FEATURES: THE CAPTIVATING SOUTHEAST • EVENT REVIEW: INTERMACH July - August 2015
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ISCAR THAILAND 57, 59, 61, 63 Soi ISCAR THAILAND Samanchan-Babos 57,Sukhumvit 59, 61, 63Rd. SoiPhra Khanong, Khlong Toey Bangkok 10110 Samanchan-Babos Tel + 66 (2) Sukhumvit Rd.7136633 Phra Khanong, Fax + Toey 66 (2)Bangkok 7136632 10110 Khlong iscar@iscarthailand.com Tel + 66 (2) 7136633 Fax + 66 (2) 7136632 iscar@iscarthailand.com
ISCAR VIETNAM (Representative Office) ISCAR Room DVIETNAM 2.8, Etown Building, (Representative Office) 364 Cong Hoa, Tan Binh Dist., Ho ChiDMinh City, Building, Room 2.8, Etown Tel Cong + 84 8Hoa, 38123 519/20 364 Tan Binh Dist., FaxChi + 84 8 38123 Ho Minh City, 521 iscarvn@hcm.fpt.vn Tel + 84 8 38123 519/20 Fax + 84 8 38123 521 iscarvn@hcm.fpt.vn
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ENQUIRY NO 117
JUL AUG
2015 CONTENTS 30
METAL CUTTING 24 Integrity, The Key
With high volumes of cast iron components, tools which can satisfy specific requirements are very much in demand. Lim Gan Shu, Walter Singapore Marketing explains.
26
Aerospace: Revolution Through Innovation
The DMG Mori Aerospace Excellence Centre develops and realises efficient and cost-saving machining processes for the aerospace industry with innovative technologies and professional expertise. By Ralph Schiffler, CEO Pressgate
30
Mill With Skill
Milling has gone through many stages of evolution and revolution with gradual technical improvements and innovations as we move forward to maximising productivity in the world of manufacturing. Contributed by Andrei Petrilin, Technical Manager, Iscar Tefen
GREAT GEAR & SYSTEM 34
Complex Manufacturing: The Need For Internal Inspection
University of Leuven applies metrology CT to research geometrical accuracy of inner and outer features of industrial components. Contributed by Chris Wright, Technical Editor, The Right Image
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Fast, Open & Dynamic
When speed and flexibility are critical in machine tool applications, laser machining is often the technology of choice while eliminating the high cost of tools. The increased use of modern materials such as carbon-fibre or fiberglass composites in high-volume manufacturing requires the use of laser machine tools. By Stefan Ziegler, Marketing Communications, Beckhoff
IN DESIGN 42
Integrated Manufacturing & The Future Of Predictive Automotive Launch
In the automotive industry, there is a growing trend towards an increasing number of product launches on a global scale. Zhao Jizheng, Siemens PLM Software explains 2
asia pacific metalworking equipment news July - August 2015
FAST FAB 45
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Customers are important to all companies, but just how far are companies willing to go in their care for their customers? The Bystronic Competence Days is just one example of companies’ commitment to customers today. By Michelle Cheong
In recent years, many of the Southeast Asian countries have opened their doors to foreign investment, and benefited in the process with flourishing economies and better lives for their people. But what exactly is it about these markets that draws foreign interest? By Michelle Cheong talks to Johan Elster, President of business unit makers, Bystronic, to find out more
Taking Customers To The Top
Asia, The Promising Land
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JUL AUG
2015 CONTENTS ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806. SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/ Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: samanthatan@epl.com.sg
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60
Industry 4.0 And Responsive Manufacturing
Industry 4.0 is changing the way products are being manufactured and facilities are communicating, resulting in greatly increased productivity and efficiency, lowering production costs in the process. By Saj Kumar, VP, Internet of Things, SAP (Asia Pacific Japan)
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INDUSTRY Endorsements Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA)
64
The Captivating Southeast
48
The Road To Tomorrow’s Production
Trumpf is investing in Industry 4.0 and is setting guideposts along the way toward the Social Machine and the Smart Factory. By Evelyn Konrad, Press Representative Machine Tools Trumpf GmbH + Co. KG
FEATURES 51
Different Thinking Drives Asymmetric Boring Revolution
Innovation in precision boring increases productivity, reduces costs. Contributed by Kennametal
54
Making the Machine Tool Connect Scott Evans and Sal Spada of ARC Advisory Group explain how the MTConnect standard facilitates data-driven operational performance improvements in machine tool environments.
56
A Place In Production
Can machine vision be the missing piece that helps satisfy quality assurance demands in manufacturing? By Didier Lacroix, senior VP, International Sales & Services, Cognex 4
asia pacific metalworking equipment news July - August 2015
The emerging markets of Southeast Asia have advanced rapidly in recent years. Why is this so, and how does this influence the metalworking industry now and in the future? By Michelle Cheong
Federation of Malaysian Foundry & Engineering Industry Associations
EVENTS & EXHIBITIONS 68
Indian Machine Tool Manufacturing Association (IMTMA)
Event Preview: Manufacturing Myanmar 2015
China Machine Tool & Tool Builders' Association (CMTBA)
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Event Preview: Wire & Tube Southeast Asia 2015
Machine Tool Club (MTC)
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Taiwan Association of Machinery Industry (TAMI)
Event Review: Intermach & Subcon Thailand 2015
REGULARS Business News 8 71 Product Finder 75 Exhibition Programmes 76A Product Enquiry Card
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Delcam headquarters Small Heath Business Park, Birmingham, B10 0HJ Tel: +44 (0)121 766 5544
Delcam (Malaysia) Sdn.Bhd. Wisma UOA II, 20-1, No.21, Jalan Pinang, 50450 Kuala Lumpur, Malaysia Tel: +603-2711 0145
PT. Delcam Indonesia Perkantoran Pulomas satu Gedung-1, Lt-3 Room 12A Jl.A Yani No2, JAKARTA, Indonesia Tel: (62)-21-4894964
Delcam S.E.A. Pte. Ltd. 6001 Beach Road, #18-01 Golden Mile Tower, Singapore 199589 Tel : +65 97233095 & +65 64511124
Delcam Vietnam Representative Office Office 602, 159 Dien Bien Phu, Binh Thanh Dist, Ho Chi Minh City, Vietnam Tel : +84 8 35144078
Beijing Delcam Integrated System Co., Ltd. Rm. A411, Jinyu Jiahua Building, No.9, 3rd Street , Shangdi, Haidian District, Beijing 100085, China Tel +8610 6298 5591
Delcam (Thailand) Co.,Ltd. 11 Rama II Road Soi 54 Lane 4-3, Samaedam, Bangkhuntien, Bangkok 10150, Thailand Tel: +66 2 899 1182-4 ENQUIRY NO 075
EDITOR’S NOTE Published by:
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Measuring Up
(a fully owned subsidiary of Eastern Holdings Ltd)
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senior editor Syed Shah
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business development manager Randy Teo randyteo@epl.com.sg
writer Michelle Cheong michellecheong@epl.com.sg
editorial assistant Sharifah Zainon
sharifah@epl.com.sg
When an engineer looks at a drawing he or she has to consider some of the following: the availability of machines, skill level of technicians, tooling designs and other pressing concerns. How the parts and designs fall into the manufacturing capability of the plant is important, there is one crucial factor the engineer has to consider before he goes ahead. He or she has to consider the availability of measuring and inspection equipment and their effective measuring range. The facility will have problems producing parts that customers require if the measuring capability of the plant is unable to keep up with its manufacturing endeavours. Third party contractors may be engaged to fulfil the QA department’s role but moving parts from one location to the other, especially dedicate ones is quite the challenge on its own. There are several methods to tackle the issue of measuring and inspection in the manufacturing environment. For example, simple matter like changes in environmental conditions such as temperature and humidity could influence the measurement results, sometimes
significantly. The form of a metal part might get distorted under undesirable temperature condition and its surface may rust if not being handled properly in humid conditions. If you look at all case studies or articles that focus on the fundamentals of measurement, they all point to a common denominator: The importance of getting measurements correct. This is arguably right up there with machining accuracy amongst other things in the “must get right list”. I n sp e c t ion te ch n ique s or philosophies have also come under increasing spotlight in the automotive industry. It would be inaccurate to say that these days; it is all about money because it has always been about money. Hence, the saying – time is money. The machine needs to have this added dimension of dynamism in terms of being both accurate and portable. That being said, we are looking at feasible returns of investment. It is safe to say that one would be hard pressed to find a cheap machine that runs like an expensive one. In terms of quality, you pay for what you get.
graphic designer Jef Pimentel
jeffreypimentel@epl.com.sg
circulation executive Nurulhuda binte Suhaimi nurulhuda@epl.com.sg
assistant circulation manager Nancy Lim nancylim@epl.com.sg
contributors Lim Gan Shu Ralph Schiffler Andrei Petrilin Chris Wright Stefan Ziegler Zhao Jizheng Evelyn Konrad Scott Evans Sal Spada Didier Lacroix Saj Kumar
All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MCI (P) No. 047/06/2015 PPS 840/09/2012 (022818) ISSN 0129/5519
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etm Syed Shah Senior Editor
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ENQUIRY NO 114
BUSINESS NEWS
Diego Delso
Vietnam’s Manufacturing Sector Set To Rise
Ho Chi Minh, Vietnam: The imports of industrial machinery and manufacturing equipment to Vietnam is expected to rise this year, as a result of lower taxes due to the Free Trade Agreements Vietnam has recently established with Australia, Chile, China, India, Japan and Korea. In January this year, Vietnam’s foreign direct investment (FDI) increased about 67 per cent to US$663 million from the same period last year. A total of 44 FDI projects were registered, with 19 new projects breaking ground in the same month. One of the investment sectors identified was manufacturing, which attracted about US$605 million. As more foreign companies look to tap on Vietnam as an export production base, the local
community as a consequence is spurred to accelerate its move up the value chain by upgrading current production capabilities with high end technologies. “Vietnam’s manufacturing industry has transformed and expanded in recent years due to opportunities presented as a result of its healthy labour pool and flow of foreign investment. Now, there is a rise in demand for high quality manufacturing tools and solutions which can help local companies increase their productivity and reduce cost in order to stay ahead of the evolving business climate,” says Willia m L im, Project Director for MTA Vietnam from the show’s organiser, Singapore Exhibition Services. The annual MTA Vietnam
exhibition has played a pivota l role in bridging the international manufacturing industry and Vietnam market, showcasing large international players of the industry whom local manufacturing companies can meet, network and possibly work with. O n l a s t y e a r ’s e d i t i o n , D r H a n s - Pe te r L a u b s c h e r, Managing Director-Asia Pacific o f Tr u mp f P r i v a te L i m i te d co m m e n te d : “ V i e t n a m h a s moved towards the production of high quality and competitive products for both domestic and international markets. Factories here are embracing advanced te chnolog y ne ce ssa r y to ac h ie ve t h i s, a nd t he M TA Vietnam plays an important role in this.”
Toshiba Expands Retail Manufacturing In Singapore Singapore: Toshiba Global Commerce Solutions have announced its continued commitment to Singapore with an expanded manufacturing presence to include the SurePOS 700 series of POS systems, which will be produced on Toshiba TEC Singapore Private Limited (TSE) premises. Toshiba’s annual spending in Singapore amounts to nearly US$200 million, and has approximately 140 combined employees from the company and TSE dedicated to retail development, engineering, 8
asia pacific metalworking equipment news July - August 2015
manufacturing, procurement, sales and services. “Retailers rely on Toshiba to keep their stores relevant by providing powerful, efficient and adaptable checkout solutions,” said Thomas Buchholz, vice president, growth markets sales and professional services of the company. “Our Singapore customers can take pride in the fact that we are expanding our manufacturing to include local sourcing of our newest and most powerful retail POS.” www.equipment-news.com
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BUSINESSNEWS
Dassault Systèmes Partners Safran
Paris, France: Dassault Systèmes and Safran Group have announced their partnership to develop expertise in the virtual validation of the additive manufacturing process using Dassault Systèmes’ 3DExperience platform. The partnership aims to develop an end-to-end digital solution for additive manufacturing to address upstream material design, downstream manufacturing processes, and testing for digital continuity for all engineering parameters necessary for the additive manufacturing of an engine part. This includes material science, functional specification, generative design, 3D printing optimisation, multi-robotic production and certification. Dominique Florack, senior executive vice president, R&D, Dassault Systèmes, said that the partnership aims to embrace and integrate new materials and methods of engineering, production and maintenance that will impact the aviation industry. “Together with Safran, we can nurture virtual world processes for a complete approach in this field that will help revolutionise tomorrow’s manufacturing.” Pierre Fabre, senior executive vice president, Research & Technology, Innovation, Safran, said: “Research and technology is a fundamental part of Safran, allowing us to drive continuous improvements for safer and more environmental-friendly air travel. By pooling expertise with Dassault Système and its 3DExperience platform, we can accelerate the innovation process to better meet customers’ needs.”
New Leaders For PTC Group Holdings Board Pennsylvania, US: PTC Group Holdings Corporation ha s announced several leadership changes to their Board. Effective from June 12, 2015, Christopher W Parker is chairman, Curtis G Solsvig III is chief executive officer (CEO) and director, and Cary Hart is president and director. Previous chairman, president and CEO Peter Whiting has resigned from his position effective from the same date to pursue new opportunities. New chairman Mr Parker said: “On behalf of the Board, we would like to thank Peter for his positive contributions to the company over the last 13 years. We are pleased that Curt and Cart have agreed to accept these new roles. We believe that their collective background and experience have made them the right choice to guide the company and lay the foundation for future success.” Both Mr Solsvig and Mr Hart have served leadership positions previously. Mr Solsvig said: “I want to thank the Board for selecting me for this leadership role. I look forward to building on the company’s strengths and to developing and implementing new strategies to ensure its growth going forward.”
Endless Possibilities
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asia pacific metalworking equipment news July - August 2015
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ENQUIRY NO 119
BUSINESSNEWS
Sumitomo Electric (Thailand) Expands To Myanmar
Yangon, Myanmar: Sumitomo Electric’s group company, Sumitomo Electric (Thailand) Limited has expanded to and established a branch in Yangon, Myanmar, to conduct marketing activities such as marketing research for infrastructure projects in the country. Myanmar’s economy has been developing significantly in recent years and is expected to have a growing need for infrastructure in the future. As such, the company has expanded into Yangon so as to be able to provide a wide variety of service in areas such as infocommunications, power cables, and transport. The new branch will conduct marketing research, promote sales and provide marketing support for local agents across the country for projects mainly related to infrastructure, thereby contributing to the development of Myanmar through a broad range of technologies developed by the group.
EMO 2015 Returns To Italy Milan, Italy: The worldwide exhibition of machine tools, EMO, is going to be held in Italy again this year, after six years. Promoted by CECIMO, the European Association for Machine Tool Industries, the tradeshow will take place from 5th to 10th October 2015 at the exhibition centre, Fieramilano. The biennia l travelling exhibition has chosen Milan as one of its locations alternating 12
asia pacific metalworking equipment news July - August 2015
with Hanover, as Italy is an imp or ta nt g loba l player in production and export. More than 110,000 sq m of net exhibition space has already been booked six months ahead of the event, exceeding the 95,000 sq m that was occupied during the last edition of EMO Milano (2009). The exhibition is expected to occupy 120,000 sq m when this year’s edition opens. C u r r e n t l y, m o r e t h a n
1,300 companies are already registered for the exhibition, of which Ita lia n compa nie s number the most, though closely followed by Germans, then Taiwanese, followed by Chinese and Swiss exhibitors. The halls of the exhibition centre of Fiera mila no R ho Pero will exhibit machine tools, robots, automation, additive manufacturing, mechatronic solutions and auxiliary technologies, expressing the sector’s international production and representing an industry that accounts for 64 billion euros (US$70.5 billion). “E MO ha s a lways been considered the most important event at the disposal of trade operators from the world's ma nu fac t u r i n g i ndu st r y to keep up -to - date on the new production technologies," stated Pier Luigi Streparava, appointed Commissioner General EMO Milano 2015. "This is why we decided to include additive manufacturing into the technological index of products of the sector’s leading international exhibition; it is one of the technologies that will be increasingly developed in future and to which the tradeshow will dedicate a special in-depth focus”. The show expects 150,000 visitors from approximately 100 countries, and also aims to take advantage of the parallel-running EXPO 2015. Milan will show a completely renovated look and an improved traffic flow, thanks to a revised and strengthened public transport service. Directly connected with the exhibition centre of Fieramilano Rho-Pero, Expo 2015 will offer t he E MO t rade op erators many attractions for a unique programme of fringe events. The concurrence of the two events will create really interesting synergies for the hundreds of thousands of visitors who will be coming to Milan from every www.equipment-news.com
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Malaysia (Central) Maxeffect Resources Sdn Bhd +603-8080-9393 mun@maxeffectresources.com
21 Bukit Batok Crescent #08-79 WCEGA Tower, Singapore 658065 +65-6515 4357 sales@hwacheon.com.sg
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BUSINESSNEWS corner of the globe. “A s o r g a n i s e r s o f t h i s exhibition we are committed to transforming the concurrence of the two tradeshows into real opportunities for our operators, by pla n n i n g ‘con ne c t ion activities’ and by activating numerous special services,” said Mr Streparava. One example he gave is the Hospitality programme that lists a large range of accommodation opt ion s re ser ve d for t rade operators. “Trade operators can reserve parking and book accommodation in and around Milan before, during and after
the exhibition period through t he e x hibit ion website,” he continued. “The first quarter of 2015 saw a 2.2 percent increase in Italian machine tool orders from the same period in 2014, making it the sixth consecutive positive quarter. With the EMO Milano 2015, a stronger positive trend is expected,” declared Alfredo Mariotti, director of EMO Milano. “With the positive forecast on the global use of machine tools as well to reach 66 billion in 2017, these are a good indication for a successful exhibition.”
Intel Acquires Altera California, US: Intel Corporation has announced their definitive agreement to acquire Altera Corporation for a total of US$16.7 billion. With the acquisition, the two companies hope to combine Intel’s manufacturing process and products with Altera’s field-programmable gate array (FPGA) technology. The combination aims to create new classes of products that meet customer needs in the data centre and Internet of Things (IoT) market segments. “Intel’s growth strategy is to expand our core assets into profitable, complementary market segments,” said Brian Krzanich, CEO of Intel. “With this acquisition, we aim to make the next generation of solutions not just better, but also more. Whether it is a new growth in the network, large cloud data centres or IoT segments, our customers and us expect better performance at lower costs. We look forward to working with Altera to serve our customers and stockholders better.” “Working with Intel has let us see first-hand the many benefits they can bring, and we look forward to having more opportunities together,” said John Daane, President, CEO and Chairman of Altera. “As part of Intel, we will be able to develop innovative FPGAs and system-on-chips for our customers in all market segments. This is an exciting transaction that provides immediate and significant value to our stockholders. We look forward to working closely with the Intel team to ensure a smooth transition and complete the transaction as quickly as possible.” Altera will become an Intel business unit to facilitate continuity of existing and new customer sales and support. Intel plans to continue support and development for Altera’s ARM-based and power management product lines. The transaction is expected to be positively benefit Intel’s non-GAAP EPS and free cash flow in the first year after close. The acquisition is expected to close within six to nine months, with a combination of cash from the balance sheet and debt. The transaction has been unanimously approved by the Boards of Directors for both companies and is subject to certain regulatory approvals and customary closing conditions, including the approval of Altera’s stockholders. 14
asia pacific metalworking equipment news July - August 2015
APPOINTMENTS Boeing Names New CEO Illinois, US: Boeing has announced that with effect from 1 July 2015, Dennis Muilenburg will take on the Dennis Muilenburg r o l e of C EO. Previously the company’s president and chief operating of ficer, he succeeds Jim McNerney, who has served the company in his position for the past 10 years. Mr Muilenburg has been with the company for the past 30 years, and has served as vice chairman since 2013. “Dennis will bring a rich combination of management skills, customer focus, business and engineering acumen, a can-do spirit and a will to win,” commented Mr McNerney. “With a deep appreciation of our past accomplishments and the energy and skill to drive those to come, he is well suited to lead our Boeing team into its second century.” To e a s e t h e t r a n s i t i o n , M r M c N e r n e y, 6 5 , t h o u g h p a s t retirement age, will continue to work as a company employee until the end of February 2016. He will also continue as Board chairman. On behalf of the company’s board of director s, Kenneth M. Duber stein, the company’s i n d e p e n d e n t l e a d d i r e c t o r, saluted both Mr Muilenburg and M r M c N e r n ey: “ We h ave h i g h confidence in Dennis, who has distinguished his career by taking on tough challenges and delivering results. In a decade as CEO, Jim restored the vitality, focus and reputation of a storied American company, and we thank him for his extraordinary leadership and congratulate him on his success.”
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TruBend press brakes spark a passion for bending technology. From the smallest electronic components to thick, large format metal sheets, they allow you to tackle an unparalleled range of parts with maximum productivity. With their exceptional precision and user-friendly operation, they cover all the bases. TruBend machines have been carefully designed to create an ergonomic workplace – and operators love working with them! That makes TruBend press brakes the perfect foundation for your success. Isn’t it time to choose TRUMPF? www.sg.trumpf.com
Contact us to find out which machine models are already available in your market: www.sg.trumpf.com The TruBend 5130 has received the following awards:
ENQUIRY NO 116
BUSINESSNEWS
Queen’s Award For Enterprise Goes To Renishaw B r it a i n , U K : Re n i sh aw w a s awarded a Queen’s Award for Enterprise 2015 in the Innovation category for the development and manufacture of its RESOLUTE family of non-contact, optical position feedback devices. With the position encoder, it is now possible to tailor the performance of motion control systems used in ma nufacturing a nd other environments. This award is the company’s 18th Queen’s Award in the 50th anniversary year of this prestigious awards scheme. A single t rack fine - pitch o p t i c a l a b s o l u te e n c o d e r, Re solute is suitable for the most demanding applications. It can determine position to a resolution of one nanometre with motion speeds of up to 100 metres per second for linear position applications, and is capable of 32-bit resolution at up to 36,000 RPM for rotary (angle) applicat ions. It deter m ine s position immediately at switchon and is compatible with a range of ‘open’ and ‘proprietary’ serial protocols. S i r D a v i d M c M u r t r y, R e n i s h aw ’s C h a i r m a n a n d Chief Executive, said: “It is a phenomenal product that marries our years of experience and expertise in areas such as optics, high speed image processing, system engineering and precision manufacturing.” It is employed in a diverse variety of applications including safety-critical position feedback for medical robots, the control o f p re c i sio n m e t a l wo rk i n g machine s, the ma nufacture of flat panel displays and the production of semiconductors. T he Q ue e n’s Awa rds for Enterprise are made each year by Her Majesty The Queen, 16
asia pacific metalworking equipment news July - August 2015
MakerBot Strengthens Asia-Pacific Presence With Stratasys Hong Kong: MakerBot and Stratasys AP Limited, a subsidiary of MakerBot's parent company Stratasys Limited, announced their plan to strengthen MakerBot's market presence in Asia Pacific through the formation of a new division, MakerBot Asia Pacific & Japan (MakerBot APJ). This new division will aim to capture the grow th potential of desktop 3D printers and scanners in the region. Also, it will leverage on Stratasys’ current regional presence to strengthen its local operations and expand availability of its products. It will also continue to support the company’s existing network of distributor and reseller partners in Asia Pacific. “With Asia being an important market for desktop 3D printing and offering great opportunities that are a strategic priority for the company such as in education, engineering and design, Stratasys can help expand our presence in the region,” Jonathan Jaglom, CEO of MakerBot believes. "This is another step in our efforts to take advantage of synergies with Stratasys to grow our business internationally and accelerate the adoption of desktop 3D printing around the world." As of present, Stratasys has an Asia Pacific headquarters in Hong Kong, and nine other regional offices in countries like China, Japan and Korea to serve its customers in Asia Pacific. These offices will support MakerBot's local business operations with marketing, sales and customer support initiatives. The new division will be led by Shiry Saar who has been appointed General Manager. It will be based in the Hong Kong headquarters and operating under Stratasys AP Limited. Ms Saar has served in several management roles at Stratasys previously. "I am excited to lead MakerBot APJ to facilitate the adoption of our 3D Printers in the region," she said. With both companies catering to education and professional verticals, she believes the collaboration, and its wider range of products, will enable them to better serve customers. "I look forward to working closely with Stratasys' local teams to extend MakerBot's leading role in the desktop 3D printing industry to the Asia Pacific region." Omer Krieger, General Manager of Stratasys Asia Pacific, agreed with Ms Saar and expects the new division to add significant scale and capabilities to the company’s 3D printing solutions business. on the advice of the British Prime Minister, who is assisted by a n Adv isor y Com m it te e that includes representatives of Government, industry and commerce, and the trade unions.
The Awards are given solely on merit and competition is fierce. The number of Awards presented each year is not preset and depends on the quality of the applications received. www.equipment-news.com
OGP SmartScope Flash CNC300 IS your parts demand high quality measurement control? OGP SmartScope has its unique Multisensor Technology capability – cooperating Vision, Laser, Touch-probe and Micro-probe in a single setup. All the sensors are calibrated to a single XYZ reference and its enhance GD&T accuracy. With powerful MeasureMind 3D MultiSensor software, the graphic and numeric analysis data are done in seconds. SmartScope Flash CNC300 features a compact 300x300x250mm XYZ axis multi-sensor capability and a high quality 12:1 AccuCentric® zoom lens:- an excellent optical performance with automatic calibration on each magnification changes.
Vici Vision Optical Measuring Machine MTL 1 DO you use traditional method to measure turned parts? MTL1, a high precision optical measuring machine for all kind of turned parts:- such as transmission-drive/cam/electric-motor shafts, hydraulic/ pneumatic/engine valves, CV joints, turbine wheels, fasteners/screws, etc. • Quick measurement:- collects hundred measurement in 10~30 seconds, compare to 30~60 minutes on traditional method • Efficient:- features with on-board step-master, this allows MTL 1 effectively used in the shop floor • Less human error:- non-contact type allows consistent and accuracy measurement (2um on diameter and 5um for length)
Itaca FlexGauge™ CMM Cost effective and portable CMM for used in the shop-floor environment Itaca FlexGauge™, a rugged, compact, flexible and cost effective CMM designed for shop floor inspection with an unprecedented speed, intrinsic accuracy and ability to face hard production environments. Inspection cycle can be easily programed by self-teaching. Built on thermally super stable architecture for hard environment, uses 100% air bearing moving table, vertical stage and a small footprint, making it a perfect portable CMM to replace the usual in-production gauging. It fits well for small parts, 160x160, eg bearing rings, small pipes, synch gears, etc.
Optical Gaging (S) Pte Ltd Multisensor Metrology
www.smartscope.com.sg Optical Gaging (S) Pte Ltd
21 Tannery Road, Singapore 347733 Tel: 65 6741 8880 • Fax: 65 6741 8998 E-mail: sales@smartscope.com.sg
Singapore • Malaysia • Indonesia • Hong Kong • South China Thailand • Philippines • Vietnam • Taiwan • Australia • New Zealand • Middle East
ENQUIRY NO 118
RS Components Keeping Up With Indonesia and TDK Join Hands In New Distributor Agreement
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Gunawan Kartapranata
BUSINESSNEWS
Singapore: RS Components (RS) have established an agreement with TDK Corporation to distribute the Japan-based manufacturer’s portfolio of TDK and EPCOS passive electronic components globally. With the agreement, it not only consolidates the existing relationship between the two companies, but also enables customers around the world to purchase TDK products through RS. RS stocks a comprehensive range of TDK passive components, including ceramic, aluminium electrolytic and film capacitors, ferrites and inductors among many others. These components are used in a diversity of applications across many market sectors, among them information and communication technology, consumer, automotive, and industrial electronics. “This agreement with R S assures our customers that they can gain fast, easy access to our pa ssive components anywhere in the world,” said Osamu Katsuta, General Manager, Global Distribution Division, TDK Corporation. “RS has an established eCommerce structure and logistics record, and our cooperation will have positive benefits on our customer service.” “TDK offers a breadth of choice in passive devices, and our collaboration will ensure that this vast product choice is passed on to customers through quick, easy online selection via the RS websites,” commented Kevin McCormack, Global Head of IP&E at RS Components. “By stocking these products in our global warehouses we are also providing a guarantee of fast delivery, which is a real advantage for engineers facing project deadlines.”
Indonesia: Indonesia recorded a lower-than-expected 4.71 percent yearon-year growth in the first quarter of 2015 (Q1), arousing concern in her investors regarding the forecast of her economy for the year. These are further fuelled by the rising inflation in the country, and the continual contraction of the manufacturing sector. Despite foreseen expectations that the GDP growth figure would be lower than five percent, the recorded GDP growth was worse than expected. Experts attribute this result to weak exports, a high interest rate environment, lower crude oil prices, and sluggish government spending. Being a large commodity exporter, with plunging commodity prices in recent years coupled with a slowing economic expansion in China and Japan— two key trading partners of Indonesia that comprise nearly a fifth of Indonesia’s non-oil & gas exports— the export performance of Indonesia has weakened accordingly. The country’s exports fell 11.7 percent year-on-year to US$39.1 billion in Q1. Apart from weak exports, another factor affecting the country’s economic growth is that the Indonesian central bank (Bank Indonesia) continues to uphold a high interest rate environment with its key rate of 7.50 percent that limits people’s purchasing power. However, the bank is also unable to cut its interest rate drastically to support domestic economic expansion due to the country’s high inflation, current account deficit and looming capital outflows ahead of higher US interest rates. In a recent May report, Indonesia’s inflation rate was reported to have accelerated to 6.79 percent year-on-year for April. Experts reasoned this higher inflation was due to higher transportation costs following a fuel price hike in late March, as well as the 0.50 percentage point increase in food, beverages, cigarettes & tobacco expenditure group. Experts foresee the possibility of the country’s economic growth to slip slightly below the World Bank’s current growth estimate of 5.2 percent for the year. In combination with tightening global financial conditions, a weak rupiah and limited fiscal room for the government to boost the economy through infrastructure investment, this will cause stagnating economy growth of the Indonesian economy. Affected by declining export orders and continued weak domestic demand, Indonesia’s manufacturing sector continues to contract, making April the seventh consecutive month of declining manufacturing activity. With rising costs of imported raw materials due to the weak rupiah, Indonesian businesses are unable to price their products competitively in international markets. Further, the sector has been affected by nonconducive weather conditions and employment cuts. Conditions are expected to remain tough for the rest of the year.
asia pacific metalworking equipment news July - August 2015
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Tungaloy Singapore Pte. Ltd. 62 Ubi Road 1 #06-11 Oxley BizHub 2 Singapore 408734 Tel: (65) 6391 1833 Fax: (65) 6299 4557 www.tungaloy.co.jp/tspl/ ENQUIRY NO 123
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BUSINESSNEWS
Jon, Beijing, China
Steady Forecast For China Steel Exports
Shanghai, China: China’s steel exports are unlikely ‘to fall much’ this year, says the China Iron & Steel Association (CISA), as low prices and a steady demand balance the scrapping of an export tax rebate on certain products. There had been a concern that exports would drop drastically following Beijing’s decision to control exports in an attempt to avoid increasing trade friction and in doing so, cut output so as to reduce environmental pollution. Also, the government has additionally stepped up on anti-dumping measures and removed the tax rebate exporters had been taking advantage of for boron-added steel. These actions did influence and slowed growth of the steel exports, but the significant drop in iron ore prices offset the overall effect. With lower prices and a firm international demand, Chinese steelmakers were able to provide overseas markets with a steady supply of cheap products. “China will continue to export large volumes of steel as the stronger demand from international markets support prices,” the CISA said. “Chinese steel exports will remain competitive and not drop substantially.”
Mitsubishi Electric Establishes New Training Centre Aichi, Japan: Mitsubishi Electric Corporation has announced its plans to build a new training centre on its current premises in Inazawa to strengthen human resources development. The centre is scheduled to start operating in April 2016. Spanning just over 1,000 sq m, the new centre will comprise several training rooms equipped with advanced IT systems for diverse training purposes, and will be used by the company’s personnel and affiliates from Japan and abroad, from new hires to mid-career employees. Training provided includes operational processes such as marketing, engineering, manufacturing, installation and maintenance. Receiving this training would be any of the company’s employees, as the centre aims to equip group-wide employees with knowledge and skills to help strengthen the company’s position in the global markets. 20
asia pacific metalworking equipment news July - August 2015
Thai Exports Continue Downward Trend Bangkok, Thailand: Thai exports have continued to contract in May for the fifth consecutive month, by 5.01 percent year- on-year to US$18.4 billion, according to Somkiat Triratpan, director of the Commerce Ministry’s Bureau of Trade and Strategy. This brings the total contraction in the five month period to 4.2 percent year-on-year, or $88.7 billion. Imports have suffered as well, declining 9.39 percent to $85.4 billion, and translating to a trade deficit of $3.32 billion. Exports for manufacturing products dropped by 4.5 percent in May, compared to the same month last year. While exports to the US, China and neighbouring countries such as Cambodia, Laos, Myanmar and Vietnam still increased in May, the drop of 13.7 percent in shipments to the European Union and 4.1 percent to Japan were responsible for the overall dip in exports, said Mr Somkiat. Despite this, Thailand has still been able to maintain market shares in several markets including the US, China, Japan, India, Singapore and more. The ministry has since forecast a 1.2 percent growth for the whole year, predicting that the outlook would improve in the second half of this year.
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Japanese Machine Tool Orders Up In May Tokyo, Japan: The total value of Japanese machine tool orders in May was 138.55 billion yen (US$1.13 billion). This was up 2.9 percent from April, and represented a 15 percent increase in growth from the same period last year. Total orders for the previous four consecutive months surpassed US$1.06 billion, with the highest record marked in May. For the first time in two months, domestic orders increa sed, rising nine percent from April to US$429 million. This translated to a 43.9 percent increase in orders as compared to that of May 2014. Delving deeper to specific industries, orders in May rose from April for industrial machinery (17 percent), electrical & precision machinery (37.7 percent) and aircraft, shipbuilding & transport equipment (25.3 percent). Orders for that in motor vehicles however fell 22.4 percent. Foreign orders registered a 0.5 percent decrease from April to US$696 million, declining for the second consecutive month. This however, still translated to an increase of 2.3 percent of foreign orders compared to that of May 2014. Compared to April this year, orders for Asia and Europe fell by 2.7 percent and 8.8 percent, to US$385 million and US$115 million respectively. That for North America in contrast rose by 9.9 percent to US$187 million. When compared to May 2014, orders for May 2015 were still higher for Asia (6.6 percent) and North America (11.1 percent). For Europe, orders declined by 14.7 percent. With orders going strong, experts from the Japan Machine Tool Builders’ Association foresee a continuing positive trend in domestic and foreign demands henceforward. www.equipment-news.com
Garuda Indonesia Buys 30 Airbus Aircraft
Indonesia: Garuda Indonesia has signed a Letter of Intent (LOI) with Airbus for the purchase of 30 A350 XWB aircraft. The airline plans to use the A350 XWB to develop and expand its medium and long haul network, as the aircraft offers the ability to fly non-stop from Jakarta or Bali to Europe. “Following our success in revitalising our regional operation in Asia and the Pacific, the development of our long haul network will be a priority in the coming years,” said Arif Wibowo, CEO of Garuda Indonesia. “With its reduced fuel consumption, range capability and extra wide cabin, the A350 XWB provides us the chance to reposition ourselves as a premium carrier in the competitive long haul market out of Asia.” “We are pleased to welcome Garuda Indonesia as the latest airline to commit to the all-new A350 XWB,” said John Leahy, Airbus Chief Operating Officer, Customers. “The aircraft has set a new mark for the larger segment of the mid-size wide body market and is already proving to exceed expectations in service with its first operator. We look forward to seeing the A350 XWB flying in the colours of Garuda Indonesia as it extends its reach to more destinations across the world.” The A350 XWB features the latest aerodynamic design, carbon fibre fuselage and wings, plus new fuel-efficient Rolls-Royce Trent XWB engines. Together, these latest technologies translate into unrivalled levels of operational efficiency, with a 25 per cent reduction in fuel burn and emissions, and significantly lower maintenance costs. The A350 XWB has been especially successful in the Asia-Pacific region, where airlines have ordered a total of 244 aircraft, representing almost a third of the 780 orders recorded so far worldwide.
Kjellberg Establishes Indian Subsidiary Pune, India: Following several years’ experience and activities, Kjellberg has expanded its presence in India with its subsidiary Kjellberg Cutting and Welding India Private Limited in Pune, in the federal state Maharashtra. The subsidiary supports Indian customers directly in all service and sales affairs, and with significantly less effort than before the subsidiary had been established. Managing directors Carsten Trentau and Falk Tzschichholz aim at further improving customer relations and making them even more reliable as the Indian market is of major importance for the company. Located in Pune, the local industries like automotive engineering further support the subsidiary and the company as it offers great potential to the company’s portfolio of cutting equipment. July - August 2015 asia pacific metalworking equipment news
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BUSINESSNEWS
Hexagon Metrology Partners Singapore Institution
Singapore: Hexagon Metrology has signed a Memorandum of Understanding ( MOU ) with Singapore institution, Republic Polytechnic (RP), to collaborate on knowledge sharing and joint projects for manufacturing applications and processes. With the partnership, a joint laboratory will be set up that will provide a full suite of solutions in product realisation, such as Computer-Aided Design (CAD), 3D prototyping, measurement, inspection and tooling design for mass production. It will thus serve to link design, manufacturing and metrology operations into a single system. Final-year students from the institution studying Industrial and Operations Management would benefit from the partnership by gaining practical skills that complement curriculum, and be allowed to intern at the company to learn diverse industrial metrology applications across various sectors. The MOU was signed by Hexagon Metrology’s Asia Pacific president, Lim Boon Choon, and RP’s deputy principal of industry services, Seto Lok Yin. Witnessing the ceremony was Carsten Struve, the company’s chief technology officer, and Yeo Li Pheow, RP’s principal and chief executive officer. “Republic Polytechnic has been making great strides in its industry engagement efforts over the years. This will benefit their students immensely as they are well attuned to industry developments when they graduate,” said Mr Lim. “We believe the industry has a responsibility to help academic institutions with technical research and in developing the great minds of the future. Republic Polytechnic and Hexagon Metrology Asia Pacific are well-positioned to cooperate on a number of interesting projects that will benefit both enormously,” added Mr Struve. The institution is honoured to partner with the company, said Mr Seto. The laboratory will enable the students to deepen their skills in metrology technology and advanced manufacturing, and allow both parties to explore projects in the area, he added. 22
asia pacific metalworking equipment news July - August 2015
Italian Additive Manufacturing Gets A Name It a ly: E stablished just this yea r, the A ita -A ssocia zione Italiana Tecnologie Additive (Italian Associate of Additive Technologies) is the reference entity for Italian industrial sectors of additive technologies and 3D printing. Making up its General Assembly and Board of Directors a re more tha n 50 members consisting machine manufacturers or dealers, design software companies, service centres and other big companies and SMEs involved in additive technologies for manufacturing. “With the high capabilities of additive process based machines that integrate machine tools and other types of instrumental goods, Italian manufacturing industries are able to develop and produce highly innovative products and services that attract attention at both domestic and overseas levels. This has contributed to the Italian industrial sector’s growth,” said Alfredo Mariotti, Association General Manager of the entity. The entity reflects the rapid growth of the additive technologies sector in the Italian m e c h a n ic a l m a nu fac t u r i n g industry, he added.
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METAL CUTTING
Integrity, The Key With high volumes of cast iron components, tools which can satisfy specific requirements are very much in demand. Lim Gan Shu, Walter Singapore Marketing explains.
Negative basic shape, positive geometry: 16 cutting edges per insert ensure maximum efficiency with the octagonal insert.
The new M2025 finishing face mill from Walter is a true plug and play solution: Loosen the clamping screws, change the inserts, retighten the clamping screws – and you’re done.
C
ast iron components are desig ned to ret ai n the integrity of their milled joint surfaces. However, optimum leak tightness and function can only be guaranteed when the surfaces are completely flat. Efficient finishing end mills are the ideal tools for that particular job: Extremely precise with easy handling that noticeably reduces setup requirements. Wherever machine tables see high volumes of cast iron components, such
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asia pacific metalworking equipment news July - August 2015
as in the passenger car and commercial vehicle industry, tools which can satisfy specific requirements are very much in demand. For example, when milling the joint faces of cylinder heads, crankcases or gearbox housings, anyone wishing to reduce processing times will require higher cutting rates and usually a single operation must suffice to meet the most exacting quality requirements. To ensure that an engine or gearbox continues to run reliably for a good many years,
the contact surfaces must be totally f lat. With the M2025 and M2026 finishing face mills, Walter offers two tool ranges designed specifically for these applications. The face mills are equipped with particularly efficient 16-edged octagonal peripheral inserts and three, 4-edged, wiper inserts. What distinguishes the two face mill ranges is their overall diameter – and, depending on this, the cutting width of the wiper inserts (with the M2025: D = 80-160 mm; and the M2026: D = 200-250 mm). The basic shape of the peripheral and wiper inserts is negative, while the cutting edge geometry is positive. Convex edge wiper inserts ensure a high level of surface quality. In terms of cutting tool materials for finishing, Walter uses grades particularly suitable for cast iron workpieces, e.g. WAK15 and WHH15. All inserts are precision-ground and the cutter bodies feature precision insert seats. For the user, this means a true plug and play solution. By loosening the clamping screws, change the inserts, retighten the clamping screws and you’re ready to cut metal. Wolfgang Vötsch, Senior Product Manager for milling at Walter AG, believes: “Our new M2025 and M2026 finishing face mills combine high efficiency and quality with extremely simple handling. These are precisely the properties our users are looking for.” The runout crucial for a good surface is accurate to the µm – even without tool presetting. But this is not the only opportunity for the user to save valuable time. The insert seats are numbered and the cutting edges can be changed extremely quickly thanks to the wedge clamping of the octagonal inserts. In stable setup conditions, maximum feed rates can be achieved, which in turn keeps production times to a minimum. The bottom line is, with the new M2025 and M2026, that are just the right tools wherever excellent surface quality and maximum output in production are required. Got a Question? Make An Enquiry.
ENQUIRY No.
5001
Turn to page 76a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 115
METALCUTTING
Aerospace:
Revolution
Through Innovation The DMG Mori Aerospace Excellence Centre develops and realises efficient and cost-saving machining processes for the aerospace industry with innovative technologies and professional expertise By Ralph Schiffler, CEO Pressgate
F
or severa l ye a rs now the aerospace industry ha s b e e n u ndergoing radical change: rising kerosene prices and the demand for an improved CO 2 balance are forcing manufacturers to i nve st i n more e conom ic a l and environmentally-friendly aircraft. This in turn gives rise to completely new challenges where the manufacture o f soph i st ic ate d aerospace components is concerned. On the other hand the increase in air traffic also means that more aircraft have to be constructed re su lt ing in ever shor ter innovation cycles. As a leader of innovation in the field of machine tool construction DMG Mori supports the development of aerospace technology with future-orientated manufacturing solutions in close cooperation with users from the sector in its Aerospace Excellence Centre at Deckel Maho Pfronten.
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asia pacific metalworking equipment news July - August 2015
The Dreamliner from Boeing or the A350 XWB from Airbus are two examples of the first responses to the increasing economic and technological cha llenge s con f ront ing t he aerospace industry. Increasing
order numbers for other fuelsaving models such as the Airbus A320 Neo or the Boeing 737 Max reflect the rethinking process that is also taking place where short and medium-haul aircraft are concerned. Michael Kirbach, Head of the DMG Mori Aerospace Excellence Center, claims that the new a ircra f ts have one thing in common: “There is no escaping the use of extremely light but at t he sa me t ime high-strength materials for the airframe structure nowadays materials such as titanium alloys or composites. In order to reduce emissions the temperatures in the engines are now higher placing even higher demands o n a p p ro p r i a te N i - a l l oy s .” The ability to machine these efficiently requires competence and future-orientated machine tool technology. DMG Mori concentrates on the most demanding applications in aerospace technology in its Aerospace Excellence Centre. The machine tool manufacturer benefits from both many years of experience in manufacture of high-value components as well as the most innovative CNC machines to be found on the
In its Aerospace Excellence Center at Deckel Maho Pfronten DMG Mori supports the development of aerospace technology with future-orientated manufacturing solutions in close cooperation with users from the sector.
Michael Kirbach, Head of the DMG Mori Aerospace Excellence Center: “We continuously strive to develop innovative processes that can revolutionise the aerospace market.” www.equipment-news.com
METALCUTTING market. The defined aim of DMG Mori is to capture the individual re quirement s of customers and develop perfectly aligned and flexible as well as reliable manufacturing processes for the respective components on the basis of its diverse product por tfolio. “A f ter a ll today’s production costs have to be brought in line with far shorter life cycles than was formerly the case”, explains Michael Kirbach. Projects can begin with technical consultations and go on right through to encompass turnkey solutions designed specifically in accordance with customer specifications. The performance spectr um in this ca se is enormous, because turnkey projects include the machine tools, their individual equipment, a component related process concept with suitable selection of tools and clamping devices as well as NC programmes and an integrated quality control. Michael Kirbach goes on: “The whole system is run in on the user’s premises, so that reliable
With both many years of experience in manufacture of high-value components as well as the most innovative CNC machines to be found on the market the DMG Mori Aerospace Excellence Center concentrates on the most demanding applications in aerospace technology.
and economic production can begin from the very first day after the system is handed over.” Manufacturing solutions for the aerospace industry focus
Complex parts such as turbine housings made from difficult to machine Nickel-alloys are common in aero engine technologies.
DMG Mori achieves the high chip volumes and necessary precision with options such as its heavy duty machining package.
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on the key trends in the branch, above all the topic of lightweight construction. Complex structural parts made of aluminium are milled from a solid block. The increasing use of composites also means a higher demand for components made of titanium. Even then DMG Mori achieves the high chip volumes and necessary precision with options such as its heavy duty machining package. This comprises with the new duoBLOCK 4th Generation a powerful gear spindle with a torque of up to 1,100 Nm and additional connectable hydraulic damping pads on the linear a xes. Specifically developed devices contribute to higher positioning tolerance and 5-axis simultaneous machining enables cost-effect production in a single setup, while pallet changers or fully automatic solutions reduce idle times thus boosting productivity even further. Lightweight construction also goes hand-in-hand with an increasing focus on fibreJuly - August 2015 asia pacific metalworking equipment news
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METALCUTTING Versatile machines with a swivel rotary table such as the DMU 85 monoBLOCK® are most appropriate for the demanding production of Blisks.
Since temperatures in turbines increase in order to reduce emissions, more precise and specially designed cooling holes become more and more important. Lasertec PowerDrill and Lasertec Shape machines from DMG Mori can produce these through the vane material including heat resisting coatings.
Nowadays, structural parts in aerospace have to be extremely light and stable at the same time.
reinforced composite s. The reason for this: their specific strength and light weight. DMG Mori envisions completely new requirements in this respect, explains Michael Kirbach: “The de ma nd for a n automate d , economical machining option for the reworking, maintenance and repair of damaged fibre composite components w ill increase in addition to the actual serial production of composite components themselves.” With its Ultrasonic technology and
i nte g ra l pro ce s s a ppro ac h DMG Mori enables the highly efficient machining of these high-performance materials in optimum component quality. In this form of ultrasonic-assisted milling t he tool rotation is superimposed with additional oscillating movement kinematics in the longitudinal direction by means of a patented, inductive Ultrasonic actor system. This reduces the effective process forces by up to 40 percent, enables clean edges and prevents
One of the latest such developments is laser deposition welding with the Lasertec 65 3D. The unique feature of this machine is that it combines laser deposition and milling in a single setup thus enabling the manufacture of highly complex components.
fibre pull-out and delamination. In addition Ultrasonic technology can, according to the latest findings, realise feed rates of more than 12 m/min and a tool service life for sold carbide tools of over 600 m. A s long - term pla nning is typical in particular for aerospace technology, DMG Mori, too, relies on farsightedness and extremely advanced manufacturing solutions. “That is the only way to guarantee sustained competitive capacity for all concerned”, says Michael Kirbach. “And it is also the reason why we continuously strive to develop innovative processes that can revolutionise the market.” One of the latest such developments is laser deposition welding with the Lasertec 65 3D. The unique feature of this machine is that it combines laser deposition and milling in a single setup thus enabling the manufacture of highly complex components. Many three dimentional geometries with undercuts can be realised, for example. Michael K irbach says that there are g reat benefits because this technology opens up dimensions in construction that would have been “unthinkable” before. Got a Question? Make An Enquiry.
ENQUIRY No.
5002
Turn to page 76a or log on to www.equipment-news.com to enquire
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asia pacific metalworking equipment news July - August 2015
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ENQUIRY NO 122
METALCUTTING
Mill with Skill Milling has gone through many stages of evolution and revolution with gradual technical improvements and innovations as we move forward to maximising productivity in the world of manufacturing. Contributed by Andrei Petrilin, Technical Manager, Iscar Tefen
S
ince the second half of the 19th century, the proce ss of remov ing stock from workpieces by the use of a rotating tool with cutting teeth, such as a milling cutter or a milling tool, has become firmly established as an invaluable part of the manufacturing processes. Over the last century and a half, as with most aspects of machining, the field of milling has developed through both evolution and revolution. Gradual technical improvements have ensured that milling machines have continually evolved, whilst innovations such as computer numerical control (CNC) technologies have provided revolutionary leaps forward in the capabilities of milling machines. Modern 5 -a xis machining allows extremely efficient milling of complex shapes. Today, milling is the main method of machining by stock removal from both flat and shaped workpieces that have a range of accuracy and surface finisher requirements. Machine tool developments explain only half of the remarkable progress made within the field of milling. The feeds and speeds available from today’s milling machines could not be exploited without the advanced capabilities provided by modern milling cutters. Although the sheer size of machine tools enables their developments to be readily observed and appreciated, the
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asia pacific metalworking equipment news July - August 2015
sub-micron, nano and molecular scale of many of the advancements made in the area of milling cutters means that their improvements are less obvious. Not so long ago, the use of polycrystalline diamond (PCD), cubic boron nitride (CBN) and whisker-reinforced ceramics, as materials for milling cutters was regarded as revolutionary; now these materials and methods are commonplace. However, cemented carbide, especially with wear-resistant protective coatings, rema ins the ma in material for use in solid carbide endmills and for indexable milling cutter, replaceable inserts.
In recent times, the extraordinary progress made w it h in t he f ield of p owder metallurgy has led to a significant reduction in the sizes of carbide g ra ins. Today, the majority of solid carbide endmills and replaceable inserts are made from submicron carbide substrates featuring minute 0.8 - 0.3 Οm grains. These small grains enable the production of extremely sharp, yet very tough cutting edges. Moreover, reductions in grain size, in combination with the introduction of advanced pressing technologies, allows the production of inserts with co mple x sha p e s t hat have considerable differences in the height of the inserts’ corners. These innovative new shapes provide optimal cutting geometries, which guarantee, not only smooth and stable milling, but also increased accuracy of the machined surface. Practical achievements in the field of nanotechnolog y have resulted in a new class of wear-resistant coatings created There are various designs of cutting tools intended for HFM, both indexable and solid
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METALCUTTING by physical vapour deposition (PVD). These radical coatings, a combination of layers with t h ic k ne s s’ o f up to 5 0 n m (nanometres), deliver significant increases in the strength of the coating, when compared to conventional methods. Also, the latest post-coating treatment of replaceable inserts eliminates defects in the upper coating layer and provides additional durability. For example, carbide grades for milling inserts – Iscar’s IC808 and IC830 - are based on the above principles. They feature nanolayer PVD TiAlN coating and further post-coating treatment in accordance with the original Iscar Sumotec technology. Due to the need to remove large amounts of stock in milling operations, roughing procedures a re usua lly ex tremely time consuming, therefore process time reductions enable users to achieve higher profitability. There are several methods of productive rough milling that allows this goal to be reached, although they make specific demands for the milling cutters. When milling with high feed per tooth (HFM) or fast feed (FF) milling, the depth of cut is small, and the feed is significant. For example, in HFM of steel work pieces, the feed per tooth is calculated in millimetres and often exceeds the depth of cut. A high feed milling tool has specially shaped cutting edges that enable the cutting force to act along the tool axis, in the direction of maximal rigidity of the milling machine and when the bending load on the tool is low. The main advantage of HFM is a very high metal removal rate (MRR) at relatively low power consumption. There are various designs of cutting tools intended for HFM, both indexable and solid. Their distinct feature is the form of their cutting edges; normally the www.equipment-news.com
The cutting edges of these advanced inserts feature specially designed chip splitting grooves.
cutting edge resembles a section of a circular arc that results in a tool cutting edge angle of approximately 10-17 degrees. The rake face of the replaceable double-sided insert Iscar Helido Upfeed H600 family of indexable milling cutters has a combination of convex and concave surfaces. This complex shape considerably improves chip formation and chip evacuation from the cutting zone. The insert geometry consists of alternating facets, inclined in opposite directions and results in an economic advantage – six indexable cutting edges on each insert (three on each side). Originally HFM was intended for the roughing and machining of complex surfaces, such as dies and molds, although it is now widely used as a highly productive roughing method for the milling of plane faces, particularly on large workpieces. However, not every machine tool has high-velocity feed drive necessary for HFM.
For slower-speed but highpower machines, moderate-feed milling cutters (MF) with cutting edge angles of 30 degrees are available. MF working feed per tooth is less than in HFM, but more tha n common va lue s, hence the ter m ‘moderate’. Conversely, the depth of cut is greater comparing with typical HFM tools. Accordingly, high productivity rough milling is achieved, but with increased power consumption. If it is necessary to efficiently remove a substantial volume of material with a considerable depth of cut (deep cavity, wide e d g e , de e p shou lde r, e tc), indexable extended flute (or longedge) cutters are the first choice milling tool. With cutting accomplished by a set of replaceable inserts, ex tended f lute cutters w ith tangentially clamped inserts (such as Iscar Helitang T490) deliver maximum performance, a s t he ta nge nt ia l cla mping July - August 2015 asia pacific metalworking equipment news
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METALCUTTING milling cutters continue to fulfil the majority of roughing operations. To reduce the costs of further finishing, cutting tool designers are constantly searching for ways of providing high-grade surface roughness as early as possible in the rough milling process. This objective prompted Iscar’s R&D staff to create Iscar DoveIQmill – a family of indexable face mills with a cutting edge angle of 50 degrees. This pioneering design of face mill features, cost-effective double-sided replaceable inserts with positive inclination of cutting edge, provides a smooth and stable cut. In addition, the advanced geometry of the inserts, and their rigid and clamping in the mill pockets, results in the mirror surface of workpieces when milling with rough cutting data as opposed to finish machining.
This objective prompted Iscar’s R&D staff to create Iscar DoveIQmill – a family of indexable face mills with a cutting edge angle of 50 degrees .
design principle ensures ultimate strength and rigidity of the cutter body. The desire to reduce power consumption and improve the dynamic behaviour of extended flute cutters led to the use of inserts with a chip splitting action. The cutting edges of these advanced inserts feature specially designed chip splitting grooves. Further developments in this area have resulted in the introduction of inserts with chip crushing ability, that literally chop chips into small segments. Further developments in powder metallurgy allow the production of tough, sintered chip crushing i n se r t s w it h h i g h - st re n g t h shredded cutting edges, such as Iscar’s indexable Millshred, that are able to withstand heavy loads throughout rough milling routines. 32
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Rough Milling With A Mirror Finish Advanced new tool materials and progressive machining techniques (HSM – high speed milling, etc) have enabled major advancements in process engineering a nd planning. In many cases it is now possible, not only to significantly reduce finish abrasive machining (grinding, etc) of hard materials, but to replace it with milling. This method significantly reduces the number of operations during manufacturing and sometimes means just a single production setup – a dre a m for ever y technologist. As with other areas of milling improvements, t he limit of material hardness continues to rise. Today solid carbide endmills can successfully machine hard steel quenched to HRC 63 and more. Nevertheless, the indexable
Emphasis On Versatility I n t h e l a te n i n e t i e s I s c a r introduced Chammill - a new family of indexable milling cutters. The prefix ‘Cham’ referenced the word chameleon to highlight the main feature of the advanced new tools. The pocket of the cutters was able to carry one -sided inserts of different shapes - two types of square inserts (for mills with cutting edge angle 90° or 45°), and round or octagonal inserts. Since the principle of versatility was realised – similar designs can now be found in in a number of ranges belonging to various cutting tool manufacturers. From the point of view of ma inly sma ll a nd medium customers, versat ilit y of inde x able m illing cut ters provides increased efficiency (utilisation rate) of the cutter and reductions in tool stock. Levels of versatility were introduced further into ISCAR products, specifically the indexable mills SOF45 of HELIDO 800 family - that are suitable for mounting the following double-sided inserts: www.equipment-news.com
METALCUTTING square with 8 cutting edges and octagonal with 16 cutting edges. The resulting face mills with 45° cutting edge angles demonstrate impressive performance. Also available are one-sided round and octagonal inserts. Reducing Set-Up Time The Multi-Master – a modular tool system with interchangeable solid carbide cutting heads, introduced by Iscar in 2001, features a range of shanks (bodies) and heads and resulted in endless tool design configurations and possibilities. The flexible properties of the system provides a means, not only of lowering tool stocks, but also of reducing the need to sourcing expensive, tailor-made mills, drills and countersinks. A costeffective feature of the system, when compared to expensive solid carbide tools of similar dimensions, is that, when worn only the small cutting head needs to be replaced. The Multi-Master features a close dimensional tolerance for the overhang of a head with respect to the contact face of a shank. Consequently, a worn head can be replaced directly on a machine tool whilst the Since the principle of versatility was realised – similar designs can now be found in in a number of ranges belonging to various cutting tool manufacturers.
A cost-effective feature of the system, when compared to expensive solid carbide tools of similar dimensions, is that, when worn only the small cutting head needs to be replaced.
shank remains clamped in the machine spindle, without loss of time required for measuring and set-up. A s the cost of modern adva nced machine tools is extremely high, it is very important to cut downtime and to ensure smooth operation. Hence, reducing set-up time connected with replacing worn tools is an
important factor in decreasing production expenses. Highly precise, this modular system guarantees high accuracy and re p e a t a b i l it y ; t he y re du ce manufacturing cycle times and translate into improved machine tool utilisation and cost saving. The sig nifica nt adva nces made within the area of milling cutters are just as important as the progress made within machine tool technology. Milling cutters are the vital cutting a ge nt lo c ate d b et we e n t he machine tool spindle and the workpiece, although they have the potential to be the weakest link in the milling process and to be a barrier to increasing productivity. Conversely, the choice of the correct milling cutter provides the ability to significantly reduce machining times, remove additional operations, improve surface finish, enhance accuracy levels and last but not least - to improve manufacturers profitability. Got a Question? Make An Enquiry.
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GREAT GEAR & SYSTEM Complex Manufacturing:
The Need For
Internal
Inspection University of Leuven applies metrology CT to research geometrical accuracy of inner and outer features of industrial components. Contributed by Chris Wright, Technical Editor, The Right Image
M
a ny components and assemblies have internal features that are difficult to inspect non-destructively, as conventional metrology requires them to be sectioned. Examples are a hollow hydroformed camshaft, a 3D printed mould with conformal cooling channels, or a plastic injection moulded electrical connector with metal inserts. Now, the PMA division of Leuven’s university is using X-ray Computed Tomography (CT) machines to research measuring the interiors of such components in 3D. CT has been widely used for many years in medicine for imaging and diagnosis, and to inspect materials to identify the presence of internal features, such as unwanted inclusions in a casting. Now, research is being carried out by Prof JeanPierre Kruth and his team at the University of Leuven, the oldest and largest university in Belgium, to broaden the application of CT into the field of dimensional metrology. With CT, components can be inspected externally, as traditionally done with a touch probe or laser scanner, but internal geometry can also be measured non-destructively in the same set-up.
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T h e u n i v e r s i t y, c a l l e d Katholieke Universiteit Leuven or KU Leuven, is close to the European headquarters of Nikon Metrology. The two organisations are collaborating closely in the development of CT as a tool for geometrical measuring and quality control. Two Nikon Metrology CT machines were recently installed at KU Leuven, enabling Prof Kruth’s PMA division, which is responsible for production engineering, machine design and automation within the university’s department of mechanical engineering, to carry out in-depth research. CT machines are also used in the metallurgy department at the Leuven university, mainly for materials examination. This department has recently upgraded one its CT machines with a new Nikon Metrology 180 keV X-ray source and control software. One of the PMA division’s X- ray machine s, a 22 5 keV model XT H 225, includes a microfocus X-ray source, linear scales, better cooling and other enha ncements that prov ide increased accuracy, making it suitable for CT metrology. The second machine is a large cabinet microfocus XT H 450, the highest power CT machine currently installed in Belgium and the
Netherlands, providing sufficient X-ray penetration for thicker metal parts to be inspected. As a guide, 450 keV microfocus source can penetrate 35 mm of steel or 110 mm of aluminium. The Hercules Foundation in Brussels, established by the Flemish Government to offer funding for scientific research, provided a grant to help the university purchase the machines. Prerequisites for receiving the money were that the equipment had to be unique in the area and that it be made available for research by other companies and institutions. Conventionally Machined Parts Measured As Well As 3D Printed Components Prof Kruth commented, “Our PMA division has a long tradition in production research, starting in the 1960s with milling, drilling and grinding, progressing through spark erosion in the 70s and implementing additive manufacturing (AM) and 3D printing techniques in the 1990s. “Dimensional metrology and quality control for components produce d using t he e a rlier machining techniques resulted in our installing co - ordinate measuring machines (CMMs) with touch probes and laser scanning heads. www.equipment-news.com
GREATGEAR&SYSTEM “Today, production techniques including five-axis milling, additive manufacturing and hydroforming make it possible to produce complex products, often with internal features or channels. “ Such complex products presented us with a challenge, as it is impossible to non-destructively inspect the internal features without X-raying the parts. “Often, one-off prototypes or small batches of components are produced. Sectioning even one component to inspect it conventionally would result in an unacceptable scrap level in percentage terms. “CT presents its own difficulties, however, as metal in particular is dense and the X-rays tend to scatter and be absorbed unless the power is high. Moreover, the standard machine platforms are not developed with sufficient rigidity and accuracy for precision measuring, as they are traditionally used for material inspection. “In fact there is a general lack of understanding within the CT community regarding the accuracy and repeatability problems associated with using the technology for measurement and traceability of the results.” To research the possibilities of using CT for metrology, KU Leuven enlisted the help of two partners, local engineering college, Group T, led by Prof Wim Dewulf, and the DeNayer Institute in nearby SintKatelijne-Waver, which merged with the university on 1st October 2013. Three groups of components
were ta rgete d – addit ive manufactured parts, conventionally produced precision components and assemblies, and highly complex parts also produced by traditional machining, such as a servo valve that goes into the F16 fighter jet and the Ariane rocket. As an example the valve has hundreds of intersecting channels whose dimensions need to be measured and there is also a need to check for internal burrs where holes meet, a job that would be difficult without destructively testing the part. Clearly 100 percent inspection, which is demanded for many such safety-critical parts, is an impossibility without some form of non-destructive testing. CT Measuring Accuracy Rivals That Of Conventional Metrology Initial results from using X-ray CT to measure these parts have proved very promising, according to Prof Kruth. Research carried out at the PMA laboratory indicated that for some metallic components and depending on the application-, measuring uncertainty (maximum permissible error) both internally and for outer dimensions of the part can be below 10 microns using the Nikon Metrology CT system. This means, its accuracy lies close to that of a typical coordinate measuring machine. For example, one of the CMMs in the laboratory has an uncertainty of 5 microns plus 5 microns per metre of component length. To help achieve this level of CT
The XT H 450 X-ray source is suited to scanning small castings to gain an insight into the inner details of the part. www.equipment-news.com
CT is an ideal tool to inspect a servo valve with complex internal channels.
scanning precision, the team at PMA houses its two Nikon Metrology machine s in a temperature controlled environment, despite each machine having its own interna l cooling system for maintaining thermal stability. Working Principle In operation, a source produces X-rays by projecting electrons onto a target. As X-rays penetrate the workpiece, they are attenuated due to absorption and scattering. The amount of attenuation is determined by the distance travelled into the material and by its composition and density (i.e. attenuation coefficient), as well as by the energy level (keV) of the X-rays. After penetrating the workpiece, the attenuated X-rays are typically captured by means of a flat panel detector, resulting in a 2D grayscale image. 2D images are taken for many rotation steps of the workpiece. Reconstruction of an industrial component based on the projected image slices, analogous to layers in a 3D printed component, leads to a voxel model (a voxel is the 3D analogue of a pixel), where the grey value of the voxels is a measure of the linear attenuation coefficient of the material. The big advantage of CT is that it eliminates the superimposition of structural images outside the area of interest. The voxel data is post-processed using algorithms to detect the edges and features of the workpiece, allowing dimensional July - August 2015 asia pacific metalworking equipment news
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GREATGEAR&SYSTEM The curved linear diode array detector (CLDA) optimizes the collection of X-rays by eliminating scatter phenomena that typically corrupt 2D radiographs of blades and other metal parts. A reference test object is used to investigate dimensional accuracy of metrology CT.
measurement and quality control. The XT H 450 installed in PMA’s laboratory also features a 1D curved linear detector in addition to a conventional 2D flat panel detector. Using the linear detector requires the workpiece to be shifted along the rotational axis in order to measure successive cross-sections of the object in a similar way as medical CT scanners. Research is currently being carried out at PMA to determine whether the linear detector, which allows higher power (higher voltage, current or exposure time and hence larger material penetration) and is less sensitive to X-ray scatter, can be used to inspect large components more accurately than with a flat panel detector. Technical Challenges Various issues are being investigated by Prof. Kruth and his staff, such as optimising the X-ray illumination parameters and adjusting the grey level thresholding parameters fo r t r a ce a b l e d i m e n si o n a l measurements, lowering the X-ray spot size for greater accuracy and increasing the power of the X-ray source for greater penetration into large metallic components.
Another research topic is beam hardening, a common problem with a polychromatic CT source whereby lower energy photons are more easily absorbed by the workpiece material. It results in chromatic aberration and deformation of the image, mainly at the edges, causing an erroneous grey value to be detected which gives the impression that the skin of the component is of a different material from the core and implies wrong edge detection. Beam hardening is undesirable when studying material composition and is corrected by beam filtration and software, but for metrology, consideration is being given to harnessing the effect to increase edge definition, making it easier to measure the outside dimensions of the workpiece more accurately. The Need For Collaboration The close relationship between KU Leuven and Nikon Metrology, which originated from a former company spun off from the university to commercialise its work, was celebrated recently by the inauguration of the PMA’s CT facilities by Kenji Yoshikawa, CEO of Nikon Metrology. Other
CT allows to slice through an object for internal analysis
university spin-off enterprises, like LayerWise, which specialises in metal additive manufacturing, and materialise, a world player in rapid prototyping, are today working with the university to progress CT metrology. It is indicative that Prof Kruth was a founding board member of all three companies. These are just a few of a large number of collaborative affiliations that PMA has with companies and academe internationally, mainly at a European level but also in the US and Japan. Research activities are very much driven by industry and are thus of a practical nature. A City Round Robin exercise involved 15 compa nies a nd laboratorie s across Europe measuring the same objects and comparing results, sharing knowledge and best practice in metrology with a view to optimising accuracy and traceability of measurements. A d e e p e r E u rop e a n co operation has just started with the help of another grant, this time from the European Union MarieCurie programme. KU Leuven has joined Nikon Metrology in the UK and Belgium, the NPL (National Physical Laboratory – the UK’s national measurement institute), the PTB (Physikalisch-Technische Bundesanstalt – Germany’s national metrology institute), Materialise in Belgium and a number of other companies and universities in the training of engineers and researchers in CT metrology. Got a Question? Make An Enquiry.
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ENQUIRY NO 112
Wieser
GREATGEAR&SYSTEM
E
stablished over 20 years a go a s a one - p e r son meta lwork ing shop, W ie se r A u to m a t io n Maschinenbau GmbH, provides complete customised solutions and serves as a systems integrator. The company’s services range from mechanical and control engineering, to production and assembly, as well as commissioning the equipment and linking it to the customer’s IT systems. Half of its customers are in the automotive industry, followed by the packaging, woodworking, steel and electronics industries. In addition to complete production lines, Wieser Automation makes custom- designed circulating systems, rotary indexing tables, assembly and machining cells, as well as production, testing, and measuring equipment. Recently, according to Ronald Hotter, sales manager for laser m a c h i n i n g e qu ip m e nt , t he company is receiving more and more inquiries for laser machining systems: “There is a clear trend
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Fast, Open & Dynamic When speed and flexibility are critical in machine tool applications, laser machining is often the technology of choice while eliminating the high cost of tools. The increased use of modern materials such as carbon-fibre or fiberglass composites in high-volume manufacturing requires the use of laser machine tools. By Stefan Ziegler, Marketing Communications, Beckhoff toward using lasers for processes such as marking, welding or cutting. For non-metal products such as plastics, fiberglassenforced plastics, leather or wood, the choices are limited. This is the gap we plan to fill with our newly developed W:Laser machine. This solution was designed as a standard system with many customisation options, including the input and output of the parts
being processed, as well as the option to integrate different laser types for different materials. It is also available as a modular or standalone system. TwinCAT And EtherCAT Form The Foundation For Powerful Machines The “laser machining” project w a s i n i t i a te d ro u g h l y t wo years ago, as was the search www.equipment-news.com
GREATGEAR&SYSTEM Roland Hutter, sales manager for laser machine tools at Wieser Automation, sees increasing demand for 3D laser machines like the W:Laser, whose axes can be controlled with exceptional speed and precision.
Wieser
Beckhoff Automation
Just like the EtherCAT Terminals, the five AX5000 Servo Drives take up very little space in the machine’s control cabinet.
for capable suppliers. Ronald Hotter recalls: “These speeds mu st b e imple me nte d w it h stable mechanical components, as well as with a specialised, powerful software platform. TwinCAT automation software from Be ck hof f prov ide d u s w ith simple prog ra mming and operation, short training periods, and extremely quick commissioning.” TwinCAT CNC provides the necessary performance to enable the multi-layered movements and 5-axis kinematics of the W:Laser machine. This is ideal for the W:Laser application, as the CNC functionality is fully PC- and software-based. The TwinCAT real-time kernel and the powerful PC platform provide the ideal foundation for software-based CNC, as the complex machine kinematics and difficult processing tasks in laser machining require real-time tra nsformation in the CNC to ensure flexible operation and programming. For instance, the user can define www.equipment-news.com
different coordinate systems o r a u to m a t i c a l l y g e n e r a te co mp e n s a t i n g m o t io n s fo r rotational axes. The 3D machining offered by Wieser Automation with its 5 -axis processing is a classic example of such an application. W ie se r A uto m at io n a l so notes that the ability to connect different I/O modules through any of today’s popular fieldbus systems was a key benefit. This is especially critical, as the laser is sourced from a supplier and operates within an existing fieldbus system. A nd since Wieser Automation selects the laser based on a customer’s specific application, absolute openne ss rega rding the I/O periphery was crucial. Open Communications Standard Is A Must The laser machining system uses the EtherCAT fieldbus system to enable I/O communication. Roland Hotter points out the importance of the protocol’s openness: “We transmit a significant amount of data in a very short period of time. In addition, the machine must also fit seamlessly into the end user’s production environment.
EtherCAT solves both challenges. The fact that EtherCAT is open – in our case integrating with Profibus – is particularly important for us, since many of our suppliers use la ser sources with this particular fieldbus. For our inhouse developments, we were independent of any customer’s specifications and could choose any fieldbus system. This is a great advantage, and we are very satisfied with our choice, because EtherCAT gives the greatest possible flexibility.” Profibus is integrated via the EL6731 master/slave terminal, which is fully compatible with all Profibus features, making it possible to include any Profibus device in the EtherCAT network. The safety functions, i.e. the drive and safety gate monitoring, are handled by the EL6900 TwinSAFE PLC in connection with EL1904 and EL2904 TwinSAFE terminals and two EP1908 TwinSAFE box modules that are installed in the system. In addition to safetyrelevant data, the Beckhoff system collects numerous analogue and digital signals via EtherCAT Terminals in the control cabinet, as well as via the EP2338 and EP3184 IP 67 box modules. July - August 2015 asia pacific metalworking equipment news
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GREATGEAR&SYSTEM
Beckhoff Automation 40
asia pacific metalworking equipment news July - August 2015
Through compact design, the Control Panel, Embedded PC and EtherCAT I/O components easily fit into the operator station housing.
Beckhoff Automation
Dynamic drives as essential control technology components In addition to the powerful individual components, the highly efficient interaction between TwinCAT and EtherCAT ensures fast, flexible operation of the laser machine. Its high precision, paired with very short cycle times and the accurate control of the drives, provides significant functionality that is put to good use. Ronald Hotter explains: “We don’t employ a robot for our laser machine tool, instead opting for a drive with three linear axes, as well as two optional rotational axes that must be controlled quickly and precisely. Our goal is to focus on these types of 3D machines for components with complex structures.” T hat is a lso why Wie ser Automation’s engineers selected the AX5000 series servo drives with EtherCAT communication for ma x imum per for ma nce. These work in concert with A M 8 0 0 0 s e r v o m o to r s t h a t feature One Cable Technology (OCT ), which combines the power supply and the feedback system into one cable. Ronald Hotter continues: “The TwinCAT drive technology and motion control solutions provide the best possible foundation for our
single- or multi-axis positioning tasks, providing an effective solution for the inherently high dynamic requirements.” In addition to the TwinCAT C N C , Tw i n C AT K i n e m a t i c Transformation makes it possible to implement various robotic f u nc t io n s. T he move me nt s are programmed in Cartesian coordinates, either with DIN66025 commands or with the PLCopen-compliant components from the PLC. An integrated dynamic pre-controller ensures very precise movements, even at high accelerations and speeds. Of particular benefit for Wieser
With its widescreen format, the CP2916 Control Panel in the operator’s station provides exceptional machine visualisation as well as multi-touch functionality.
Automation’s la ser machine is the fact that the TwinCAT Kinematic Transformation is optimised for t he Beck hoff AX5000 Servo Drives. A Beckhoff CX2030 Embedded PC with a dual-core Intel Core i7 processor running at 1.5 GHz serves as the core of the control system. This unit wa s a n obv ious choice for Wieser Automation, as the engineers wanted a powerful, DIN ra il - mountable PC w ith extensive interface expansion options. The laser machine tool is operated via a built-in CP2916 multi-touch Control Panel with a 15.6 -inch screen, linked to the Embedded PC via DVI/USB Extended. Service Makes The Difference To test the machinability of materials, Wieser Automation keeps one of its laser machines in-house, enabling the design of optimally configured systems for each customer’s specific requirements. Additional services a re a lso ava ilable, such a s process flow animations, training, production support, process optimisation, and service calls. Got a Question? Make An Enquiry.
ENQUIRY No.
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Infinite SolutionS.
One Show.
For manufacturers across ASEAN, overcoming challenges in production lines is about to be easier than before. Approaching the 29th years of being the official metalworking technology launch pad of ASEAN, “METALEX 2015” will usher the industrialists into the new era of AEC by providing them with infinite number of solutions to all metalworking problems, including the need for high precision manufacturing in the auto parts, aerospace, building and construction sector. Technology experts of leading brands from around the world will be there to show the manufacturers how innovations from the 2,700 brands can help them realize their dream production process and competitive edge.
NOV.
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INDESIGN
Integrated Manufacturing
& The Future Of Predictive Automotive Launch In the automotive industry, there is a growing trend towards an increasing number of product launches on a global scale. Zhao Jizheng, Siemens PLM Software explains.
O
riginal equipment manufacturers (OEMs) are trying to increase their market share in new regions, and are looking toward regional production to support this goal. That means that often enough, the same vehicle s a re being bu ilt in multiple production facilities. But that’s just the beginning of the challenges. In Asia, automakers are under pressure to provide a greater variety of personalised options than ever before. They have to reduce costs to compete in global markets, while accommodating an increasing number of process variations to meet the demands from more consumers. A s a result, automotive OEMs face continual pressure to squeeze
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more time out of schedules that have contracted significantly during the past decade. To meet these challenges, automa kers in A sia ne e d to adopt new manufacturing strategies that will allow them to quickly plan and design new processes, accurately assess the impact of changes, rapidly deploy best practices across global operations and better predict the timing, cost and quality of every program launch. Additionally, they must deliver more environmentally-friendly vehicles and build them with more energy-efficient processes. To facilitate these strategies, many leading automakers are implementing a collaborative approach t hat inte g rate s engineering and manufacturing
i n t he de ve lopme nt of t he launch process. This approach a l low s for e a rl y acce s s to product engineering data so that manufacturing operations work in parallel and processes can be planned, optimised and validated concurrently with design. An integrated approach incre a se s t he ef ficienc y of deploying a modular platform that allows for a more predictable launch operation, and provides management with clear visibility into programme performance. This predictive launch approach g i v e s a u to m a k e r s g r e a te r confidence that their powertrain, body-in-white (BIW), stamping and final assembly processes will meet delivery expectations, first- time qua lity goa ls a nd programme profitability targets. www.equipment-news.com
INDESIGN
Automotive OEMs face continual pressure to squeeze more time out of schedules that have contracted significantly during the past decade.
As Asia continues to be the growth engine for the automotive industr y a nd China leaping to number one back in 2009, McKinsey & Company projected that the next seven years will be profitable for the industry in Asia with emerging markets driving the majority of gains. For these predictions to come true, local automakers need to build a better impression in both “Brand” and “Quality” to market. Japan and Korea automakers have long been put on the same level as industry leaders US and Europe. With globalisation, n e w te c h n o l o g y a n d l o c a l market requirements are now their key challenges to keep up with the quality expected of t hem. E x a mple s like t he Takata recall that hurt Toyota ra i se d a que st ion ma rk on quality control that is often perceived to have fallen short of meeting international standards of sa fety a nd technolog ica l advancement. To help avoid such recalls, a framework to predict a nd eliminate these errors before production and full visibility for teams sitting across different geographical locations to access and edit the design data is needed. www.equipment-news.com
Predictive Launches To Manage Growing Complexity A successful launch is measured not on ly by t he e xe cut ion excellence of the entire ma nufacturing process, but also the cost and time it took to develop and build it. To be competitive, automakers must master the transition from mass production to mass customisation, while fulfilling a variety of local regulations while consistently meeting consumer demands.
New mater ia ls a nd coat ing te chnolog ie s cre ate de sig n changes that can have a significant impact on manufacturability, but can be easily missed without a n i nte g rate d plat for m for collaboration. In 2010, Swedish-based Volvo Car Corporation (Volvo Cars) was acquired by Zhejiang Geely Holdings Group of China with the aim to establish China as the company’s second biggest ma rket, a f ter t he U S. A s a result, Volvo Cars planned for new plants in China and major investments to contribute to the development of new global car models. To achieve that, the company needed to increase its production line flexibility to support multiple car models and change its engineering processes to suppor t operations a s a wholly independent organisation. Through the adoption of mixedmodel production scenarios and the utilisation of manufacturing process management on variants and changes, Volvo was able to enhance collaboration with manufacturing system suppliers, increase engineering productivity, and significantly reduce time
An integrated approach increases the efficiency of deploying a modular platform that allows for a more predictable launch operation.
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INDESIGN
The automotive industry stands to gain the most from predictive analytics.
Automakers need to achieve first-time quality requirements, reduce the time to ramp up and eliminate cost overruns in order to rapidly design, re-use and validate manufacturing processes.
needed to generate shop floor documentation. Automakers need to achieve first-time quality requirements, reduce the time to ramp up and eliminate cost overruns in order to rapidly design, re-use and validate manufacturing processes. Getting all the parameters to the precise required point through trial and error on a v irtual platform before implementation have proven critical to the success of automotive OEMs. With the help of integrated manufacturing, companies can optimise the product launch. The predictive launch platform is the catalyst in aiding today’s digitalised world of process management for automa kers to compete successfully in the marketplace. Automotive OEMs must operate effectively and efficiently in this manufacturing and production 44
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environment while managing the increase in product complexity across the globe. Enhanced Connectedness For Optimised Launch Frameworks Integrated manufacturing helps automakers implement global car programmes across the world with maximum efficiency and achieve first-time quality goals. To ensure automakers realise more predictive launches on a global basis, they must establish a collaborative development of manufacturing systems. This includes hav ing a ma naged environment for early access to product engineering data during manufacturing system development, a n integrated validation of manufacturing to optimise process productivity a n d e f f ic i e nc y, a fa s t a n d efficient process development
and predictable program for performance and profitability. Leading carmakers like BMW are already executing practices that employ various cutting edge industrial connectivity tools to achieve better results. For this, they are using predictive analytics for production as well as repair processes. Predictive modelling and analytics have the potential to turn traditional manufacturing frameworks on their heads. Employing technologies like Big Data can mine crucial and timely data, pre-empt and adjust the design parameters accordingly to swiftly changing specifications and leveraging the Industrial Internet of Things (IoT), thereby making sure that each part of the process can talk to the other parts. This is set to usher in a new phase of launch practices for a number of verticals. The automotive industry stands to gain the most from predictive analytics and companies engaging these easily customisable robust solutions for their launch programmes will steer ahead of the competition by achieving unprecedented control and speed for design and production processes while staying highly energy-efficient. Got a Question? Make An Enquiry.
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FAST FAB
T
he Bystronic Competence Days 2015 took place at t he co mp a ny ’s headquarters in Niederönz, Switzerland, from June 1st to 15th. Held every two years alternate from the Ha n nover Me sse t rade fa ir that creates a regular platform for the company to meet with customers, the company uses its Competence Days to interact more intimately with customers from all around the world. They also use this opportunity to showca se their latest sheet p r o c e s si n g i n n o v a t i o n s i n software, bending, and laser and waterjet cutting. Wit h a t heme for ‘ World C l a s s M a n u f a c t u r i n g ’, t h e company’s leaders took their tur ns to update v isitors on different seg ments of the company’s progress. Norbert Seo, senior vice president for the marketing division of Asia & Australia, emphasised the company motto of “We will take you to the top (of your class)” implying the company’s strong position in sheet processing machinery and how it would help customers. Fol low i n g t he sp e e c he s, visitors were shown interesting v ideo pre sentations, such as the simulation for how to u se t he i r she e t pro ce ssi n g s o f t w a r e , B y S o f t7. T h e company used these to not only demonstrate how to use their products, but also the ease of them and how they could serve customers better. While at the headquarters, visitors had the chance to tour the company’s demo centre and experience first-hand how the machines or software worked. T he va r ious products e ach machine could produce were on display to exhibit the quality, precision and versatility of the machines. When time permitted, visitors
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Taking Customers
To The Top
Customers are important to all companies, but just how far are companies willing to go in their care for their customers? The Bystronic Competence Days is just one example of companies’ commitment to customers today. Michelle Cheong reports.
were also allowed and even encouraged to work some of the machines themselves, such as the press brakes. Further, visitors could take home desired finished products for reference. Through the two weeks, the company catered to customers
from different countries every day, following similar schedules so a ll v isitors were equa lly up date d on t he comp a ny ’s products and matters. Got a Question? Make An Enquiry.
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FASTFAB
Asia, The
Promising Land
In recent years, many of the Southeast Asian countries have opened their doors to foreign investment, benefitting in the process with flourishing economies and better lives for their people. But what exactly is it about these markets that draws foreign interest? By Michelle Cheong talks to Johan Elster, President of business unit makers, Bystronic, to find out more.
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he ma rkets of A sia, especially Southeast Asia, are fast rising in recent years and captivating the eyes of many, such as those of the metalworking industry who are looking to invest in new markets. The Bystronic Group, involved in developing a nd selling systems for sheet metal processing such as laser and water cutting technology, bending technology and software, has been one such party that has invested in these markets over the years in a number of places. Johan Elster, president of business unit markets of the group shares more regarding the company’s position and future plans. Mr Elster, how would you describe Bystronic’s presence in the Asia-Pacific Region? We have a good set-up in Asia. We have sales and service companies in several countries in the region, such as Singapore, Taiwan, India, and South Korea. We also have one in Shanghai, China, as well as two manufacturing factories in Tianjin.
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The Singapore sa les a nd service company is our hub, so we work from there directly with our own sales people or sales agents from neighbouring countries, such as in Thailand, Indonesia, Malaysia, Australia and Vietnam. Does the company expect to expand into any new markets in future? Or perhaps open more factories here in Asia? We are looking to expand into new markets, such as the Philippines, but not just yet. Perhaps a few years down the road. As of today, the market is still small there. The sales a nd ser v ice companies we have in Southeast Asia are sufficient for now. As for factories, we see no need for more in Asia yet; having the two in China are adequate. As we can see in the next five years, the total capacity of these two factories is enough to support the Asian market. From sourcing and purchasing, through to production, a certain volume of production is required to achieve lean production. And
production can only be lean and highly efficient if you have a certain number of like products. As a company catering to different markets, is there a difference in the products required by these markets? There is a partial difference in the performance of the products. We have a high-end line, and a performance line—similar to a midrange line. In Europe, 95 percent of what we sell is of the high-end line. In Asia, it is the opposite. In China for example, majority of what we sell is the performance line, and made in China. It is different from country to country in Asia, because they are of different development stages. In places like Taiwan and Korea, they are very well developed in the fabrication business, so what we sell there is mostly of the high-end line. In other countries like India, or other emerging markets, we sell more of the performance line. One possible reason to explain this would be because emerging markets expand quickly, and may www.equipment-news.com
FASTFAB
Which markets do you see as promising for the future, and what is hindering them today? Of the developing countries, Thailand is the biggest market for us today. I think Indonesia has the biggest potential, but at the moment the market is not that big. There are a lot of small job shops in the fabrication area, but the hurdle is still quite high for them to invest in laser technology. For some, even some products on our performance line can be quite a hurdle for most of these job shops already. That said, I believe Indonesia has one of the hugest potential in Southeast Asia. They have a large population, and the middle class is growing, so that is a good sign. The political situation is stable as well, though the economy is still a little slow. It will still be some time till we see bigger potential for our products there. Perhaps within the next five years. Southeast Asia in general is expanding quite quickly today, and one of the hurdles they have is the political situation in each country. As soon as the countries stabilise, we see that there is potential for our products there. For example, Thailand’s economy was slow for a while a few years back because of its political situation. Now that it is stable again, you can see that the population has trust in the future, and wants to invest and move forward, so there’s business for us there. When considering investments in big capital goods, one needs a vision of about five years, rather than say, six months, so stability is important. Why do you think Asia shows such promise for the future? In Southeast Asia, there are customers who have reached a www.equipment-news.com
Stefan Magdalinski
not have the same possibilities for big investments, so they would need to start on a lower level with products of the performance line.
Among the emerging markets, Indonesia is touted as the one with the biggest potential for growth due to its large population and rapidly growing middle class.
really high level in technology, similar to that of Europe. These have invested and been successful in t heir ma rket s. However, there are also small clients and businesses that are in the starting phases, and this makes Asia different from Europe. In Europe, there are almost no start-ups anymore, so companies have very few new customers. Because of this reason, every company has to be very highly automated just to be able to compete. Therefore in contrast, A sia’s potential is huge. We foresee that in 20 years, a lot of production will move to Asia because demand is there and not in Europe. This is not to say that there will be no production in Europe. Though the consumption there is limited, Europe will still produce for itself. In Asia however, because of the growing populations, the consumption needs are much higher than Europe, so production will take place in Asia. In fact, a big volume of production is already ongoing in Asia, such as in countries like China and Vietnam. Also, though the technology used in Europe and in Asia is
basically the same, efficiency and automation in particular, are things that have not reached a very ‘used’ stage in Asia. In Europe, automation has been there for many years, so without automation, you are seen as inefficient, and out of business. We h a v e s e e n t h e f i r s t dema nds for automation in Asia, but as labour today is still very cheap, I believe it will take some time before companies make the switch. It is always a comparison with what you get with automation, and what you get by having people do the same work. If people are more flexible, and the costs are not too high, companies would still prefer to use labour. Also, some countries prefer labour over automation because they have a large population to support. Even if you want to go everywhere in automatic mode, we also need work for our people. So as long as you can finance it, and you are still competitive, then it will be good for you and for the country. Got a Question? Make An Enquiry.
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FASTFAB
The Road To
Tomorrow’s Production Trumpf is investing in Industry 4.0 and is setting guideposts along the way toward the Social Machine and the Smart Factory. By Ms. Evelyn Konrad, Press Representative Machine Tools Trumpf GmbH + Co. KG
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a nu fa c t u r i n g w i l l become more efficient, flexible and productive, even when making up just a single item. This is what Industry 4.0 promises. Behind this concept is the vision for the factory of the future: the “Smart Factory”. The implementation of this vision is being called the Fourth Industrial Revolution. Tr u m p f , i n v o l v e d i n engineering machine tools for flexible sheet metal processing, sees this development as a major opportunity. It will help to ensure its customers’ competitiveness on world markets. T hat i s why, w it h g re at foresight, this German mechanical engineering company is investing in the necessary technologies and is supporting research projects dedicated to Industry 4.0. Even today, the company can present some of the initial modules for a Smart Factory. The Vision Of The Smart Factory – In Theory At the heart of Industry 4.0 is
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the Smart Factory, comprising self- config uring production resources and the associated planning and control systems. It uses a network to connect virtual and physical production elements by introducing the “Internet of things and services” to manufacturing operations. Five terms designate a cyber-physical system like this: augmented operator, social machine, global facility, smart product and virtual production. The central element in this kind of network is the human being, the “augmented operator” who controls a nd monitors manufacturing from a remote point. “Both as a source of experience and decision maker, the human quite consciously retain an important role in all the pertinent procedures of the production network. This is because he or she can modify targets, taking the situation and the context into account,” confirms Klaus Bauer, Head of System Development Fundamental Technology at Trumpf.
The augmented operator is supported by IT-based assistance systems. Included here a re planning systems and virtual production, by way of which manufacturing sequences can be organised for optimum results. In addition, the augmented operator can also intervene in production using mobile devices, from any point on the planet, and can monitor operating and production states by way of real time images. To b e f o u n d o n t h e manufacturing floor are social machines, connected with each other and with supplier and customer systems by way of intelligent networks. Considering the current situation, they can independently and immediately respond to potential deviations from the plan. This means that the global facility will achieve the overall optimum in productivity. Passing through the ma nufactur ing line are smart products which incorporate a chip, for instance, to com mu nicate w it h t heir www.equipment-news.com
FASTFAB
Using the iPad, the production manager or chief operating officer can monitor production from any point in the world.
Thanks to its RFID chip, the intelligent lens, when queried by the LensLine status monitoring sensors, can report whether it needs cleaning.
environment. Even the blank for a product is “aware” of its own status, its history and its destination. In this way the product can tell the machine how it is to be processed. This way, products with a batch size of just one can be produced just as economically as in mass production. In a networked production system like this, no capacity bottlenecks and no underused resources would go undetected. The system is transparent and can respond flexibly to deviations. If need be, it will call for human involveme nt in t he role of intelligent decision maker. A smart factory like this is still a vision. Implementing it at large scale is, at present, hindered by the lack of standards for the infrastructure, interfaces and information media. IT security is also a challenge in a networked system like this. In their efforts to identify solutions, various technical fields will have to undertake interdisciplinary cooperation and learn from one another. www.equipment-news.com
Roadmap For The Smart Factory “The ter m ‘Industr y 4.0’ is relatively new. But the idea behind it has been around at Trumpf for much longer,” Mr Bauer notes. Here he is referring to products and development projects with which the vision for the smart factory will be transformed into reality, step by step. One particular focus of this machine tool manufacturer’s work is the development of the social machine. As early as 1996, the company implemented remote diagnosis as a standard feature; it has in the meantime been installed in more than 30,000 machines. “Initially, the company used analogue modem technology, in the mainframe. In the year 2010, the cloud-based “Telepresence Portal” was implemented. If need be, a machine in China can, for instance, contact an expert at Trumpf in Germany. That expert can read the machine’s status and even intervene in the production process.
Several thousand machines are intelligently networked by way of this new platform. A further step in the direction of decentra lised control of networked production systems is effected by utilising intelligent manufacturing control systems and the introduction of mobile terminal devices. With TruTops Fab, Trumpf offers software with which customers can monitor various machine tools on their production floors. In addition, they can insert customer orders and plan the production sequence. Customers can already access some of these functions, from all over the world, using an iPad, provided that Internet access is available. The trend toward using mobile devices in manufacturing continues. July - August 2015 asia pacific metalworking equipment news
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FASTFAB Machine operators can control and keep an overview of their machines using the MobileControl app, even when they are not standing right beside the fixed control panel.
“The term ‘Industry 4.0’ is relatively new. But the idea behind it has been around at Trumpf for much longer,” notes Klaus Bauer, Head of System Development Fundamental Technology at Trumpf Werkzeugmaschinen GmbH + Co. KG.
“Mobile equipment, in the framework of Industry 4.0, will find ever more integration into modern production operations,” Mr Bauer confirms. The company already offers other products such a s the Mobile Cont rol app, wh ich for instance, enables mobile operation of machines from the area around the machine. The app transfers the user interface of the 2D laser machine’s standard control panel to an iPad touch screen, giv ing operators a n additional means of monitoring and controlling the machine besides the fixed control panel. Visual Online Support, on the other hand, is a new tool that will make finding a solution considerably simpler whenever a malfunction occurs during ongoing operations. Within the fra mework of a TruSer v ices S e r v ice A g re e me nt , V i su a l Online Support offers customers the ability to exchange image, audio and video files with the technical service of Trumpf, simply using an app. Over and above that, images can be edited by both parties to the conversation, in real 50
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time. This lets customers give feedback about the situation. The company can also present initial approaches to the subject of smart products. In laser cutting machines, lenses focus the laser beam on the sheet metal. Some of these lenses come with an integrated RFID chip, in which specific data on the technology are stored. Thanks to this RFID, the intelligent lens can, when queried by the LensLine status monitoring sensors, report whether it requires cleaning. The machine’s operator thus learns – easily, positively and quickly – whether to clean or change out the lens and can keep track of the lens cleaning cycle. Unnecessary cleaning operations are eliminated, costs are lowered, and the availability of the machine climbs. The Beginning Of Intelligently Networked Production Using just these initial elements of Industry 4.0 makes it possible to
depict a scenario for an integrated industry. The operating officer will monitor manufacturing from a remote point using a mobile device and the TruTops Fab app. If, for instance, a capacity bottleneck is detected, contact can be made with the local production manager. If that person lacks certain technical knowledge, then an expert at Trumpf can be called upon. The Telepresence Portal as well as Visual Online Support delivers an exact view of the machine, so that the expert can provide highly qualified help. The objectives of developing Industry 4.0 are far more flexible, efficient a nd tra nspa rent ma nufacturing processes, increased overall productivity and improved resource utilisation. “This will help our customers maintain a competitive edge in the world’s markets,” Mr Bauer explains. Got a Question? Make An Enquiry.
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FEATURES
P
re c i sio n b or i n g i s a v it a l pro ce s s i n t he manufacturing of many critical components. The accuracy and finish of a multijournal crank bore in an engine block relates directly to power and fuel efficiency, and the time it takes relates directly to the engine company’s profits. Precision bores in numerous engineered components are essential to critical performance metrics. Such bores must meet critical tolerances; but the downside is that precision boring can be costly and time-consuming, with a small mistake or error resulting in the scrapping of expensive parts. By definition, boring, a s opposed to drilling, is a machining p ro ce s s i n w h ic h i nte r n a l diameters are made in true relation to the spindle centerline. This process is most commonly performed with the workpiece held stationary and the cutting tool both rotating and advancing into the workpiece, although boring is also done with the cutting tool and the workpiece being adjustable. Common applications for boring include the enlarging or finishing of cored, pierced, or drilled holes and contoured internal surfaces. Related operations sometimes performed simultaneously with boring include turning, facing, c h a m fe r i n g, g ro ov i n g, a nd threading. How It’s Done Envision a small engine block with five in-line journals requiring crank bores. Conventional thinking for a multi-journal finishing assignment, for example, involves a multi-blade guidepad reamer with the following suggested process (here designated as Option 1.0): - A pilot reamer finishes the first journal
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Different Thinking Drives
Asymmetric Boring Revolution Innovation in precision boring increases productivity, reduces costs. Contributed by Kennametal
- The multi-blade reamer is fed in and semi- and final-finishes journals 2 through 5. - The reamer is then retracted. The adva ntage of such a process is that it lends itself to use on CNC horizontal or multia x is machining centres a nd does not require a dedicated boring machine with dedicated
fixtures. However, depending on the size of the workpiece, the machine tool must be of sufficient rigidity or quality can fall off dramatically. Also, feedin and feed-out of the reaming tool over finished bores must be done slowly and precisely or retraction marks and/or damage to the cutting edges will occur. Another general option for machining this kind of bore is July - August 2015 asia pacific metalworking equipment news
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FEATURES - The boring bar with guide pads is centered into journal 5 - Guide pads are expanded - Journals 1 through 4 are semiand final-finished - Guide pads are fed back in - The boring bar is retracted offcentre
line boring (Option 2.0). The basic issue to be solved at this option is how can the cutting blades and the tool’s guide pads pass through unfinished journals with smaller hole diameters? CNC machine tool builders have responded to this quandary by u si n g conve nt iona l l i ne b o r i n g b a r s a n d ‘co u n te rbearing’ capabilities on their equipment. The process looks like the following: - The workpiece area of the machine tool lifts the cylinder block up - The line boring bar is fed through the component into a bearing at the opposite end - The cylinder block is adjusted down and clamped - Crank bores are semi- and finalfinished - The cylinder block is lifted up and the boring bar retracted 52
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The process speeds up feedin and feed-out, and because the tool is supported on both ends; the geometric quality of the finished bore is improved compared to reaming option 1.0. On the downside, lift functions require special fixturing and CNC control, and the required counter-bearing on the fixture makes any additional back-side machining impossible. Multi-axis machine tools with tilting worktables and/or tilting spindles together with more evolved boring bars contribute to Line Boring Option 2.1 with expandable guide pads, where t he proce ss evolve s to t he following: - A pilot reamer is fed in and finishes journal 5 - The component (or machine table) gets rotated 180 degrees - The machining center X-Y axis is adjusted to feed the boring bar in off-centre
Option 2.1 uses the multi-axis adjustability of the machine tool. It retains the advantages of Option 1.0 by eliminating the need for any lift function or counterbearing and Option 2.0 with support on both ends of the tool. The disadvantages are that the complex internal mechanics of this type of boring bar are costly and can be difficult to handle. Insufficient lubrication use ca n da mage sensitive internal mechanics, and if not monitored exactly, the tool can jam or hook in the workpiece and cause damage to the machine, fixture, tool, and part. An Asymmetric Solution In collaboration with a major automot ive ma nu fac t u re r’s engine block operations, Kennametal engineering staff has advanced the boring function with Option 3.0, asymmetric line boring. This is a geometric leap forward that accentuates t he adva nta ge s of re a m ing and line boring while virtually eliminating the disadvantages of both. A s w ith most adva nced s o lu t io n s, t he pr i nc iple a t the foundation is quite basic. Normal guide diameters are of full material or build of three or more guide pads, providing no degree of freedom from the bore wall while feeding in and out. The Kennametal solution supp or t s on g u ide p ad s i n a setup simila r to a ty pica l www.equipment-news.com
FEATURES g u ide p ad re a me r, but t he guide pad, normally located 180 deg to the cutting edge, was rotated so the resulting design prov ide s f re e do m to e nte r and exit the guide part even passing through the raw bores. This geometry allows feeding the bar through raw bores on an eccentric path. The process, then, looks like this: - A pilot reamer is fed in and finishes journal 5 - The component (or machine table) gets rotated 180 degrees - The asymmetric boring bar is fed in off-centre using the machining center’s X-Y axis - The tool is moved to the centre and finishes journals 1 through 4 simultaneously
- The tool is retracted off-centre with fast feed out. Such asymmetric line boring retains all the advantages of previous line boring efforts — high-quality precision bores, support on both ends of the tool, while no expensive lift functions, obstructive counter bearings or critical mechanisms inside the tool are needed. It also adds the fact that complete feed-in and feed-out moves can be done at increased fe e d rate s on convent iona l m ac h i n i n g ce nt re s, add i n g efficiency to the process. The indexable inserts offered with this eccentric boring bar solution are also advanced. RI8 inserts have eight cutting edges with pre - defined back taper, which allows for high feed rates. Diameter can be adjusted to
the precision of 1 micron. The clamping force provided by the conical clamp screw avoids any settling effects. Both inserts and the a sy m met r ic bor ing ba r a re designed so the inserts clamp directly into the boring bar b o d y. T h i s e l i m i n a te s t h e need for cartridges and the additional tolerances and space they require. In short, this asymmetric line-boring solution increases machining robustness, process s p e e d s , a n d r e d u c e s to o l maintenance and handling, all while being compatible with CNC machining centres — a solution any manufacturer in search of process improvements will find anything but boring. Got a Question? Make An Enquiry.
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FEATURES
Making The Machine Tool
Connect
Scott Evans and Sal Spada of ARC Advisory Group explains how the MTConnect standard facilitates data-driven operational performance improvements in machine tool environments.
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he machine tool is the workhorse of the metal cutting manufacturing processes, but the consensus is that machine tools are widely underutilised in both highly automated and job shop facilities. According to A RC Advisory Group research and conversations with industry experts, only 25 to 40 percent of available machine tool time is actually used for material removal. Many manufacturers operate blindly, rarely able to pinpoint the root cause of low utilisation rates. However, progressive manufacturers seek to identify the cause of poor machine and operator performance. Manual data collection is often the first approach used to collect manufacturing metrics, but productivity improvements require real-time monitoring and data-driven management de cision s. T he M TCon ne c t standard, developed for t he machine tool indust r y, has emerged to help resolve this problem. T he co nu nd r u m for t he machine tool industry is that machines are replete with a vast amount of runtime production data, but each machine builder utilises proprietary internal data representations with proprietary communication methods. Thus, machine monitoring, condition monitoring, and production management software require a multitude of unique interfaces to
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extract information from machine controllers on the shop floor. By prov iding a com mon standard, MTConnect enables “plug-and-play” interconnectivity between devices, equipment, and systems. An open and royaltyfree standard, the tool functions through both hardware and software adapters, facilitating effective data monitoring for machine tools through the Internet. During a session at the 2015 ARC Advisory Group Industry For um in Orla ndo, F lorida , attendees learned how the tool has lowered the cost for integrating machine tools with information management systems used in manufacturing operations. Key takeaways: • MTConnect is an industr y standard for plug-and-play interconnectiv ity between machine tools and production management software. • Machine tool builder, Mazak, employed MTConnect a nd improved machine availability by understanding why machines were stopped. • Ma nu fac tu rers employ ing MTConnect along with factory monitoring software experience up to 30 percent increase in utilisation. MTConnect Gaining Momentum At the Forum session, “MTConnect
for Internet of Things,” the audience heard from two speakers who sha red the substa ntia l benefits their organisations’ received from adopting the MTConnect standard. The first spea ker wa s Br ia n Side s, Director of Technology at Okuma America Corporation. He was followed by Rocky Rowland, Production Manager, FMF Department, at Ma za k Corporation. During the panel discussion following the presentations, Mr Sides and Mr Rowland were joined by Jeff Rizzie, Senior Manager, Business Development, at Sandvik Coromant. These speakers offered a wide spectrum of perspectives on MTConnect within the machine tool industry ecosystem. Improving Machine Tool Productivity Okuma Corporation is a machine tool supplier, headquartered in Oguchi, Japan. Its American headquarters, based in Charlotte, North Carolina, is responsible for selling, engineering, and servicing CNC lathes, machining centers, and grinders. The company also supports over 40 distributors in the Americas region. Mr Sides shared the startling fact that the average machine tool only spends around 25 percent of its time in “process time,” or running and producing parts. Contributing to this problem is the fact that very few machine tools are monitored. This is partly due www.equipment-news.com
FEATURES to the myriad native languages of machinery and controllers from different suppliers. Many shops u sing machine to ols to produce parts still rely on post-production data entr y, paper forms, and whiteboards. These factors contribute to poor visibility into overall equipment effectiveness (OEE). Connecting machine tools to collect real-time manufacturing data is an essential first step toward improving machine tool productivity. Mr Sides views the open, royalty-free MTConnect standard, which he compares to U S B o r B lu e to o t h , a s a proven and reliable conduit for equipment to communicate with the outside world. With MTConnect, m a nu fa c t u re r s c a n a cce s s machine tool information using a common protocol to display real-time production information directly at the operator control level at the machinery in addition to supporting mobile devices. For Okuma, it was an easy decision to support MTConnect on its machine tools since the company also offers MTConnect as an app available to download from its Okuma App Store. In his conclusion, Mr Sides out l i ne d re a l pro du c t i v it y incre a se s were re a lised by customers operating machine tools using the M TConnect standard. He added, the customer OEE rose dramatically from around 30 percent to over 60 percent in addition to other measures ultimately impacting the bottom line. Mazak Offers Unique Perspective M a z a k ’s p r e s e n c e i n t h e US dates back to 1974, when it became the first Japanesebased manufacturing company to establish itself in Kentucky. Today, it ma nu facture s 114 different CNC lathes & machining www.equipment-news.com
Machine tools are widely underutilised in both highly automated and job shop facilities.
centers in Kentucky for the North American market. Mr Rowland explained that Mazak is in a unique position among machine tool suppliers in that it manufactures its products using its own products. Therefore, the company was interested in exploring issues impacting OEE and utilised Memex’s condition monitoring software, which takes in data through the MTConnect standard. In particular, the company wanted to know the reasons causing downtime. By analysing downtime data and implementing corresponding action items, the company was able to reduce idle time in its machines. Mr Rowland opined that MTConnect was vital in this project by providing live and accurate data on the status of equipment, work flow, quality standards, and part counts, among other metrics. Overall, he believes that implementing the MTConnect standard will result in anywhere from a 3 percent to 15 percent return on investment. Looking At The Future Of Digital Manufacturing Sandvik Coromant, part of the Sandvik Machining Solutions business within the Sandvik global industrial group, is a supplier of cutting tools, tooling solutions, and know-how to the metalworking i n du s t r y. W it h ov e r 8 ,0 0 0 employees, the company serves automotive, aerospace and energy industries worldwide. During the panel discussion, Jeff Rizzie from Sandvik emphasised
The average machine tool only spends around 25 percent of its time in “process time,” or running and producing parts.
that adopting MTConnect as the de facto industry standard could pave the way for a true digital manufacturing explosion. With an abundance of existing sensor te ch nolog y, data a na ly t ic s capability, and process intelligence, the tool puts manufacturing companies only a few steps away from realising much better results to their bottom line. According to Mr Rizzie, the future of digital manufacturing will likely lead to additional capabilities such as automated in-process adjustments, tool and asset logistics tracking, tool and asset predictive analysis, remote process diagnostics, and optimised alternative machining strategies based on variable inputs and selectable desired outcomes. Adopt As An Enabler MTConnect, a lightweight, open, and extensible protocol and data representation, allows the exchange of dynamic sensor data, configuration data, and control information among MTConnectcompliant machines, software applications, and controllers. End users looking to extend the value of their assets should consider adopting the MTConnect standard as an enabler to perform analysis on their machinery utilisation rates. ARC believes that, eventually, more and more machine builders will support this important standard. Got a Question? Make An Enquiry.
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A Place In Production Can machine vision be the missing piece that helps satisfy quality assurance demands in manufacturing? By Didier Lacroix, senior VP, International Sales & Services, Cognex
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t is not just about staying i n t h e g a m e . Fo r m a n y corporations, keeping ahead of competition is also the aim. In an increasingly challenging g l ob a l c l i m a te , co mp a n i e s continue in their pursuit for ways that reduce costs while raising quality standards. This
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t wo - pronged approach is a concerted effort to make their products more attractive and to increase profitability. One proven avenue that can satisfy these requirements is the adoption of vision technology. Its use is well-known for inspecting products on the manufacturing
line — to ensure that any errors or mista ke s a re ef fe ct ively weeded out. This form of Quality Control (QC ) is superior to human-eye inspections as it is not subject to variable factors such a s fatig ue or operator experience. T he te ch nolog y simply s c r u t i n i s e s e v e r y i te m b y using the sa me pa ra meters and requirements that it has been programmed with. Even on fast-moving lines that are impossible for the human-eye to keep up with, machine vision can perform its role with 100 percent accuracy and reliability. Simplifying The Process A semi-automated production facility manufactures complete control systems for the www.equipment-news.com
FEATURES
In an increasingly challenging global climate, companies continue in their pursuit for ways that reduce costs while raising quality. switchbox industry. As customer specifications for such devices can vary widely, the facility’s out- of-the -box solution aids customers by allowing them to avoid time-consuming and cost-intensive parts handling processes. To meet its needs for effective QC, the company has deployed a n i n sp e c t io n s y s te m t h at comprises of optical test stations. The latter comes in the form of camera tunnels that ensure the production of error-free parts. This system is equipped with a five -megapixel camera and uses application software that is based on VisionPro machine vision software. The entire production process is controlled and represented via SAP enterprise software. This ensures that the correct components and individual parts are located on all three manual workstations. Internal transport trays called ‘pirate ships’, are used for preparing each specific orde r. For e ac h i nd iv idua l component, the operator simply keys in the code and places it in the pirate ship. If a part is scanned but does not belong to the order, a n error message is generated and will appear on the workstation screen. After the pirate ship has followed its path back to the first assembly station, an operator removes all of the components a nd puts them together, level by level to create a finished control. The first is the bus module, followed by the www.equipment-news.com
Machine vision aids in the production process by ensuring quality is kept under control.
various electronics modules and lastly the final terminal blocks. For greater assurance, opto electronic sensors are deployed to check each slot. This ensures that the correct part has been installed. In order to simplify work for the operator, laser lines indicate the next position to be installed. Working Systematically Transport sleds are used to move each control system to the first camera tunnel — for a total of three inspections. These inspections check for presence, component type, and the exact part position by measuring; they also confirm the correct setting of the node number switch at the bus module level. If an error is recognised, the control returns to the workplace, where the operator will resolve the error indicated. It is only after successful testing in the camera tunnel that the system will release the component. The camera, software and an
additional operating interface ensure the exact identification of a part’s characteristics. The PC - ba sed sof t wa re ha s t he intelligence to ignore superficial changes in appearance, while focusing only on the critical characteristics that determine the acceptance/rejection of a product. The software tools do not require the use of expensive image pre-processing for the QC solution. This accelerates application development for the vision engineer and reduces lifecycle costs. The drag-anddrop connection between the individual tools ensures a rapid transmission of data. At the same time, intelligent software positions tools dynamically and simplifies their settings. In the second camera tunnel, t he s y s te m e l i m i n ate s 10 0 percent of errors in the automatic labelling process. The vision system checks the labelling for each terminal block, one at a time. The system determines July - August 2015 asia pacific metalworking equipment news
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FEATURES if the position, signage and signage colour are correct on the labels. Each individual value of the several hundred labels per control, is compared with the values that are saved in the vision system software. Only when all positions are verified to be correct by the system, will the release and transfer of the finished coded product be carried out. The QC system stores a detailed test sample for every type of control, which can be called up automatically during product changeovers. Stringent Production Requirements Another company manufactures thermostats, thermal link s, temperature limiters. It a lso produces a ra nge of complimentar y products for cont rolling a nd monitor ing te m p e r a t u r e i n h o u s e h o l d appliances, as well as for heating and ventilation. One of the items in need of QC is a temperature controller that is used for home appliances.
The controller consists of a cera m ic ba se w it h bimeta l mechanism, along with different con ne c t ion a nd fa ste n ing options. Manufactured in a fullyautomated process, all faults in each controller must be reliably detected, to ensure that there are no cracks in its ceramic base. D u e to t he re qu i re m e nt to ensure quality, one of the compa ny’s production sites decided to explore the use of vision systems for QC. The QC system has to be able to process about 50 million ceramic bodies per year. Besides this, it needs to handle various types of ceramic b a se s, w it h t he i r d i f fe re nt components — a total of 200 different controller variants. Although there were initially 17 solutions under consideration, none of them were able to hold up in series production. After much searching and consideration, the company decided to adopt an In-Sight vision solution. The solution is c ap able of prof i l i n g 15 0 variants for a series of test
characteristics to be achieved. It has a cycle rate of 80 parts per minute and provides a reliable fully- automated production operation. Identical base plates in automated production can be paired with different ceramic b a s e s , a n d m o u n te d w i t h different contacts. In addition, there are also contacts with identical design but that have differently angled connections. Model Management The efficient administration of model variety in the program is essential, so an object-oriented approach was adopted, together with the use of a compact vision sensor. One test program would be compiled for each model for every 10 different variants. The object-oriented procedure means that only the base plate is scanned and all test programs are then adapted to it. This simplifies the administration of test programs, while cutting costs and making work more transparent, safer and flexible. Requiring minimal
Vision systems can be used in a number of configurations, depending upon the application being designed for.
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FEATURES
Many applications use vision systems to improve upon the quality of their products.
installation space, the In-Sight 5400 vision system is integrated directly into the automated assembly machine. All test programs for the 150 variants are filed in the vision system. The specia l objectoriented structure of the test programs enables approximately 15 0 d i f f e r e n t te m p e r a t u r e controller variants to be stored directly in the vision sensor, which ca n be automatically called up when required. Each indiv idua l test pa r t is then inspected for an entire sequence of possible fault characteristics. The vision system comes with Ingress Protection ( IP) 67 protection, and runs as a fully autonomous unit without requiring a PC, where vision a l g o r i t h m s e n s u r e s y s te m reliability. The user interface is easy to use and allows operators to easily program and teach-in new variants. Ev e r y m i nu te , a b o u t 8 0 components are moved down the line through the inspection station. Each individual te m p e r a t u r e c o n t r o l l e r i s inspected with the vision system to detect errors such as ceramic www.equipment-news.com
separation, cracks and correct angle of the contacts. The object cha racter istics te sted here include: inspection of specific zones in the lateral supports, geometr y of connections, angular position of contacts, base plate hole diameters, the type of flange, and the colour coding on the ceramic part. All of these are carried out within an image-processing cycle time of approximately 0.3 seconds. False Rejects Are History QC has markedly improved after implementation of the system. Previously, one or two wrong parts were often mistakenly s e nt to c u s to m e r s, du e to oversight during production batch changeovers. Since the geometry of these parts are now detected immediately, any noncompliant items are considered faulty and are rejected. Other areas in fault detection — such as oil contamination — are also dealt with. In the past, discolourations caused by oil stains could cause a ‘false alarm’, indicating a fault where there was none. These areas have since been rectified. As soon as
three faulty parts in succession pass through the test system, the machine is automatically halted. Fault sources in the production process are statistically recorded and analysed. Countermeasures have been implemented, which allow a better flow in the production process. Although the fault rate used to be minimal (between 25 to 50 parts per million), quality inspection through using vision has lowered it further. At the sa me time, compla ints a nd return deliveries have fallen to nearly zero. Investing in a technology is not always an easy decision. Very often, the major consideration is whether the expense can be justified by the benefits. Yet, many manufacturers that have adopted machine vision, bear witness to successful QC outcomes. Vision technology has and continues to h e l p to e n s u r e qu a l i t y products with its precision and accuracy — a feat that humaneye inspections can neither effectively nor reliably replicate. Got a Question? Make An Enquiry.
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FEATURES
Industry 4.0
And Responsive
Manufacturing
Benjamin Earwicker, Boise, Idaho, US
Industry 4.0 is changing the way products are being manufactured and facilities are communicating, resulting in greatly increased productivity and efficiency, lowering production costs in the process. By Saj Kumar, VP, Internet of Things, SAP (Asia Pacific Japan)
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he Internet of Things (IoT) is being called the fourth industrial revolution, as it allows the physical and digital worlds to converge through all layers of production to completely transform the way manufacturing operations are run. This is critical for a number of reasons. First, industrial production requirements are
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changing. As customers grow sav vier, they are demanding products that more precisely meet their expectations. And second, companies face increasing pressure to manufacture at more competitive prices. To adapt to these changing conditions, the fields of systems engineering, production IT, and business systems must fuse together more
closely than ever to achieve higher levels of efficiency. To address these challenges, we need a comprehensive set of manufacturing solutions that form the foundation of Industry 4.0 solutions. The Networked Economy Metcalfe’s law teaches us that the value of a communications network increases with every new node that joins the network. Over the past decade, we have seen this law demonstrate its power in the realm of the Internet and the growth of social networks is one example of this phenomenon at work. At the same time, we are beginning to see enterprises take advantage of this principle. They a re creating va lue by leveraging hundreds of millions of potential connections on the Internet. For example, online professiona l network s have streamlined the act of recruiting the best talent. Business networks have prospered, with millions of companies connecting their supplier, customer, and payment systems to seamlessly engage in online, collaborative commerce. More recently, we are starting to se e ma ssive volu me s of connected sensors and smart devices leveraged to transform business models and simplify complex tasks. This is the IoT, and it will increasingly connect people and businesses to everything else to become, in essence, the very fabric that supports a new networked economy. W hen the se cha nge s a re coupled with improvements in network infrastructure, Big Data analytics, and smart applications – all connected in the cloud – businesses will enter the era of true hyperconnectivity. IoT For Business The number of Internet users worldwide has grown enormously www.equipment-news.com
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over the last 15 years and is now estimated to be close to three billion. Even more striking is the huge array of intelligent devices that are now connecting to the vast information network around them. Estimates vary, but many analysts speculate that the number of connected devices could be more than 50 billion by 2020 – extending the reach of software-enabled insight by an order of magnitude. Along with the growth in connected devices comes a wide array of opportunity. For the first time in modern history, insight can be offered to businesses and consumers wherever products exist. Devices ranging from connected toasters to connected turbines can analyse their own contextual information and advise customers about optimal ways they can be put to use. While we have long envisioned these types of ‘intelligent devices,’ they are now a reality thanks to recent gains in the realms of connectivity, sensor technology, and real-time data processing for a wide array of products. It has never been cheaper, easier, or faster to embed software in a product and deliver insight. The act of adding intelligence to an ever-expanding network of connected devices is poised to create tangible value for enterprises around the globe. Whether there will be 30, 40, 50, or 60 billion connected devices by 2020, the implication is the same: the way we all conduct business will change. For supporting evidence, look no further than the impact on enterprises. Numerous analysts and other experts have weighed in on the potential impact of the IoT, citing trillions of dollars in financial impact, with 50 percent of the world’s industries being affected.
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Industry 4.0 And Responsive Manufacturing The IoT is being called the fourth industrial revolution, as it allows the physical and digital worlds to converge through all layers of production to completely transform the way manufacturing operations are run. This is critical for a number of reasons. Firstly, industrial production requirements are changing. As customers grow savvier, they are demanding products that more precisely meet their expectations. Secondly, companies are facing increasing pressure to manufacture at more competitive prices. To adapt to these changing conditions, the fields of systems engineering, production IT, and business systems must fuse together more closely than ever to achieve higher levels of efficiency. To address these challenges, a comprehensive set of manufacturing solutions that form the foundation of Industry 4.0 is needed. Our Industry 4.0 vision is not limited to automation of a single production facility. It incorporates integration www.equipment-news.com
ENQUIRY NO 124
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FEATURES you to take a measured approach to improve the key performance metrics on customer delivery, quality, and costs.
Five Levels of Connectedness
across core functions, from production, materials sourcing, supply chain, and warehousing all the way to sale of the final product. This high level of integration and visibility across business processes will enable greater operational efficiency, responsive manufacturing, and improved product design. Compa nie s like Ha rleyDavidson are at the forefront of Industry 4.0 innovation with its use of end-to - end digital engineering. In Harley-Davidson’s new ma nufacturing facility, every machine is a connected device, and every variable is continuously mea sured a nd analysed. Equipment provides p er for ma nce data t hat t he manufacturing system uses to anticipate maintenance issues before machines break, which minimises workflow interruptions. Five Levels Of Connectedness 1. Shop Floor To Top Floor — Intra Company Vertical Integration The first level of integration is to connect business systems to shop floor systems. Enterprises have historically created a divide between systems on the shop floor and business sy ste m s for a v a r iet y of 62
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reasons. Typically shop floor systems are standalone and unique to each factory or line requirements. On the plant floor, the ra mp a nt prol i fe rat ion of localised deployments has led to disparate but dedicated systems for manufacturing planning, execution, process control, and tracking and tracing for each plant. This creates an environment that is inefficient, difficult to integrate, and inherently expensive, as maintaining interfaces for all these systems is ongoing and time consuming. At the same time, increasingly lean supply chains apply constant pressure on manufacturers to respond quickly and efficiently in order to ma inta in a nd increa se profitability. Consequently, managing and scaling ma nu factur ing proce sse s and IT solutions globally is a constant challenge. To a c h i e v e t h e s e objectives, what is needed is a holistic transformation of manufacturing operations. The transformation should be uniquely tailored to supporting your end objectives, or your ‘perfect plant,’ ideally enabling
2. Machine To Machine — Autonomous Machines Machines are now becoming more intelligent, are able to self-diagnose and self-correct. With increased deployment of sensors in machines and production lines, machines will ‘talk’ to each other and change parameters to meet overall objectives. For instance, if a downstream machine detects a problem and needs to slow down, this machine can inform the upstream machine and change the conveyor speed to slow down the line. Currently, we are seeing the deployment of autonomous machines in warehouses and production operations. Kiva Systems (now acquired by Amazon) is a Massachusetts based company that manufactures mobile robotic fulfillment systems. Traditionally, goods are moved around a distribution centre using a conveyor system or by human operated machines (such as forklifts). In Kiva’s approach, items are stored on portable storage u n it s. W he n a n orde r i s entered into the Kiva database system, the software locates the closest automated guided vehicle (bot) to the item and directs it to retrieve it. The mobile robots navigate around the warehouse by following a series of computerised barcode stickers on the floor. Each drive unit has a sensor, which prevents it from colliding with other robots. 3. eCommerce Integration — Direct Integration Of Online Configurations Consumers expect a high www.equipment-news.com
FEATURES degree of personalisation and products have become highly configurable. Industrial products by nature a re config urable a nd these configurations need to be managed all the way from order entry to the shop floor. Configurations such as the ones below for a robotic arm need to be managed from an eCommerce engine to a valid product configuration in the enterprise application and converted to manufacturing steps for production a nd assembly. 4. Manufacturing Collaboration — Visibility — Genealogy — Quality — Kanban / Direct Replenishment In an increasingly interconnected world collaboration with suppliers, contract manufacturing, design partners, Original Equipment Manufacturers (OEMs) and customers is not only essential, but critical to survival. In a Hy perconnected world enterprises can communicate with partners in real time to inform, analyse and act. Design partners can work on prototypes and test designs with real time integration to shop floor systems and adjust parameters to improve quality and reduce time-to-market. With the advent of 3D printing, this gives design partners the ability to do rapid prototyping. Suppliers a nd contract manufacturers can communicate with business and shop floor systems. With Industry 4.0 and IoT machines on the shop floor can send Kanban replenishment signals directly to suppliers. Machines in the contract manufactures location can constantly update the OEM regarding the status of production orders and adherence to schedules. www.equipment-news.com
5. Machine Cloud — Predictive Maintenance — Predictive Quality O w ners, operators, or manufacturers of machines and equipment often have to manage their assets at remote sites, limiting their visibility into performance and usage. For example, if a problem occurs on a construction crane or wind turbine — it is often costly to identify and even more costly to address in a timely way. Furthermore, if maintenance crews fail to resolve an issue, it can result in system failure, equipment dow nt i me , or ha z a rdou s conditions for workers. Predictive maintenance and service solutions, allows equipment manufacturers and operators of machinery and assets to monitor machine health remotely, predict failures, and proactively maintain assets. Specifically, owners, operators, or manufacturers of machines and equipment can collect sensor and telemetry data from remote assets and merge it with business data, such as past maintenance records and contextual data including weather and traffic data.They can then analyse this data to find patterns and root causes for failures — insights that help them predict when an asset or equipment will fail and proactively apply preventive measures to stop the failure from occurring. Siemens recently announced an open cloud platform for analysing large datasets in industry. This will provide a platform for data-based services for predictive maintenance, asset and energy data management. OEMs can also create their own applications to exploit the open infrastructure for data analytics. For example, data can be analysed to optimise operation of the OEM’s machinery fleets
(Platform as a Service). This development further extends the data-based services Siemens unveiled in 2014. With these Plant Data Services, machinery and systems data is continuously recorded, preprocessed and analysed, providing real added value to manufacturing companies. For instance, the ‘Asset Analytics’ services enable companies to increase the ava ilabilit y of machine s, production lines or entire systems through continuous online monitoring. Intelligent pattern recognition or simulation is used to identify potential problems well in advance to enable corrective measures before unplanned downtimes occur. ‘Energy Analytics’ energy data management services support plant operators by providing the transparency of usage data and revealing hidden energy savings potential. Conclusion The IoT will be increasingly significant in the business world over the coming years. Enterprises will discover that solutions based on these new layers of connectedness can transform their operational processes, unlocking enormous value through greater efficiency. These enterprises will also find themselves with opportunities to transform their customers’ experiences. When intelligence can be gathered from and applied to the edge of your network, anything is possible. I n o u r p e r sp e c t i v e , t he underpinning of the business transformation to come is software architecture optimised for the unique needs of edge computing, machine-data storage, real-time analysis, and connectivity in the IoT ecosystem. Got a Question? Make An Enquiry.
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Nate Robert
FEATURES
The
Captivating Southeast The emerging markets of Southeast Asia have advanced rapidly in recent years. Why is this so, and how does this influence the metalworking industry now and in the future? By Michelle Cheong
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t is not news to many that the Association of Southeast Asian Nations (ASEAN ) markets have been growing rapidly in recent years. With the opening of doors in some countries and the encouragement of their governments in others came a flurry of foreign investments
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a s well a s expa nsions from foreign companies as better-off companies raced to make their mark in various industries of these countries, such as the manufacturing industries. According to an Economist Intelligence Unit (EIU) report re le a se d e a rl ie r t h i s ye a r,
ASEAN makes up 3.2 percent of global economic output, and accounts for 4.3 percent of global manufacturing. Drawn by various reasons, more and more global manufacturers have set up camp in the region. Benefiting from expansions of global manufacturers is the sector of metalworking that includes aspects such as machine tool production, metal fabrication, metrology and manufacturing software. The metalworking industry in turn serves various others including but not limited to automotive, aerospace, die & mould and oil & gas. As industry professionals looking to advance their footprint across the globe, the future is always a concern. In the midst of the rapidly developing economies, sometimes it may be hard to see the entire picture, and this may www.equipment-news.com
FEATURES influence decisions for the future. So as to understand markets today and make future decisions with regard to the metalworking industry, it is essential to find out what is captivating about the Southeast, how the metalworking industry has been affected and how it will change in time to come. The Southeast In Short As a whole, ASEAN countries have been experiencing strong growth in recent years; 2013 saw the world’s GDP growth at 3 percent, while that of ASEAN was 4.9 percent despite the successive international crisis. In fact, the World Bank forecast that the region’s growth would continue to remain resilient against the international situation and see a five percent growth of the region annually over the next five years versus only that of three to four percent in the global economy for the same period. A large reason for the growth in ASEAN is the increased foreign direct investments (FDI) that the countries have received over the years. From 2012 to 2014 alone, the ASEAN region totalled an average of US$365 billion in FDI inflow despite the slow growth of the global economy. Singapore recorded the highest net FDI inflow in 2014, at US$72 billion. Indonesia ranked second with US$22 billion and Thailand with US$11.5 billion. But what is it about ASEAN that lures foreign investors? Lures Of The Southeast Distance And Cheap Labour For some foreign companies such as automobile makers Ford and General Motors, US-based ON Semiconductor, or aerospace manufacturer Pratt & Whitney, reasons for expanding into the region include cost savings on transportation of products, parts or machines from further regions to the Southeast, as well as www.equipment-news.com
The rising middle class such as in Jakarta have increased income and spending power, making them an attractive market to foreign investors.
increasing the company’s global footprint as a means to compete against the local companies. These established companies hence set up offices, manufacturing plants, or simply opened service and sales companies to serve their existing customers in the region better, and these also then act as a platform to gather new ones. The region’s cheap labour is another incentive for these ma nufacturers. Most of the countries are known for their cheap labour costs, and Indonesia and Myanmar especially have their labour-intensive industries for ma ss production that allowing businesses to produce more for less. Rising Middle Class Surprisingly, despite the appeal of cheap labour, it only placed
10th for rea sons why some manufacturers have expanded to the Southeast, according to the EIU report. The most attractive incentive for them was catering to the surging demand of the rising middle classes in the region. How these rapidly growing middle classes have come about is but a natural progression with FDI into a country. FDI contributes to higher gross domestic product (GDP) growth and improves the economy of the country. This raises the standards of living and education levels of the country’s citizens as the country becomes wealthier, and creates a growing middle class. This has thus taken place in most of the ASEAN countries such as Singapore, Malaysia, Thailand, Indonesia, Vietnam, the Philippines, and Myanmar, especially with the increased FDI July - August 2015 asia pacific metalworking equipment news
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FEATURES especially true and seen in the ASEAN countries. For example, the political instability in 2011 in Thailand caused FDI inflow to the country to drop to US$3.9 billion, versus the $9.14 billion that was recorded in 2010. In their second bout of political instability in 2013, the FDI inflow was affected similarly and recorded $12.9 billion, down from the $20.7 billion of 2012. In these cases, political instability affected investment flow as investors reconsidered certain projects and withdrew totally from others. In contrast, countries with strong political stability maintain high records of F DI inf low. Singapore for instance, with its superior economic and political conditions, has always been the major recipient of FDI in the ASEAN region.
Increased spending power has triggered a ripple of effects down the line for many industries, especially metalworking, creating a positively growing cycle.
inflow in recent years. The total number of people in the middle class is expected to reach 144 million by 2017. With more money in their pockets, the people of the middle class are hence equipped with more spending power, which they can then invest in their businesses. Attractive Future Prospects G a in ing intere st to foreig n investors is also the region’s plan to become a single economy w it h t he A S E A N E co no m ic Community (AEC) that will form by the end of 2015. With the growth success of the ASEAN countries today, combined they would ra nk seventh - la rge st economy in the world. If all goes well with the plan, the AEC would offer freer flow of goods, services, investment and skilled labour across the region. 66
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This is attractive to those outside the region as the member countries of ASEAN each have their own expertise industries, such as Thailand and Indonesia for automobile, Vietnam for electrics & electronics, and Singapore for aerospace and precision engineering. Combining these into a single market and production base would establish a network of industries across the region, and allow businesses access to all products and services easily. Stability To foreign investors, stability in a country is always a concern; economic and political risks are always evaluated before an investment in made. No investor would want to invest in a country where the chances of receiving low returns are high. This was
On The Metalworking Industry G row ing bu sine sse s in t he Southeast have been beneficial for the metalworking industry, and created a positively growing cycle. With the rising middle classes, the increased spending power has triggered a ripple of effects down the line for many industries, especially in metalworking. For e x a mple , w it h more people being able to afford cars, demand for cars have increased. However, this demand not only increased sales of car companies; it also in turn drove up demands for the machines required to make these cars, thus boosting the metalworking industry. Another example would be that of aerospace. With more money to invest, governments such as in Singapore invest more into the aerospace industry, requiring more metalworking equipment for aeroplane parts. T he se a nd ot her simila r examples show that the growing middle class has hence created a l a r g e r m a rke t i n A S E A N www.equipment-news.com
for metalworking equipment required to ser ve the other i n du s t r i e s , a n d c u l t i v a te d business opportunities between local and foreign companies. Meta lwork ing industr y professionals can therefore now invest more into their businesses, purcha sing more expensive equipment so as to produce higher quality products which they then can export to other countries for higher prices. In recent years, the metalworking industries of ASEAN have also progressed in their own ways. With the monetary means, some companies have adopted sophisticated technology such as plasma cutting systems or laser equipment, thus expanding their repertoire of skills and products. This has hence created a positive cycle as in bringing more profit to businesses, they expand and adopt additional technologies or purchase more expensive equipment, widen their range of products and skills in the process, which ultimately benefit and build up the middle classes. S out he a st A sia ha s a lso established its own network of industry professionals in the area of metalworking who come together at large international trade fairs such as Metalex, M TA A sia , a nd M e t a lTe c h . These shows grow with every e dit ion, fe atu r ing not on ly more international companies interested in expanding to the country, but also more local companies looking to increase their global reach. So what can we expect for the future of the metalworking industry in the Southeast? For The Future Southeast Asia can be expected to be the future hub of the manufacturing industry, including that of metalworking. With the rapidly increasing populations, r i si n g m i d d l e c l a s s e s a n d www.equipment-news.com
William M. Plate Jr
FEATURES
Southeast Asia can be expected to be the future hub of the manufacturing industry, including that of metalworking.
improving economies of the region, product consumption would likely continue an upward trend. Manufacturers would still find the need to shift production closer to the growing ASEAN consumer markets and set up more plants and facilities here to cater to them. Trends such as in automation, robotics and 3D printing are likely to spre ad across the Southeast as well. Though it might be a challenge in labourdependent countries such as I ndone sia a nd Mya n ma r to switch to automation, the need to meet production, quality and precision demands will act as a catalyst and a means for countries to remain competitive in the metalworking scene. In tur n, this would then increase demands for industrial robots to help manufacturers and
industry professionals to achieve their purposes and enhance the robotics market. These robots would be involved in not only the metalworking sector, but also other related industries such as automotive, electrical & electronics or machinery. I nve stors, sto c k holde rs, manufacturers, and industry professionals alike can likely look forward to more trade and business opportunities in the Southeast in time to come, with promises of freer trade, a bustling network of manufacturers and suppliers, and easier access to goods that will accompany the impending AEC formation. The already captivating Southeast will certainly become even more striking in the near future. Got a Question? Make An Enquiry.
ENQUIRY No.
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67
EVENTS& EXHIBITIONS Show Preview: Manufacturing Myanmar 2015 –
Enhancing
Productivity and Sustainability As each year progresses, Myanmar flexes more of its long dormant economic muscle – and this is especially so in the manufacturing sector.
I
t was recently reported that Myanmar has received more than US$8 billion in Foreign Direct Investment (FDI), and a senior official from the Myanmar Investment Commission has attributed this to the expansion of the telecoms industry and wooing of manufacturers and energy companies. Myanmar’s economy is also projected to grow at a rate of 9.3 per cent this year due to the large amount of foreign investment and the blooming telecoms sector. Technology To Enhance Sustainability And Productivity Hitachi, one of the premier e x h i b i t o r s o f t h i s y e a r ’s M a n u f a c t u r i n g M y a n m a r, has been developing and enha ncing the technologies in our equipment such as air
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asia pacific metalworking equipment news July - August 2015
Manufacturing Myanmar 2015 will potentially be a good platform to meet new potential buyers in the manufacturing sector.
compressors for more than a century, and in ink jet printers that have entered the market since 1975. The latest generation of compre ssors, ca lle d t he “NEXT Series”, was developed to offer more efficiency, energy savings and easy maintenance for the Myanmar market. Hitachi has been providing social infra structure for development projects in Myanmar since 1958, with the supply of generators to the Baluchaung No. 2 Hydro Power Plant. The company’s business ha s since g row n to include sectors such as home appliance, construction machinery, elevator, i n du s t r i a l e qu ip m e nt , a n d medical equipment. Myanmar’s vision is to become a modern, developed nation by 2030, and is putting in place urban
infrastructure and measures aimed at promoting trade with other countries, to support the development of science and technology as well as growth in the manufacturing industry. These new social infrastructure systems are expected to stimulate economic growth, as Japanese companies and other foreign capital companies continue to set up establishments in Myanmar. T h e co m p a n y p l a ce s h i g h importance on Myanmar as one of the focus markets in its Southeast Asia’s business, as it targets to increase its overseas sales ratio to more than 50 per cent. Myanmar’s Potential As A Manufacturing Hub Myanmar holds huge potential as a manufacturing hub in this region. There are many Special Economic Zones (SEZs) and the Myanmar government makes an effort to promote them. Many multi-national companies are also looking to establish their factories in Myanmar. Thus, Manufacturing Myanmar 2015 will potentially be a good platform to meet new potential buyers in the manufacturing sector. Fo l l o w i n g i t s i n a u g u r a l e d i t i o n’s s u c c e s s i n 2 014 , Manufacturing Myanmar 2015 will return from 15 to 17 October at a new venue, the Myanmar Event Park. The exhibition will feature a range of machinery, equipment, technologies and solutions from around the world, ta ilored to meet t he needs of the countr y’s burgeoning manufacturing sector. Manufacturing Myanmar 2015 will be co-located with Oil & Gas Myanmar 2015, a key oil and gas event for industry professionals to congregate and source for a myriad of international oil and gas suppliers and service providers. Got a Question? Make An Enquiry.
ENQUIRY No.
5501
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EVENTS&EXHIBITIONS
T
he 11th International Wire & Cable Trade Fair and the 10th International Tube and Pipe Trade Fair for Southeast Asia will be held at Bangkok Trade & Exhibition Centre (BITEC) from 16 to 18 September 2015. These are set to be the region’s most impressive machinery and product showcase for the wire, cable, tube and pipe industries. Converging four synergistic key sectors of Wire, Cable, Tube and Pipes in a single staging, manufacturers, processing and finishing companies, measuring and control technology providers, as well as those in the materials, tools and auxiliary business can look towards an all-encompassing venue that will meet their procurement and sourcing needs from 300 international companies including National Pavilions and Groups from Austria, China, France, Germany, Italy, Taiwan, the UK and USA. The latest staging of Wire and Tube Southeast Asia 2015 comes at a time where robust industrial, manufacturing, construction and infrastructure, automotive and telecommunications developments are expected across the region, and will see strong demand for the wire and tube industries. According to Global Industry Analysts, telecommunications improvements are expected to fuel growth in the overall cable and wire markets by more than 11 percent annually through to 2018. The most significant gains will be seen in power cables – the biggest slice of the wire and cable markets – which is expected to grow nearly 9 per cent a year. The report also indicates the global market for seamless pipes and tubes is projected to reach 70.5 million tonnes by 2020, driven by increasing oil and gas exploration and production activity as well as growing demand for premium pipes. Asia-Pacific represents the largest market worldwide supported by rapid increase in
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Show Preview:
Wire And Tube
Southeast Asia 2015
Visions, Innovations and Solutions Trade visitors to Wire and Tube Southeast Asia can look forward to an impressive array of innovative solutions.
infrastructure development across emerging Asian countries. Catering to the demands and needs of the industry segments brought about by ma rket projections, trade visitors can look forward to an impressive array of innovative solutions and a notable range of machines and technology at the two synergistic trade fairs. Some companies on highlight include Eder Engineering who will be showcasing its USP-Twin ultrasonic machine at the trade fair. Automated and easy to operate, the machine offers unique efficiency and work range. Manufacturer and supplier of measuring, control, inspection and sorting technology, Sikora will also be showcasing its noncontact measuring systems based on progressive laser and X-ray technology at the trade fair. A third company to note is Niehoff and its MSM 85 rod breakdown machine. Operated by the network-compatible NMI (Niehoff Machine Interface), it is designed to produce wires made of copper, copper alloys, aluminium, aluminium alloys, and other nonferrous materials, and is capable of drawing copper wires with a
maximum inlet diameter of 10 mm to a final diameter of 1.0 mm at a maximum line speed of 40 m/s. I n t u n e w it h t he l a te s t advancements and developments in the industry, industry-specific seminars by reputable speakers will also prov ide attendees with key market knowledge and critical business insights required to effectively navigate the highvalue wire, cable, tube and pipe industries. Seminar topics include: New Standards for wire and cable installation, Certified Electrical Engineering Training, Lean Seminar for Manufacturing, Latest Tools and Materials for the wire and tube industries, Underground Cable and many more. With almost 10,000 quality trade visitors expected at the show, a complimentary pre-event business matching service will allow exhibitors and visitors to engage in fruitful business meetings with potential customers, distributors and business partners from targeted segments of the trade and related industries prior to and during their visit. Got a Question? Make An Enquiry.
ENQUIRY No.
5502
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69
EVENTS&EXHIBITIONS
Intermach & Subcon Thailand 2015:
A Record Setting Event The four day event achieved 4,611 business pairings with a value of US$233 million
I
ntermach and Subcon Thailand 2015 organised by UBM Asia ( T ha ila nd ) had re ceived excellent feedback and the success of the combined events proved outstanding according
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to show organisers. The four-day event was attended by 40,284 top quality visitors and buyers from 43 countries. Mr Sanchai Noombunnam, Group Director of UBM Asia
(Thailand) mentioned that the 2015 show’s overall objective w a s “ to e s t a b l i s h f u r t h e r e x p a n s i o n o f t h e r e g i o n’s manufacturing industries” and this was duly achieved. The show featured more than 1,200 global companies and displayed with almost 150 machines were displayed for the first time in Thailand and ASEAN such as Fibre laser with full automation system plus the cutting-edge technologies from Japanese brands such as Mazak, Mitsubishi, Okuma, Sodick, and Toyoda. Mr Noombannam also made mention of another highlight – a special Program of unique Seminars in the Automotive, Medical Device and Aerospace Industries that enabled i n d u s t r i a l i s t s to i n c r e a s e their knowledge and expand opportunities in new areas. Miss Sonk lin Ploy mee, Director of the BOI Unit for Industrial Linkage Development ( BU I L D), T ha ila nd B oa rd of Investment ( BOI ) said that Subcon Thailand is now recognised as “the largest and best industrial subcontracting exhibition” for industrial parts and business matchmaking in the ASEAN region. Of the exhibitors, there were 264 manufacturers of industrial parts from 15 countries who exhibited technology covering the Automotive, Electrical and Electronic, Machinery and other key manufacturing areas. There was also a new exhibition section featuring Medical Device parts. The four day event achieved 4,611 business pairings with a value of 7.9 billion baht (US$233 million). Miss Ploymee also mentioned that over 50 special seminars were held throughout the show including the BOI’s new policy seminar which drew over 500 attendees. Got a Question? Make An Enquiry.
ENQUIRY No.
5503
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PRODUCT FINDER Comau: High Payload Robot
Dormer Pramet: Rotary Burrs
Comau has added a new model, the Smart NJ 650, to its line of high payload robots. With a compact design, the robot has an elevated payload of up to 650 kg, a maximum horizontal reach of 2.70 m, and ISO repeatability from 0.15 mm. The large payload capacity makes it suitable not only for specific applications dealing with heavy loads like handling and spot welding in the automotive industry, but also for general applications such as packaging and machining. The robot can therefore be used in virtually any industrial sector.
Dormer Pramet has released a range of carbide rotary burrs for general machining processes, varying in designs and shapes such as ball nosed cylinder, oval or cones. The double cut designs of the burrs increase control, and the ball-end geometry improves cutting action closer to the centre. Comprising of a carbide head and steel shank that gives it rigidity and strength to improve tool life, the burrs are targeted to machine an assortment of materials from hardened steel to plastics.
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5601
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ENQUIRY No.
5602
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FARO: 3D Metrology Software
HAAS Automation: Spindle
The new FARO CAM2 Measure 10.5 is the latest software for the FaroArm, FARO Laser ScanArm and FARO Laser Tracker. With the ability to connect multiple 3D measurement devices within the same coordinate system, the software can also simultaneously scan larger objects at higher speeds and greater precision, and record 20 times more data on a single computer. It also enables automated repeat inspections and has an enhanced Geometric Dimensioning and Tolerancing functionality to provide users with streamlined analysis and visual reporting of parts to determine part quality.
The DT-1 Drill/Tap centre from HAAS Automation is now available with a 20,000 revolutions per minute (rpm) inline direct-drive spindle that enables users to run higher feedrates for small tools a nd high speed machining operations. It can also mill hard-to-machine materials, and allow rigid tapping to 5000 rpm with up to four times retract speed to reduce cycle times. The compact lean-style machining centre offers space-saving while maintaining a small footprint, and features efficient chip removal through its steeply sloped internal sheet metal. The accompanying 45-gallon flood coolant system offers a programmable coolant nozzle and highpressure through-spindle coolant system.
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ENQUIRY No.
5603
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ENQUIRY No.
5604
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71
PRODUCTFINDER Kemper: Mobile Extraction And Filter Unit
Kennametal: Hydraulic Chuck
Kemper ha s added the MaxiFil Clean, a system with cleanable filter, to its line of mobile extraction and filter units. Fe atu re s of t he s y s te m i n c l u d e a flexible extraction arm available in lengths of up to four metres, and a 360 -degree rotatable specialised extraction hood that collects up to 40 percent more welding fumes than their conventional counterparts. Also, with its automated cleaning and filtering feature that feeds dust particles to an easy-to-seal disposable cartridge, the system suits permanent use to create safer environments for employees.
Kennametal has launched a universal hydraulic chuck, the HydroForce HT, which can maximise high-torque performance in all rotating applications. With a compact design, a 40 percent thicker front-wall cross-section to provide increased rigidity, and a clamping force up to three times better than regular hydraulic chucks, it simplifies inventory while maximising tool life and machining results. It also dampens vibration, and has a balance quality of G2.5 at speeds up to 25,000 rpm. The chuck requires 20 and 32 mm diameters for direct clamping, and reducer sleeves are applied for all other diameters.
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NCG CAM Solutions Limited have released the NCG CAM v14 software bearing new features such as 5-axis along curve machining, UV surface machining to generate machining passes, tools to align 3+2 axis boundary planes. It has an ability to cover pockets, change the background colour or translucency of all surfaces. The software also includes several improvements in automation of the drilling in macros, an ability to copy and paste strategy parameters, and to do rest finishing with a toroidal reference cutter. Got a Question? Make An Enquiry.
5607
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5606
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Perceptron: 3D Laser Scanning System
NCG CAM: Software
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Percept ron has released the SMART3D, a portable laser scanning system for reverse engineering and modelling sectors. It offers a fully integrated automatic rotary table that allows for full 360 deg real-time scanning of parts without the need for targets or best fit alignment, a scanning volume of 200 mm x 225 mm x 225 mm, and an ‘Auto Rescan’ feature. With a volumetric accuracy of 50 microns and a configurable line density for programmable scan line intervals down to 0.1 mm, it delivers more accuracy than manually operated scanning systems. It also provides 3D polygonised models for reverse engineering, 3D printing or graphical web content, and can also be used for verification of production parts against nominal part geometry data. Got a Question? Make An Enquiry.
ENQUIRY No.
5608
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PRODUCTFINDER PTC & Stratasys: 3D CAD Software
Sandvik Coromant: Insert
The PTC Creo 3.0 is a new integrated workflow developed by PTC and Stratasys, in a joint effort to enable users a seamless workflow from design to 3D print. Users can perform informed design specification, file preparation, print optimisation and print execution for Stratasys 3D printing solutions using the PTC software. This integrated solution also overcomes conventionally cumbersome and inefficient processes in additive manufacturing by combining the use of multiple tools with 3D CAD software. This would essentially benefit all additive manufacturers of the different industries.
Sandvik Coromant has introduced the GC4305, an insert for steel turning to maximise metal removal rates, shorten processing times and enable superior component quality. It offers high cutting data, an ability to withstand high temperatures, and has a wear-resistant Inveio coating to achieve long tool life. The insert can also be used for dry machining. T he inser t of fers cost sav ings w it h it s aforementioned properties, as well as with the elimination of the need for cooling lubricants and associated wastes, and cheaper disposal of chips.
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73
PRODUCTFINDER Schuler: Monoblock Servo Press
Seco: TP Insert Grades
Schuler has released the MSD-400, a servo press with a force of 4 0 0 m e t r ic to n ne s t hat incre a se s f le x ibil it y a nd efficiency of manufacturing, and hence productivity. The servo press allows manufacturers to individually programme both stroke height and forming speed, while simultaneously reducing energy consumption at the same output level. As such, it can positively influence die service lives. With a coil line and roll feed, the press comprises a complete forming system.
Seco has released three insert grades TP2501, TP1501 and TP0501, for steel turning with the latest Duratomic coating technology to provide improved toughness, heat resistance and chemical inertness. This lengthens tool life and offers the potential for higher cutting speeds. TP2501 suits a variety of workpiece material requirements and unpredictable working conditions with its highly secure edge toughness behaviour. TP1501 is well-balanced and suits applications requiring high wear resistance in low-alloy steel workpieces. TP0501 provides the highest possible wear resistance and cutting speeds, and suits stable machining conditions and situations requiring high output. The TP grades also feature used-edge detection that do not impact tool performance, yet allows machinists to quickly and accurately identify used edges with the naked eye.
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ENQUIRY No.
5611
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5612
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Tailift: Punching Press
Universal Robots: Table-top Robot
Tailift’s latest punching press, the Elektro Servo (ES) 13, features higher speed and precision while being energy-saving. A quiet press, the model is also equipped with overload protection and serves well when dealing with thinner sheet metal. The all-in-one machine combines all functions, such as punching, forming, roller cutting and tapping. The model is also compact to help save space in factories, and saves on costs for electricity as it does not possess a hydraulic and cooling system, thus consuming less electricity on average.
The Universal Robots UR3 robot is a compact lightweight 11 kg table-top robot with a payload of three kilogrammes, equipped with 360-degree rotatable wrist joints and an infinitely rotatable end joint. The robot is capable of working with a human team or as a standalone operator, and can be used in applications requiring 6-axis capabilities such as assembly, polish, glue and screw to create products of uniform quality. The robot optimises production workflow while maintaining safety, and reduces production costs.
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5613
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ENQUIRY No.
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EXHIBITION PROGRAMMES AUGUST
OCTOBER
NOVEMBER
JIExpo Kemayoran Jakarta, Indonesia ECMI exh@mtt-indonesia.com mtt-indonesia.com
Fiera Milano SpA Milan, Italy EFIM-ENTE FIERE ITALIANE MACCHINE SPA info@emo-milan.com www.emo-milano.com
BITEC Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th
4–7 MTT Expo
12 - 14 Inapa Surabaya
Grand City Convention & Exhibition Centre Surabaya, Indonesia info@gem-indonesia.net www.inapa-exhibition.net
26-29 PDMEX 2015
World Trade Center Metro Manila, Philippines MAI (Market Access & Innovation) Management Philippines mai_mgt@compass.com.ph
SEPTEMBER 7–9 Aluminium India Bombay Exhibition Centre Mumbai, India Reed SI Exhibitions aluminium@reedsi.com www.aluminium-india.com
10 – 12 Assembly Technology Vietnam
5-10 EMO Milano 2015
8-10 Metalex Vietnam
SECC Ho Chi Minh, Vietnam Reed Tradex contactcenter@reedtradex.co.th www.metalexvietnam.com
15-17 Manufacturing Myanmar 2015
Myanmar Event Park Yangon, Myanmar Singapore Exhibition Services Pte Ltd mm@sesallworld.com www.manufacturingmyanmar.com
2015
18 – 21 Metalex
DECEMBER
2–4 International Metal Technology Taiwan
Kaohsiung Exhibition Centre Kaohsiung, Taiwan KAIGO imt@kaigo.com.tw www.imttaiwan.com/main.php?lang=en
2–5 Manufacturing Indonesia 2015
Jakarta International Expo (JIExpo), Indonesia PT Pamerindo Indonesia maysia@pamerindo.com www.manufacturingindonesia.com
28 – 31 Korea Metal Week
KINTEX Seoul, South Korea Korea Trade Fairs master1@ktfairs.com www.korea-metal.com/en/asp/main.asp
I.C.E Hanoi, Vietnam Reed Tradex Company rtdx@reedtradex.co.th
16 – 18 Wire & Tube Southeast Asia 2015
BITEC, Thailand Messe Dusseldorf Asia wire@mda.com.sg_tube@mda.com.sg www.wire-southeastasia.com www.tube-southeastasia.com
24 – 26 Intermach Myanmar 2015
Yangon, Myanmar UBM Asia (Thailand) Co Ltd info@intermachmyanmar.com www.intermachmyanmar.com www.equipment-news.com
To be considered for inclusion in the calendar of events, send details of event to:
The Editor (APMEN) Eastern Trade Media
1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Email: syedshah@epl.com.sg Tel: +65 63792888 July - August 2015 asia pacific metalworking equipment news
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BENIGN ENTERPRISE CO LTD
29
122
BYSTRONIC PTE LTD
03
120
DELCAM LTD
05
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DMG ASIA PACIFIC PTE LTD
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125
EXXON MOBIL
25
115
HAAS AUTOMATION INC
09
110
HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD
11
119
HWACHEON ASIA PACIFIC PTE LTD
13
113
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ISCAR LTD
IFC
121
KENNAMETAL INC
BC
104
MESSE DUSSELDORF ASIA PTE LTD (WIRE & TUBE 2015)
61
124
OKUMA CORPORATION
IBC
126
OPTICAL GAGING (S) PTE LTD
17
118
REED TRADEX CO LTD (METALEX THAILAND 2015)
41
127
SECO TOOLS (S.E.A) PTE LTD
01
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SINGAPORE EXHIBITION SERVICES PTE LTD (MANUFACTURING MYANMAR 2015)
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TAILIFT CO LTD
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TRUMPF PTE LTD
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TUNGALOY SINGAPORE PTE LTD
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WALTER AG SINGAPORE PTE LTD
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ASIA PACIFIC METALWORKING
No. 5 2015
The Engineering Journal For Manufacturing,Automation & Quality Control
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Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating
❑ 350 OTHERS (Please specify)_____________________________________________________________________________________________
YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122 ❑ 123
Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg. Dies & Moulds mfg. Motor Vehicles Parts Shipbuilding
❑ 160 Design & Consultancy Services ❑ 180 Govt bodies, Trade Assns, Exhibitions Cos. ❑ 200 Agent/Distributor/Trader of Machine Tools & Accessories ❑ 224 Mechanical, Fabrication and all other metal engineering works ❑ 078 OTHERS (Please specify)__________________________________
JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt
❑ 028 Testing & Inspection ❑ 030 Sales & Marketing
❑ 022 Production Engineering ❑ 024 Quality Control/Assurance
❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing
❑ 027 OTHERS (Please specify)
SIZE OF COMPANY ❑ 001 1 – 10
❑ 002 11 – 30
❑ 003 31 – 50
❑ 004 51 – 100
❑ 005 101+
www.equipment-news.com FAST PERSONAL COPY SUBSCRIPTION FORM INVEST $0.15 PER DAY IN TECHNICAL AND BUSINESS INFORMATION FOR YOUR CORPORATE STRATEGIES IN SOUTHEAST ASIA
Name: (Surname)____________________________________ (Given Name)__________________________ Company: _________________________________________ Job Title:______________________________ Address:_________________________________________________________________________________ Country: __________________________________________ Telephone No: _________________________ E-mail:____________________________________________ Fax No:______________________________ Signature _________________________________________ Date_________________________________ SUBSCRIPTION RATES
Commencing from:
AIRMAIL (1 YEAR – EIGHT ISSUES)
■ *Singapore/Malaysia S$60.00
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TYPE OF BUSINESS (Please ✔ ONE box only) Do you use METAL in your production/manufacturing process? Do you use machine tools and related equipment? Do you use automation systems & equipment?
❑ Yes ❑ Yes ❑ Yes
❑ No ❑ No ❑ No
YOUR METAL PROCESS USED ? (Please be specific) ❑ 300 ❑ 303 ❑ 306 ❑ 309 ❑ 315 ❑ 318
CNC Machining Milling Gear Cutting Grinding Stamping Shearing
❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310
EDM/ECM Inspection/Measuring/Testing Design with CAD/CAM Drilling/Boring Tapping/Threading Lapping/Honing
❑ 313 ❑ 316 ❑ 319 ❑ 322 ❑ 302 ❑ 305
Forging Rolling Die Casting Welding Turning Coil Forming
❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323
Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating
❑ 350 OTHERS (Please specify)
YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122
Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg. Dies & Moulds mfg. Motor Vehicles Parts
JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt
❑ 123 Shipbuilding ❑ 160 Design & Consultancy Services ❑ 180 Govt bodies, Trade Assns, Exhibitions Cos. ❑ 200 Agent/Distributor/Trader of Machine Tools & Accessories ❑ 224 Mechanical, Fabrication and all other metal engineering works ❑ 078 OTHERS (Please specify)__________________________________
❑ 028 Testing & Inspection ❑ 030 Sales & Marketing ❑ 027 OTHERS (Please specify)
❑ 022 Production Engineering ❑ 024 Quality Control/Assurance
Send this Fast SUBSCRIPTION FORM to Circulation Department, Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-02, Singapore 169206 or Fax: 65-6379 2806 Note: This form must be duly completed and signed.
❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing
ENQUIRY NO 126
Simply a smarter insert. That’s Beyond Drive. That’s TM
TM
With Wear Detection Technology Black Insert
Hard to detect wear.
BEYOND DRIVE TM
TM
Our most advanced surface treatment: • Bronze outer layer simplifies wear detection • Reduces coating stresses • Improves coating adhesion
At Kennametal, our inspiration is driven by asking “what if?” Engineering a complete portfolio of inserts that utilizes advanced wear detection technology while also increasing metal removal rates — is a result of that drive. A simply smarter insert. Now That’s Different Thinking, That’s Better Thinking. That’s Kennametal. Beyond Drive inserts coupled with NOVO — our suite of powerful digital tools — will lead to increased performance. To learn more about your productivity gains using Beyond Drive inserts and NOVO, call +1 800 835 3668 or visit www.kennametal.com/BeyondDrive TM
TM
TM
TM
TM
TM
ENQUIRY NO 104 ©2015 Kennametal Inc. l All rights reserved. l A-15-04413
www.kennametal.com/BeyondDrive