Adjusted for oil pricing, prices are flat year over year suggesting soft demand in the second half of 2013. For OEM shops, the news is positive, with major manufacturing input pricing stable as vehicle sales remain strong, supporting OEM margins.

GET READY FOR ALUMINUM A major factor that is underreported in the mainstream media is the effect of lightweighting. Alcoa has broken ground on a $275 million expansion of the firm’s Ten­ nessee operations to meet growing aluminum demand for auto production. Aluminum use, already the number two material used to build cars, is expected to nearly double by 2025. The previously announced expansion will convert some of the plant’s can sheet capacity to high­strength automotive aluminum capacity, as well as install incremental automotive capacity, making it a key supplier to both the packaging and automotive markets. The Tennessee expansion is the second major automotive expansion by Alcoa in North America to meet car makers’ demand; a $300 million expansion of Alcoa’s Davenport, Iowa plant has already begun commissioning and is set to be completed by the end of 2013.

Much of the volume for the automotive expansions is secured under long­term supply agreements. The important point for the tool and die industry is that the expansion is in sheet, as the low hanging fruit of weight savings in chassis components such as control arms, differential carriers and driveshafts has been exploited, with new alloys allowing faster cycle times than were possible with conventional die casting techniques. With the unibody “balloon” as the last stand of the sheet steel sector, dies for stamping aluminum will be in demand.

For full­service shops with in­house design capability, the shift to aluminum will mean more than simply modifying a steel design to accommodate spring back. Increasingly stringent crash test requirements, combined with an

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“Doing business in the US takes research and has higher up front costs until strong supplier relationships are established.” almost impossible U.S. CAFE (Corporate Average Fuel Economy) rule targeting 54.5 Miles per gallon by 2025 are bumping up against continued strong consumer demand for SUV’s and light trucks that are larger and heavier than vehicles bought in other nations.

Big vehicles will need to be light to meet the stan­ dard, so expect aluminum to become the norm for big­volume stampings. Another trend that is expected to continue is the move to larger tooling. GM quietly introduced a single side panel stamping in the Oshawa­ built Camaro, citing better build quality, but the com­ bination of high­tech fixturing and automated welding (with laser welding on the rise) means significant cost saving with the reduced part count. This will translate

to fewer, larger tools that OEMs will need to perform over longer production runs with minimal downtime.

Shops with the ability to integrate tool life monitoring into their customer’s production systems will have a competitive advantage. According to the Conference Board of Canada’s Canadian Industrial Profile, Sum­ mer 2013, auto parts production will increase by only 0.1 per cent this year due to weakening automaker demand late in 2012 and early in 2013. The Board’s projection for next year is an increase of 5.5 per cent next year, following strong U.S. vehicle sales. Industry pre­tax profits will decline by 16.5 per cent to $1.16 billion this year, although they are significantly better than their pre­recession level.

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WINNING STRATEGIES FOR CANADIAN SHOPS So what can Canadian shops do to win their share of the tool and mold business going forward? There are several areas where “smarter” will trump “cheaper” in the tool­ ing wars. One is a stronger focus on predictive, rather than preventative maintenance. With longer, guaranteed tool and mold life at a lower price, processing a wider variety of materials, future Canadian shops will either specialize in a narrow range of materials or widen their knowledge base to accommodate fast­changing tool design demands from OEM’s. Mold makers specializing

in tough materials like highly filled commodity polymers or corrosives like PVC may position themselves as spe­ cialists in those resins.

Similarly, tool and die shops may find profitability with specialization by material, like advanced HSLA or light alloys, or by process. It may be advantageous for example, to position a tool and die operation as a deep draw specialist, rather than a Detroit Three OEM shop. In all cases, successful shops will have to take better advantage of available resources, on both the technical and marketing aspects of the business.

Longer life tooling will require a shift from “P20, oil hard, air hard” think­ ing to advanced metals, meaning a closer relationship with mold and tool steel suppliers. Shops with pilot run capability will consider captive short run production, or at least a deal with a local production shop to verify tools before shipping.

Other risk minimizing strategies will be necessary as OEM’s drive harder contractual terms for part quality • Aluminum, Steel, or Cast Iron - diameter size range from and tool life, with punitive terms for unscheduled downtime.

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“Longer life tooling will require a shift from “P20, oil hard, air hard” thinking to advanced metals, meaning a closer relationship with mold and tool steel suppliers.”

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DESROSIER’S VIEW Analyst Dennis DesRosiers is legendary for his strong opinions about the state of the Canadian auto industry — and they’re troubling. According to DesRosiers, “the beating heart of Canadian vehicle and parts manufacturing” is slowing down. Decline is visible in nearly every metric DesRosiers Automotive Consulting tracks. More worrying is that this deterioration in Canada’s vehicle and parts output appears to be linked not to the ebb and flow of vehicle sales in the North American market (as were prior production busts) but rather to “a long-term reorientation for the production landscape on this continent”. Can this situation be turned around? According to DesRosiers, “Vehicle and parts manufacturing in Canada is by no means safe, nor long term sustainable in its present form and will require additional supports from government, either through direct subsidization of producers or a focused amelioration of investment hurdles in order to retain what remains.”

So far, governments at the federal and provincial levels

appear willing to continue support of the parts industry, and indirectly, the supporting tool, die and mold sectors, but as OEMs move south, the supporting Tier One and Two suppliers will face margin erosion and higher costs due to the (literally) longer supply chain. Tool, die and mold shops that can secure business among the new southern US assembly Dennis DesRosiers plants can profit from the shift, especially with historically low interest rates, but doing business in the US takes research and has higher up front costs until strong supplier relationships are established. Export Development Canada has several useful services for fledgling exporters, from advice to receivables and contract frustration insurance.

See www.edc.ca for details

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MINISTER FAST ANNOUNCES FUNDING TO APMA, CAMM, CTMA AND OTHER CANADIAN INDUSTRY ASSOCIATIONS The Honourable Ed Fast, Minister of International announced on September 16, at the Linamar Corporation facility in Guelph, Ontario, that 39 industry associations will receive up to $3 million from the Government of Canada’s Global Opportunities for Associations (GOA) program this year to create new opportunities for Canadian companies in markets throughout the world.

“Our government is committed to helping workers and businesses within key sectors of our economy expand and succeed in new markets around the world because we know this creates jobs, growth and long-term prosperity for hard-working Canadians here at home,” said Minister Fast.

“Today’s announcement will help them do just that through investments in every region of our country that will put in place new tools and programs to help world-class Canadian businesses succeed in global markets.”

Linamar, Guelph’s single largest employer, is a member of the Automotive Parts Manufacturers’ Association (APMA).

APMA will receive $89,480 in matching funds from the federal government to participate in

activities that will help Canadian companies highlight their world-class products in large and dynamic markets, including Europe, India and the United States. Other automotive sector recipients include the Canadian Association of Moldmakers and the Canadian Tooling & Machining Association.

Automotive exports grew by $8.6 billion in 2012 over the previous year’s total of $61.9 billion—a 16-percent rise. The sector is among Canada’s leading employers, with more than 1,300 facilities employing over 115,000 Canadians.

“There are several areas where “smarter” will trump “cheaper” in the tooling wars.”

The skilled labour shortage will not be addressed by current govern­­ ment policies, so the move to highly automated multi­axis axis equipment will continue, driven by excellent financing terms and low interest rates. Concurrently, training will move in­house, with semi­skilled skilled workers moving into roles tradition­­ ally reserved for ticketed tool and mold makers. One characteristic common among many winning Can­­ adian shops are partnerships with local high schools and community colleges, allowing them to “cherry pick” the best apprentices. Training provided by machinery suppliers will partially fill the gap, but with the labour shortage extending across the continent, it’s a level playing field for well­equipped operations. CM www.canadianmetalworking.com | OCTOBER 2013 | 29

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Water or Oil for EDM Hole Drilling?

Makino’s Brian Pfluger on two EDM processes for very small, very precise holes

By Brian Pfluger, EDM Product Line Manager Makino, Inc. .......................................................................................................................

“E

DM”, or Electrical Discharge Machining is referred to as an “Non-Traditional” type of manufacturing process due to the non-mechanical nature of the machining process. The EDM process works by using electricity to physically erode and vaporize a conductive material, and this is a thermal process. It can be thought of as machining with lightning bolts, called sparks. The process is so finely controlled that the number and power of each spark can be set and manipulated down to the sub-microsecond level. By modifying these settings, the material removal rate and attained surface finish can be changed and controlled.

There are three main types of EDM machines: Wire EDM, which uses a small diameter wire electrode to machine contoured details that pass completely through the work piece, Sinker EDM which uses a pre-machined electrode that is the negative shape of the part that is to be created, and EDM hole drill machines that use a small diameter tube electrode to produce holes. With a focus on EDM Drilling, there is a broad range and increasing demand for EDM hole drilling in the manufacturing industry, and the end applications and final produced results may lie at opposite ends of the speed/ accuracy spectrum.

Most EDM hole drill machines use a small diameter open tube or multi-channel tube electrode made of brass to EDM drill through holes into work pieces very quickly. Multi-channel tube electrodes have an inner webbing that provides coreless machining; this helps to improve machining speed by preventing the formation of a material slug inside the ID of the electrode. Speed is typically the main criteria, and the produced hole sizes range from 3.0mmØ down to 0.5mmØ. EDM drilling machines can be manual or CNC positioning, and most use pressurized water flushing through the electrode with an external flush line/hose for debris evacuation, and most are non-submerged machining units.

BASIC APPLICATIONS The machined hole size, straightness, surface finish, and circularity are generally not precise or to a high degree of accuracy (±0.050mm or greater) when compared to traditional die/mold needs (±0.005mm). Many are used for start holes for the wire EDM process. Unlike conventional machining, hole sizes at the entrance and exit can be different. CNC versions can be programmed for positioning, and also allow for automated electrode tool changes. The process can achieve high L/D Ratios

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(100:1), with the biggest use of EDM drilling in the aerospace and power generation industry to produce engine component cooling holes. Higher accuracy EDM hole drilling applications exist in the medical and micromachining industries.

machines. Production-based machines are CNC and usually have some form of tool changer. In both applications, EDM drill machines usually are non-submerged machines that use thru-electrode flushing and an external flush hose during operation. Water-based EDM drilling provides the fastest speeds and deepest L/D’s MACHINE TYPES and typically use brass electrodes. There are some Oil or Water based di-electric machines are available. disadvantages: accuracy is usually held to ±0.050mm Water machines are the most common type of EDM hole or greater and hole entry and exit sizes can vary. Hole drilling machine. Most are non-submerged machines edge quality usually shows signs of rounding or roughthat use thru-electrode flushing and anOctober-2013_CM_Speed_3NC_Layout 1 8/26/13 4:09 PM Page 1 external flush ness and most struggle with electrode diameters under hose. Water types provide the fastest machining speeds and deepest L/D’s, although most struggle with electrode diameters under 0.5mmØ.

In contrast, Oil machines are used to provide the highest level of accuracy and surface finish, produce High performance, titanium dragster clutch the smallest possible hole sizes and cover courtesy of most are based on standard SEDM CNC Performance Engineering machine platforms (like Makino’s Charlotte, NC EDAF2 – Fine Hole machine), and can perform orbiting functions and also do standard SEDM type work.

Like standard SEDM operations, oil-based EDM drilling is performed completely submerged under oil.

WHY WATER? Water is an effective and inexpensive dielectric fluid, and is the most widely used type of EDM drilling machine. Water-based EDM drilling uses deionized water to control water conductivity to provide stable and reliable machining. Most machines will have a filtration system and deionization system to control water quality. Water-based EDM drill machines are a dedicated process machine (they can only produce holes), but water is used to provide the fastest possible machining speeds. Water’s di-electric properties allow for stable high-power EDM discharge machining. Its conductive nature creates a large spark-gap area for increase flushing ability.

Water’s light viscosity provides for efficient cooling and debris evacuation (flushing).

Tool room type machines are very simple, and typically are manual

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NEW CAPABILITY IN GENERAL PURPOSE EDM

0.5mmØ. Water-based EDM drilling systems also have very limited capability to controlling surface finish.

THE OIL ALTERNATIVE Oil EDM hole drilling is typically reserved for highaccuracy or special needs machining, enhancing the overall machining versatility by allowing standard sinker EDM operations. Oil dielectric allows orbiting and finish machining operations. Oil is used to provide the highest accuracy and best surface quality holes. As a dielectric, oil is a true insulator, and therefore provides more precise control over the machining spark gap, which allows low-power finish machining to improve accuracy and surface finish. Due to the true insulating qualities of oil, the spark-gap is significantly smaller than with a water di-electric, which directly impacts the machining speed. Oil will produce a machining speed that can be up to 5 times slower than water (depending on diameter), but will support finishing operations to improve surface/ metallurgical quality, and can also eliminate work piece corrosion issues.

Most oil-based EDM drilling machines are derived from standard sinker EDM units. Most provide automatic tool change capability and all machine with the work piece completely submerged under the oil.

Oil-based equipment typically uses copper electrodes.

Accuracy is usually held to ±0.005mm or finer range, and hole straightness and location can be very precise.

Hole entry and exit sizes are typically held to within high accuracies to each other and hole edge quality is

Makino’s U3 and U6 EDM machines are designed for ease of operation, versatility and low operating cost, offering X-, Y- and Z-axis travels of 370mm by 270mm by 220mm and 650mm by 450mm by 420mm for the U3 and U6 respectively. The U3 will accommodate a maximum workpiece size of 770mm by 590mm by 220mm with a payload of 1,322 lbs, while the U6 holds sizes up to 1,000mm by 800mm by 400mm with a maximum payload of 3,307 lbs. Other features of the U3 and U6 include reduced wire-consumption rates, dual digitally-controlled flush pumps and a choice of two wire-guide configurations—conventional round or Split V guide system—to accommodate any material types and flushing conditions from 0.004" to 0.012"Ø wire (0.1~0.3mmØ). An extensive cutting condition library provides optimized conditions for standard hard brass wires, high-speed coated wires and high-taper soft wires. The depth and versatility of the entire cutting condition library ensure that all applications can be machined at optimum productive levels.

Both the wire EDM machine are equipped with the next evolution of Makino’s advanced machine control, known as Hyper-i. This control system features a user-friendly interface similar to that found on tablets and Smartphones, making operation very intuitive. A 24-inch HD touch-screen display provides many intelligent functions, including onboard electronic manuals, instructional videos and a diagnosis tool, providing operators with all of the resources necessary to remain highly productive. The Hyper-i control can also be customized to individual operators and/or for certain shifts, and an optional dual display screen can be configured for use with an onboard CAD/CAM system. Makino has dramatically reduced one of the single largest operating costs of a wire EDM machine—wire consumption. With the U3 and U6, there are no special settings required to experience wire saving; every cutting condition, including sealed and poor flush applications, is automatically optimized for low wire consumption. Combined with the machines’ speed and accuracy, the U3 and U6 offer the highest level of overall efficiency, throughput and low operational cost. The U3 and U6 feature Makino’s new HyperCut technology, a special three-pass process technology developed to produce surface finishes as fine ashes as fine as 3µm Rz in standard tool steels. This performance enhancement represents a 20 percent reduction in cycle time and 14 percent reduction in wire consumption, compared to previous technology.

W li

S a v

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We estimate We’ve seen “ a 40 to 60 percent reduction in cycle times on all jobs moved to the makino cell.

”

the machine’s rapid acceleration/ “ deceleration rates and 0.9-second tool changes have reduced part cycle times by 50 percent.

”

makino machining “cell,WithWethereplaced five machines

With tWo, While doubling production capacity and improving quality and flexibility.

”

When you talk to people who make what matters, the bottom line on what matters most to them is just that—the bottom line.

See why, for so many manufacturers, Makino and productivity are two words for the same thing. Read their stories. Watch their videos and cutting demos at Makino.com/productivity.

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TIPS TO ENSURE CONSISTENCY IN EDM DRILLING MAKINO SPONSORS AN EDM-SPECIFIC BLOG AT WWW.EDMMATTERS.COM The blog is full of useful tips about the process. Here’s an example: Are you having problems with your EDM Drilling applications? Have you evaluated the precision or consistency of the drilling electrodes?

Below are a couple of items to consider and investigate as potential process variables: • Electrode OD size precision (variations can cause guide jamming) • Electrode ID size consistency (variations can cause machining speed and electrode wear differences, as electrode wall thickness can vary) • Break-Thru Difficulty: If the electrode wear is uneven, a tapered bullet-nose shape will develop at the tip of the electrode. This tapered nose on the electrode tip will cause very unstable break-thru conditions that will require an extended amount of cycle time to machine completely thru the work piece. EDM drilling power settings play a major role in this as well, but the electrode quality and electrode condition also represent an important process factor.

0.026 Top at 205x: hole machined using Oil-Based EDM Drilling at 205x magnification of a 0.6mmØ hole.

Exit: Typical hole produced by WaterBased EDM Drilling at 107x magnification of a 0.6mmØ hole.

very clean and crisp with no edge rounding or roughness, so much so that often no additional finishing or sizing operations are needed. The only limitation to oil-based operation is machining speed, and due to this limitation, oil-based EDM drilling is typically reserved for special needs and holes under 0.5mmØ.

WATER OR OIL? Like all machining processes, it’s important to use the right tool for the right job. Both water and oil-based EDM machining offer EDM drilling capabilities. Chose the machine with the performance and characteristics

that best suit the task at hand; accuracy, surface finish, and hole size requirements are key factors in switching to oil-based EDM drilling. Water is fastest, but produces lower quality holes, and water-based EDM drilling may require post-machine finishing operations. Oil allows finishing operations; a one-machine-process is often employed with oil-based EDM drilling, replacing a waterbased EDM rough machining process with wire EDM finishing/sizing process which can eliminate post-EDM processing … work piece requirements ultimately drive which machine type is used. Water-based EDM drilling machines are dedicated to only hole drilling operations, which is perfect for high-volume production, while oilbased EDM drilling may provide greater flexibility in a job shop environment by allowing EDM drilling and sinker EDM machining on a single platform. Remember, time is money, so the most productive machine that meets the work piece requirements is typically best.

Brian Pfluger is EDM Product Line manager for Makino Inc. Visit www.makino.com for more details. CM

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Toolroom Machines: Steady as She Goes The tool room remains the last bastion of manual machining

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

“S

teady as she goes” seems to be the prevailing philosophy of the toolroom machine sector.

The latter primarily consists of lathes and mills but can also include machining centres, grinders, drill presses, etc., used for short-runs, one-off parts and repairs as opposed to mass production. Toolroom machining emphasizes manual operations and easy programmability.

“Our lines of toolroom mills and toolroom lathes have been stable for a number of years. We have not added any new machines recently and don’t have any planned for the immediate future,” says Scott Rathburn, marketing product manager at Haas Automation in Oxnard, California.

“Toolroom machines, by definition, are pretty basic machines. The major technical development, really, was moving from manual machines to full CNC. The basic progression was from full manual machines, to manual machines with DROs (digital readouts), to manual machines with retrofit CNC controls (often only two-axis, as the Z-axis quill was difficult to automate), to full CNC,” continues Rathburn.

Jim Endsley, product specialist machining centres at Okuma America Corporation in Charlotte, North

Carolina, says the lack of technological breakthroughs can be traced in part to shop floor conservatism.

“Why develop new techniques or specific machines for a market that always comes back and says, “No, this is the way I’ve always done it’? ... Machining in general is kind of a slow, step-by-step, stodgy business. It’s always been this way,” says Endsley.

None of this, however, should be construed as a sign that toolroom machines are on their way out.

“Sales [of toolroom machines] are steady, even in bad times, as these are used for repair work and light production,” notes Phil Hanna, machinery product manager at Sunnen of St. Louis, Missouri.

There are also emerging trends in terms of the actual use of toolroom machines.

High speed-machining “is slowly gaining” popularity in toolroom settings, says Endsley, who adds, “five-axis is coming back pretty strong” in part because such machines are getting less expensive.

While they don’t have a plethora of new product, machine tool companies have no plans to stop selling toolroom lathes, mills, etc.

With this in mind, here’s a look at what’s popular in toolroom machines:

HAAS Haas introduced a line of Toolroom Mills (TM) in 2001 and Toolroom Lathes (TL) two years later.

The TM and TL lines both continue to be strong sellers, despite a lack of major revisions in recent years. “The majority of our Toolroom Mills sold are TM-2Ps, with TM-1Ps a close second. The P models come standard with tool changers, whereas the standard Toolroom Mills do not, which is why the P models are more popular ... the majority of our Toolroom Lathes sold are TL-1s, with TL-2s close behind,” says Rathburn.

The TM-2P Toolroom Mill has X, Y, Z, travels of 40 inches x 16 inches x 16 inches (1016 x 406 x 406 mm), a 40 taper, 7.5 hp (5.6 kW) vector drive, 6,000 rpm, full enclosure, 10-station automatic tool changer, Y- and Z-Axis way covers, Intuitive Programming System, 1 MB program memory, memory lock keyswitch, 15 inch color LCD monitor and USB port and 5-gal-

The Haas TL-1 Toolroom Lathe

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lon (19 liter) flood coolant system.The TM-1P Toolroom Mill has X, Y, Z travels of 30 inches x 12 inches x 16 inches (762 x 305 x 406 mm), a 40 taper, 7.5 hp (5.6 kW) vector drive, 6,000 rpm, full enclosure, 10-station automatic tool changer, Y- and Z-Axis way covers, Intuitive Programming System, 1 MB program memory, memory lock keyswitch, 15 inch color LCD monitor and USB port and 5-gallon (19 liter) flood coolant system.

TL-1 -CNC/Manual Toolroom Lathe has 16 inch x 29 inch (406 x 737 mm) maximum capacity, 16 inch (406 mm) swing, 7.5 hp (5.6 kW) vector drive, 2000 rpm, A2-5 spindle, Intuitive Programming System, 1 MB program memory, memory lock keyswitch, 15 inch color LCD monitor and USB port.

TL-2 CNC/Manual Toolroom Lathe has maximum capacity of 16 inches x 48 inches (406 x 1219 mm), 16 inch (406 mm) swing, 12 hp (8.9 kW) vector drive, 2000 rpm, A2-6 spindle, Intuitive Programming System, 1 MB program memory, memory lock keyswitch, 15 inch color LCD monitor and USB port.

“Our toolroom machines (and all Haas machines, for that matter) can be easily programmed right at the machine ... our toolroom machines all come standard with the Haas Intuitive Programming System, a conversational programming system with a graphical interface that makes part programming easy, even without knowledge of G-code,” says Rathburn.

“Both our Toolroom Mill and Toolroom Lathe lines offer a good selection of models to meet the needs of most customers looking for that type of machine. They’re very capable machines for what they are: affordable, entry-level, CNC machine tools that are easy to learn and use. Any new, big changes to these machines — faster, more powerful spindles, faster rapids, more capacity, etc. — would necessarily increase the cost of the machines. And Haas already offers extensive product lines of VMCs, HMCs, and turning centers that meet the needs of customers wanting more performance and capability,” he adds. www.haascnc.com

OKUMA Okuma’s “Millac series 852 and 1052 vertical machining centers are both very popular in toolroom applications for die/ mould, and similar types of work,” says Endsley.

The Millac 852V has X, Y, Z travels of 80.71 inches (2,050 mm), 33.46 inches (850 mm) and 29.53 inches (750 mm) while the Millac 1052V has X, Y, Z travels of 80.71 inches (2050 mm), 41.73 inches (1060 mm) and 31.50 inches (800 mm).

Okuma recently redesigned the Millac 1052’s cabinet for better chip disposal.

“We also do a lot of toolroom applications with our MB series of vertical mills—mostly the MB56 and MB66,” continues Endsley.

The compact MB-56V vertical machining center has an extremely rigid double column structure, a high speed 40 taper, 8,000 rpm spindle, a high-speed 20 position automatic tool changer and 1,574 ipm rapid traverse. This vertical mill has a table size of 560 mm x 1,300 mm (22.05 inches x 51.18 inches).

The MB-66V vertical machining center also boasts a double-column structure. It has a high speed, 40 Taper 8,000 rpm spindle, a high-speed 20 position automatic tool changer and 1,574 ipm rapid traverse. The MB-66V has a rotary pallet size of 1,530 mm x 660 mm (60.24 x 25.98 inches).

Okuma’s recently introduced Genos series entry-level three-axis vertical machining centers also have toolroom

Okuma’s Millac 1052V vertical machining center

possibilities, thanks to their compact size, affordable price tag and easy operability, says Endsley.

The Genos M460-VE has a machining volume of 762 mm x 460 mm x 460 mm (30 inches x 18.11 inches x 18.11 inches) a table size of 460 mm x 1,000 mm (18.11 x 39.37 inches) and a magazine capacity of 32 tools.

The Genos M560-V meanwhile, has a maximum machining volume of 1,050 mm x 560 mm x 460 mm (41.34 inches x 22.05 inches x 18.11 inches) a table size of 560 mm x 1300 mm (22.05 x 51.18 inches) and a magazine capacity of 32 tools. www.okuma.com

GF AGIECHARMILLES GF AgieCharmilles’ recently released HEM500U five-axis milling machine and compact HSM200U LP high-speed mill are “perfect machines for the toolroom” according to Gisbert Ledvon, director of business development at GF AgieCharmilles, based in Lincolnshire, Illinois.

By this, he means both machines boast conversational programming and are user-friendly.

The HEM500 U has X, Y, Z travels of 500 x 450 x 400 mm, weighs 5,700 kilograms and can take a maximum table load of 200 kilograms. www.canadianmetalworking.com | OCTOBER 2013 | 37

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The HSM200U LP is available in three and five-axis versions and can produce workpieces via true five-axis simultaneous high-speed machining. It features a powerful 50,000 rpm, 11.4 hp Step-Tec spindle and has a compact footprint.

“Both machines can also be equipped with a pallet changer allowing an easy setup and short automation runs,” says Ledvon.

GF AgieCharmilles plans to “introduce a new pallet changer and some new tooling options for both machines” at EMO 2013, he adds. www.gfac.com The HSM200U LP high speed mill from GF AgieCharmilles

SUNNEN Sunnen has not introduced any new toolroom machines for some time, but still enjoys healthy sales.

“What I refer to toolroom machines are our very basic hones that utilize our standard mandrel line to provide economical coverage of many diameters for repair work or making a few parts. … the MBB-1660 was introduced in 1975 and its predecessors go back much further … we have sold literally thousands of these small machines … we [still sell an] average 65 – 75 of these machines per year. In fact we have sold 44 so far in 2013,” says Hanna.

Sunnen’s MBB-1660 honing machine

The workhorse MBB-1660 honing machine can hone bores up to 16 inches (400 mm) in length depending on diameter, has a spindle speed up to 2,500 rpm, is 30 inches (762 mm) wide, 60 inches (1524 mm) deep and 63 inches (1600 mm) high and weighs 630 pounds (287 kilograms).

Asked to cite the MBB-1660’s most notable features, Hanna says the machine is “extremely reliable and cost effective and a proven design.” www.sunnen.com

IS THIS THE FMS EXPERIENCE YOU WANT? IF NOT, CALL FASTEMS FIRST Freedom means doing what you want, when you want, the way you want. But when it comes to FMS, proprietary systems steal your freedom by restricting your ability to change and grow.

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38 | OCTOBER 2013 | www.canadianmetalworking.com

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FRYER Fryer Machine Systems of Patterson, New York produce what they call ‘the world’s best made toolroom mill’.

“Fryer Machine Systems builds a full line of high quality, American made toolroom bed mills [and lathes] designed for fast and efficient production of short-run and one-off parts.

User friendly, conversational software and unique manual automatic operation makes these machines ideal for the toolroom,” states company literature.

Fryer’s toolroom mills are classed into the MB-Q and MB-R Series. The MB-Q Series has a manual quill and manual handwheels and can be operated in manual, semi-CNC or full-CNC modes. The mill boasts a box way construction, electronic spindle speed control, one button fast-setup, simple menu (no codes needed) and 15 inch touch screen colour display.

The MB-R Series have a rigid spindle and optional tool changer and are capable of single or multi-part production.

The mill features conversational control, box way construction, 8,000 rpm high torque spindle motor, electronic spindle speed control, one button fast set-up, and a high performance 12 hp spindle motor connected to an 8,000 rpm spindle cartridge.

The Easy Turn Series lathe boasts rugged construction, high accuracy and compact size. Fryer claims Easy Turn lathes are simpler to use than a conventional lathe but has the productivity of a CNC. ET Large Capacity Series lathes

Fryer’s Easy Turn toolroom lathe

are designed for applications where high rigidity is required.

This lathe can be custom configured and has a user-friendly operator interface for simple shop floor programming.

The Easy Turn Series XL Series lathes are designed for large part machining. These lathes feature a wide bed (30 inches) heavy duty engine lathes, spindle bores up to 16 inches, live tooling, C and Y axis, automatic chucks and auto steady function.

The VT Series of vertical turret lathe are affordable and compact. These lathes have a traveling column design that integrates high rigidity and notable positioning accuracy. This lathe is available with full C axis contouring and positioning as well as live tooling. www.fryermachine.com

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

Tools are stocked uncoated and ALTiN coated.

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

Solid carbide grooving, boring and threading tools.

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

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Available in coated AlTiN or uncoated sub micrograin carbide

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

Low profile screw keeps chips flowing

SCIENTIFIC CUTTING TOOLS, INC. 110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com www.canadianmetalworking.com | OCTOBER 2013 | 39

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New Grades, New Inserts in Turning Tools Coatings, geometries are changing to boost productivity

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

I

mprovement is continuous in the cutting tool industry, with new ideas and new products rolling out constantly. When asked about turning tool trends, industry experts point to insert coatings.

The sector is seeing “higher demands [put] on coating technology along with geometries that control chips in a wider application range. Both of these are crucial to the productivity improvements required to keep shops competitive in the global market,” says Kurt Ludeking, product manager for turning at Walter in Waukesha, Wisconsin.

“It seems most carbide manufacturers are searching for ways to reduce heat in the cut, which promotes tool life and allows for higher cutting data. Advancement in coating technology and improved chip grooves are two ways where this can be achieved. Higher cutting data

means more productivity and lower machining costs,” adds Tim Aydt, product manager, ISO Turning at Seco Tools in Troy, Michigan.

Steve Geisel, product manager for non-rotating tools at Iscar Canada in Oakville, Ontario, cites no trends but offers some advice.

Machinists should take the time to “evaluate what they’re using for their turning product ... like any other tool, they can’t sit back and think that what they used a year ago is going to be the best thing that’s still out there today. They need to keep evaluating turning tools, need to stay on top of it to stay competitive in global market,” he states.

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

SANDVIK COROMANT October 1st sees Sandvik Coromant introduce GC4325; a newgeneration coated cemented-carbide grade for steel turning.

This latest innovation in tool material provides a new, higher potential for increasing cutting speeds and a longer, more predictable tool life with very high reliability, over an extended broad ISO P25 application area. A challenge is the breadth of the ISO P25 application area, which includes several very different materials, from ductile low-carbon steels to high-alloy hard steels, bar material to forgings, castings to pre-machined parts. The advances with the new grade, GC4325, will actually help users resist holding back on cutting-data levels. The grade provides extremely high process security through its ability to retain an intact edge line. The insert substrate and coating of GC4325 have been developed to better withstand high temperatures, thereby reducing the effect that causes excessive wear. As a bonus, the grade is highly capable of maintaining the insert edge line at higher temperatures, which translates into the capability for higher cutting speeds with added security through more predictable, longer tool life.

An average productivity increase of 30 percent from today’s existing levels is now available. The grade represents a new generation of performance with coated cemented-carbide indexable inserts, providing a new potential to be tapped throughout a large and diversified application area.

www.sandvik.coromant.com

40 | OCTOBER 2013 | www.canadianmetalworking.com

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Die MolD Ball - Nose series (DM-BN)

New Metric Offering Re-engineered Imperial Offering Data Flute is pleased to introduce our new Die Mold series of solid carbide, ball-nose end-mills for hard milling, mold applications. These material and application specific tools are designed to use the most productive, leading-edge, high-speed machining techniques. The result is superior finishes, extended tool life and a work piece requiring little or no handwork.

Please contact us to have one of our application specialists help you with this and all your machining needs.

Toll Free 800-447-1476 or 413-499-3875 www.dataflute.com

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ISCAR “Turning was never a line that Iscar really focused on until now. We started off as a grooving company, then moved into milling, then started focusing on our holemaking line ... about three years ago, Iscar said ‘enough is enough’—now that the rest of our lines are considered some of the best on the market, we need to look at turning because we’re not there, to be honest,” says Giesel.

Today, nobody can accuse Iscar of slacking in terms of tooling tools.

“When it comes to our turning line, we came out with a lot of new products this year,” Geisel proudly notes.

The new, double-sided M3P insert chipbreaker for medium machining of steel boasts a reinforced cutting edge and positive rake for smooth cutting and decreased cutting forces, reducing wear and boosting tool life.

“For machining steel, we came out with a chipformer called F3P. We’re finding this is a very, very excellent chipformer for finishing operations,” says Geisel.

The F3P chipbreaker for finishing machining boasts positive rake angles that allow smooth cutting and lower cutting forces.

The F3P chipbreaker features a depth of cut from .001 to .1 inches and feed rate from .002 inch/rev to .012 inch/rev.

“We’ve also released a chipformer called M3M, which is a new medium machining insert ... so far we’re finding it unbeat-

able when it comes to machining stainless,” continues Geisel.

The M3M chipformer boasts a reinforced cutting edge that enhances tool life. Additional geometric elements such as an optimal positive rake angle contribute to a smooth cutting process while decreasing cutting forces by five – 10 percent, thus reducing wear and boosting tool life. The M3M also has a wide chipbreaking range (making it a good choice for stainless steel applications, says Iscar). Iscar recommends using the M3M chipformer with advanced Sumo Tec grades IC6015 and IC6025 for high productivity.

The R3P chipbreaker is a single-sided insert for rough machining of steel with a reinforced cutting edge and positive rake angle for smooth cutting and reduced cutting forces.

Iscar also recently added a new geometry to their line of small, economical inserts. The YNMG 33... geometry fits into the standard pocket of the VNMG33... insert and features a 25 degree corner angle. This insert was designed for turning very narrow V-shaped grooves which can’t be machined by standard 35 degree inserts.

“We’re also designing a whole new set of chipformers for finishing, medium and roughing, specifically for high-temp alloys. These chipformers will go along with our ISO 806 grade,” adds Geisel. www.iscar.ca

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November 18-21, 2013 McCormick Place - Chicago, IL visit us in Booth S1755

Messer Cutting Systems, Inc. Menomonee Falls, WI www.messer-cs.com 42 | OCTOBER 2013 | www.canadianmetalworking.com

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WALTER

SCT’s Boring Bar insert

SCIENTIFIC CUTTING TOOLS “We manufacture and sell small diameter boring bars and inserts. We start at a 3/16 inch diameter bar and go up to a ¾ inch diameter. We also manufacture the inserts that go into these holders and our inserts are really premium in that they are lapped on the top surface, have a ground cutting edge and a ground in chipbreaker,” says Todd White, sales director, Scientific Cutting Tools in Simi Valley, California.

Scientific’s main boring bar is officially known as the SCT Advantage Indexable Boring Bar. Said bar consists of micro grain carbide shanks with heat-treated heads of steel. Selected tools are made with a top cut that strengthens the pocket by 40 percent and directs chips away from the cut zone. Inserts are available uncoated or with ALTiN or ZrCN coating and come in diamond or triangular shapes.

SCT plans to add a coolant through feature to the Advantage Indexable Boring Bar in early 2014, says White. www.sct-usa.com

Walter continues to grow the Tiger-tec Silver Turning line.

“Next up is the expansion of the Tiger∙tec Silver negative style inserts for iron applications, followed by positive style inserts for steel,” says Ludeking.

“Tiger∙tec Silver grade technology has shown such large gains in productivity for our customers Walter’s Tiger∙tec Silver® negative style that we are expanding it as inserts for iron applications quickly as we can. The newest additions are grade WMP20S for stainless steel and steel turning.

This new CVD grade is offered in the existing and performanceproven NF4, NM4 and NR4 geometries. These geometries work very well in austenitic stainless steel applications and with the new WMP20S grade are capable of higher speeds and longer tool life. Typical tool life increases of 30 percent to 50 percent are seen in customer applications,” he continues.

The WMP20S grade/NF4, NM4, NR4 geometries combination “works quite well for small to medium-sized shops where production runs are shorter and they need an insert that works well in a wide variety of materials. This universal machining grade simplifies insert choice and thereby reduces inventory,” says Ludeking. www.walter-tools.com/us

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Tel: 416-675-7760 Fax: 416-675-6988

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GREENLEAF “G-5135 is our latest turning grade developed for heavy machining of forged steels and nodular and ductile irons. G-5135 provides extended tool life in heavy depths of cut in medium to high feed rates. G-5135 is an extremely tough carbide substrate with an MT-CVD coating enabling it to handle heavy scale and interrupted cuts and machine at a broad cutting speed range up to 850 sfm (260 m/min) with consistent and predictable performance,” says Jim Wyant, applications engineer at Greenleaf Corporation, based in Saegertown, Pennsylvania.

G-5135 has become a popular choice for oil industry applications, he adds.

“G-9230 is our latest turning grade developed for heavyduty machining of abrasive and difficult-to-machine materials.

Typical applications include high-temp alloys, titanium, stainless steels and alloyed cast irons. With a multi-layer PVD coating over a tough, wear resistant micro-grain substrate, G-9230 excels in machining cast and forge scale conditions and interrupted cuts where traditional micro-grain carbide grades will not hold up. The toughness of G-9230 allows the use of sharp edges, high positive rakes and intermittent cuts,” continues Wyant.

Greenleaf’s new G-5135 turning grade for heavy machining of forged steels and nodular and ductile irons

“G-9120 is our latest turning and milling grade for highproductivity machining of rough steel forgings and castings, primarily tool steels. With a multi-layer PVD coating over a wear resistant substrate, G-9120 provides excellent tool life at moderate speeds and feeds where toughness and abrasion resistance is needed. G-9120 is capable of heavy-duty milling of steel forgings with proven performance at speeds up to 500 sfm (150 m/min) at heavy depths of cut for maximum metal removal rates and productivity,” he adds. www.greenleafcorporation.com

SUMITOMO

Sumitomo’s MESI Chipbreaker

Sumitomo Electric Carbide of Mount Prospect, Illinois recently added the MESI Chipbreaker for Swiss turning and small parts machining to their product lineup. This chipbreaker features a 15 degree nose and eight degree main edge. A wavy cutting edge contributes to good chip control while the incorporation of dimples lowers cutting temperature. The MESI Chipbreaker is suitable for medical parts and high precision parts machining and is available in CCGT, DCGT and VCGT geometries and AC510U, 520U, 530U, AC610M and 630M grades.

Sumitomo also recently expanded its AC400K Series for cast iron turning to include new finishing and general purpose grades AC405K and AC415K. AC405K provides excellent wear and deformation resistance for finishing grey cast iron at continuous, high speeds. AC415K is a general purpose grade that offers stable turning in a wide variety of grey and ductile cast iron applications. Sumitomo’s original AC420K grade boasts excellent fracture resistance that offers very stable conditions when doing interrupted or unstable turning www.sumicarbide.com

SECO Introduced earlier this year for steels, Seco’s M6 chip groove will be launched in cast iron grades in mid-October.

Intended for roughing and semi-finishing steel alloys, these double-sided high feed wiper inserts with the M6 chipbreaker can handle a range of applications in various industries. The new wiper design leads to higher feed rates, better productivity and more secure chip control. The M6 chipbreaker can achieve a smooth surface finish which eliminates the requirement for finishing operations in some applications.

Seco also recently introduced CBN010, a new uncoated PCBN (Polycrystalline Cubic Boron Nitride) insert grade mainly used for turning in hardened steels. CBN010 is designed to

Seco’s M6 negative insert chipbreaker

provide premium performance in continuous to moderately interrupted cuts. The new grade offers stable performance and consistent tool life to decrease downtime and machining costs. CBN010 inserts are available in solid, full-face, tipped and multi-tipped formats. www.secotools.com

44 | OCTOBER 2013 | www.canadianmetalworking.com

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TOOL TALK

Mazak rolls out 30,000 Kentucky-built machine

T

he Mazak Corporation marked a significant milestone at its facility in Florence, Kentucky, with the completion of their 30,000th machine tool built at the location.

The machine is a Quick Turn Smart 350 Turning Center, and was shipped September 5, 2013, to Custom Machine Inc. in Tiffin, Ohio — a company specializing in precision machining services.

Since 1974, Mazak’s Kentucky manufacturing operations have grown from producing a select number of less complex machines to more than 100 different models, including sophis­ ticated 5­axis and multi­tasking machines. Many of these models are designed, and manufactured in the United States, but shipped across North America, and to export markets.

The company’s customer base currently encompasses a wide range of sectors, such as automotive, aerospace, energy, electronics, heavy equipment, medical, and contract machining industries among others.

th

“This is an exciting milestone for our entire company, and Mazak extends its sincerest gratitude to Custom Machine and to all our customers for their continued loyalty and trust over the years,” said Brian Papke, president of Mazak Corporation.

“Our customers consistently drive us to grow and develop new and innovative manufacturing solutions to meet their toughest challenges — we share this success together with them.”

The company has also recently made three major expansions to its Kentucky operations, which increased total floor space to 800,000 square feet.

With the completion of its plant expansion, Mazak manufacturing plant production capacity now sits at around 200 machines per month, depending on the mix of models. www.mazakusa.com

Wa N22 Wau 800 serv

ww

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WA

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The high-performance drill for increased productivity and process reliability.

Walter Titex is attracting buyers from across different industries with more process reliability accompanied by an increase in productivity. You too can benefit from innovative point geometries and coatings, and from assured chip evacuation and ground-breaking internal cooling.

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Walter Canada N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.ca@walter-tools.com

Walter Tools S.A. de C.V. Boulevard Louis Donaldo Colosio 2255 2do Piso, Colonia San Patricio 25204 Saltillo, Coahuila, Mexico +52 (844) 450-3500 service.mx@walter-tools.com

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TOOL TALK

Mark Kirby joins Renishaw Kirby will take on the role of Additive Business Manager for Canada

M

ark Kirby has joined Renishaw Canada as their new Business Manager for Additive Manufacturing.

After graduating from MIT in Aero/Astro Engineering, Kirby joined Rolls Royce as an advanced project engineer working on the HOTOL space shuttle, before joining his father’s company, Jet Blades.

Mark worked his way through the company from CAD/CAM programmer to Managing Director, responsible for managing a design and production team engaged in producing high technology components for a global customer base.

Mark Kirby

In 2007 Mark emigrated to Canada with his family. As a professional engineer Mark provided practical hands­on advice for companies seeking to apply new technology to compete effectively.

Projects within the aerospace and nuclear sectors involved companies seeking to reduce labour content and develop robust manufacturing processes. Kirby also taught Engineering at the University of New Brunswick before joining Renishaw in the fall of 2013.

He has a Diploma in University Teaching and an MBA from Warwick University. CM

48 | OCTOBER 2013 | www.canadianmetalworking.com

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TOOL TALK

DMG and Mori Seiki begin collaboration in Canada The Canadian market has become a cornerstone of the company’s global strategy.

H

aving successfully integrated in other markets such as Europe, Asia, and the Americas, DMG and Mori Seiki have combined their activities in Canada as of October 1st, 2013.

The new DMG/Mori Seiki will support the complete sales and service of the entire product portfolio of both manufacturers through their distribution partner Ellison Technologies.

Along with Ellison Technologies, and an extended sales and service network, Canadian customers will experience the same sales and service support for the installed user base as before the agreement.

According to the company, the Canadian market has become a cornerstone of their global strategy, with a determination to create a comprehensive system to supply the manufacturing industry in Canada.

The cooperation of DMG/Mori Seiki and Ellison Technologies will maximize the integration of resources to achieve this goal, and provide one­stop access to a full range of solutions, from entry­level to high­tech machining, a powerful and fast nationwide service network, as well as the most innovative applications for different sectors.

DMG, Mori Seiki, and Ellison Technologies will celebrate their cooperative debut at CMTS 2013, showcasing 10 high­tech machines plus innovative solutions in software, automation, and presetting.

GILDEMEISTER AG and Mori Seiki Co., Ltd., two global machine tool manufacturers, closely collaborate in Canada and other markets around the globe. The strategic partnership between GILDEMEISTER and Mori Seiki includes production, purchasing, research and development as well as sales and service in selected markets and customer financing. ... continued on page 50 www.canadianmetalworking.com | OCTOBER 2013 | 49

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TOOL TALK

... continues from page 49

The company has a strong focus on a number of sectors, including aerospace and automotive.

DMG/Mori Seiki in the aerospace sector: The aerospace sector already ranks among the biggest and especially most customer industries for high­tech machine tools from DMG and Mori Seiki. The trend towards integral construction methods, innovations in engine design and the use of new and more effective materials all constitute great challenges for the machine tool industry.

With the “Aerospace Excellence Centre”, DMG/Mori Seiki gives customers the possibility of direct contact for the international aerospace industry. Its portfolio of services encompasses technology and process development as well as product development and ranges from seminars, workshops and machine demonstrations right on through to specific trial machining.

However, the high­tech machines will always remain at the core of every process chain; machines with modules developed specifically for the aerospace industry that can be tailored to meet the individual demands of the industry.

DMG/Mori Seiki in the automotive sector: From serial production over composite manufacturing to machining of turnkey solution for parts up to 40t. The list of companies supplied by the firm includes all well­known Canadian and

international brands in the automotive industry, and includes the Formula 1 team Red Bull Racing.

The company’s range of machines for the automotive industry is designed for maximum speed, accuracy and reliability. DMG/Mori Seiki has established some permanent collaborations with customers that use the firm’s machines not only in the production of automotive components, but also in dies and moulds. The company is also involved in a project to produce components for electric vehicles. dmgmoriseiki.com

ellisontechnologies.com

50 | OCTOBER 2013 | www.canadianmetalworking.com

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TOOL TALK

Okuma opens new high-efficiency factory The company is expecting efficiency to increase because of a greater emphasis on automation, robotics and unmanned operations.

C

harlotte, N.C. – The Okuma Corporation has held a formal dedication ceremony to celebrate the opening of the first building of their new manufacturing facilities in Oguchi, Japan.

The new factory transforms operations into an agile manufacturing environment, where an increased range of CNC machine products, in short run production, will be produced efficiently.

This enables shorter delivery times, reduced costs, and enhanced market competitiveness.

Phase 1 of the project began in August, 2012 when the original Oguchi facility was demolished.

The new facility is 23,600 square metres (254,000 square feet) and will cost approximately 8 billion yen, or approximately $82 million USD. Production efficiency in the new facility will be two times that of the second half of the fiscal year 2011. The efficiency improvements are a result of investment in a new manufacturing management system and a greater emphasis on automation, robotics and unmanned operations.

Products produced at this facility will include medium­ and large­sized multi­ tasking machines and CNC lathes.

Production has already begun in the first building and will be a highlight of Okuma’s Machine Fair being held in November, 2013. The total investment in new manufacturing facilities will include three phases, at a cost of 20 billion yen (approximately $205 million USD).

In addition to the investment in buildings, equipment and business systems, the new facilities are being built for environmental efficiency and will include features such as solar panels and natural lighting, to reduce the environmental burden. www.okuma.com

Okuma Corporation President & CEO, Yoshimaro (Dean) Hanaki, officially dedicates the new Okuma manufacturing plant in Oguchi, Japan. (Photo: Okuma)

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THE BUSINESS OF TOOLING

Turn-Milling Can Increase Your Efficiency

By Andrei Petrilin, Technical Advisor, Iscar ................................................................................................................

T

urn-milling is a process whereby a milling cutter machines a rotating workpiece. This method combines milling and turning techniques and has many advantages, but only relatively recently the introduction of multitasking machine tools has allowed turn-milling to display its benefits.

For years, even under mass adoption of CNC technology, development of metalcutting machine tools was traditional enough, when progress of specific machines like turning, milling or drilling moved towards a separate direction. If machining centres already successfully integrate machining by rotating tools – milling and drilling – turning CNC machines continued with their own progress. Looking for new ways to make manufac-

turing process more efficient by reducing settings of a machined part and its transfer from one machine to another led to adding a tool head with rotary drive to typical CNC turning machines and allowed realization of turn-milling. Today modern multitasking machine tools feature additional axes of the head movement, advanced control systems and upgraded software that provide the opportunity to perform the majority of machining operations with only one setting per workpiece.

In turn-milling, there are two principal kinds of machining: peripheral when axes of a workpiece and a cutter are parallel; and face, for which these axes cross. Peripheral turn-milling is similar to milling by helical interpolation and may apply both to external and

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THE BUSINESS OF TOOLING “Introducing turn-milling in manufacturing process can solve serious problems and substantially improve your output.”

internal surfaces of the revolution, while with the use of face turn-milling only the external surfaces can be machined.

Despite that, turn-milling seems to be very similar to turning (“turning by rotating mill”), there is a substantial difference between these two machining processes. The cutting speed in turn-milling is defined by the peripheral speed of the milling cutter and not by the rotary velocity of the workpiece like in turning. The workpiece rotation relates to feed.

What are the advantages of turn-milling and where is its application practical?

First of all, machining of non-continuous surfaces may cause interrupted cutting (various grooves, undercuts, etc.). In classical turning, this operation results in unwanted impact load, poor surface finish and early tool wear. In turn-milling, the tool is a milling cutter that

is intended exactly for interrupted cuts with cyclic load.

Machining materials produces long chips. In turning, chip disposal is difficult; and finding a proper chipbreaking geometry of a cutting tool is not such a simple task. The milling cutter used in turn-milling generates a short chip that considerably improves swarf handling.

Take for example, machining eccentric areas of rotating components such as crankshafts or camshafts: In turning, off-centre masses of these components (crank journal, eccentric cam, etc.) cause unbalanced forces that adversely affect performance. Turn-milling with its low rotary velocity of a workpiece gives the possibility to prevent this negative effect.

Also, consider machining heavyweight parts: Their rotation, which defines cutting speed in turning, is connected with limitations of the main drive of a machine tool. If the drive does not allow rotation of large masses with required velocity, cutting speed is far from the optimal range; and turning performance will be low. Turn-milling provides a way to overcome the above difficulties effectively.

ISCAR indexable face milling cutters are good tools for turn-milling. However, productive machining with the use of the turn-milling method demands right cutter positioning with respect to the workpiece, correct choice of insert geometry and tool path. Cutter positioning, for instance, influences form errors, and insert geometry – surface finish. Usually the final shape is produced by a wiper insert, which is mounted on the cutter. The questions of applying turn-milling, tool choice and defining cutting data deserve fuller consideration and should be examined specifically.

Introducing turn-milling in manufacturing process can solve serious problems and substantially improve your output. Productivity using this relatively new and promising machining method is possible when you have a suitable modern machine and correctly chosen cutting tools. www.iscar.com CM www.canadianmetalworking.com | OCTOBER 2013 | 53

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WELDING NEWS POWER SOURCES FOR M3 PLASMA CUTTING SYSTEMS Offering precise control of the plasma current using an all-digital control circuitry, ESAB’s EPP-202 and EPP-362, are the next generation of Precision Plasmarc power sources for the m3 Plasma System. This precision plasma system combines plasma cutting and marking capabilities in a fully integrated, easy-to-use package. The new EPP units feature a new high-speed data bus connection that provides precise current

control and gas regulation, as well as enhanced diagnostic capabilities, including advanced status and process monitoring.

The digital power circuits in the EPP-202 (200A) and EPP-362 (360A) allow the new power sources to handle a full range of cutting and marking tasks, delivering consistent, repeatable results while maximizing consumable life, without sacrificing output power or stability. www.esab.com

HOBART’S NEW FLUX-CORED WIRES

Hobart’s FabCO 70XHP gas-shielded flux-cored wire offers low fume generation rates to help improve operator comfort and high deposition rates that help increase productivity. The new wire complements the FabCO TR-70 and FabCO RXR wires currently offered. This new wire offers a high level of performance and low visible fume levels. Designed for use in applications found in heavy equipment manufacturing, shipbuilding, and railroad car maintenance and repair, all of which tend to have enclosed environments where fume reduction is desirable, the FabCO 70XHP wire can also be used to weld nonalloyed and fine grain steels, as well as steel structures. It features a shiny weld bead with an easy-to-remove slag, which not only makes the completed weld more aesthetically pleasing, but it also helps minimize time for clean-up. Low spatter levels contribute to the wire’s ease of clean-up. www.hobartbrothers.com

LOW-ALLOY STICK ELECTRODE DESIGNED FOR ROOT PASS WELDING

Designed for root pass welding up to X80-grade pipe, and fill and cap pass welding for X70-grade pipe, the Pipeliner Arc 80 is classified as E8010-G and E8010-P1 per AWS. This low-alloy stick electrode has the same AWS classification as Shield-Arc70+ and Pipeliner8P+, without the intentional addition of boron. This allows for a variety of choices based upon the application and operator needs. Featuring high productivity in vertical down and out-of-position pipe welding with deep penetration, these electrodes are available in 4.0-mm, 3/16-inch and 5.0-mm diameters. www.lincolnelectric.com

POWERFUL MULTI-PROCESS 25-HP ENGINE WELDER

The Ranger 305 G EFI from Lincoln Electric combines a powerful multi-process, engine-driven welder with a Kohler 25-hp electronic-fuel-injection (EFI) engine.

This new option provides easier starting in cold weather as compared to the carburetor engine since there is no choke to adjust. Another advantage is a fuel savings of 12 per cent at 300 amps and 30 per cent at high idle. Ruggedly built it features stick, TIG, wire and pipe welding, and includes Lincoln Chopper Technology, providing simple starts, a smooth arc, low spatter and excellent bead appearance. The single-phase AC generator provides 12,000 watts peak for motor starting and 9,500 watts of continuous AC power for tools. The control panel offers a single, full-range output control dial, four welding modes selector and other simple controls. www.lincolnelectric.com 54 | OCTOBER 2013 | www.canadianmetalworking.com

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THE BUSINESS OF WELDING

Back to Work

By Ian Campbell .......................................................................................................................................................

B

y the time you read this we will be heading into a new season – one I like to call “back to business”. I’ve always liked this time of the year as people come back with renewed energy, making everyone that little bit more productive. Regardless of where you sit – the corner office or shop floor, productivity is likely something that is going to cross your mind as people start working.

NOT ALL WORK IS GOOD WORK. Lots of work takes place that is highly unproductive due to poor practices, old machinery and maybe even older ideas, and business practices. It should be no surprise to anyone that lots of things get done - and continue to be done - just because they’ve always been done that way. In such cases issues like rework, spoilage, and failures simply become a cost of doing business – rather than productivity issues that can be addressed. The problem for some is that the re-think required to fix the issues takes time and effort up front, which eats into the traditional definition of “work time”. So, depending on how you look things, you end up with “lost productivity” by trying to improve it. The issue here is simple enough – people are confusing productivity with work.

PRODUCTIVITY IS NOT THE SAME AS WORK. Technically speaking, productivity is the ratio between inputs (work) and outputs (products) in business. You could say productivity is the “thinking” part of “work”; it’s what drives the act of doing, not the act itself. For example, you can grab a torch and start to work while moving things out of the way, searching for material or tools, all the while making (and likely grinding out) welds as you go. Or, you can think about what you need to do, make a plan and optimize the process to get the most benefit out of each step. Both are work, both produce an output, but clearly one is going to be much more productive. Knowing what we now know – you might ask why are we not all pushing for real changes to productivity?

OLD HABITS DIE HARD. The reality is that old ways or habits (sometimes described as “experience”) can get in the way of productivity. Simply put, technology, processes, and materials change – and so should we. Just because it was done a specific way for some time does not mean it is still the best way to do it. For example, Ford still uses assembly lines, but they are no longer building Model Ts on them.

Welding is no different. The processes are the same, but we need to start thinking about what we do, and how we do it, to be more productive with them.

LEAN AND GREEN Here’s a solution in the form of a question: Have you heard about Ian Campbell, Director of LEAN manufacturing? If you have, Marketing and New Product Development, CWB you might have been told it’s not for welding, or that it is too big, too complex and too much bother. Well, that might be a bit of the “old-ways thinking” kicking in, or simply a fear of change. What you need to know is LEAN is only as complex as you want it to be; its only goal is to help you improve your productivity – and hopefully as a result your bottom-line. It’s about optimizing work and reducing waste in all forms, basically getting the most out of what you put in. The CWB is going LEAN, so why not talk to us and see what we can help you achieve in your welding organization?

YES, YOU CAN(WELD) ATTEND… October is the launch of our new CWA CanWeld Conference in Niagara Falls. This is Canada’s biggest welding event with three solid days of welding process, technology and business advice. We will have over three dozen speakers, and yes, one will be discussing LEAN for welding! Have you registered yet? www.cwaevents.org.

Check out the CWA on Facebook for conference speaker and event announcements. If you are involved in welding this is your new yearly event, hope to see you there.

SERVICING THE “OTHER” STEEL As many of you know, there are more than a few companies working with stainless steel in Canada. We have also seen the results of how bad things can get if traditional carbon steel “experience” (and equipment) are used for stainless steel work – namely rework, rejection and out right failures. As a result we are pleased to announce the launch of the CWB Stainless Steel Welding Resource Centre. The goal of the centre is to provide the industry with both the knowledge and skills needed to successfully work with stainless. Contact our call centre at 1-800-844-6790 to find out more, book a seminar or request technical welding support.

Finally, the usual ending applies – if the CWB or CWA can help move you business forward let us know – as Canada’s national welding organization we are here to help.

Canadian Welding Bureau/Canadian Welding Association www.canadianmetalworking.com | OCTOBER 2013 | 57

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Welding Automation for the People

Robotic welding is not just for the big boys

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

L

ike everything else in this world welding has evolved in the last decade. Welding automation is one branch that has seen a rapid evolution. “The robots are smarter and faster today than ever,” said Kevin Summers, Commercial Business Manager-Miller Welding Automation. “Automation 10 years ago was only for the shops with high volume production. The advent of easier programming, built in software features and off-line programming all make robots a great choice for any manufacturer, even the low volume, high mix customers.”

Welding automation is accessible because it is easier to use, and the equipment has become smaller due to inverter technology and software driven programs. “Generally, welding automation has become more important to the success of manufacturing companies in North America as they compete in global markets,” said George M. Learmonth, Vice President of Automation for ESAB. “The general acceptance of technology in the welding business has accelerated as new generations of kids accustom to computers quickly embrace new technology.”

Welding automation has become an important contributor to the black ink on the bottom line of many manufacturers in North America. “Many adaptive options (Vision, Touch Sensing and Seam Tracking) have greatly improved to aid in the welding of general industrial components,” said Chris Barber, Manager Sales and Applications - Flexible Automation for Lincoln Electric.

“These options may mitigate fit up tolerance, heat distor-

tion and can even minimize fixture complexity and cost.

Offline programming has allowed companies to easily cope with high change over and low volumes of parts.

Programmers can work independent of the system and create programs before the part is on the fixture. Robots and robotic systems have become more economical, physically smaller in size, and easier to use. The new systems also offer an excellent return on investment.”

SMALL SHOP INVESTMENT For a small shop looking to invest in automated welding equipment, three factors need to be looked at - the quantity of parts needing to be produced, the amount of time allotted for parts to be produced and whether the process is suitable for a robotic system. “Automation can be a genuine advantage for a business process that contains numerous routine activities. Small shops can achieve efficiencies and consistency through automation,” said Lloyd Steed, Product Manager for Tregaskiss. “The challenge is that as a process becomes more automated there appears to be less understanding of how it actually works. When that understanding breaks down, business process improvement becomes far more difficult and costly, so it is important that small shops understand what they are undertaking and have the proper training.” Before adding automated or robotic welding a shop should consider various factors beyond the simple cost of the robotic cell equipment. Items such as feed systems or conveyors to keep the machines supplied, fixturing,

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safety equipment, robotic controls, and integration into your computer system, programming the automated welding robot, electrical upgrades, training, service, and maintenance among others need to be considered. “Look at the mix of products that you are running. Where is the majority of your production? What are the reasons for you to automate?” asks Barber. “The best advice is to start simple and take the time to develop your automation plan in steps that will allow you to be successful as you move forward. Many shops will create multiple fixtures over time and create a versatile, flexible welding cell. In the industry we say, ‘crawl before you walk, walk before you run.’” Not all parts are good candidates for automation according to Summers. “You need to work with a knowledgeable partner to help you with the system first. It’s important to have a flexible system,” he said. “Sub-assemblies for larger parts are often good automation parts. Tolerances are critical regardless of the application and you need highly repeatable parts to be successful with automation.” The initial cost of a simple automated robotic welding cell can be the least expensive item when compared to the total cost of the complete system and the structural changes needed in a company.

However, not finding the right balance and investing is also a path into the unknown. “Small shops that

don’t invest in automation, will soon find themselves on the outside looking in,” said Summers. “Automation is critical to helping you stay competitive and show a differentiation over your competition. Small shops will also experience the shortage of qualified welders and a robot helps overcome that limitation. The ROI is easy to prove through time studies and simulations. The capability to program parts off-line with 3D models allow the smaller shop to weld as few as three or four items of a single part on the robot.” Robots will increase productivity compared to manual welding, resulting in the deployment of quality welders to critical manual jobs, while less skilled operators load and unload the robot cells. Although automated robotic welding cells

PLASMA AUTOMATION Manual cutting is going the way of the dodo, and automated plasma cutting is a very inexpensive option for small shops. Overall prices in plasma have come down in terms of amperage per dollar. “If a shop has a lot of repetitive work to do,” they might be good candidates for an automated plasma cutter according to Dirk Ott, VP — Global Plasma Automation Brand for Victor Technologies. He said that the new generation of automated plasma cutters are flexible and the job shop doesn’t have to go to a service center to get the material cut, saving money and potentially being able to expand his business.

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come with advanced easy to use software, they are still complex machines that need to be understood and operated by a trained crew. “Welding shops need to understand that robotic cells are like any new piece of welding technology. There is a learning curve to using the equipment properly,” said Steed. “Robotic cells are not plug and play. No matter what the sales person tells them, someone must be trained to use and understand what the robot is doing. Robotics is not rocket science but it isn’t your fathers old stick machine at the farm.”

UPGRADING While older equipment can be upgraded to be used with automated welding machines, you have to ask yourself, ‘is it worth it?’“Yes, older MIG equipment can be used, but with the changes in inverter technology and newer wave forms available, you may get significant improvements in throughput and quality depending on the process,” said Barber.

Depending on how old the equipment is it may not be compatible with the automated systems. “The communication systems and software used between power sources and robotic equipment are in many cases very well adapted to talk with specific equipment. It will likely be more trouble than it’s worth to use older equipment,”

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said Learmonth. “Older equipment is limited in technology and really can limit the potential of the robotic cell,” explained Steed. “My experience has been that the raw savings in capital equipment is spent in the system integration and/or programming of the machine. There is no true savings if there is any downtime in your robotic cell as a result of the re-used older equipment; that cost could have been avoided by purchasing new.”

STANDALONE WELDING SYSTEM The System 15 from Lincoln Electric, is a pre-engineered robotic welding systems that increases part production by improving productivity and quality.

This welding robot cell is a dual zone, manual turntable workstation designed for small to medium sized parts that can be welded without reorientation. The cell’s layout size of 62.5” x 89” (1588 mm x 2260 mm) and is optimized to maximize the work envelope of the robot while minimizing the floor space requirements. System 15 is suitable for first time robot welding system buyers and job shop-type manufacturing environments. www.lincolncanadaautomation.ca

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SMALL FOOTPRINT SYSTEM With easy-to-slide access doors that keep the system slim, and allow for tight stacking to maximize production and minimize floor space, Miller’s PerformArc 550 ships completely pre-wired and pre-assembled to eliminate assembly time. Once delivered, it is easy to move with forklift access from the front or rear of the cell and to connect to the utilities. Outboard Servo Positioners allow the parts to be rotated into the desired welding position, maximizing torch access and welding quality. It features a control panel that provides full system control, diagnostics and programming capability in one central location. www.millerwelds.com

SERIOUS PLASMA SYSTEM The Ultra-Cut 400 plasma power supply can cut non-ferrous materials up to 65mm with Ar-H2/N2 or up to 40mm using Water Mist Secondary (WMS) technology . With a fast and easy installation and quick-change consumable design the system saves money by reducing downtime during parts changes. It is microprocessor controlled to produce a quality cut each time. The fibre-optic communication system results in less HF interference. www.victortechnologies.com

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WELDING CELL READY-TO-GO ESAB’s Swift Arc series of pre-engineered, robotic welding cells are available in three models: Swift Arc AL (angle-load), Swift Arc FL (front-load), and Swift Arc SL (side-load) robot cells. Each system is a complete work cell suitable for job shops.

The system is delivered ready-to-weld after hooking up the input power, gas, and wire. www.esab.com

TMS Direct Drive Motor With HIWIN Drive Package Continuous Torque: 3.1- 150Nm Gearless. Maintenance Free.

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Copper Cost Climbing?

A new global report suggests future upward pricing pressure on the essential metal

By Jim Anderton, editor ...........................................................................................................................................................................

S

NL Metals Economics Group’s recently released Strategies for Copper Reserves Replacement Study reveals that lower copper grades and higher taxation, royalty, and environmental approval costs are pushing up the copper mining industry’s capital and operating costs. Ore head grades decline over time as companies initially mine high-grade zones to

recoup capital costs and other early expenditures.

From 2001 to 2012, the weighted-average head grade at 47 producing mines with comparable data declined by almost 30 per cent. Not only are head and reserve grades declining at existing mines, the average ore grades of copper in new discoveries and developing projects also declined over the period.

A a

COPPER PRODUCTION, HEAD GRADES, AND PRICE CHANGES BY YEAR, 2001-12 (47 Mines with 40% of 2012 World Copper Production)

Ch

Total Reserves, Resources, and Past Production of 395 million mt Ore Quality Down, Prices Up: While copper production is stable, the quality of copper ores (head grade) is decreasing, meaning more mining is required for reach ton of metallic copper produced. The effect on pricing is upward pressure

With declining ore grades exacerbated by increasing energy and other costs, and significant deposits being found at greater depths or in more remote areas, the average capital costs for copper production capacity

in new mines increased an average of 15 per cent per year over the past 20 years, with much of the increase evident since 2008. Cash operating costs at major mines also increased significantly, more than tripling over the

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past 10 years, to an average of almost $1.50/lb in 2012.

Besides the costs of operating mines, companies had to find or purchase reserves to replace mined copper, build mines to replace exhausted ones, continually upgrade equipment, and pay treatment and refining charges.

Net of administrative costs, a mining company had an average total cost of about $1.95/lb to replace reserves and produce copper over the period, increasing from about $0.76/lb in 2003 to more than $3.30/lb in 2012.

MAJOR COPPER DISCOVERIES BY COUNTRY, 1998-2012 (Total Reserves, Resources, and Past Production of 395 million mt)

Chile a Copper Powerhouse: New discoveries of high grade ore are essential to keep prices stable. South America, particularly Chile is a major source for future rowth. Despite Canada’s global reputation for mining, only two percent of

Globally, 100 significant copper discoveries (defined as a deposit containing at least 500,000 mt of copper in reserves, resources, and past production) have been reported so far in the 1998-2012 period, containing almost 395 million mt of copper. Benefiting from the largest share of discovery-oriented exploration budgets over the period, Latin America hosts more than half of the discovered copper, followed distantly by North America, Africa, Asia, Australia-Pacific, and Europe.

Overall, the industry found more copper in these significant discoveries than it produced; however, the economic viability of new resources is influenced by factors such as location and politics, capital and operating costs, and market conditions that inevitably reduce the amount of copper that reaches production.

To date, only about one-tenth of the copper in these 100 discoveries has been converted to reserves with only 15 deposits having reached production.

Meanwhile, the 22 major copper producers (those that mined at least 140,000 mt of copper in 2012) replaced almost 300 per cent of their copper production over the

past 10 years. These producers also increased their aggregate annual production by 39 per cent to 11.2 million mt in 2012, and held sufficient reserves for 36 years of production at 2012 rates. The majors’ increased production exacerbates their need to add reserves to maintain a steady production pipeline, however, and based on 2012 production these producers need to replace an average of at least 500,000 mt of copper reserves each year, ranging from a high 1.8 million mt for Codelco to less than 142,000 mt for Vedanta Resources.

SNL Metals Economics Group’s Copper Reserves Replacement Strategies study addresses key growth strategy issues facing the copper mining industry and compares the relative costs per pound of discovering or acquiring copper in the ground. The study provides an industry-wide review of the copper pipeline, acquisition activity, copper exploration budgets, and major discovery successes, and a variety of metrics for measuring and comparing the relative costs of various growth strategies for the 22 largest copper miners and the industry as a whole. CM

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Manufacturing on a High Fiber Diet

Fiber lasers for quick, efficient and accurate cutting

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

P

roducing parts faster, more accurately, and more efficiently is the goal of every manufacturer.

Whereas the process used to be labour intensive in the past, modern technology has stepped in allowing manufacturers achieve high throughput with an increase in quality and a reduced cost per part.

Commercial fiber lasers have been around for about 15 years and have proven themselves to be an effective tool in cutting thin stock. “It is about parts per hour.

With the fiber laser and thin materials, you can produce parts significantly faster with higher cut rates than you can with a CO2 laser counterpart,” said Jason Hillenbrand, Laser Product Manager for Amada. “The reason a fibre laser can cut thin material so much faster than a CO2 is because of the spot density - the amount of power it can deliver to such a small spot.”

Fiber lasers systems excel on thinner materials. “Fiber lasers have displaced the CO2 systems primarily in sheet metal and thin gauge cutting,” said Terry VanderWert, President of Prima Power Laserdyne, LLC. “4-millimeter thicknesses is the number that seems to be a cross over point that we hear from customers and end users.

For sheet metal fabricating application, fiber lasers

offer benefits in terms of speed and operating costs.”

He explained that the 4-millimeters or under is a rule of thumb, a sort of demarcation point where the fiber laser cutting systems are the most efficient. “They can cut thick material but it is a matter of speed and finish advantages,” he added. “If you are a job shop that has one laser machine and your business covers a wide range of metal thicknesses, the CO2 system is more flexible.”

Fiber laser has some advantages because of the wavelength of the light as compared to CO2 lasers. “With the one micron range of the fiber laser the absorption of that beam by the plasma that is formed at the surface of the metal is lower than it is for the 10 micron CO2 laser. So it is a more consistent and stable process,” said VanderWert. “Fiber laser systems rely on multiple solid-state pump diodes to generate a laser beam with a very short wavelength (est. 1 micron compared to a 10.6 micron wavelength for CO2 systems) that is then moved through a flexible fiber optic cable to the laser cutting head,” said Jon Blom, Product Specialist for Hypertherm’s Fiber Laser team. “A CO2 system, on the other hand, relies on mirrors, installed a set distance apart, to transfer the light beam.” This difference in

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Invented by Salvagnini, Perfected by Salvagnini Continuous improvement and technological leadership have propelled and sustained Salvagnini’s dominance of the fiber laser cutting market – a product category it created in 2007.

The L5 Laser Cutter Able to cut through both plastic films and reflective materials at warp speed, the Salvagnini L5 uses its patented carbon fiber Compass® drive to achieve a 5g acceleration with a level of accuracy, smoothness and quiet never seen before on a laser of any type.

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Salvagnini Experience With more fiber lasers in the field than all competitors combined, Salvagnini has not only the technological expertise, but also the application experience to get you up and running quickly and with cost per part reductions of up to 50%.

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the beam delivery method gives fiber laser systems several advantages.

ECONOMY Cutting costs are also a prime reason for switching to fiber laser systems. “A 3kW fiber costs almost 50 per cent less to operate than a 3kW CO2 laser,” said Steve Aleshin, product manager for laser systems at Salvagnini America. “The main components of this are maintenance, laser gas and energy cost.” For the energy costs the fiber laser is about 25 per cent efficient converting electrical energy in to light energy.

“It sounds bad but in actuality it is very good,” he said.

“For example a CO2 laser typical efficiency is around 5 per cent to 10 per cent efficient. That means a 4kW fiber uses 16kW compared to a CO2 laser using from 40kW to 80kW, depending on resonator in question.

This is not including the increase in chiller size to cool the laser source. This makes a difference in electric cost per year between $13,070 and $4,900 dollars, assuming one shift and a total of 2,000 hours use. Most current commercial U.S. average rates were used from www.eia.gov to calculate electric cost difference. It is a modest amount of savings compared to a CO2.”

The initial capital invest in fiber laser system might

make one sit up and take notice, but the advantages of these systems speak for themselves. “There is a price premium of about 25 per cent to go from a CO2 to a fiber laser cutting system of the same wattage and configuration,” said Frank Arteaga, Head of Product Marketing, Market Region NAFTA for Bystronics. He added that there is a 50 per cent lower cost of operation with fiber as compared to CO2. “Certainly the initial investment for a fiber laser is higher than that of a comparable CO2,” said Marc Lobit, Marketing Manager for Mazak Optonics Corporation.

“However the overall productivity advantages combined with a 50 per cent reduction in cost of operation can quickly pay profit dividends in a lower cost per part, and more parts per hour.”

Fiber laser systems save money in energy costs because of their inherit energy efficiency. “Because fiber laser is a completely solid state, monolithic design, the systems have higher wall-plug efficiency,” explains Blom. “A fiber system consumes about three to five times less energy making it roughly 86 per cent more energy efficient. The benefit of this is not only lower energy consumption (and lower power bills) compared to CO2 systems, but also the associated cooling requirements are significantly reduced.”

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SPEED & QUALITY While the operating costs of a fiber laser are much less than of a comparable CO2 system, this is not the primary advantage. “As one customer put it — companies don’t buy a fiber laser because of the money it saves them. They buy a laser because of the money it makes them,” stated Amada’s Hillenbrand.

“With fiber lasers, in certain thicknesses, you can reach higher feed rates than with CO2,” said Stefan Colle Laser Product Sales Manager for LVD Strippit, Inc. “The gain in speed in thin material with a 2 kw fiber laser versus a 4 kw CO2 laser can be as much as four times faster.” If you are cutting 1/4-inch and down it will be cheaper and faster to produce the part. “And that is the real reason you would get a machine,” said Brett Thompson, TRUMPF’s TruLaser Product Manager. “The primary advantage is dependent on the workpiece. For the thinner gauge of materials, with a solid state laser you can go considerably faster especially with the more power you have available.

You start to lose the speed advantage at about 1/4-inch.

With a 5 kw solid state laser as an example 1/4-inch, is where you start losing the speed advantage.”

Part of the speed and quality advantage of the fiber laser is the concentrated beam that produces a thin kerf. “What the fiber laser gives you is a smaller

kerf,” said Hillenbrand. “Generally the cut width is about 4/1,000 of an inch on a CO2, it may be around 8 to 10 thousandths of an inch for a fiber laser.” The motion controls for these systems are similar to the ones used by the CO2 machines and have a repeatability and accuracy of 4/10,000 of an inch. “Laser will produce tolerances between +/–0.002 to 0.005 of an inch. This compares with plasma tolerances in a range from +/–0.015 to 0.030 and oxyfuel ranges between +/–0.020 to 0.030,” said Blom. “Another consideration is the thickness of material to be cut. Fiber lasers are generally best suited for cutting thinner materials.

Though a 3kw fiber laser can cut thicker materials (up to 3/4 inches), fiber laser cutting speeds are faster on thin materials compared to CO2, but the cutting speeds decrease faster with thickness compared to CO2. It is important to consider the volumes of each thickness that are needed to be cut, then balance the run cost with productivity to choose the correct system.”

FLEXIBILITY Flexibility of a fiber laser comes in the way the light is delivered via a flexible fiber and not a static light source.

“There is no practical limit to a solid-state laser’s table size,” said Blom. “A larger cutting table requires merely

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a longer delivery fiber. In fact, it is even possible to install a fiber laser head right next to a plasma cutting head on a plasma cutting table, something that is not an option for CO2 laser. At the same time, the ability to bend or coil fiber optics means the systems are relatively compact when compared with gas systems of comparable power. This is especially beneficial to shops with limited floor space.”

Some job shops might opt for a CO2 laser, as they work better on thicker material, but Hillenbrand maintains, “you can cut it with fiber laser as well, but generally it will be slower and the edge quality will not be the same as with CO2 — at least not with the technology that we have in place today.”

“One of the applications where fiber lasers have made a big splash in the last few years is cutting of three-dimensional hot formed steel components,” said VanderWert. “Those are up to two millimetre thick so perfect for fiber lasers. These are structural components for A-pillars and B-Pillars.”

The ability to cut reflective metals is another strong suit of fiber lasers. “Fiber lasers feature positive light properties such as a shorter wavelength, which improves beam absorption into the material being cut, and enables the cutting of reflective metals such as brass

and copper,” said Blom. “A more concentrated light source creates a smaller spot and longer depth of focus so fiber laser can cut thin materials fast and medium thickness materials more efficiently. With stainless steel and thinner mild steel, up to est. 6 mm (1/4 inch), a 1.5kW fiber laser can cut just as quickly as a 3kW CO2 laser. This very high power density translates to increased output, yet with lower business costs because the operating costs for fiber cutting are lower than that of traditional CO2 systems.”

The ability to etch, mark, clad and weld also lends flexibility to a fiber laser system. “For cladding you would use different optics to focus and control and manage the beam profile and on top of that you need a means of delivering the cladding material to the focus point of the beam so that it melts and deposited on the surface,” said VanderWert.

MAINTENANCE AND CONSUMABLES CO2 laser systems require regular maintenance with mirrors that need to be maintained and calibrated.

Resonators and turbines that move the laser gas need to be inspected and replaced when needed. “All of this maintenance adds up,” said Blom. “A CO2 system can cost up to $20,000 per year to maintain. Fiber lasers

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on the other hand, require little to no maintenance since they don’t rely on mirrors or turbines.” Bystronic’s Arteaga concurs. “There is virtually no maintenance as there are no mirrors in either the fiber laser unit or the beam path delivery as it is a monolithic fiber to fiber design,” he said. “Fiber lasers does not use laser gas, gas turbines, laser mirrors, delivery mirrors, bellows beam path, beam purge. The only maintenance is in the mechanical aspects of the machine and also the cutting head consumables like nozzles.” Colle states that typical long-term preventative maintenances, which you face with CO2 lasers, are no longer required with a fiber laser. “The only daily maintenance we see now with fiber lasers is the cleaning of the protective window.

This is small piece of glass that protects the lens from getting contaminated by back splatter.” While there is less maintenance required to the cutting head, Al Bohlen, National Sales Manager Mazak Optonics Corp. said, “There is a chiller system, which is smaller than a CO2 but still requires periodic water changes and also filter replacement. Otherwise the machine aspects are very similar, but with a CO2 machine there are many more maintenance items related to the beam delivery system as well as the CO2 Laser unit itself.”

“The largest portion of the consumable that have been

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eliminated are the optical components,” said TRUMPF’s Thompson. “There are no optical components inside the laser that need to be maintained or replaced. That has really dropped down the operating costs even more so than the efficiency of the actual machine itself.”

The fiber laser systems eliminated the need for laser gas but did not remove the need for assist gas. “The assist gas can be significant cost. The assist gas is that used to help remove the laser’s melted materials. It can be compressed air, compressed oxygen, or compressed nitrogen,” said Prima Power’s VanderWert. “In cutting, the goal is to melt material and with the assistance of the gas jet, remove the material from the cut. In welding you want to melt the material but you don’t want to remove it. You want to protect it from the oxygen in the air. Therefore you shield it with a low flow. In cutting it is a high flow rate of gas.”

The assist gas primarily used is nitrogen because if oxygen is used, “then you can get a thermic reaction where it is giving off heat and burning the materials,” said Hillenbrand. “You will not be using all of the power of the fiber laser. When you use nitrogen you can use all of the power and the nitrogen is blowing all of the material through the kerf. Shop air can be used but you have to have enough pressure. Most of the air compressors in shops do not have enough pressure for cutting so they have to have special air compressors and it has to be a very clean and dry air. Most air in shops is not that clean or dry so you have to have filtration systems put into the system.”

“The fiber laser really shines when using nitrogen as assist gas,” said Colle. “There is almost no gain with using oxygen as assist gas. A 2kW CO2 laser versus a 2kW fiber laser cutting mild steel with oxygen will produce very similar cutting speeds.”

A STRONGER BOTTOM LINE While there are many benefits of a fiber laser cutting system, manufacturers are looking at this technology because it can process parts at a high rate of speed while maintaining high quality. If a company primarily cuts thin gauge material, “they can generate higher profit or reduce their cost per part to secure a higher volume of bids. Basically you can drive a stronger bottom line,” said Bystronic’s Arteaga. “The reason a company would switch from a CO2 laser to a fiber is for three reasons. One is to increase capacity, two to replace worn equipment, and three reduce operating cost,” said Salvagnini’s Aleshin. “It is usually easy and universal, that is the reasons for replacing a machine.

One precursor is to make sure that a fiber laser will cut the material in question, and to the quality that the part needs to be cut.”

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Fiber Laser Systems Roundup AMADA’S ECONOMICAL FLC-AJ SERIES Representing the latest generation of fiber laser cutting systems, the FLC-AJ series have energy-efficient AJ2000 and AJ4000 oscillators (fiber engines) that greatly reduce electrical consumption by requiring a quarter of the amount of energy consumed by the typical CO2 oscillators.

The compact oscillator also requires a minimal amount of valuable floor space. Boasting a maximum light conversion efficiency of 75 per cent and a maximum “wall plug” efficiency of 30 per cent, these systems provide excellent beam stability and quality while requiring no warm-up time. The extremely small spot density of the focused fiber laser beam results in unparalleled cutting speeds in thin materials — in some cases, up to five times faster than the comparable CO2 lasers. The full range of laser cutting systems are available from 1kW to 6kW. www.Amada.com

BYSPRINT HIGH-POWER FIBER LASER The recently introduced Fiber 4000 watt laser source can process sheet metal in the thickness range previously reserved for CO2 laser cutting systems, providing the user with even greater flexibility. It is powerful enough to cut steel, stainless steel, aluminum, and non-ferrous metals, such as copper and brass, with high process reliability and precision.

The electrical consumption of the BySprint Fiber is up 70 per cent less than conventional CO2 lasers. The result is lower operating and maintenance costs, in addition to significant energy savings as a result of using the Fiber 4000 laser source. Featuring up to 2.5 times faster cutting speeds in the material range under 1/8-inch thick due to the high energy of the fiber laser beam, the cutting head has been optimized enabling it to cut both thin and thick material with optimum performance, providing job shops with the optimum in machine flexibility.

In addition to the 5’ x 10’ cutting area of the 3015 model, a larger BySprint 4020 model provides a cutting area of 6’ x 13’. www.bystronicusa.com

FULLY OPTIMIZED CUTTING SYSTEM The HyIntensity Fiber Laser systems use a low maintenance solid-state laser source to generate a laser beam that is delivered through a fiber optic cable to the laser head. The HFL015 has a1.5 kW fiber laser supply with rated cutting capacity up to 12 mm mild steel (10 mm stainless steel) and is optimized for cutting a full range of materials (mild steel, stainless steel, aluminum) and thicknesses. The series consists of a 1.0 kW fiber laser (HFL010), 1.5 kW (HFL015) , 2.0 kW (HFL020) , 3.0 kW (HFL030). All systems have the ability to cut and mark with the same consumables for easy process changeover and efficient operation and feature easy plug and play integration with other Hypertherm products. www.hypertherm.com

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FAST AND FLEXIBLE PROCESSING OF PARTS The Electra FL fiber laser cutting system offers high-speed, thin sheet processing, low operating cost and the ability to cut a wide range of ferrous and non-ferrous materials. Fast and flexible, this system is easy to use and operate, featuring Touch-L, a 19-inch touch screen and graphic user interface that efficiently and effortlessly guide the user through all necessary man-machine interactions. It also incorporates a part programming and nesting feature to import parts directly to the control, apply cutting technology and nest sheets at the machine. This compact design maximizes uptime with an integrated shuttle table system or modular automation options that include a compact material warehousing tower (CT-L) inclusive of integrated load/unload system. www.strippit.com

OPTIPLEX 3015 FIBER The Optiplex Fiber increases the productivity of thin worksheet cutting with impressive accuracy and cuts up to 0.750-inch in CRS. It is designed to process reflective materials with greater thicknesses and at greater speeds than its CO2 counterpart. The fiber design can significantly reduce operating costs for applicable material types and thicknesses. With a rapid traverse rate of up to 4,724 ipm, the rugged construction of this system provides heightened productivity, reliability, and greater part throughput. The machine also uses the new Mazak PreView 2 CNC Control which features a user-friendly 15-inch touch-screen control and automatically determines the required processing conditions for the material prior to cutting. www.mazakoptonics.com

L3 MINIMIZES CONSUMPTION

All Salvagnini laser machines feature mechanical and control solutions and original programming and nesting software, to assure ease of use and maximum flexibility and productivity. The system features a focusing head designed entirely in-house, which features a single optic for high quality cutting across the entire range of thicknesses, assuring fast production changeovers and slashing retooling times. The characteristics of the fiber source and the optical chain developed by Salvagnini, comprising the fiber that transports the beam and the focusing head, generate a laser beam with a high power density for high-speed cutting (more than 60 m/min) on medium and thin material and high-quality cutting on thicker sheets. www.salvagnini.com

3KW TRUMPF TRU3030

The TruLaser 3030 fiber is a flexible, productive and universal choice for high-quality laser processing across a wide range of material types and thicknesses. With three kilowatts of power and a one-micron wavelength, the laser is able to cut up to 3/4-inch mild steel, 5/8-inch stainless steel and aluminum, and 1/4-inch copper and brass. The machine is suitable for contract manufacturers looking to cut thin sheet metal, mild steel in all sheet thicknesses, non-ferrous or highly-reflective metals, or whose production volumes are served by a single machine. Designed to be simple and self-explanatory, the machine is operated from an ergonomic swiveling operator console. The universal cutting head can process all sheet thicknesses, eliminating the need to change processing heads between applications. www.us.trumpf.com

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The British Bloodhound SSC land speed record car uses a titanium nosecone created with a Renishaw additive process. One-off or low volume, high value parts like these are ideal for additive processes.

Additive Value

Renishaw’s Dafydd Williams and Mark Kirby on the what, why and how of additive manufacturing

I

t’s still called “3D printing” in the media, but know­ ledgeable industry insiders are taking additive manufacturing across traditional design and material constraints to create services that can do much more than simply reverse engineer simple parts.

Canadian Metalworking discussed the future of addi­ tive manufacturing — and what it can bring to Canada’s part making community — with Renishaw’s additive manufacturing experts, Dafydd Williams and Mark Kirby: Canadian Metalworking: The popular press has reported extensively on “3D printing”. Is additive manufacturing ready for serious metal part making?

Mark Kirby: This is moving from a prototype technology to a production process, whether it’s aerospace parts or implants that go into the body…it’s about process capability. Until a couple of years ago the AM industry lacked the capability to make parts with confidence.

Dafydd Williams: We have to get away from the idea that it’s about rapid prototyping. Printing implies it’s a copy of something…it’s actually an original item. Print­ ing is almost virtual, this is real.

Canadian Metalworking: What is the actual part making process?

Dafydd Williams: The process is direct from CAD to file preparation software that slices the part into layers … that’s the point at which support mechanisms are designed in to minimise part distortion. We take a 3D CAD model, typically in STL format, which is easy to deal with, and load it to the file prep software, which automatically “slices” it to a layer thickness that’s user determined. For Renishaw, it’s typically 20­100 micron layers. 100 microns is the thickness of a piece of paper.

It changes a 3D part into a series of two­dimensional slices. The user is not involved in the path the laser takes … the machine decides on a strategy to best run the melt pool. Our system uses a proprietary algorithm to achieve the best result. If you built a cylinder, for example, you might start at zero degrees and finish at 360 degrees.

In our system, we never repeat the start and stop and constantly rotate in order to reduce the residual stress in the component. The machine does it automatically so the user is not bogged down with complex strategies.

There are some residual stresses in any melt process, but it greatly reduces them.

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Mark Kirby: Early 3D printing was a lamination process…you glued the layers together. If you wanted to machine something you wouldn’t start with a finishing tool to capture every single detail; it would be too inefficient. The ability of the laser to build it slice-by-slice actually simplifies the process.

Dafydd Wiliams: We’re using standard metals. Right now we’re building in cobalt-chrome, titanium, stainless steel, Inconel, all high melting point materials as well as simpler steels.

Canadian Metalworking: How does the Renishaw process differ from sintering?

Dafydd Williams: We’re depositing a very thin layer of metallic powder and then melting it with a very fine laser beam. It’s not a sintering process. The spot size of the beam is very small, 70 microns. It’s photons, so you can move it incredibly quickly, 7 meters per second.

That’s typically melting 25 micron layers. The metal particles are small, 10-45 microns in diameter and the powder is very fluidic, because the particles are spherical. That‘s very important to how the machine works.

Canadian Metalworking: Are there issues working with these high melting point metals ?

Dafydd Williams: No. We can achieve well in excess of 3000°C. Inconel is the highest melting point materials we currently use. There will be more alloys available on an ongoing basis. It’s a constant development. It is possible for a user to use their own powders. That’s important where the user needs to protect their intellectual property. There are many suppliers of powders. Naturally, we’d like users to use our powders, but we don’t restrict them to our material. We do grade our powders in-house, however, allowing us to guarantee performance. We have an advanced materials training course where they can learn to make their own materials.

Canadian Metalworking: What metals can be processed?

Can users develop their own powders?

Canadian Metalworking: Compared to sintering processes, it sounds like there’s some alloying going on at the beam spot.

Dafydd Williams: There is alloying. It’s a weld pool, and it; has significant swirl as the pool traverses across the beam path.

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Mark Kirby: We are melting material to full density … the physics are different from CNC machining. CNC machining is well understood, but we still have part distortion issues there. Normally with subtractive, by the time you’re machining, you’re no longer concerned with metallurgy.

Canadian Metalworking: Additive manufacturing is perceived as a high-cost prototyping technology. Can it really scale to production?

Mark Kirby: There’s not a lot of low hanging fruit…these are low volume, high added value parts. For subtractive processes, you have large lead times for material, a need to machine 90 per cent of it away, plus the tools move slowly in tough materials like Inconel. The up­front costs are considerable. Often the customer orders more than they want to make it economically viable. With additive manufacturing you can create one complex part and be cost competitive. Additive is decoupling complexity and cost. Which is not true of traditional machining. You can put more and more complex features into a part and the laser handles it, but a machining process adds tools and new cutting paths for every additional hole or feature if in fact it is possible to achieve with a tool! At the programing stage of conventional machining, you’ve really just begun. With additive you’re not roughing and finishing, you’re finishing as you go.

Canadian Metalworking: How difficult is it to make parts with the technology?

Mark Kirby: The materials properties are quite well understood, but there’s a huge education job here.

Designers are conditioned to subtractive technologies.

The current industry is great with computers, but need to learn how to win with additive. We’re dealing with a new generation. Not all new designers think about the subtractive process. They may simply design what they want on the screen, not knowing whether it’s possible to make any part that’s on their screen. The question is, ‘is this a good case for additive?’ It’s not going to completely replace CNC; you still need to ask the right questions.

Dafydd Williams: It’s still about high value, low to medium volume parts. If it’s an iterative design and we need to find out if it works, the question is, ‘what if it doesn’t?’ If it’s a cast part, for example, you‘ve committed to expensive tooling and a delay that could be months long. With additive you could have a new part in 24 hours. And you can create internal features like lattice geometries, which would be impossible to achieve by subtractive processes. Plus they’re truly functional parts. There’s a perception out there from the plastics side, that it’s about throwing a CAD model

Additive can achieve complex internal structures that cannot be machined, reducing weight and freeing the design process from traditional constraints.

on the machine, walking away and the part’s finished.

No. In the same manner that a subtractive process needs an understanding of coolants, tools and fixturing, there is a skill required on the design side. The skill is based on an understanding of what happens as the part is built. Where it could distort? Where do I need to constrain it? What fidelity do I need? Do I use a 25 micron layer or a 50 micron layer? There is application skill in using the machine.

Mark Kirby: I still see a misconception….with my mil­ lion dollar machine, I just push a button and the parts emerge. There’s more to it than that. When you get the process right, the process is like a chocolate factory… you push the button and go. In either case, additive or subtractive, you need the process knowhow. In every industry, there is a general trend toward smaller vol­ umes, delivered more quickly. The discussion about low volumes was accelerated by palletization on subtractive processes. You can build an order in blocks of five or six units at a time, for example. When will additive ma­ chines appear in job shops? When the business case is there … world­class job shops used to making million dollar CNC machine investments are ready to adopt additive technology.

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CUTTING EDGE

OMAX holds open house event in Seattle The event discussed some of the major changes since the firm’s origins in 1993.

By Jim Anderton ................................................................................................................................................................................................

T

he OMAX Corporation held an open house event on August 19, at the firm’s Seattle plant. Several new products were presented, both machinery and software.

OMAX makes extensive use of their own equipment to build water jet machinery, with 220 major parts cut with OMAX machines, including foam and rubber parts.

Machining to two “tenths” is common, with 1.8 million parts per year machined in house, with 11,000 different part numbers. Extensive in house capability results in delivery times in as little as two weeks from the initial order.

Modern quality control processes were demonstrated, with Brown & Sharpe CMM equipment and Renishaw probes fed by a statistical part sampling process.

Machine assembly is controlled by standard process instructions delivered by monitors at each workstation, with procedures and images laid out in step by step fashion. Pumps are all direct drive for high efficiency (90 per cent versus 65-70 per cent for intensifier types) and are run in for four hours before assembly into machines.

Service intervals are five times longer compared to technology of twenty years ago. Nozzle technology has evolved to the point where diamond orifice parts are guaranteed for 500 hours, and are proved by cutting metal on a testing machine. In-house training facilities include hands on sessions with machines, and includes software, machine operation and maintenance.

Training is free for life with OMAX equipment and

OMAX makes extensive use of their own equipment to build water jet machines.

Modern quality control processes were demonstrated, with Brown & Sharpe CMM equipment and Renishaw probes fed by a statistical part sampling process.

free for one year with MAXIEM machines. The program is used by OMAX employees as well as distributor field service personnel and includes instruction on pump rebuilding.

Materials handling is paperless, with inventory control managed with tablet computers, including an optimized walking pattern for efficient part picking. An automated shipping system also tracks deliveries using

Training is free for life with OMAX equipment and free for one year with MAXIEM machines. The program is used by OMAX employees as well as distributor field service personnel and includes instruction on pump rebuilding.

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CUTTING EDGE

an company-developed ERP system, and a part ordered by 3:00PM PST is usually shipped the same day.

OMAX co-founder and water jet cutting pioneers Dr. John Olsen and Dr. John Cheung gave a speech outlining the history of abrasive water jet cutting and the company’s origins, from their beginnings in 1993 with six employees in a 5,000 square foot facility.

“Nobody would accept a PC on the shop floor”, said Olsen about the early days, noting that the market was originally predicted to be only 60,000 shops in the US. The current lineup offers eight machines in each of

the OMAX and MAXIEM brands. Future developments will automate the tool path generation for three-dimensional cutting.

“There are maybe 90 to 100 competitive companies in China alone … we have to innovate to stay ahead. Low cost manufacturing is key to the future”, added Cheung, who noted that the lack of a heat affected zone in the cut, combined with ten times the speed of laser or wire EDM makes abrasive waterjet a useful complimentary technology to conventional cutting and machining processes. CM

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

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

ABB Robotics Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Sirco Machinery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 AMT Machine Tools Ltd.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Schunk Intec Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Benz Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Scientific Cutting Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Bohler-Uddeholm Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Scotchman Industries, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Cecor Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 SGS Tool Company. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 CWB Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Shop Data Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Data Flute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SST Canada. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Dillon Manufacturing, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Sumitomo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Dipaolo CNC Retrofit Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Thomas Skinner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Elliott Matsuura Canada Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TRUMPF Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC Fastems, LLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Tungaloy America Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fein Power Tool Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 United Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Flexovit Canada Abrasives Ltd.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Ursviken Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Forkardt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 US Shop Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Gibbs & Assoc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Victor Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,69 Gravotech - Gravograph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Walter Surface Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Gravotech - Technifor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Walter USA, LLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Haas Automation Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 YCM CNC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 8CMM20186 01/07/2008 08:19 AM Henkel Canada . . . . . . . . . . . . . . . . . . . 28 Hiwin . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 HORN USA, Inc. . . . . . . . . . . . . . . . . . . . . 7 Filter coolant faster, easier, Hurco USA . . . . . . . . . . . . . . . . . . . . . . . IFC cleaner and save!

Ingersoll Cutting Tools . . . . . . . . . . . . . . 19 Iscar Tools Inc.. . . . . . . . . . . . . . . . . . . OBC The power of CECOR high suction lift cleans ITI Tooling Company Inc. . . . . . . . . . . . . 49 sumps down to the bare metal in minutes.

Kyocera Cutting Tool division . . . . . . . . . 51 Lincoln Electric Co. of Canada . . . . . . . . 55 IN STOCK Makino Inc. . . . . . . . . . . . . . . . . . . . . . . 33 American Standards and specials.

Megatel Inc.. . . . . . . . . . . . . . . . . . . . . . 12 Japanese Standards Messer Cutting Systems . . . . . . . . . . . . 42 inch or metric.

Miller Electric. . . . . . . . . . . . . . . . . . . . . 56 Multicyl Inc. . . . . . . . . . . . . . . . . . . . . . . 70 FOR FAST DELIVERY: Nederman Canada Ltd. . . . . . . . . . . . . . 60 Contact your local tooling dealer or order direct.

North American Laser Systems Inc. . . . . 70 TEL 937-686-6405 PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . 63 FAX 937-686-4125 CECOR Sump Cleaners pick up everything Power Pusher Canada . . . . . . . . . . . . . . 10 www.retentionknobsupply.com in the sump - coolant, chips and swarf.

Retention Knob Supply Company Renishaw (Canada) Ltd. . . . . . . . . . . . . . 35 Filter separates solids from the coolant.

P.O. Box 61 Retention Knob Supply & Mfg. Co. Inc. . . 81 Bellefontaine, OH 43311 www.cecor.net Salvagnini America, Inc.. . . . . . . . . . . . . 67 1-800-356-9042 Sandvik . . . . . . . . . . . . . . . . . . . . . . . . . 13

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By The NUMBERS Industrial R&D, Productivity Closely Linked Canada lags, despite sound macroeconomic policy

A

new report released by the Council of Canadian Academies paints a troubling picture for research and development in Canadian industry. Although there is no single method for measuring R&D strength, by using a wide range of indicators, including new patenting, publication, and expenditure data, a panel found that IR&D activity is concentrated in Central Canada, with Ontario and Quebec ranking highest, followed by Alberta and British Columbia. However, this does not exclude the potential impact one small firm can have anywhere in Canada.

The panel’s assessment also revealed that IR&D in Canada is relatively personnel intensive and less capital intensive than in other comparative countries, and that fewer large firms

undertake IR&D in Canada. IR&D expenditures in Canada are now roughly half of the U.S. level and declining. This gap is largely driven by low IR&D intensity in Canadian high-tech manufacturing sectors, such as semiconductor and computer equipment manufacturing. There are bright spots, however.

Four key areas of strength are aerospace products and parts manufacturing, information and communication technologies, oil and gas extraction, and pharmaceutical and medicine manufacturing. The State of Industrial R&D in Canada report can be viewed at: www.scienceadvice.ca

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Machining Intelligently

ISCAR HIGH Q LINES

Wave-Shaped Shredding Cutting Edge Guarantees No Vibrations

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