Canadian Metalworking February 2013

February 2013 • www.canadianmetalworking.com

Higher, Farther, Faster New report points the way forward for Canada’s aerospace sector

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Vol. 108 | No. 1 | FEBRUARY 2013 | www.canadianmetalworking.com

20

HIGHER, FARTHER, FASTER .................................. 22

Canada’s aviation sector is set to soar

JOB SHOP SNAPSHOT .......................................20 Pure Ingenuity, Kingston, Ontario

LASER: THE FIBRE EDGE.......................................30 More power from fibre options

KEEPING WATCH ............................................. 36 Monitoring for 24/7 operations

NEW HORIZONS FOR HORIZONTALS ..................40 Turning productivity takes centre stage

30

MILLING GETS EDGY..........................................50 Cutting tools for minimum waste and fast cutting

FUME CONTROL FOR HEALTH AND PROFIT ...........68 Controllling welding fumes

ART AND SCIENCE ............................................74 Polishing is still a meticulous job

CLEAN, DRY AND STEADY ..................................78 Good CMM installation for repeatability

40

DEPARTMENTS View from the Floor .......................................................... 6

68

News ............................................................................. 8 Tool Talk........................................................................ 46 The Business of Metalworking .......................................... 56 Metals Report ................................................................ 58 The Cutting Edge ........................................................... 60

CONTENTS...

COVER STORY:

Welding News .............................................................. 64 By the Numbers ............................................................. 82

74

Cover image courtesy Bombardier Inc.

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PUBLISHER Steve Devonport 416-442-5125 | SDevonport@canadianmetalworking.com ACCOUNT MANAGER Rob Swan 416-510-5225, cell 416-725-0145 | RSwan@canadianmetalworking.com EDITOR Jim Anderton 416-510-5148 | janderton@canadianmetalworking.com ASSISTANT 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.........................................................

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

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View From the Floor Picking winners … and losers

W

ith Prime Minister Harper’s recent announcement of Federal money for automotive R&D, it’s official: Canada is no longer a market economy. Granted, we’re far from Socialist, but the new reality of manufacturing is that nothing moves unless there are taxpayer dollars baiting the process. Automakers won’t innovate without incentives?

Nonsense, but where they are correct is that as long as some jurisdictions use taxpayer dollars to attract an assembly plant or head office relocation, others must do the same, or lose those jobs. Remember when businesses chose a location based on access to major markets and labour costs?

Long gone. The net effect of this gerrymandering is a race to economic inefficiency as manufacturing operations chase easy money instead of sustained, low-cost production. It also has the effect of picking winners and losers, something at which government has rarely succeeded.

In the automotive example, Bricklin and DeLorean come to mind… good ideas hampered by poor financing, engineering and marketing with production facilities in locations ridiculously distant from both retail markets and parts suppliers. Building cars in Belfast? Nuts, but there was of course the 100 million pounds chipped in by the Northern Ireland Development Agency. The outcome was inevitable, as it was for Malcolm Bricklin, who attempted to manufacture a similar sports car to the Delorean in that massproduction mecca, Saint John, New Brunswick. That enterprise only soaked up four-and-a-half million dollars from the good people of New Brunswick, a relative bargain.

Sadly, there are many other examples. Why do politicians keep throwing taxpayers’ money at the problem? “Votes” are the obvious answer, but cynicism aside, even where governments have good intentions, the outcomes are frequently poor. Where they “succeed”, as with the Automotive Innovation Fund, that success is strictly for the shareholders.

There is a better way. Form a joint venture research firm as a true publicprivate partnership and let that firm hold patents in new technologies. Then license the innovations at modest cost to automakers building vehicles in Canada and recycle the profits back into the enterprise.

Integrate university engineering programs and the resulting true co-op programs will train top-flight automotive engineers. Even if run as a nonprofit, the value of the venture would be held as an asset on the books, one which should be immune from capital gains tax. Restrict production licenses to firms building vehicles in Canada and the stream of innovation would seed the process and give carmakers a real incentive to invest here. And perhaps return a profit to the taxpayer for a change.

JIM ANDERTON, EDITOR

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

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

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News Growth in a difficult economy Despite lackluster economic news from Europe, Italy remains a machine tool powerhouse BY: JIM ANDERTON, EDITOR

Above: Italian design is everywhere in Milan, including the exhibition halls for the BI-MU 2012 metalworking trade show, hosted by the UCIMU-SISTEMI PER PRODURRE, the Italian national association for machinery and automation companies.

Left: This large wind turbine blade was on display in the “Things for Life, Technologies and Doing” exhibit showcasing everyday examples of the machine tool industry’s impact on the public.

W

hile media coverage of the ongoing European economic crisis depicts Germany as the sole strong market, in machine tools, Italy remains fourth in production globally (third in exports), ahead of Korea, Taiwan and the United States. Data compiled by the Italian industry association UCIMU-SISTEMI PER PRODURRE shows that in 2012 Italian production in the sector reached 4,930 million euros,

a 3.5% increase compared with the previous year. The strong result was driven by very good export performance, which grew by 12%, reaching 3,650 million euros. Main Italian machine tool export markets were China, the United States, Germany, Russia, France, Brazil, Turkey, India, Poland, and Mexico.

Sales grew in China (+9.5%), in the United States (+42.5%), in Russia (+31.3%), in France (+9.9%), in Turkey (+52.2%) , in India (+1.2%), in Poland (+36.2%), and in Mexico (+93.9%). An opposite trend was recorded in Germany (–1.4%), which is still the third largest export market of the sector for Italy, with sales reaching 259 million euros. Domestically, Italian machine tool consumption decreased by 13%, reaching 2,220 million euros, with imports declining 10.4%, for a total value of 940 million euros. When tracked as import to consumption ratio versus export to production ratio, however, the import figure rose by 1.2 per cent, while the export ratio gained six percentage points.

Overall, the figures suggest that the Italian machine tool industry is much stronger than widely reported domestic economic data suggests. ... continues on page 10

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News ... from page 8

High-tech industry applications were everywhere at BI-MU, including these jet engine and airframe parts (left); Size was no object at BI-MU with many massive horizontal and vertical centres on display (right).

This was confirmed at the recent BI-MU 2012 trade show.

The 28th BI-MU exhibition, hosted by the UCIMU-SISTEMI PER PRODURRE, the Italian national association for machinery and automation companies, was held October 2nd to 6th, 2012 at the trade and conference centre Fiera Milano in Milan. The large exhibition occupied five halls of the Fiera Milano site

covering 90,000 square metres, (980,000 square feet) with 1160 companies exhibiting. Fully 53 per cent of exhibiting firms were Italian. All aspects of the industry were on display, from cutting and machining tools to stamping, sawing, and bending equipment along with automation and software.

Special themed areas included “The World of Surface Finishing“ and “The World of Forming” and the event included a special exhibition, “Things for Life, Technologies for Doing”, which illustrated the impact of machine tools in everyday life.

58,875 visits were recorded with a total of 2,837 foreign visitors from 77 different countries. Luigi Galdabini, president of UCIMU-SISTEMI PER PRODURRE, said: “In spite of the difficult situation, and the recession affecting most countries of the Euro Zone, 28.BI-MU/SFORTEC was successful in maintaining its size, even exceeding targets with a cautious optimism that gives good hope for the near future”.

The outlook is positive, adds Galdabini: “Looking beyond the numbers, in line with the previous edition it was the impression of the companies interviewed on the stands that confirmed the good results of the event, which after 2010, a year of deep crisis, shows us a sector that has started again to invest in innovation, and believes in the recovery of the Italian market. Recovery is expected for the second half of 2013”.

The 2013 forecasts indicate a slowing down in the Italian machine tool, robot, and automation system manufacturing industry, however production is expected to increase by 1.2%, reaching 4,990 million euros. Luigi Galdabini stated: “The positive results of Italian manufacturers are due to a good performance in the foreign markets. Exports, both to emerging and traditional markets, have in fact enabled the companies to close the year at the same levels of 2011”.

The UCIMU-SISTEMI PER PRODURRE has announced its support for a fall 2013 machine tool general meeting, open to all Italian manufacturers, but also import agents, distributors, and branches of foreign companies. The objective will be the analysis of weaknesses, strengths, and opportunities, as well as the needs of the sector. CM

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News Report recommends re-establish­ ment of aerospace hub in Southern Ontario Suggests the location could work in tandem with existing cluster in Montreal A recent review of the country’s aerospace sector has called for drastic improvements to the industry and suggested the redevelopment of an aerospace hub in the Toronto region.

The government-mandated report, which was led by David Emerson, the former Minister for International Trade, covered a broad range of topics and noted the importance that updated infrastructure has on the industry.

A proposal included in the report suggested that Toronto’s Downsview Park would be a good location for an “aerospace campus”.

The proposed campus would involve Centennial College, the University of Toronto’s Institute for Aerospace Studies, and Bombardier, who already have facilities at Downsview Airport.

“This would leverage Ontario’s very best educational institutions in a unique partnership designed to develop innovative new technologies, aid in workforce training and skills development, and participate in supply chain development activities,” the report said.

“This campus would provide an anchor point to a proposed aerospace technology corridor between Toronto and Montreal and enhance the capabilities of both centres,” it continues.

However, one major question is where the funding for the hub would come from. The report suggested the government cofund the project along with the province, academic institutions, and additional industry companies like Pratt & Whitney or Messier-Dowty.

The new research hub would be a boon for the industry, which is currently struggling with an aging workforce and a skilled labour shortage.

The Canadian Auto Workers Union – who represent approximately 10,000 aerospace workers across Canada

– responded to news of the report by lamenting the fact that Canada had not been performing as strongly in the sector as it had in the past.

Union President Ken Lewenza blamed a “lack of concerted effort by government” for Canada’s diminished presence in the industry.

“Our aerospace sector cannot and should not be taken for granted,” he said.

According to the government, Canada ranks fifth in the world in overall aerospace production and third in civil aircraft production. Montreal is also ranked as the third-largest aerospace hub in the world.

Since 2006, the government has committed $827 million to research and development projects through the Strategic Aerospace and Defence Initiative.

“Our government is taking steps to ensure that Canada remains at the forefront of the global aerospace industry,” stated Christian Paradis, the Minister of Industry.

Enhancing R&D, more training for workers in aerospace environments, and stabilizing funding to the Canadian Space Agency were some of the other recommendations mentioned in the report.

CAW ends strike at Wescast Industries TORONTO – On November 16, CAW Local 504 members voted 98 per cent in favour of a new collective agreement with auto parts maker Wescast Industries. The vote ended a threeweek strike at the Strathroy, Ontario facility.

The workers, who had been on strike since October 27, reached an agreement that resisted concessions and extended a commitment on the life of the plant for at least another year.

Jerry Dias, assistant to the CAW president, said “In addition, the company has agreed to a process that will hopefully transition the plant from iron to stainless steel production”.

The union’s national representative, Jim Woods, also lauded other important gains such as an increase in the severance ... continues on page 14

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News ... from page 12

entitlement to 2.4 weeks per year of service for any permanent layoff.

Local 504 President Dave Reston said, “The activism of CAW area local unions as well as other unions and community members in providing support to the picket line was critical in maintaining the membership’s spirits in Strathroy, as they walked in bitter cold conditions many days.”

CAW Local 504 represents 65 workers at Wescast, which produces exhaust manifolds for General Motors.

Wescast was recently bought by Chinese manufacturer Bohong for $195 million this past summer, which has led to the changes at the company.

Volkswagen using new steel to lighten their next generation of vehicles The world’s largest steel company, ArcelorMittal, is supplying Volkswagen with a new type of steel to help make their cars lighter and more fuel-efficient.

The steel, called Usibor 1500P, is lighter than standard steel and is able to retain its strength through the various forming processes – particularly hot stamping.

Because of this, automakers can then use a thinner gauge of steel in the vehicle construction, which can create weight savings of up to 50 per cent, decreasing

fuel consumption in the process.

Greg Ludkovsky, the head of global research and development at ArcelorMittal stated, “Despite their lower gauges, high-strength steels offer the same or better performance for cars than conventional steels in terms of mechanical behaviour.”

“High-strength and ultra high-strength steels contribute to significant weight saving of the vehicles without sacrificing the safety requirements. For most of them, they even contribute to increased crash performance.”

Currently, applications for Usibor 1500P are typically in the body of the vehicles, such as the front and rear bumpers, door reinforcements, and the floor and roof of the car.

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2012 Canadian Aerospace Summit

T

ate Social Responsibility at Bombardier Aerospace was also elected Chair of the Board of the AIAC for 2012-2013.

Quick, officially welcomed Ms. Gagnon to her new role at AIAC’s Annual General Meeting on Dec. 5th.

She succeeded David Schellenberg, president of Cascade Aerospace, who occupied the role over the course of the past year.

“I am greatly honoured to serve as Chair of the Aerospace Industries Association of Canada for 2012-2013, and I look forward to working with the Board and membership over the coming year as we face the challenges and unparalleled opportunities which lie ahead,” said Ms. Gagnon.

“2013 will be a critical year for our industry. With the publication of the Emerson Aerospace Policy Review Report, we will now concentrate our efforts on transforming its recommendations into actions, policies, and budget items.”

“The AIAC looks forward to working together with the government to ensure the timely implementation of the report’s findings,” she concluded. CM

he Aerospace Industries Association of Canada (AIAC) held their 2012 Canadian Aerospace Summit at the Ottawa Conven­tion Centre on December 5th and 6th.

AIAC CEO Jim Quick introduced a full slate of speakers and seminars covering issues from the legislative environment to NASA procurement. Some 650 delegates from industry, government, and the military attended the event. Quick noted that this year is the 50th anniversary of Canada in space.

In 1962, the Canadian designed and built Alouette communications satellite made Canada the third nation to put a satellite in orbit, after the U.S. and the Soviet Union.

The Minister of Industry, Christian Paradis, delivered the opening address, noting that, “We have some of the strongest economic fundamentals in the world. The manufacturing sector is the foundation on which the economy is built. The aerospace industry supports 160,000 direct and indirect jobs, with productivity growth that has outpaced the G20”.

Hélène V. Gagnon, the Vice President of Public Affairs, Communications and Corpor-

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News On the Move Mitutoyo Canada Mitutoyo has announced organizational changes leading to new appointments for two current employees: • Jay Summers is the new Executive Vice President of Canadian Operations effective November 1, 2012. Jay is a 25-year veteran with Mitutoyo Canada Inc. and has served as vice president since 2005.

• Peter Detmers has been named as Vice President of Sales, overseeing all aspects of Canadian sales and sales support operations. Peter has over 20 years of service with Mitutoyo in various roles including national sales manager since 2007.

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SST Canada Single Source Technologies (SST), a North American distributor of machinery brands such as Makino and Muratec, has announced the addition of Greg James to its Toronto sales territory. James possesses over a decade of experience in machine tool operation and CAD/CAM programming. He will be supporting SST’s expansion of milling consumables in Canada as a tooling sales engineer.

“At SST Canada, we are committed to offering the tooling, services and engineering expertise necessary to improve manufacturers’ machining performance,” said Juergen Moeglich, president of SST Canada. “Greg’s expertise and talent will help us continue to excel in this area.”

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News Labour Minister Lisa Raitt participates in Canadian Welding Bureau roundtable Raitt was part of a meeting discussing issues facing the Canadian welding industry.

Labour Minister Lisa Raitt discusses the welding industry challenges with CWB members, during a facility tour.

TORONTO — Labour Minister Lisa Raitt met with members of the Canadian Welding Bureau (CWB) on January 7th, to discuss challenges facing the country’s welding industry.

The meeting featured a roundtable that tackled issues such as worker mobility, creating a national welding education program to address the shortage of welders, and the skills and knowledge gap within the government.

The CWB’s Director of Marketing and Product Development, Ian Campbell described the meeting as “the CWB offering a helping hand (to the government) where they need it, with respect to welding.”

Raitt, who is the MP for Halton where the CWB’s headquarters are located, also had strong praise for the health and safety initiatives the group has undertaken.

“I am very pleased to see that organizations such as the CWB Group have made health and safety a key component of their learning system and training courses,” Raitt stated.

“Everyone has a role to play when it comes to promoting safe and healthy workplaces across Canada. That is why we work with provincial and territorial representatives, and employer and employee organizations, to promote the importance of occupational health and safety,” she continued.

The CWB Group is based in Milton, Ontario and provides certification, and training services to the Canadian welding sector. CM

Visit Canadian Metalworking online: www.canadianmetalworking.com follow us on twitter: @CdnMetalworking visit us on facebook: www.facebook.com/pages/ Canadian-Metalworking-Magazine

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Job Shop Snapshot

Pure Ingenuity As the economy recovers this Kingston shop sees a bright future ahead

A

few years ago, Ontario’s manufacturing industry underwent a Darwinian purge as it struggled through the Great Recession.

Shops closed, workers went west for bigger salaries, and oil sands revenues spiked our dollar, making the cost of our goods less attractive to U.S. buyers. It truly was a time when only the strong would survive. Case in point – Pure Ingenuity in Kingston, Ontario.

The 13,000 square foot facility in Kingston’s west end is own­ed and run by company President Richard Ward, and serves as an example of how shops can persevere in an adverse economy.

Ideally situated between Ontario’s golden horseshoe, Quebec, and the manufacturing base in New York state, the shop primarily fabricates stainless steel equipment for the food and beverage and pharmaceutical industries, but does a variety of other custom jobs. It employs five engineers (Ward included), about 15 shop workers and office staff to cater to these regions and beyond.

By focusing on custom work for clients and “adding value through engineering,” as Ward puts it, the customer-oriented approach has allowed them to carve out a niche in the market.

“I really like dealing with the customers. I like going to the factories, seeing what their points of pain are, trying to figure out solutions,” Ward says. “Supervising design, seeing the finished thing go in, seeing it run and be successful, that’s very gratifying.”

Ward admits the state of the economy has been challenging for the business, but as the economy rebounds so too has the business and they are now considering moving to a larger facility.

“We’re trying to grow, trying to find new partners, not only in Ontario but in the U.S. as well,” Ward says.

The growth is a positive sign that the industry in general may be shaking off the problems of the last few years. And while the high Canadian dollar impedes sales to some degree, there is a silver lining in that shops like Pure Ingenuity can now buy equipment from the U.S. at a much better rate, and keep their tooling costs down.

Notably, they’ve added a TRUMPF 1080 laser, a welding positioner, and a Bluco modular fixturing table, which Ward calls “an awesome piece of equipment.” With this new equipment and a concerted effort to add more automation he sees an opportunity to increase production and continue improving the business.

“I’m pretty optimistic about the future. I think the U.S. economy is going to recover and start to roll along, and I think we’re headed for some good times.” www.pureingenuity.com CM

(Left:) A brand new TRUMPF 1030 laser is increasing productivity. (Above:) This access platform for the Sudbury Neutrino Observatory is an example of the kind of custom work the shop does.

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FOUNDED: 1971 OWNER: Richard Ward SIZE: 13,000 square feet NUMBER OF EMPLOYEES: 22 SPECIALTIES: Stainless steel sanitary equipment for food and beverage, pharmaceutical, and chemical industries FIVE-YEAR OUTLOOK: Grow operation, move to a larger facility RECENT MACHINES: TRUMPF 1030 laser, Bluco modular fixturing table 20 | FEBRUARY 2013 | www.canadianmetalworking.com

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HIGHER, A new comprehensive report points the way forward for Canada’s aerospace sector

Image courtesy The Boeing Company

22 | FEBRUARY 2013 | www.canadianmetalworking.com

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FARTHER, FASTER

by Jim Anderton, Editor..........................................................................................................................................

B

y the numbers, Canada is an aerospace overachiever.

Ranking 35th in population globally, we have the world’s fifth largest aerospace industry in absolute terms. Only the US, France, Germany and Great Britain exceed our share. When measured relative to the size of national economies, Canada is even more

impressive, behind only the United States. In the current economic reality however, can we maintain our position?

Despite global recessionary pressures, the future looks bright, according to Aerospace Industries Association of Canada president and CEO Jim Quick. “Based on our information we’re expecting that major OEM’s like Boeing, Airbus and www.canadianmetalworking.com | FEBRUARY 2013 | 23

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Bombardier that we are on track for the next 20 years to see a dramatic increase in passenger travel”, says Quick. “That means 34,000 new aircraft; it’s the equivalent of 4.5 trillion dollars’ worth of work. We’re going to start to see some changes in the industry with increased travel in emerging economies. They’ll build their own aerospace capability, but they won’t be able to accommodate the growth within their own industries so there will be opportunities for Canada.”

commercial airframe and engine capacity, although all four have the technology to build airliners. Growing demand for air travel isn’t the only driver of commercial aircraft orders.

Fuel costs, which account for over half of many airlines operation costs, are stubbornly high, while modern aircraft like Boeing’s 787 Dreamliner offer up to 20 percent lower fuel burn per passenger mile compared to current airliners. And although expensive (a 787-8 carries a list price of over 200 million dollars) interest rates are at generational lows, and AGING FLEETS, MORE ORDERS the airline fleet is aging. Air Canada is an example. According Those opportunities have emerged because of a “perfect to airfleets.net, Air Canada’s average fleet age is 12.3 years, storm” of global economic factors favouring civil aerospace. with the A320 aircraft averaging 19.4 years. Aircraft used for The dramatic rise of the developing world, in particular the short haul domestic routes can become uneconomic after “BRIC” economies of Brazil, Russia, India and China has left 20 years of service and over 200 airlines use the A320, so the those nations’ indigenous aerospace sectors lagging in large replacement market is enormous. Boeing alone carries a three year delivery backlog.

The potential for Canadian suppliers is obvious. Boeing’s director of business development and global strategy for the firm’s commercial airplane business, Dustin Robinson, describes the environment: “Boeing spent 900 million dollars with more than 400 Canadian suppliers in 2011. World air travel has grown five percent per year since 1980, despite four recessions, two Gulf Wars, an oil shock and 9-11. We predict that commercial airplanes will generate 1.2 trillion dollars in sales opportunity over the next twenty years.”

Robinson feels that this growth will • Always in stock • Made from 4140 steel result in changes to the way parts are sourced by major OEM’s, stating “We’re • Made in the USA • Competitively Priced working closely with our suppliers to address supply chain issues. It’s one of the most significant challenges we have in new programs ... it can be a significant enabler to program success. We’ve spent a lot of time looking at financing; with a growth of 40 percent we will have constraints. It will take capital and technology.”

It will also take a new approach from Tier One and Two suppliers to the firm.

“We have a fewer number of suppliers than in past programs. We will focus on those suppliers but recognize the need to manage the whole supply chain in a highly competitive market. There was a view that information sharing with Boeing will work against you, usually a ‘cost down’. We really want to work together to achieve cost efficiencies....

ISO 9000 Certied QMS when Boeing requests a price reduction from a supplier, someone in the chain will ultimately pay for it in a highly competitive environment.”

Just who will pay isn’t clear, but several Tier Two and Three suppliers contacted by Canadian Metalworking, and who declined to be named, expressed doubt that major OEM’s will be able to push cost cutting entirely Peter Seessle | Expertech Dist. & Tech. Inc. down to the bottom of the supply chain, 44 Goodfellow Crest | Bolton, Ontario | citing already tight margins and the Phone: 647-960-4478 | Email: peteseessle@rodgers.com | increasing specialization and certification

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26 | FEBRUARY 2013 | www.canadianmetalworking.com

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of downstream suppliers. If your shop is a certified supplier and has years of experience with landing gear trunnions for example, competition will more likely come from foreign firms than Canadian companies.

THE GLOBAL CHALLENGE

Protecting Canadian suppliers from that threat will require a new emphasis on net benefits analysis and tighter control over technology transfer and intellectual property rights. Jim Quick agrees: “The single largest challenge is the globalization of the industry. It’s changing how you build and structure the supply chains. At some point platforms (airplane types-ed) having 300 suppliers will have 50, because major OEMs are asking their supply chains to take on more and larger segments of the work. You’ll see that kind of phenomenon down through the Tier Ones to tiers Three and Four. This is the way the industry is evolving. Businesses need to stay competitive and get onto the platforms that they need to be on. If you miss a platform, it can be a thirty year project in terms of (aircraft) longevity.

To miss an opportunity can be a thirty year issue.”

Veteran aerospace manufacturing consultant Dr. Kevin Michaels notes that consolidation is ongoing, citing a recent deal in the lucrative landing gear segment. “The United Technologies Corporation -Goodrich merger could be a harbinger for further Tier One consolidation in the future. One reason is a changing supply chain strategy from OEMs. They want to simplify their supply chains. Rolls- Royce went from 400 suppliers in 1977 to less than 50 for the firm’s new Trent jet engine program. Tier Twos and smaller companies need

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to work closely with Tier Ones. OEM’s now want to source complete aircraft systems, not just parts. Another example is integrated propulsion systems, combining engines, nacelles and thrust reversers, controlled by a single integrator.”

Michaels cites Nexcelle, a joint venture between US major GE Aviation and France’s SAFRAN as an example, as well as Rolls Royce’s collaboration with United Technologies’ Pratt and Whitney engine business.

Michaels also notes that the major deals conceal a larger movement further down the supply chain: “Tier Four supplier consolidation is under reported. These are the raw materials suppliers and are consolidating quickly. Smaller firms here could go the way of the family farm. Tier One consolidation is changing the downstream industry.”

DEFENSE: DIFFERENT RULES, DIFFERENT GAME

Globalization and consolidation are nothing new in manufacturing, but the aerospace industry’s defense sector operates by different priorities than the civil market. Both emerging and advanced countries regard indigenous defense manufacturing capability as a source of national pride and a security issue, while the advanced technologies inherent in modern weapons programs add issues of secrecy and supplier security qualification. On the price side, many programs are decades-long, making total life cycle costs difficult to predict and highly political. Nowhere is this more true that in the ongoing CF-35 procurement debate, which at press time, was “reset” by Minister of Public Works and Government Services and Minister for Status of Women Rona Ambrose, who publicly released the selection criteria for fighter aircraft.

“Last April, we set out a Seven-Point Plan to hit the reset button on the process to replace the CF-18 aircraft,” said the Minister. “With the release of the Terms of Reference that will guide the evaluation of alternative fighter aircraft, we are demonstrating that we are serious about looking at all available options to replace the CF-18’s.”

While “all available options” doesn’t exclude the CF-35, the operational requirements were written around the unique stealth capability of the aircraft, making a new selection process difficult and possibly too lengthy to deliver aircraft before the current CF-18 airframes reach their maximum allowable flight hours. And export markets will be dominated by fiscal restraint for some time to come, adds Jim Quick: “I think there are two environments. On the defense side, we’re seeing two phenomena. Emerging economies are increasing defense spending. With that increase comes opportunity, but there is a decline in traditional defense markets like the US and Europe. We have a very unique relationship between the Canadian and US industries, so every time they reduce spending there’s a ripple effect on our industry. If we see the kind of reductions in the US that they’re contemplating we will definitely see effects in Canada.”

REPORT CALLS FOR INVESTMENT

The challenge to the Canadian industry is the backdrop to a new Government of Canada aerospace review entitled Beyond the Horizon: Canada’s Interests and Future in Aerospace. Released to coincide with the 2012 Canadian Aerospace Summit in Ottawa on November 29th, the report was announced as part of the 2011 Federal budget and formally launched on February 27th. The two-volume document was produced by a team headed by former Minister of Foreign Affairs David Emerson with an advisory 28 | FEBRUARY 2013 | www.canadianmetalworking.com

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council that included former Ontario Minister of Economic Development Sandra Pupatello, aviation management and supply chain expert Professor Jacques Roy and Aerospace Industries Association of Canada President and CEO Jim Quick.

The review’s 17 recommendations, if implemented, would streamline bureaucracy and add government funding to a host of enabling programs from education to large scale technology demonstration. Normally, major aerospace reports focus on OEMs and defense procurement but significantly, the importance of suppliers are recognized. According to the report the government should “co-fund initiatives aimed at strengthening the Canadian aerospace supply chain.”

The recommendations of the review suggest a significantly larger role for public funding at all levels of the industry, a position that would seem to be at odds with the Federal government’s conservative economic doctrine. According to David Emerson, “the Fraser institute wants to remove public support for the aerospace sector. We looked at what other countries are doing ... in the developing world, they want what we have in Canada and they often don’t operate by the same rules as Canada. They are building their aerospace industries. The good old days of a rules-based level playing field in trade are going away. In the global economy, these factors will manifest themselves. To sell planes in a country we may have to build planes in that country. The nature of global supply chains are changing; now they are total product cycle driven. The value chain has to start with innovation and may require partnering with nations like China and India. The large supply chain of 10 years ago is changing. OEMs don’t want to deal with hundreds of suppliers.

This has important implications for the many small businesses in the aerospace industry. It’s not about cheaper financing, it’s about their ability to continue to feed the Canadian supply chain. We’re working at making government programs more accessible to small business.”

Should governments backstop aerospace investment? UK Prime Minister David Cameron, in a statement at the Airbus Broughton plant, where wing assemblies are produced said: “The government will continue to back UK aerospace, cutting business taxes, investing in exports and working in partnership with the industry to ensure it is fully equipped to compete and thrive in the global race.”

The global consensus is that aerospace is a strategic sector, one important enough to protect with taxpayer dollars.

To what extent emerging nations will be able and willing to subsidize their sectors will depend on multiple factors including the current economic crisis,

regional conflicts and trade agreements. Canada has an advantage because of a mature technology base and preferred access to the world’s biggest market, the U.S., as well as the ability to participate in advanced, sensitive-technology projects.

With a major backlog in commercial airliner production, the Canadian aerospace supply chain enjoys a cushion against weak spending in the defense sector, but the CF-35 program or its replacement will likely define the industry’s advanced capabilities for decades to come. Implementation of some or all of the Aerospace Review recommendations may decide whether Canada continues to punch above our weight in the global industry, or goes the way of the Avro Arrow. www.aerosapcereview.ca www.aiac.ca CM

www.canadianmetalworking.com | FEBRUARY 2013 | 29

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Laser: The Fibre Edge Fibre laser technology and more power are hot this year

By Jeremy Wiebe...................................................................................................................................................

I

n laser cutting, the only thing that increases more quickly than power and efficiency is the demand for these two things. Fortunately, recent developments in the market are taking huge steps forward in both areas, with 2-kilowatt machines being quickly outpaced by 4- or even 5-kilowatt powerhouses that cut deeper and faster. And with trends developing toward increased, efficient automation, the industry is fast becoming a leading source for quick, costeffective production.

With a growing demand for laser advancements comes a

need for industry frontrunners to stay at the head of the pack.

More powerful resonators allow for deeper, quicker material processing. Fibre lasers allow for depths approaching one inch at cutting speeds of well over 1,000 inches per minute. And while laser production is often handled by automated tables for quick turnaround, further advancements in pallet changers, as well as quick lens- and nozzle-changers help optimize speed by allowing for workpiece setup outside the machine and minimize downtime by streamlining all changeout processes.

Here’s a look at what the industry has to offer.

SALVAGNINI – L3 AND L5 LASER

Salvagnini offers several fibre laser options. The L3 and L5, with 2kW and 3kW resonators, offer significant savings in running costs over CO2 alternatives, with up to 55% gain and vastly improved energy consumption rates of greater than 70% increase over the alternative. These systems have 120” x 60” or 160” x 60” work tables with 4700 IPM travel speed.

Recent developments in both L3 and L5 lasers have expanded the flexibility of these already versatile machines, allowing for processing of film-covered stainless steel. This adds to the lasers’ already broad list of capabilities, making them some of the most versatile, costefficient lasers available today. www.salvagninigroup.com

TRUMPF – TRULASER 5030 FIBER

With its featured 5kW TruDisk 5001 laser, the TruLaser 5030 is the most powerful 2D laser cutting machine available, cutting mild steel as deep as one inch at five times the speed of a similar CO2 machine.

It handles materials from mild steel and aluminum to ferrous materials like brass and copper and offers up to a 160 x 80-inch work area for large workpieces.

The TruLaser system utilizes tried-and-true methods to keep production swift, with a single cutting head strategy, automatic nozzle changer and use of standard cutting data. This, coupled with the benefits of a solid-state laser allow for flexible material processing. And with the option of Trumpf’s LiftMaster Compact and PartMaster, finished sheets can automatically be transported to be sorted with a minimal footprint. www.trumpf.com

BYSTRONIC – BYSPRINT FIBER 3015

Equipped with a Fiber 4000 laser, the is a 4kW fibre laser capable of processing steel in thicknesses previously reserved for CO2 operations. It handles materials from steel to copper and brass with precision. With a focal length of 150mm, the laser cutting head is able to cut both thick and thin material reliably.

Bystronic also offers additional components for their laser systems. The BySpeed Pro 3015 is a nozzle centring and automatic nozzle and lens cassette changer. Cutting with the optimum nozzle and lens ensures high quality parts and processing times. And with ByTower automated storage and retrieval system and the ByTrans load/unload system, it’s possible to run a mostly lights out laser operation with little hassle. http://www.bystronic.com/ 30 | FEBRUARY 2013 | www.canadianmetalworking.com

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MAZAK OPTRONICS – OPTIPLEX 3015 FIBER AND 3D FABRI GEAR MK II

Mazak recently introduced both the Optiplex 3015 in fibre and a more traditional 3D Fabri Gear Mk II. While many would still prefer CO2, the Optiplex 3015 is designed to complement Mazak CO2 offerings while providing fibre’s ease of handling reflective or thick materials at much higher speeds.

At 4kW, the Optiplex 3015 can cut up to 0.75” in CRS and has rapid traverse speeds at up to 4724 IPM. It utilizes the new Mazak PreView 2 CNC to provide a 15” touch screen interface that automatically determines the correct processing conditions for specified material.

The energy-efficient 3D Fabri Gear Mk II, available in both 2.5kW and 4kW, cuts a huge variety of parts, including most pipe shapes and is capable of handling I- and H-beans, C-channels, angle iron or any other user-specified shape in materials ranging from mild to stainless steel. Its 6-axis laser works in a vast number of applications, handling larger and thicker materials than most machines, and can even be used for drilling and tapping. www.mazaklaser.com

HYPERTHERM – HIINTENSITY FIBRE LASER

Hypertherm’s claim to have the industry’s “first complete fibre laser system specifically optimized for cutting applications” seems like a large promise to keep, but the HiIntensity fibre laser, now with offerings from 1kW to 3kW, can cut up to 0.78” in mild steel and over 0.3” in non-ferrous materials like copper.

And with cutting speeds reaching 1000 IPM in soft materials, it backs its claim with performance.

The HiIntensity line comes with pre-set optimizations for a wide range of materials and thicknesses to make operation easy and trouble-free. Its patented LF150 cutting head features integrated capacitive height control to make machine setup fast and easy. www.hypertherm.com

PRIMA POWER – PLATINO AND SYNCRONO FIBRE LASER

Prima Power’s Syncrono laser system boasts acceleration speeds exceeding 6G while cutting. With flying optics, the workpiece remains stationary throughout the entire process. It uses two separate cutting heads: 5” and 7.5” lenses working together to cut different depths in sync. The smaller head moves with minimal mass in small distances while the larger tool travels up to 118’ x 59’.

With a 2kW resonator, the Syncrono laser system is an ideal choice for a wide variety of sheet metal. An optional pallet switcher and workpiece loader help decrease machine downtime without sacrificing workpiece quality. And a 15” touchscreen with web technology and Windows OS enables easy setup.

Prima Power’s Platino fibre laser has been designed specifically for sheet metal processing, with up to 3kW in power and open access to the working area from three sides. The machine’s frame uses a synthetic granite frame for vibration dampening and thermal stability. www.primapower.com

AMADA CANADA – FOL3015AJ

Amada’s FOL-AJ laser system is a 4kW production fibre laser specifically optimized for cutting. While other companies offer 2D fibre laser options, Amada’s 4kW resonator allows for speeds and depths that exceed most other options, with thin material speeds at 2 to 3 times that of CO2 machines.

Touting cutting speeds up to 2,360 IPM, the FOL-AJ has the fastest traverse rate of any 5’ x 10’ machine available. And with three-way linear drives, wear common in other drive systems is eliminated. A shuttle table system allows workpiece setup to be externalized so the cutting process can continue without interference.

An automatic nozzle changer also quickens operation without manual switching. www.amada.com www.canadianmetalworking.com | FEBRUARY 2013 | 31

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ROFIN – UW 505F AND DC045 LASERS

Rofin’s UW 505F system is a 3D fibre laser solution to operations that would otherwise damage or deform parts. With easy programming, quick setup and high-speed processing, the UW 505F laser can finish parts quickly and accurately with a high-quality end product.

Rofin’s DC045 laser featured on the Adira LP-4020 has a 4.5kW resonator.

According to Adira Executive Vice Chairman, Francisco Cardoso Pinto, the decision was made to go with Rofin’s system because ‘they offer excellent design and performance.’ In recent years, Rofin’s improvements have led to significant increase in cut speed and pierce time. www.rofin.com

T

CINCINNATI – CL-900

Cincinnati Incorporated’s CL-900 fibre laser system combines solid-state laser technology with a 12,000 IPM linear drive system. It can cut thin steel at two to three times the speed of conventional CO2 with three times the efficiency. Since fibre brings more energy into the cutting area, intricate shapes and part designs in thin material can be processed much more quickly.

Cincinnati provides a PC-based HMI control with its Programming and Nesting software and offers an optional webcam to help monitor the machine. www.e-ci.com

LVD STRIPPIT – ELECTRA FL AND ALC SYSTEM

LVD Strippit added to its line this year with the Electra FL, a fibre laser system capable of cutting traditional metals as well as more difficult materials such as copper or brass. It boasts processing times of up to 50% faster than CO2 sources with wall-plug efficiency to 30%.

Designed from the ground up, the Electra FL takes full advantage of fibre laser benefits and includes an integrated shuttle table that loads another table while the machine is working. And with a 19” touch screen that incorporates a programming and nesting feature, the user is able to import parts directly into the control for cutting technology and nesting sheets to be applied.

Adaptive Laser Cutting (ALC) is LVD Strippit’s newest contribution to the machine intelligence field. It monitors and regulates laser power, speed and gas pressure in real time through a dynamic feedback system during the cutting process. www.lvdgroup.com

MITSUBISHI – 3015 NX-F FIBRE LASER

Mitsubishi has entered the fibre laser market with their 3015 NX-F machine.

It features a 125.9 x 62.9-inch work area and comes standard with fibre laser oscillator, a Z-axis linear drive, preset auto-focus processing, a 64-bit NC with 15” touch screen, as well as many other top-of-the-line features. It boasts 0.0019/20” positioning accuracy and 4724 IPM rapid traverse on their single axis offering, with rapid speeds up to 6680 IPM on simultaneous machines.

“This isn’t the first fibre laser, but we took the time in research and development to make sure that when we entered the market, we had it right,” said Bill Isaac, VP of Mitsubishi Laser. www.mitsubishi-world.com

L

32 | FEBRUARY 2013 | www.canadianmetalworking.com

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Keep it cutting!

Utilization rates are still relevant for profitable laser cutting

By Ken Lafleur, Amada Canada ..............................................................................................................................

The Amada FOL-AJ (FOL3015AJ pictured) is the first high-powered fibre laser designed for the sole purpose of cutting and features an advanced motion system to keep pace with the speed of the fibre resonator. The FOL-AJ consumes approximately one-third the energy of a 4kW CO2 laser with a beam wavelength one tenth of that produced by a gas laser. This allows dramatic increases in speed and expands capability to difficult to cut materials. A “No Lens Change” option eliminates the need for the operator to change the lens using “Adaptive Optics” technology. Amada supplies automated nesting software and training for all areas of Amada Products, including software and operator training.

T

he basic premise of keeping the machine cutting rather than sitting idle seems rather obvious, but it continues to be a relevant issue for many manufacturers and fabricators in Canada.

There is a lot of talk about fiber lasers and it is definitely the next generation in laser cutting machines. The main benefit of fiber lasers is the ability to process thin gauge materials at a very high rate. Amada has certainly recognized this and has invested considerably in developing this technology, so much so that in North America we have not sold our fiber laser without automation. This is because our customers have recognized that this machine’s capacity for productivity can only be utilized if the machine utilization rate stays as high as high as possible.

Basically, having a machine that can produce parts much faster than a CO2 laser that sits idle more, will cut into the benefit of this technology.

So the “keep it cutting” concept which applies to all lasers perhaps becomes even more important with new processing technologies. Here are key factors for high productivity:

customers to explore ways to reduce material handling time including investing in some automation.

MATERIAL HANDLING

C) Material type and thickness

According to studies CO2 lasers which have high speed shuttle tables average about a 65% utilization rate. So, I encourage

SETUP

Efficient Setups including clear setup instructions are important especially with less experienced operators.

A) Plan ahead

I encourage operators to setup for the next job/jobs while the machine is cutting. Amada machines have a pre-edit and schedule mode to allow operators to pull up programs and setup for the next job/jobs while the machine is running the current one.

B) Program name and folder location

Amada software, for example, can print a bar-code on the setup sheet which can be scanned, in order to call up the program/ programs automatically to avoid any confusion or errors in this process.

This information is provided by the program and calls up the appropriate cut conditions for the operator and can prompt the

34 | FEBRUARY 2013 | www.canadianmetalworking.com

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operator with this information so that he or she can ensure the correct material is loaded on the machine.

D) Lens focal length

Again based on the cut condition the operator can be prompted to install the appropriate lens.

E) Nozzle type and size

Once again based on the cut condition the operator can be prompted to install the appropriate nozzle. This too can be automated with an automatic nozzle changer which provides storage for nozzles and automated cleaning and exchange of nozzles.

F) Optimum processing speeds with consistent results

I know everyone wants to pierce and cut as fast as possible and you should, but you should not compromise the repeatability or the quality of the cut. If the pierce time and/or feed rate is maximized for 1 piece of material on a particular day and then the quality of the material changes (due to corrosion, for example), or the lens, mirrors, nozzles are not at peak performance condition, this can interfere with overall productivity as well as possibly wasting an expensive piece of material, or possibly some consumable parts.

High-efficiency machines monitor and adjust for variations to ensure successful piercing and cutting. This allows for optimum pierce times and cutting feed rates without the risks mentioned above.

PLANNED PREVENTATIVE MAINTENANCE

PM actually increases machine utilization rates and productivity by avoiding unexpected down-time. An appropriate level and commitment to support right here in Canada is important to ensure a customer’s machine is maintained properly and to minimize down-time.

GOOD PROGRAMMING TECHNIQUES

Programmers who frequently visit the shop floor to view the machine running and have discussions with the operators tend to have improved productivity and avoid unnecessary interruptions. In my opinion programming is the most important part of laser applications, and good programmers and operators should work together to ensure maximum productivity and machine and material utilization. For example, a well-placed micro-tab or simply cutting a slug into 2 can eliminate problems which can cause interruptions in processing. CM

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www.canadianmetalworking.com | FEBRUARY 2013 | 35

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Keeping Watch New software monitors 24/7 production

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

W

orried about downtime but not sure how long your machines are idle for? Keep forgetting when to do preventive maintenance on the machines in your shop? Want real-time data about the progress of work on your plant floor? Manufacturers and shop owners concerned about such matters might want to invest in hardware/software programs that offer 24/7 production monitoring.

One of the more prominent programs in this field is called ProductionACE and was created by Production Process, a company based in Londonderry, New Hampshire.

ProductionACE is “a combination of software and hardware—the hardware attaches to the machinery and collects information from there … then we have software … management uses it to track what’s going on on the floor,” says Tim Goyette, senior systems analyst at Production Process.

ProductionACE can be installed in a single facility or in multiple plants within a company.

Operator/machine interfaces called “Machine Data Transducers (MDTs)” gather production data from machines and transmit it to a central PC. This data includes machine downtime, the number of successfully completed parts, number of rejected parts, etc. Automating the production data

collection process eliminates errors and delays associated with manual data collection and transcription from shop workers.

Productivity data can be viewed in real-time on a connected PC, allowing shop staff to react instantly to problems, “rather than finding out some time later,” says Goyette.

Utilizing the ProductionACE system means a faulty machine “doesn’t sit idle for a couple of hours waiting for someone to go out there and do maintenance to it,” he adds.

REAL TIME DATA

A computerized “dashboard” utilizes colour codes to flag plant floor progress or issues that require attention, such as bottlenecks and slowdowns. Production data is stored, analyzed and used to create reports.

ProductionACE is designed for lights out manufacturing: “Most of our customers are running 24/7,” notes Goyette, adding that the system is “fully autonomous within each plant.”

“Ultimately, the purpose of getting a system like this is to get greater productivity on your shop floor. Make more widgets per day then you were before and have each one cost a little bit less,” he continues.

As Goyette notes, one of the most important keys to

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productivity is tracking machine downtime then reducing it.

ProductionACE excels at the former. The system can tell when a machine is running and when it’s down, and automatically makes precise records of work stoppages.

“Many manufacturers don’t really know how much downtime they are losing … when they find out, they can have changes to procedures or equipment or policies that recover that downtime,” says Goyette.

Goyette refers to “a metal stamping example” as he calls it, to illustrate his point.

“We had a customer who put in our system. One of the downtimes he had was reel charge—the [plant] would run out of metal. They didn’t know how much time they were losing— they just considered it a normal part [of daily operations]. They found out they were losing 16 hours a day to reel change. So we worked with them and put in an alarm, that would go off just before the reel was going to end ... they put a second coil out, so when the alarm went off, the operator went over and welded the coils together and ran them through. They were able to reduce their downtime from 16 hours a day to about an hour,” says Goyette.

Production Process claims that 5 – 15 percent productivity gains are common with users of their system.

ProductionACE can be programmed to issue customized email alerts. Users can stagger these alerts on a hierarchical basis, if they choose.

“If a machine has been down more than 10 minutes [the system] sends a message to the maintenance manager … after 20 minutes a message goes to a supervisor, after half-an-hour [a message goes] to the production manager, etc … and if you have a smart phone, it’ll actually ring your phone and let you know that machine number seven has been down for half-anhour,” says Goyette.

The system provides details about machine condition, OEE (overall equipment effectiveness) and can analyze the reasons behind downtime and rejected parts.

DOWNTIME REDUCED

ProductionACE also contains a Maintenance Scheduler function that automatically reminds operators when to perform preventive

A screen capture from the OMAX Intelli-VISOR system

maintenance duties, based on run time and cycle count. A Report Generator function, meanwhile, takes collected data to put together production reports, available after each shift if required. Said reports contain detailed information on downtime, production results, costs, etc. Data can also be used for historical reports, looking back over a period of days or years.

Another popular feature involves a so-called “Visual Job Queue”.

“You merely ‘drag and drop’ to insert jobs in the Job Queue and move jobs to each production machine. Then the system calculates accurate job completion dates based on production quantity scheduled, shift schedule, planned maintenance schedule, machine setup/change-over-time, individual machine or job-specific efficiencies, performance of currently running jobs,” explains Production Process literature.

The Visual Job Queue allows shop owners to give customers definitive dates for the completion of projects and work.

ant real-time data about the progress of work on your plant “ W floor? Shop owners might want to invest in hardware/software

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Production Process’ Production ACE system

Training requirements are minimal: “Most of our customers install the system with about an hour or two of training ... then it’s another two and four hours training, which we do remotely.

That’s about all they need,” says Goyette.

The ProductionACE system can be scaled up or down depending on the size of the facility.

“We have very low-priced options … if a plant only has a couple of machines, they can get a system for less than $10,000,” says Goyette.

PIECE OF MIND – AND DOLLARS

A system for a medium or large-sized enterprise might range between $10 – 50,000, with systems for the largest firms ranging between $70 – 80,000.

At present, about 700 companies — primarily in the United States — use ProductionACE. The system is particularly common in the plastics and metal industries. Big name users include Kennametal, Siemens and The Gillette Company.

The Intelli-VISOR System Monitoring Package by waterjet manufacturer OMAX of Kent, Washington state is similar to ProductionACE but intended only for use in waterjet facilities.

The system enables shops using waterjets for cutting purposes to operate in lights out fashion.

The Intelli-VISOR System collects real-time production data from a machine sensor network set up inside waterjet shops and transmits it to a computer. The Intelli-VISOR System offers an automated maintenance tracking function that alerts operators via email or text message about necessary preventive maintenance operations. A pump monitoring function keeps watch on

the pumps “to see if any abnormal actions are going on,” says Mark Trimper, senior regional manager, OMAX. The pump function monitors pressure, water temperature, water supply, etc. If a pump fault is detected or water pressure is off, the system can automatically pause machine operations.

Another function offers feedback on abrasive levels to manage supply.

“The heart of the Intelli-VISOR System Monitoring Package is its Modules. Modules are custom-programmed parameters that gather data from the sensor suite and process it according to the limits set by the user. When a limit is reached, the Module logs the data and can send an alert to the controller PC, an email address or a cell phone text message. The Modules can also pause the machine to protect the cutting head and the part being cut,” reads company literature.

The full Intelli-VISOR Package costs around $9,000, and, like ProductionACE, is user-friendly, says Trimper.

While greater productivity is the stated goal, what production monitoring systems such as ProductionACE and IntelliVISOR really provide is peace-of-mind.

“If you have an error somewhere or there is something in the equipment that fails for whatever reason … you have the ability for immediate shutdown … sometimes material is in there that is very expensive … things do happen … if you have the ability to save that material or save that particular part or project you’re working on, that means dollars,” says Trimper.

Website info: Omax – www.omax.com/waterjets/omax-intelli-visor CM Production Process – www.productionprocess.com

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New Horizons for Horizontals

Productivity takes centre stage for horizontal turning centre technology

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

W

hen asked to comment on trends in the manufacture or use of horizontal turning centers, Brad Devon, sales manager at machine tool builder Hardinge in Elmira, New York, turns the conversation to the economy.

“The machine tool market as a whole has seen tougher tolerance requirements each year. Hardinge feels that these demands will continue, especially in North America. Jobs that were typical 2-axis turning jobs have become less prevalent and are more difficult to keep a business profitable when competing with foreign companies that enjoy lower labour rates and overall costs. Hardinge feels the manufacturing future in America will be [based on] complex parts that have smaller lot

sizes and fit into the lean/Six Sigma manufacturing concepts,” says Devon.

Milton Ramirez, product technical specialist, turning centers for machine tool maker Haas Automation, based in Oxnard, California, offers a more micro-level analysis.

“In terms of turning techniques, there have been recent improvements in turning inserts technology that have helped improve productivity ... lighter, modern, better designed machines, when combined with the latest insert technology, make for very efficient machining,” notes Ramirez.

Here’s a look at what’s new and/or noteworthy in horizontal turning centers: 10-inch chuck, a spindle speed of 4,000 rpm, bar capacity of 2.5 inches (65 mm), maximum machining diameter of 12.35 inches (313.7 mm) and maximum machining length of 22.47 inches (570.7 mm) with tailstock and BMT. It takes up 91.04 inches x 12.23 inches (2,312.4 mm x 3,257 mm) of floor space and weighs approximately 17,900 (8,118 kg). www.hardingeus.com

STREAMLINED DESIGN AND FLEXIBLE CONTROL

REINFORCED BASES AND HEAVY-DUTY MOTORS

At IMTS 2012, Hardinge unveiled the T-51 and T-65—two new Super-Precision T-Series turning centers. “[For these lathes] Hardinge reintroduced their 45-degree cast iron base, reinforced with Harcrete, that was absent from their Super-Precision models. Hardinge also introduced new heavy-duty integral motors on both main and sub spindles along with a patented BMT tooling design. Their T-series controls were upgraded to a state of the art 3liFANUC control with a .00001 inch program resolution,” says Devon.

Harcrete is a polymer composite reinforcement developed

by Hardinge.

Machines in the T-Series “are ideal for two axis high precision machining or complex multi-tasking operations that require a high level of precision, delicate part handling and for parts made complete in a single setup,” states Hardinge information.

The T-51 has a top spindle speed of 5,000 rpm, 12 turret stations (standard), an 8-inch chuck, a bar capacity of two inches (51 mm), a maximum machining diameter of 12.35 inches (313.7 mm) and maximum machining length of 22.47 inches (570.7 mm) with tailstock and BMT. The center takes up 91.04 inches x 12.23 inches (2,312.4 mm x 3,257mm) of floor space and weighs approximately 17,900 (8,118 kg).

The T-65, meanwhile, also has 12 turret stations (standard),

Indianapolis, Indiana-based machine tool maker Hurco showed off their latest turning center, the TMX8MYSi at IMTS 2012.

Turning centers in this line “feature a streamlined design and WinMax9 control software. The most notable feature, which is central to fulfilling our mission to help shops increase profitability through increased productivity, is the integrated Hurco control. The control can be programmed on the shop floor with Hurco’s patented conversational programming or industry standard NC. No other control offers the level of flexibility that the Hurco integrated control provides,” says Maggie Smith, Hurco media relations manager.

“Some popular features of the Hurco control include 3D Verification Graphics that display half and quarter views with semi-transparency to see more of the toolpath information especially inside the part, which means wasted materials and

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machine crashes are virtually eliminated ... a feature called Auto Tool Nose Radius Compensation eliminates the need to use trigonometry to compensate for the tool nose radius on start and end positions of the toolpath,” adds Smith.

The TMX8MYSi has an X, Z, W, Y axis travel of 8 x 22 x 25.2 x 4.4 inches (203 x 560 x 640 x 110 mm). Maximum turning diameter is 13.2 inches (336 mm), maximum turning length is 20.75 inches (527 mm) and maximum bar capacity is 2.5 inches (64 mm). The center has a 12 station tool capacity, chuck diameter of 8 inches (203 mm) and a spindle capable of 37.3 hp (27.8 kW).

Rapid traverse X, Z, W, Y axis is 945, 1,181, 1,181, 472 in/min (24, 30, 30, 12 m/min). The center is 102.2 inches (2,597 mm) high, takes up 224.4 x 120 inches (5,700 x 3,048 mm) of floor space and weighs 14,520 pounds (6,600 kilograms). www.elliottmachinery.com

BUILT-IN OFF-CENTRE FEATURE MACHINING

Haas Automation describes the ST-10Y as a “small footprint Y-axis turning center.”

The “Y-axis provides four inches of travel (+/- 2 inches from the spindle centerline) for off-center milling, drilling and tapping. Because the Y-axis provides interpolated motion on the G17 and G19 planes, it’s possible to use built-in canned cycles for such off-center feature machining as radial and axial drilling, boring, tapping and grooving ... most importantly it allows for three-dimensional motion for the helical interpolation required for thread milling and pocket milling. The major advantage of Y-axis is the fact that what used to take three or four set-ups to make and a lathe and a mill now can be done in one set-up and one operation which increases accuracy, throughput and

decreases work in process on the floor” says Ramirez.

Standard equipment on this turning center includes hightorque live tooling with C axis, rigid tapping, spindle orientation, a 15 inch colour LCD monitor and a USB port. Options available for a high-production setting include a belt-type chip conveyor, manual tailstock with hydraulic quill, automatic parts catcher, automatic tool probe, etc.

The ST-10Y has a maximum cutting capacity of 9 inches x 14 inches with a swing of 16.25 inches over the cross side. It comes with a 6.5 inch hydraulic 3-jaw chuck and a 12 station VDI turret.

The ST-10Y’s A2-5 spindle nose boasts a 2.31 inch spindle bore and a bar capacity of 1.75 inches. The machine’s 15 hp vector dual-drive spindle can turn to 6,000 rpm and put out 75 ft-lb of torque. www.haascnc.com

INTRODUCING...

MACHINE TOOL SOLUTIONS Toronto - 905.565.8888 - 1.888.565.8807 - Montreal - 514.333.0717 - 1.888.595.5157 - Email: info@megatelcnc.com Web: megatelcnc.com

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HIGH RIGIDITY FOR HEAVY CUTS

In October, 2012, Methods Machine Tools, a Sudbury, Massachusetts based machine tool supplier, introduced the Feeler FT-Series High Performance CNC Turning Centers.

“For exceptional rigidity when performing heavy duty cutting, each of the models has a single-piece structure with boxways, 45 degree slant bed and robust base ... additional new design features include a more rigid Z-axis and tailstock rail for maximum support and accurate tracking. The FT-Series includes a new spindle head stock with a Feeler sleeve-type spindle and the latest high-rigidity servo turret including clamping with curvic coupling for stable and swift tool changes. For excellent multi-tasking capabilities, 7 ½ hp milling motor with 51.6ft-ld torque is provided,” reads a Methods press release.

Four different gear boxes and two spindle types are available for turning centers in the FT-Series.

Spindles in the FT-Series range from 2,500 rpm to 4,500 rpm. Chuck diameters range from 8 inches (210 mm) to 15 inches (381 mm), while bar capacity goes from 2.6 inches (65 mm) to 4.5 inches (115 mm). The maximum turning diameter ranges from 13.0 inches (330 mm) to 25.0 inches (620 mm), with maximum turning length ranging from 21 inches (530 mm) to 60.2 inches (1,530 mm). The machine can weigh anything from 9,925 pounds (4,500 kg) to 21,500 pounds (9,750 kg) depending on the model.

Feeler machines are manufactured by Fair Friend Group (FFG), a machine tool builder with operations in Taiwan, China, Japan and the United States.

“Right now, there’s four centers [in the FT-Series]—FT-200, FT-250, FT-350 and FT-350L, which is the long bed version.

We’re expanding to a 500, 500L and a 600 ... by the mid-point of [2013], we should have the 500 size machine done,” says Rich Parenteau, director of applications at Methods. www.methodsmachine.com

(upper) mm (in) of Ø 340 (13.38) and maximum turning diameter (lower) mm (in) of Ø 220 (8.66). The lathe is recommended for service in the auto manufacturing sector and can also be used for hobbing, says Fischer.

Okuma also recently unveiled the LT3000EX, a two-spindle CNC lathe, with either two (standard) or three turrets (optional) that can also be used in high production environments.

“The LT family of machines is ideal for the machining of parts where every second counts. With two opposing spindles, two or three 16 station turrets, this machine has the capacity to produce complex parts in a minimum of time. [Utilizing] Okuma’s user-friendly OSP P300-L control, the LT has the same advantages as the LU3000EX. A single program, the use of P-codes for synchronization and the way all turret/spindle combinations are programmed from the left spindle/upper turret perspective makes it easier to harness the power of this machine,” says Fischer.

The LT3000EX has a maximum turning diameter of Ø 13.77 in (350 mm), 8-inch chuck class and speed range of 45~5,000 rpm (45~4,200 rpm optional). www.okuma.com

P-CODE SYNCHRONIZATION FOR SIMPLICITY

The 4-axis LU3000EX is the latest update in machine tool maker Okuma’s LU series of horizontal lathes.

“Improvements include larger spindle bores, bolt-on milling tools and the latest Okuma control, the OSP P300-L. This machine is ideal for high production work or on parts that require the removal of large amounts of material,” says David Fischer, lathe product specialist, Okuma America Corporation, which is based in Charlotte, North Carolina with a parent firm in Japan.

“Okuma uses a single program for both turrets where most other 4-axis machines require two programs—one per turret.

Okuma uses P-codes to synchronize the turrets instead of M-codes making the synchronization of programs easier to manage,” adds Fischer.

The LU3000EX has a maximum diameter of 13.38 inches, maximum length of 23.62 inches, maximum turning diameter

MULTI-PROCESS PRODUCTION TURNING

The Doosan Puma TT1800SY features twin turrets and opposed spindles for multi-process mass production turning. With a fast z-axis traverse of 40m/min and optional bar feeders, gantry and part unloaders, the TT1800SY is optimized for speed. Both spindles have 5000rpm speed and can handle part diameters of 230mm on each turret. Part length up to 980mm can be accommodated. Both turrets mount up to 12 tools and a large variety of optional accessories from automatic measuring equipment to oil skimmers are available. www.ferrotechnique.com Ontario-east www.mooreindustiral.com Manitoba-west www.painemachine.com British Columbia CM

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RIGID, POWERFUL TURNING

FOUR-SPINDLE TURNING CENTRE HAS MULTIPLE WORK MODES

Kitako-Shimada’s four spindle allows continuous indexing for high productivity. When the carrier is indexed 180 degrees, two spindles/parts move from the loading zone to the machining zone. At the same time, the other two spindles/parts move from the machining zone to the loading zone. As two parts are being machined, two new parts are being loaded. This continuous indexing is similar to that of a pallet changer on a machining center, but can take as little as two seconds to complete. The spindles, slides, and turrets work independently and simultaneously for “operation matching” flexibility.

Spindle rigidity and positioning are ensured by the use of a large diameter, precision-toothed curvic coupling. The solid headstock, bed, and box shaped ways, over-sized ball-screws and servo motors, and robust turrets are all designed to perform heavy cutting with impressive chip removal rates. www.smsmachine.com

The SC-450L from Nakamura-Tome turns parts up to 1520mm in length with a swing of 810mm, allowing a part of 5200mm diameter. The SC-450L uses an NC-driven tailstock and has a 12-station turret. Motors with 30/22kW power cut easily and a massive 45-degree slant bed adds rigidity. Box-type slides and an extra rigid turret offer high accuracy and precision. “Non-lift” turret indexing technology cuts idle time for maximum productivity. www.elliottmachinery.com

ACCURACY WITH HIGH MANUFACTURING PRODUCTIVITY

MILLING AND TURNING IN SINGLE SETUPS

The Mazak QUICK TURN NEXUS Series brings together advanced technology, productivity and value to deliver exceptional performance for shops large and small. The series delivers MultiTasking capability with milling and turning in single part setups.

Power and speed is increased in virtually every category. The machines come equipped with the Matrix CNC control, featuring simple, smart conversational programming, complete with monitoring and diagnostics. The series features main turning spindles from 15-40 HP and a second spindle for back-side finishing of parts is available on most models. Other available technologies include Y-axis milling capability, servo tailstock, double turrets and gantry robots for unmanned operation. www.mazakcanada.ca

The DMG/Mori Seki NLX series, impresses with excellent precision and fast machining speeds in a high power density compact design requiring little floor space.

The NLX series’ thermo-symmetrical design and high stability minimises undesired vibrations while the thermal properties of the turning machines are additionally optimised by the integrated cooling system in the machine bed. Liquid circulates through the casting to keep the temperature constant and to eliminate thermal irregularities. The dynamic process precision also benefits from wide guideways in all axes. BMT technology, with which rotating tools are driven by an integrated motor in the turret, reduces heat, which increases accuracy. The system also minimises vibrations and improves the transmission efficiency, which significantly and increases milling performance and speed. The tool turret provides space for 10 or optionally 12 tools with a unique option to use corner milling tools. The NLX2500SY/700 model provides a counter spindle as well as the benefits of an integrated Y-axis. The turning length is 705 mm, with a diameter of 366 mm. Bar loading can be machined at a diameter of 80 mm – for traverse paths in X- and Z-axis of 260 or 795 mm respectively. NLX series machines are controlled by the MAPPS IV system with a 10.4“-TFT display. The Esprit CAM module is an available option.

CM www.ca-en.dmg.com

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Tool Talk

T

DMG/MORI SEIKI USA HOST GRAND OPENING OF THEIR NEW FACILITY

DMG / Mori Seiki USA marked the Grand Opening of the Mori Seiki Manufacturing on November 7, 2012 with a ceremonial ribbon cutting at the Davis, CA plant.

O

n November 7, DMG Mori Seiki held a ribbon cutting and grand opening at their new facility in Davis, California.

Company President Dr. Masahiko Mori addressed key members of the local government, manufacturing community, and press at the event.

At IMTS 2012 in Chicago company officials expressed optimism that manufacturing would return to North America. At the opening of the new factory (which is the company’s first in the U.S.) they discussed how it would be a resource for more than just machine tools. The facility is also meant to be a venue for general manufacturing concerns, such as factory automation.

In addition to the ceremonial ribbon cutting, behind‐the‐ scenes tours of the factory gave a glimpse inside the $50 million state‐of‐the‐art facility.

Robert Dunbar, the vice president of Ellison Technologies, praised the arrival of the new facility by saying, “It’s certainly an advantage… it allows us to take customers to the facility to show things off, and discuss things on this continent as opposed to having to go to Japan.”

The machines being built are the Mori Seiki NHX4000, NHX5000, and NHX5500. Production started in July of 2012 and current capacity is 80 units per month. CM 46 | FEBRUARY 2013 | www.canadianmetalworking.com

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Tool Talk MAZAK RESTRUCTURES SALES RESPONSIBILITIES IN ONTARIO Company makes changes to operations to meet the needs of province’s manufacturers.

T

he Mazak Corporation has assumed all sales responsibilities in Ontario. The decision, which went into effect at the beginning of December, will allow Mazak to work more closely with the province’s customers and provide service geared specifically toward Ontario manufacturers.

Ray Buxton, general manager of Mazak Corporation Canada Headquarters and Technology Centre, has said the change allows Mazak to better interact with customers in Ontario’s automotive and aerospace sectors.

“These industries often involve highly complex projects requiring very sophisticated machines and systems. In working even more closely with Mazak on such projects, our customers gain every possible advantage from the company’s advanced and innovative technologies and its manufacturing support network,” stated Buxton.

In other provinces Mazak will continue to use its distributor network of Machine Toolworks Inc. and A.W. Miller Canada.

In addition, the company has also announced a new seven-member sales team that will serve its customer base in Ontario. The team will include both existing staff members and three recently hired sales professionals: Bob Kanarek, Martin Craven and Darcy Ball.

The sales team will be based out of Mazak’s Canada Headquarters and Technology Centre in Cambridge, Ontario – one of eight regional technology centres that Mazak operates in North America.

Mazak will also be hosting a series of events at their Cambridge facility throughout the year with the first taking place on March 1st.

For more information visit: www.mazakcanada.ca

Mazak Corporation’s new headquarters in Ontario.

@MazakCorp

Visit Canadian Metalworking online: www.canadianmetalworking.com follow us on twitter: @CdnMetalworking visit us on facebook: www.facebook.com/pages/ Canadian-Metalworking-Magazine www.canadianmetalworking.com | FEBRUARY 2013 | 47

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Tool Talk KENNAMETAL EXTEND KSEM PLUS PRODUCT LINE WITH B1 HEADS

MAKINO RELEASES NEW EDBV3 FAST-HOLE DRILL EDM

Kennametal is expanding its KSEM PLUS range by introducing new KSEM PLUS B1 Heads with DFC guiding pads to deliver reduced cost per hole in difficult drilling conditions.

The KSEM PLUSTM modular system combines the benefits of the KSEMTM modular drill (high feeds and length-to-diameter [L/D] ratios) with the benefits of an indexable drill (high speeds and low consumable costs).

The B1 Heads can drill through stacked materials, inclined exits, cross holes, and interrupted cut conditions. The new pads give the KSEM PLUS B1 Heads accurate guidance of the head when drilling through cross holes with widths up to 50 per cent of the drill’s diameter. They also eliminate spiral marks and grooves and enable high-quality hole exits for reliable drilling from two sides when indexing drilling directions.

KSEM PLUS B1 Heads offer two effective cutting edges that work well at high feed rates to reduce the load per edge, compensate for radial forces, and prevent disk build up with only two chips per edge. They are available in standard sized from 28–70mm and customized solutions from 28–127mm. www.kennametal.com

Makino has announced the release of their new EDBV3 Fast Hole Drill EDM, which is designed for discharge machining of cooling air holes and shaped diffuser holes in blade and vane segments. A wide range of hole shapes and sizes can be created within a single set-up, which helps reduce the required tool variety and overall cycle times.

All EDM drilling on the EDBV3 is performed fully submerged under water for higher part quality, improved stability and faster processing speeds.

The machine uses a singleelectrode processing approach, which reduces cost compared to custom multi-electrode holders and standardizes the tool holders with a more flexible system. For unattended burning of varying cooling hole diameters, the machine uses automatic tool change (ATC) and automatic guide change (AGC) systems.

The EDBV3 uses a rigid guide-arm assembly to hold, locate and support the die guide, which can be alternately used as a programmable axis (W-axis). An integrated “middle-guide”

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

Tools are stocked uncoated and ALTiN coated.

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

Solid carbide grooving, boring and threading tools.

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

Threadmills

Available in coated AlTiN or uncoated sub micrograin carbide

Port tools

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

Low profile screw keeps chips flowing

SCIENTIFIC CUTTING TOOLS, INC. 110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com 48 | FEBRUARY 2013 | www.canadianmetalworking.com

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Tool Talk system can be applied for small-diameter electrodes, preventing whipping, bending and vibration. Additionally, the middle-guide “fingers” automatically retract as the electrode tube reduces in size, using as much of the electrode length as possible.

The standard configuration of the EDBV3 includes a 24-station tool carousel system and 24 holder assemblies to fully tool up the machine. The tool carousel can be exchanged as a palletized magazine for extended hours of automated operation.

Brian Pfluger, Makino’s EDM product line manager said of the new machine, “The need for EDM drilling with advanced capabilities in blade and vane components has grown substantially due to new engine production requirements, as aerospace manufacturers strive to improve engine performance and reduce fuel consumption.”

“Its 2-axis rotary table combined with automatic tool and guide change systems enable manufacturers to reliably machine complex features fully unattended.”

For more information visit: www.makino.com

At higher coolant pressures, above ~30 bars (435 psi), the new insert geometry collects the coolant jets to form an even, powerful wedge that breaks the chips, cools the insert and improves the insert tool life.

Until now the technology had primarily been a solution for customers using quick change with Coromant Capto, SL- and QS holding systems. Now, the same technology can be applied with general shank tools, making it possible for everyone working with wet machining to use this coolant solution, even in small lathes. www.sandvik.com CM

SANDVIK COROMANT RELEASES NEW RANGE OF TOOL HOLDERS

Sandvik Coromant has introduced a range of new insert geometries and customized tool holders that feature fixed nozzles for coolant jet flow. This helps ensure that coolant gets right to the centre of the cutting zone.

By focusing on the cutting zone a wedge of coolant is produced that efficiently removes the heat from the cutting zone and forms the chip. Two benefits are improved chip control and longer tool life, which contribute to secure, predictable machining and help prevent machine stoppages.

Increased productivity can even be achieved in tricky applications and in materials, which are difficult to machine, regardless of the pressure you use. www.canadianmetalworking.com | FEBRUARY 2013 | 49

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Milling Cutters Get Edgy New cutting tools for new processes minimize waste and maximize productivity

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

“T

Courtesy Data Flute

he biggest trend in milling has been increasing the number of cutting edges to help reduce cost. The products we have been releasing over the past few years have addressed this need while maintaining high performance machining. Machine tools continue to get faster while maintaining rigidity, allowing for higher metal removal rates,” says Todd Miller, manager of rotating products for the U.S. branch of Swedish tool giant Seco, in Troy, Michigan.

“There is also a new trend when machining with solid carbide.

There are multiple names for it, Trochoidal milling, peel milling or volume milling. This principle is similar to high feed machining because it also takes advantage of average chip thickness principles.

The difference with this method, you use the entire flute length with a light radial depth of cut. It generates less forces and heat which increases tool life, while increasing metal removal rates,” he adds.

Minimizing waste is also on the mind of trend-spotting Wolfgang Ruff, vice-president of engineering at Komet of America.

“The aerospace industry is talking about ‘near-net shape’ where, instead of milling large and thick solid pieces and removing large quantities of material to make a finished part, they are looking at reducing the “buy-to-fly” ratio—i.e., minimizing waste and material removed by working from thinner pieces,” says Ruff, whose company is based in Schaumburg, Illinois and has a German parent firm.

There is a “need for miniature high performance tools to address the growing micro machining industry … as tools become

smaller it becomes more difficult to incorporate the unique geometries of high performance end mills,” adds Jason Wells, product manager for the SGS Tool Company in Munroe Falls, Ohio.

Here’s a look at what’s new and/or noteworthy in milling cutters:

SANDVIK COROMANT

Swedish tool giant Sandvik Coromant released the CoroMill Plura 1 Series and CoroMill Plura 2 Series end mills in 2012.

“The CoroMill 1-Series is the offering for customers with requirements on high performance end mills, without the complication of having many different tools. The tools are optimized for versatility in multi-materials. Benefits to customers include reduction of set-up time between batches, rationalization of tool stock, having a general set-up in the machine, high flexibility and less optimized tooling,” says Kevin Burton, product and application manager milling products, at Sandvik’s Canadian headquarters in Mississauga, Ontario.

“The CoroMill 2 Series is offered where the demand is for optimized performance in specific materials, where a superior performance is required ... some specific areas where the performance is outstanding are: ISO-H hardened material, ISO-S HRSA (Heat resistant super alloys) and titanium, ISO-M stainless steels, etc.,” he continues.

The CoroMill 357, meanwhile “is a new addition to our Heavy Duty Face Milling offer. It’s a new 10 edge face milling cutter for roughing and cubing in mainly ISO P and ISO K materials,” says Burton.

The CoroMill 357 offers a secure cutter body design with shim protected insert tip seats and an insert clamping system designed for quick and easy indexing and changing of inserts. www.sandvik.coromant.com

WALTER USA

Walter USA, the Waukesha, Wisconsin-based branch of a German parent firm, has released two shoulder mills in the new Blaxx line. This line features “groundbreaking” shoulder mills that offer precision, high metal removal rates and process reliability in a single tool, according to the company.

The F5041 and F5141 Blaxx shoulder mills boast precise indexable insert pockets and Tiger-tec

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Courtesy OSG

Silver coating. This high-performance coating is designed to enhance tool life and boost productivity. The shoulder mills are available with diameters starting at 25 mm.

Walter USA will be releasing more Blaxx milling cutters in 2013, adds Thomas Benjamin, manager of product marketing for Walter USA. www.walter-tools.com

SECO TOOLS

In the fall of 2011, Seco Tools updated its Sq6 (Square 6) shoulder milling cutters, which offer six cutting edges and a true 90-degree shoulder.

“Customers are always looking for ways to reduce cost and an increased number of cutting edges is a direct reduction in cost. Not only do [machinists] get extra cutting edges, but

win &

the design of this negative style cutter, which incorporates positive cutting geometry, allows for increased performance and smooth cutting action,” says Miller.

The update involved the introduction of “a smaller insert called Square 6 - 04. It has all the same features as the Square 6 - 08 but with a diameter range from 0.75 inches - 2.5 inches,” continues Miller.

In February, 2013, Seco will be releasing a “high feed version of the Double Octomill … [and] MK2050, a new high performance, secure grade for milling cast iron,” he adds. www.secotools.com

KOMET

Komet of America is proud of their unique JEL PCD (Polycrystalline diamond) milling cutters.

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“The JEL PCD milling cutters come in two styles: a face milling cutter and a slot milling cutter. They are both designed to fit into a coolant-through heavy metal adapter which features a cylindrical shank and a screw-on connection. This connection essentially transforms the tool into a modular system which we believe no competitor offers for PCD tools at the present time,” says Ruff.

“The heavy metal dampening adapter eliminates vibration issues common with high-speed milling and is offered in a wide variety of lengths for each diameter. The slot milling cutter, which can be used for milling and plunge milling, is offered in diameters from 10 to 25 mm while the face milling cutter comes in diameters from 10 to 32 mm,” Ruff continues. www.komet.com

OSG

In late 2011, OSG Canada of Burlington, Ontario unveiled the new Phoenix Indexable Carbide Cutting Tools Series.

“The initial offering consisted of four main product groups: the Phoenix PSE, Phoenix PRC, Phoenix PHC and Phoenix PFB, each of which provides a solution to a particular niche of the indexable milling market,” explains Sam Joynt, a technical sales manager at OSG Canada, which has a Japanese parent company.

“The Phoenix-PSE series offers 90-degree end mills and face mills for square shoulder milling applications … the Phoenix PRC series offers round insert end mills for multiple milling applications including face milling, helical milling and 3D rough milling … the Phoenix PHC high feed end mills and face mills offer optimal metal removal rates in a variety of milling applications including pocketing, helical milling, face milling and 3D rough milling … the Phoenix PFB series offers indexable ballnose end mills for superior tool life and work piece finish in semi-finishing and finishing applications,” states Joynt. www.osgcanada.com

ISCAR

Israeli tool firm Iscar unveiled its new “IQ” line at IMTS 2012 in Chicago.

“It’s all new products. It’s a new way of thinking of machining, really. What it stands for is ‘intelligent machining’,” explains Tom Hagan, milling product manager Iscar’s Canadian headquarters in Oakville, Ontario.

The HeliIQMill 390 cutter comes with triangular inserts that have three helical cutting edges.

“The new family ensures productive milling of true 90 degree shoulders, providing an improved cost per cutting edge for various milling applications. The new HeliIQMill tools are available for inserts with 10 and 15 mm cutting edge lengths,” states Iscar literature.

The DoveIQMill 845 line, meanwhile, are indexable face mills. The IQ845 FSY...-R07 mills feature IQ845 SYHU 0704 square double-sided inserts with eight cutting edges. These face mills can machine up to a 4.6 mm depth of cut and are available in a nominal diameter range of 50 to 160 mm in coarse and fine-pitch configurations.

Other new ISCAR mills include the MillShred P290 line.

This 90 degree line of shred milling tools is based on the P290 ACKT 1806PDR-FW and P290 ACKT 1806PDR-FWE serrated

cutting edged inserts. MillShred tools are “ideal” for machining deep cavities, as chips can be removed easily from the machining zone, says Iscar.

Milling cutters in the IQ line “increase the output of [our customer’s] production, so they can maintain competitiveness in the market and improve their overall return on profit.

It all comes down to … cost per part. If the customer can produce more parts he is able to increase his production capacity,” continues Hagan. www.iscar.ca

SGS

In April, 2012, SGS released its new Multi-Carb end mill, available with seven, nine or 11 flutes.

“The Multi-Carb is an engineered geometry optimized for high feed finishing in challenging materials such as titanium and stainless steel. The design incorporates an odd number of flutes for reduced harmonics and better cutter engagement during the cut. The balanced design makes it optimal for smooth operation at aggressive parameters,” says SGS product manager Jason Wells.

Ideal applications for the Multi-Carb include aerospace structure components, ferrous housings, pumps and manifolds, defence applications and medical components, says SGS. SGS has big plans for the future: “SGS will be completely rebuilding its long time line of roughing mils with high performance versions” and also plans on “introducing a unique end mill for plunging and pocketing in stainless steel materials,” reports Wells. www.sgstool.com

DATA FLUTE

Data Flute of Pittsfield, Massachusetts released the new Triple Threat line of solid carbide endmills at IMTS 2012 in Chicago.

The tool boasts a three flute design with patented geometries and is aimed at finishing and roughing operations in aluminum and non-ferrous metals. The high shear, 45 degree helix and inter-flute geometries boost chip evacuation and feed rates.

Daniel Holmes, Data Flute’s Canadian sales director, says Triple Threat fills a need: “With feedback from the market in aluminum machining, we at Data Flute realized there was a void in tools that would allow customers with 8,000- 12,000 rpm machines get maximum material removal without sacrificing tool life. The Triple Threat line of tools now provides high performance to large companies running very expensive, high-speed machining centers, as well as the gent in a local shop. This tool will shine on a broad range of CNC machining centers and will provide high performance across the board.”

The tool has been winning kudos from users.

“I have been consistently impressed with the performance of Data Flute’s Triple Threat in aluminum. The tool responds exceptionally well in demanding situations where the cutting length is buried, even with radial engagements above 75 per cent. Chip evacuation is excellent even at these very high MMR rates. I have not seen any evidence of chip jamming, part marking or any other evacuation issues,” says Ian Candolini, applications engineer for the Canadian branch of Japanese machine tool firm Makino, in Mississauga, Ontario. www.dataflute.com CM

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Countdown to CMTS 2013 — Expect More

E Kevin O’Leary delivered the keynote speech at the 2011 edition of CMTS, but SME won’t reveal their big plans for 2013 just yet.

T

he Canadian Manufacturing Technology Show (CMTS) — Canada’s National Manufacturing Event is returning to the International Centre in Mississauga. Just minutes from Toronto’s Pearson International Airport, the event will be held this fall — September 30 – October 3, 2013. The event producer, the Society of Manufacturing Engineers (SME), is touting the tagline ‘expect more’, as Canada’s manufacturing community continues to buzz about the dynamic changes coming to the show.

“The market response of CMTS returning to the International Centre has been overwhelmingly positive and exciting for our team at SME,” says Event Manager, Julie Pike.

“While we’re still about eight months away from the event, we’ve already had to expand our hall space and we’re more than 80 per cent sold out. We know that listening to our customers — both exhibitors and attendees — was the best decision we could have made for CMTS and we couldn’t be more thrilled,” Pike added.

After 14 years of locating CMTS in downtown Toronto, visitors and exhibitors should expect big changes to Canada’s largest and most respected manufacturing event. At its core, the show brings together more than 10,000 manufacturing professionals over four days to source the latest advancements in technologies and solutions in the machine tool, tooling, metal forming and fabricating, automation, design engineering, and plant management segments. The event also draws a growing national and international audience from other major

industries including automotive, aerospace, medical, and energy, among others.

EXPECT MORE…

Among the changes to CMTS, participants can expect more social and networking activities. Imagine a European feel and ambiance. The return to the airport venue has allowed SME the opportunity to create an outdoor area connecting the exhibit halls and providing a meeting and socializing area reminiscent of the traditional ‘messe-style’ hospitality tent. Exhibitors and visitors can relax, grab a drink, a bite, listen to live music, and network with peers under the tent.

And if you’re looking for a more formal business setting to meet with prospects, customers, and peers, the SME team is creating an upscale interactive networking experience that promises to be the talk of CMTS for years to come. “We’ve been working on a monumental new element for CMTS that is like nothing we’ve ever done before,” Pike commented. “Mum’s the word for now on specifics, but we expect to begin teasing the marketplace by early spring”.

Watch for regular updates in Canadian Metalworking as we ‘countdown’ to CMTS and share exciting announcements and highlights in future issues. For the latest event news, or to find information on exhibiting, attending or sponsoring at CMTS, visit the newly re-launched CMTS website — www.cmts.ca or contact Julie Pike, Event Manager, at 888-322-7333, ext. 4471 or jpike@sme.org CM

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M

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The Business of Metalworking The evolution of the chip-breaker The humble origins of an important advancement in cutting technology

by John Mitchell.....................................................................................................................

N

ot that long ago inserts had no chip breakers. All inserts were flat tops. This created a lot of issues with chip control. Turning was a particular issue, since in many cases turning was a continuous operation and created long, stringy chips. On the other hand milling was considered an interrupted cut and chips were not as long as turning due to the insert only cutting for half of a revolution. Naturally, turning inserts were the first to be developed with chip-breakers. The primary function of these early chip-breakers was to curl the chip and force it to break. However, the only chip-breakers available were “G” type. For example CNMG, TNMG, SNMG etc.

Cutting forces were generally controlled by the rake angles of the cutter. That is axial rake and radial rake. These rake angles were built into the cutter bodies, so in order to run a negative insert and take advantage of multiple edges (double-sided) the tool needed to be double negative — that is negative axially and negative radially. This allowed for clearance on the 90 degree edges. The trade off with getting double sided inserts with multiple corners was the double negative geometry created tremendous cutting pressure and heat. (Double negative inserts

worked, provided the part and set-up were rigid, the machine had ample horse power and the material was not “sticky” by nature, such as aluminum, stainless John Mitchell, General Manager of Tungaloy or low carbon steel.) Due to the nature Canada of the operation, boring operations required positive inserts, since the tool was extended and had a tendency to chatter. During this same era, machine tool builders were making lighter duty machines with less horse power. These factors increased the popularity of positive geometry inserts. These inserts drew less horsepower, created less chatter, were easier on the part due to freer cutting forces, and reduced “built up edge” on the inserts since they created less heat. The trade-off was the inserts were single-sided and had half the number of cutting edges. The popular milling inserts of this era were SEKN and TPKN. Insert pressing technology evolved and this technology was quickly implemented into turning inserts. By producing a deep, positive chip groove on an insert it was discovered that a negative insert could have positive cutting forces. This technology meant

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turning inserts could be double-sided, and have lower cutting forces. Another feature the chip-breaker provided was its ability to keep the heat from the chip out of the insert. With a flat-top insert the hot chip would slide across the face of the insert and the heat from the chip was transferred into the insert, shortening the tool life. With chip-breakers, a small “single bump” or groove would reduce the amount of contact the chip had with the insert, and thereby reduce the amount of heat transferred into the insert, extending tool life. Slight differences in chip-breakers produced substantial differences in performance. Insert manufacturers began to differentiate themselves with the use of proprietary chip breakers. No longer were turning inserts labeled CNMG or TNMG, with generic breakers — the new chip-breaker designations were added to the description, such as CNMG 432-TH or TM. Initially, chip-breakers were added to positive milling inserts

and the term chip-breaker was aptly changed to “top form geometry” since its main function in milling was not to break a chip, rather it was designed to change cutting forces, direct chip expulsion, reduce heat and increase tool life .

As pressing technology evolved, insert manufacturers were able to press highly positive top form geometries on double-sided inserts. This allowed multiple cutting edges on inserts that were free cutting.

Pressing technology has evolved even further. Today some insert companies are capable of pressing unprecedented types of complex geometries. Some of these geometries allow for double sided positive inserts. These inserts actually have clearances built into the insert itself. Rather than a traditional 90 degree angle on a double-sided insert this new technology allows for inserts to have a positive clearance angle on the insert such as 5 or 11 degrees and still be double-sided.

This technology has the added benefit of providing extra security by having the insert fit into a “dovetailed” pocket. The Dovetailed pockets adds more stability, and less chance of any insert movement. This has allowed double-sided inserts on very small boring bars and indexable drills with 6 cutting edges per insert, milling inserts with 16 cutting edges or grooving tools with 4 edges. No longer is the term “top form geometry” applicable since this new technology applies to more than just the top form. Perhaps a better term may be three dimensional pressing technologies? CM

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Titanium on the upswing The light, strong metal benefits from strong aerospace demand

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

T

itanium isn’t the cheapest or the easiest metal to machine or form, but with steel-like strength at aluminum weight, the material is a natural for critical aerospace components.

Consumption is up year over year since 2011, and with a

massive order backlog stretching to eight years in the case of Airbus, civil aviation demand should be more than enough to compensate for declining military aircraft spending.

Courtesy ITA

The above chart predicts compound annual growth between 2011 and 2016 of 14.1 percent, well over even the most

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optimistic estimates of overall GDP growth even for red-hot markets like China.

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Import sources, U.S. titanium metal n n n n n

Kazakhstan = 51% Japan = 37% China = 5% Russia = 4% Others = 3%

The above pie chart shows the major import sources for US titanium metal. Although Canada is number three in global ore production (rutile and ilmenite, from which titanium is extracted), we are not major sources of finished metal for

the crucial US market, although Canada is a major exporter of titanium products for pigment and coating uses.

For more information visit www.titanium.org CM

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Cutting Edge NEW BANDSAW DESIGNED SPECIFICALLY FOR OIL AND GAS PIPES

Behringer has introduced their new high performance HBP-610A bandsaw for cutting large pipes and solid materials up to 24 inches in diameter.

The saw has a dual column design with a cast iron frame, and uses positive hydraulic downfeed with a heavy-duty gearbox and a high horsepower motor.

The solid cast bow frame is designed to eliminate vibration and provide rigid support for blade tensioning. These design features provide controlled downfeed power helping to make accurate cuts with tight tolerances.

“The dual column downfeed is superior to swing frame and vertical systems because it assures uniform downfeed pressure across the blade with no leverage points,” said Joe Suydam, an inside sales engineer with the company. “The cutting path is shorter and therefore cutting is faster and more efficient”.

Suydam also said the new saw features constant chip load removal, which facilitates high downfeed rates. This creates a smoother, more even surface on cut pieces.

The equipment was developed particularly for the North American market, with the idea of bandsawing of pipes from 0.75” to 24” in diameter — the range of pipes commonly used in the natural gas and oil production industries. www.behringersaws.com

NEW PROGRAMMABLE LASER OPTICS INCREASES POWER, ACCURACY

TRUMPF has introduced the latest generation of its programmable focusing optics, for scanner welding, cutting, and drilling. The new PFO 3D features a larger work area, higher maximum laser power, and enhanced electronics for increased accuracy.

The work area of the laser has increased to 20.8 inches x 30.7 inches in elliptical form with a Z stroke of up to ± 18.7 inches. The maximum laser power has also been increased to up to 8 kW. To minimize repositioning time and maximize performance in larger applications, a robot-mounted PFO can be controlled to process “on the fly” through real time synchronization of the scanner axes and robot axes. These changes to the PFO 3D electronics ensure increased accuracy at the workpiece.

The Mirror Stabilization Program (MSP) corrects mirror positions measured in offset and gain, independent of temperature and humidity.

The addition of the “wobble” feature improves material processing capabilities in bridging gaps, battery welding, and creating repeating patterns for larger contact area with a small focus spot. www.us.trumpf.com

MAGNETS SIMPLIFY STEEL HANDLING

SafeHold MPL Series Permanent Lifting Magnets from Eriez provide the ultimate in operator convenience, safety, and reliability. These durable magnets make quick work of previously difficult, time-consuming steel handling. With SafeHold MPL Series Permanent Lifting Magnets, users can lift, move, or position materials in less time, without having to manually release the magnet and without the need for slings, hooks, or cables. SafeHold MPL Series Lifting Magnets are ideal for loading and unloading steel sheets from burning tables or anywhere that operator access is limited.

They operate on 115 VAC power and turn on and off, so there is no need for a high cost, high maintenance battery system. In the event of an interruption in power supply, the magnets remain in their current position (on or off) and cannot be operated until power is restored. This capability keeps plant workers safe from accidental dropped loads.

SafeHold MPL Lifting Magnets are superb for handling both flat and round materials, especially semi-finished products with flat surfaces such as machine parts, press molds for forming and steel plates. These magnets are also an excellent choice for loading round bars into lathes.

Maximum lifting capacity (with 2:1 safety factor) is 4,500 pounds (2041 kg) for a flat steel plate and 3,000 pounds (1363 kg) for a round surface product. Thin sheets, rough and irregular surfaces, odd shapes, and scale all affect holding power and must be considered when establishing a safety factor. www.eriez.com 60 | FEBRUARY 2013 | www.canadianmetalworking.com

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Cutting Edge PORTABLE RADIOS IDEAL FOR MANUFACTURING ENVIRONMENTS

PT Series portable radios from Ritron, Inc., are an ideal solution for virtually any 2-way radio use — especially in manufacturing environments, warehousing, shipping & receiving distribution facilities, and more. Ultra small and lightweight, these ergonomically designed radios are easier to hold and use. They feature narrow frequency channel steps for clearer communication with less interference. Nine programmable function buttons allow the PT series to be customized to particular application requirements. These narrow band compliant radios feature 255 channels with channel scan, priority scan, and scan resume functions.

Built-in selective signaling alerts the user to priority messaging automatically. Loud 1 Watt audio output makes the PT radio easy to hear, even in noisy manufacturing locations.

Weighing just 10 ounces, these robust radios are tested to Mil-STD 810 F for temperature, humidity, shock, and vibration, and are IP65 rated for resistance to dust and water. Each PT series radio includes DTMF encode, an Emergency Call button, status icons, and an easy-toread alphanumeric LED display. A 13-hour 1800mAh Li-ion battery pack provides ample power for shift-plus operations while a low battery alert indicates time to recharge. Each radio includes a spring-action belt clip, flex antenna, long-lasting battery, and a rapid rate charger.

Options include remote speaker mic, ear hook earset, and gang chargers. All PT series radios are compatible with other Ritron products such as Liberty Repeater, radio callboxes, wireless PA systems, and more — so that customers can add other radios to the system as their needs grow. www.ritron.com

RECIP SAW BLADES ARE MORE RIGID, LONGER LASTING

Milwaukee Electric Tool Corporation’s new Metal SAWZALL Blade line is aptly named Double Duty Upgrade for delivering over two times more life than current generation blades.The new blades will be available in both a THIN KERF profile for fast, flexible cuts and a DEMO blade profile, known as The TORCH, for tough, straight cuts. “When blades break at the tang and buckle under stress, users have to waste valuable time on the job replacing them to continue the task at hand,” says Dan Wolfgram, Sr. Product Manager for Milwaukee Electric Tool. “As a result of this frustration, Milwaukee has created several new-toworld solutions that strengthen the blade at its weakest points, delivering the longest lasting blade on the market today”. The Double Duty Upgrade TORCH blades feature a tooth form that is

NEW FORGING DIE TECH MAKES HARD, TOUGH TOOLS

Manufacturers of forging dies are often forced to compromise between hard and tough materials. However, scientists from the Fraunhofer Institute for Production Technology (IPT) in Aachen, Germany have discovered a way to combine both characteristics and expand the useful life of forging dies. Forging dies must withstand a lot. They must be hard so that their surface does not get too worn out and is able to last through great changes in temperature and handle the blows of the forge.

However, the harder a material is, the more brittle it becomes – and forging dies are less able to handle the stress from the impact. For this reason, the manufacturers had to find a compromise between hardness and strength. One of the possibilities is to surround a semi-hard, strong material with a hard layer. The problem is that the layer rests on the softer

optimized for long life and maximum durability. They also feature a new stamped honeycomb pattern throughout the body of the blade called Grid Iron that greatly increases the rigidity of the blade, making it the stiffest metal cutting SAWZALL blade on the market. These blades are ideal for making tough, straight cuts.

Maintaining a short profile and thin body, these blades are ideal for making fast, flexible cuts. Both of the blade profiles feature a deep stamp design in the tang of the blade, where it connects to the tool, appropriately named Tough Neck. Engineered to protect against breakage, Tough Neck delivers the strongest SAWZALL blade tang on the market. www.milwaukeetool.com

material and can be indented by blows, like the shell of an egg.“The forging dies we have been working on have a useful life that is up to twice as long,“ explains Kristian Arntz, head of department at the IPT. “We are using a working material that is less hard and able to handle the impact stress well. We melt the uppermost layer of the material with a laser and introduce a powder into the melt material that is used to chemically alter the characteristics of the material. We have therefore achieved a large degree of hardness in the upper millimeter. The advantage is that since the characteristics of the outer layer do not change abruptly (as is the case in a deposited layer), but increase in hardness gradually (this is also called a hardness gradient), the “egg shell effect” can be avoided. www.ipt.fraunhofer.de CM

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Welding News TRAINING SYSTEM FOR ADVANCED MANUFACTURING ROBOTIC SKILLS Suitable for use in for use in manufacturing training centres, as well as schools and colleges the Robotic Welding Education Cell 2.0 is intended to help the manufacturing industry respond to a critical shortage of skilled labour. This system will train workers on advanced automated welding techniques that deliver the productivity and quality the manufacturing industry in Canada needs to remain successfully competitive. The new cell provides access to robotic technology and advanced training, allowing the students to develop the skills that meet the needs of the industry. The Education Cell is mobile and includes a collapsible workspace that allows it to be used as a training tool in multiple classrooms, welding labs or other environments. It can be easily transported to where it is needed.

The robotic system design caters to industrial, welding education and robotic training needs and will give workers and students a foundation in robotic welding basics, as well as more sophisticated technologies, helping them to succeed in industries ranging from building and fabrication to automotive, transportation, and structural steel. Ready to work right out of the box the packages include integrated shielding gas bottle rack/storage, fume extraction system mounting and integrated safety devices.

It features a Lincoln Electric PowerWave R350 welding power source, AutoDrive 4R100 wire feeder, Magnum PRO robotic welding torch and consumables, SuperArc L-56 GMAW welding wire, Lincoln Electric PowerWave and Production Monitoring Software Capability, CheckPoint cloud-based production monitoring software, Production Monitoring 2.2 server-based software, FANUC ARC Mate 50iC/5L with the R-30iA Mate Controller and LR ArcTool Software. www.lincolnelectric.com

MULTI-PROCESS WARRIOR COMES TO THE BATTLE

Delivering up to 500 amps at a 60% duty cycle the Warrior is a new multi-process power source and feeder from ESAB. Designed for general fabrication, shipbuilding, rail car construction, mobile machinery construction, energy generation construction, pipe welding, and repair and maintenance, it performs MIG, Flux-Cored, Stick, and Live TIG welding, as well as Arc Gouging. It carbon arc gouges up to 3/8,” welds .030–5/64 inch flux-cored and solid wires, and has 7018 and 6010 cellulosic capability.

The design has a “clean” side and a “dirty” side inside the machine to ensure long-term reliability. All controls are on the front panel and the knobs are designed for use when wearing welding gloves. The simple and clear user interface makes it easy for anyone to get started welding within a few seconds.

Suitable for remote job sites, the ergonomically designed handles are built to withstand mechanical hoisting, and the IP-23 rating (can be used in blowing rain within 15 minutes of rain stopping) allows Warrior to be used outside in any weather.

It is generator-compatible, and the sun-friendly display makes it easy to see when welding outside.

In addition to the Warrior power source, the Warrior Feed 304 is an all-new rugged, user-friendly wire feeder. It features a high-torque 4-roll drive, which gives superior feed even with long MIG guns and better feedability than a 2-roll drive. This simple functionality feeder includes all the controls you need to get the job done – including remote voltage, gas purge, inch wire, and wire feed speed (WFS). www.esabna.com

HARDFACING AND HARDBANDING WIRES FOR THE OIL PATCH

Developed to meet specific challenges of erosion, corrosion and needs of the oil and natural gas industries, these wires extend wire life and support greater productivity when hardfacing and hardbanding. For Drilling and exploration applications, the Stoody HB-62 (62 Rockwell C hardness) and Stoody HB-56 (56 Rockwell C hardness) now have Fearnley Procter NS-1 certification. The HB-Ti has been developed for titanium alloys.

ThermaClad 104TJ is a submerged arc wire intended for the multiple layer build-up and repair of worn tool joints. Weld deposits are crack free, can be machined with high-speed tools, carbide tools and can be flame cut.

For pipeline transportation, the StoodCor 136 was designed specifically for applications where erosion and corrosion are of equal concern. It is suited for ID cladding on pipe, pipe elbows or plate subjected to a combination of abrasive wear and corrosion.

For processing and storage, Stoody has developed a nickelbased family of flux cored wires designed to weld Inconel and similar alloys used to build liquefied natural gas (LNG) tanks and flue gas desulphurization units (FGDs). These all-position nickelbased flux cored wires deposit 10 to 15 lbs. of weld metal per hour. www.victortechnologies.com

PORTABLE POWER

With advanced AC TIG and pulsed TIG outputs that enable operators to tailor arc characteristics, weld bead shape for superior performance when welding aluminium, stainless, chrome-moly and thin metal, the Thermal Arc 186 AC/DC TIG Welder has 15 amps more TIG welding power than the previous model and sports a new digital operator interface that makes setting weld parameters more intuitive. Suitable for fabricators looking to weld ferrous and non-ferrous metals in the field and the shop, it provides a welding output of 10 to 200 amps with a duty cycle of 20% when TIG welding 200 amps/18 volts.

Stick welding duty cycle is 16% when welding at 120 amps/26.6 volts and is suitable for welding with 6011, 6013, 7014, 7018 and other electrodes up to 5/32” diameter.

Designed for mobile contractors and fabricators, as well as applications in the aircraft/aerospace, appliance, maintenance/ repair, automotive, boat and trailer industries, the unit weighs 48.4 lbs., uses 208-230V input power and enable operators to improve weld puddle control, control the weld bead profile, reduce heat input and increase travel speeds. www.victortechnologies.com

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The Business of Welding

New Year brings changes E

ach New Year I find myself wondering how the action that took place in the previous year will impact the coming year.

Having spent the best part of 25 years in design, marketing and product development, I have learned a few things about how a good idea one year one can be turned into a functional campaign, initiative or product offering in the next. Conveniently, as of this January, I’ve been running the CWB Group’s Marketing and New Products group for two years – which means that some of the things the leadership team and I thought up last year will see the light in this new year. Although the CWB Group has been a continually evolving organization for the past 65 years, I feel that this year will be a high point for us, with a lot of positive things that will help the industry as a whole.

So what’s in store for 2013? Well, starting with the CWB side of the organization you will see several new “welding awareness” activities including the national launch of our CWB QualityMark program for CWB Certified companies. This will dovetail with a similar program for welding education providers and some specialized programs for welders, welding inspectors and engineers.

Most of this will be delivered through our newly launched Office of Public Safety, which you will be hearing from a lot in 2013.

GOING PUBLIC

No, I’m not talking about listing the CWB on the stock market. This year the CWB Group will be stepping things up in the PR department. By the time you read this we will have already had a visit from the Honourable Lisa Raitt, Minister of Labour for a round table discussion on welding in Canada. This will be followed by a focused outreach campaign to help spread the word on welding and offer our services in areas where we can help. Ever notice that every article about labour seems to include a picture of someone welding? Well, from now on that picture is going be part of a bigger story, one that gets told on your behalf by the CWA and CWB.

GROWTH THROUGH ASSOCIATION

We are also starting 2013 with the launch of a new association – The Canadian Association of Professional Inspectors (CAPI – pronounced “CAP-ee”). Why a new association? Well the CWB Group has been helping to train welding inspectors for many years and with a number now totaling over 7000 it was time to deliver some focused services to this group, as well as other inspectors who have come through other training organizations.

The CAPI mission is very similar to that of the Canadian Welding Association; namely to provide a platform for fellowship, training and the promotion of the profession. CAPI is intended to draw together a range of “metal inspectors” from aligned industries: Manufacturing, Structural, NDE/ NDT, Coatings, etc. Involved in inspection? Join the association at www.capi.info — it’s free!

A FRESH START TO TRAINING

To state the obvious - Canada’s a big place. Distance learning, online learning or whatever you want to call it is where we, as the national welding organization, need to be to provide truly national training. With that in mind, for the past two years the CWB Group has been looking at, testing and building out an online training solution that will bring our welding courses to people from coast to coast. Starting early in the new year we will be rolling out our new online learning environment (the

CWB Institute) that brings together some ideas we have been working on for some time. If you are on a waiting list for a CWB course this will be an opportunity to fast-track your training, from the comfort of your own home. Throughout the year you will see a number of re-launched courses Ian Campbell, Director of that represent major technological Marketing and New Product upgrades in online trades skills Development, CWB learning. Although not yet online, I would also like to mention our newly revised CWB Institute (CWBi) NDE courses – over 2 years in development with all new material, all new samples and all new instructors, just the beginning of the good stuff to come.

GOING LOCAL

Over the past couple of years we have been looking at a number of local vertical markets that are tied directly to welding. From Shipbuilding to Pipelines the CWB will be rolling out a range of services to provide support to these industries. Some, like our newly launched Z662 procedure registry, you may already know of, while others, like our Industry Smart Groups (CWB ISGs) and focused training and certification offerings, you will see coming very soon. This work is backed up by some new additions to our staff, some of these people you may recognize from the welding side of the pipe and pressure world as well as NDE and inspection.

In short, if it is welding related we are Canada’s national body - we have the greatest depth of knowledge and we want to help.

GOING INTERNATIONAL

2013 will see the first of several international training organizations rolling out CWB developed welder-training programs for foreign as well as “local market” welders. It is our honest opinion that all new foreign welders coming into Canada should have a solid working knowledge of their trade as well as the Canadian welding codes and standards that regulate the work, and ensure the safety of all Canadians. Interestingly, many developing countries are looking to the CWB Group for assistance in setting up their own Canada-like welding standards as they recognize that quality and safety only come from oversight and consistent delivery through a national administration organization. In 2012 we saw a lot of interest coming in from all over the globe, including just south of our own border. In 2013 you will see the CWB brand popping up all over the place.

Finally – I would like to wish you and your families a happy and prosperous New Year. I look forward to meeting you and hearing from you throughout the year. If you have a question or comment about what’s going on at the CWB Group or the wider welding world feel free to drop me a line at ian_campbell@cwbgroup.org.

Canadian Welding Bureau/Canadian Welding Association

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Fume control for health and profit

Minimizing welding fumes

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

C

lean, crisp air is a wonderful thing.

We often vacation where the air is clean and breathable. The days of working in a smoke-filled shop are over as now it’s possible to have a welding shop with quality air.

Welding fumes can be nasty.

Depending on the metal being used, welders can come down with metal fume fever. Sometimes called “metal dust fever”, zinc shakes, or Monday morning fever, this illness is primarily caused by exposure to certain metal fumes. Welding stainless steel releases Chromium and magnesium oxide (MgO), while zinc oxide (ZnO) is created by heating or welding certain metals — particularly galvanized steel. With more and more alloys being used in the manufacturing industry, there are more toxic fumes being produced by welding. The symptoms of metal dust fever are similar to the flu with fever, chills, fatigue, and others. Like the flu, it can take a worker up to four days to recover from this affliction.

Preventing metal dust fever is not difficult as it simply calls for the worker to avoid direct exposure to potentially toxic fumes — something easily saved by ventilation systems and personal protective equipment. Having an unhealthy work area leads to an unhealthy workforce.

Besides the well being of the workforce, the loss of production will have a negative impact on the balance sheet.

“We’re getting to a point where we can extensively tailor solutions to each end user,” said Al Hilbert, product manager, Miller Electric. “In addition to the choices businesses already have (low vacuum/ high volume vs. high vacuum/low volume, portable, mobile, wall mounted, stationary, etc.), Miller is introducing new low-profile hoods that are modular and range in size from 4- x 4-ft. up to 16- x 32-ft., varying in 1-foot increments. This allows businesses to customize a solution specifically to the size and shape of their cell, and the hoods are compatible with any kind of work cell or process.

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HEALTH CONSEQUENCES OF EXPOSURE TO HARMFUL AGENTS HARMFUL AGENT

PROCESS

HEALTH CONCERN

Chromium (hexavlent)

Stainless steel welding

Carcinogen

Nickel

Stainless steel welding

Carcinogen

Ozone

Welding of aluminum alloys and stainless steel by gas metal arc welding and gas tungsten arc welding

Severe irritant to the respiratory system

Oxides of Nitrogen

Oxyfuel gas cutting (can build up in confined spaces)

Delayed pulmonary edema (build-up of fluid in lungs)

Fluorides

Low hydrogen or alkaline flux used in shielded metal arc welding and flux cored arc welding

Mucous membrane (eyes, throat, lung lining, etc) irritation

Manganese

Potential for excessive exposure during hardfacing welding with high manganese alloys

Acute (short-term) respiratory problems and chronic (longterm) nervous system disorder similar to Parkinson’s

Phosgene

Potential for excessive exposure during arc welding in work area or on workpieces contaminated with chlorinated hydrocarbon degreasing solvents

Respiratory irritation and pulmonary edema; delayed onset of symptoms

Zinc

Potential for excessive exposure in welding and cutting of galvanized steel

Metal fume fever; pulmonary edema and pneumonia; effects usually temporary

Copper

Potential exposure when welding with copper base metal and consumable; excessive exposure less likely in any ferrous welding even when using copper coated gas metal arc welding wire

Metal fume fever and respiratory irritation

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Source capture works well when welding these brackets.

hood, they require up to 50 per cent less airflow and are much more efficient. These hoods also do not require large collectors, which helps create energy and space savings. They also feature built-in spark abatement, which is an important safety feature.”

CATCH IT AT THE SOURCE

Besides creating unhealthy fumes, “welding on oily parts creates oil smoke, and oil mist, that can clog filters and cause fires,” said Bruce Clark, Director of Marketing & Export Sales for Lincoln Electric Canada. The company has introduced the Guardian Fire Prevention System that has three categories: prevention, detection, and suppression. These components may be combined to create a customized system solution.

Although the fumes might smell bad — how dangerous are they? Some bad smells pose no danger while odourless and colourless fumes can kill. “It is important to differentiate

Miller’s Filtair MWX Series Mobile Fume Extractors captures up to 95% of weld fume particulates

between particulate and noxious gasses. The particulate is collected onto the filter, which is then cleaned and/or removed,” said Hilbert. “Noxious fumes and gasses have to be addressed separately or in addition to the existing fume extraction technology. It is more effective and it is ultimately what OSHA recommends as the best way to solve fume problems. Source capture is preferred because it removes contaminated air at the source before it reaches a worker’s breathing zone. Once that particulate gets up in the air, it’s really hard to capture or control.”

Capturing the fumes at the source works the best. “Fume extraction guns have been introduced to help capture the weld fume almost as quickly as it is generated. These guns, capable of MIG and Flux Cored welding, capture the fume right at the gun and connect back to a high-vacuum fume extraction system,” said Hilbert. “Typically rated up to about 400 amps, these models have become more efficient and user friendly with features like adjustable extraction control (so as not to disturb shielding gas flow while still providing excellent fume extraction), a smaller vacuum chamber (for ease-of-handling) and improved neck designs for better joint access.”

Even though at source fume capture should be in place, a proper general ventilation system must also be implemented said Clark. “The concept is to remove welding fumes from the entire shop in addition to or in place of source capture. When source capture is not effective general ventilation is required.”

UNDER THE HOOD

The Mobiflex vacuum systems is suitable for smaller manufacturing facilities that require light to medium duty welding fume extraction in variable locations.

One disadvantage with some source capture solutions is that they are difficult to position over large weldments or other obstructions within the weld cell. A welding business could consider either a canopy style hood, or an environmental solution. “Environmental solutions, such as industrial ambient

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or push/pull ventilation systems, may be an option for some but lack the efficiency of source capture through a fume extraction device,” said Hilbert. “These systems are designed to protect the whole shop, which is important when you have other workers in close proximity to the welding activity. These systems, however, are not without inefficiencies. They do not protect the welder’s immediate breathing zone. They can be extremely expensive to implement with changes to the building. While weld fume tends to naturally rise, it eventually levels out and falls back down to the surface — buildings with tall ceilings may prove inefficient at actually removing the particulate.”

DISPOSE WITH CAUTION

With robotic welding finding its way onto more and more shop floors the ability to control fumes is increased. Most robotic welding cells are enclosed and have red plastic sheets that hang down to contain the fumes and guard against eye damage from the welding sparks. The hoods that are mounted on top of the cells draw fumes up and into the filter. “When these red plastic strips that are hanging down don’t capture everything then you have fumes escaping into the general atmosphere around the shop then you put in something like the Circulator,” said Clark. This FilTek XL filter packs have easy-grip handles, weigh less than the 50-pound OSHA lift limit, and require unit, which works like the lunar lander grabs the no tools for maintenance. fume and puts the air through a set of filters that can then be disposed of in an environmentally responsible way.

When the filters need to be changed, it is not like changing the air filter in your vehicle. “Depending on what’s being Oil Mist collected, it is critical to work with your industrial hygienist is on surrounding shop equipment and follow OSHA guidelines to determine the best way to handle these materials based on the welding processes you without Nederman by your side are performing. For instance, if you are dealing with hexavalent Oil mist poses a health and safety risk chromium, you will want to take added precautions,” said to you and your work environment.

Hilbert. According to Clark, most system manufacturers provide The most effective way to control the specific instructions for safe handling. “We recommend that exposure is to capture the mist right at the source. operators wear personal protective equipment (gloves, long sleeves/pants, half mask respirator or other mask) when changing filters to prevent exposure to any potentially harmful materials. There are also key points to remember related to the system itself: disconnect the power and perform required lockout/tagout steps, and turn off the compressed air supply and bleed the air lines.”

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Filter technology is has advanced, becoming more efficient and more compact. Some filter media technology in fume extraction systems can replace up to three old cartridge-style filters with one single filter. “Surface loading filters are also becoming preferred as they capture the particulate at the surface rather than depth loading, improving cleaning and performance,” said Hilbert. “The new compact filter pack designs are considerably more efficient, which allows you to get more done with less and at lower costs, and much of that can be tied back to the improvements with surface loading technologies. These are easier to clean because particulate does not penetrate down into the substrate, they provide longer filter life and improved performance over pleated filters and older technologies featuring cellulose and spun-bound polyester media.”

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The Statiflex200-M and 400-MS base units are stationary, wall-mounted low vacuum systems suitable for facilities with fixed location workstations and little available floor space.

Disposing the filters is not as simple as tossing it in the trash. Local laws and regulations covering the disposal of hazardous material come into effect.

“The most important factor is to understand what has been collected on the filter. Businesses should get a profile of their waste by sending samples to a lab to get a toxicity characteristics test,” said Hilbert. “A waste hauler is a potential source of assistance. This will then guide the business on the best way to dispose of and label the waste. This is also critical, as the waste hauler then knows how to handle it. The most important thing to remember is that it is up to the customer to understand what their waste profile is.”

SAFETY FIRST

No matter how effective the current fume extraction system is, proper protection by staff and workers must be worn.

According to Clark, “proper gloves, welding jacket, safety boots, welding helmet, and safety glasses must be worn.” In some cases consulting with an industrial hygienist or other safety professional to determine best practices for your operation might be necessary. “If testing is done in the immediate work area and elevated levels of the particulate still exist, you may have to outfit workers with additional PPE/respiratory solutions

Lincoln’s welding booth with optional telescopic Arm with 360° Rotatable Hood

beyond the standard helmet, gloves and long sleeve shirt,” said Hilbert. “This may likely be the case when working in confined/ restricted spaces, and when working with certain materials.

Similarly, if it is not feasible to use a source capture solution due to the layout of the weld cell, then the added PPE will likely be required.” CM

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Art and Science Polishing is still a place for craftsmen with patience and skill

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

T

here is still on bastion of craftsmanship left in the manufacturing world. Automation has not entered the realm of mold polishing. “Polishing is more of an art than a science and requires patience and skills, which will be rewarded by a perfect mirror finish,” according to Angelo Cipriano, owner and president of Brasmold in Chambly, Quebec. The company has been polishing a variety of moulds for over 30 years.

“Usually the final touch is by hand,” said Cipriano. He notes that the while hand sanding and buffing is the usual method, because of some of the complexities of the molds, they do use handheld power tools, as well as an ultrasonic machine and a deep profile machine. He said it is difficult to generalize as each job is so different, “it depends on the on the mold that you have to have polished and the finish you need to achieve.”

It is important to remember that when polishing metal you are actually scratching it. When looking through a microscope at some base unpolished petal you will see a surface that resembles the moon, with irregular mountains and valleys.

Polishing is a process that removes these “mountains” and creates a smooth and shiny surface. A process of abrasion accomplishes the desired polished finish. These “mountains” are worn down by sandblasting, sandpaper or diamond grit, until they are flat and the surface starts to bear a more consistent look — rolling hills. The process starts with coarse abrasives and then moves, in steps, to finer and finer abrasives. Whether polishing a stainless steel mold, a golden ring or a high precision lens for a telescope, the process is the same. When polishing with a very fine grain abrasive the materials are removed on a molecular level and often need some sort of medium to remove the loosened material.

HOW SMOOTH IS SMOOTH

It stands to reason that a rough mould will produce a rough product. A set of standards was developed by the Society of the Plastics Industry (SPI) that determines the quality of finish that the finished mold should have. There are 12 finishing levels divided into four categories with each having a further three levels. The finish level ranges from a dull sandblasted like finish to a highly polished mirror or lens finish. These are relatively new standards that were adopted in 1988. The old standard had only six levels of finish. These standards show how to attain the desired finish. (See Table 1) An SPI Mold Finish Comparison Kit can be ordered directly from SPI or from other supplies such as DME. This kit consists of 12 disks polished to the appropriate level and is a handy tool for measuring or checking on the finish level.

The level of finish of the mold will frequently be determined by the product that will eventually emerge from the mold. “It depends on the customer request,” said Cipriano. “We use different finish levels because that affects the parts that will come out of the mold.

For example if you needed to do something in polypropylene and the request is for a finish for an optical finish, that is impossible because of the material will not handle that finish.” The level of finish must match the material that will come out of the mold.

The SPI Mold Finish Comparison Kit from DME lets you do quality control checks on a mold’s level of finish

DEALING WITH DEFECTS

Whatever defect is left on the mold will be replicated, and on occasion amplified, in the finished product. It goes without saying that the mold has to be perfect. A common fault, made by inexperienced, hurried or uncaring mold polishers, is a surface irregularity sometimes known as the orange peel effect. Common in painting large surfaces, especially high gloss surfaces on custom cars, this effect will look somewhat like the surface of an orange peel. This surface fault is a result of over polishing while using too much pressure. This surface irregularity can be removed by hand by polishing the affected surface with finer grit size than the one used previously.

Another is pitting where small pits occur in a polish surface of the mold surface. This occurs when hard non-metallic particles are dislodged from the surface during polishing. To fix this one should apply light pressure during polishing and avoid over polishing. One must just polish enough to remove the pits that were left by the previous grit.

ART IN A SCIENCE WORLD

As Angelo Cipriano of Brasmold noted polishing molds is more of an art than a science. In art foundries, molds can be made rougher, they are very rarely made of metal, because for the most part the pieces are one off items or limited runs where

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SPI FINISH GUIDE FOR MOLD POLISHING Level

Description

Typical Applications

A-1

Grade #3 Diamond

Lens / Mirror – requires 420 SS material

A-2

Grade #6 Diamond

High Polish parts

A-3

Grade #15 Diamond

High polish parts

B-1

600 Grit paper

Medium polish parts

B-2

400 Grit paper

Medium polish

B-3

320 Grit paper

Med – Low polish

C-1

600 Stone

Low polish parts

C-2

400 Stone

Low polish parts

C-3

320 Stone

Low polish parts

D-1

Dry Blast Glass Bead

Satin finish

D-2

Dry Blast # 240 Oxide

Dull finish

D-3

Dry Blast # 24 Oxide

Dull finish

the finished product can be brought to the required standard of finish. In production mold making where the molds are used to make thousands of identical plastic products, the molds must be scientifically accurate. While there are many

courses for mold and die making there are no specific courses for mold polishing, as this is a skill, which on the surface is relatively simple, takes years to hone to perfection.

Before jumping into a project an experienced mold

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(left) Blow applicati finishes a designer molding grit blast texture w

(lower le adopted take adv to conve bottled w with mirr is also im drink bot cavity on identical

(right) Co than the machinin require a coating, part finis

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(left) Blow molds are a common high-volume application for polishing services. Not all surface finishes are mirror smooth...in some cases packaging designers specify a matte or opaque surface when molding an otherwise clear resin. The solution is a grit blasting process, which can deliver the desired texture with consistency and uniformity. (lower left) The bottling industry has widely adopted PET as the material of choice and often take advantage of the material’s clarity. The ability to convey an image of purity in soft drinks and bottled water, for example, requires mold finishes with mirror smoothness. Repeatability of the finish is also important for high-volume molds like these drink bottles; the surface must be the same from each cavity on each machine to make every bottle appear identical on the store shelf. (right) Consistency is vital, perhaps more important than the overall finish for many applications. Post machining plating or coating on mold surfaces require a surface textured enough to hold the coating, but smooth enough to deliver the desired part finish.

polisher will study the rough mold and plan the best way to polish it to the required surface level. The first steps are usually to remove the machining marks and then work towards the desired finish. There are certain methods and sequences that the polisher must follow and these greatly depend on the condition of the machined mold and the material it is made of. Although many molds are made out of stainless steel they can also be made out of

aluminum. Since aluminum is lightweight and soft, the molds are susceptible to scratches from the tooling and machinery process and from handling in the shop. CM

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Clean, Dry and Steady Keep your CMM repeatable with good installation practices

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

T

aking care of precision measuring instruments is one of the first skills taught to every machining apprentice, for good reason. They were once expensive relative to wages and a dropped “mike” or vernier caliper risked a serious investment.

Scale up the measuring task to today’s coordinate measuring machines and that principle still holds true: they’re expensive and need care to perform reliably.

Modern CMM’s are much more rugged than early machines, but basic principles of care and feeding are still relevant today.

Location of the equipment is the first factor to consider. CMM’s are moving from their traditional place front and centre in the QC lab to end-of-line and open shop environments. The basic measuring principles however, are the same so the standard rules for maximizing repeatability in service still apply. A solid, level surface for mounting is important for larger machines. The original mounting points for the equipment should be used to set and level the unit. Shims should be avoided. Vibration is not as serious a problem as production equipment has moved to servo drives and away from mechanical presses, but location near known sources, such as vibratory part feeders is poor practice, especially if harmonics can be transmitted easily through a floor or wall. Even steel air lines are a possible conduit for vibration if rigidly mounted near the instrument. A short length

SOME CMM COST CONSIDERATIONS Should a buyer purchase new software when moving up to a new machine? Canadian Measurement and Metrology President Elliott Foster states: “In most cases a new software product should be purchased. Software over the last five years has radically changed and entry-level software generally gives only basic dimensional results and not more advanced data, including GD&T (geometric dimensioning and tolerancing-ed) or graphical analysis. New or upgraded software in any equipment from smartphones to supercomputers is rarely plug-and-play.”

Do buyers moving up in CMM equipment properly cost in software training, support and upgrades when buying a machine? “No”, declares Foster, adding “most customers do not factor in short-term costs (1 to 3 years), never mind long-term.” What are those costs? According to Foster, they can be summarized: 1. Expenses involved in training, including travel to the training site as well as hotels, meals and time away from work.

2. Support costs. Does the service technician have to travel from the United States? Who pays that tab?. What is the cost and downtime for calibration?

3. Spare Parts. What is the cost of critical spare parts?

(Robotic head, probe, encoders and control components.)

What is the general lead time for service and parts?

Foster notes that there are cut-rate service providers that may or may not have the necessary expertise to service your machine: “It’s always a good idea to get referrals from the CMM provider in order that you can find out yourself.”

Large, fixed units like this Leitz moving bridge unit are a significant investment.

It’s essential to buy on service and support, rather than price especially with large or special purpose CMM’s. www.cmmxyz.com

of rubber or polymer airline with sufficient slack should form the final coupling to the unit.

Air is the working fluid of larger machines…that massive bridge floats on an air bearing requiring clean, dry air for smooth, friction-free operation. Large production equipment is more tolerant of poor air quality, and as importantly, the bulk oil injected downstream from the condenser or desiccant pack must be kept away from the instrument. Air requirements for CMM’s are very low by production standards; it may be cheaper to use a small stand-alone compressor rather than engineer a special loop for lab quality air.

Electric power is a similar situation. Computers used in most machines use familiar off-the-shelf hardware, so the same rules for reliable current apply for the CMM as they do for a CAD suite or office desktop. Shop floor environments, especially in older shops, are notorious for unbalanced loads in low voltage single phase circuits. Tapping a local 115VAC circuit is convenient, but shop floor loops have numerous intermittent loads and since major machines are powered from three-phase circuits, few bother to check regulation on the low voltage side. Simple insurance is to run a line from the office circuit or dedicate a breaker to the unit or QC lab. A simple panel meter can be added to a junction box or surface-mount loop to remove doubt.

Analog meters also detect transients and dropouts effectively at very low cost.

Most modern computer driven equipment is networked, and

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Baty Vision Systems’ Venture Plus is available in three models with measuring ranges up to 1000mm x 1500mm x 400mm and ships complete with standard zoom optics and lighting. The all-aluminum bridge type construction results in low inertia and low thermal mass.

Air bearings are used on all axes and a granite Y-beam is used for increased accuracy. Ambient temperature can be compensated for within the Fusion software making Venture Plus ideal for use on the shop floor. Data can be imported and exported to CAD programs and SPC capability is standard. The Venture Plus features a Renishaw TP20 probe. www.eclipsetoolsinc.com

Modern CMM’s are compact and tough. This Brown and Sharpe 4.5.4SF is temperature compensated and resists vibration for use anywhere in the shop floor environment. The unit fits through standard doorways, operates on simple 110/220V power and doesn’t require shop air. www.cmmxyz.com.

standard rules regarding network security should apply for a CMM. If hard wiring a LAN, however, it’s important to remember that some shop floor environments use very high current circuits and frequently power transformers that can affect the data stream. Locate the data cabling well away from any possible inductive coupling with power circuits and remember that shorter is better for wired runs. Avoid looping and tying off excess cabling, and run it to the machine so that the cable

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Mitutoyo’s Ko-ga-me measuring system can be used stand-alone or integrated into a custom designed cell for inspection of small or large work pieces.

A variety of probes such as touch-trigger, optical, or constant contact scanning, can be added for even more versatility. Users can provide their own fixed mount or design a moving structure to take Ko-ga-me to the inspection measurement location. Ko-ga-me is available in 40mm, 80mm and 120mm stroke types and offers a resolution of 0.02µm, measuring accuracy from 1.5 x (3L/1000)um, maximum drive speed of 200mm/s (1 axis), maximum acceleration of 0.4G (1 axis) and supports the TP200+PH6 probe, SP25+PH6M probe as well as QVP (Quick Vision Probe). Koga-me is designed as a 3-axis or 2-axis measurement system and is available in either horizontal or vertical models. www. mitutoyo.ca

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The Zeiss DuraMax is a natural upgrade from manual measuring equipment to a CNC machine. The DuraMax is made for production use with temperature stability up to +30ºC with minimal space requirements and easy setup. The wellequipped standard configuration is easy to use and can be loaded from three sides. The unit features completely covered guideways, an integrated damping system and compensation for guideway errors (CAA corrected). A single point probe and Zeiss VAST XXT scanning sensor feeds data to CALYPSO measuring software, with no special machine installation or power requirements. www. elliottmachinery.com

can‘t be damaged or pulled in service; most failures occur at the connector. Broken connectors, often taped into place are a warning sign that action should be taken.

Protection from dust and grit should be a given, yet a surprising number of shops won’t add a $2000 prefab cubicle to their investment in a $75,000 (or more) machine. Similarly, if the instrument is exposed, what happens if a sprinkler triggers or a hydraulic line leaks? Guarding against mechanical shock is also often overlooked. Fork lifts and tow motors are a constant threat, as are pallet trucks and overhead hoists. Railings are cheap insurance and also clearly define a no-go area where skids and product must not be stored. While fire is unlikely, Halon-type extinguishers won’t flood the instrument or blow soda into the mechanism.

When sourcing new equipment, it may be simpler to use instruments designed for rugged shop floor use, but in every case, good installation and maintenance practice makes troubleshooting much easier by removing multiple potential issues.

Use a level, solid base, provide clean air and power, then protect the instrument from environmental threats and your CMM will run longer between repair and overhaul and hold calibration between inspections…as well as demonstrate your commitment to total quality management as well as quality production. CM

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

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

ABB Robotics . . . . . . . . . . . . . . . . . . . . . . . 35

Lubricor . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

American Torch Tip . . . . . . . . . . . . . . . . . . . 71

LVD Strippit . . . . . . . . . . . . . . . . . . . . . . . . 33

AMT Machine Tools Ltd. . . . . . . . . . . . . . 15,43

Megatel Inc. . . . . . . . . . . . . . . . . . . . . . . . 41

Brubaker Tool . . . . . . . . . . . . . . . . . . . . . . . 53

Metalworking Mfg & Production Expo . . . . . 79

Canadian Measurement-Metrology . . . . . . . 27

Miller Electric . . . . . . . . . . . . . . . . . . . . . . . 21

Carl Zeiss IMT Corporation . . . . . . . . . . . . . . 4 CWB Group . . . . . . . . . . . . . . . 57,69,73,77 Data Flute . . . . . . . . . . . . . . . . . . . . . . . . . 53 Dillon Manufacturing, Inc. . . . . . . . . . . . . . . 26 Dipaolo Machine Tools . . . . . . . . . . . . . . . . 11 Dobco Equipment . . . . . . . . . . . . . . . . . . . . 12 Elliott Matsuura Canada Inc. . . . . . . . . . . . . . 4 Eriez Magnetics . . . . . . . . . . . . . . . . . . . . . 59 Fastcut Tool . . . . . . . . . . . . . . . . . . . . . . . . 53 Gibbs & Associates . . . . . . . . . . . . . . . . . . 18 GMN USA . . . . . . . . . . . . . . . . . . . . . . . . 16 Gravotech - Gravograph . . . . . . . . . . . . . . . 29 Gravotech - Technifor . . . . . . . . . . . . . . . . . 49 Haas Automation . . . . . . . . . . . . . . . . . . . . 19 HORN USA, Inc. . . . . . . . . . . . . . . . . . . . . . 7 Hurco USA . . . . . . . . . . . . . . . . . . . . . . . . IFC

8CMM20186

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Multicyl Inc. . . . . . . . . . . . . . . . . . . . . . . . . 10 Nederman . . . . . . . . . . . . . . . . . . . . . . . . . 72 PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Renishaw (Canada) Ltd. . . . . . . . . . . . . . . . 25 Retention Knob Supply &Mfg. Co. Inc. . . . . . 81

IN STOCK

Rofin-Baasel . . . . . . . . . . . . . . . . . . . . . . . . 63

American Standards and specials.

Japanese Standards inch or metric.

Sandvik . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Schunk Intec Corp. . . . . . . . . . . . . . . . . . . . 46 Scientific Cutting Tools . . . . . . . . . . . . . . . . 48 SGS Tool Company . . . . . . . . . . . . . . . . . . 28 SME - CMTS . . . . . . . . . . . . . . . . . . . . . . . 55 SME - PMDS . . . . . . . . . . . . . . . . . . . . . . . 75 SME - WMTS . . . . . . . . . . . . . . . . . . . . . . . 56 Star CNC Machine Tool Co. . . . . . . . . . . . . 43 Sumitomo . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TE-CO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 TRUMPF Inc. . . . . . . . . . . . . . . . . . . . . . . . IBC

Ingersoll . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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

Iscar . . . . . . . . . . . . . . . . . . . . . . . . . . . . OBC

Victor Technologies . . . . . . . . . . . . . . . . . . . 67

ITI Tooling Company Inc. . . . . . . . . . . . . . . . 47

Walter USA, LLC . . . . . . . . . . . . . . . . . . . . 17

Lincoln Electric Co. of Canada . . . . . . . . . . 65

Weldon . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

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

www.canadianmetalworking.com | FEBRUARY 2013 | 81

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By The NUMBERS More planes, fewer workers PROJECTED GLOBAL DELIVERIES OF COMMERCIAL AIRPLANES BY REGION, 2012-2031

Source: Beyond the Horizon: Canada’s Interests and Future in Aerospace, November 2012. www.aerospacereview.ca

A

s described in this month’s cover story, “Higher, Farther, Faster” on page 22, commercial aircraft deliveries are set to trump military aviation in the short term as defense budgets are scaled back. The graph on the left shows where the growth will be and it’s no surprise that it will be centered on Asia. The combination of large distances, an increasingly affluent population hungry for air travel and an underdeveloped domestic airframe and power plant industry in the region makes Asia ripe for the picking for heavyweights Boeing and Airbus, but even more so for regional jet makers Bombardier and Embraer, among others. The graph projects deliveries to 2031, however and that’s where the second graph (right) becomes significant. With the

WORKER AGE PROFILE, CANADIAN INDUSTRY AND CANADIAN AEROSPACE MANUFACTURING, 2011

Source: Beyond the Horizon: Canada’s Interests and Future in Aerospace, November 2012. www.aerospacereview.ca

average age of Canadian aerospace manufacturing workers pushing 50, where are the skilled hands going to come from to build the aircraft? Robotics will be limited in an industry like aero, where production volumes are low, but semi-automated processes for forming, bonding and riveting require higher levels of skill and knowledge compared to the bucking-bar processes of yesterday.

Look for major airframers to push responsibility down to Tier One and Two suppliers for large subassemblies, allowing them to focus on design, final assembly and marketing. The need for skilled workers however, won’t go away, putting pressure on government and industry to take a close look at training and certification beyond the current apprenticeship/engineering model. CM

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